JPH01139253A - Production of dust-arresting integrated mat - Google Patents

Abstract

PURPOSE:To enhance dimensional stability and prevent coming-off of pile yarns or corrugation from occurring, even after repeated cleaning and regeneration, by providing a precoat layer in an unvulcanized or incompletely vulcanized state, and pressing an unvulcanized rubber sheet against the precoat layer with heating to simultaneously perform integration of the two members and vulcanization. CONSTITUTION:A mat material is prepared in which pile yarns 2 are added tufts to a base fabric 1 and the tips thereof are trimmed flush to form a mat surface. A rubber latex comprising a vulcanizing agent and a vulcanization accelerator is applied to the back side of the base fabric 1 to provide an unvulcanized or incompletely vulcanized precoat layer 3. The precoated mat material and an unvulcanized rubber sheet 4 comprising the same kind of rubber as that constituting the precoat layer, a vulcanizing agent and a vulcanization are superposed on each other, with the precoat layer 3 facing the rubber sheet 4, and they are pressed with heating, whereby the rubber precoat layer 3 and the rubber sheet 4 are bonded to each other with simultaneous vulcanization. In the rubber latex and in the rubber sheet, the vulcanizing agent is used in an amount of 0.1-3wt.% based on the rubber, and the vulcanization accelerator is added in an appropriate amount.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing an integrated mat for de-escorting, and more specifically, the present invention relates to a method for manufacturing an integrated mat for de-escorting. A dust-removal integrated product that can stably and well adhere even pile yarns, prevents the occurrence of waviness, and has significantly improved dimensional stability even when used for long periods of time after repeated cleaning and recycling treatments. Regarding the manufacturing method of stop mats.

(Prior Art) Conventionally, as an integrated dust removal mat that is used by laying at entrances and exits of entrances, etc., it is well known that a tufted mat with rubber and vinyl chloride sheets integrated into the backstitched surface is used. There is.

This one-piece mat can be produced by bonding a soft resin such as vinyl chloride to the fibers of the mat (base fabric and pile) in sol form and then heat-treating to harden it, or by attaching the fibers of the mat to an unvulcanized rubber sheet. It was manufactured by applying a heat press treatment to bond and solidify the adhesive.

There is also a method, as disclosed in JP-A-59-95016, in which an elastomer is applied to the stitched surface of a mat material to form a thin backing layer, and a frame-shaped thick elastomer is integrated.

(Problems to be Solved by the Invention) Since these fixed mats are placed at entrances and exits for people, the pile surface is repeatedly subjected to friction from the soles of shoes.Furthermore, the mats are used for a certain period of time. Since it is used in a rental system where the mat is washed and recycled after use and rented out again, it has the disadvantage that the mat material becomes wavy due to expansion and contraction due to repeated friction and washing processes as described above. Another problem is that the pile threads fall off the mat, resulting in so-called thinning of the mat.In particular, polyvinyl alcohol fibers and polyester fibers, which have excellent texture and durability, have poor adhesion to rubber. , this tendency was particularly strong.

Therefore, the object of the present invention is to make the pile yarn elastic.

To provide a method for producing an integral fixing mat for dust removal, which prevents pile threads from falling off and waving even when washed and regenerated repeatedly, and has significantly improved dimensional stability, by firmly adhering and fixing the mat to a king. It is in.

(Means for Solving the Problems) According to the present invention, 0.1 to 3 wt. Rubber latex containing a vulcanizing agent and an appropriate amount of vulcanization accelerator is applied to form an unvulcanized or semi-vulcanized rubber precoat layer on the stitched surface, and the precoat mat material and the same type of precoat layer are coated. Rubber, 0.1
An unvulcanized rubber sheet containing 3 to 3% by weight of a vulcanizing agent and an appropriate amount of a vulcanization accelerator is stacked so that the precoat layer and the rubber sheet face each other, and pressed under heat to form the precoat. Provided is a method for producing an integral mat for dust removal, which is characterized by adhering a layer and a rubber sheet, and vulcanizing a precoat layer and a rubber sheet.

(Function) According to the present invention, rubber latex containing a vulcanizing agent is provided as a precoat layer on the stitched surface of the mat material in an unvulcanized or semi-vulcanized state. This makes it possible to infiltrate the rubber component into the mat material in advance, and also allows for strong adhesion to the rubber sheet that will be applied later. In addition, the rubber sheet to be applied later contains the same kind of rubber, vulcanizing agent, and vulcanization accelerator as the pre-coat layer, and by pressing the pre-coat mat material and the rubber sheet under heating, the rubber pre-coat layer is formed. and the rubber sheet are simultaneously vulcanized and bonded.

In order to introduce a dimensionally stable and durable adhesive structure with residual bacteria at the interface between the mat material and the rubber sheet, the rubber component must penetrate into the mat material and preferably have an anchoring effect; It is also necessary that a strong crosslinked structure (vulcanized structure) be introduced into the rubber itself.

According to the present invention, the precoat layer is provided in an unvulcanized or semi-vulcanized state, and an unvulcanized rubber sheet is pressed onto it under heat to simultaneously integrate and vulcanize the two.
The pile yarn is sufficiently fixed, preventing the pile yarn from falling off, the raw fabric from peeling off, and causing waves.

(Preferred embodiment of the invention) A first explanation of the manufacturing process of the integral mat for dust removal of the present invention.
In step A of the figure, a mat material is prepared for the base fabric 1, in which the pile threads 2 are tufted and the ends thereof are trimmed to form a matte surface.

In step B, a rubber latex containing a vulcanizing agent and a vulcanization accelerator is applied to the back surface (stitched surface) of the base fabric 1 to form an unvulcanized or semi-vulcanized precoat layer 3. In step C, the precoat mat material and the unvulcanized rubber sheet 4 containing the same type of rubber as the precoat layer, a vulcanizing agent, and a vulcanization accelerator are stacked so that the precoat layer 3 and the rubber sheet 4 face each other, Press under heat.

The base fabric 1 used in the present invention is a woven or nonwoven fabric made of synthetic fibers with excellent dimensional stability, such as acetalized polyvinyl alcohol fibers or polyester fibers, while the pile yarn 2 is made of nylon fibers, vinylon fibers, In addition to multifilament yarns of synthetic fibers such as acrylic fibers, spun base yarns, or blended yarns thereof, conventional natural fibers can also be used.

As the elastomer used for rubber latex and rubber sheets, nitrile-butadiene rubber is particularly preferably used, but other vulcanizable rubbers such as styrene-butadiene copolymer rubber (5BR), chloroprene rubber, polyester rubber, etc. Butadiene rubber, polyisoprene rubber, chlorosulfonated polyethylene, etc. can also be used.

In addition, as vulcanizing agents that are mixed into rubber latex and rubber sheets, inorganic vulcanizing agents include metal salts such as sulfur, zinc chloride, ferrous chloride, and tin chloride, and sulfur chloride. As a peroxide vulcanizing agent, dicumyl peroxide, acetylene peroxide, benzoyl peroxide,
Examples include ethyl methyl ketone peroxide, and others such as thiuramis sulfide, quinonedioxime thiol,
Examples include dithioic acids, but sulfur is usually used.

As a vulcanization accelerator for thiazole compounds, 2-mercaptobenzothiazole and its copper salt,
Examples of vulcanization accelerators for sulfenamide compounds include zinc salts, 2,2-dibenzothiazole disulfide, and N-cyclohexyl-2-benzothiazylsulfenamide, N-oxydiethylene-2-benzo Thiadylsulfenamide, N,N'-diisopropyl-2-
Examples include benzothiazylsulfenamide, and examples of crosslinking accelerators for thiazoline compounds include 2-mercaptothiazoline. In addition, vulcanization accelerators such as thiuram compounds, dithiocarbanate compounds, aldehyde/amine compounds, guanidine compounds, and carbamoylthiazole compounds can be used.

The amount of the vulcanizing agent added to the rubber latex and rubber sheet is preferably in the range of 0.1 to 3% by weight per rubber.
A range of 0.5 to 2% by weight is particularly preferred. Further, the amount of the vulcanization accelerator is added in an appropriate amount depending on the amount of the vulcanizing agent, vulcanization conditions, etc.

Rubber latex and rubber sheets can be compounded with compounding agents known per se according to known formulations, such as fillers such as carbon black, softeners such as process oil, anti-aging agents, dispersants, plasticizers, etc. Can be blended.

Rubber latex can be applied to the mat material using conventional methods such as coating with a roll coater, spray, or spacing, but it is necessary that the rubber components of the latex are uniformly dispersed. be. In addition, rubber latex has a solid content of 25 to 10% in the mat material.
It is preferable that the rubber latex be coated at a rate of 00 g/m2, especially 30 to 600 g/ln2, and after coating, a precoat layer must be formed so that the rubber latex is in an unvulcanized or semi-vulcanized state. .

For this reason, rubber latex is generally dried at 90 to 1
It is carried out at a temperature of 80° C. for 1 to 120 minutes under conditions such that the precoat layer becomes unvulcanized or semi-vulcanized depending on the content of the vulcanizing agent and vulcanization accelerator.

The basis weight of the rubber sheet is preferably 100 to 4000 g/m', particularly 200 to 2000 g/m2.

(Examples) Example 1 Cut pile A mat of the above material was prepared, and two levels of drying and vulcanization conditions were set for the precoat layer.

Dry in a dryer at 150°C for 20 minutes, and the precoat layer is uncured or semi-vulcanized as Matte A at 150°C.
Matte B is obtained by drying for 60 minutes and the precoat layer is completely vulcanized.

These mats A and B were each cut to 70 x 85 cm to produce an integrated mat in the following manner.

The mat cut to the above dimensions was placed on an unvulcanized NBR sheet with a thickness of 4 mm containing 1% by weight of a vulcanizing agent (sulfur) and 1% by weight of a vulcanization accelerator (2-mercaptobenzothiazole), and heated at 150°C. Adhesion and vulcanization were performed by pressing at a pressure of 5 g/cm2 for 15 minutes to produce nylon pile mats A and B.

Place these mats in 3 locations with 3,000 pedestrians per day.
After being laid for several days, the conventional integrated mat cleaning and regeneration process is carried out. After repeating this operation 20 times, the pile thread removal strength and the adhesive strength between the base fabric and the rubber were measured, and the results are shown in Table 1.

In addition, Table 1 shows the degree of waviness of the mat before use and after 20 rental cleaning and regenerations in terms of the height (mm) and number of waviness.

The tests for thread removal strength and adhesion strength (between base fabric and rubber) were carried out in accordance with JIS L 1021 Vile thread pullout strength and peel strength of lining material.

Example 2 A precoat layer of a mat made of the above material was dried at 90°C for 20 minutes to produce matte C in an unvulcanized state, and matte C and image quality matte D were also combined, except that no precoat layer was provided. Then, single-stock mats C and D were produced in the same manner as in Example 1, respectively. Example 1 for these mats
A similar test was conducted to measure the pile suture removal strength. The measurement results are shown in Table 1.

Example 3 As in Example 2, one precoat layer was made of the mat of the above material.
Matte E was dried at 50°C for 20 minutes to produce matte E in an unvulcanized or semi-vulcanized state, and matte F, which was the same as matte E except that no precoat layer was provided, was also produced. Single-stock mats E and F were produced in the same manner. These mats were subjected to the same tests as in Example 1, and the pile removal strength was measured. The measurement results are shown in Table 1.

Table 1 (Effects of the Invention) According to the present invention, as is clear from Table 1 above, even when subjected to severe cleaning and regeneration treatment, the thread removal strength and adhesive strength are unlikely to decrease, resulting in pile threads falling off and matting. This prevents waving.

[Brief explanation of the drawing]

FIG. 1 is a side view illustrating the manufacturing process of the integral mat for dust removal of the present invention. 1...Base fabric, 2...Pile thread, 3...
...Precoat layer, 4...Rubber sheet.

Claims (5)

[Claims] (1) A vulcanizing agent of 0.1 to 3% by weight per rubber solid content and an appropriate amount of vulcanization necessary for vulcanization are applied to the stitched surface of a mat material consisting of a base material and a pile tufted to the base material. A rubber latex containing an accelerator is applied to form an unvulcanized or semi-vulcanized rubber precoat layer on the stitched surface, and the precoat mat material, the same type of rubber as the precoat layer, and 0.00% rubber latex containing an accelerator are applied.
An unvulcanized rubber sheet containing 1 to 3% by weight of a vulcanizing agent and an appropriate amount of a vulcanization accelerator is stacked so that the precoat layer and the rubber sheet face each other, and pressed under heat. A method for producing an integrated mat for dust removal, characterized by adhering a precoat layer and a rubber sheet, and vulcanizing the precoat layer and rubber sheet. (2) Precoat layer has a solid content of 25 to 1000g
2. The manufacturing method according to claim 1, wherein the amount of carbon dioxide is formed in an amount of /m^2. (3) The rubber of the precoat layer and rubber sheet is nitrile.
The manufacturing method according to claim 1, which is butadiene rubber. (4) A patent claim in which the precoat layer consists of a rubber composition containing a vulcanizing agent but not a vulcanization accelerator, and the unvulcanized rubber sheet consists of a rubber composition containing a vulcanizing agent and a vulcanization accelerator. The manufacturing method according to item 1. (5) The manufacturing method according to claim 1, wherein the tufted pile is a pile yarn containing polyvinyl alcohol fiber or polyester fiber.