JP3222890U - Mat - Google Patents

Abstract

[PROBLEMS] To provide a mat with good touch, rich elasticity, high designability, durability and productivity. A mat 1 includes a first layer 4 in which a nonwoven fabric 3 made of thermoplastic resin fibers is bonded to the back surface of a surface material 2 which is a knitted fabric made of natural fibers, and a heat disposed on the back side of the first layer 4. A laminated body comprising a second layer 5 that is a batting layer made of plastic resin fibers, and a third layer 6 that is a sheet made of thermoplastic resin fibers disposed on the back side of the second layer 5, The bonding surface 9 between the surface material 2 of the first layer 4 and the nonwoven fabric 3 has a convex portion 10 formed in the thickness direction of the laminate by the pressing force of an ultrasonic welder, and the nonwoven fabric 3 of the first layer 4 of the laminate. The second layer 5 and the third layer 6 are formed by ultrasonic welding and pressing with an ultrasonic welder and frictional heat. [Selection] Figure 2

Description

  The present invention relates to a mat that is rich in stretch and uses a knitted fabric made of natural fibers as an outer material and is excellent in design, durability, and productivity.

  As a method for fixing a plurality of sheets of a laminate used for a mat, there have been proposed quilt sewing, adhesion using an adhesive or heat welding, ultrasonic welding, and the like.

  Among them, ultrasonic welding is safe because there is no risk of needles being mixed into the product, as is the case with quilt sewing, and it can also reduce manufacturing costs because no adhesive is used to fix the sheets. It is an excellent method.

  On the other hand, ultrasonic welding is a method in which a target member is instantly melted and welded by frictional heat generated by ultrasonic vibration from an ultrasonic welder. Therefore, natural fibers such as cotton that do not melt by heat cannot be ultrasonically welded as they are. could not.

  Therefore, a method for ultrasonic welding of a laminate including a layer made of natural fibers that is not melted by heat has been proposed.

  The invention described in Patent Document 1 is a combination of at least one layer of a heat-weldable fiber layer and at least one layer of a non-heat-weldable fiber layer, and has a non-heat-weldable fiber layer on at least one surface. It is an exposed laminate, in which a heat-weldable substance is scattered on the exposed non-heat-weldable fiber layer, and the weldable substance and the melted part of the heat-weldable fiber layer are not heat-welded. An air-permeable laminate is disclosed, which penetrates from both surfaces of a porous fiber layer to bond and sandwich the non-heat-weldable fiber layer.

  The invention described in Patent Document 2 is composed of a three-dimensional network-structured fiber mainly composed of a fibril fiber made of a polyolefin-based polymer and a fibril fiber made of a polyester-based polymer. A non-woven fabric in which natural fibers are mechanically entangled with each other is laminated on both sides of a network-structured fiber nonwoven fabric that is thermally bonded to each other, and the network-structured fibers and the natural fibers are fused. Natural fibers located at least at the boundary surface of each non-woven fabric layer in the dotted fused area are fixed as a whole by being fixed in a state of being embedded in the melting portion of the network-structured fiber. A laminated nonwoven structure is disclosed.

Japanese Patent No. 54-24506 JP-A-8-118526

  However, the invention described in Patent Document 1 includes a step of laminating a heat-weldable fiber layer and a non-heat-weldable fiber layer when manufacturing a laminate, and heat-welding for impregnation further outside the non-heat-weldable fiber layer. A process of forming a structure in which the non-heat-weldable fiber layer is bonded and sandwiched by superposing the heat-sensitive sheets and infiltrating the heat-weldable material from the heat-weldable sheet for impregnation into the non-heat-weldable fiber layer by ultrasonic fusion treatment And after forming the laminate, the process of peeling the heat-welding sheet for impregnation is necessary, and the manufacturing process is complicated. It was a burden on the environment.

  In addition, since the invention described in Patent Document 2 needs to be a nonwoven fabric in which natural fibers are mechanically entangled in advance, the manufacturing process must be complicated, and it is difficult to reduce the manufacturing cost. It was impossible to form a laminate having a texture of a natural fiber fabric, for example, a knitted fabric rich in stretchability.

  As described above, the above-described invention ultrasonically welds a fiber layer having no heat-weldability, so that it is impregnated with a heat-weldable material or mechanically entangled to form a peel strength between layers. In addition, a process for processing a fiber structure having no heat-weldability is required in advance, and the manufacturing process is complicated and the cost is increased. In addition, the fiber structure is greatly impaired.

  In addition, the fibers of the non-heat-weldable fiber layer are pushed apart to infiltrate the heat-weldable material, so that the aesthetics of the melted part is impaired, and the part to be fused by ultrasonic waves is used to form the peel strength between layers. Since it is necessary to satisfy a predetermined ratio with respect to the total surface area, the product design is limited.

  Therefore, the present invention provides a mat that does not impair the stretchable function and texture of the knitted fabric used for the mat mat, is highly productive, durable, and easy to express. The issue is to provide.

In order to solve the above-mentioned problems, in the mat of the invention according to claim 1, the basis weight made of thermoplastic resin fibers on the back surface of the outer fabric which is a knitted fabric having a basis weight made of natural fibers of 50 to 300 g / m ^2. Is a first layer to which a non-woven fabric of 8 to 40 g / m ² is bonded, and a basis weight consisting of thermoplastic resin fibers disposed on the back side of the first layer is a batting layer of 50 to 200 g / m ² A laminate composed of two layers and a third layer made of thermoplastic resin fibers disposed on the back side of the second layer and having a basis weight of 80 to 260 gram / m ^2. An adhesive surface between the outer layer of the first layer and the nonwoven fabric has a convex portion formed in the thickness direction of the laminate, and the nonwoven fabric of the first layer, the second layer, and the third layer of the laminate. Is fixed by ultrasonic welding.

  “Knitted fabric” refers to a fibrous structure in which looped stitches are made and yarns are entangled.

  “Natural fibers” include plant fibers such as cotton and hemp, and animal fibers such as silk, wool and cashmere.

  Examples of the “thermoplastic resin” include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), polyester such as liquid crystal polyester, polyethylene (PE), There are polyolefins such as polypropylene (PP) and polybutylene, styrene resins, fluorine resins, and resins obtained by blending at least two of these.

  As the “filling layer”, fiber cotton is used.

  In the “first layer”, a surface material that is a knitted fabric made of the natural fibers and a nonwoven fabric made of the thermoplastic resin fibers are fixed by adhesion.

  “Adhesion” can be by heat welding as well as by an adhesive. As the adhesive, an emulsion resin, a water-soluble paste, or a hot melt resin can be used. In the case of thermal welding, it is bonded by thermal melting of a heat-bonding fiber, a heat-bonding resin, or a heat-bonding non-woven fabric disposed on the facing surfaces of the surface material and the non-woven fabric.

  In the floor mat of the invention according to claim 2, the surface material is a knitted fabric made of fibers not having heat-welding properties in which natural fibers and thermoplastic resin fibers are mixed. Similarly to the mat according to claim 1, the outer surface of the first layer is fixed by ultrasonic welding to the other layers of the laminate through a nonwoven fabric made of bonded thermoplastic resin fibers.

  The laid mat according to claim 3 is characterized in that the outer fabric is a knitted fabric made of thermoplastic resin fibers or fibers having heat-welding characteristics obtained by mixing natural fibers and thermoplastic resin fibers. And Since the outer material is a knitted fabric made of fibers having heat welding characteristics, the first layer to the third layer are integrally ultrasonically welded and fixed.

  According to the first aspect of the present invention, it is possible to provide a laying mat that is a knitted fabric having a texture of natural fibers and rich in stretch.

  Since the outer fabric, which is a knitted fabric made of natural fibers, and the non-woven fabric, which is made of thermoplastic resin fibers, are bonded in advance to the back surface of the outer fabric, it is thermally welded to the outer fabric that is a knitted fabric made of natural fibers during ultrasonic welding. Therefore, it is not necessary to impregnate an active substance or mechanically entangle a surface material which is a knitted fabric made of natural fibers in advance, so that the manufacturing process is simple and the manufacturing cost can be kept low.

  A convex portion formed in the thickness direction of the laminate is formed by pressing an outer surface which is a knitted fabric made of natural fibers and an adhesive surface of a nonwoven fabric made of thermoplastic resin fibers on the back surface of the outer fabric with an ultrasonic welder. Therefore, the adhesive surface is difficult to peel off and is durable.

  Since the nonwoven fabric, the second layer, and the third layer of the laminate are welded only by ultrasonic welding, the manufacturing process is simple and the manufacturing cost can be kept low.

  According to the invention described in claim 2, since a knitted fabric made of fibers having no heat-welding characteristics in which natural fibers and thermoplastic resin fibers are mixed in the outer fabric is used, the knitted fabric made of natural fibers is rich in stretchability. It is possible to provide a mat with higher durability while maintaining the texture and texture.

  According to the invention described in claim 3, since a knitted fabric made of a thermoplastic resin fiber or a fiber having a thermal welding characteristic in which a natural fiber and a thermoplastic resin fiber are mixed is used for the surface material, the production efficiency is high. Further, it is possible to provide a low-priced mat with high durability while maintaining the function of the knitted fabric rich in elasticity.

It is the enlarged view which shows the top view and ultrasonic welding part of embodiment of this invention. It is AA sectional drawing and the enlarged view of an ultrasonic welding part of embodiment of this invention. It is a comparison figure of the knitting structure | tissue used for the surface material which is embodiment of this invention, and a textile structure. It is an ultrasonic welding processing machine which welds the 1st layer of the embodiment of the present invention, the 2nd layer, and the 3rd layer. It is a conceptual diagram which shows the formation process of the 1st layer, 2nd layer, and 3rd layer of embodiment of this invention. It is a conceptual diagram explaining skew.

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

As shown in FIGS. 1 and 2, the mat 1 has a basis weight of 8 to 40 g / m made of thermoplastic resin fibers on the back surface of the outer fabric 2 which is a knitted fabric having a basis weight of 50 to 300 g / m ^{2 made} of natural fibers. ^A first layer 4 to which ^two nonwoven fabrics 3 are bonded; a second layer 5 having a basis weight of 50 to 200 g / m ² of a batting layer made of thermoplastic resin fibers disposed on the back side of the first layer 4; And a third layer 6 made of thermoplastic resin fibers disposed on the back side of the second layer 5 and having a basis weight of 80 to 260 grams / m ² , and a first layer 4 of the layered body. The adhesive surface 9 between the outer material 2 and the nonwoven fabric 3 has a convex portion 10 formed in the thickness direction of the laminate by the pressing force of the ultrasonic welder 105, and the nonwoven fabric 3 of the first layer 4 of the laminate The second layer 5 and the third layer 6 are formed by the ultrasonic welder 105. It is characterized by being fixed by ultrasonic welding with pressing force and frictional heat.

  As shown to Fig.3 (a), a knitted fabric says the structure | tissue which makes a loop-shaped stitch and twists a thread | yarn. The knitted fabric has the property of stretching in the direction of the yarn, whereas the woven fabric (FIG. 3 (b)) has poor stretchability due to the structure that crosses the warp and weft yarns.

  Since the knitted fabric has the property of expanding and contracting in the direction of the yarn, the knitted fabric is difficult to tear and is resistant to impact. For this reason, it is possible to sufficiently withstand the pressing force by the ultrasonic welder 105 during ultrasonic welding.

The surface material 2 can exemplify a basis weight of 50 to 300 grams / m ² , preferably 120 to 260 grams / m ² , particularly preferably 120 to 200 grams / m ² . At the time of ultrasonic welding, the surface material 2 which is a knitted fabric made of natural fibers is not welded, but is welded to the second layer 5 and the third layer 6 through the nonwoven fabric 3 made of bonded thermoplastic resin fibers. When the basis weight is less than 50 grams / m ² , sufficient durability cannot be obtained. 120 to 260 g / m ² is preferable because it has an appropriate thickness, and 120 to 200 g / m ² from the viewpoint of ensuring the texture of natural fibers and the elasticity of the knitted fabric, and good transmission of vibration waves during ultrasonic welding. m ² is particularly preferred. When the basis weight exceeds 300 g / m ² , the thickness becomes too large, and therefore, delamination or the like of the ultrasonic weld 7 tends to occur.

  Examples of natural fibers include plant fibers such as cotton and hemp, and animal fibers such as silk, wool, and cashmere.

  Since knitted fabrics often use sweet twisted yarns having a long fiber length and few twists, a soft feel can be obtained as compared with a fabric using a strong twisted yarn having a short fiber length and many twists. In addition, it has stretchability, is difficult to wrinkle, has large air permeability and heat retention, has water absorbency, and has quick drying properties.

Nonwoven 3, a basis weight of 8-40 g / ^{m 2,} preferably 10-35 g / ^{m 2,} particularly preferably exemplified 10-25 g / ^{m 2.} When the basis weight is less than 8 grams / m ² , sufficient durability cannot be obtained. 10-35 gram / m < ² > is preferable in what has moderate thickness, and 10-25 gram / m < ² > is especially preferable from a viewpoint of durability and the followable | trackability with the shape of the surface material 2. FIG. When the basis weight exceeds 40 g / m ² , the thickness becomes too large, and the followability with the shape of the surface material 2 is inferior.

  Examples of the thermoplastic resin include polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polytrimethylene terephthalate (PTT), polyethylene naphthalate (PEN), and liquid crystal polyester, but are not limited thereto. Examples thereof include polyolefins such as PE), polypropylene (PP), and polybutylene, styrene resins, fluorine resins, and resins obtained by blending at least two of these.

  As shown in FIG. 5, the first layer 4 is fixed by bonding a surface material 2 that is a knitted fabric made of natural fibers and a nonwoven fabric 3 made of thermoplastic resin fibers.

  The adhesion between the outer material 2 and the nonwoven fabric 3 can be exemplified by a hot melt resin in the case of using an adhesive, but is not limited thereto. An emulsion resin and a water-soluble paste can also be used.

  When the outer material 2 and the non-woven fabric 3 are bonded by thermal welding, a heat-bonding fiber (not shown, the same applies hereinafter) or a heat-adhesive resin powder (not shown, the same applies hereinafter) disposed on the opposing surface of each layer. Bond together by heat melting. An adhesive fiber or adhesive resin powder having a low melting point or a low softening point is temporarily fixed, and strong adhesion is formed through the temporarily fixed adhesive fiber or adhesive resin powder.

Batting layer of the second layer 5 shown in FIG. 2, the basis weight is 50-200 g / ^{m 2,} preferably 80-200 g / ^{m 2,} particularly preferably exemplified 100-180 g / ^{m 2.} Although fiber cotton is used and the solid cotton which consists of a fiber containing the said polyester can be illustrated, a solid cotton raw material is not limited to these. When the fabric weight of the batting layer is less than 50 g / m ² , sufficient cushion performance and ventilation performance cannot be exhibited. 80-200 gram / m < ² > is preferable in what has moderate thickness, and 100-180 gram / m < ² > is especially preferable from a moderate cushioning property, hygroscopic property, and a breathable viewpoint. When the basis weight exceeds 200 g / m ² , the thickness becomes too large, and therefore, delamination or the like of the ultrasonic weld 7 tends to occur.

  Since ultrasonic welding has the following advantages, it is used in a wide range of fields. That is, the cycle is fast (generally, the welding time is 1 second or less), the cost is low (there is no running cost because no consumables such as adhesives are required), and the finish is clean (the surface is painted) Can be welded), high in strength (if the same material is welded, it can be welded at a level close to the strength of the base material), easy to automate (designed to be easily introduced into an automatic machine) High airtightness is obtained (since the resin on the bonding surface is completely melted, high airtightness is obtained), low power consumption (only standby power except during ultrasonic oscillation), and high reproducibility ( Parameters are numerically managed and programs can be saved), easy to control (each parameter is digitally controlled and precise control is possible), and there is an advantage that no bad smell is generated.

  The ultrasonic welding is a processing technique in which a thermoplastic resin is instantaneously melted and bonded by fine ultrasonic vibration and pressure. Plastics to which ultrasonic welding can be applied are not limited to thermoplastic resins (resins that melt when heat is applied), but can also be applied to thermosetting resins such as urethane and epoxy resins, vinyl chloride resins, and the like. This is because the laminated body melts and adheres. The ultrasonic welder 105 converts electric energy into mechanical vibration energy and simultaneously applies pressure to generate strong frictional heat on the joint surface of the laminate, thereby melting and bonding the resin. Unlike the vibration feedback method, the ultrasonic oscillation method can start vibration even from a very heavy load, and immediately after the vibration starts, it coincides with the most efficient output voltage current phase of the oscillator output. Automatically tuned to frequency. Even if there is a frequency fluctuation due to temperature rise or load fluctuation, the same phase point of voltage and current is continuously tracked and tuned. Further, the frequency at the end of oscillation is held, and the next oscillation starts from this frequency. For this reason, reliable and smooth rise is possible, and tracking without phase error is possible in a wide range.

  As shown in FIG. 4, the ultrasonic welding machine 100 is an apparatus including an ultrasonic welder 105 and a pattern roll 107. The ultrasonic welder 105 generates a high-frequency alternating current from the power source obtained from the power source unit 103. This high-frequency electrical energy is supplied to a built-in vibrator and converted into mechanical vibration (ultrasonic waves). This ultrasonic energy is transmitted through the horn 106 to the first layer 4 non-woven fabric 3, the second layer 5 batting layer and the third layer 6 sheet through the horn 106, and between these contact surfaces or between molecules. Frictional heat is generated, local melting occurs, and welding is performed instantaneously at the ultrasonic weld 7.

  As shown in FIG. 4, the sheets of the first layer 4, the second layer 5, and the third layer 6 made of the outer fabric 2 and the nonwoven fabric 3 are supplied from the raw fabric discharge unit 101 to the host unit 102. The laminated body welded and welded by the ultrasonic welder 105 provided to the product is transferred to the product winding unit 104 and wound.

  As shown in FIG. 5, the nonwoven fabric 3 of the first layer 4, the batting layer of the second layer 5, and the sheet of the third layer 6 are instantly welded by forming a melted portion 8 in the ultrasonic welded portion 7. Thereby, the batting layer of the second layer 5 is stably sandwiched between the first layer 4 and the third layer 6. When the filling layer of the second layer 5 is made of thermoplastic resin fibers, the filling layer of the second layer 5 is also welded and fixed together with the outer material 2 and the nonwoven fabric 3 at the ultrasonic welding portion 7.

  The material to be welded is passed between the ultrasonic welder 105 and the pattern roll 107. In the welding process, air pressure is applied to the ultrasonic welder 105 to pressurize it. When the linear pressure between the ultrasonic welder 105 and the pattern roll 107 is usually 2 to 5 kg / cm and the linear pressure is less than 2 kg / cm, the pressure on the laminate is insufficient and no fusion occurs. If the pressure exceeds 5 kg / cm, the pressure on the ultrasonic weld 7 is too high and the thermoplastic resin fiber corresponding to the ultrasonic weld 7 may be thermally decomposed or, in extreme cases, perforation may occur. The adhesive strength of the resulting laminate is reduced, which is not preferable.

  The outer surface 2 and the nonwoven fabric 3 of the first layer 4 fixed by adhesion are pressed by the ultrasonic welder 105 at the time of ultrasonic welding, and an adhesive surface 9 between the outer material 2 and the nonwoven fabric 3 is formed at the ultrasonic welding portion 7. The nonwoven fabric 3 made of thermoplastic resin fibers, the second layer 5 and the third layer 6 are melted by the frictional heat generated by the ultrasonic welder 105 at the same time as they protrude into the second layer 5 in a convex shape. The portion 8 is formed and fixed by ultrasonic welding.

  Hereinafter, an example of the effect of the mat of the embodiment will be specifically described with reference to the drawings.

  As shown in FIGS. 1, 2, and 5, the mat 1 is bonded to the nonwoven fabric 3 without damaging the fiber structure of the knitted fabric of the outer fabric 2, and the first layer 4 and the third layer 6 are the second layer. The non-woven fabric 3, the second layer 5, and the third layer 6 of the first layer 4 are ultrasonically welded by the frictional heat and pressing force of the ultrasonic welder 105 while sandwiching the batting layer of the layer 5.

  Since the fiber structure of the knitted fabric of the outer material 2 is not damaged during ultrasonic welding, the outer material 2 has a function of expanding and contracting in the direction of the yarn, is not easily torn, and has a mat 1 that makes use of the function of the knitted fabric that is resistant to impact. Can be provided.

  As shown in FIG. 2, during ultrasonic welding, the adhesive surface 9 of the outer fabric 2 and the nonwoven fabric 3 has a convex portion 10 formed in the thickness direction of the laminate, and the adhesive surface 9 of the outer fabric 2 and the nonwoven fabric 3 The extension of the cross section increases the height h of the convex portion in addition to the width W of the convex portion. This means that the surface area of the bonding surface 9 in the ultrasonic welded portion 7 is increased, and the pulling stress of the outer fabric 2 is increased accordingly. The adhesion of the outer fabric 2 and the nonwoven fabric 3 in the ultrasonic welded portion 7 is simply the outer fabric 2. It becomes stronger than the case where the nonwoven fabric 3 is placed and bonded.

  As shown in FIGS. 2, 5, and 6, the outer fabric 2 and the nonwoven fabric 3 are bonded to each other, and the nonwoven fabric 3, the second layer 5, and the third layer 6 of the first layer 4 are ultrasonically welded. The skew that tends to occur (FIG. 6B) can be prevented, and the mat 1 can be formed with a beautiful finish.

  In the ultrasonic welding, it is easy to change the arrangement interval and the arrangement shape of the ultrasonic welding portions 7, and the arrangement of the ultrasonic welding portions 7 can be expressed in various shapes by combining straight lines and curves. Complex forms such as flowers and highly designable forms can be easily expressed.

  Ultrasonic welding does not use a needle as in quilt sewing, can ensure safety, can save the trouble of inspection with a needle, and can reduce the manufacturing cost.

  Since ultrasonic welding does not require an adhesive or the like, the running cost can be kept low.

  In ultrasonic welding, since materials are welded to each other, when thermoplastic resin fibers made of the same material are welded, the mat 1 can be provided with a strength close to the strength of the base material and excellent in durability.

  In addition, ultrasonic welding has advantages such as low power consumption in the manufacturing process (only standby power except during ultrasonic oscillation) and no bad odor.

  Hereinafter, the present invention will be further described with reference to examples, but the present invention is not limited to these examples.

<Creation of the first layer>

Adhesive fabric with a fabric weight of 200 g / m ^{2 and} a nonwoven fabric 3 made of polypropylene or polyester with a fabric weight of 25 g / m ² arranged on the back side of the outer fabric 2 are bonded with a hot melt resin adhesive. A first layer 4 is created.

<Welding from the first layer to the third layer>
Next, the first layer 4, the second layer 5, and the third layer 6 are set on the original fabric discharge unit 101 of the ultrasonic welding machine 100.

  The first layer 4, the second layer 5, and the third layer 6 are sent from the raw material discharge unit 101 to the host unit 102 and overlapped by the host unit 102. When the ultrasonic welder 105 presses the laminated object, the outer surface 2 of the first layer 4 and the adhesive surface 9 of the nonwoven fabric 3 form a convex portion 10 in the thickness direction of the laminated body, and at the same time, thermoplastic resin fibers The nonwoven fabric 3, the second layer 5, and the third layer 6 of the first layer 4 are ultrasonically welded and fixed by the pressing force and frictional heat of the ultrasonic welder 105, and are integrated as a laminate.

  During ultrasonic welding, the woven fabric structure of the cotton fabric of the outer fabric 2 is not damaged, so that it is possible to provide a mat 1 which is rich in elasticity utilizing the texture of natural fibers, is hard to tear, and is strong against impact.

The second layer 5, which is a batting layer made of polyester fiber solid cotton having a basis weight of 180 g / m ² , is sandwiched between the first layer 4 and the third layer 6 made of polyester fiber, and an ultrasonic welder 105. By the frictional heat and the pressing force due to the above, it is possible to provide the mat 1 having cushioning properties, which is fixed at the ultrasonic weld 7.

  The fixing of the top sheet 2 made of cotton fibers is performed by adhesion, and therefore there is no restriction on the number and arrangement of the ultrasonic welds 7 in order to increase the fixing strength. Therefore, the freedom degree of arrangement | sequence of the ultrasonic welding part 7 is high, and it can draw the figure of the rose flower with high design property.

  As described above, it is possible to provide a mat 1 having a good touch, rich in elasticity, high designability, durability, and high productivity, utilizing the texture of a cotton woven fabric made of cotton fibers.

  Examples 2 and 3 show examples in which thermoplastic resin fibers are mixed in the outer material. Regarding the configuration common to the first embodiment, from the reference numerals attached to the respective configurations of the first embodiment, the second embodiment adds “200” to the numeral, and the third embodiment adds “300”. Therefore, the detailed description is omitted, and the differences are described.

  Example 2 is characterized in that the outer material 202 is a knitted fabric made of fibers not having heat-welding characteristics in which natural fibers and thermoplastic resin fibers are mixed. Thereby, it is possible to provide a mat 201 that is rich in stretchability, has high designability, durability, and high productivity, making use of the natural fiber texture of the knitted fabric of the outer material 202.

  Since the outer material 202 is a knitted fabric made of fibers that do not have heat welding characteristics, the mat mat 201 is formed in the same manner as in the first embodiment.

  Example 3 is characterized in that the outer material 302 is a knitted fabric made of thermoplastic resin fibers or fibers having heat-welding characteristics obtained by mixing natural fibers and thermoplastic resin fibers. Thereby, the mat mat 301 having high stretchability, high designability, durability and high productivity utilizing the functionality of the knitted fabric of the outer material 302 can be provided.

  Since the outer material 302 is a knitted fabric made of fibers having heat-welding properties, the laminate can be integrated by ultrasonic welding including the outer material 302, so that it is possible to omit the adhesion between the outer material 302 and the nonwoven fabric 303. Especially excellent in productivity.

  INDUSTRIAL APPLICABILITY The present invention can provide a mat with good touch, rich elasticity, designability, durability, and high productivity, and its industrial utility value is great.

1, 201, 301 ... laying mat 2, 202, 302 ... outer material 3, 303 ... non-woven fabric 4 ... first layer 5 ... second layer 6 ... third layer 7 ... · Ultrasonic welding portion 8 ··· Melting portion 9 ··· Adhesion surface 10 ··· convex portion W ··· convex portion width h · · · convex portion height 100 · · · ultrasonic welding Processing machine 101 ... Raw material discharge unit 102 ... Host unit 103 ... Power supply unit 104 ... Product winding unit 105 ... Ultrasonic welder 106 ... Horn 107 ... Pattern roll

Claims (3)

A first layer of natural fibers consisting of basis weight of 50-300 g / m ² basis weight of a thermoplastic resin fibers on the rear surface of the outer material is a knitted fabric of 8-40 g / m ² nonwoven fabric is adhered,
A ^second layer that is a batting layer having a basis weight of 50 to 200 g / m ^{2 made} of thermoplastic resin fibers disposed on the back side of the first layer;
A third layer composed of a thermoplastic resin fiber disposed on the back side of the second layer and having a basis weight of 80 to 260 g / m ² , and a laminate comprising:
An adhesive surface between the outer surface of the first layer of the laminate and the nonwoven fabric has a convex portion formed in the thickness direction of the laminate, and the nonwoven fabric and the first layer of the first layer of the laminate. A floor mat, wherein two layers and the third layer are fixed by ultrasonic welding.   2. The mat according to claim 1, wherein the surface material is a knitted fabric made of fibers not having heat-welding characteristics in which natural fibers and thermoplastic resin fibers are mixed.   2. The mat according to claim 1, wherein the surface material is a knitted fabric made of thermoplastic resin fibers or fibers having heat-welding characteristics in which natural fibers and thermoplastic resin fibers are mixed.