JP2011045641A - Rubber mat - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a rubber mat which has an excellent shock-absorbing effect and slip-suppressing effect and moreover has excellent durability. <P>SOLUTION: The rubber mat includes a body and a peripheral edge portion, and the body integrally includes a large number of columnar protrusions on the surface. In the plane view, protrusion parts 31 are arranged so that the centers thereof are at all the vertex positions and the center positions of a regular hexagon to constitute a first unit X composed of seven protrusions parts 31. First units X are arranged so that the centers thereof are at all the vertex positions and the center positions of a regular hexagon to constitute a second unit Y composed of seven first units X. The second unit Y are arranged so as to avoid overlapping and to align in four directions to constitute the arrangement form of the protrusions parts 31. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a rubber mat that is excellent in impact absorption effect, slip suppression effect, and the like, and also has excellent durability.

  A rubber mat having a large number of cylindrical protrusions on the surface is conventionally known. As an arrangement of the protrusions, for example, “60 degree staggered arrangement” shown in FIG. 5 is known. In such a conventional rubber mat, the gap 30 between the protrusions 31 constitutes a wide linear passage 300 (see Patent Document 1).

Japanese Patent No. 3450775

In the conventional rubber mat in which the protrusions 31 are arranged in a staggered manner, the gap 30 between the protrusions 31 constitutes a wide linear passage 300, and thus has the following problems.
(1) The grip force tends to be relatively weak in a direction parallel to the straight passage 300.
(2) The impact absorbing effect varies in the surface direction of the rubber mat.
(3) When a bowl or other utensil falls on the rubber mat, the damage prevention effect is extremely insufficient on the wide straight passage 300 even if the damage prevention effect is sufficient on the protrusion 31. It is.

  An object of the present invention is to provide a rubber mat which is excellent in impact absorption effect, slip suppression effect and the like, and further has excellent durability.

  The present invention has a main body portion and an edge portion at the peripheral edge of the main body portion, and the main body portion has a large number of cylindrical or substantially cylindrical protrusions integrally on the surface. The protrusions have a center that is located at all or substantially vertex positions of a regular hexagon or a substantially regular hexagon, and at a center position or a substantially center position in a plan view. , Arranged to constitute a first unit composed of seven protrusions, and the first unit has a center that is a regular hexagon or a substantially regular hexagon at all vertex positions or substantially vertex positions; and It is arranged so as to be at the central position or the substantially central position, and constitutes a second unit composed of seven first units, and the second units are arranged so as not to overlap each other and arranged in four directions. Thus, the arrangement form of the protrusions is configured. It is characterized by a door. Such an arrangement of the protrusions is referred to as a “hexagonal arrangement”.

The present invention preferably further adopts the following configurations (a) to (c).
(A) The ratio of the total area of the upper end surface of a projection part with respect to the total area in planar view of a main-body part is 20 to 35%.
(B) The protrusion has a cylindrical shape or a substantially cylindrical shape, the diameter of the upper end surface of the protrusion is 2 to 4 mm, and the height of the protrusion is 1.5 to 3 mm. The gap between adjacent protrusions is 2 to 3 mm.
(C) The main body has a structure in which a reinforcing sheet and further a non-foamed rubber layer are laminated and integrated on the foamed rubber layer, and the non-foamed rubber layer is integrated on the surface. In addition, it has a large number of protrusions.

  According to the rubber mat of the present invention, since the protrusions are arranged in a “hexagonal arrangement”, the following effects can be exhibited.

(1) When the size of the gap between adjacent protrusions is the same as, for example, “60 degree staggered arrangement”, the rubber mat of the present invention has a unit per unit area as compared with the case of “60 degree staggered arrangement”. The number of protrusions can be reduced. Therefore, the production cost can be reduced and the weight of the mat can be reduced as compared with the case of “60 degrees staggered arrangement”.

(2) In “hexagonal arrangement”, when a straight line segment passing through the gap between adjacent protrusions is drawn in a plan view, even if the pitch of the protrusions is relatively large, Regardless of whether the diameter is relatively small or drawn in any direction from any position (in any direction to the inside of the mat), a configuration in which the line segment has a finite length can be designed. That is, since the protrusions can be randomly arranged as compared to the staggered arrangement, it is possible to suppress the gap between the protrusions from forming a wide linear passage. Therefore, the mat can exhibit excellent gripping force in any linear direction.

(3) It is possible to prevent all of the long objects from being fitted into the gaps between adjacent protrusions. For example, when a thin dish falls on a mat with the surface vertical, and the length of the edge part of the dish is equal to or longer than a predetermined value, the edge parts of the dish are adjacent to each other according to the present invention. It can be prevented from fitting into the gap between the protrusions, and thus can exhibit an effect of preventing damage. However, according to the case of “60 degrees staggered arrangement”, the edge portion of the dish is fitted into the gap between the adjacent protrusions. The danger cannot be avoided.

  When the ratio of the total area of the upper end surfaces of the protrusions to the total area of the main body in plan view is less than 20%, a sufficient impact absorbing effect may not be exhibited. On the other hand, when the ratio exceeds 35%, the rebound height of the fixtures dropped on the mat increases, and the dropped fixtures may jump out of the mat and hit the floor and be damaged. However, according to the configuration (a), such a problem can be solved.

  Moreover, when the diameter of the upper end surface of a projection part is less than 2 mm, durability of a projection part may be inferior. On the other hand, if the diameter of the upper end surface of the protrusion exceeds 4 mm, it may not be possible to make as many protrusions as necessary to exhibit a sufficient impact absorbing effect in the unit area. When a fixture such as a cup or a dish falls on the mat, there is a possibility that a place where the rebound becomes large is generated. However, according to the said structure (b), such a malfunction can be eliminated.

  Moreover, when the height of the protrusion is less than 1.5 mm, the mat becomes unsatisfactory, and the impact absorbing effect of the mat may not be sufficient. On the other hand, when the height of the protrusion exceeds 3 mm, the durability of the protrusion may be inferior. However, according to the said structure (b), such a malfunction can be eliminated.

  Furthermore, when the gap between the closest protrusions is less than 2 mm, it is difficult to remove the foreign matter sandwiched between the protrusions. On the other hand, when the gap between the closest protrusions exceeds 3 mm, the impact absorption effect may be insufficient. However, according to the said structure (b), such a malfunction can be eliminated.

According to the configuration (c), the following effects can be exhibited.
(I) Since the foam rubber layer is provided, the weight per unit area can be reduced as compared with a mat made of only non-foam rubber. Therefore, it is easy to handle.

(Ii) Since the non-foamed rubber layer has a large number of protrusions on the surface, the impact received by the entire non-foamed rubber layer can be suitably mitigated. In addition, since the foamed rubber layer is provided below the non-foamed rubber layer, the impact received by the non-foamed rubber layer can be reduced by the foamed rubber layer. Therefore, an excellent impact absorbing effect can be exhibited as compared to a mat made of only non-foamed rubber. In addition, since an excellent impact absorbing effect can be exhibited, a suitable fatigue reducing effect can be exhibited when stepping on the mat or working on the mat for a long time. Moreover, since the outstanding impact-absorbing effect can be exhibited, when a fixture such as a cup or a dish falls on the mat, a suitable damage prevention effect can be exhibited. Moreover, since it has the outstanding impact-absorbing effect and has many protrusion parts, when walking on a mat | matte, a suitable slip suppression effect can be exhibited.

(Iii) The non-foamed rubber layer has a protrusion on the surface, and the protrusion is integrally formed as a part of the non-foamed rubber layer. As compared with the rubber mat 1, excellent durability can be exhibited.

(Iv) Since the reinforcing sheet is provided under the non-foamed rubber layer, the impact received by the non-foamed rubber layer can be further reduced. Further, since the entire mat can be reinforced by the reinforcing sheet, the durability of the mat can be improved.

It is a plane fragmentary view of the rubber mat of one embodiment of the present invention. It is II-II arrow sectional drawing of FIG. It is sectional drawing which shows the manufacturing method of the rubber mat of FIG. FIG. 2 is a partial plan view of a porous plate for producing the rubber mat of FIG. 1. FIG. 6 is a partial plan view of a conventional “60 ° staggered arrangement” rubber mat. FIG. 6 is a partial plan view of a conventional “parallel arrangement” rubber mat. FIG. 6 is a partial plan view of a conventional “square staggered” rubber mat.

  FIG. 1 is a partial plan view of a rubber mat according to an embodiment of the present invention. 2 is a cross-sectional view taken along the line II-II in FIG. In FIG. 2, a part of the perforated plate used for manufacturing the rubber mat is also shown.

  The rubber mat 10 according to this embodiment includes a main body portion 101 and an edge portion 102. The edge portion 102 is formed on the periphery of the main body portion 101. Therefore, according to the rubber mat 10 of this embodiment, the edge part 102 can protect the edge part of the main-body part 101 suitably. Therefore, a mat with good durability can be obtained.

  The main body 101 has a three-layer structure in which a reinforcing sheet 2 and a non-foamed rubber layer 3 are laminated and integrated on the foamed rubber layer 1. The non-foamed rubber layer 3 has a large number of protrusions 31 integrally on the surface. The edge portion 102 is made of non-foamed rubber. Therefore, according to the rubber mat 10 of this embodiment, the following effects can be exhibited.

(1) Since the foamed rubber layer 1 is provided, the weight per unit area can be reduced as compared with a mat made only of non-foamed rubber. Therefore, it is easy to handle.

(2) Since the non-foamed rubber layer 3 has a large number of protrusions 31 on the surface, the impact received by the entire non-foamed rubber layer 3 can be suitably mitigated. In addition, since the foamed rubber layer 1 is provided below the non-foamed rubber layer 3, the impact received by the non-foamed rubber layer 3 can be reduced by the foamed rubber layer 1. Therefore, an excellent impact absorbing effect can be exhibited as compared to a mat made of only non-foamed rubber. In addition, since an excellent impact absorbing effect can be exhibited, a suitable fatigue reducing effect can be exhibited when stepping on the mat or working on the mat for a long time. Moreover, since the outstanding impact-absorbing effect can be exhibited, when a fixture such as a cup or a dish falls on the mat, a suitable damage prevention effect can be exhibited. Moreover, since it can exhibit the outstanding impact-absorbing effect and has many projection parts 31, when walking on a mat | matte, a suitable slip suppression effect can be exhibited.

(3) The non-foamed rubber layer 3 has a protruding portion 31 on the surface, and the protruding portion 31 is integrally formed as a part of the non-foamed rubber layer 3 and therefore is made of only foamed rubber. Compared to the mat and the rubber mat disclosed in Patent Document 1, excellent durability can be exhibited.

(4) Since the reinforcing sheet 2 is provided below the non-foamed rubber layer 3, the impact received by the non-foamed rubber layer 3 can be further alleviated. Further, since the entire mat can be reinforced by the reinforcing sheet 2, the durability of the mat can be improved.

  In the present embodiment, the protrusions 31 are arranged in a “hexagonal arrangement” as shown in FIG. In other words, as shown by the alternate long and short dash line A, the protrusion 31 is arranged at each vertex position of the small regular hexagon and the center position thereof, whereby the unit X composed of the seven protrusions 31 is configured. Has been. Further, as indicated by the alternate long and short dash line B, the unit X is arranged at each vertex position of the large regular hexagon and the center position thereof, whereby seven units X (ie, 49 protrusions) are arranged. A unit Y consisting of part 31) is constructed. And the unit Y is arrange | positioned so that it may not mutually overlap and it is located in a line in four directions. The regular hexagon may be a substantially regular hexagon, the vertex position may be a substantially vertex position, and the center position may be a substantially center position.

  In the above arrangement of the protrusions 31, in a plan view, when a straight line segment passing through the gap 30 between the adjacent protrusions 31 is drawn, it is drawn from which position to which direction (which direction to the inside of the mat). Even so, the line segment has a finite length. However, even when the gap 30 of the protrusion 31 is designed to be wide or when the diameter D of the protrusion 31 is designed to be small, the line segment is not finite (becomes a straight line or a half line). When the above-described arrangement of the protrusions 31 draws a straight line E having a width of 1 mm passing through the gap 30 between the adjacent protrusions 31 in plan view, from which position to which direction (inward to the mat) In any direction, if the line segment E has a finite length, substantially the same effect can be exhibited.

  The rubber mat 10 according to the present embodiment can exhibit the following effects when the protrusions 31 are arranged in a “hexagonal arrangement”.

(1) In the case where the dimension C of the gap 30 between the adjacent protrusions 31 is the same as in the “60 degree staggered arrangement” shown in FIG. 5, the rubber mat 10 of the present embodiment has the “60 degree staggered arrangement”. Compared to the case, the number of protrusions 31 per unit area can be reduced. Therefore, the production cost can be reduced and the weight of the mat can be reduced as compared with the case of “60 degrees staggered arrangement”.

(2) Since the protruding portion 31 is arranged so that the line segment E has a finite length as described above, the protruding portion 31 is arranged with no gap or almost no gap in any linear direction of the mat. Yes. Therefore, the mat can exhibit excellent gripping force in any linear direction. When the width of the line segment E is less than 1 mm, substantially the same grip force can be exhibited regardless of the width dimension. On the other hand, when the width of the line segment E is larger than 1 mm, there is a tendency that a linear direction with a weak grip force is generated particularly in a state where water or oil adheres to the mat. In particular, when the length of all the line segments E is 20 mm or less, more excellent grip force can be exhibited. On the other hand, in the part where the length of the line segment E is longer than 20 mm, there is a tendency that a linear direction having a weaker gripping force than that in the above case occurs particularly in a state where water or oil adheres to the mat.

(3) It is possible to prevent all the long objects 200 having the dimension L longer than the longest line segment E from being fitted into the gap 30 between the adjacent protrusions 31. Incidentally, in the case of “60 degrees staggered arrangement”, the long object 200 is fitted into the gap 30 as shown in FIG. 5. For example, when a thin plate falls on the mat with the surface vertical, and the length of the edge portion of the plate is L or more, according to the present embodiment, the edge portion of the plate is adjacent. It is possible to prevent the protrusions 31 from being fitted into the gaps 30, and thus to exhibit a damage prevention effect. However, according to the “60 degree staggered arrangement”, it is impossible to avoid the risk that the edge portion of the dish fits into the gap 30 between the adjacent protrusions 31. When the length of the line segment E is 20 mm or less, it is possible to prevent most of the edge portion from fitting into the gap 30 even if the edge portion is a sharp dish.

  Furthermore, in the rubber mat 10 of the present embodiment, the ratio of the total area of the upper end surface 310 of the protrusion 31 to the total area of the main body 101 in plan view is preferably 20 to 35%. If it is less than 20%, sufficient impact absorbing effect may not be exhibited. On the other hand, if it exceeds 35%, the rebound height of the fixture dropped on the mat becomes high, and the dropped fixture is outside the mat. There is a risk of jumping out and hitting the floor and damaging it.

  As can be seen from FIGS. 1 and 2, the protrusion 31 has a cylindrical shape. Note that the protrusion 31 may have a substantially cylindrical shape. The diameter D of the upper end surface 310 of the protrusion 31 is preferably 2 to 4 mm, and the height H of the protrusion 31 is preferably 1.5 to 3 mm.

  Since the protrusion 31 has a columnar shape or a substantially columnar shape, the durability of the protrusion 31 can be improved. In addition, when the diameter D of the protrusion 31 is less than 2 mm, the durability of the protrusion 31 may be inferior. On the other hand, when the diameter D exceeds 4 mm, it is necessary to exhibit a sufficient impact absorbing effect. There are cases where it is impossible to make as many protrusions 31 as possible, and there is a possibility that a place where rebound becomes large when a fixture such as a cup or a dish falls on the mat. In addition, when the height H of the protrusion 31 is less than 1.5 mm, the mat becomes sparse, and the impact absorbing effect of the mat may not be sufficient, while when the height exceeds 3 mm. The durability of the protrusion 31 may be inferior.

  The rubber mat 10 of the present embodiment preferably further has the following configuration.

(A) As for thickness T1 of the main-body part 101, 4-6 mm is preferable. If it is less than 4 mm, the impact absorbing effect tends to be insufficient, and the durability of the mat may be insufficient. On the other hand, when the distance exceeds 6 mm, there is a case where the user feels a difference in height and feels uncomfortable when moving from the floor to the mat while walking. In particular, in the case of a rubber mat, compared to a pile mat, there is a tendency to easily have discomfort due to a difference in height. In particular, in order to eliminate discomfort caused by the height difference, the thickness T1 of the main body 101 is preferably 5 mm or less.

(B) The thickness T3 of the foamed rubber layer 1 is preferably 1.5 to 4 mm. If it is less than 1.5 mm, the impact absorbing effect may not be sufficient. On the other hand, if it exceeds 4 mm, the mat sinking depth becomes large when the mat is stepped on, and the degree of freedom of the foot is likely to be restrained, and therefore there is a possibility that sufficient fatigue reduction effect cannot be exhibited. .

(C) The foaming ratio of the foamed rubber layer 1 is preferably 1.5 to 3 times. If it is less than 1.5 times, the impact absorbing effect may not be sufficient. On the other hand, if it exceeds three times, the depth of the mat sinking when the mat is stepped on becomes large, and the freedom of the foot is liable to be restrained. is there.

(D) The thickness T4 of the non-foamed rubber layer 3 other than the protrusions 31 is preferably 0.5 to 2 mm. If it is less than 0.5 mm, the impact absorbing effect may not be sufficient. On the other hand, when it exceeds 2 mm, it becomes difficult to bend and roll and store the mat, and it becomes difficult to handle.

(E) The hardness of the non-foamed rubber layer 3 is preferably 55 to 80 degrees. If it is less than 55 degrees, the impact absorbing effect may not be sufficient. On the other hand, when the hardness of the non-foamed rubber layer exceeds 80 degrees, the flexibility of the main body portion 101 is impaired, and it becomes difficult to store the mat by folding or winding it, which makes it difficult to handle. This hardness is measured by a durometer type A hardness meter.

(F) The end portion 102 has a thickness T2 of preferably 1 to 3 mm. When it is less than 1 mm, the durability of the edge portion 102 tends to be insufficient. On the other hand, when it is 3 mm or more, when the foot hits the edge part 102, the difference in height between the mat and the floor may be felt, and there may be an uncomfortable feeling. In particular, the thickness T2 of the end portion of the edge portion 102 is preferably 1.5 to 2 mm in order to sufficiently improve the durability and to eliminate the uncomfortable feeling caused by the difference in height.

(G) It is preferable that the foamed rubber layer 1, or the non-foamed rubber layer 3 and the foamed rubber layer 1 contain an ozone-resistant agent. According to this, even when rubber having low ozone resistance such as NBR is used, a mat having good durability can be obtained. When not only the foamed rubber layer 1 but also the non-foamed rubber layer 3 contains an ozone-resistant agent, a more durable mat can be obtained.

(H) The reinforcing sheet 2 is preferably made of a fiber structure, and particularly preferably has a mesh structure. As the fiber, synthetic fiber, natural fiber, regenerated fiber and the like can be used. In the case of the mesh structure, there is an advantage that the foamed rubber layer 1 and the non-foamed rubber layer 3 are brought into contact with each other through each mesh of the mesh structure and are reliably bonded. That is, since the foamed rubber layer 1 and the non-foamed rubber layer 3 can be suitably integrated, a more durable mat can be obtained. If the reinforcing sheet 2 is subjected to an adhesive treatment or an adhesive treatment, the foamed rubber layer 1 and the non-foamed rubber layer 3 can be more preferably integrated.

(I) It is preferable that the protrusion 31 has a texture or cut on the upper end surface 310. According to this, the slip suppression effect and the like can be enhanced.

(J) The foamed rubber layer 1 and / or the non-foamed rubber layer 3 may contain an antibacterial agent and / or an antifungal agent. According to this, hygiene can be further improved.

  Next, a method for manufacturing the rubber mat 10 having the above configuration will be described with reference to FIG.

[I] First, an unvulcanized foam rubber sheet 1A and an unvulcanized non-foam rubber sheet 3A are prepared. Both rubber sheets 1A and 3A are made of a predetermined rubber compound. As the rubber component in the rubber compound, nitrile rubber, acrylic rubber, urethane rubber, ethylene butadiene rubber, silicone rubber, isoprene rubber, styrene butadiene rubber, chloroprene rubber, butyl rubber, etc. can be used. From the viewpoint, nitrile rubber can be preferably used. Note that the rubber compound of the rubber sheet 1A contains a foaming agent.

[Ii] Next, the reinforcing sheet 2 and further the unvulcanized non-foamed rubber sheet 3A are laminated on the unvulcanized foamed rubber sheet 1A to form the laminate 100. At this time, an unvulcanized non-foamed rubber tape 102A made of the same rubber composition as the unvulcanized non-foamed rubber sheet 3A is placed on the periphery of the laminate 100 so that a part 102B is superimposed on the laminate 100. The unvulcanized non-foamed rubber tape 102A may be made of a rubber compound different from the unvulcanized non-foamed rubber sheet 3A.

[Iii] Next, with the porous plate 5 pressed against the surface of the unvulcanized non-foamed rubber sheet 3A and the surface of the part 102C of the unvulcanized non-foamed rubber tape 102A, the laminate 100 is thickened. The rubber sheets 1A and 3A and the rubber tape 102A are vulcanized by pressurizing and heating in the vertical direction. At this time, a part of the unvulcanized non-foamed rubber sheet 3 </ b> A flows into the holes 51 of the perforated plate 5 and is vulcanized to form the protrusions 31. In FIG. 3, the width dimension X1 of the part 102C is preferably 5 to 10 mm, and the width dimension X2 of the part 102B is preferably 10 to 20 mm. A release sheet (not shown) is stacked on the upper surface of the porous plate 5. As the perforated plate 5, a punching metal or a porous sheet made of silicone rubber can be preferably used.

  At this time, a part of the unvulcanized foamed rubber sheet 1A flows into the hole 51 of the perforated plate 5 together with a part of the unvulcanized non-foamed rubber sheet 3A, and the unvulcanized foamed foam is formed in the protrusion 31. A foamed rubber part derived from the rubber sheet 1A may be formed. In that case, the height of the foamed rubber portion in the protrusion 31 is preferably 30% or less of the height H of the protrusion 31, most preferably 10% or less, and most preferably none. This is because the impact absorbing effect of the mat is lowered and the durability of the protrusion 31 is lowered.

[Iv] Next, the porous plate 5 is removed from the surface of the obtained non-foamed rubber layer 3 and from the surface of the obtained non-foamed rubber tape (that is, the vulcanized non-foamed rubber tape portion).

[V] Then, the obtained non-foamed rubber tape (that is, the vulcanized non-foamed rubber tape portion) is trimmed to an appropriate width to obtain the edge portion 102.

  Thereby, the rubber mat 10 which has many protrusion parts 31 on the surface of the non-foamed rubber layer 3 is obtained.

(Examples 1-7 and Comparative Examples 1-3)
The rubber mats of Examples 1 to 7 have the form shown in FIGS. The rubber mat of Comparative Example 1 has the form shown in FIG. The rubber mat of Comparative Example 2 has the form shown in FIG. The rubber mat of Comparative Example 3 has the form shown in FIG.

  FIG. 5 shows “60 degree staggered arrangement”. In FIG. 5, a large number of protrusions 31 are arranged at equal intervals, and are arranged in a staggered manner in adjacent rows 3A and 3B. In the arrangement of FIG. 5, the apex angle α of the triangle Z formed by the protrusions 31 in the row 3A and the protrusions in the row 3B is 60 degrees. FIG. 6 shows “parallel arrangement”. In FIG. 6, a large number of protrusions 31 are arranged at equal intervals and in parallel in the vertical and horizontal directions. FIG. 7 shows a “square staggered arrangement”. In FIG. 7, a large number of protrusions 31 are arranged in a staggered manner in adjacent rows 3A and 3B. In the arrangement of FIG. 7, the apex angle β of the isosceles triangle Z constituted by the protrusions 31 in the row 3A and the protrusions 31 in the row 3B is 90 degrees. And Table 1 has shown eight structures of the rubber mat 10 of Examples 1-7 and Comparative Examples 1-3.

  The eight configurations include “thickness T3 of the foamed rubber layer 1”, “thickness T4 of the non-foamed rubber layer 3”, “height H of the protrusion 31”, “thickness T1 of the main body 101”, “ The diameter D of the protrusions 31, “average pitch P of the protrusions 31”, “ratio of the protrusions 31”, and “minimum gap dimension C between adjacent protrusions 31”.

  The rubber mats of these examples and comparative examples were manufactured as follows (see FIG. 3).

[I] An unvulcanized foam rubber sheet 1A was prepared. The unvulcanized foam rubber sheet 1A is obtained by blending a NBR polymer with a vulcanization acceleration aid, an activator, a reinforcing agent, a filler, a plasticizer, a vulcanizing agent, a vulcanization accelerator, an antiaging agent, a foaming agent, and the like. It consists of a rubber compound. Table 2 shows the rubber physical properties of the unvulcanized foam rubber sheet 1A. The rubber physical properties shown in Table 2 are physical properties when the unvulcanized foamed rubber sheet 1A is vulcanized without containing a foaming agent. Actually, the unvulcanized foam rubber sheet 1A contains a foaming agent so as to foam twice by vulcanization.

  An unvulcanized non-foamed rubber sheet 3A was also prepared. The unvulcanized non-foamed rubber sheet 3A is formed by blending a NBR polymer with a vulcanization acceleration aid, an activator, a reinforcing agent, a filler, a plasticizer, a vulcanizing agent, a vulcanization accelerator, an antiaging agent, and the like. It consists of a rubber compound. The rubber physical properties of the unvulcanized non-foamed rubber sheet 3A are as shown in Table 3.

  Further, as the reinforcing sheet 2, a sheet having a net structure made of polyester fibers (specifically, a trade name “Kurenet E4500” manufactured by Kurashiki Boseki Co., Ltd.) was prepared.

  An unvulcanized non-foamed rubber tape 102A was also prepared. The unvulcanized non-foamed rubber tape 102A is made of the same rubber compound as the unvulcanized non-foamed rubber sheet 3A. The unvulcanized non-foamed rubber tape 102A may be made of a rubber compound different from the unvulcanized non-foamed rubber sheet 3A.

  Furthermore, an aluminum punching metal was prepared as the porous plate 5. As shown in FIG. 4, the perforated plate 5 has a large number of holes 51 in the above-described “hexagonal arrangement”. The pitch P between adjacent holes 51 is 5.5 mm, and the diameter D of the holes 51 is 3 mm. It is. Therefore, in the rubber mat 10 manufactured using the perforated plate 5, the diameter D of the protrusion 31 is 3 mm, and the dimension C of the gap 30 between the adjacent protrusions 31 is 2.5 mm.

  The unvulcanized foamed rubber sheet 1A and the unvulcanized non-foamed rubber sheet 3A have thicknesses that can satisfy the values of the four configurations shown in Table 1 according to the respective examples and comparative examples. Prepared. Here, the four configurations are “the thickness T3 of the foamed rubber layer 1”, “the thickness T4 of the non-foamed rubber layer 3”, “the height H of the protrusion 31”, and “the thickness of the main body 101”. Is "T1". The perforated plate 5 was prepared in accordance with each of the examples and comparative examples with a thickness that can secure the “height H of the protrusion 31” shown in Table 1.

[Ii] Next, the reinforcing sheet 2 and further the unvulcanized non-foamed rubber sheet 3A were laminated on the unvulcanized foamed rubber sheet 1A to form a laminate 100. At this time, an unvulcanized non-foamed rubber tape 102A was placed on the periphery of the laminate 100 so that a part 102B was superimposed on the laminate 100. The unvulcanized non-foamed rubber tape 102A has a thickness of 2 mm and a width of 4.5 mm.

[Iii] Next, with the porous plate 5 pressed against the surface of the unvulcanized non-foamed rubber sheet 3A and the surface of the part 102C of the unvulcanized non-foamed rubber tape 102A, the laminate 100 is thickened. The rubber sheets 1A and 3A and the rubber tape 102A were vulcanized by pressing and heating in the vertical direction. The strength of pressurization is 0.2 MPa, and the heating temperature is 180 ° C.

[Iv] Next, the porous plate 5 was taken out from the surface of the obtained non-foamed rubber layer 3 and from the surface of the obtained non-foamed rubber tape (that is, the vulcanized non-foamed rubber tape portion).

[V] Then, the obtained non-foamed rubber tape (that is, the vulcanized non-foamed rubber tape portion) was trimmed to an appropriate width to obtain an edge portion 102.

  For the rubber mat 10 thus obtained, five effects were evaluated. The results are shown in Table 4.

The evaluation means for the five effects are as follows.
(I) “Shock acceleration (G)”
The impact acceleration was measured when a predetermined cylindrical weight was dropped from the height of 10 cm onto the mat so that the cylindrical side surface collided with the mat surface in parallel. Here, the weight has a bottom diameter of 8 cm, a height of 1.8 cm, and a weight of 500 g. As a measuring machine, SR1100-1000B impact vibration acceleration recorder manufactured by Wistar was used. Similarly, the impact acceleration was also measured when it was dropped freely on the concrete floor. In addition, the numerical value of each Example in Table 4 is a ratio when the impact acceleration in the case of a concrete floor is set to 100.

(II) “Effect of falling object damage prevention”
Ten commercially available glass cups were dropped freely on a mat from a height of 85 cm with the drinking mouth facing downward, and the number of broken glass cups was determined. In the case of 0, it was determined as “◯”, in the case of 1-2, “Δ”, in the case of 3-5, “□”, and in the case of 6 or more, “x”.

(III) "Rebound height (maximum value, cm)"
A commercially available glass cup was dropped freely on a mat from a height of 85 cm with the drinking mouth facing downward, and the height of the glass cup was measured. In addition, when the glass cup broke, the height of the broken piece was measured.

(IV) “Direction of grip force”
It was investigated whether or not the user felt that the stepped-on force fell out in a specific direction when stepping on the rubber mat. The case of feeling is defined as “feeling direction”. When it did not feel, it was judged as “◯”, when it felt slightly, “□”, when it felt a little, “△”, when it felt, “×”.

(V) “Effect of preventing damage to protrusions”
It was determined whether or not the protrusion 31 was damaged when a load of 60 kgf and 400 cm ² was repeatedly applied 10,000 times to the mat from above. When it was not damaged at all, it was determined as “◯”, and when even a part was damaged, it was determined as “x”.

  As shown in Table 4, the impact acceleration of the rubber mats of Examples 1 to 7 is considerably smaller than that of the concrete floor. Therefore, the rubber mats of Examples 1 to 7 are excellent in impact absorbing effect.

  Moreover, the fall object damage prevention effect of the rubber mat of Examples 1-7 is excellent compared with the case of a concrete floor.

  Moreover, the other effects of the rubber mats of Examples 1 to 7 were also excellent as compared with the comparative example.

  Further, comparing Example 1 and Comparative Examples 1 to 3 in which the ratio (%) of the protrusions 31 is set to be approximately the same, it can be seen that various effects of Example 1 are excellent. Therefore, according to arrangement | positioning of the projection part 31 of Example 1, although the number of the projection parts 31 is small, the outstanding effect can be exhibited. Therefore, it can be said that the “hexagonal arrangement” is a very excellent arrangement.

  The rubber mat of the present invention has an excellent impact absorption effect, slip suppression effect, and the like, and also has excellent durability, and thus has great industrial utility value.

    DESCRIPTION OF SYMBOLS 1 Foam rubber layer 2 Reinforcement sheet 3 Non-foam rubber layer 31 Protrusion part 310 Upper end surface 100 Laminated body 101 Main body part 102 Edge part

Claims (4)

A main body part, and an edge part of a peripheral edge of the main body part;
The main body is a rubber mat having a large number of cylindrical or substantially cylindrical protrusions integrally on the surface,
In the plan view, the protrusions are arranged such that the center thereof is located at all the vertex positions or substantially vertex positions of the regular hexagon or the substantially regular hexagon, and at the center position or the substantially center position. The center of the first unit is a regular hexagon or a substantially regular hexagon at all vertex positions or substantially vertex positions, and at the center position or substantially center position. , Arranged so as to constitute a second unit composed of seven first units, the second units being arranged so as not to overlap each other and arranged in four directions, The arrangement form of the protrusion is configured,
A rubber mat characterized by that. The ratio of the total area of the upper end surface of the protrusion to the total area in plan view of the main body is 20 to 35%.
The rubber mat according to claim 1. The protrusion has a cylindrical shape or a substantially cylindrical shape,
The diameter of the upper end surface of the protrusion is 2 to 4 mm,
The height of the protrusion is 1.5 to 3 mm,
The gap between the closest projections is 2 to 3 mm.
The rubber mat according to claim 1. The main body has a structure in which a reinforcing sheet and further a non-foamed rubber layer are laminated and integrated on the foamed rubber layer,
The non-foamed rubber layer has a large number of protrusions integrally on the surface.
The rubber mat according to claim 1.

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