JPH06296576A - Regeneration method of integrated dust cleaning mat for rental use - Google Patents

Abstract

PURPOSE:To eliminate the wave phenomena, etc., generated by repeated uses of an integrated type mat, to prevent re-wave phenomena and a rupture of the outer rubber part, etc., and to prolong the usable duration term remarkably. CONSTITUTION:An outer part 2 of the raw fabric located inside of a frame-like structured outer rubber part 1 is cut at the inside 1mm to 20mm from the periphery, unvulcanized rubber for repairs is applied, after polished if necessary, on the backside of the raw fabric facing to the rubber part 4, then pressed and heated to vulcanize integrally with outer rubber part 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for recycling an integrated mat for dust removal, which is one of the dust control products provided for rental, and more specifically, it relates to a method for regenerating it under severe conditions. Deformation of the mat due to use, etc.
The present invention relates to a complete method for regenerating a rental dust-removing integrated mat that has been wavy, torn, or peeled off.

[0002]

BACKGROUND OF THE INVENTION The present invention is a method of recycling an integrated mat which belongs to the category of dust control products used in rental systems. This is due to the fact that the rental system is used repeatedly under severe conditions and is washed, and the present invention is an integrated mat, that is, 4% to 1%.
The integrated mat itself can be essentially avoided from deformation and waviness due to the fact that the base fabric and the rubber sheet, which can shrink to 0%, are integrated into the product. It includes the fact that there is no. As a result, it is necessary to understand firstly that the meaning of the reproduction of integral mats belonging to this category is fundamentally different from mere partial repair and repair of mats, and further repair. Based on this premise, we will look at conventional technologies.

Conventionally, as a dust-removing integrated mat which is laid and used at entrances and exits of entrances and the like, one in which rubber and vinyl chloride sheets are integrated on the backstitch surface of a tufted mat is well known.

This integrated mat is manufactured by a method in which a soft resin such as vinyl chloride is bonded in a sol form to the fiber parts (base cloth and pile) of the mat and heat-treated to solidify,
It was manufactured by a method in which a mat fiber portion was placed on an unvulcanized rubber sheet, and then hot press treatment was performed to integrate the mat fiber portion.

Further, as in Japanese Patent Laid-Open No. 59-95016, there is also provided a method in which an elastomer is applied to the stitch surface of a mat material to form a thin backing layer and a thick frame-shaped elastomer is integrated. .

[0006] Furthermore, as a solution of how the integrated mat manufactured by such a manufacturing method should be dealt with in the case of need for repair in the course of use, the prior art is a method of deforming mat. Cut the edge rubber and the outer edge of the back rubber inside the edge rubber by the appropriate width and thickness, grasp the cause of distortion of the deformed mat and the progress state and apply a press with a repair rubber with a composition that is compatible with the back rubber left uncut. A mat restoration method that involves pressure vulcanization molding and leaving the cut surface of the back rubber and the joint surface of the repair rubber bonded together (Patent Publication 5-
4900) is provided.

Since these integrated mats are laid at the entrance and exit of people, the pile surface is repeatedly subjected to friction by the back surface of the shoe. Furthermore, since the mat is used in a rental system in which it is washed and reclaimed after a certain period of use, and then rented again, the mat is expanded and contracted due to expansion and contraction of the mat material by repeatedly receiving the above-mentioned friction and washing treatment. Ripples may occur.

In particular, repeated use of the mat, washing and drying for a long period of time causes shrinkage of 4% to 10% in the raw fabric portion composed of the pile and the base fabric, and the raw fabric. Since the rubber part shrinks relatively less than the contraction of the part, the result is that the size of the rubber part of the outer periphery, which is configured like a frame, is larger than that of the central part. It was happening.

[0009] As another cause, as a result of repetitive application of kinetic force to the mat such as twisting or bending of the mat during washing or drying, the mat itself gradually distorts in response to this. In particular, the force and momentum applied to the mat is
Since the outer peripheral portion is larger than the central portion, as a result, permanent stretch of the raw material and rubber portion of the outer peripheral portion occurs, causing a wavy phenomenon due to the relative dimensional difference with the central portion. .
Due to the occurrence of such a wavy phenomenon, the period during which a single mat can be used is extremely short in the rental industry, which is a major factor in the high cost.

[0010]

[Problems to be Solved by the Invention] In order to solve the drawbacks and problems of the conventional technique, a specific technique is provided from the angle of mat restoration method (Japanese Patent Publication No. 5-4900). Has already been done. However, this technique is merely a method of simply cutting the permanently stretched rubber portion and re-bonding the rubber again.

However, since the mat which has actually been used and has a wavy defect has a relative permanent elongation as compared with the central portion of the outer peripheral portion of the raw cloth, in this conventional technique, only the rubber portion is cut, and By re-adhesion, the wavy can be restored by making the size of the rubber part smaller than the size before cutting the rubber in the short term, but when it is used as a rental mat, it must be used in the long term. Therefore, it is impossible to avoid the generation of waviness due to the relative dimensional difference between the central portion and the outer peripheral portion existing in the raw fabric caused by long-term use.

[0012] In addition, the reason why the mat restoration method belonging to this prior art cannot be used for a long period of time is that there is a problem in that the strength of the boundary between the rubber and the base cloth is lowered. Specifically, the mat produced by press-heating and molding the mat raw fabric and the unvulcanized rubber is the end of the raw fabric on the rubber part due to the pressure distribution of the press, the raw fabric part, and the height difference of the rubber part. Tend to be molded into a depressed shape.

Because of this, the force applied during the processing steps such as cleaning and drying tends to concentrate on the boundary between the raw cloth portion and the rubber portion, and as a result, tearing failure in the vertical direction of the ears occurs. Occurs. Therefore, cutting only the rubber part,
The matte wavy repair method by re-adhesion was only half-finished repair in the state where the cause of the defect was not avoided, so similar defects such as tears continued to occur. This included a serious problem that the occurrence of defects due to tearing of the parts was unavoidable.

As described above, in the prior art of Japanese Examined Patent Publication No. 5-4900, the integrated mat as a dust control product cannot solve the fundamental defect inherently possessed, and is merely a repair method. It is a thing. This is also apparent from the comparative examples shown below.

Therefore, the object of the present invention is to eliminate the ripple phenomenon of the integrated mat caused by repeated use, to prevent the ripple from recurring and the outer peripheral rubber portion to be broken, and further to be usable. It is an object of the present invention to provide a method for recycling an integrated mat for rental dust removal intended to remarkably extend the period.

[0016]

The constitution of the present invention having the above-mentioned characteristics is such that the outer peripheral rubber portion having a frame-like shape is formed when the integrated mat for dust removal for rental having a defective waviness is regenerated. After cutting 1 mm to 20 mm inside the outer peripheral portion of the original fabric located inside, the surface of the original fabric is faced to the rubber surface of the outer peripheral portion, and the cutting surface is polished as needed. The vulcanized rubber is arranged and heated under pressure to integrally vulcanize the outer peripheral rubber portion.

The present invention having such features will be described below in detail with reference to the accompanying drawings.

According to the present invention, after cutting the inside 1 mm to 20 mm of the raw outer peripheral portion (2) adjacent to the outer peripheral rubber portion (1) of the wavy defective mat, the rubber surface on the back surface is cut, if necessary. 5 mm to 30 on the outer circumference of (4)
After polishing by millimeters, an unvulcanized rubber (5) for repair is appropriately arranged so as to face the polished portion (6),
If necessary, an adhesive is interposed, and after the adhesive is dried, vulcanization and integration are carried out by pressure heating processing.

Next, an actual regenerating method will be described with reference to the accompanying drawings. FIG. 1 shows an example of a mat showing a state before the regenerating, in which a pile (7) is vegetated on a base cloth (8). There is. A latex layer (9) is provided on the back surface of the base fabric (8) and functions as a sealing material for the pile (7) over the entire surface. Thus, the base fabric (8) is made integral by coating the latex layer (9). The state shown in FIG. 1 results in cracks (1
2) shows a state in which distortion is generated due to occurrence of 2). In the present invention, as shown in the figure, a portion 1 mm to 20 mm inward from the end of the base fabric (8) is cut vertically in the longitudinal direction.

In this case, the cutting point is the same as in the prior art.
Rather than cutting only the outer peripheral rubber part (1), it goes from 1 mm to 20 mm toward the inner side of the raw outer peripheral part (2).
Cut the millimeter part. In this case, the cut portion is cut in this manner rather than simply cutting an appropriate portion of the outer peripheral rubber portion (1) as in the prior art. The reason is to remove the distortion of the raw fabric portion (2) and to prevent the occurrence of cracks in the outer peripheral rubber portion (1), which has important meaning. 2 is shown in FIG.
FIG. 4 is a partially enlarged view of the figure, clearly showing the state of crack initiation.

FIG. 3 shows a polishing step which is carried out if necessary after cutting according to FIG. 1, and the polishing is performed more firmly by integrating it with an unvulcanized rubber (5) for repair which will be adhered later. This is because one of the reclaiming steps is performed to form a rough surface on the polishing part (6) by polishing, thereby increasing the surface area of the surface to be joined, and consequently improving the adhesive strength. is there. In this case, the polishing step is not a necessary requirement, but the unvulcanized rubber (5) itself can be blended with a chemical to improve the adhesive strength.

FIG. 4 is a reproduction mat (10) showing the mat after cutting in FIG.
Shows an unvulcanized rubber for repair which has a frame-like shape, and FIG. 5 shows a state in which a regenerating mat (10) is placed on the unvulcanized rubber (5). FIG. 3 is an explanatory view showing a state of vulcanization and integration of the outer peripheral rubber portion (1) by pressing and heating with a press machine (11) from above and below.

Next, the requirements and the like constituting the present invention will be described. First, as a dust mat to be recycled according to the present invention, a pile (7) yarn is tufted on a base fabric (8), and the tips thereof are trimmed to form a mat surface.

An elastomer latex layer (9) is optionally provided on the back surface of the base cloth (8) on the base cloth (14) applied to the entire surface of the base cloth (8), as a vulcanizing agent and a vulcanization accelerator. And an unvulcanized rubber (5) sheet containing appropriately are superposed such that the precoat layer as a sealing agent and the rubber sheet face each other, and pressed under heating to bond the precoat layer and the rubber sheet. A mat obtained by vulcanizing the precoat layer and the rubber sheet is often used as a mat for dust control. As the rubber sheet, a rubber sheet in which the thickness of the rubber sheet portion facing the raw material outer peripheral portion (2) is largely reinforced in advance for reinforcement is also used, if necessary.

Next, as the base fabric (8) used for the dust control mat, a woven fabric or a non-woven fabric of synthetic fibers having excellent dimensional stability such as acetalized polyvinyl alcohol fiber and polyester fiber is used, while the pile (7) is used. As the yarn, a multifilament yarn of synthetic fiber such as nylon fiber, vinylon fiber, acrylic fiber, spun yarn or a blended yarn thereof can be used, and also conventional natural fiber can be used.

Nitrile-butadiene rubber is particularly preferably used as the elastomer used for the rubber latex and the rubber sheet, but other vulcanizable rubbers such as styrene-butadiene copolymer rubber (SBR), chloroprene rubber, Polybutadiene rubber, isobutylene / isobrene rubber, etc. can be used.

Examples of the vulcanizing agent to be blended in the rubber sheet include inorganic vulcanizing agents such as metal salts of sulfur, zinc chloride, ferrous chloride and tin chloride, and sulfur chloride. Examples of the vulcanizing agent for oxides include dicumyl peroxide, acetylene peroxide, benzoyl oxide, ethyl methyl ketone peroxide, and the like, and thiurami sulfide, quinone dioxime thiol, dithio acid, and the like. However, it is common to use sulfur.

Examples of the vulcanization accelerator include thiol compound vulcanization accelerators such as 2-mercaptobenzothiazole, its copper salt, zinc salt, and 2,2-dibenzothiazole disulfide. As a compound vulcanization accelerator, N-cyclohexyl-2-benzothiazylsulfenamide, N-oxydiethylene-2-benzothiazylsulfenamide, N, N-diisoprovir-2-benzothiazylsulfenamide, etc. 2-mercaptothiazoline and the like can be mentioned as the crosslinking accelerator of the thiazoline compound. In addition, vulcanization accelerators such as thiuram compounds, dithiocarbamate compounds, aldehyde / amine compounds, guanidine compounds, carbamoylthiazole compounds and the like can be used.

The amount of the vulcanizing agent compounded in the rubber sheet is preferably in the range of 0.1 to 3% by weight based on the rubber, and the amount of the vulcanizing agent is 0.1.
It is particularly preferably in the range of 5 to 2% by weight. Also,
An appropriate amount of the vulcanization accelerator is added depending on the amount of the vulcanizing agent, the vulcanization conditions and the like.

The rubber latex and the rubber sheet may be compounded with a compounding agent known per se according to a known formulation. For example, a filler such as carbon black, a softening agent such as process oil, an antiaging agent, a dispersant, and a plasticizer. Agents and the like can be added.

[0031]

Example 1 The pile used in the example is 100% vinylon, 8.5 stitches / inch, and gauge 5/3.
2 (32/5 inches), pile height 10 mm, pile weight 660 g / m ² , and the base fabric is polyester plain woven fabric, weight 200
g / m ² , pre-coated NBR latex 60 g / m
² (based on solid content), the rubber sheet has a rubber sheet thickness of 1.2
A mat manufactured under the conditions of millimeter (center) and 2.2 millimeter (outer circumference), which was used for long-term rental, was used as a sample.

[0032]

Example 1-1 An example based on this Example 1-1 is
It is a confirmation experiment which concerns on the said prior art. Specifically, as shown in FIG. 1, the above mat was cut in a vertical direction from a rubber base line, a rubber surface of the mat was ground, an adhesive was applied, and the mat was dried. The adhesive used was one having the same composition as the unvulcanized rubber used for the outer peripheral rubber portion dissolved in methyl ethyl ketone and diluted 10 times. Then, an unvulcanized rubber sheet was superposed in a direction facing the coated surface of the mat after the adhesive was applied, and press-heated and processed at 180 ° C. for 20 minutes at 3 kg / cm ² . The size of the mat after vulcanization was 750 mm × 900 mm. 3000 people /
After laying in the sun place for 3 days, the usual integrated mat is washed and regenerated. This operation 20 times, 40 times, 60
Table 1 shows the occurrence of waviness and the condition of breakage of the outer peripheral portion after repeated repetition.

[0033]

[Embodiment 1-2] This embodiment 1-2 shows an example of a reproducing method according to the present invention. That is, Example 1-1
The same mat as the above was used as the base cloth outer peripheral raw material, and the outer peripheral portion 5 mm inward from the rubber boundary was cut, ground, coated with an adhesive, dried, and processed in the same manner as in Example 1-1. Then, after the mat is laid in a place where the number of people passing by is 3,000 / day for 3 days, the usual mat is washed and regenerated. Table 1 shows the occurrence of waviness and the situation of breakage of the outer peripheral portion after repeating this operation 20, 40, and 60 times.

[0034]

[Table 1]

Note that the corrugation display in Table 1 above indicates the height and number of corrugated rubber, and the breakage display shows the total when the base cloth and the outer peripheral rubber portion are completely cut. It shows the length of the outer circumference and the number thereof. In addition, the display of 1500 mm after 60 times of washing shows that one side shows the outer peripheral rubber falling off, and the other one side shows the partial falling off.

[0036]

As a result of the above constitutional requirements, the present invention corrects all the drawbacks and problems included in the above-mentioned prior art. That is, as a specific effect of the reproducing method according to the present invention, first, the wavy phenomenon of the mat can be avoided. This is because there is a significant difference in the permanent elongation of the mat between the outer peripheral portion and the central portion, so by cutting not the outer peripheral rubber portion but the raw fabric portion, the permanent elongation of the outer peripheral portion and the central portion is cut. It was possible to avoid the difference between. Further, according to the reproducing method of the present invention, it is possible to contribute to the prevention of the breakage of the mat. That is, at the same time, the occurrence of cracks in the rubber portion on the outer peripheral portion of the original fabric is prevented.

Furthermore, the present invention can improve the appearance of the reproduction mat. As a result of long-term use, in general, the piles on the outer peripheral portion of the original fabric are often removed, and the areas where the piles have poor adhesion are often exposed, but these are completely removed by regeneration. A beautiful surface appears again on the outer peripheral portion of the mat, and according to the present invention, it is possible to realize a completely integrated reproduction with respect to the phenomenon of mat peeling. That is, due to the long-term use of the mat, the peeling phenomenon of the outer peripheral portion of the base fabric at the same time when the pile comes off is completely adhered again by this reprocessing.

Further, according to the present invention, the waviness phenomenon of the mat can be completely avoided, so that sand or the like can be prevented from entering from the wavy portion to the bottom of the mat during actual use, and as a result, Therefore, it is possible to prevent the mat from shifting and to maintain the positional stability.

As described above, the method of recycling the rental dust-removing integrated mat according to the present invention can be expected to have many effects, and is a negative factor in terms of the time and cost required for the recycling as compared with the prior art. Notwithstanding, the above object of the present invention can be sufficiently achieved, and it is a method of recycling an integrated mat for rental dust removal which is remarkably useful in that the number of times of rental use after recycling is remarkably increased.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a mat to be recycled.

FIG. 2 is an enlarged cross-sectional view showing a state where cracks are generated in the mat to be regenerated.

FIG. 3 is an explanatory view showing a polishing state.

FIG. 4 is an explanatory diagram showing unvulcanized rubber and the like required for regeneration.

FIG. 5 is an explanatory diagram showing a state of vulcanization integration by pressure heating.

[Explanation of symbols]

 1 Outer peripheral rubber part 2 Outer peripheral part 3 Outer peripheral part of original plate 4 Rubber surface 5 Unvulcanized rubber 6 Abrasive part 7 Pile 8 Base cloth 9 Latex layer 10 Regeneration mat 11 Press machine 12 Crack 13 Cut section 14 Original cloth

Claims (1)

[Claims] 1. A 1 mm to 20 mm inner side of a raw fabric outer peripheral portion (2) positioned inside a frame-shaped outer peripheral rubber portion (1) is cut, and the outer peripheral portion (3) of the raw fabric rear surface (3) is cut. After polishing, if necessary, at a position facing the rubber surface (4), an unvulcanized rubber (5) for repair is arranged and heated under pressure to integrally vulcanize the outer peripheral rubber portion (1). A method of recycling an integrated mat for dust removal for rental, which is characterized by performing