JP3434035B2 - Dust mat - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a dust mat such as an entrance mat and a foot wipe mat.

[0002]

2. Description of the Related Art Conventionally, not only dust mats but also various mats have various uneven shapes formed on their contact surfaces for the purpose of preventing slippage and reducing weight. For example, it is known that a texture is formed as fine unevenness, and in addition, it is disclosed in Japanese Utility Model Laid-Open No. 63-3
Japanese Patent No. 5636 and Japanese Utility Model Laid-Open No. 60-187687 disclose that a large number of small protrusions and a large number of suction disks are formed. Further, Japanese Patent Application Laid-Open No. 5-329092 discloses that in which a continuous checkerboard-like or continuous circular shallow linear groove is formed.

[0003]

However, the cloth-formed product not only has an insufficient anti-slip effect, but is heavy and has poor contact surface air permeability. In addition, the other dust mats with non-slip concavities and convexities have good air permeability on the contact surface because the recesses communicate with the outer periphery of the mat in a straight line, but the thickness of the recesses is reduced to reduce the weight of the mat. When it is thin, it tends to be bent and does not have sufficient durability. Further, although a large number of small projections have a great effect of preventing slippage, when repeatedly washed and used in a large washing machine, a large number of small projections cause the surface of the pile fabric to be damaged. It is an object of the present invention to provide a dust mat that can solve the above problems at the same time. More specifically, it is intended to provide a dust mat that is lightweight, has less tendency to fold, has good anti-slip properties, can be stably laid, has sufficient durability during washing, and can be easily manufactured. .

[0004]

The dust mat of the present invention is a dust mat having a backing layer in which a large number of convex portions made of rubber or synthetic resin are formed on the back surface of a pile fabric, and the convex portions are mutually flat on a plane. Two types of elongated protrusions 4A and 4B which are different in direction and are substantially orthogonal to each other on an extension line
Consists, convex portions 4A, 4B is configured through sequence a are arranged parallel to each, b and Nukiretsu c, and d, 該経columns a and b
And at least one of the weft rows c and d are adjacent rows.
Interlaced and uninterlaced rows a and b or latitude c
d is characterized in that they are alternately located close to each other, and preferably, in the longitudinal rows and the weft rows, adjacent rows intersect each other.

Further, the area of one of the elongated protrusions is 3
And 0～300Mm ^2, it is preferable to the occupied area of the projection in the dust mat back surface 30 to 50%, more preferably, a 0.3~1.5mm the height of the convex portion.

The present invention will be described in detail below. 1, 2, and 3 are cross-sectional views of the dust mat of the present invention, and FIG. 4 is a plan view showing the shape of the convex portion. The pile material constituting the mat is composed of the pile 1 and the base cloth 2. The pile shape is not limited to the type having the ordinary ring shape shown in FIGS. 1 and 3, but the ring of the pile shown in FIG. It may be a type in which the top of the shape is cut. The pile material is not particularly limited, and natural fibers, chemical fibers, and synthetic fibers can be used. Nonwoven fabric is mainly used as the base fabric, but woven fabric may be used. In addition, the lower the height of the bottom portion 11 of the pile, that is, the thinner the pile 1 of the pile material is, the thinner the thickness t of the recess 5 described later is, which is preferable.

As the rubber forming the backing layer 3, natural rubber (NR), isoprene rubber (IR), styrene butadiene rubber (SBR), butadiene rubber (BR), chloroprene rubber (CR), acrylonitrile butadiene rubber (NBR, Diene rubbers such as NIR and NBIR, butyl rubber (IIR), ethylene propylene rubber (EPD)
M), silicone rubber, chlorosulfonated polyethylene (CSM), chlorinated polyethylene (CM), acrylic rubber (ACM, ANM), epichlorohydrin rubber (C
O, ECO), fluororubber (FFKM, FKM), polysulfide rubber (OT, EOT), and other non-diene rubbers, but NBR, SBR, EP in terms of weather resistance, oil resistance, and wear resistance.
DM is preferred.

As the synthetic resin, soft and weather resistant,
The material is not particularly limited as long as it has excellent abrasion resistance, and for example, soft polyvinyl chloride, polyurethane, thermoplastic elastomer and the like can be used.

The shape of the convex portion 4 is preferably an elongated shape having no acute angle portion. For example, the elliptical shape shown in FIG. 4 (a), the elliptical shape shown in FIG. 4 (b), etc. are considered. More preferably, the long side / short side is 2 to 5. Moreover,
Chamfering the corner 41 of the cross-section as shown in FIG. 3 reduces the anti-slip performance, but is preferable because it does not catch the pile fabric during washing. Similarly, it is preferable to chamfer the corner portion 51 of the concave portion because the durability of the convex portion is improved.

Further, by setting the area of one of the protrusions to be 30 mm ² or more, the ring-shaped fibers of the pile fabric are less likely to be caught even when washed, and the effect of preventing the pile from falling can be improved. In the case of, the pile will not be damaged. Further, when it is larger than 300 mm ² , the concave portion becomes large and not only the walking feeling is deteriorated but also the concave portion contacts the installation surface when stepped on, and the durability of the rubber or synthetic resin backing layer concave portion is deteriorated. There is.

Further, when the occupying area of the convex portion on the back surface of the dust mat is 30 to 60%, the concave portion is less likely to contact the installation surface even when stepped on, and the durability of the concave portion of the rubber or synthetic resin backing layer is improved. improves. Occupied area of convex part is 60
If it is larger than%, the weight reduction is not sufficient.

It is effective that the height h of the convex portion is 0.3 to 1.5 mm. If the height h is lower than 0.3 mm, it becomes difficult to obtain the anti-slip action, and if it is higher than 1.5 mm, the mat is stepped on. when not in a state where the protrusion is compressed, a state of being defeated, laid state is not stable, more hard to Re sufficient weight reduction lack of mat.

The thickness t of the recess of the rubber or synthetic resin backing layer depends on the pile material 1 as described above, and it is preferable that the thickness t is so thin that the bottom 11 of the pile is not exposed.

FIGS. 5, 6, 7, and 8 are plan views showing the shape and arrangement pattern of the convex portions. In the present invention, the convex portions 4A and 4B have different directions on a plane.
There are two types, and these convex portions 4A and 4B are in a relationship of being substantially orthogonal to each other on their extension lines. Moreover, the convex portions 4A and 4B are arranged in parallel with the rows a and b, respectively.
And the parallels c and d. The rows a and b and the latitude
At least one of c and d has adjacent rows intermingled.
The alternating rows a and b or the parallels c and d that do not intersect
It is located close to .

Here, the "longitudinal row" or "latitude row" being close to each other means that the rows a and b shown in FIG.
In, the tangent line (dotted line) of column a and the tangent line (dotted line) of column b are
It means a state in which they are substantially coincident with each other, and the intersection of the longitude and latitude lines means that the rows a and b or the rows c and d shown in FIG. 6 are overlapped {in FIG. )When
The state where the tangent line (dotted line) of column b overlaps, or c
Column tangent (dotted line) and column d tangent (dotted line) overlap
Means that are adjacent in the state}.

In FIG. 5, the latitude lines c and d intersect with each other, and the longitude lines a and b
6 and 7 show an array pattern of convex portions in contact with each other.
Indicates an array pattern of convex portions in which both the parallel rows c and d and the parallel rows a and b intersect, and the mats of the present invention having the convex portions of these patterns are both lightweight and have sufficient slippage. Not only does it have stopping properties and sufficient breathability, it also does not easily break. If the longitude and latitude lines are not arranged close to each other as shown in FIG. 8 and both the longitude and latitude lines are not intersected with each other, the mat will gradually be bent.

In particular, as shown in FIGS. 6 and 7, the convex portion 4A,
If the rows a and b and the rows c and d of 4B are intersected with each other, all the recesses do not communicate in a straight line at all and communicate with the peripheral surface of the dust mat, and there is no tendency to bend. .

As the method for producing the dust mat of the present invention, a method of applying an adhesive to a sheet of rubber or synthetic resin separately formed with a convex shape and laminating pile fabrics can be adopted, but molding by pressing is preferable. Preferred is a method of laminating with pile fabric by vulcanization adhesion in the case of rubber and fusion adhesion in the case of synthetic resin, and simultaneously forming the shape of the convex portion with a mold at this time.

[0019]

EXAMPLES Examples and comparative examples will be described below with reference to the drawings. The example product has a thickness of 0.
An unvulcanized rubber sheet containing a vulcanizing agent and the like is layered on 8 mm NBR (acrylonitrile butadiene rubber), and the rubber sheet is vulcanized and adhered to the pile fabric by a conventionally known pressure type press to obtain a 750 mm x 900 mm dust mat. It was At this time, the convex shape shown in FIG. 7 was formed on the surface of the rubber sheet with a mold so that the thickness t of the concave portion was 0.5 mm, the height h of the convex portion was 0.5 mm, and the occupied area of the convex portion on the back surface was about 50%. Was formed. Also, the long side of one protrusion is 13 m
m, the short side was 3 mm (the area of the convex portion was 39 mm ² ) . The comparative example product is a NBR with a thickness of 1.3 mm on the back of the pile fabric.
(Acrylonitrile butadiene rubber) is overlaid with an unvulcanized rubber sheet containing a vulcanizing agent and the like, and the rubber sheet is vulcanized and adhered to the pile fabric by a conventionally known pressure type press.
A dust mat of mm × 900 mm was obtained. At this time, a mesh was formed with a lattice woven cloth having a rubber sheet surface coated with Teflon resin, and the maximum thickness was 1.0 mm.

Weight comparison between the example product and the comparative product. Example product is 1480 g / sheet, Comparative example product is 1905 g / sheet,
The weight of the entire dust mat was reduced by about 22%. In addition,
The weight of the pile fabrics used in the example product and the comparative product was both 800 g / sheet.

Next, when the Example product and the Comparative Example product were laid on the outdoor floor and the anti-slip effect was confirmed, the Example product had some slippage immediately after laying, but only a few people walked. A sufficient anti-slip effect was recognized. At this time, when observing the back surface of the dust mat, sand, small dust, and the like were gathered in the concave portions, and the anti-slip effect of the convex portions was recognized, so that the dust mat could be stably laid.
The comparative example product was also laid on the same outdoor floor surface. 1 immediately after laying
Even after walking 0 people, there was some slippery feeling, and no significant improvement was made thereafter.

To check the durability during washing, wash at 40 ° C.
For 20 minutes, dehydration 10 minutes, tumbler drying 80 ° C. × 15 minutes as one cycle, continuous washing was performed 40 times, and the damage of the pile fabric and the rubber layer was observed. No damage to the fabric and rubber layer was found.

Further, the walking feeling of the example was softer and better than that of the comparative example. In addition, although it is rolled in a cylindrical shape during transportation, it can be rolled into a cylindrical shape more easily than the comparative example because the concave portion of the example article is flexible.

[0024]

Since the dust mat of the present invention is constructed as described above, it is light in weight, hard to fold, has good anti-slip properties, can be stably laid, and has sufficient durability during washing. And a dust mat that can be easily manufactured.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a dust mat of the present invention.

FIG. 2 is a sectional view showing another example of the dust mat of the present invention.

FIG. 3 is a sectional view showing still another example of another dust mat of the present invention.

FIG. 4 is a plan view showing the shape of a convex portion of the present invention.

FIG. 5 is an example of an array pattern of convex portions according to the present invention.

FIG. 6 is a diagram showing an example of another arrangement pattern of the convex portions of the present invention.

FIG. 7 is a diagram showing still another arrangement pattern example of convex portions of the present invention.

FIG. 8 is a diagram showing an example of an array pattern of convex portions for comparison.

[Explanation of Codes] 1 pile of pile cloth 11 bottom of pile 2 base cloth of pile cloth 3 backing layer 4 convex portions 4A, 4B convex portions a, b convex rows 4A, 4B formed by c, d convex portions 4A, 4B Weft 41 Convex section corner h h Convex height 5 Recess 51 Concave section corner t Concave thickness

Claims (4)

(57) [Claims] 1. A dust mat having a backing layer in which a large number of convex portions made of rubber or synthetic resin are formed on the back surface of a pile fabric, and the convex portions have different directions on a plane and are substantially orthogonal to each other on an extension line. slender two convex portions 4A, consists 4B, convex portions 4A, 4B is configured through sequence a are arranged parallel to each, b and Nukiretsu c, and d, the
At least one of the rows a and b and the rows c and d are adjacent
The rows a and b are not intersected, and the rows a and b which are not intersected
The dust mat is characterized in that the weft rows c and d are alternately located close to each other . 2. The longitude rows a and b and the weft rows c and d are such that adjacent rows intersect each other.
Dust mat described in. 3. The area of one of the short convex portions is 30 to 300.
a mm ^2, dust mat according to claim 1 or 2 occupying the area of the projection in the dust mat back surface is 30 to 60%. 4. The height of the short convex portion is 0.3 to 1.5 mm.
The dust mat according to claim 1, 2, or 3.