JPH01139254A - 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 a crosslinked or incompletely crosslinked 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 in prepared in which pile yarns 2 are added as tufts to a base fabric 1 and the tips thereof are trimmed flush to form a mat surface. A rubber latex comprising a crosslinking agent is applied to the back side of the base fabric 1 to provide a crosslinked or incompletely crosslinked 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 accelerator 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 are bonded to each other with simultaneous vulcanization. The amount of the crosslinking agent mixed in the carboxylated modified rubber latex is 0.1-10wt.%, whereas the amount of the vulcanizing agent mixed in the rubber sheet is 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 manufacturing an integrated mat for dust removal, and more specifically, the present invention relates to a method for manufacturing an integrated mat for dust removal. 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. Concerning the manufacturing method of matte.

(Prior Art) Conventionally, as an integrated de-escorting mat used by laying at entrances and exits such as entrances, it is well known that rubber and vinyl chloride sheets are integrated into the backstitched surface of a tufted mat. There is.

This integrated mat can be produced by attaching 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 mat fibers 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 integrated mats are installed at entrances and exits for people, the pile surface is repeatedly subjected to friction from the soles of shoes. Furthermore, since the mats are used in a rental system where the mats are washed and regenerated after being used for a certain period of time and then rented out again, the mats may become wavy due to the expansion and contraction of the mat material due to repeated friction and washing treatments as described above. The disadvantage is that this occurs. Another problem is that the pile threads fall off the mat, causing the mat to become thinner. In particular, polyvinyl alcohol fibers and polyester fibers, which have excellent texture and durability, have poor adhesion to rubber. This trend was particularly large.

Therefore, an object of the present invention is to firmly adhesively fix the pile yarn to the rubber backing, thereby preventing the pile yarn from falling off or waving even after repeated washing and regeneration, and significantly improving dimensional stability. An object of the present invention is to provide a method for manufacturing an improved integrated mat for dust removal.

(Means for Solving the Problems) According to the present invention, the stitched surface of a mat material consisting of a base material and a rubber tufted on the base material has a rubber solid content of 0.
．． A rubber latex containing 1 to 10% by weight of a crosslinking agent is applied to form a crosslinked or semi-crosslinked rubber precoat layer on the stitched surface, and the precoat mat material and the same type of rubber as the precoat layer are coated. An unvulcanized rubber sheet containing 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 layer. Provided is a method for producing a dust-removing mat, which is characterized by adhering a rubber sheet to a rubber sheet, crosslinking a precoat layer, and vulcanizing the rubber sheet.

(Function) According to the present invention, rubber latex containing a crosslinking agent is provided as a precoat layer on the stitched surface of the mat material in a crosslinked or semi-crosslinked state. This makes it possible to infiltrate the mat material with the rubber component in advance, and also enables strong adhesion to the rubber sheet 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 strong, dimensionally stable, and durable adhesive structure at the interface between the mat material and the rubber sheet, it is necessary to infiltrate the rubber component into the mat material and introduce a crosslinked structure into the rubber itself. Both are necessary.

According to the present invention, the precoat layer is provided in a crosslinked or semi-crosslinked state, and an unvulcanized rubber sheet is pressed onto the precoat layer under heat to simultaneously integrate and vulcanize the two. This prevents pile threads from falling off, peeling of the original fabric, and ripples. The vulcanization of the precoat layer during this hot pressing is performed by the vulcanizing agent and vulcanization accelerator contained in the rubber sheet diffusing and transferring into the precoat layer, resulting in re-vulcanization at the crosslinked interface between the precoat layer and the rubber sheet. However, it is carried out effectively in the same way as when unvulcanized rubber is vulcanized and bonded.

(Preferred Embodiment of the Invention) A first explanation of the manufacturing process of the integrated 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, rubber latex containing a crosslinking agent is applied to the back side (stitched side) of the base fabric 1 to form a crosslinked or semi-crosslinked brush/coat 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 yarns, or blended yarns thereof, conventional natural fibers can also be used.

As the elastomer used for the rubber sheet, nitrile-butadiene rubber is particularly preferably used, but other vulcanizable rubbers such as styrene-butadiene copolymer rubber (
5BR), chloroprene rubber, polybutadiene rubber, chlorosulfonated polyethylene, etc. can also be used. Similarly, nitrile-butadiene rubber is particularly preferably used as the rubber latex, but other carboxylated modified latexes such as SBR, CR, BR, isoprene, vinyl and lysine latex, etc. can also be used.

In addition, as vulcanizing agents to be mixed into the rubber sheet, inorganic vulcanizing agents include metal salts such as sulfur, zinc chloride, ferrous chloride, tin chloride, sulfur chloride, etc., and organic peroxides. Examples of the vulcanizing agent include dicumyl peroxide, acetylene peroxide, benzoyl peroxide, and ethyl methyl ketone peroxide.Other examples include thiuramis sulfide, quinone dioximthiol, and dithioic acid. It is common to use

Glycol HOCH2-CH20H amine as a crosslinking agent blended into carboxylated modified rubber latex
Mention may be made of RI NH2 polyvalent metal oxides MeO polyvalent metal salts and hydroxides MeX.

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, thiuram compounds, dithiocarbamate compounds, aldehyde/amine compounds, guanidine compounds, carbamoylthiazole compounds, etc.

Vulcanization accelerators can be used.

The amount of crosslinking agent added to the rubber latex is 0.1 to 1
It is preferably in the range of 0% by weight, particularly preferably in the range of 1 to 5%.

The amount of the vulcanizing agent blended into the rubber sheet is preferably in the range of 0.1 to 3% by weight, and 0.5 to 2% by weight per rubber.
It is particularly preferable that it be within the range of . The amount of vulcanization accelerator to be added to the rubber sheet is determined depending on the amount of 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, desensitizers, etc. can be blended.

Rubber latex can be applied to the mat material using conventional methods such as roll coater, spray, and spacing, but it is necessary that the rubber components of the latex are uniformly dispersed. be. In addition, rubber latex is applied to the mat material at a rate of 25 to 1000 g/m2.
It is particularly preferable that the rubber latex be coated at a rate of 30 to 600 g/rn2, and after coating, the precoat layer must be formed so that the rubber latex is in a crosslinked or semi-crosslinked state.

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

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

(Example) Example 1 Cut pile carboxylation A mat of the above material was created, and a precoat layer was heated at 150°C.
A mat in a crosslinked state was prepared by drying and curing for 20 minutes, and a mat B, which was the same as mat A except that no precoat layer was provided, was also prepared.

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 (01+11) 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 150°C for 10 minutes to produce a crosslinked mat C, and a similar mat D except that no precoat layer was provided, and each was carried out. Single-stock mats C and D were produced in the same manner as in Example 1. These mats were subjected to the same test 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, the removal strength and adhesive strength do not decrease even when subjected to severe washing and regeneration treatment, so that pile yarns do not fall off or mats do not form. This prevents ripples.

[Brief explanation of the drawing]

FIG. 1 is a side view illustrating the manufacturing process of the integrated dust removal mat of the present invention. 1...Base fabric, 2...Pile thread, 3...
...Precoat layer, 4...Rubber sheet. Patent applicant Daskin Co., Ltd.
, Agent Patent Attorney Ikuo Suzuki (1,...J'!n

Claims (4)

[Claims] (1) A carboxylated modified rubber latex containing 0.1 to 10% by weight of a crosslinking agent per solid rubber content is applied to the stitched surface of a mat material consisting of a base material and a pile tufted to the base material. , a crosslinked or semi-crosslinked rubber precoat layer is formed on the stitched surface, and a precoat material containing the precoat mat material, the same type of rubber as the precoat layer, and 0.1 to 3% by weight of a vulcanizing agent and a vulcanization accelerator. A vulcanized rubber sheet is stacked so that the precoat layer and the rubber sheet face each other and pressed under heat to bond the precoat layer and the rubber sheet, crosslink the precoat layer, and vulcanize the rubber sheet. A method for manufacturing an integrated mat for dust removal, characterized by performing the following steps. (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 manufacturing method according to claim 1, wherein the rubber of the rubber sheet is nitrile-butadiene rubber. (4) The manufacturing method according to claim 1, wherein the tufted pile is a pile yarn containing polyvinyl alcohol fiber or polyester fiber.