JP4489271B2 - Non-slip sheet for tatami mat - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an anti-slip sheet for tatami mat backing. More specifically, the present invention relates to a non-slip sheet used for backing a floor mat or the like used on a flooring of a house.
[0002]
[Prior art]
In recent years, especially in residential buildings such as condominiums, rooms have become western and flooring (wood floor) has been promoted due to the trend of Western-style living, but tatami is placed as a rug to be used by changing the western space into a Japanese space. The use of etc. is prevalent. As such a tatami mat, for example, a tatami mat formed by combining a tatami mat and a tatami core made of an insulation board is often used. And since the tatami mat is usually not fixed to the floor surface, it is easy to move during use, and when a person walks on it and a stepping action is applied, the tatami mat slid on the floor surface and the person falls etc. Therefore, a non-slip sheet is generally laminated on the back surface.
[0003]
The anti-slip surface where the non-slip sheet is in contact with the floor surface is usually excellent in workability such as low density polyethylene, ethylene-vinyl acetate copolymer, ethylene-alkyl acrylate copolymer, and coefficient of friction. A film made of a polyethylene-based resin having a large thickness was laminated, but if the film was used as a single layer laminated on kraft paper, the scratch resistance of the projections was weak, so that the damage propagated just by hitting the projections There was a problem. In order to bond the non-slip sheet to the insulation board to form the tatami core material, the anti-slip sheet insulation can be used so that the water-soluble adhesive can be used for the purpose of improving the adhesion and the safety of the bonding operation. Usually, kraft paper or the like is laminated on the bonding surface to be bonded to the construction board.
[0004]
[Problems to be solved by the invention]
As a method of forming a tatami mat having the above-described configuration, first, the insulation board is put on a high-frequency press device to perform moisture adjustment processing, and then a non-slip sheet laminated with kraft paper is laminated and dried to tatami mat. The core material is formed, and finally the tatami mat is completed through the tatami mat bonding process. However, if the insulation board and the anti-slip sheet laminated with kraft paper are first bonded to simplify the moisture adjustment process and the anti-slip sheet laminating process into one process and reduce costs, the high frequency press device Since the temperature rises to about 105 ° C. in the moisture adjustment processing step, the film surface made of the polyethylene resin laminated on the anti-slip surface of the anti-slip sheet is smoothed due to the temperature increase, and the anti-slip property is lost as the anti-slip sheet. There was a problem that.
[0005]
The present invention has been made paying attention to the above problems, and is a water-soluble adhesive binder that performs moisture adjustment processing of the insulation board and bonds the insulation board and the kraft paper laminated on the non-slip sheet. It is possible to reduce the cost by simplifying the moisture adjustment process and the non-slip sheet laminating process to one process so as to quickly evaporate some moisture and improve the adhesion, and the temperature during the moisture adjustment process An object of the present invention is to provide an anti-slip sheet for backing a tatami mat that has excellent anti-projection scratch resistance and anti-slip property, and does not lose the anti-slip property by smoothing the surface of the resin film.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the anti-slip sheet for backing tatami mat of the first invention of the present application is a rubber component such as a crystalline polypropylene component and a propylene-ethylene copolymer on one side of a woven or knitted fabric or nonwoven fabric made of a thermoplastic resin. And a laminate layer made of a reactor type thermoplastic elastomer.
[0007]
Further, the anti-slip sheet for tatami mat backing of the second invention of the present application has a configuration in which a laminate layer composed of the following components a) and b) is provided on one surface of a woven or knitted fabric made of a thermoplastic resin or a non-woven fabric. . a) a reactor-type thermoplastic elastomer composed of a crystalline polypropylene component and a rubber component such as a propylene-ethylene copolymer, 70 to 99% by weight, b) a polyethylene having a density of 0.91 to 0.94 g / cm ³ , 1 to 30% by weight of at least one selected from ethylene-vinyl ester copolymer, ethylene- (meth) acrylic acid alkyl ester copolymer and rubber
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
The woven or knitted fabric used in the present invention is knitted using a drawn yarn made of a thermoplastic resin as a warp and weft. Any thermoplastic resin may be used as long as the drawn yarn has high strength, and examples thereof include polyolefin, polyester, and nylon. Among these, polyolefins that are inexpensive and excellent in moldability are preferable, and specifically, high-density polyethylene and polypropylene that can obtain a stretching effect are preferable.
[0009]
In addition, as the form of the drawn yarn, any of monofilament, multifilament, flat yarn, split yarn and the like can be used, but flat yarn is preferable from the viewpoint of formability and smoothness. The method for producing the drawn yarn is not particularly limited, and a known technique may be adopted.
[0010]
The fineness of the drawn yarn is preferably 100 to 2000 decitex (hereinafter referred to as dt), more preferably 300 to 1200 dt. When the fineness is less than 100 dt, mechanical properties such as tear strength are insufficient as a woven or knitted fabric, and when it exceeds 2000 dt, the flexibility is inferior and adhesion between the woven and knitted fabric and the laminate layer is insufficient.
[0011]
The drawn yarn is used for warp and weft to form a woven or knitted fabric. The driving density is preferably 10-20 pieces / 2.54 cm. Various shapes such as plain weave, twill weave, twine weave and imitation weave may be used as the woven fabric, and weave may be either flat knitting or warp knitting. Specifically, tricot knitting, Miranese knitting, Russell knitting Hen etc. are mentioned.
[0012]
The non-woven fabric used in the present invention is a non-woven fabric in which synthetic resin long fiber filaments are deposited and bonded in a high density and non-directional manner. The non-woven fabric is long by a direct spinning method in which spinning, stretching, opening and bonding steps are continuously performed. It is obtained by randomly depositing fibers and bonding them. Specifically, a synthetic resin that can be spun into an extruder and put into a molten state, a nonwoven fabric obtained by a spunbond method in which fibers extruded from a spinning nozzle are drawn by a roller method or an air jet method, or a molten resin Non-woven fabric by melt-blowing method in which a fiber is jetted from a spinning nozzle together with a high-pressure gas stream, and a solution prepared by dissolving a spinnable synthetic resin in a solvent at high temperature and high pressure is released into the atmosphere through the spinning nozzle to vaporize the solvent. Non-woven fabric by flash spinning method to be fiberized can be used. Of these, non-woven fabrics by a spunbond method are preferable because they have high strength and good handleability.
[0013]
The reactor-type thermoplastic elastomer used in the present invention contains a crystalline polypropylene component as a hard segment and is composed of a rubber component such as a propylene-ethylene copolymer as a soft segment, which is disclosed in JP-A-6-25367. According to a method described in JP-A-6-25439, ethylene, propylene and, if necessary, a diene can be copolymerized by multistage polymerization in a reactor. As a commercially available product, Catalloy (trade name: manufactured by Montel Sdecay Sunrise “MSS” Co., Ltd.) can be mentioned. The reactor-type thermoplastic elastomer is used as component a) in the second invention of the present application.
[0014]
In the second invention of the present application, the polyethylene having a density of 0.91 to 0.94 g / cm ³ used as the component b) is a low-density polyethylene by a high-pressure method, a linear low-density polyethylene, an ethylene. It is at least one selected from α-olefin copolymers. Examples of the α-olefin include propylene, 1-butene, 1-hexene, 1-octene and the like.
[0015]
In the second invention of the present application, the ethylene-vinyl ester copolymer used as the component b) is a vinyl ester monomer such as vinyl acetate or vinyl propionate having ethylene as a main component produced by a high-pressure radical polymerization method. And a copolymer. Among these, an ethylene-vinyl acetate copolymer is preferable. A copolymer consisting of 1 to 40% by weight of vinyl acetate is preferred.
[0016]
In the second invention of the present application, the copolymer with ethylene- (meth) acrylic acid alkyl ester or its derivative used as component b) is produced by a high pressure radical polymerization method, specifically ethylene. -Methyl (meth) acrylate copolymer, ethylene- (meth) ethyl acrylate copolymer, etc. are mentioned, and ethylene-ethyl acrylate copolymer is particularly preferable. A copolymer comprising 1 to 40% by weight of acrylic acid ethyl ester is preferred.
[0017]
In the second invention of the present application, examples of the rubber used as component b) include ethylene propylene rubber, butadiene rubber, isoprene rubber, natural rubber and the like, and these may be used alone or in a mixture. Of these, ethylene propylene rubber is preferred.
[0018]
By blending the component b), workability is improved in the extrusion laminating method described later, and the productivity is improved.
As the component b), polyethylene having a density of 0.91 to 0.94 g / cm ³ is preferable from the viewpoint of moldability.
[0019]
The blending ratio of the component a) and the component b) is a) 70 to 99% by weight, b) 1 to 30% by weight, a) 80 to 95% by weight, b) 5 to 20% by weight. Is preferred. If the component a) is less than 70% by weight, the slip resistance is insufficient and the object of the present invention is difficult to achieve. If it exceeds 99% by weight, the moldability becomes insufficient.
[0020]
In the present invention, the anti-slip sheet for backing tatami mats is produced by using the thermoplastic elastomer or the composition comprising the components a) and b) on one side of the woven or knitted fabric or nonwoven fabric made of the thermoplastic resin. It is formed by providing a laminate layer by an extrusion laminating method.
[0021]
As thickness of the said laminate layer, 50-200 micrometers is preferable and 80-120 micrometers is more preferable. If the thickness is less than 50 μm, the wear resistance is insufficient, and if it exceeds 200 μm, the anti-slip property is not further improved, and the weight increases, which is uneconomical.
[0022]
The anti-slip sheet for tatami mat backing obtained as described above is obtained by laminating kraft paper on the woven or knitted fabric surface through an adhesive layer with an adhesive, or sandwiched between the woven and knitted fabric surface and kraft paper. An adhesive layer is provided by a laminating method to form a laminate. The resin used in the sandwich lamination method is not particularly limited as long as it is a resin usually used in the sandwich lamination method, such as low density polyethylene and polypropylene. Further, the thickness of the adhesive layer by the sandwich lamination method is preferably 30 to 100 μm, and more preferably 50 to 80 μm.
[0023]
The kraft paper is not particularly limited and is usually used, and those having a basis weight in the range of 60 to 90 g / m ² are preferably used. Kraft paper can be used with a water-soluble adhesive to improve the adhesion and to secure the adhesion when the tatami core material is formed by bonding the anti-slip sheet for backing tatami mat to the insulation board. Used to make
[0024]
As a method of forming the tatami core material by laminating the anti-slip sheet for tatami mat backing obtained as described above on an insulation board (fiber board specified in JIS A5905), the anti-slip sheet for tatami mat backing is used. A water-soluble adhesive is applied to the surface of the kraft paper and adhered to the insulation board, and then moisture adjustment processing is performed with a high-frequency press. In the high frequency press apparatus, the temperature rises to about 105 ° C. by dielectric heat generation due to the high frequency in the process of the temperature rising time of 10 minutes to the heating time of about 10 minutes, so that the moisture content of the insulation board is adjusted to a predetermined range. At the same time, the moisture that is the binder of the adhesive is also evaporated, and the adhesive layer is quickly fixed to form a tatami core material with good adhesion.
[0025]
At this time, the anti-slip sheet for tatami mat backing laminated on the back surface of the tatami core has excellent heat resistance with a melting point of the thermoplastic elastomer or a laminate layer composed of the components a) and b) of around 150 ° C. Therefore, it is possible to maintain good anti-slip properties as a slip-proof sheet for tatami mat backing without softening the resin and losing anti-slip properties.
[0026]
According to the manufacturing method of the tatami core material, the moisture adjustment process of the insulation board and the lamination process of the insulation board and the anti-slip sheet for attaching the tatami back can be simplified to one process, and there is a practical effect of reducing the cost. . The tatami mat is completed by attaching a tatami surface to the tatami core material and, if desired, a nonwoven fabric as a cushion material.
[0027]
Additives such as antioxidants, ultraviolet absorbers, light stabilizers, lubricants, antistatic agents, pigments, flame retardants, crosslinking agents, foaming agents, nucleating agents, etc. are added to the thermoplastic resin used in the present invention. It can be added to the extent that it does not substantially impair the characteristics of the invention.
[0028]
【The invention's effect】
As described above, the present invention relates to an anti-slip sheet for backing a tatami mat using an insulation board as a tatami core material, and a specific resin or woven fabric or a non-woven fabric made of a thermoplastic resin on one side. Since the laminate layer made of the resin composition is provided, it has excellent anti-projection scratch resistance, and the process of adhering the anti-slip sheet for backing the tatami mat and the insulation board and the moisture adjustment process of the insulation board are one step. In addition, the laminate layer does not lose its anti-slip property due to deformation, despite the high temperature during the moisture adjustment processing of the insulation board using a high-frequency press machine. An anti-slip sheet for tatami mat backing is provided.
[0029]
【Example】
Example 1:
Using a flat yarn made of polypropylene (MFR = 2.0 g / 10 min) as a warp weft, a plain woven fabric 3 was obtained with warp 440 dt-18 × weft 1020 dt-11 pieces / 2.54 cm.
On the other hand, a thermoplastic elastomer (Cataloy KS-357P (trade name: manufactured by Montelu Esdecay Sunrise “MSS” Co., Ltd.)) is used as a resin for the laminate layer 6, and the woven fabric 3 is thickened by an extrusion lamination method. A laminate layer 6 was laminated at a thickness of 50 μm to obtain a non-slip sheet 2 for attaching a tatami mat.
Next, a thickness of 60 μm is obtained by sandwich lamination using polypropylene (MFR = 4.0 g / 10 min) between the woven fabric 3 side of the anti-slip sheet 2 for backing the tatami mat and the kraft paper 4 having a basis weight of 70 g / m ^2. The adhesive layer 5 was formed and laminated to form a laminate. A tatami mat coated with water-soluble adhesive on the surface of the kraft paper 4 obtained in this way, adhered to an insulation board 7 having a thickness of 10 mm, and then subjected to moisture adjustment processing by generating heat with a high frequency press. A core material 1 was obtained. As a result, the moisture of the insulation board 7 is adjusted and the water of the water-soluble adhesive is also dried and firmly bonded, and the lamination and drying process of the anti-slip sheet 2 for backing the tatami mat is simplified and the productivity is improved. Improved significantly. A tatami mat was placed on the obtained tatami core material 1 to complete the tatami mat. This tatami mat has an anti-slip sheet 2 for backing tatami mats, which has excellent anti-projection scratch resistance and anti-slip properties. Even if a stepping action was added, the tatami mat itself slipped on the floor surface, and it was used suitably without the danger of a person falling.
[0030]
Example 2:
Low density polyethylene (MFR = 8.0 g / 10 min) with respect to 90% by weight of thermoplastic elastomer (Cataloy KS-357P (trade name: Montel ES Decay Sunrise “MSS” Co., Ltd.)) as a resin for laminate layer 6 The density was 0.917 g / cm ³ ). In the process of laminating the laminate layer 6 with a thickness of 50 μm on one side of the woven fabric 3 by the extrusion laminating method, the moldability was excellent and the productivity was improved by 5%.
The tatami surface was pasted on the obtained tatami core material 1 to complete the tatami mat. As in Example 1, the tatami mat surface 1 was excellent in anti-projection scratch resistance and anti-slip property, and was suitably used.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view of a tatami core material in which an anti-slip sheet for tatami mat backing is bonded to an insulation board according to an embodiment of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Tatami core material 2 Non-slip sheet for tatami mat backing 3 Woven knitted fabric or nonwoven fabric 4 Kraft paper 5 Adhesive layer 6 Laminate layer 7 Insulation board

Claims (2)

Anti-slip for backing tatami mats with a laminated layer made of a reactor type thermoplastic elastomer composed of a rubber component such as a crystalline polypropylene component and a propylene-ethylene copolymer on one side of a woven or knitted fabric made of a thermoplastic resin Sheet. An anti-slip sheet for backing a tatami mat provided with a laminate layer comprising the following components a) and b) on one side of a woven or knitted fabric made of a thermoplastic resin or a non-woven fabric.
a) Reactor type thermoplastic elastomer composed of crystalline polypropylene component and rubber component such as propylene-ethylene copolymer 70 to 99% by weight
b) At least one selected from polyethylene having a density of 0.91 to 0.94 g / cm ³ , an ethylene-vinyl ester copolymer, an ethylene- (meth) acrylic acid alkyl ester copolymer, and rubber 1 to 30 weights %

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