JPH0419127A - Manufacture of mat and device thereof - Google Patents

Abstract

PURPOSE:To easily manufacture a mat having certain thickness, hardness and the like a method wherein a diaphragm is arranged between an upper and a lower spaces so as to uniformly press stacked sheets with the diaphragm against the bottom in a mold by pressurizing the upper space in the mold or evacuating the lower space so as to bond the rubber sheet with the raised fiber sheet and vulcanize the rubber sheet. CONSTITUTION:A heat-resistant and rubbery diaphragm 7 is mounted to the internal lower part of an upper mold 4 so as to form an airtight upper space 9 between the inner wall 6 of the upper mold and the diaphragm 7. On a lower mold 5, a ground fabric 2, on the surface of which raised fibers 1 are provided, and an unvulcanized rubber sheet 3 are placed one upon the other. After the molds are closed under the above-mentioned conditions, both the upper space 9 and a lower space 10 are respectively evacuated through vent holes 11 and 12 by means of vacuum pumps. When the degree of evacuation reaches 10 - 50 Torr, the upper space 9 is abruptly released, resulting in pressing the diaphragm 7 against the bottom in the lower mold so as to press the raised fiber group 1 and the ground fabric 2. By being heated with the lower mold 5, the vulcanization of the rubber sheet 3 proceeds and, at the same time, its bonding to the ground fabric is performed.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to the production of a mat in which a napped fiber sort and a rubber note are integrated.

<Prior art> As a means of manufacturing a mat such as an entrance mat that integrates the sorted napped fibers and a rubber notebook, the sorted napped fibers and a rubber sheet are stacked and inserted between a hot plate or a mold. There is a method of simply pressing, adhering, and vulcanizing.

In such cases, the hot plate is in direct contact with the napped side of the fiber sort, and a large amount of pressure is applied between the two ends, causing the napped fibers to collapse. If the napped fibers are severely collapsed, post-processing such as moist heat treatment can restore the napped state. It is difficult to serve.

Also, depending on the parallelism and flatness of the heating plate, pressure may not be applied uniformly to both notebooks, resulting in uneven surface conditions of the napped fibers, or partial fiber notebooks sinking into the rubber sheet, resulting in matte surfaces. However, it is difficult to maintain the parallelism and flatness of the hot plate at a constant level. In particular, flatness and smoothness are impaired due to wear and deformation of the surfaces of hot plates, etc., but it is economically disadvantageous to constantly maintain them or replace them with new ones.

As a means to solve these inconveniences, a method is proposed in which a woven fabric with mold releasability is interposed between the napped fiber sheet and the hot plate, etc., in order to prevent the napped fibers from coming into direct contact with the hot plate or mold ( Japanese Patent Publication No. 62-137029) or a method of adhering and vulcanizing while keeping the temperature of the napped fibers low (Japanese Patent Publication No. 63-47611) is known; The above-mentioned disadvantages are not solved.

The present invention eliminates these inconveniences, and produces a napped fabric with less heat influence on the napped fibers, less lodging of the napped fibers, uniform surface condition of the napped fiber layer, and constant mat thickness, hardness, etc. It is an object of the present invention to provide a method and apparatus for easily manufacturing a bonded integrated mat of a fiber sheet and a rubber notebook.

Means for Solving the Problems> The present invention is characterized in that the rubber sheet surface of a polymerized piece, in which an unvulcanized rubber sheet is superimposed on the back surface of a napped fiber sheet, is set in the inner bottom of a mold, and the mold is placed above the napped fiber sheet. A diaphragm having heat resistance and rubber-like elasticity is arranged to airtightly divide the interior into upper and lower spaces, and the polymeric sheet is placed in the mold by pressurizing the upper space in the mold or reducing the pressure in the lower space. A mat manufacturing method characterized by adhering and vulcanizing a napped fiber sheet and a rubber sheet while uniformly pressing them on the inner bottom, and a mold that can be separated or opened and closed in the upper and lower parts, with a heat-resistant inside of the upper mold. and an airtight diaphragm having rubber-like elasticity, the inside of the mold can be divided into an airtight upper space and a lower space by the diaphragm, and an injection/exhaust port is provided for each upper and lower space. The present invention relates to a mat manufacturing device.

The present invention will be explained below with reference to the drawings.

FIG. 1 is an exemplary cross-sectional view of an apparatus for carrying out the method of the present invention. This device shown in FIG. 1 consists of an upper mold 4 and a lower mold 5, and a heat-resistant and rubber-like (elastic) diaphragm 7 is placed in the lower part of the inside of the upper mold 4 through a presser plate 8. It is attached with bolts, and the inner wall 6 of the upper mold and the diaphragm 7 form an airtight upper space 9, and the space is provided with an inlet/exhaust hole 11 communicating with the outside. Furthermore, when both molds are closed, an airtight lower space 10 is formed between the diaphragm 7 and the inner wall of the lower mold 5, and the lower space 10 is provided with an inlet/exhaust hole I2 leading to the outside. . Note that a seal gasket 13 is provided to maintain airtightness when the upper mold 4 and the lower mold 5 are closed.

Reference numeral 14 denotes a hinge, which is provided for convenient opening and closing of the mold. The lower mold 5 is heated by a conventional method. That is, a heating device using electricity, steam, oil, etc. may be built into the lower mold 5, or heating may be performed using an external heating means.

When carrying out the present invention, the base fabric 2 having the raised surface 11 and the unvulcanized rubber notebook 3 are stacked and placed on the lower mold 5, the mold is closed, and a vacuum pump ( ), the pressure in the upper space 9 and lower space 10 is reduced. When both the upper space 9 and the lower space 1O reach a reduced pressure of 10 to 50 Torr, only the upper ventilation hole 11 is opened, and the upper space 9 is suddenly opened. As a result, the diaphragm 7 is pressed against the inner bottom surface of the lower mold all at once, pressing the raised fiber group 1 and the base fabric 2 as shown by the broken line in the figure. In this state, the rubber notebook 3 is vulcanized by heating from the lower mold 5, and at the same time adhesion to the base fabric 2 is performed. When vulcanization and adhesion are completed, the lower ventilation hole 12 is opened to return the pressure to atmospheric pressure, the mold is opened, and the mat is taken out.

This can also be carried out by filling the upper space 9 and the lower space 10 with pressurized fluid, respectively. In this case, the ventilation hole 11.1
2 are each connected to a pressure pump, 0.5 to 1 y5k
Then, only the lower vent hole 12 is opened to open the lower space 10 to atmospheric pressure.

Then, the diaphragm 7 will descend and press in the same way as above.

Note that only the lower space 10 can be depressurized from the beginning, or only the upper space 9 can be pressurized from the beginning. If only the upper space 9 is pressurized from the beginning, the knoll packing 13 is not necessary.

When reducing the pressure, 10 to 50 Torr is practical. 1
If the pressure is lower than 0 Torr, equipment problems such as vacuum equipment or air nozzles will occur, and if it exceeds 50 Torr, the pressing force will become weak.

When applying pressure, 0.5 to 1.5 kgf/a11" is practical. If it is lower than 0.5 kgf/cI11", the pressing force is weak and adhesive strength cannot be secured, and 1.5 kgf/a
If it exceeds m', the napping fibers will become severely collapsed and equipment restrictions will occur.

The base fabric may be back-coated with rubber latex or the like, if necessary, or may be treated with another adhesive.

As the diaphragm that can be used in the present invention, a vulcanized rubber sheet, for example a sheet having heat resistance and rubber-like elasticity, such as a silicone rubber sheet, is used. By pressurizing or depressurizing the upper and lower spaces, this sheet can be brought into close contact with the napped fiber notebook surface, and the napped fiber sheet can be evenly pressed against the rubber sheet surface, and the napped fibers can be damaged by heat caused by the mold surface. can be prevented.

In addition, in the present invention, for example, a mesh body or a notebook made of glass fiber woven fabric or non-woven fabric treated with fluororesin is superimposed on the surface of the sorted napped fibers and/or the back surface of the rubber sheet, and the above-mentioned vulcanization and Gluing can also be done. In this case, the gas generated during rubber vulcanization is discharged from the mesh or the fine gaps in the fiber sheet, so there is no gas accumulation between the two sheets and the adhesion between the two sheets can be improved. It is possible to create patterns using

(Example 1) As shown in Fig. 1, a napped fiber sheet 2 (size 720 mm 870m
m), an unvulcanized nitrile rubber sheet (size 750 m)
mX 900mw, thickness 1.5mm) 3, put it in the lower mold 5, close the upper mold 4 and the lower mold 5, and open the ventilation hole 11. , the pressure is reduced from I2 with a vacuum pump, and when the pressure reaches 10 Torr, only the upper ventilation hole 11 is opened, and the upper space 9 is
Return to atmospheric pressure. While keeping the pressure in the lower space 10 at 10 Torr, vulcanization is performed at 170°C for 10 minutes (heating of the lower mold 5).
I did it. The diaphragm used has a hardness of 60 degrees and a thickness of 3 cm.
Manufactured by Nido JJ Rugomu.

The thus obtained mat has slight pile lodging, but the napped fibers have little heat damage, are easily restored by moist heat treatment, have sufficient adhesion between the base fabric and the rubber, and can be heated for 20 minutes in hot water at 50°C. Even after repeated washing in a washing machine for 30 minutes, no separation occurred between the base fabric and the rubber.

Further, there was no uneven thickness between the napped fiber sheet and the rubber sheet, and the thickness and hardness of the napped fiber layer were uniform over the entire surface.

(Example 2) Using the same napped fiber sheet 2 and rubber sheet as in Example 1, the upper space 9 and the lower space 10 each have a load of 10 kgf/a.
After applying an air pressure of m', only the lower space IO was opened to atmospheric pressure and a similar vulcanization operation was performed, and a mat having the same performance as Example 1 was obtained.

<Effects of the Invention> According to the present invention, there is little damage to the napped fibers due to heat due to contact with the hot plate, there is no possibility that the fiber sheet is partially embedded in the rubber notebook, and the length of the napped fibers and the thickness of the base fabric are Even if the thickness of the back coat or rubber sheet changes, a product with uniform raised layer and mat thickness can be obtained, and there is no need to make major changes to the equipment.

Moreover, pressure is applied uniformly between both sheets, and adhesion is also uniform. Manufacturing conditions can be easily controlled and the life of the mold can be extended.

[Brief explanation of the drawing]

FIG. 1 is a vertical cross-sectional side view showing the outline of the present invention, 2 is a napped fiber sheet having napped fibers l, 3 is a rubber sheet,
4 is an upper mold, 5 is a lower mold, 7 is a diaphragm, 9 is an upper space, and 11 and 12 are injection and exhaust holes.

Claims (1)

[Scope of Claims] 1) The rubber sheet side of a polymerized sheet with an unvulcanized rubber sheet layered on the back side of the napped fiber sheet is set in the inner bottom of a mold, and the inside of the mold is made airtight above the napped fiber sheet. A diaphragm having heat resistance and rubber-like elasticity is arranged to divide the upper and lower spaces into upper and lower spaces, and the polymeric sheet is placed in the mold by pressurizing the upper space in the mold or reducing the pressure in the lower space. A method for producing a mat, characterized by adhering and vulcanizing a napped fiber sheet and a rubber sheet while uniformly pressing the bottom part. 2) The method for producing a mat according to claim 1, characterized in that a heat-resistant and flexible mesh or fiber sheet is interposed between the diaphragm and the napped fiber sheet and/or between the rubber sheet and the mold. 3) It consists of a mold that can be separated into upper and lower parts or can be opened and closed, and has an airtight diaphragm with heat resistance and rubber-like elasticity inside the upper mold, and the diaphragm makes the inside of the mold an airtight upper space and a lower space. A mat manufacturing device that can be divided into sections and has an inlet and an outlet for each upper and lower space.