JP3933958B2 - Manufacturing method of mat - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a mat, and more particularly to a method for manufacturing a mat backed with a rubber sheet.
[0002]
[Prior art]
In general, as the entrance mat, as shown in FIG. 6 and FIG. 7 respectively, the mat body is formed by a pile 33 implanted in the base fabric 32 in order to obtain a beautiful appearance and a good feel. In order to prevent slippage movement and waterproof, the back surface of the mat body on which a rubber sheet material 7 having a large number of non-slip leg pieces 22 is attached is popular.
[0003]
Conventionally, as this type of mat, a pile fabric and an unvulcanized rubber sheet are laminated, and this is pressure-bonded by a vulcanizing press and heat-cured, and the rubber sheet is vulcanized and bonded together. Things are well known.
[0004]
[Problems to be solved by the invention]
However, although the method described above is simple, the pile is heated to a high temperature in a strongly compressed state, and therefore, the pile hair is not restored after vulcanization molding and is deformed and cured while being compressed, and the appearance of the product is The beauty and good feel were significantly impaired.
[0005]
As a measure for solving this problem, for example, there is a mat manufacturing method disclosed in Japanese Patent Publication No. 4-64252. The above publication discloses a mat manufacturing method that can obtain a beautiful appearance without causing deformation of the pile hair by pressing the pile against the sheet material by air pressure without contacting the mold. Yes.
[0006]
However, the mat manufacturing method disclosed in the above publication has a problem in terms of cost because it requires a pair of upper and lower dedicated molds and air introduction means.
[0007]
The present invention pays attention to such problems, and provides a method for producing a mat that can easily produce a mat with a rubber sheet material having a beautiful appearance by using conventional equipment such as a general-purpose press as it is. Objective.
[0008]
[Means for Solving the Problems]
That is, the invention according to claim 1 of the present invention is a mat manufacturing method in which a rubber sheet having a plurality of non-slip leg pieces provided on the back surface of a base fabric on which piles are planted is provided. Inside the press board, a mold frame sandwiching a metal plate provided with a plurality of through-holes forming anti-slip leg pieces, an unvulcanized rubber sheet, a base fabric in which a pile is implanted, and a thickness of the base plate after placing the spacers is less than 2-fold 0.5-fold or more of the fabric thickness in the order, without the pile is subjected to excessive deformation, performs the press vulcanization to fall down while maintaining sufficient restoring force This is a method for manufacturing a mat.
[0009]
Invention of Claim 2 of this application is a manufacturing method of the mat | matte in which the said spacer is a frame which has an opening including the outer periphery of the said base fabric.
[0011]
Invention of Claim 3 of this application is a manufacturing method of the mat | matte of Claim 1 or 2 in which the said spacer consists of duralumin.
[0012]
According to the invention described in the claims of the present application, a mat with a rubber sheet material having a beautiful appearance can be easily produced by using a conventional equipment such as a general-purpose press as it is by relaxing the pressing pressure with the spacer.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the method for producing a mat according to the present invention will be described in detail.
FIG. 1 shows a longitudinal sectional view of each member housed in a press board in the mat manufacturing method of the present invention. A mold 2 holding a metal plate 5 is placed on the lower board 1 of the press board. As shown in FIG. 4, the mold frame 2 is a set of frame bodies including an upper mold frame 3 and a lower mold frame 4, and sandwiches the metal plate 5 by screwing at the peripheral portion. The metal plate 5 has a plurality of through holes 21 for forming anti-slip leg pieces on the back surface of the rubber sheet of the mat. The shape of the through hole 21 is not particularly limited, and is provided on the entire surface of the metal plate 5 according to an arbitrary pattern. The upper mold 3 is preferably provided with a burr groove 23.
[0014]
An unvulcanized rubber sheet 6 formed into a sheet shape is placed on the metal plate 5. The rubber constituting the unvulcanized rubber sheet 6 is natural rubber or the like, and its components are not particularly limited, and any of natural rubber, synthetic rubber such as chloroprene rubber, nitrile rubber and hydrogenated nitrile rubber, and recycled rubber May be used. A rubber compound in which a vulcanizing agent, a vulcanization accelerator, a reinforcing agent, a plasticizer, an anti-aging agent and the like are blended with these rubbers can be used.
[0015]
The thickness of the unvulcanized rubber sheet 6 is not particularly limited, but is preferably 2 mm to 5 mm.
[0016]
As shown in FIG. 1, the unvulcanized rubber sheet 6 is placed on a step formed by the upper mold frame 3 and the metal plate 5, and the peripheral portion is bent so as to follow this step.
[0017]
Next, the surface material 31 is placed on the unvulcanized rubber sheet 6. The outer material 31 is obtained by implanting a pile 33 of acrylic, nylon, polyester, or the like having a length of 5 mm to 10 mm on a base cloth 32 having a thickness of about 1 mm. The base fabric 32 is preferably a non-woven fabric made of synthetic fibers such as polyester, and a rubber paste is applied to the back surface thereof.
[0018]
Subsequently, the spacer 10 is installed. The spacer 10 relieves the press pressure applied to the pile 33 and prevents the pile from undergoing excessive deformation. For example, a plurality of spacers 10 are disposed at any position surrounding the base fabric 32. The spacer 10 may be an integral frame having an opening including the entire outer periphery of the base cloth 32 as shown in FIG. 5, and the opening is sized so as to substantially contact the outer periphery of the base cloth 32. Preferably there is.
[0019]
The thickness of the spacer 10 is desirably 0.5 to 2.0 times the thickness of the base fabric 32. If the thickness of the spacer 10 is less than 0.5 times the thickness of the base fabric 32, sufficient press pressure relaxation effect will not be exhibited, and if it exceeds 2.0 times, the press pressure will be insufficient. There is a problem in that the adhesion between the unvulcanized rubber sheet 6 and the unvulcanized rubber sheet 6 becomes insufficient, and the rubber does not sufficiently flow into the through hole 21.
[0020]
The material constituting the spacer is not particularly limited as long as it is rigid and has heat resistance, but a light metal is preferable in consideration of workability, and duralumin is most preferable.
[0021]
After the above members are installed, the upper plate 11 of the press plate is set, the press plate is heated to a predetermined temperature, and press vulcanization is performed at a predetermined pressure for a predetermined time. Here, the predetermined temperature is 130 ° C. to 170 ° C., the predetermined pressure is 2.0 × 10 ³ N / m ^{2 to} 2.0 × 10 ⁴ N / m ² , and the predetermined time is 5 minutes to 15 Minutes. These conditions vary depending on the type of surface material used. For example, in the case of an acrylic pile, the temperature of the press panel is around 140 ° C., and the press pressure is 7.0 × 10 ³ N / m ^{2 to} 8.0 × 10 ³ N. / M ² , pressing time of 5 to 6 minutes is most preferable.
[0022]
When press vulcanization is performed under the above conditions, as shown in FIG. 2, the unvulcanized rubber sheet 6 flows into the through-holes 21 and the burr grooves 23 in a state where the pile 33 is lying down, and becomes a vulcanized rubber sheet 7. Stop leg pieces 22 and burrs 24 are formed. Here, since the spacer 10 relieves the press pressure, the pile 33 does not receive excessive deformation and falls while maintaining a sufficient restoring force.
[0023]
Open the press panel and remove the mat. The lying pile 33 is raised as it is as shown in FIG. 3, but a mat with a more beautiful appearance can be obtained by applying air to the entire surface of the mat with a device capable of ejecting pressurized air from a nozzle, for example. Finally, the burr 24 around the entire mat is cut off to obtain a mat of a prescribed size.
[0024]
【Example】
Example 1
Using a non-vulcanized rubber sheet made of natural rubber, a base material made of polyester nonwoven fabric with an acrylic pile planted on it, a spacer that is a 1 mm thick duralumin frame, press panel temperature 140 ° C, press pressure The mat was produced by press vulcanization for 6.5 minutes at 7.2 × 10 ³ N / m ² . The mat pile piled up was easily raised and a mat with a beautiful appearance without deformation and hardening of the pile was obtained.
Comparative Example 1
A mat was produced under the same conditions as in Example 1 except that no spacer was used. In the obtained mat, the pile was deformed and hardened.
[0025]
【The invention's effect】
As described above, according to the mat manufacturing method of the present invention, in the mat manufacturing method in which a rubber sheet provided with a plurality of anti-slip leg pieces on the back surface is attached to a base fabric on which a pile is planted. A mold frame sandwiching a metal plate provided with a plurality of through-holes for forming a non-slip leg piece, an unvulcanized rubber sheet, and a base fabric in which a pile is implanted, and after the thickness is established the spacer is less than 2-fold 0.5-fold or more the thickness of the base fabric in order, without the pile is subjected to excessive deformation so as to fall down while maintaining sufficient restoring force By performing press vulcanization, it is possible to provide a mat manufacturing method in which the press pressure is relaxed by the spacers, and it is possible to manufacture a mat with a beautiful appearance that is not accompanied by unrecoverable deformation of the pile.
[0026]
Further, according to the mat manufacturing method of the present invention, a mat with a rubber sheet material having a beautiful appearance can be easily manufactured by using conventional equipment such as a general-purpose press as it is without preparing a dedicated mold. .
[Brief description of the drawings]
FIG. 1 is a longitudinal sectional view of each member before pressing.
FIG. 2 is a longitudinal sectional view of each member during pressing.
FIG. 3 is a longitudinal sectional view of each member after pressing.
FIG. 4 is a perspective view of a metal plate held between molds.
FIG. 5 is a perspective view of a spacer.
FIG. 6 is a partial perspective view of the mat surface.
FIG. 7 is a partial perspective view of the back surface of the mat.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Lower board 2 Mold 3 Upper mold 4 Lower mold 5 Metal plate 6 Unvulcanized rubber sheet 7 Vulcanized rubber sheet 10 Spacer 11 Upper board 21 Through hole 22 Non-slip leg piece 23 Burr groove 24 Burr 31 Surface 32 33 fabric piles

Claims (3)

In a mat manufacturing method in which a rubber sheet provided with a plurality of anti-slip leg pieces on the back side is attached to the back of a base fabric on which piles are planted, an anti-slip leg is provided inside the press panel consisting of an upper panel and a lower panel. Formwork sandwiching a metal plate with a plurality of through-holes forming a piece, an unvulcanized rubber sheet, a base fabric in which a pile is implanted, and a thickness not less than 0.5 times the thickness of the base fabric 2 A method for manufacturing a mat, comprising: sequentially placing spacers that are less than or equal to twice, and performing press vulcanization so that the pile does not undergo excessive deformation and falls while maintaining a sufficient restoring force.   The method for manufacturing a mat according to claim 1, wherein the spacer is a frame having an opening including the entire outer periphery of the base fabric.   The method for manufacturing a mat according to claim 1, wherein the spacer is made of duralumin.

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