JP2012034929A - Method of manufacturing cleated mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing a cleated mat which has a high degree of freedom for choosing the shape of antiskid projections formed in the lower surface, enables pile of pile fabric to stand firmly and prevents the pile fabric from exfoliating from a rubber sheet easily.SOLUTION: The cleated mat is manufactured through the first vulcanization step in which an unvulcanized first rubber sheet 31 is set to a lower mold 10, an upper mold 20 is lowered and the top of the first rubber sheet is pressed with high pressure and vulcanized to form antiskid projections in the lower surface of the first rubber sheet and the second vulcanization step in which the top of the first rubber sheet finishing the first vulcanization step is covered with an unvulcanized second rubber sheet 32, the top is covered with a knitting fabric 33, the top of the knitting fabric is pressed with low pressure and the second rubber sheet is vulcanized to make the knitting fabric and the first rubber sheet integrated.

Description

  The present invention relates to a method for manufacturing a mat with anti-slip material for manufacturing a mat with anti-slip material that can be suitably used as an entrance mat or the like.

  A non-slip mat used for entrance mats, etc., which has a non-slip layer on the bottom side that is in contact with the installation surface such as the floor or the ground, and is provided with a plurality of piles on the top surface (hereinafter referred to as “pile” (Sometimes referred to as a “non-slip mat of the type”) (for example, Patent Documents 1 to 12). The pile-type mat with anti-slip is not only difficult to move against the installation surface, but also removes dirt on the shoe sole by scraping with the pile, so it is laid on the entrance of ordinary households and stores In addition, it is used for various purposes.

  Several methods of manufacturing a pile-type non-slip mat have been proposed. Among them, an unvulcanized rubber sheet is laid on the upper surface of the lower mold, and a pile fabric is laid on the upper surface of the rubber sheet. Manufacturing the rubber sheet is vulcanized and integrated into the rubber sheet by lowering the upper mold from above the fabric and heating the lower mold and / or the upper mold while pressing the upper surface of the pile fabric with the upper mold The method has become commonplace. On the upper surface of the lower mold, a concave portion for forming a non-slip convex portion is usually formed on the lower surface of the rubber sheet.

  However, the above-described method for producing a non-slip mat has a drawback that the degree of freedom in selecting the shape of the non-slip convex portion formed on the lower surface of the rubber sheet is low. This is because, in the above manufacturing method, if the convex portion for preventing slip formed on the lower surface of the rubber sheet is to have a complicated shape, it is necessary to press the rubber sheet at a high pressure when vulcanizing the rubber sheet. This is because when the pressing is performed at such a high pressure, the raw rubber forming the rubber sheet enters the upper part of the pile fabric, and the pile fabric pile is stuck to the rubber sheet and cannot be stood. If the pile of the pile fabric remains asleep, the dirt removal performance of the mat with anti-slip property cannot be expected.

  On the other hand, if the pressure of the upper mold when the rubber sheet is vulcanized is set low, the raw rubber forming the rubber sheet can be prevented from entering the top of the pile fabric, but the raw rubber is It becomes difficult to get into the recess formed on the upper surface of the mold. This tendency is particularly remarkable when the concave portion has a complicated shape or when the concave portion is formed deeply. As described above, in the manufacturing method described above, it is impossible to achieve both the formation of the convex portion for the slip prevention having a complicated shape on the lower surface of the rubber sheet and the pile of the pile fabric, and the slip prevention As a result, the shape of the convex portion was limited to a simple shape. Therefore, in the manufacturing method described above, there is a great limitation in improving the anti-slip performance of the resulting anti-slip mat.

  By the way, until now, instead of pressing the unvulcanized rubber sheet together with the pile fabric as in the above production method, by bonding the pile fabric to the upper surface of the rubber sheet after vulcanization with an adhesive, A method for producing a non-slip mat has also been proposed. According to the manufacturing method using this adhesive, since the formation of the anti-slip protrusion on the lower surface of the rubber sheet is performed independently of the adhesion of the pile fabric, the anti-slip protrusion having a complicated shape is formed. And making a pile of pile fabric stand up.

  However, a pile-type non-slip mat that adheres a rubber sheet and a pile fabric with an adhesive has difficulty in bonding strength between the rubber sheet and the pile fabric. In particular, when the mat with a non-slip is used outdoors exposed to wind and rain, the adhesive may deteriorate, and the pile fabric may naturally peel from the rubber sheet.

  The degree of freedom in selecting the shape of the anti-slip projections formed on the lower surface of the rubber sheet is high, and the anti-slip performance can be easily increased, and the pile fabric pile can stand firmly and exhibit excellent dirt removal performance. Although there is a demand for anti-slip mats that can prevent pile fabric from peeling off from rubber sheets and have excellent weather resistance and durability, anti-slip mats that combine all these conditions have been proposed so far. There wasn't.

No. 07-006848 Japanese Utility Model Publication No. 05-056059 Japanese Patent Laid-Open No. 05-329092 JP 05-245098 A Japanese Patent Laid-Open No. 08-047475 Japanese National Patent Publication No. 10-509341 Japanese Patent Laid-Open No. 08-215131 JP-A-10-225423 JP 2000-070107 A JP 2000-350696 A JP-A-2005-237800 Japanese Patent No. 4356082

  The present invention has been made to solve the above-described problems, and has a high degree of freedom in selecting the shape of the anti-slip convex portion formed on the lower surface of the anti-slip performance. Produce an anti-slip mat that can stand the pile of the pile fabric firmly and exhibit excellent dirt removal performance, and also has excellent weather resistance and durability that the pile fabric is difficult to peel off from the rubber sheet With the goal.

  [1] The first rubber sheet is formed by setting an unvulcanized first rubber sheet in a lower mold, lowering the upper mold, and vulcanizing while pressing the upper surface of the first rubber sheet at a high pressure. A first vulcanization step of forming a non-slip projection on the lower surface of the sheet, and [2] laying an unvulcanized second rubber sheet on the upper surface of the first rubber sheet after the first vulcanization step The second vulcanization that unifies the woven fabric with the first rubber sheet by laying the woven fabric (superior concept of pile fabric) on the upper surface and vulcanizing the second rubber sheet while pressing the upper surface of the knitted fabric at low pressure And a process for producing a non-slip mat having the following steps.

  Here, the description “pressing at high pressure” in the first vulcanization step and the description “pressing at low pressure” in the second vulcanization step are only relative descriptions, and the press pressure ( It only shows that the first vulcanization pressure is higher than the press pressure (second vulcanization pressure) in the second vulcanization step. In this way, by pressing (vulcanizing) in two steps, not only the convex part for slip prevention of complicated shape is formed, but also the first rubber sheet and the raw rubber that forms the rubber sheet on the punch are knitted It becomes possible not to enter the upper part of the ground. Therefore, it is possible to provide an anti-slip mat that not only has a high anti-slip effect but also can reliably remove dirt and moisture adhering to the sole. In addition, since the woven fabric is integrated with the first rubber sheet by vulcanizing the second rubber sheet, the knitted fabric is difficult to peel off from the first rubber sheet, and has a non-slip material that has excellent weather resistance and durability. It is also possible to provide a mat.

  In the method for producing a non-slip mat according to the present invention, the specific value of the first vulcanization pressure varies depending on the type of rubber used for the first rubber sheet, the size of the first rubber sheet, and the like, and is not particularly limited. . However, if the first vulcanization pressure is too low, there is a possibility that a convex portion having a complicated shape cannot be formed on the lower surface of the first rubber sheet. For this reason, the first vulcanization pressure is usually 5 MPa or more. The first vulcanization pressure is preferably 8 MPa or more, and more preferably 10 MPa or more. On the other hand, if the first vulcanization pressure is too high, the productivity of the mat with anti-slip may be lowered. For this reason, the first vulcanization pressure is usually 30 MPa or less. The first vulcanization pressure is preferably 25 MPa or less, and more preferably 20 MPa or less.

  The second vulcanization pressure is not particularly limited as long as it is lower than the first vulcanization pressure. However, if the second vulcanization pressure is too close to the first vulcanization pressure, the significance of performing pressing (vulcanization) in two stages is reduced. For this reason, the second vulcanization pressure is usually set 1 MPa or more lower than the first vulcanization pressure. The second vulcanization pressure is preferably 3 MPa or more lower than the first vulcanization pressure, and more preferably 5 MPa or more.

  The specific value of the second vulcanization pressure varies depending on the type of rubber used for the second rubber sheet, the dimensions of the second rubber sheet, and the like, and is not particularly limited. However, if the second vulcanization pressure is too low, the woven fabric becomes difficult to be integrated with the first rubber sheet, and the woven fabric may be easily peeled off from the first rubber sheet. For this reason, the second vulcanization pressure is usually 1 MPa or more. The second vulcanization pressure is preferably 1.5 MPa or more, and more preferably 2 MPa or more. On the other hand, if the second vulcanization pressure is too high, the unvulcanized rubber forming the second rubber sheet may enter the upper part of the woven fabric during the second vulcanization step. For this reason, the second vulcanization pressure is usually 10 MPa or less. The second vulcanization pressure is preferably 5 MPa or less, and more preferably 4 MPa or less.

  In the production method of the present invention, the type of the knitted fabric to be used is not particularly limited as long as it can remove dirt and moisture, but is preferably a pile fabric. Here, the “pile fabric” refers to a knitted fabric on which at least one side has a loop (loop pile) or fluff (cut pile) formed. In this way, the knitted fabric forming the upper surface of the mat with anti-slip is made of pile fabric, so that the mat with anti-slip is made easier to remove dirt and moisture, and the mat with anti-slip obtained is the entrance mat. For example, it can be used more suitably. In addition, when the pile fabric is strongly pressed against the unvulcanized rubber sheet, the unvulcanized rubber easily enters the eyes, and the significance of adopting the configuration of the present invention is deepened.

  In the production method of the present invention, the height of the convex portion formed on the lower surface of the first rubber sheet in the first vulcanization step varies depending on the use of the mat with anti-slip to be produced and is not particularly limited. However, if the convex portion on the lower surface of the first rubber sheet is too low, the significance of employing the manufacturing method of the present invention is reduced. For this reason, the height of the convex portion on the lower surface of the first rubber sheet is usually 0.5 mm or more. The height of the convex portion on the lower surface of the first rubber sheet is preferably 0.8 mm or more, and more preferably 1 mm or more. On the other hand, if the convex portion on the lower surface of the first rubber sheet is too high, the mat with anti-slip produced by the production method of the present invention may not be suitable for use as a rug. For this reason, the height of the convex part on the lower surface of the first rubber sheet is usually 10 mm or less, preferably 7 mm or less, more preferably 5 mm or less.

  As described above, according to the present invention, the degree of freedom in selecting the shape of the anti-slip convex portion formed on the lower surface of the pile can be increased, and the anti-slip performance can be easily improved, and the pile of the pile fabric can be made to stand firmly. In addition, it is possible to produce an anti-slip mat that can exhibit excellent dirt removal performance, and that the pile fabric is not easily peeled off from the rubber sheet and has excellent weather resistance and durability.

It is sectional drawing which cut | disconnected the state which set the unvulcanized 1st rubber sheet to the lower mold | die by the plane perpendicular | vertical to a 1st rubber sheet. The lower die is lowered from the state shown in FIG. 1, and the state in which the first rubber sheet is vulcanized while being pressed with the upper die (first vulcanization step) is cut along a plane perpendicular to the first rubber sheet. FIG. FIG. 3 is a cross-sectional view of the state in which the upper mold is raised from the state of FIG. 2 and the first vulcanization step is terminated, cut along a plane perpendicular to the first rubber sheet. It is sectional drawing which cut | disconnected the state which spread | laid the unvulcanized 2nd rubber sheet on the upper surface of the 1st rubber sheet of the state of FIG. 3 by the plane perpendicular | vertical to a 1st rubber sheet. FIG. 5 is a cross-sectional view of a state in which a knitted fabric is laid on the upper surface of the second rubber sheet in the state of FIG. 4 cut along a plane perpendicular to the first rubber sheet. The state in which the upper mold is lowered from the state of FIG. 5 and the second rubber sheet is vulcanized while pressing the upper surface of the knitted fabric with the upper mold at a low pressure (second vulcanization step) is perpendicular to the first rubber sheet. It is sectional drawing which showed the state cut | disconnected by the plane. FIG. 7 is a cross-sectional view of the state in which the upper mold is raised from the state of FIG. 6 and the second vulcanization step is terminated, cut along a plane perpendicular to the first rubber sheet. It is sectional drawing which showed the state which cut | disconnected the mat with a non-slip manufactured by the manufacturing method of this invention by the plane perpendicular | vertical to this mat with a non-slip. It is the bottom view which expanded and showed the lower surface of the mat | matte with a non-slip | skid manufactured by the manufacturing method of this invention. FIG. 10 is a bottom view further enlarging and showing the periphery of one convex portion in FIG. 9. It is sectional drawing which showed the state which cut | disconnected the one convex part for slip prevention formed in the lower surface of the mat with a slipper manufactured by the manufacturing method of this invention by the plane perpendicular | vertical to this convex part. It is the bottom view which expanded and showed the lower surface of the mat | matte with a non-slip | skid manufactured by the manufacturing method of another embodiment of this invention. It is the bottom view which expanded further and showed the periphery of the one convex part in FIG.

0. Outline of manufacturing method of mat with anti-slip A preferred embodiment of the manufacturing method of the mat with anti-slip of the present invention will be described more specifically with reference to the drawings. The manufacturing method of the mat with anti-slip of the present invention is to manufacture the mat 30 with anti-slip (see FIG. 8) through two vulcanization steps of the first vulcanization step and the second vulcanization step. Yes. The first vulcanization step and the second vulcanization step will be sequentially described in detail.

1. First vulcanization step The first vulcanization step is performed as follows. First, as shown in FIG. 1, an unvulcanized first rubber sheet 31 is set on the lower mold 10. FIG. 1 is a cross-sectional view of a state in which an unvulcanized first rubber sheet 31 is set in the lower mold 10, cut along a plane perpendicular to the first rubber sheet 31. On the upper surface of the lower mold 10, a plurality of recesses 11 for forming a non-slip protrusion 31 a (see FIG. 2) is formed on the lower surface of the first rubber sheet 31. The lower mold 10 is formed of a metal having excellent thermal conductivity, and the temperature can be easily increased.

  Each concave portion 11 formed in the lower mold 10 has a shape obtained by inverting a convex portion 31 a (see FIG. 8) provided on the lower surface of the first rubber sheet 31. The shape of the convex part 31a provided on the lower surface of the first rubber sheet 31 is not particularly limited as long as it has an anti-slip effect. The lower surface shape of each convex part 31a (the shape of the surface in contact with the laying surface (the ground surface, floor surface, etc.) of the convex part 31a) is appropriately determined according to the use of the mat with anti-slip obtained. Examples of the shape of the lower surface of each convex portion 31a include a polygon such as a triangle or a quadrangle, and a non-polygon having at least a part of its side formed by a curve, such as a circle, an ellipse, or a stag shape. . The plurality of convex portions 31 may be provided in a dot shape, or may be provided in a linear shape (linear shape or curved shape). When the convex portions 31 are formed in a linear shape, the respective linear convex portions may be provided in a matrix by intersecting in a plurality of directions.

  In the manufacturing method of this embodiment, as shown in FIG. 9 and FIG. 10, a mat 30 with a non-slip is provided in which a convex portion 31 a having a substantially V-shaped bottom surface is repeatedly provided. FIG. 9 is an enlarged bottom view of the lower surface of the non-slip mat 30 manufactured by the manufacturing method of the present invention. FIG. 10 is a bottom view further enlarging and showing the periphery of one convex portion 31a in FIG. Each convex part 31a belongs to any one of the convex part rows composed of a plurality of convex parts 31a arranged in the same direction. One convex part row | line | column is formed facing the other convex part row | line | column adjacent to this one convex part row | line | column. Thereby, it becomes possible to make the mat | matte 30 with a slipper excellent in the slip prevention performance in multiple directions. Moreover, all the gaps formed between the adjacent convex portions 31a are continuous. As a result, it is possible to prevent water or the like from accumulating between the mat 30 with anti-slip and the mat laying surface. This configuration is suitable when the mat 30 with a non-slip is used in a place where water is splashed (outdoors, bathroom, pool, etc.).

  The bending angle θ (see FIG. 10) of each convex portion 31a is not particularly limited as long as it is larger than 0 ° and smaller than 180 °. However, if the bending angle θ is too small, the bent portion of the convex portion 31a may not be effective for slip prevention, and water may easily accumulate in the gap between the convex portions 31a. For this reason, the bending angle θ is normally set to 30 ° or more. The bending angle θ is preferably 40 ° or more, and more preferably 50 ° or more. On the other hand, if the bending angle θ is too large, the strength of the convex portion 31a may be reduced, and the anti-slip performance in the longitudinal direction of the convex portion 31a may be reduced. For this reason, the bending angle θ is normally set to 150 ° or less. The bending angle θ is preferably 140 ° or less, and more preferably 130 ° or less.

In the production method of the present embodiment, as shown in FIG. 11, it is formed to be inclined a pair of side walls alpha ₂ of the base near the convex portion 31a. FIG. 11 is a cross-sectional view showing a state in which one anti-slip convex portion 31a formed on the lower surface of the anti-slip mat 30 manufactured by the manufacturing method of the present invention is cut along a plane perpendicular to the convex portion 31a. It is. Thus, by forming the inclined side walls alpha ₂ in the vicinity of the base of the convex portion 31a, increasing the section modulus around the base of the convex portion 31a, it is possible to increase the strength of the protrusion 31a. Inclination angle of the pair of side walls alpha ₂ in the vicinity of the base of the convex portion 31a phi (see Figure 11) is not particularly limited, is too small or too large, the effect of increasing the strength of the protrusion 31a Lower. For this reason, the inclination angle φ is normally 10 to 80 °. The inclination angle φ is preferably 20 to 70 °, and more preferably 30 to 60 °.

  By the way, when the lower surface shape of the convex portion 31a provided on the lower surface of the first rubber sheet 31 is substantially V-shaped, in addition to the arrangement shown in FIG. 9, N pieces (see FIG. 12 and FIG. 13) It is also preferable to repeatedly provide a group of convex portions 31 a having six convex portions 31 a arranged in N rotation symmetry (6 rotation symmetry in the examples of FIGS. 12 and 13). FIG. 12 is an enlarged bottom view of the lower surface of the anti-slip mat 30 manufactured by the manufacturing method according to another embodiment of the present invention. FIG. 13 is a bottom view further enlarging and showing the periphery of one convex portion 31a in FIG. Thereby, it becomes possible to make the convex part 31a further in multiple directions (N direction) and to make the mat 30 with anti-slip excellent in anti-slip performance in multiple directions. The value of N is not particularly limited, but is usually 3 to 10, preferably 4 to 8. The points where the gaps formed between adjacent convex portions 31a are all continuous, the pair of side walls in the vicinity of the root of the convex portion 31a are inclined, etc. are shown in FIG. 11). This configuration is also suitable when the mat 30 with a non-slip is used in a place where water is applied.

  In the first vulcanization step, the unvulcanized first rubber sheet 31 set in the lower mold 10 is obtained by masticating and kneading raw material rubber into a sheet shape. As raw material rubber to be used, natural rubber can be used in addition to synthetic rubber such as nitrile rubber, polybutadiene rubber or chloroprene rubber. Synthetic rubbers include nitrile rubber (NBR), acrylic rubber (ACM), isoprene rubber (IR), urethane rubber (U), ethylene propylene rubber (EPM), epichlorohydrin rubber (CO), chloroprene rubber (CR), silicone rubber Examples include (Q), styrene-butadiene rubber (SBR), butadiene rubber (BR) fluorine rubber (FKM), polyisobutylene rubber (IIR), and the like. In the manufacturing method of the present embodiment, nitrile rubber that is excellent in wear resistance, tear strength, oil resistance, and is inexpensive is used as the raw rubber of the first rubber sheet 31. When kneading the raw rubber, a reinforcing agent (carbon black or white carbon) is added to the kneaded raw rubber. The reinforcing agent is usually added in an amount of 30 to 60 parts by weight with respect to 100 parts by weight of the raw rubber. In addition to the reinforcing agent, additives such as a vulcanizing agent, a filler, an accelerator and a plasticizer may be added to the raw rubber.

  The planar view shape and dimension of the first rubber sheet 31 are not particularly limited. The shape and dimensions of the first rubber sheet 31 are appropriately determined according to the application of the mat with anti-slip to be manufactured. For example, when manufacturing an entrance mat laid at the entrance of a general household, the shape of the first rubber sheet 31 in plan view is usually a rectangular shape having a long side, a long axis, or a diameter of about 30 to 200 cm. , An elliptic shape (including a semi-elliptical shape) or a circular shape (including a semi-circular shape). When it is desired to obtain a mat with a non-slip having excellent design properties, other shapes such as a star shape can be selected. In the manufacturing method of this embodiment, the planar view shape of the first rubber sheet 31 is a rectangular shape having a long side length of 80 to 240 cm and a short side length of 60 to 150 cm. The planar view shape of the second rubber sheet 32 to be described later is also a rectangular shape having the same dimensions as the first rubber sheet 31.

  The thickness of the first rubber sheet 31 (thickness before vulcanizing the first rubber sheet 31) varies depending on the height of the convex portion formed on the lower surface thereof, and is not particularly limited. However, if the first rubber sheet 31 is too thin, it is impossible to form a high anti-slip projection on the lower surface of the first rubber sheet 31. For this reason, the thickness of the first rubber sheet 31 is usually not less than a value obtained by adding 0.3 mm to the height of the convex portion formed on the lower surface thereof. The thickness of the first rubber sheet is preferably not less than a value obtained by adding 0.5 mm to the height of the convex portion formed on the lower surface, and preferably not less than a value obtained by adding 0.7 mm to the height of the convex portion. . On the other hand, if the first rubber sheet 31 is made too thick, the resulting anti-slip mat will also become thick and may not be suitable for use as a non-slip mat such as a doormat. For this reason, the thickness of the first rubber sheet 31 is usually 4 mm or less. The thickness of the first rubber sheet 31 is preferably 3 mm or less, and more preferably 2.5 mm or less. In the manufacturing method of this embodiment, the thickness of the first rubber sheet 31 is 2 mm.

  Subsequently, as shown in FIG. 2, the upper mold 20 is lowered and the lower mold 10 and the upper mold 20 are heated by a heater (not shown) while pressing the upper surface of the first rubber sheet 31 with a high pressure. The rubber sheet 31 is vulcanized. FIG. 2 shows a state (first vulcanization step) in which the upper mold 20 is lowered from the state of FIG. 1 and the first rubber sheet 31 is vulcanized while being high-pressure pressed by the upper mold 20 (first vulcanization step). It is sectional drawing cut | disconnected by the plane perpendicular | vertical to. The upper mold 20 is formed of a metal having excellent thermal conductivity, like the lower mold 10, and can easily increase its temperature. In the manufacturing method of this embodiment, the press pressure (first vulcanization pressure) when pressing the first rubber sheet 31 with the upper mold 20 is 15 MPa. In this way, the first rubber sheet 31 is vulcanized while being pressed at a high pressure, whereby a non-slip convex portion 31 a can be formed on the lower surface of the first rubber sheet 31.

  The temperature at which the first rubber sheet 31 is vulcanized (first vulcanization temperature) varies depending on the raw rubber used for the first rubber sheet 31 and the type of vulcanizing agent added thereto, and is not particularly limited. However, if the first vulcanization temperature is too low, the first rubber sheet 31 may not be sufficiently vulcanized. In addition, the first rubber sheet 31 must be vulcanized for a long time, and the productivity of the mat 30 with anti-slip (see FIG. 8) may be reduced. For this reason, the first vulcanization temperature is usually 120 ° C. or higher. The first vulcanization temperature is preferably 130 ° C. or higher, and more preferably 140 ° C. or higher. On the other hand, if the first vulcanization temperature is too high, the time for vulcanizing the first rubber sheet 31 can be shortened, but the strength of the first rubber sheet 31 after vulcanization may be reduced. For this reason, the first vulcanization temperature is usually 200 ° C. or lower. The first vulcanization temperature is preferably 180 ° C. or lower, and more preferably 160 ° C. or lower. In the manufacturing method of this embodiment, the first vulcanization temperature is 150 ° C.

  The time for vulcanizing the first rubber sheet 31 (first vulcanization time) is the thickness of the first rubber sheet 31, the raw rubber used for the first rubber sheet 31, and the type of vulcanizing agent added thereto. There are no particular limitations. However, if the first vulcanization time is too short, the first rubber sheet 31 may not be sufficiently vulcanized. For this reason, the first vulcanization time is usually 2 minutes or longer. The first vulcanization time is preferably 3 minutes or more, and more preferably 4 minutes or more. On the other hand, if the first vulcanization time is too long, the productivity of the mat with anti-slip properties decreases. For this reason, the first vulcanization time is usually 15 minutes or less. The first vulcanization time is preferably 10 minutes or less, and more preferably 8 minutes or less. In the manufacturing method of this embodiment, the first vulcanization time is 6 minutes.

  When the vulcanization of the first vulcanized sheet 31 is completed, as shown in FIG. 3, the upper mold 20 is raised to the initial position, and the first vulcanization process is completed. FIG. 3 is a cross-sectional view of the state in which the upper mold 20 is raised from the state of FIG. 2 and the first vulcanization process is terminated, cut along a plane perpendicular to the first rubber sheet 31. When the first vulcanization step is completed, the following second vulcanization step is started.

2. Second vulcanization step The second vulcanization step is performed as follows. First, as shown in FIG. 4, an unvulcanized second rubber sheet 32 is laid on the upper surface of the first rubber sheet 31 after the first vulcanization step. FIG. 4 is a cross-sectional view of a state in which an unvulcanized second rubber sheet 32 is laid on the upper surface of the first rubber sheet 31 in the state of FIG. 3, cut along a plane perpendicular to the first rubber sheet 31. Similar to the first rubber sheet 31, the unvulcanized second rubber sheet 32 can be obtained by molding a raw rubber kneaded into a sheet. As the raw rubber for forming the second rubber sheet 32, the same rubber as mentioned for the first rubber sheet 31 can be employed. In the manufacturing method of the present embodiment, the same nitrile rubber as that of the first rubber sheet 31 is used as the raw rubber for forming the second rubber sheet 32. When kneading the raw rubber, 30 to 60 parts by weight of a reinforcing agent is added to 100 parts by weight of the kneaded raw rubber. Similar to the first rubber sheet 31, the raw rubber forming the second rubber sheet 32 may be separately added with additives such as vulcanizing agents, fillers, accelerators and plasticizers.

  The shape of the second rubber sheet 32 in plan view is not particularly limited as long as it is wider than a knitted fabric 33 (see FIG. 4) described later, but is usually the same as the first rubber sheet 31 or from the first rubber sheet 31. Is a little smaller. In the manufacturing method of this embodiment, the planar view shape of the second rubber sheet 32 is a rectangular shape having a long side length of 80 to 240 cm and a short side length of 60 to 150 cm. 31.

  The thickness of the second rubber sheet 32 (thickness before the second rubber sheet 32 is vulcanized) is determined depending on the type of raw rubber forming the second rubber sheet 32 and the woven fabric 33 (see FIG. 4) described later. It varies depending on the situation and is not particularly limited. However, if the second rubber sheet 32 is made too thin, there is a possibility that it will be difficult to integrate the woven fabric 33 described later into the first rubber sheet 31. In addition, there is a risk that the second rubber sheet 32 may be easily torn or that the second rubber sheet 32 may be difficult to lay on the upper surface of the first rubber sheet 31. For this reason, the thickness of the second rubber sheet 32 is usually 0.3 mm or more. The thickness of the second rubber sheet 32 is preferably 0.4 mm or more, and more preferably 0.5 mm or more.

  On the other hand, if the second rubber sheet 32 is too thick, the raw rubber forming the second rubber sheet 32 may enter the upper part of the knitted fabric 33 when the second rubber sheet 32 is vulcanized. That is, when the knitted fabric 33 is made of a pile fabric, the pile sticks to the second rubber sheet 32 and may not stand up. Moreover, the mat 30 with an anti-slip | skid (refer FIG. 8) obtained also becomes thick, and there exists a possibility that it may become unsuitable for use as mats with an anti-slip, such as a doormat. For this reason, the thickness of the second rubber sheet 32 is usually 3 mm or less. For this reason, the thickness of the second rubber sheet 32 is usually 3 mm or less. The thickness of the second rubber sheet is preferably 2 mm or less, and more preferably 1.5 mm or less. In the manufacturing method of this embodiment, the thickness of the second rubber sheet 32 is 1 mm.

  Subsequently, as shown in FIG. 5, a knitted fabric 33 is laid on the upper surface of the second rubber sheet 32. FIG. 5 is a cross-sectional view of the state in which the knitted fabric 33 is laid on the upper surface of the second rubber sheet 32 in the state of FIG. 4, cut along a plane perpendicular to the first rubber sheet 31. This knitted fabric 33 forms the upper surface of the mat 30 with anti-slip, and gives the mat 30 with anti-slip function. In the manufacturing method of the present embodiment, the knitted fabric 33 is made of a pile fabric, and the obtained mat 30 with anti-slip can be used as various mats such as an entrance mat. In the following, for the convenience of explanation, “knitted fabric” is referred to as “pile fabric”. The pile in the pile fabric 33 removes dirt and moisture from the shoe sole. The pile of the pile fabric 33 may be a cut pile, but is a loop pile in the manufacturing method of this embodiment.

  The type of yarn for knitting the pile fabric 33 is appropriately determined according to the use of the mat 30 with the non-slip. As the yarn for knitting the pile fabric 33, various yarns that do not change at the second vulcanization temperature described later can be used. Although natural fibers can be used for the yarn for knitting the pile fabric 33, the use of chemical fibers such as polyester-based synthetic fibers and polyamide-based synthetic fibers makes the pile fabric 33 excellent in strength and durability. be able to. Further, as the yarn for knitting the pile fabric 33, a yarn that has not been crimped may be used. However, in the manufacturing method of the present embodiment, the crimped yarn that has been crimped is piled up. The dough 33 is formed. This not only improves the pile return elasticity of the pile fabric 33 so that the pile does not stay asleep, but also improves the cushioning properties of the pile fabric 33. In addition, since the crimped yarn is easier to enter the raw rubber than the normal yarn because it is crimped, the use of the configuration of the present invention is deepened when the pile fabric 33 knitted with the crimped yarn is used. .

  The pile height of the pile fabric 33 (the height from the upper surface of the second rubber sheet 32 after vulcanization to the highest point of the pile) is not particularly limited, but if it is too low, dirt may not be removed by the pile. There is. For this reason, the pile height of the pile fabric 33 is normally 0.5 mm or more. The pile height of the pile fabric 33 is preferably 1 mm or more, more preferably 1.5 mm or more, and further preferably 2 mm or more. On the other hand, if the pile of the pile fabric 33 is too high, the resulting anti-slip mat 30 becomes thick and may not be suitable for use as an anti-slip mat such as a doormat. Further, in the second vulcanization step, the pressing force of the upper mold 20 described later may not be uniformly transmitted to the second rubber sheet 32. For this reason, the pile height of the pile fabric 33 is normally set to 30 mm or less. The pile height of the pile fabric 33 is preferably 20 mm or less, more preferably 15 mm or less, and even more preferably 10 mm or less. In the manufacturing method of this embodiment, the pile height of the pile fabric 33 is about 5 mm.

  Subsequently, as shown in FIG. 6, the upper mold 20 is lowered, and the lower mold 10 and the upper mold 20 are heated with a heater (not shown) while pressing the upper surface of the pile fabric 33 at a low pressure, and the second rubber sheet. 32 is vulcanized. FIG. 6 shows a state where the upper mold 20 is lowered from the state of FIG. 5 and the second rubber sheet 32 is vulcanized while pressing the upper surface of the knitted fabric 33 with the upper mold at a low pressure (second vulcanization step). 3 is a cross-sectional view showing a state cut along a plane perpendicular to the first rubber sheet 31. FIG. In the manufacturing method of this embodiment, the press pressure (second vulcanization pressure) when vulcanizing the second rubber sheet 32 (pressing the pile fabric 33 with the upper mold 20) is 3 MPa. In this way, the second rubber sheet 32 is vulcanized while being pressed at a low pressure, so that the raw material rubber forming the second rubber sheet 32 does not penetrate deep into the pile portion of the pile cloth 33 and the pile cloth 33 is moved to the first position. One rubber sheet 31 can be integrated. Therefore, the pile of the pile fabric 33 can stand firmly, and it is possible to obtain the non-slip mat 30 having a high dirt removing effect.

  By the way, the temperature at which the second rubber sheet 32 is vulcanized (second vulcanization temperature) varies depending on the raw rubber used for the second rubber sheet 32 and the type of vulcanizing agent added thereto, and is not particularly limited. . However, if the second vulcanization temperature is too low, the second rubber sheet 32 may not be sufficiently vulcanized. In addition, the second rubber sheet 32 has to be vulcanized for a long time, and the productivity of the mat 30 with anti-slip may be lowered. On the other hand, if the second vulcanization temperature is too high, the time for vulcanizing the second rubber sheet 32 can be shortened, but the strength of the second rubber sheet 32 after vulcanization is reduced, and the pile fabric 33 becomes the first. There is a possibility that the rubber sheet 31 may be easily peeled off. For this reason, the second vulcanization temperature is set in the same range as the first vulcanization temperature already described. In the manufacturing method of this embodiment, the second vulcanization temperature is 150 ° C.

  The time for vulcanizing the second rubber sheet 32 (second vulcanization time) is the thickness of the second rubber sheet 32, the raw rubber used for the second rubber sheet 32, and the type of vulcanizing agent added thereto. There are no particular limitations. However, if the second vulcanization time is too short, the second rubber sheet 32 may not be sufficiently vulcanized. On the other hand, if the second vulcanization time is too long, the productivity of the mat 30 with the anti-slip property is lowered. For this reason, the second vulcanization time is set in the same range as the second vulcanization time already described. In the manufacturing method of this embodiment, the second vulcanization time is 6 minutes.

  When the vulcanization of the second vulcanized sheet 32 is completed, the upper mold 20 is raised to the initial position as shown in FIG. 7, and the second vulcanization process is completed. FIG. 7 is a cross-sectional view of the state in which the upper mold 20 is raised from the state of FIG. 6 and the second vulcanization step is terminated, cut along a plane perpendicular to the first rubber sheet 31. The obtained anti-slip mat 30 may be cooled and packaged and then shipped as it is, but immediately after the second vulcanization process is completed, the pile of the pile fabric 33 is crushed by the upper mold 20. Therefore, the raising process which raises the pile by brushing the upper surface of the pile fabric 33 etc. may be performed. FIG. 8 is a cross-sectional view showing a state in which the anti-slip mat 30 manufactured by the manufacturing method of the present invention is cut along a plane perpendicular to the anti-slip mat 30.

3. Applications The anti-slip mat 30 manufactured by the manufacturing method of the present invention can be used as various mats. Among them, entrance mats, dust control mats, dustproof mats, water absorption mats, oiling mats, etc. can be used as mats to remove moisture and dirt from shoes and soles by placing them on the ground or floor. .

10 Lower mold 11 Recess 20 Upper mold 30 Non-slip mat 31 First rubber sheet 31a Projection 32 Second rubber sheet 33 Pile fabric (knitted fabric)

Here, the description “pressing at high pressure” in the first vulcanization step and the description “pressing at low pressure” in the second vulcanization step are only relative descriptions, and the press pressure ( It only shows that the first vulcanization pressure is higher than the press pressure (second vulcanization pressure) in the second vulcanization step. In this way, by performing pressing (vulcanization) in two stages, not only the convex part for slip prevention having a complicated shape is formed, but also the raw rubber forming the first rubber sheet and the second rubber sheet is knitted. It becomes possible not to enter the upper part of the ground. Therefore, it is possible to provide an anti-slip mat that not only has a high anti-slip effect but also can reliably remove dirt and moisture adhering to the sole. In addition, since the woven fabric is integrated with the first rubber sheet by vulcanizing the second rubber sheet, the knitted fabric is difficult to peel off from the first rubber sheet, and has a non-slip material that has excellent weather resistance and durability. It is also possible to provide a mat.

The time for vulcanizing the second rubber sheet 32 (second vulcanization time) is the thickness of the second rubber sheet 32, the raw rubber used for the second rubber sheet 32, and the type of vulcanizing agent added thereto. There are no particular limitations. However, if the second vulcanization time is too short, the second rubber sheet 32 may not be sufficiently vulcanized. On the other hand, if the second vulcanization time is too long, the productivity of the mat 30 with the anti-slip property is lowered. For this reason, the second vulcanization time is set in the same range as the first vulcanization time already described. In the manufacturing method of this embodiment, the second vulcanization time is 6 minutes.

Claims (4)

Set the unvulcanized first rubber sheet in the lower mold, lower the upper mold, and vulcanize while pressing the upper surface of the first rubber sheet with high pressure, to prevent slipping on the lower surface of the first rubber sheet A first vulcanization step for forming a convex portion;
An unvulcanized second rubber sheet is laid on the upper surface of the first rubber sheet after the first vulcanization step, and a woven fabric is further laid on the upper surface. The second rubber sheet is pressed while pressing the upper surface of the woven fabric at a low pressure. A second vulcanization step of integrating the knitted fabric with the first rubber sheet by vulcanization;
The manufacturing method of the mat | matte with a non-slip characterized by passing through.   The press pressure in the first vulcanization step is 5 to 30 MPa, the press pressure in the second vulcanization step is 1 to 10 MPa, and the press pressure in the second vulcanization step is 1 MPa than the press pressure in the first vulcanization step. The manufacturing method of the mat | matte with a non-slip | skid of Claim 1 made low above.   The manufacturing method of the mat | matte with a non-slip | skid of Claim 1 or 2 whose knitted fabric is a pile fabric by which the pile was formed in the upper surface. The manufacturing method of the mat | matte with a slip prevention in any one of Claims 1-3 which made 0.5-10 mm the height of the convex part formed in the lower surface of a 1st rubber sheet at a 1st vulcanization process.

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