JPS5995016A - Dust control mat - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a mat K for dust control.
More specifically, the present invention relates to a dust control mat that has excellent fit to the floor, light weight, edge protection, breathability, dehydration properties during washing, drying properties, etc. In this specification, dust control mats are used to remove dust, dirt, etc. that adhere to shoe floors, etc. by placing them at entrances where people enter and exit various stores, hotels, hospitals, offices, residences, etc. This refers to mats used for the purpose of preventing intrusion into indoor spaces.

The mainstream of these dust control mats is woven mats whose front surface is made of fiber material and whose back surface is made of rubber or resin, and their shapes can be broadly classified into the following six types.

■ A mat with a cover (overlock) around the mat, ■ A mat that is fixed with Velcro to a base with a frame, ■ A thick rubber or resin backing that improves the appearance of the mat, and The backing is a frame part that protrudes outward from the surface fiber part so that the part fits well on the floor (hereinafter sometimes simply referred to as an integrated mat).

This integrated mat must fit well against the floor surface when walking on it, so that it does not shift its position or cause the mat itself to become loose.From this point of view, the The backing used was quite thick.

Conventionally, this integrated mat has been 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 placing the mat fibers on an uncured rubber sheet. After the mats are placed on the mats, they are bonded and solidified using a heat press process. However, since the entire back side of mats manufactured using these methods is made of thick resin or rubber, Therefore, conventional dust control mats require a large amount of elastomer, resulting in high manufacturing costs, and are heavy, making it difficult to distribute.

In particular, this type of mat is used in a rental system where after a certain period of use, the mat is washed and recycled and then rented out again. This has the disadvantage that it is inconvenient and requires cleaning and recycling costs.

In this way, in the field of dust control mats,
There is a strong desire to reduce the weight of the mat while improving its fit to the floor.

An object of the present invention is to provide a dust control mat which eliminates the above-mentioned drawbacks of conventional mats and which is light in weight and has significantly improved fit to the floor surface.

According to the present invention, in a dust control mat comprising a base fabric, a pile yarn tufted to the base fabric, and an elastomer backing applied to the back side of the base fabric, the backing is formed by applying an elastomer to the entire surface of the base fabric. The weight area ratio formed by curing if necessary is 250 to 1000 f/W? A thin backing layer with a weight area ratio of 1000 to 4000 f/r provided so as to overlap and be integrated with the edge of this thin backing layer.
r? A dust control mat is provided, comprising a frame-shaped thick nitrogen backing.

The invention will be explained in detail below with reference to the accompanying drawings.

In FIG. 1 showing the cross-sectional structure of the dust control mat of the present invention, a base fabric 1 has pile threads 2 tufted and their tips are trimmed to form a mat surface.

On the back side of the base fabric 1, elastomer latex is applied over the entire surface of the base fabric and cured to form a thin backing layer 6.

In the present invention, this backing layer 3 is
It is possible to stop the removal of water and can withstand repeated washing, and the area weight ratio as solid content is 250 to 1001.
: l/m', particularly 250 to 500 f/-, and a frame-shaped thick backing 4 is provided so as to overlap and be integrated with the edge of this thin backing layer B.

This frame-shaped thick backing 4 is made of an elastomer 5-- of the same type as the elastomer constituting the thin backing layer 3, and the shaping of the thick backing 4 and the integration with the thin backing layer 6 can be carried out, for example, by
This can be easily done by placing an unvulcanized nystomer sheet of the same type on the back side of a mat with a thin backing layer, and subjecting it to hot press processing to bond the two together and to cure the sheet itself.

In the specific example shown in the drawings, a thick frame-shaped backing 4
is a portion 5 overlaid and glued with a thin backing layer 6
and a portion 7 projecting outward from the edge 6 of the mat with a thin backing layer, this projecting portion 7 serves to protect the edge 6 of the mat and prevent blistering.

This thick backing 4 may be present only as four sides 4a, 4b, 4c, 4d at the edge of the mat, as shown in FIG. 2, or as shown in FIG.
, 4h, and 46.4d, there may be a bridge or reinforcing rib 4-14f that bridges the middle part of these four sides, and as shown in FIG. , may have diagonal reinforcing ribs 4y, 4k connecting the corners of the bridge 6.

Similarly, the seam between the sheet sides of each elastomer, for example, the seam 8 (FIG. 2) between the sheet side 4α and the sheet side 4b, is preferably formed by overlapping the sheets by a width of about 5 cm.

In the present invention, the thick backing 4 has a thickness of 1000 to 400 to improve the fit to the floor, prevent the mat from slipping off the edges, and maintain the shape of the mat.
Provided with a heavy lid area ratio of 0r/-.

In the pine of the present invention, the backing in the center of the mat is provided as an extremely thin layer that can prevent the pile threads from falling off, and the thick sheet-like backing is provided only in the frame shape, which is different from the conventional method. It is significantly lighter and easier to handle than integrated mats, and the savings in elastomer material can reduce manufacturing costs, and the weight reduction can also reduce distribution costs. In addition, the thick frame-shaped backing maintains the shape and dimensional stability of the mat, improves its fit to the floor, and reliably protects the edges of the mat from fraying. Furthermore, due to the suction cup effect formed by the thick backing and the thin backing, an advantage is also achieved in that displacement from the floor surface is also prevented. In addition, since the backing layer in the center of the mat is thin, it maintains breathability to the floor surface and prevents moisture from condensing and remaining between the floor surface and the mat, making it ideal for flooring, carpets, etc. It also prevents deterioration of the body. In addition, this integrated mat allows a greater number of mats to be loaded into the washer during cleaning compared to conventional mats, making it possible to reduce the unit cost of cleaning and reprocessing. Further, many advantages are brought about, such as high dehydration efficiency after washing and drying in a short time.

In the present invention, woven or non-woven fabrics made of synthetic fibers with excellent dimensional stability such as polyester fibers are used as the base fabric, while pile yarns include crimped nylon fibers, vinylon fibers, acrylic fibers, etc. Spun yarns or multifilament yarns of synthetic fibers, spun yarns of natural fibers such as cotton, or blended yarns thereof are used.

The backing material includes synthetic rubbers such as acrylonitrile-butadiene copolymer comb (NBR), styrene-butadiene copolymer comb (SBR), chloroprene rubber, soft vinyl chloride resin, polyurethane, acrylic elastomer, and styrene. - Thermoplastic resin distomers such as butadiene block copolymer elastomers can be mentioned. These elastomers are
It is applied in the form of latex to the surface of the matte base fabric so as to have the above-mentioned weight-to-area ratio, dried, and rectified if necessary. In this case, since only a thin backing layer is provided on most of the back side of the base fabric, when cleaning and recycling the mat after use, it is necessary to prevent the formation of corrugations on the frame due to shrinkage of the base fabric. In addition, it is desirable that the base fabric etc. be sufficiently compressed at some stage before the frame-shaped backing is fixed.

Next, as shown in the attached drawing, an unvulcanized sheet made of the same type of elastomer as the latex used for coating is placed on the thin backing surface of the mat, and heated and pressed. The thin backing layer and the thick frame-shaped backing are bonded together and vulcanized.

Similarly, in order to strengthen the adhesion between both backing layers, it is of course possible to apply only the latex and dry it, overlay the elastomer sheets, and heat and vulcanize both elastomers at the same time.

In the present invention, the pile threads of the dust control mat have the effect of adsorbing and holding dust adhering to the soles of shoes etc. on the pile threads by rubbing against the soles of shoes. In order to further enhance the dust adsorption and retention effect of the pile yarn,
The pile yarn can be coated or impregnated with a dust-absorbing liquid. Such dust-absorbing liquids include, for example, liquid paraffin, spindle oil, alkylbenzene oil, dimostel oil, mineral oil such as castor oil, synthetic oil, or vegetable oil-based oils, and Japanese Patent Publication No. 53-10194 and 5-Ro-1 37471. Examples include the aqueous dust adsorbent described in Japanese Patent No.

-1α- The invention is illustrated by the following example.

Examples A mat consisting of the following structure was manufactured.

Pile: BCF nylon (stitch 6/4% cA, gauge 5/62, pile height 9
Fabric, fabric weight 880r/m", cut pile] Base fabric: Polyester plain woven fabric (200t7rr?) Buff = Ii-7g: NBR latex (10009/m')
(Solid content: 46%) This mat was cut into 70 cm x 85 cm pieces, and an integral mat was manufactured in the following manner.

1) Place the mat cut to the above dimensions on an uncured NBR sheet with a thickness of 11 wI, and heat it at 150°C for 16 minutes.
The mat and the NBR sheet were bonded and solidified by pressing at a pressure of /cJ. Next, the NBR sheet that has been bonded and assimilated is cut into a width of 1.5 mm from the edge of the mat.
．． An integral mat of nylon pile with a 5-width frame was manufactured.

I) Uncured NBR with the same thickness of 1 mm as in 1 as shown in Figure 5.
The sheets were assembled into frames as shown in the shaded area in Figure 4, and the nylon pile mat described above was placed on the broken line and hot press treated under the same conditions as 1). Next, in the same manner as in 1), the NBR sheet was cut to have a total frame width of 1.5 crn, and an integral mat having the frame but without sheet backing on the inside was manufactured. The unit of dimensions shown in FIG. 5 is rust.

The integral mats manufactured as in 1) and 1) were immersed in water and the dehydration efficiency and drying time were measured. For comparison, dehydration efficiency and drying time were similarly measured for a mat not backed with an NBR sheet (the above nylon pile mat).

The results were as shown in Table 1.

As mentioned above, the pine (II) mat with NBR sheet backing only on the edges and the mat (+) with NER sheet backing on the entire surface have good dewatering efficiency and drying time. It turned out that there was no big difference between the mat and the mat without the seat backing.

Example 2゜ A mat consisting of the following structure was manufactured.

Vile: 100% vinylon (cut pile, pile height 1)
Base fabric: Polyester plain woven fabric (Weight 70097m) Repacking: NBR latex (
Coating amount: 900 t/m (solid content: 46%)) This mat was cut into pieces of 87 crrL x 142 cm, and an integral mat was manufactured in the following manner.

1) Same as 1) of Example 1, the entire back side of the mat and 1.5
A mat having a cIrL width frame portion made of an NBR sheet was manufactured.

It) As shown in FIG. 6, the NBR sheet was placed in the shaded area and the mat was placed in the broken line area to produce a mat that also had an NBR sheet part on the inside.

1) and H) were heat-pressed at 4160° C. for 10 minutes at a pressure of 811+/m to produce a mat.

The NBA sheet used was 1.5 m thick.

The unit of dimensions shown in FIG. 6 is also brocade.

The integral mats manufactured as in 1) and If) were immersed in water in the same manner as in Example 1, and the dewatering efficiency and drying time were measured. In this case, as a comparison, the dewatering efficiency and drying time were also measured for the above-mentioned vinylon pile mat.

The results were as shown in Table 2.

As mentioned above, we measured the dehydration efficiency and drying time of the VCs partially crimped with sheet metal on the inside for reinforcement, and found that the dewatering efficiency and drying time were much more efficient than those with sheet backing on the entire surface. I found it to be dry.

Example 3 The mat used in Example 2 was cut into 701:m x 85m (m) to produce a partial mat as shown in FIG.

Unused Cure NBR is 1.5m+x and heat press is 160
℃, 8 kg/CIIL'' for 10 minutes.

This one-piece mat was placed at the entrance/exit of a business office where about 1,000 people come and go each day, and tests were conducted to see if mat creases or wrinkles would occur on the inside of the mat. The flooring material was a cushion floor made of polyvinyl chloride.

Observations were made for two consecutive days, and no appearance of wrinkles or wrinkles was observed on both days.

[Brief explanation of drawings]

Figure 1 is a partial sectional view of the dust control IT of the present invention, Figure 2 is a plan view of the mat backing, Figures 3 and 4.
The figure is a plan view showing another example of the shape of the frame-shaped thick backing, Figure 5 is a plan view showing the shape and dimensions of the frame-shaped thick backing used in Example 1, and Figure 6 is the plan view showing the shape and dimensions of the frame-shaped thick backing used in Example 2. FIG. 2 is a plan view showing the shape and dimensions of a frame-like thick backing. Reference numeral 1 indicates the base fabric, 2 indicates the pile yarn, 6 indicates the thin backing layer, and 4 indicates the frame-shaped thick backing. Patent applicant: Duskin Franchise Co., Ltd. Figure 7 Procedural amendment (method) % formula % 1. Indication of the case Japanese Patent Application No. 57-204680 2. Name of the invention Dust control mat 3. Person making the amendment Relationship with the case Patent Applicant Address: 4-11-16 Toyosaki, Oyodo-ku, Osaka Name
Duskin Franchise Co., Ltd. 4, Agent 105 Address Atagoyama Lawyer Building 6, 1-6-7 Atago, Minato-ku, Tokyo Column 7 for a brief explanation of the drawings in the specification subject to amendment, Contents of amendment (1) Specification page 18, lines 6 to 7 K “Figure 6...
It is... ” is corrected as follows. "FIG. 6 is a plan view showing the shape and dimensions of the thick frame backing used in Example 2. FIG. 7 is a plan view showing the shape of the thick frame backing used in Example 6." Above 2-

Claims (1)

[Claims] (1) It is applied to a dust control mat consisting of a base fabric, a tactified pile yarn on the base fabric, and a backing of Nistomer applied to the back side of the base fabric, and the backing is
The weight area ratio formed by applying the elastomer to the entire surface of the base fabric and curing if necessary is 250 to 100.
(A thin backing layer of 1/- and a frame-shaped thick nitrogen backing with a weight-to-area ratio of 1000 to 4000 r/-, which is provided so as to overlap and be integrated with the edge of this thin backing layer. A dust control mat featuring Naruko Tora.