JP2012223476A - Mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mat which is excellent in antislip property, cushioning property, and the adhesion between a facing material and a lining material.SOLUTION: The mat 10 is formed by integrating the facing material 11 including piles 11b planted in a base cloth 11a and the lining material 12 formed of polyolefin resin foam through an adhesive layer 13 formed of a thermoplastic resin. The mat has satisfactory antislip property and cushioning property since the lining material 12 is formed of the polyolefin resin foam. The mat also has satisfactory adhesion, since the facing material 11 and the lining material 12 are thermally bonded through the adhesive layer 13.

Description

  The present invention relates to a mat excellent in cushioning effect and anti-slip effect, and excellent in adhesion between a skin material and a backing material.

  For mats such as car mats (hereinafter referred to as rugs in general in the present specification), a nonwoven fabric is generally used as a backing material. In order to impart anti-slip performance to the mat, a resin is sprayed on the back surface of the nonwoven fabric to increase the frictional resistance, or a special processing is applied to the nonwoven fabric (see Patent Document 1).

However, since this type of conventional mat has insufficient anti-slip performance, the anti-slip performance is often improved by using an optional non-slip sheet or the like under the mat.
Thus, since it is complicated to prepare a separate anti-slip sheet, it is required that the mat itself has sufficient anti-slip performance.

  In addition, since this type of mat has a non-woven fabric backing and poor cushioning as a whole, it is also required that the mat itself has sufficient cushioning performance.

Further, when the adhesion between the skin material and the backing material of the mat is weak, if a load is applied by walking on the mat or the like, peeling or misalignment may occur between the skin material and the backing material.
Therefore, it is also required to improve the adhesion between the mat skin material and the backing material.

JP 2008-155865 A

  Therefore, the problem to be solved by the present invention is to provide a mat that is excellent in all of the anti-slip properties and cushioning properties and the adhesion between the skin material and the backing material.

  In order to solve the above-described problems, as a mat according to the present invention, a skin material obtained by tufting a pile on a base fabric, a backing material made of polyolefin resin foam, and the skin material and the backing material are thermally bonded. The structure provided with the contact bonding layer which consists of a thermoplastic resin was employ | adopted.

  Since the resin foam constituting the backing, particularly the polyolefin resin foam, has good cushioning properties, the cushion performance of the entire mat is improved.

  Moreover, since the resin foam constituting the backing material is porous in addition to having high frictional resistance, it has high adhesion to the floor surface due to the sucker effect, so that the anti-slip performance of the entire mat is improved.

  Since the backing material and the skin material are thermally bonded via an adhesive layer made of a thermoplastic resin, the adhesiveness is also improved.

Cross-sectional schematic diagram of mat of embodiment

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

  As shown in FIG. 1, the mat 10 according to the embodiment is formed by integrally bonding a skin material 11 and a backing material 12 by an adhesive layer 13, and has anti-slip performance, cushion performance, and skin material. 11 and the backing material 12 are both excellent in bonding performance.

  Specifically, the skin material 11 is a general pile fabric formed by tufting a pile 11b (cut pile) on a base cloth 11a. A rubber retaining layer 11c is laminated.

Here, the material of the base fabric 11a and the pile 11b is not particularly limited, and examples thereof include polyester, polypropylene, nylon, and acrylic.
The type of pile 11b yarn is not particularly limited, but it is preferable to use a filament yarn in order to suppress loosening.
Further, the fineness of the pile 11b single yarn is not particularly limited, but generally 1 to 80 dtex and the pile weight per unit area is 200 to 2500 g / m ² .
The pile 11b may be a loop pile.

On the other hand, the backing 12 is made of a polyolefin resin foam which is a mixture of a polyolefin resin and a gas.
Since the backing 12 is a resin foam, it has a high frictional resistance and also has good adhesion to the floor surface due to the suction cup effect, so that the mat 10 is provided with a good anti-slip performance.

The production method is not particularly limited, and examples thereof include an extrusion foaming method, a normal pressure foaming method, and a press foaming method.
Although the thickness of the backing 12 is not particularly limited, the smaller the thickness, the lighter and the smaller the size can be achieved. On the other hand, if the thickness is too small, the cushioning property is inferior. Is more preferable.

  Furthermore, the surface of the backing 12 facing the floor is embossed to form irregularities 12a. Since the frictional resistance of the backing 12 is further increased by the unevenness 12a, the anti-slip effect is further improved.

Here, the type of polyolefin resin of the backing 12 is not particularly limited, but low density polyethylene, linear polyethylene obtained by copolymerizing ethylene and an α-olefin having 4 to 12 carbon atoms, high density polyethylene, polypropylene, and the like. Can be illustrated.
In order to provide the backing 12 with a non-slip effect, an ethylene / vinyl acetate copolymer, an ethylene / ethyl acrylate copolymer, an ethylene / propylene copolymer, a styrene / butadiene copolymer, an acrylonitrile / butadiene copolymer It is preferable to include at least one of the coalescence. Of these, ethylene / vinyl acetate copolymer (EVA) is particularly preferable from the viewpoint of hardness, cost, and the like.

Various crosslinking methods may be used to improve the heat resistance and mechanical strength of the polyolefin resin foam. The crosslinking method is not particularly limited, and examples thereof include an electron beam crosslinking method, a chemical crosslinking method, and a silane crosslinking method. You may use crosslinking adjuvants, such as divinylbenzene and a trimethylol propane trimethacrylate, which improve a crosslinking characteristic as needed.
Various additives may be added as long as the cushioning property and anti-slip property of the polyolefin resin foam are not impaired.

The apparent density of the polyolefin resin foam is preferably 25 to 250 kg / m ^3, more preferably 33 to 200 kg / m ³ .
When the apparent density is less than 25 kg / m ³ , the compression hardness and the thickness recoverability are lowered, and the thickness may become extremely thin due to a long-term load by a figurine or the like, or the thinned thickness may not be recovered and may become a dent. Because.
On the other hand, if the apparent density exceeds 250 kg / m ³ , the rigidity may increase and it may be difficult to impart an appropriate cushioning property.
The apparent density shown here indicates a numerical value measured by a measuring method according to JIS K 7222 (2001 edition). The polyolefin resin foam has a thickness of preferably 0.5 to 20 mm, more preferably 1 to 5 mm. If the thickness is less than 0.5 mm, moderate cushioning due to a feeling of bottoming may be hindered. On the other hand, if the thickness exceeds 20 mm, discomfort may occur due to poor handling due to weight increase or excessive cushioning. This is because it may be considered that the door is hindered from being opened and closed. The thickness shown here indicates a numerical value measured by a measuring method according to JIS K 7222 (2001 edition).

Polyolefin-based resin foam gives a suitable cushioning property that repels moderately,
The closed cell ratio is preferably 50% or more, more preferably 60% to 95%.
If the closed cell ratio is less than 50%, an appropriate cushioning property due to the feeling of bottoming may be inhibited. The closed cell ratio shown here is measured in accordance with JIS K7138 (2006) “Measurement of non-ventilated volume by volume expansion method” of “Hard foamed plastic-Determination of open cell ratio and closed cell ratio”. It is a thing.

The adhesive layer 13 that bonds the skin material 11 and the backing material 12 is made of a thermoplastic resin.
Since the skin material 11 and the backing material 12 are not directly bonded to each other but are thermally bonded with an adhesive layer 13 made of a thermoplastic resin, good adhesion performance is imparted.

Although the formation aspect of this contact bonding layer 13 is not specifically limited, Extrusion adhesion method and spray adhesion method can be illustrated.
It is preferably formed by applying a thermoplastic resin to the back surface of the skin material 11 and heat setting.
The thickness of the adhesive layer 13 is not particularly limited, but is preferably 0.2 mm to 2.0 mm. Furthermore, for balance between the demand for weight reduction and miniaturization and the guarantee of adhesive performance, the thickness is 0.3 to 0.00. 7 mm is preferred.

  The thermoplastic resin of the adhesive layer 13 is made of ethylene / vinyl acetate copolymer, ethylene / ethyl acrylate copolymer, ethylene / propylene copolymer, styrene / butadiene copolymer, styrene / isoprene copolymer from the viewpoint of thermal adhesion. It preferably contains at least one of a polymer, acrylonitrile-butadiene copolymer, chloroprene, styrene-butadiene copolymer, butadiene, and polyisobutylene.

Examples and comparative examples are given below to further clarify the content of the present invention.
First, the following foams were prepared as polyolefin resin foams used for the mat backing of the examples.
Low-density polyethylene resin (Tosoh Corp .: Petrocene 342) 65.5%, ethylene / vinyl acetate copolymer (Mitsui / DuPont Polychemical Co., Ltd .: Everflex V421) 28%, foaming agent azodicarbonamide (Eiwa Chemical) Kogyo Co., Ltd .: VINYHALL AC # 3) 3.5% and antioxidant (BASF Co., Ltd .: IRGANOX 1010) 3% were melt-kneaded with a pressure kneader heated to 170 ° C. and then pelleted through an extruder. Shaped chips were obtained. This chip was extruded at a temperature of 150 ° C. using a 45 mφ vent type single screw extruder provided with a T die to obtain a sheet-like composition having a thickness of 1 mm. The sheet-like composition is crosslinked by irradiation with 40 kGy ionization, then foamed in a hot air oven heated to 240 ° C., smoothed with a cooling roll, and used for the backing material of the example. Foam thickness 1.5 mm, apparent density 140 kg / M ³ , a foam having an independent foam ratio of 87% was obtained (hereinafter referred to as the above-mentioned foam).

(Test 1)
In order to confirm the anti-slip effect, a slip resistance / horizontal test was conducted.
As for the slip resistance between the floor and the mat, a numerical value measured using this resistance / horizontal test as a measurement method is shown.
First, as Example 1, a mat having the same configuration as that of the embodiment and using the above-mentioned foam as a backing and having no irregularities formed on the back surface is referred to as Example 2 as the embodiment. A mat having the same configuration and using the above-mentioned foam as a backing, and having an uneven surface formed by embossing on the back surface was prepared.
Further, as Comparative Example 1, the skin material is the same as that of the embodiment, and the backing is a mat using a polyethylene foam sheet laminated with a polyethylene resin, and as Comparative Example 2, the skin material is the same as that of the embodiment. A mat using a material in which an appropriate amount of acrylic resin was sprayed on the back surface of the nonwoven fabric was prepared.

Next, with respect to the mats of these examples and comparative examples, 100 mm × 125 mm test pieces were collected and adjusted so as not to slide on a table or the like.
Further, a load of 100 g / 1000 g (distributed load) was added to each test piece, and the maximum load when sliding on the flooring and the loop carpet at a pulling speed of 100 mm / 1 min for 150 m was measured five times, and the maximum and minimum values were deleted. The average value of 3 points was calculated to 1 digit after the decimal point and expressed in N / kgf. The results are shown in Table 1.

  As shown in Table 1, the mats of the examples had a high anti-slip effect since the slip resistance values were high on the flooring or on the loop carpet as high as 6.8 or more and 8.2 or more, respectively. .

(Test 2)
In order to confirm the cushioning property, a compression elastic modulus test was measured according to a thickness reduction test by a static load of JIS L 1021-6 (revised edition in 2007).
First, as an example, a mat having the same configuration as that of the embodiment and using the foam as a backing material was prepared. Further, as Comparative Example 1, the skin material is the same as that of the embodiment, and the backing material is made of a nonwoven fabric (270 g / m ² ). As Comparative Example 2, the skin material is the same as that of the embodiment, and the backing material is a nonwoven fabric (400 g). / M ² ) as Comparative Example 3, the skin material is the same as that of the embodiment and the backing material is made of jute, and as Comparative Example 4, the skin material is the same as that of the embodiment and the backing material is polyethylene. A material made of a foam was used as Comparative Example 5, and a skin material similar to that of the embodiment and a material made of urethane were prepared.

Next, 100 mm × 100 mm test pieces were collected from the mats of the examples and the comparative examples, and the thickness (mm) of the test piece at the central portion under a standard pressure of 2.0 kPa ± 0.2 kPa was set to 1 after the decimal point. Measured to the nearest digit.
Further, a constant pressure of 98 kPa was applied to the central portion of each test piece, and the thickness (mm) after 5 minutes was measured.
Immediately after the measurement, the load was removed, and the thickness (mm) under a standard pressure of 2.0 kPa ± 0.2 kPa after 5 minutes was measured to one decimal place.

  For each specimen, from the thickness under standard pressure before compression (mm), the thickness after 5 minutes under constant pressure (mm), and the thickness (mm) when standard pressure is applied again after removing the load, The compression modulus (%) was calculated, and the average value was calculated to 1 decimal place. The results are shown in Table 2.

  As shown in Table 2, as a result of testing a typical backing material using the same standard pile skin material as a mat, it was found that the example had the highest elastic recovery rate and good cushioning properties. It could be confirmed.

(Test 3)
In order to confirm adhesiveness, it measured according to the peel strength test method of JISL1201-9 (2007 revision), and obtained the measurement result.
First, as Example 1, a mat having the same configuration as that of the embodiment and using the foam as a backing material was prepared. Adhesion between the skin material and the backing material was performed by an extrusion bonding method in which a styrene / butadiene copolymer, a mixture of styrene / isoprene copolymer, and a resin amount of 230 to 320 g / m ² was used.
Further, as Example 2, a mat having the same configuration as that of the embodiment and using the above foam as a backing material was prepared. Adhesion between the skin material and the backing material was performed by a spray adhesion method in which a styrene / butadiene copolymer, a mixture of styrene / isoprene copolymer, and a resin amount of 160 to 190 g / m ² were used.
As Comparative Example 1, a mat having the same configuration as that of the embodiment and using the foam as a backing material was prepared. Adhesion between the skin material and the backing material was a polyethylene resin, and the resin amount was 200 to 290 g / m ^{2 by} an extrusion adhesion method.
As Comparative Example 2, a mat having the same configuration as that of the embodiment and using the foam as a backing material was prepared. Adhesion between the skin material and the backing material was based on a spray adhesion method using a polyethylene resin and the amount of resin was 120 to 150 g / m ² .
As Comparative Example 3, a mat having the same configuration as that of the embodiment and using the foam as a backing material was prepared. Adhesion between the skin material and the backing material uses a polyethylene-based resin, and in order to increase the adhesive strength, the resin amount is 30 g / m ² from Comparative Example 2 by the spray adhesion method, and the coating amount is increased to 150 to 180 g / m. ² .

  Next, about the mat | matte of Examples 1-2 and Comparative Examples 1-3, each test piece of width 50mm and length 200mm is extract | collected, and 50 mm is peeled beforehand by hand from the short side one side. . The peeling is performed in the length direction of the test piece. Each separated test piece is sandwiched between grips of a tensile tester, pulled at a constant speed of 300 mm / min ± 10 mm / min, the stress-elongation behavior during the test is recorded, and the fluctuation of the stress (N) during peeling The test was conducted until the test pieces were separated.

The peel strength was obtained by equally dividing the 50% region at the center of the stress-elongation variation record of each test piece into five equal parts to obtain the maximum value of the peak in each section, and obtaining the average value (N) up to one decimal place. The results are shown in Table 3.
Moreover, the standard of the peel strength of the backing material of the tufted carpet is 24.5 (N) or more for both the vertical and horizontal. However, this excludes those lined with foamed materials (such as synthetic rubber) and those without a backing material. It is prescribed. (JIS L 4405 2000 edition)

  As shown in Table 3, in Examples 1 and 2, the peel strength that is a normal standard is cleared and the adhesiveness is good, but in Comparative Examples 1 to 3, the adhesiveness is weak and has reached the standard. I knew it was n’t there. In particular, for Example 1, the result of remarkably good adhesiveness was obtained by the combination of the bonding method and the selected resin, and it was proved that a safe mat could be provided.

DESCRIPTION OF SYMBOLS 10 Mat | matte 11 Embodiment Skin material 11a Base cloth 11b Pile 11c Retaining layer 12 Backing material 12a Concavity and convexity 13 Adhesive layer

Claims (5)

A skin material 11 obtained by tufting a pile on a base fabric;
A backing 12 made of a polyolefin resin foam;
And a bonding layer 13 made of a thermoplastic resin for thermally bonding the skin material and the backing material.   The backing 12 includes at least one of an ethylene / vinyl acetate copolymer, an ethylene / ethyl acrylate copolymer, an ethylene / propylene copolymer, a styrene / butadiene copolymer, and an acrylonitrile / butadiene copolymer. The mat according to claim 1.   The mat according to claim 1, wherein the backing material has a closed cell ratio of 50% or more.   The mat according to any one of claims 1 to 3, wherein the backing 12 has irregularities 12a formed by embossing.   The adhesive layer 13 includes an ethylene / vinyl acetate copolymer, an ethylene / ethyl acrylate copolymer, an ethylene / propylene copolymer, a styrene / butadiene copolymer, a styrene / isoprene copolymer, an acrylonitrile / butadiene copolymer, The mat according to any one of claims 1 to 4, comprising at least one of chloroprene, styrene-butadiene copolymer, butadiene, and polyisobutylene.

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