JP7130225B2 - Manufacturing method of phosphorescent mat - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a luminous mat provided with a luminous portion, a manufacturing method of the luminous mat, and a luminous sheet provided with a luminous portion.

Conventionally, there has been proposed a stair mat comprising a stair mat main body and a fluorescent mat to be fitted into the stair mat main body (see, for example, Patent Document 1). A fitting hole is provided in the stair mat body, and the fluorescent mat is fitted into the fitting hole.

A stair mat is provided on the stairs. In the dark, the user can recognize the fluorescent mat and prevent the user from missing the stairs.

Japanese Patent No. 3407052

When manufacturing a fluorescent mat, a step of dyeing the original mat with a fluorescent color and a step of cutting the dyed original mat are required. That is, it is necessary to prepare the fluorescent mat separately from the stair mat main body. Furthermore, a step of forming fitting holes is required when manufacturing the stair mat main body, and in addition, fitting holes must be formed with high precision so that the fluorescent mat can be fitted into the fitting holes.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a luminous mat, a method for manufacturing a luminous mat, and a luminous sheet that can simplify the manufacturing process and ensure luminance.

A luminous mat according to the present invention includes a mat and a luminous part disposed on one surface of the mat and projecting in a direction perpendicular to the one surface.

In the luminous mat according to the present invention, the luminous portion has a thickness of 0.3 mm or more.

In the luminous mat according to the present invention, the luminous portion is formed directly on the mat.

In the method for producing a luminous mat according to the present invention, a paint containing a luminous pigment is directly screen-printed on one surface of a raw material, and the paint is dried to form a luminous part protruding in a direction perpendicular to the one surface. The raw fabric on which the luminous portion is formed is cut.

A luminous sheet according to the present invention includes a sheet, and a luminous portion disposed on one surface of the sheet and projecting in a direction perpendicular to the one surface.

In the present invention, the luminous portion is provided on one surface of the mat or sheet, and the luminous portion protrudes from the one surface. That is, a luminous portion is provided on one surface of the mat or sheet with a thickness of a predetermined dimension or more so that the protruding portion can be recognized.

In the present invention, by setting the thickness of the phosphorescent portion to 0.3 mm or more, the phosphorescent component is secured in an amount that enables the phosphorescent portion to emit light with high luminance.

In the present invention, by directly forming the luminous portion on the mat or sheet, an increase in the number of manufacturing steps is suppressed.

In the luminous mat, the manufacturing method of the luminous mat, and the luminous sheet according to the present invention, the luminous portion is provided on one surface of the mat or sheet, and the luminous portion protrudes from the one surface. That is, a luminous portion is provided on one surface of the mat or sheet with a thickness of a predetermined dimension or more so that the protruding portion can be recognized. By providing a thickness equal to or greater than a predetermined dimension, it is possible to ensure a sufficient amount of phosphorescent component that can glow with high brightness even in the dark. Moreover, there is no need to prepare a separate mat having a luminous portion, and the manufacturing process can be simplified. Moreover, a step is generated between the mat or sheet and the phosphorescent portion, and the user can recognize the shape of the phosphorescent portion by touch.

1 is a plan view schematically showing a phosphorescent mat according to Embodiment 1. FIG. FIG. 2 is a schematic cross-sectional view of a phosphorescent mat taken along line II-II in FIG. 1; It is a bottom view which briefly shows a phosphorescent mat. FIG. 3 is a perspective view illustrating a state in which a phosphorescent mat is provided on stairs; 4 is a table showing test results of phosphorescent brightness of a phosphorescent part. 1 is a table showing the minimum phosphorescent luminance of phosphorescent materials using a common light source fluorescent lamp D65 defined by "JIS _Z9107 ". FIG. 11 is a schematic perspective view schematically showing a phosphorescent mat according to a modification. It is a front view which briefly shows a luminous sheet. FIG. 9 is a schematic cross-sectional view of the phosphorescent sheet taken along line IX-IX in FIG. 8; FIG. 10 is a front view illustrating a state in which a phosphorescent sheet is provided on a wall;

(Embodiment 1)
BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described below with reference to drawings showing a phosphorescent mat according to Embodiment 1. FIG. 1 is a schematic plan view of the luminous mat, FIG. 2 is a schematic sectional view of the luminous mat with the II-II line in FIG. 1 as a cutting line, and FIG. 3 is a bottom view of the luminous mat. be.

As shown in FIG. 1, the phosphorescent mat 1 includes, for example, a horizontally long rectangular mat 2 . A first long side 2a of the mat 2 is curved so as to protrude outward. The second long side 2b of the mat 2 is linear. The mat 2 is made of nonwoven fabric, for example. A plurality of luminous portions 3 are arranged side by side on the surface of the mat 2 along the second long side 2 b of the mat 2 . The luminous portion 3 is formed directly on the mat 2 and has, for example, a rectangular shape in plan view. Note that the shape of the luminous portion 3 is not limited to a quadrangle, and may be another shape such as a triangle, a circle, or a star when viewed from above. The light storing section 3 absorbs light energy, converts the absorbed energy into visible light, and emits light.

The luminous portion 3 is composed of a binder and a luminous pigment. Binders include, for example, acrylic resin material, petroleum naphtha, polyoxyethylene alkyl ether, aqueous ammonia, water, and the like. Luminous pigments include, for example, strontium aluminate (luminous component) activated with dysprosium or europium.

The luminous portion 3 is formed by screen-printing a paint containing a binder and a luminous pigment on the original fabric. The weight percent of the binder and the phosphorescent pigment is, for example, 3% or more of the phosphorescent pigment and 97% or less of the binder. The weight percentages of the binder and the phosphorescent pigment are determined in consideration of ensuring the brightness of the phosphorescent portion 3 and the ease with which the paint is separated from the screen during screen printing. As shown in FIG. 2, the thickness D of the phosphorescent portion 3 is 0.3 mm or more. The thickness D is set within a range of 0.3 mm to 1.0 mm, for example.

As shown in FIGS. 2 and 3, an adsorption layer 4 is provided on the back surface of the mat 2, and the adsorption layer 4 has a plurality of adsorption strips 4a extending in the longitudinal direction of the mat 2. As shown in FIGS. The adsorption layer 4 is made of a synthetic resin material obtained by blending an emulsion of an acrylic acid ester copolymer having adsorption properties with additives and fillers for stabilizing bubbles.

FIG. 4 is a perspective view illustrating a state in which the phosphorescent mat 1 is provided on stairs. As shown in FIG. 4, the user can install the phosphorescent mat 1 on the stairs. For example, the phosphorescent mat 1 is provided on the upper surface of the stairs so that the back surface faces the upper surface of the stairs and the second long side 2b is along the outer edge of the upper surface of the stairs. The adsorption strip 4a is adhered to the upper surface of the stairs, and the phosphorescent mat 1 is fixed to the stairs.

In the dark, the phosphorescent part 3 of the phosphorescent mat 1 emits light, and the user recognizes the phosphorescent part 3 . The user can recognize the position of the edge of the staircase by the luminescence part 3 emitting light along the outer edge of the staircase. Therefore, it is possible to prevent the user from missing the stairs in the dark.

By setting the weight percentage of the binder and the luminous pigment to, for example, 3% or more for the luminous pigment and 97% or less for the binder, and setting the thickness D of the luminous part 3 to 0.3 mm or more, it is possible to emit light with high luminance. amount of the phosphorescent component is secured in the phosphorescent portion 3 .

FIG. 5 is a table showing test results of the phosphorescent brightness of the phosphorescent portion 3. As shown in FIG. The thickness of the phosphorescent portion 3 in the test object 1 is approximately 0.5 mm, and the thickness of the phosphorescent portion 3 in the test object 2 is approximately 0.8 mm. The test method conformed to "JIS Z9107:2008 Safety signs-Classification of performance, performance criteria and test method 6. Test method 6.3.2 Phosphorescence brightness test of phosphorescent material".

The test conditions are as follows. BM-5A manufactured by Topcon Corporation was used as a luminance meter. The viewing angle was set to 0.2 degrees. The measurement distance is 33 cm. The lamp type is a common light source fluorescent lamp _D65 . Excitation light conditions are irradiation at 200 [lx], and excitation time is 20 minutes.

FIG. 6 is a table showing the minimum phosphorescent luminance of phosphorescent materials using a common light source fluorescent lamp D65 defined by "JIS _Z9107 ". As shown in FIGS. 5 and 6, the phosphorescent mat 1 has at least the brightness performance of subclass JA, and can ensure brightness.

The phosphorescent mat 1 is manufactured as follows. First, the adsorption layer 4 is formed. The adsorption layer 4 is formed by the following steps. A stirring chamber communicating with an air source is provided in the middle of the delivery path for sending out the solution of the synthetic resin material described above by a pump, and the solution supplied to the stirring chamber is stirred while blowing air into the stirring chamber. The solution is foamed, and this foamy solution is applied from the outlet of the delivery path to the back surface of the original fabric of the nonwoven fabric, and after leveling the coated foamy solution with a doctor blade, it is dried in a drying room at about 130 to 220°C. Dry, thermally and self-crosslink. After that, it is taken out from the drying chamber and cooled to harden the foamy solution in an adsorbent state to form an adsorption layer 4 having a plurality of microbubbles. Part of the solution applied to the back surface of the raw fabric permeates the nonwoven fabric. Low-melting-point fibers are blended in the raw nonwoven fabric. By blending the low-melting-point fibers, the fiber bonding of the raw nonwoven fabric is strengthened, the occurrence of wrinkles is suppressed, and the abrasion resistance is improved.

Microbubbles are generated on the surface of the adsorption layer 4, and when the adsorption layer 4 is pressed against the upper surface of an object (such as a staircase), each of the plurality of microbubbles exposed on the surface exhausts the internal air, resulting in a vacuum adsorption action. This vacuum adsorption action enhances the adhesiveness of the adsorption layer 4 .

Next, the luminous portion 3 is formed. A paint containing a binder and a phosphorescent pigment is printed on the surface of the raw fabric using a screen. After that, it is dried to form the luminous portion 3 . The screens used are coarse, eg 25-36 meshes per inch. By setting the screen to be coarse, even when the viscosity of the paint forming the phosphorescent portion 3 is high, the paint printed on the raw fabric is easily separated from the screen. The raw fabric on which the luminous portions 3 and the adsorption layer 4 are formed as described above is cut into, for example, a horizontally long rectangle, and the luminous mat 1 is manufactured. At this time, the raw fabric is cut so that the phosphorescent portions 3 are arranged along the second long side 2b.

In the luminous mat 1 according to Embodiment 1, the luminous portion 3 is provided on one surface of the mat 2, and the luminous portion 3 protrudes from the one surface. That is, the luminous portion 3 is provided on one surface of the mat 2 with a thickness equal to or greater than a predetermined dimension so that the protruding portion can be recognized. By providing a thickness equal to or greater than a predetermined dimension, it is possible to ensure a sufficient amount of phosphorescent component that can glow with high brightness even in the dark. Moreover, there is no need to create a separate mat 2, and the manufacturing process can be simplified.

Further, by setting the thickness of the accumulating part 3 to 0.3 mm or more, the accumulating part 3 can be provided with an amount of the accumulating component that can emit light with high luminance.

Instead of Embodiment 1, a paint containing a reflective agent is applied to a predetermined portion of the surface of the mat 2 and dried to form a reflective portion, and then a thin film-like luminous portion of 0.1 mm or less is applied to the predetermined portion. It is conceivable to form a light beam to ensure sufficient brightness. By providing the reflecting portion, the light directed from the phosphorescent portion 3 to the rear surface of the mat 2 is reflected by the reflecting portion and directed to the surface of the mat 2. - 特許庁As a result, the weak light emitted by the thin phosphorescent portion can be enhanced. Note that when a thin phosphorescent portion is provided on the mat 2 without providing a reflecting portion, the light from the phosphorescent portion 3 directed to the back surface of the mat 2 does not go to the surface of the mat 2, and the brightness of the phosphorescent portion 3 when viewed from the front side. decreases.

However, when a reflecting portion is provided, a step of applying a coating containing a reflecting agent and a step of drying the coating are required, and furthermore, it is necessary to accurately position the accumulating portion 3 on the reflecting portion. In the embodiment, by screen-printing a thick luminous portion 3 on the mat 2, the luminous portion 3 having a sufficient amount of luminous component is directly formed on the mat 2, suppressing an increase in the manufacturing process, The phosphorescent mat 1 ensuring sufficient brightness can be efficiently manufactured.

Conventionally, a luminous tape is attached to a mat, but the luminous tape is easily peeled off from the mat. In the embodiment, since the luminous portion is directly printed on the mat, the luminous portion is difficult to peel off from the mat.

FIG. 7 is a schematic perspective view schematically showing a phosphorescent mat 11 according to a modification. The luminous mat 11 may include a panel-shaped mat 20 and an arrow-shaped luminous portion 30 . The phosphorescent mat 11 may be installed on the floor 50 or attached to the wall 51 so that the arrow of the phosphorescent part 30 points to an object (for example, an emergency exit). In FIG. 7 , the light storing section 30 is shown relatively large in order to clearly show the light storing section 30 , but the size of the light storing section 30 is not limited to that shown in FIG. 7 .

By directing the arrow of the phosphorescent part 30 toward the emergency exit, the user can visually recognize the arrow of the phosphorescent part 30 and smoothly move toward the emergency exit in the dark. Further, when a luminous panel is provided on the wall 51 , since there is a step between the mat 20 and the luminous part 30 , the user moves while touching the wall 51 with his/her hand, thereby not only visual but also , the user can smoothly move toward the emergency exit while recognizing the arrow of the luminous unit 30 with a sense of touch.

The thickness D of the luminous portion 3 is appropriately set according to the purpose of use. When the luminous mats 1 and 11 are installed on the stairs or the floor 50, the height is set within a range of 0.3 to 0.8 mm, for example, because too high a height may hinder walking. Further, the thickness D is preferably set to 0.5 to 0.8 mm in order to ensure the luminance. Further, when the phosphorescent mat 11 is installed on the wall 51, the thickness D is set in the range of 0.8 to 1.0 mm, for example, in order to improve tactile recognition.

(Embodiment 2)
The present invention will be described below with reference to the drawings showing a phosphorescent sheet 10 according to Embodiment 2. FIG. 8 is a schematic front view of the luminous sheet 10, and FIG. 9 is a schematic sectional view of the luminous sheet 10 taken along line IX-IX in FIG. The phosphorescent sheet 10 includes, for example, a horizontally long rectangular sheet 40 . The sheet 40 is made of nonwoven fabric, for example. A luminous portion 3 is provided on the surface of the sheet 40 .

The luminous portion 3 is formed directly on the sheet 40 and has, for example, a circular shape when viewed from the front. The shape of the luminous portion 3 is not limited to a circular shape, and may be a square shape, a triangle shape, a star shape, or other shapes such as the shape of a pumpkin or Santa Claus when viewed from the front. A picture or pattern 41 is drawn on the surface of the sheet 40 . For example, in FIG. 8, a pattern 41 of a cat playing with the luminous portion 3 that looks like a ball is drawn, and the pattern 41 is drawn as one design including the luminous portion 3 .

An adsorption layer 4 is provided on the back surface of the sheet 40. The adsorption layer 4 has, for example, a plurality of adsorption strips 4a extending in the vertical direction of the sheet 40, and the plurality of adsorption strips 4a are arranged in the horizontal direction. As with the luminous mat 1, the luminous sheet 10 is produced by directly screen-printing a paint containing a luminous pigment on one surface of the original sheet, drying the printed paint, and forming a luminous portion protruding in a direction perpendicular to the one surface. It is manufactured by cutting the raw fabric on which the luminous portion is formed.

FIG. 10 is a front view illustrating a state in which the luminous sheet 10 is provided on the wall 51. FIG. As shown in FIG. 4, the user can provide the luminous sheet 10 on the wall 51 . When the switch 51a is attached to the wall 51, the luminous sheet 10 can be attached near the switch 51a. Since the picture or pattern 41 is drawn on the luminous sheet 10, the luminous sheet 10 can be used as interior decoration during the daytime when the visibility is high, and the luminous part 3 emits light during the night when the visibility is low. Thus, the luminous sheet 10 can be used as an indicator for indicating the position of the switch 51a.

The place where the luminous sheet 10 is provided is not limited to the wall 51 or the window, and may be provided on the floor, for example. Alternatively, only the portion of the light-accumulating portion 3 may be punched and cut from the sheet 40 or the original sheet 40 . In this case, only the part of the luminous part 3 that is rectangular, triangular, star-shaped, pumpkin- or Santa Claus-shaped when viewed from the front can be provided as a decoration on a wall, a window, a frame part of the switch 51a, a floor, or the like. In this case, since the sheet 40 exists only in the luminous portion 3 and its vicinity, and the sheet 40 does not exist in other portions, it is possible to avoid dust from adhering to the sheet 40 other than the luminous portion 3 and its vicinity. can.

Among the configurations according to the second embodiment, the configurations similar to those of the first embodiment are denoted by the same reference numerals, and detailed description thereof will be omitted.

The embodiments disclosed this time should be considered as examples in all respects and not restrictive. The technical features described in each embodiment can be combined with each other, and the scope of the present invention is intended to include all modifications within the scope of the claims and the scope of equivalents to the scope of the claims. be done.

1, 11 luminous mat 2, 20 mat 3, 30 luminous part 10 luminous sheet 40 sheet

Claims (2)

A paint containing a phosphorescent pigment is directly screen-printed on one surface of the raw fabric using a screen having a mesh number of 25 to 36 per inch,
drying the paint to form a luminous portion projecting in a direction perpendicular to the one surface;
A method for manufacturing a luminous mat, comprising: cutting the original fabric on which the luminous portion is formed. printing the paint on the raw fabric so that a plurality of the luminous parts are arranged side by side;
Cut the raw fabric so as to form a horizontally long rectangular mat in which a plurality of the phosphorescent parts are arranged along the long sides.
The method for producing a phosphorescent mat according to claim 1.

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