JP2527654B2 - Antistatic mat and method of manufacturing the same - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a static elimination mat and a method for manufacturing the same. More specifically, the present invention relates to a static elimination mat in which the static elimination effect of the mat is not impaired even by an external force applied at the time of getting on and off by reinforcing a discharge paper having an air discharge function, and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, as this type of static elimination mat, there is one disclosed in JP-A-2-267893 filed by the present applicant. As shown in FIG. 7, this static elimination mat 1 is made by making paper using conductive fibers, and the discharge paper 3 with a part of the conductive fibers protruding from the surface of the paper is part of the back surface of the base cloth 2. The base paper 2 and the discharge paper 3 are bonded to each other, and a pile 5 containing conductive fibers 4 is planted on the discharge paper 3 and the discharge paper 3
The backing layer 6 is formed on the back surface side.
In this static eliminator mat 1, the discharge paper 3 having extremely low mechanical strength is partially adhered to the back surface of the base fabric 2 so as to reinforce the discharge paper 3 itself and not to be directly affected by an external force applied when getting on or off the vehicle. Has become.

[0003]

SUMMARY OF THE INVENTION However, Japanese Patent Laid-Open No.
In the static elimination mat described in Japanese Patent No. 267893, in addition to the influence of external force applied at the time of getting on and off, various external forces such as being bent or pressed when removing the mat from the floor surface of the automobile or cleaning the mat. Will be affected. Therefore, during long-term use,
There has been a problem that the sheet structure of the discharge paper inside the mat is gradually destroyed and it becomes impossible to maintain a sufficient charge eliminating function.

In view of such circumstances, the present invention is a further improvement of the static elimination mat described in Japanese Patent Laid-Open No. 2-267893, and the static elimination effect of the mat is also exerted by external force applied when getting on and off the vehicle. It is an object of the present invention to provide an antistatic mat and a method for manufacturing the same, which are not damaged.

[0005]

In order to achieve the above object, the invention according to claim 1 is that "a paper is made by using conductive fibers, and a part of the conductive fibers is formed from the surface of the paper. The discharge paper that is protruding is partially bonded to one side of the base cloth,
In the static elimination mat in which a pile containing conductive fibers is planted in the base cloth and the discharge paper and a backing layer is formed on the discharge paper or the base cloth side, the discharge paper contains a conductive fiber and a thermoplastic binder. The outline of this is a static elimination mat characterized in that a part of the backing layer penetrates into the discharge paper through the gaps formed in the discharge paper by the thermal melting of the thermoplastic binder.
The gist of the invention according to claim 2 is "a static elimination mat characterized in that a conductive layer made of a conductive material is provided on a part of the surface of the discharge paper which is not adhered to the base cloth". According to a third aspect of the present invention, "a discharge paper formed by making paper using conductive fibers and a thermoplastic binder, and a part of the conductive fibers protruding from the surface of the paper is partially bonded to one surface of the base cloth. Then, a pile containing conductive fibers is planted on the base cloth and the discharge paper, and then the discharge paper and the base cloth are placed on the backing material applied to the mold, and the mold is heated to backing material. By semi-gelling and heat melting the thermoplastic binder of the discharge paper to form a gap in the discharge paper, allowing a part of the backing material to penetrate into the discharge paper through this gap, and then cooling the mold. The manufacturing method of an antistatic mat, which is characterized in that the backing material is gelled.

Hereinafter, the static elimination mat of the present invention will be described in detail with reference to the drawings. The static elimination mat 11 of the present invention comprises a base cloth 12
A discharge paper 13 partially adhered to one side of the base cloth 12, a pile 15 planted so as to penetrate the base cloth 12 and the discharge paper 13, and a backing formed on the discharge paper 13 or the base cloth side. And a layer 16. As shown in FIGS. 1 and 6, in the static elimination mat 11, the base cloth 12
A porous sheet material such as a non-woven fabric, a mesh, or a polyamide woven cloth is used as the base material, and the base cloth 12 is obtained by cutting each of these materials into a predetermined shape. In this base cloth 12,
As shown in FIG. 6, a plurality of piles 15 are planted so as to have a substantially U-shape while penetrating the base cloth 12 and the discharge paper 13. There are two types of piles 15 to be planted, one consisting only of synthetic fibers such as polyamide fibers and the other containing synthetic fibers containing conductive fibers 14.
The ratio of these two types of piles 13 to be planted in the mat 11 is appropriately determined in consideration of the size, usage condition, price, etc. of the mat 11.

The discharge paper 13 is made by using conductive fibers such as carbon fibers and a thermoplastic binder such as polyvinyl alcohol, and a part of the conductive fibers is projected on the surface of the paper. Examples of the discharge paper 13 include 3 to 15% by weight of conductive fibers such as carbon fibers, metal fibers and conductive ceramics fibers, 20 to 70% by weight of synthetic fibers such as acrylic fibers and polyester fibers, and the balance wood pulp and Paper made of fibrous thermoplastic binder is preferred. The fineness of each of the conductive fiber and the synthetic fiber is preferably 1 to 5 d, and the fiber length is preferably 3 to 20 mm. The discharge paper 13 is a mixture of these conductive fibers, synthetic fibers, wood pulp and thermoplastic binder in a ratio within the above range,
This mixture was further cut into a uniform mixture through a beater and then produced by a wet papermaking method.
In one square centimeter of the discharge paper 13 manufactured in this way, 50 or more conductive fibers (not shown) are irregularly projected vertically or obliquely from the surface of the discharge paper 13, and the projections are formed. More static electricity is discharged in the air.

An adhesive 17 is interposed between the discharge paper 13 and the base cloth 12 in a dot shape, a net shape, a linear shape, a circular shape or the like so that the discharge paper 13 and the base cloth 12 are partially formed. Is glued to. With the adhesive 17, the discharge paper 13 and the base cloth 1
2 is partially adhered, as shown in FIG. 2, between the discharge paper 13 and the base cloth 12, a part adhered by the adhesive 17 and a part not adhered are formed. become. The bonded portion acts to prevent the discharge paper 13 and the base cloth 12 from being separated from each other. A gap 20 is formed between the discharge paper 13 and the base cloth 12 in the unbonded portion.

A backing layer 16 is formed on the discharge paper 13 or the base cloth 12 side. The backing layer 16 is made of a thermoplastic resin such as vinyl chloride resin,
Part of the permeation penetrates into the discharge paper 13 through a gap (not shown) formed in the discharge paper 13 by thermal melting of the thermoplastic binder contained in No. 3, and the fiber structure of the discharge paper 13 (electrostatic air discharge The structure) is maintained by the backing layer 16 along with the thermoplastic binder. still,
The penetration of the backing layer 16 into the discharge paper 13 is caused by the discharge paper 1
3 or the process of forming the backing layer 16 on the base fabric 12 side. That is, the thermoplastic binder in the discharge paper 13 is melted by heat when the backing material is semi-gelled, whereby the discharge paper 13 is melted.
That is, a gap is formed in the backing material, and a part of the backing material permeates into the discharge paper 13 through the clearance (not shown). In this state, the backing material gels and the backing layer 16 is formed. In the case where the backing layer 16 is formed on the base cloth 12 side, the backing layer 1
As a matter of course, a part of 6 also penetrates into the inside of the base cloth 12, and the discharge paper 13 penetrates part of the backing layer 16 that has penetrated into the discharge paper 13 as well as part of the backing layer 16. The base fabric 12 is used to maintain the fiber structure.

The static elimination mat 11 of the present invention having the above structure
In that case, the static electricity charged on the human body in the car
When the human body comes into contact with the static elimination mat 11, it is grounded to the pile 15 of the static elimination mat 11, and a part of the backing layer 16 penetrates into the discharge paper 13 by the pile 15, and the fiber structure of the discharge paper 13 is It is maintained by the backing layer 16 together with the thermoplastic binder, and the mechanical strength of the discharge paper 13 is improved. For this reason, the discharge paper 1 having a discharge function by an external force applied when getting on and off or washing.
3 is not destroyed, and the charge removal effect of the mat is not impaired.

A conductive layer 18 may be provided on a part of the surface of the discharge paper 13 which is not adhered to the base cloth. The conductive layer 18 is formed by stacking a conductive material formed by molding carbon, conductive ceramics, metal, or the like into a fibrous or powdery shape on a surface of the discharge paper 13 that is not bonded to the base cloth 12 to form a layer. is there. A conductive layer 18 is formed on a part of the surface of the discharge paper 13 which is not adhered to the base cloth 12.
As a mode in which the is provided, a net shape, a stripe shape, or the like can be freely set. By providing the conductive layer 18, the electrostatic capacity of the mat 11 is increased, which greatly contributes to the improvement of the static elimination function.

A method of manufacturing the static elimination mat having the above structure will be described with reference to the drawings. First, as shown in FIG.
A base cloth 12 made of a porous sheet material such as a non-woven fabric, a mesh, a polyamide woven cloth, or a thread is cut into a predetermined shape, and the adhesive 17 is applied on the base cloth 12 in a dot shape, a net shape, a linear shape or a circular shape. Approximately 30 per square meter of base fabric 12
Partially apply so that the applied amount is around g. In addition,
Any adhesive may be used as the adhesive 17, but a thermoplastic resin such as polyethylene, polyamide, polyethylene terephthalate, polybutylene terephthalate, polypropylene or polyvinyl chloride is preferable. In particular, if a resin having a high heat-fusible property such as polyethylene is molded in a net shape in advance, it is only necessary to place it on the base cloth 12, and the labor for manufacturing can be saved. Also,
A conductive material such as carbon, metal or conductive ceramics can be added to the adhesive 17, and it is considered that the electrostatic capacity of the mat 11 can be improved by using the adhesive 17.

Next, as shown in FIG. 2, the discharge paper 13 is laminated on the adhesive 17 applied to the base cloth 12, and the discharge paper 13 is partially adhered to the base cloth 12. Discharge paper 1 on one side of base cloth 12
After partially adhering 3 to each other, as shown in FIG.
2 and the discharge paper 13 have a pile 15 containing conductive fibers 14.
U in a state where it penetrates from the base cloth 12 side to the discharge paper 13 side
Plant in a letter shape. In addition, the pile 15 is the discharge paper 1
You may make it penetrate from the 3rd side to the base fabric 12 side.

Next, as shown in FIG. 4, the base cloth 12 and the discharge paper 13 are placed on a backing material made of a thermoplastic resin such as sol-like polyvinyl chloride coated on a mold 19, and the mold is placed. 19 is heated to semi-gelate the backing material. As a result, as shown in FIG. 5, the heat transferred through the backing material melts the thermoplastic binder of the discharge paper 13 to form a gap in the discharge paper 13, and the backing material passes through the gap in the discharge paper 13 inside the discharge paper 13. Will penetrate into. Then, by cooling the mold 19, the backing material is gelated and the backing layer 16 is formed, so that a static elimination mat having a structure as shown in FIG. 6 can be manufactured. Although the backing layer 16 is formed on the discharge paper 13 side in the drawing, it may be formed on the base cloth 12 side.

A conductive layer 18 may be provided on the surface of the discharge paper 13 which is not adhered to the base cloth 12. The conductive layer 18 is formed by adding fibers or powder made of a conductive material to an adhesive and applying the same to the discharge paper 13, or after applying the adhesive to the discharge paper 13 and then making the fibers or powder made of the conductive material. It can be provided by sprinkling powder. The adhesive used for the conductive layer 18 may be the same as the adhesive used for partially bonding the base cloth 12 and the discharge paper 13. The amount of the conductive layer 18 applied to the discharge paper 13 is preferably such that the conductive material is contained in an amount of at least 1% by weight with respect to 30 g of the adhesive per square meter of the discharge paper 13. This is because below 1% by weight, this conductive layer 18
This is because it is considered that the function of holding the static electricity cannot be fully exerted.

[0016]

EXAMPLES An example of the static elimination mat of the present invention will be described below. Static eliminator mat: having a structure shown in FIGS. 1 and 6, in which an adhesive for adhering the discharge paper and the base cloth is provided in a dot shape, size: 0.50 × 0.74 = 0.37 m ² “base cloth : Polyester non-woven fabric, Pile: Polyamide fiber (1600 denier), Conductive fiber contained in the pile: Sanderlon [manufactured by Japan Silkworm Dyeing Co., Ltd.], Discharge paper: Carbon fiber, acrylic fiber, pulp, fibrous polyvinyl alcohol Used for paper making by wet papermaking method, adhesive for adhering discharge paper and base cloth: polyamide adhesive, conductive layer:
(Carbon powder + polyamide adhesive) provided on a part of the back surface of the discharge paper, backing layer: vinyl chloride resin. "

[0017]

According to the above configuration, the first aspect of the present invention is provided.
In the static elimination mat described, a part of the backing layer penetrates into the discharge paper through the gap formed in the discharge paper by the thermal melting of the thermoplastic binder contained in the discharge paper, and the fiber structure of the discharge paper. Is maintained by a backing layer together with a thermoplastic binder to improve the mechanical strength of the discharge paper. For this reason, the discharge paper having the discharge function is not destroyed by the external force applied when getting on or off or washing, and the charge removal effect of the mat is not impaired. In the static elimination mat according to claim 2, the electrostatic capacity of the mat can be increased by providing a conductive layer on a part of the surface of the discharge paper that is not bonded to the base cloth.
The charge removal function of the mat can be further improved.
According to the method of manufacturing the static elimination mat according to claim 3, the thermoplastic binder in the discharge paper is thermally melted by the heat accompanying the backing to form a gap in the discharge paper, and the backing material permeates through the gap. , A static elimination mat with a reinforced structure of the discharge paper having an electrostatic discharge function in the air can be obtained easily and by the same process as before without requiring a special device or process for permeating the backing material into the discharge paper. be able to.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional perspective view showing a static elimination mat of the present invention.

FIG. 2 is an enlarged cross-sectional view showing a state in which a discharge paper is partially adhered to a base cloth.

FIG. 3 is an enlarged cross-sectional view showing a state in which a pile is planted on the base cloth and the discharge paper of FIG.

FIG. 4 is an enlarged cross-sectional view showing a state in which a base cloth and discharge paper are arranged in a mold coated with a backing material.

FIG. 5 is an enlarged cross-sectional view showing a state in which a backing material has penetrated into the discharge paper.

FIG. 6 is an enlarged cross-sectional view showing the static elimination mat of the present invention.

FIG. 7 is an enlarged cross-sectional view showing a conventional static elimination mat.

[Explanation of symbols]

 12 ... Base cloth 13 ... Discharge paper 15 ... Pile 16 ... Backing layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical indication H05F 1/00 9470-5G H05F 1/00 H

Claims (3)

(57) [Claims] 1. A discharge paper obtained by making paper using conductive fibers, the discharge paper having a part of the conductive fibers protruding from the surface of the paper, which is partially adhered to one side of a base cloth. In a static elimination mat in which a pile containing conductive fibers is planted in the discharge paper or a backing layer is formed on the side of the base cloth, the discharge paper contains conductive fibers and a thermoplastic binder. A static elimination mat, characterized in that a part of the backing layer penetrates into the discharge paper through a gap formed in the discharge paper by heat melting of the binder. 2. The static elimination mat according to claim 1, wherein a conductive layer made of a conductive material is provided on a part of the surface of the discharge paper which is not adhered to the base cloth. 3. A discharge paper formed by making paper using conductive fibers and a thermoplastic binder, and a part of the conductive fibers protruding from the surface of the paper is partially adhered to one side of a base cloth. A pile containing conductive fibers is planted on cloth and discharge paper, and then these discharge paper and base cloth are placed on the backing material applied to the mold, and the backing material is semi-gelled by heating the mold. At the same time, the thermoplastic binder of the discharge paper is melted by heat to form a gap in the discharge paper, and a part of the backing material is permeated into the discharge paper through this gap,
After that, the backing material is gelated by cooling the mold, and the method for producing an antistatic mat.