JP2009254488A - Mat and its manufacture method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mat provided with a highly decorative design through having a relief-like pictures, patterns or the like on the surface, easy to manufacture it and excellent in productivity. <P>SOLUTION: An upper-sheet raw fabric made of fibers and provided with an adhesive bond 5 on the back is cut into a specified form. The upper sheet 2A cut into the specified form is placed on a mat backing 1. The sheet 2A is high-frequency welded along the periphery. Thereby the periphery of the sheet 2A is bonded to the backing 1, and a recess groove 3 is formed along the periphery of the sheet 2A. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a mat having a design or pattern such as a relief on the surface and having high designability, and is suitably used, for example, as a floor mat for automobiles and the like and a method for manufacturing the same.

  Conventionally, a floor mat with high design that cannot be expressed with tufted carpets, is a traditional carpet that is made by tying pile yarns to warp yarns. Is known in the form of a relief.

  Also, as a mat with a high design that can not be expressed with tufted carpet, Wilton carpet, a kind of woven carpet in which piles are woven in high density with mechanical weaving, mechanically piles by a method similar to hand knotting Printed carpets are known in addition to Akisminster carpets, which are a kind of woven carpets inserted into a base fabric.

Further, as a floor mat having a high design property, there is also known a carving mat in which a pattern or the like is formed on a pile surface by cutting the front end portion of a cut pile with a cutting tool such as a scissors (see Patent Document 1). .
Japanese Unexamined Patent Publication No. 63-235584

  However, the above-described soot carpet has a problem of low productivity and high cost because it requires a great deal of labor and time for the pile trimming work.

  Further, the Wilton carpet, the Akisminster carpet, and the printed carpet all have the problem of low productivity and high cost.

  Moreover, the carving mat is also low in productivity and high cost because the cutting process using a cutting tool such as a scissors requires a great deal of time.

  The present invention has been made in view of such a technical background, and has a design and a pattern such as a relief on the surface, has a high designability, and a mat that is easy to manufacture and excellent in productivity. An object is to provide a manufacturing method.

  In order to achieve the above object, the present invention provides the following means.

  [1] A fiber upper sheet is bonded to a part of the upper surface of the mat base material, and a concave groove along the peripheral edge is formed at the peripheral edge of the upper sheet. mat.

  [2] A fiber upper sheet is bonded to a part of the upper surface of the fiber mat base material via a breathable hot melt resin layer, and the peripheral edge of the upper sheet is along the peripheral edge. A mat having a concave groove.

  [3] The mat according to item 2 above, wherein a breathable thermoplastic resin film is laminated between the fiber mat substrate and the breathable hot melt resin layer.

  [4] The mat according to item 2 or 3, wherein the breathable hot melt resin layer is formed of a porous resin layer formed by applying molten hot melt resin in a fibrous form by being discharged from an application nozzle hole.

  [5] A fiber upper sheet original fabric provided with an adhesive layer on the back surface side is cut into a required shape, and the obtained upper sheet of the required shape is placed on the mat base material and disposed. By applying high-frequency welder processing along the peripheral edge of the sheet, the peripheral edge of the upper sheet is adhered to the mat base material, and a concave groove along the peripheral edge is formed at the peripheral edge of the upper sheet. A method for producing a mat characterized by the above.

  [6] A fiber upper sheet having a breathable hot melt resin layer formed on the back side is cut into a required shape, and the obtained upper sheet is overlapped with a fiber mat substrate. By arranging and applying a high frequency welder process along the peripheral edge of the upper sheet, the peripheral edge of the upper sheet is bonded to the fiber mat substrate via the hot melt resin layer, and the upper sheet A method for manufacturing a mat, comprising forming a concave groove along the peripheral edge of the peripheral edge of the mat.

  [7] A breathable thermoplastic resin film is continuously superposed on the back side of the upper sheet original fabric on which the breathable hot melt resin layer is formed, and taken up by a pair of rolls, and then the thermoplastic resin film. 7. The method for producing a mat according to item 6 above, wherein the high-frequency welder process is performed in a state having the thermoplastic resin film, using an upper sheet obtained by cutting an original sheet of the upper sheet laminated on the sheet.

[8] After the resin film is continuously superposed on the back side of the upper sheet original fabric on which the breathable hot melt resin layer is formed, and taken up by a pair of rolls,
The high frequency welder process is performed using an upper sheet obtained by peeling the resin film and cutting into a required shape, or using an upper sheet obtained by peeling the resin film after cutting into a required shape. The manufacturing method of the mat | matte of description.

  [9] A curtain formed by bringing the hot melt resin into a fibrous form by bringing the melted hot melt resin discharged from the application nozzle hole into contact with the air stream ejected from the air stream forming nozzle hole and stretching it. The manufacturing method of the mat | matte of any one of the preceding clauses 6-8 which forms the said breathable hot-melt resin layer by apply | coating a hot-melt resin of a shape on the back surface side of the said upper sheet | seat original fabric.

  The mat according to the invention of [1] can display various designs, patterns, and the like by the upper sheet adhered on the mat base material, but has a groove portion along the periphery of the upper sheet. The patterns and the like are raised and viewed three-dimensionally as if they are embossed, so that a very high design is obtained. In addition, when this mat is manufactured, the adhesion of the upper sheet and the formation of the concave groove at the peripheral edge can be easily performed by high-frequency welding, etc., so that high productivity can be obtained.

  The mat according to the invention of [2] can display various designs, patterns, and the like by a fiber upholstery sheet bonded onto a fiber mat base material, but has a concave groove along the peripheral edge of the upholstery sheet. As a result, the design and pattern are raised in a three-dimensional manner as if they were embossed, so that a very high design can be obtained, and the fiber upholstery sheet is made of a fiber mat via a breathable hot melt resin layer. By adhering to the base material, the fiber upholstery sheet and the breathable hot melt resin layer further contribute to the improvement of the sound absorption, so that an extremely excellent sound absorbing effect is exhibited. In addition, when this mat is manufactured, the adhesion of the upper sheet and the formation of the concave groove at the peripheral edge can be easily performed by high-frequency welding, etc., so that high productivity can be obtained.

  According to the mat according to the invention of [3], since a breathable thermoplastic resin film is interposed between the fiber mat substrate and the breathable hot melt resin layer, the breathable hot resin is formed on the back surface side of the upper sheet. When the melt resin layer is continuously formed and taken up by a roll, the thermoplastic resin film can prevent the hot melt resin layer from adhering to the roll, and the thermoplastic resin film is breathable so that sound absorption is achieved. There is an advantage of not inhibiting the sex.

  In the mat according to the invention of [4], the breathable hot melt resin layer is composed of a porous resin layer formed by applying the molten hot melt resin in a fibrous form by discharging from the application nozzle hole. The air permeability can be set within a suitable range in relation to the sound absorption characteristics to ensure good sound absorption, and the air permeability hot melt resin layer becomes a uniform fiber layer, so that good adhesion can be obtained even with a small amount of application. In addition, sufficient flexibility as a mat can be secured.

  According to the manufacturing method according to the invention of [5], the grooved portion can be formed along the peripheral edge portion of the upper sheet at the same time that the upper sheet is bonded to the mat base material by high-frequency welding. The mat according to the invention of [1] having high performance can be easily and reliably manufactured with high production efficiency.

  According to the manufacturing method according to the invention of [6], the grooved portion can be formed along the peripheral edge portion of the upper sheet at the same time as the fiber upper sheet is bonded to the fiber mat substrate by high-frequency welding. Thus, the mat of the invention of [2] having excellent design and sound absorption can be easily and reliably manufactured with high production efficiency.

  According to the manufacturing method according to the invention of [7], when a breathable hot melt resin layer is continuously formed on the back surface side of the upper sheet original fabric and taken up by the roll, the thermoplastic resin film is applied to the roll. Since the adhesion of the hot melt resin layer can be prevented, an upholstery sheet having a breathable hot melt resin layer can be mass-produced with high efficiency, and the obtained sound absorbing mat is provided between the fiber mat base material and the fiber upper sheet. Even if a thermoplastic resin film is interposed between the resin film and the resin film, the resin film has air permeability, so that the original excellent sound absorbing performance is exhibited.

  According to the manufacturing method according to the invention of [8], when a breathable hot melt resin layer is continuously formed on the back surface side of the upper sheet original fabric and is taken up by the roll, the hot melt is applied to the roll by the resin film. Since the adhesion of the resin layer can be prevented, the upper sheet having a breathable hot melt resin layer can be mass-produced with high efficiency, and the fiber upper sheet is adhered to the fiber mat substrate with the resin film peeled off. Therefore, the obtained sound absorbing mat has originally excellent sound absorbing performance.

  According to the manufacturing method according to the invention of [9], the breathable hot melt is formed by applying a molten hot melt resin in a fibrous form by discharging from a coating nozzle hole to the back surface side of the upper sheet original fabric. Since the resin layer is formed, the air permeability of the hot melt resin layer can be set within a suitable range in relation to the sound absorption characteristics, and good sound absorption can be secured, and the breathable hot melt resin layer can be formed into a uniform fiber layer. Therefore, good adhesiveness can be obtained even with a small amount of coating, and flexibility as a mat can be sufficiently secured.

  Hereinafter, the mat according to the present invention will be specifically described with reference to the drawings. FIG. 1 is a plan view showing a structural example of the mat of the present invention used as a driver's seat floor mat of an automobile, FIG. 2 (a) is a sectional view of the mat according to the first embodiment, and FIG. 2 (b) is the same. FIG. 3 is a cross-sectional view of the second embodiment, FIG. 3 is a production process diagram of the raw sheet of the upper sheet used for the mat, and FIGS. 4 (a) and 4 (b) are operations for bonding the upper sheet to the mat substrate by high frequency welding. It is sectional drawing shown.

  A mat M shown in FIG. 1 has a fiber-shaped base sheet 1 and fiber-shaped upper sheets 2A and 2B having different shades adhered to the surface of the fiber mat substrate 1 and peripheral edges of the upper sheets 2A and 2B. A recessed groove portion 3 is formed in the upper portion. The concave groove 3 is a linear concave groove formed in a plan view along the peripheral edge of the upper sheets 2A and 2B. The surface of the fiber mat substrate 1 has a different color from the surfaces of the upholstery sheets 2A and 2B. The mat base material 1 is edged 4 over the entire circumference.

  Therefore, in the mat M1 of the first embodiment shown in FIG. 2 (a), the breathable hot melt resin layer 5 is interposed between the upper sheets 2A and 2B and the fiber mat base material 1. This breathable hot melt resin layer 5 is integrated on the back side of the upper sheets 2A and 2B, and is melted to the mat substrate 1 at the concave groove portions 3 along the peripheral edges of the upper sheets 2A and 2B. I wear it.

  Further, in the mat M2 of the second embodiment shown in FIG. 2 (b), a breathable hot melt resin layer 5 is laminated on the lower surface side between the upper sheets 2A and 2B and the fiber mat base material 1. The ventilated thermoplastic resin film 6A is interposed. The breathable hot-melt resin layer 5 and the breathable thermoplastic resin film 6A are fused to the mat substrate 1 at the recessed groove portions 3 along the peripheral edge portions of the both overlaid sheets 2A and 2B. The breathable thermoplastic resin film 6A is not particularly limited, and examples thereof include a thermoplastic resin film having a large number of fine holes.

  In the fiber mat base material 1 in the mats M1 and M2 of the first and second embodiments, the upper skin material layer 11 and the lower sound absorbing layer 12 are interposed through the breathable hot melt resin layer 13. It consists of an integrated adhesive.

  In these mats M1, M2, the leaf pattern of the upholstery sheets 2A, 2B is three-dimensionally raised like a relief by the concave groove portion 3 on the periphery, so that a very high design can be obtained, and the fiber can be made. In addition to the good sound absorption by the mat substrate 1, the fiber upholstery sheets 2A and 2B and the breathable hot melt resin layer 5 contribute to the improvement of the sound absorption, thereby exhibiting an extremely excellent sound absorption effect. Further, in these mats M1 and M2, the upper sheets 2A and 2B are bonded to the mat substrate 1 only at the peripheral edge, and the breathable hot melt resin layers 5 and 13 have a soft porous structure. Therefore, sufficient flexibility as a mat can be obtained. In addition, since the thermoplastic resin film 6A in the mat M2 of the second embodiment has air permeability, the sound absorbing performance is not hindered.

  In the above embodiment, a mat base material made of fiber is used as the mat base material 1. However, the mat base material is not particularly limited to such a configuration. For example, a non-breathable mat base material (for example, a base fabric) A mat base material or the like in which a non-breathable rubber backing layer is laminated on the back surface thereof may be used. Among these, a fiber mat base material is preferably used in that the sound absorption characteristics can be further improved.

  Although it does not specifically limit as the skin material layer 11 of the said fiber mat base material 1, For example, the thing by which the pile was planted on the base fabric, a needle punch nonwoven fabric, etc. are mentioned. And there is no restriction | limiting in particular as a fiber which comprises this skin material layer 11, For example, a polypropylene fiber, a polyester fiber, a polyamide fiber, an acrylic fiber etc. are mentioned. In addition, in the structure where the pile was planted on the base fabric, latex for preventing the pile from coming off may be applied to the back surface of the base fabric. In addition, the form of the pile and the type of yarn and fiber are not limited, but the form is cut pile or loop pile, the type of thread is BCF yarn, spun yarn, monofilament yarn, etc. The type of fiber is polyester, polypropylene, polyamide , Acrylic, cotton, wool and the like.

The sound absorbing layer 12 of the fiber mat substrate 1 is not particularly limited, but a nonwoven fabric such as a needle punched nonwoven fabric or a spunbonded nonwoven fabric is suitable because it is lightweight and excellent in sound absorbing properties. Therefore, it is recommended that such a nonwoven fabric has a thickness of about 3 to 30 mm and a basis weight of about 200 to 1000 g / m ^{2 in} order to ensure sufficient sound absorption performance.

  Although it does not specifically limit as said upper sheet | seat 2A, 2B, Like the skin material layer 11 of the said mat | matte base material 1, the thing by which the pile was planted on the base fabric, a needle punch nonwoven fabric, etc. are mentioned. . Further, there are no particular restrictions on the form of the piles and the types of yarns and fibers in the construction in which the piles are planted on the constituent fibers of the upholstery sheets 2A and 2B. Specifically, the mat base material The thing similar to what was already described as 1 skin material layer 11 is mentioned.

  In the above embodiment, the mat base material 1 and the upper sheets 2A and 2B are configured to be bonded by the breathable hot melt resin layer 5, but are not particularly limited to such a configuration. For example, it may be configured to be bonded by a non-breathable adhesive layer. However, it is preferable to adopt a configuration in which the breathable hot-melt resin layer 5 is adhered in that the sound absorption characteristics can be further improved.

  The means for forming the breathable hot melt resin layer 5 on the back side of the upper sheet 2A, 2B is not particularly limited, but the melt hot melt resin is applied from the application nozzle hole by a so-called curtain coating technique. A method of applying a fiber by discharging (for example, see JP-A-2006-111256) is recommended. In this method, the breathability of the breathable hot melt resin layer 5 can be set within a suitable range in relation to the sound absorption characteristics to ensure good sound absorption, and the breathable hot melt resin layer 5 is formed into a uniform fiber layer shape. Therefore, there is an advantage that good adhesiveness can be obtained even with a small amount of application, and flexibility as a mat can be sufficiently secured.

  That is, as shown in FIG. 3, the upper sheet original fabric 20 is pulled up from the original fabric roll 20a between the pair of downstream conveying rolls 7 and 7 so that the back side when used as the upper sheet is directed upward. When the resin 5a is continuously fed out and passed over the support base 8, the molten hot melt resin 5a is discharged from a large number of nozzle holes of the curtain spray coating device 9 disposed above, and the resin 5a is discharged into the airflow forming nozzle. The fiber is stretched into a fiber shape by contact with a pressurized air flow from and then lowered into a curtain shape in the width direction as a whole. The descending molten hot melt resin 5a is applied to the surface of the upper sheet raw fabric 20 to form a porous resin layer in a state where the adjacent fibrous bodies come into contact with each other to form a mesh.

  And when the upper sheet | seat original fabric 20 which provided the said porous resin layer is drawn in between a pair of conveyance rolls 7 and 7, in order to prevent that hot-melt resin adheres to the conveyance rolls 7 and 7 surface. The resin film 6 continuously drawn out from the film roll 60 is laminated on the porous resin layer side, and then the porous resin layer is cooled in the process of passing through the air-cooling type cooling device 21 so that the air-permeable hot melt resin. Layer 5 is formed.

  Thus, the obtained upper sheet original fabric 20 in which the obtained breathable hot melt resin layer 5 and the resin film 6 are integrated is cut into a required shape (in this embodiment, a leaf shape) (including punching), and the upper sheet. And At this time, in the upper sheet M1 of the first embodiment, the resin film 6 is peeled off and cut into a required shape, or the resin film 6 is peeled off after cutting into a required shape. Therefore, in this first embodiment, there are no restrictions on the material and properties of the resin film 6. On the other hand, in the upper sheet M <b> 2 of the second embodiment, a breathable thermoplastic resin film 6 </ b> A is used as the resin film 6 and is used in a state where it is attached.

  Further, the mat base material 1 having a laminated structure used for the mats M1 and M2 of the first and second embodiments is a skin material layer instead of the upper sheet original fabric 20 and the resin film 6 in the curtain coating technique described above. 11 and the sound-absorbing layer 12 are used in the same manner and are continuously manufactured in the same manner. The molten hot melt resin 5a in this case forms the breathable hot melt resin layer 13.

  The hot melt resin used for the breathable hot melt resin layers 5 and 13 is not particularly limited, and examples thereof include ethylene-vinyl acetate copolymer, styrene elastomer resin, polyester resin, olefin resin, and polyamide resin. Can be mentioned. Among these, from the viewpoint of securing sufficient heat resistance and water resistance as a mat, an olefin resin is particularly preferable, and a resin composition containing an olefin resin and a rubber component is more preferable. In other words, by containing a rubber component, the resin is modified, and it becomes difficult to cut when the molten hot melt resin is brought into contact with the air flow, so that the molten hot melt resin is sufficiently stretched. A quality resin layer can be formed.

  Although it does not specifically limit as said olefin resin, For example, polyethylene, a polypropylene, an amorphous poly alpha olefin resin etc. are mentioned. Among these, the amorphous polyα-olefin resin is particularly preferable because of the advantage of improving the adhesive strength. Although it does not specifically limit as this amorphous poly alpha olefin resin, For example, an amorphous polypropylene, an amorphous ethylene-propylene copolymer, an amorphous propylene-butene-1 copolymer etc. are mentioned.

  Although it does not specifically limit as said rubber component, For example, polybutylene, SBR, NBR, SEBS (styrene-ethylene-butylene-styrene copolymer), SIS (styrene-isoprene-styrene copolymer) etc. are mentioned. Among these, polybutylene is particularly recommended because it has the effect of further improving the stretchability of the molten resin and the uniformity of the coating state.

  Further, the hot melt resin used for the breathable hot melt resin layers 5 and 13 preferably contains a tackifier. Examples of the tackifier include rosin resin, terpene resin, petroleum resin (C5 to C9 fraction, etc.) and the like. Examples of the rosin resin include raw rosin, esterified rosin, polymerized rosin, hydrogenated rosin, and disproportionated rosin. Examples of the terpene resin include aromatic modified terpenes and phenol modified terpenes. Examples of the petroleum resin include aliphatic, aromatic, copolymers thereof, and hydrogenated systems.

  The hot melt resin preferably contains a liquid component such as wax. Examples of the wax include paraffin wax and microcrystalline wax. Furthermore, it is also possible to use a foamable hot melt resin as the hot melt resin.

  As a means for adhering the upper sheets 2A and 2B to the mat substrate 1, for example, a method that can utilize the weldability of the breathable hot melt resin layer 5 is preferable, but high-frequency welder processing is particularly recommended. This high-frequency welder process is a technique in which a substance having a large dielectric loss is placed in a high-frequency electric field to generate heat and soften it, and pressure welding is performed, and there is an advantage that it can be reliably welded in a short time. In the present invention, in addition to the above advantages, the concave groove 3 along the peripheral edge can be formed simultaneously with the adhesion of the upper sheets 2A and 2B by high-frequency welder processing, so that high productivity can be obtained.

  In this high-frequency welder processing, first, as shown in FIG. 4 (a), the upper sheets 2A and 2B having the breathable hot melt resin layer 5 on the back side are arranged at predetermined positions on the fiber mat substrate 1, The high frequency electrode 22 is positioned on the peripheral edge. Then, as shown in FIG. 4 (b), the high-frequency electrode 22 is lowered and pressed against the peripheral portions of the upper sheets 2A and 2B to apply a high-frequency electric field. The layer 5 generates heat by high frequency and melts, and the peripheral portions of the upper sheets 2A and 2B adhere to the mat substrate 1 through the molten resin, and the upper sheets 2A and 2B and the mat base are bonded at the pressing position. The material 1 is compressed while being heated and melted by a high frequency, and a concave groove portion 3 is formed along the peripheral edge portion at the peripheral edge portions of the upper sheets 2A and 2B.

  In the present embodiment, the contact surface (pressing surface) of the high-frequency electrode 22 is formed as a flat surface (see FIG. 4). As a result of such a flat surface, the embossed feeling due to the formation of the recessed groove portion 3 is emphasized, and the designs and patterns by the upper sheets 2A and 2B are visually recognized with a sufficient three-dimensional effect as in the embossed. As a result, a very high design property can be obtained. Especially, it is preferable that the width (W) of this flat surface is set to 4-9 mm, and especially preferable width (W) is 5-8 mm.

  In FIG. 4, the electrode disposed opposite to the high-frequency electrode 22 is omitted, but the entire lower surface side of the mat substrate 1 is placed on the electrode. Although not shown, in the mat M2 of the second embodiment, the thermoplastic resin film 6A bonded to the lower surface side of the upper sheets 2A and 2B is the same as the breathable hot melt resin layer 5 by high-frequency welding. Then, it melts at the pressing position of the high-frequency electrode 22 and has an adhesive (welding) effect on the mat substrate 1.

  In the above-described embodiment, the high-frequency electrode 22 is pressed against only the peripheral portions of the upper sheets 2A and 2B to apply a high-frequency electric field. In addition, for example, the high-frequency electrode 22 is applied to the upper sheets 2A and 2B. A high-frequency electric field may be applied by pressing also on the center line portion. In this case, linear concave grooves are also formed in the centerline regions (positions corresponding to the thickest leaf vein (main vein) at the center of the leaf) of the leaf-shaped upper sheets 2A and 2B in the mat M shown in FIG. Will be.

  In the above embodiment, the mat substrate 1 has a laminated structure in which the skin material layer 11 and the sound absorbing layer 12 are joined via the breathable hot melt resin layer 13. It includes various configurations in which the mat substrate includes a single layer structure and configurations of various fiber materials.

  Moreover, in this invention, the shape of the mat | matte base material 1 and the upper sheet | seats 2A and 2B, a structure | tissue form, a hue, the width and depth of the groove part 3 along the periphery of the upper sheet | seats 2A and 2B, and the thickness of each component part For the detailed configuration, various design changes can be made in addition to the above embodiment.

  For example, the mat substrate 1 and the upper sheets 2A and 2B may have different structures and colors. For example, a configuration in which the skin material layer 11 of the mat substrate 1 includes a cut pile, a surface layer of the upper sheets 2A and 2B includes a loop pile, and a structure in which colors are different between the cut pile and the loop pile. Is mentioned.

  Or it is good also as a structure from which the mat | matte base material 1 and upper sheet | seat 2A, 2B differ only by a structure | tissue form. For example, a configuration in which the skin material layer 11 of the mat base material 1 includes a cut pile, and a surface layer of the upper sheets 2A and 2B includes a loop pile of the same color as the cut pile is exemplified.

  Alternatively, the mat substrate 1 and the upper sheets 2A and 2B may be different from each other only in hue. For example, the skin material layer 11 of the mat substrate 1 includes a cut pile, and the surface layers of the upper sheets 2A and 2B include a cut pile, and the former cut pile and the latter cut pile have different colors. Examples include a squeezed configuration.

  Moreover, in the said embodiment, although leaf shape was employ | adopted as a planar view shape of upholstery sheet 2A, 2B, it is not limited to such a shape in particular, For example, a triangle, a square, a pentagon, etc. In addition to polygonal shapes, circular shapes, and the like, shapes punched into various designs and patterns, and the like can be given.

It is a top view which shows an example which applied the mat of this invention to the floor mat for driver's seats of a motor vehicle. FIG. 1 is a cross-sectional view taken along line XX in FIG. 1, (A) is a cross-sectional view in the first embodiment, and (B) is a cross-sectional view in the second embodiment. It is a manufacturing process figure of the raw material of the upper sheet used for the mat. The adhesion operation by the high frequency welding process of the upper sheet | seat with respect to the mat base material in the same mat | matte is shown, (A) is sectional drawing before adhesion | attachment, (B) is sectional drawing at the time of adhesion | attachment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Mat base material 2A, 2B ... Overlay sheet 3 ... Groove part 5 ... Breathable hot melt resin layer 5a ... Molten hot melt resin 6 ... Resin film 6A ... Breathable thermoplastic resin film 7 ... Conveyance roll 9 ... Curtain Spray coating device 20 ... Upper sheet original fabric M, M1, M2 ... Matte

Claims (9)

  A mat, wherein a fiber upper sheet is bonded to a part of the upper surface of the mat base material, and a concave groove along the peripheral edge is formed at the peripheral edge of the upper sheet.   A fiber upper sheet is bonded to a part of the upper surface of the fiber mat base material through a breathable hot melt resin layer, and a concave groove along the peripheral edge is formed at the peripheral edge of the upper sheet. A mat that is formed.   The mat according to claim 2, wherein a breathable thermoplastic resin film is laminated between the fiber mat substrate and the breathable hot melt resin layer.   4. The mat according to claim 2, wherein the breathable hot melt resin layer is composed of a porous resin layer formed by applying a molten hot melt resin in a fibrous form by being discharged from an application nozzle hole.   The fiber upper sheet original fabric provided with an adhesive layer on the back side is cut into a required shape, and the obtained upper sheet of the required shape is placed on the mat substrate, and the periphery of the upper sheet By applying a high frequency welder process along the part, the peripheral part of the upper sheet is bonded to the mat base material, and a concave groove part along the peripheral part is formed in the peripheral part of the upper sheet. A method for manufacturing a mat.   Cutting the fiber upper sheet raw fabric with a breathable hot melt resin layer formed on the back side into a required shape, and placing the obtained upper sheet of the required shape on the fiber mat substrate, By applying high-frequency welder processing along the peripheral edge of the upper sheet, the peripheral edge of the upper sheet is bonded to the fiber mat substrate via the hot melt resin layer, and the peripheral edge of the upper sheet A method for producing a mat according to claim 1, wherein a concave groove portion is formed along the peripheral edge portion.   A breathable thermoplastic resin film is continuously laminated on the back side of the upper sheet original fabric on which the breathable hot melt resin layer is formed, and is taken up by a pair of rolls, and then the thermoplastic resin film is laminated. The method for producing a mat according to claim 6, wherein the high-frequency welder process is performed in a state where the thermoplastic resin film is provided using an upper sheet obtained by cutting an original upper sheet into a required shape. On the back side where the breathable hot melt resin layer of the upper sheet original fabric is formed, the resin film is continuously overlapped and taken up by a pair of rolls,
The high frequency welder process is performed using an upper sheet obtained by peeling the resin film and cutting into a required shape, or using an upper sheet obtained by peeling the resin film after cutting into a required shape. The manufacturing method of the mat | matte of description.   The melted hot melt resin discharged from the coating nozzle hole is brought into contact with the air stream ejected from the air stream forming nozzle hole and stretched to make the hot melt resin into a fibrous form, and the curtain-like hot formed by these fibrous bodies. The method for producing a mat according to any one of claims 6 to 8, wherein the breathable hot melt resin layer is formed by applying a melt resin to a back surface side of the original sheet of the upper sheet.

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