JP2726665B2 - Manufacturing method of integrated mat for dust removal with preventing waving - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a method for manufacturing an integrated mat for dust removal, and more particularly, to a method for producing a rubber-adhesive fiber and a rubber-non-adhesive synthetic resin. Pile yarns can be stably and well adhered, and even when used repeatedly for a long period of time after repeated washing and regenerating treatment, generation of waving is prevented and dimensional stability is significantly improved for rental. The present invention relates to a method for producing an integrated mat for dust removal. (Prior art) Conventionally, as an integrated dust-removing mat laid and used at an entrance or the like of an entrance or the like, a tufted mat in which rubber and a vinyl chloride sheet are integrated with a back stitch surface is well known. I have. This integrated mat is made by bonding a soft resin such as vinyl chloride to the fiber part (base cloth and pile) of the mat in a sol form, and heat-treating the mat part. Alternatively, the mat fiber part is placed on an unvulcanized rubber sheet. After being placed, it was manufactured by a method of performing a hot press treatment to bond and solidify. Further, as disclosed in JP-A-59-95016, there is a method in which an elastomer is applied to a stitch surface of a mat material to form a thin backing layer, and a frame-shaped thick elastomer is integrated. (Problems to be Solved by the Invention) Since these integrated mats are laid at entrances and exits of people, the pile surface is repeatedly subjected to friction by the back surface of the shoe. Further, since the mat is used in a rental system in which the mat is used after being used for a certain period of time, the mat is washed, regenerated, and lent again. Disadvantageously occurs. Further, it is also a problem that the pile yarns fall off from the mat to cause a so-called thinness of the mat, and in particular, polyvinyl alcohol fiber or polyester fiber, which is excellent in texture and durability, has poor adhesion to rubber, This tendency was particularly significant. Accordingly, an object of the present invention is to firmly fix the pile yarn to the rubber backing to prevent the pile yarn from falling off and waving even when washing and regenerating are repeated, and to remarkably improve the dimensional stability. An object of the present invention is to provide an improved method of manufacturing an integrated mat for dust removal for rental. (Means for Solving the Problems) According to the present invention, a rubber latex containing no vulcanizing agent is applied to a stitch surface of a mat material comprising a substrate and a pile tufted to the substrate, Dry to form an unvulcanized rubber precoat layer on the stitched surface, containing the precoat mat material, the same type of rubber as the precoat layer, 0.1 to 3% by weight of a vulcanizing agent and an appropriate amount of a vulcanization accelerator. An unvulcanized rubber sheet to be laminated is superposed so that the precoat layer and the rubber sheet face each other, and pressed under heating to bond the precoat layer and the rubber sheet, and vulcanize the precoat layer and the rubber sheet. And a method for producing an integrated mat for dust removal for rental, wherein the mat is prevented from waving. (Action) According to the present invention, a rubber latex containing no vulcanizing agent is provided as an unvulcanized precoat layer on a stitch surface of a mat material. This makes it possible to infiltrate the rubber component in the rubber latex into the mat material in advance, and also enables strong adhesion and integration with the rubber sheet to be applied later. The rubber sheet to be applied later contains the same kind of rubber as the precoat layer, a vulcanizing agent and a vulcanization accelerator, and the rubber precoat layer is formed by pressing the precoated mat material and the rubber sheet under heating. And the rubber sheet are simultaneously vulcanized and bonded. According to the present invention, a strong, dimensionally stable and durable adhesive structure is introduced at both interfaces between the mat material and the precoat layer, and between the precoat layer and the rubber sheet, the pile yarn is sufficiently fixed, and the pile yarn It is possible to manufacture an integrated mat in which falling off, peeling of the original cloth, and generation of waving are prevented. Such an integrated mat is extremely unlikely to cause the pile yarns to fall off, can be repeatedly subjected to severe washing and regenerating treatment, and is useful as an integrated mat for dust removal for rental. Such effects of the present invention are attributable to the above-described features of the present invention. That is, when the precoat layer provided on the stitch surface of the mat material in an unvulcanized state is applied to a heating press, the rubber component of the rubber latex easily penetrates deep into the gaps of the fibers of the mat material by the pressure. I do. Further, when the pressure of the heating press is continuously applied, the vulcanizing agent and the vulcanizing agent are transferred from the unvulcanized rubber sheet containing the vulcanizing agent and the vulcanization accelerator into the unvulcanized precoat layer. Diffusion transfer of the accelerator occurs effectively. Thus, the rubber component of the latex of the precoat layer penetrates into the mat material, followed by diffusion transfer of the vulcanizing agent and the vulcanization accelerator into the unvulcanized precoat layer, and then the precoat layer and the rubber sheet Vulcanization occurs simultaneously, and as a result, the rubber component that has permeated the mat material is vulcanized in a timely manner by a vulcanizing agent and a vulcanization accelerator diffused and transferred into the precoat layer, and a part of the precoat layer is formed on the mat material. A vulcanized state occurs as if it is hard to anchor like an anchor (anchoring effect). Furthermore, the unvulcanized precoat layer and the unvulcanized rubber sheet are made of the same type of rubber, and each have the same type of vulcanizing agent and vulcanization accelerator due to diffusion transfer of the vulcanizing agent and vulcanization accelerator. As a result, the vulcanized structure after hot pressing is uniformly and sufficiently formed between the precoat layer and the rubber sheet. (Preferred Aspect of the Invention) In step A of FIG. 1 illustrating the manufacturing process of the integrated dust-removing mat of the present invention, the pile yarn 2 is tufted on the base cloth 1 and the ends thereof are trimmed to form a mat. A mat material forming the surface is prepared. In step B, a rubber latex containing no vulcanizing agent is applied to the back surface (stitch surface) of the base fabric 1 and dried to form an unvulcanized precoat layer 3. In step C, the same type of rubber as the precoat mat material and the precoat layer is overlaid on an unvulcanized rubber sheet 4 containing a vulcanizing agent and a vulcanization accelerator so that the precoat layer 3 and the rubber sheet 4 face each other, Press under heat. As the base fabric 1 used in the present invention, a woven or non-woven fabric of synthetic resin having excellent dimensional stability such as acetalized polyvinyl alcohol fiber and polyester fiber is used. On the other hand, as the pile yarn 2, nylon fiber, vinylon fiber, In addition to multifilament yarns, spun yarns, and blended yarns of synthetic fibers such as acrylic fibers, conventional natural fibers and the like can also be used. As the rubber latex and the elastomer used for the rubber sheet, nitrile-butadiene rubber is particularly preferably used, and other vulcanizable rubbers such as styrene-butadiene copolymer rubber (SBR), chloroprene rubber, polybutadiene rubber, Isobutylene / isoprene rubber and the like can be used. Examples of the vulcanizing agent blended in the rubber sheet include, as inorganic vulcanizing agents, metal salts such as sulfur, zinc chloride, ferrous chloride, and tin chloride, and sulfur chloride. Examples of the vulcanizing agent include dicumyl peroxide, acetylene peroxide, benzoyl peroxide, ethyl methyl ketone peroxide, and the like.In addition, thiuramisulphide, quinone dioximuthiol, dithioic acid, and the like can be used, and sulfur is used. Is common. Examples of the vulcanization accelerator include, as vulcanization accelerators for thiazole compounds, 2-mercaptobenzothiazole, copper salts and zinc salts thereof, and 2,2-dibenzothiazole disulfide. Examples of the accelerator include N-cyclohexyl-2-benzothiazylsulfenamide, N-oxydiethylene-2-benzothiazylsulfenamide, N, N'-diisopropyl-2-benzothiazylsulfenamide and the like. And 2-mercaptothiazoline as a crosslinking accelerator for thiazoline-based compounds. In addition, thiuram compounds,
Vulcanization accelerators such as dithiocarbamate compounds, aldehyde / amine compounds, guanidine compounds and carbamoylthiazole compounds can be used. The amount of the vulcanizing agent blended in the rubber sheet is preferably in the range of 0.1 to 3% by weight per rubber, and particularly preferably in the range of 0.5 to 2% by weight. An appropriate amount of the vulcanization accelerator to be added to the rubber sheet is added depending on the amount of the vulcanizing agent, vulcanization conditions and the like. The rubber latex and the rubber sheet can be blended with a compounding agent known per se in accordance with a known formulation, for example, a filler such as carbon black, a softening agent such as process oil, an antioxidant, a dispersant, a plasticizer, and the like. Can be blended. As a method of applying rubber latex to the mat material,
The coating can be carried out by a usual coating method such as coating with a roll coater, spraying or brushing, but it is necessary that the rubber component of the latex is uniformly dispersed. Also, rubber latex is added to the mat material in an amount of 25 to 1000 g / m ² , especially 30
It is preferably applied at a rate of from about 600 g / m ^{2 to} 600 g / m ² , and after the application, a precoat layer must be formed so that the rubber latex is in an unvulcanized state. For this reason, drying of rubber latex is generally 90 to 18
The reaction is performed at a temperature of 0 ° C. for 1 to 120 minutes. The weight of the rubber sheet is 100 to 4000 g / m ² , especially 200 to 4000 g / m ²
2000g / m ² is recommended. The unvulcanized rubber sheet having the above composition is overlapped so as to face the precoat layer, pressed under heating, and the adhesion between the precoat layer and the rubber sheet and the vulcanization of the precoat layer and the rubber sheet are simultaneously performed. The conditions at the time of hot pressing may be any conditions as long as the above-mentioned bonding and vulcanization are performed.
Temperatures of around ° C. and pressures of around 5 kg / cm ² are preferably used. (Example) The present invention is described in the following example. Example 1 pile BCF nylon stitch 6 / inch, gauge 5/32, pile height 9mm, basis weight 880g
/ m ² , Cut pile base fabric Polyester plain woven fabric Weight 200g / m ² Pre-coated NBR (acrylonitrile butadiene copolymer rubber) latex 600g / m ² (as solid content) BCF nylon on the above base cloth and tuft under the above conditions Into a mat. The above amount of NBR latex was applied to the stitched surface of this mat and dried at 150 ° C. for 60 minutes to produce Mat A having an unvulcanized precoat layer. A mat B was prepared in the same manner as described above except that the NBR latex was prepared by blending 1% by weight of sulfur as a vulcanizing agent and 2% by weight of 2-mercaptobenzothiazole as a vulcanization accelerator on a solid basis. Produced. These mats A and B were cut into 70 × 85 cm, respectively, to produce integrated mats A and B in the following manner. On a 4 mm thick unvulcanized NBR sheet containing 1% by weight of a vulcanizing agent (sulfur) and 1% by weight of a vulcanization accelerator (2-mercaptobenzothiazole), place a mat cut in the above dimensions at 150 ° C. Adhesion and vulcanization by pressing at a pressure of 5 kg / cm ² for 15 minutes, integrated mat of nylon pile
A and B were prepared. After laying these mats in a place where the number of people passing by is 3,000 / day for three days, a normal integrated mat is washed and regenerated. After repeating this operation 20 times,
Table 1 shows the results of measuring the adhesive strength between the base fabric and the rubber. Also, Table 1 shows the degree of undulation of the mat before use and after 20 times of rental cleaning / reproduction in terms of undulation height (mm) and number. In addition, the tests of the yarn pulling strength and the adhesive strength (between the base fabric and the rubber) were performed in accordance with the terms of JIS L 1021 pile yarn pulling strength and peeling strength of the backing material. Example 2 Pas Lee Le Vinylon 100% Stitch plane 8.5 / inch, gauge 5/32, pile height 10 mm, weight per unit area 660 g / m ² base cloth polyester plain weave fabric having a basis weight 200 g / m ² pre-coat NBR latex 60 g / m ² (solid As a part) Vinylon was tufted on the base cloth under the above conditions to produce a mat. The above-mentioned amount of NBR latex was applied to the stitched surface of this mat, and dried at 150 ° C. for 30 minutes to produce Mat C having an unvulcanized precoat layer. The same mat was used as the mat D except that the precoat layer was not formed. In the above mats C and D, the uncured NBR sheet was bonded and vulcanized by a hot press in the same manner as in Example 1 to prepare integrated vinylon mats C and D. The same tests as in Example 1 were performed on these integrated mats C and D, and pile removal strength and the like were measured. Table 1 shows the measurement results. According to the results in Table 1, the integrated mat B in which the vulcanizing agent and the vulcanization accelerator were blended in the pre-coat layer exhibited excellent thread removal strength and adhesive strength before the rental and cleaning / recycling treatments. After 20 times of regeneration, the adhesive strength is significantly reduced and the waving occurs.On the other hand, the pre-coat layer does not contain a vulcanizing agent, etc. It is clear that in the integrated mat A which was simultaneously subjected to the vulcanization and vulcanization, the high adhesive strength was maintained even after 20 times of rental and washing and regeneration, and no waviness was generated. In the case of the integrated mat D without the precoat layer, the thread removal strength and the adhesive strength were reduced and the occurrence of waving was remarkable after 20 rental and washing / reproduction times. (Effect of the Invention) According to the present invention, an unvulcanized precoat layer is formed,
Adhesion and vulcanization of the pre-coat layer and rubber sheet are performed simultaneously by the rubber sheet heating press, so even if severe rental and cleaning / reproduction are repeated many times, it is possible to prevent a decrease in adhesive strength and a mat wave. Was.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view for explaining the manufacturing process of the integrated dust removing mat of the present invention. 1 ... base cloth, 2 ... pile yarn, 3 ... pre-coat layer, 4
…… Rubber sheet.

Claims (1)

(57) [Claims] A base material, a rubber latex containing no vulcanizing agent is applied to a stitch surface of a mat material composed of a pile tufted to the base material, and dried to form an unvulcanized rubber precoat layer on the stitch surface. The precoated mat material and an unvulcanized rubber sheet containing the same type of rubber as the precoated layer, 0.1 to 3% by weight of a vulcanizing agent and an appropriate amount of a vulcanization accelerator are combined with the precoated layer and the rubber sheet. Are laminated so that they face each other, pressed under heating, and simultaneously bonding the pre-coat layer and the rubber sheet and vulcanizing the pre-coat layer and the rubber sheet. Manufacturing method of integrated mat for dust removal. 2. ^2. The method according to claim 1, wherein the precoat layer is formed in an amount of 25 to 1000 g / m ² as a solid content. 3. 2. The method according to claim 1, wherein the rubber of the precoat layer and the rubber sheet is a nitrile-butadiene rubber. 4. 2. The method according to claim 1, wherein the tufted pile comprises a pile yarn containing polyvinyl alcohol fiber or polyester fiber.