JPS60167982A - Manufacture of mat - Google Patents

Abstract

PURPOSE:To achieve the complete bonding and integration of a carpet with rubber without causing the deformation and the hardening of the pile of the carpet, by applying an unvulcanized rubber sheet to the back surface of the carpet inserting a cushioning material therebetween with a press without heating, and vulcanizing the rubber under atmospheric pressure. CONSTITUTION:The carpet 1 is contacted and laminated with the unvulcanized rubber sheet 3, and the obtained laminate A is inserted between a pair of vertically arranged press molds 5, 5'. The cushioning materials 4, 4' composed of felt, sponge rubber, etc. are inserted between the laminate A and the press molds 5, 5', and the laminate A is hot-pressed. The heating temperature is adjusted to a level (about 60 deg.C) to keep the pressed carpet files 1' from permanent deformation and hardening. The bonded laminate A is taken out of the molds, and the rubber sheet is vulcanized under atmospheric pressure to bond the rubber sheet firmly to the back surface of the carpet. The heating operation can be omited by preheating the unvulcanized rubber sheet 3.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a mat in which a rubber sheet is integrally bonded to the back side of a carpet.

Conventionally, the method for producing this type of mat is to laminate carpet and unvulcanized rubber sheets, heat and press them using a vulcanization press, and simultaneously vulcanize the rubber sheet and bond it to the carpet. is well known. However, in the above method, the carpet hair is heated to a high temperature while being strongly compressed, so the carpet hair does not restore its shape even after vulcanization and is deformed and hardened while being compressed. In addition to interfering with the functions of the product, it also had the disadvantage of having a poor appearance, reducing the product's value.

In addition, the base fabric on the back of the carpet has small irregularities, and it is difficult to fit the rubber sheet along these irregularities, resulting in insufficient adhesion between the carpet and the rubber sheet. There was also the drawback that it was not possible to IM.

The present invention was devised for the purpose of eliminating these drawbacks, and provides a new manufacturing method that does not cause deformation and hardening of the carpet hair and can completely bond and integrate the carpet and the rubber sheet. This is what I am trying to do.

That is, the present invention consists of a first step and a second step, and in the first step, a laminate made of an unvulcanized rubber sheet is brought into contact with the back side of a carpet, and the hair of the carpet is deformed and hardened without heating. After the carpet and the unvulcanized rubber sheet were brought into close contact with each other by applying pressure through the cushioning material while being heated to such an extent that the rubber sheet was heated to such an extent that the rubber sheet was not vulcanized, in the second step, the unvulcanized rubber sheet was vulcanized at normal pressure. It is characterized by this.

Next, the present invention will be explained with reference to the drawings.

The drawing shows an outline of the first step of the present invention, and ill shows a carpet with adhesive applied to the back side of the base fabric (2), and (3)
) is an unvulcanized rubber sheet that is brought into contact with the back surface of the carpet +11.

In the first step, the carpet (1) and the unvulcanized rubber sheet (3) are laminated in contact with each other, and this laminated body (8) is charged into the upper and lower press molds +51 t5r, and heated and pressurized. At this time, a cutter material (41 (41') made of felt, sponge rubber, etc.) is interposed between the laminate (A) and the press mold +51t5r to pressurize the laminate (A), and at the same time pressurizes the laminate (A). The temperature is controlled to such an extent that the hair +11' does not deform and harden while being compressed, in other words, the temperature is such that when the compressive force is released, the carpet hair returns to its original length.

In this example, the pressure and heat treatment was performed under a pressure of 2 kg/cd and a temperature of 60°C.

In this first step, heat treatment is not necessarily required, and can be omitted if the unvulcanized rubber sheet (3) is preheated in the previous step.

In this example, a cloth (61 (
61' is placed between the laminate (A) and the cushion material +41 (4r) and compressed, and the peripheral edge of the unvulcanized rubber sheet (3a)
Although we have shown an example of forming a cloth pattern on the back side (3b),
This is not essential to the invention, and either one of the upper and lower cushioning materials (41+41') may be omitted, and the pressing means for the laminate (A) is not limited to a press; In the case of a thick laminate, pressure may be continuously applied using a roto-curing device, or other known pressurizing methods may be used.

In this way, carpet +11 and unvulcanized rubber sheet)
(Laminated body iA with 31 in close contact) is a press mold +50
51' - After taking out the carpet, the rubber sheet (3) is vulcanized under normal pressure as a second step, and it is possible to obtain a product in which the rubber sheet is firmly adhered to the back side of the carpet without applying pressure during vulcanization. can.

In the second step, the rubber sheet can be vulcanized at normal pressure by employing an appropriate vulcanization means such as a hot air circulation type.

According to the method of the present invention explained above, the following effects can be achieved.

■ In the first step, the laminate is pressurized through the cushioning material, and the cushioning material deforms when pressure is applied so that even pressure is applied over the entire surface, even the small irregularities of the carpet base fabric. The rubber sheet can be followed and penetrated without any gaps, and a product in which the carpet and the rubber sheet are firmly bonded and integrated can be obtained.

■ In the first step, if the car vent and the rubber sheet are to be brought into airtight contact, the GoJ sheet must be softened to some extent and then pressurized, but the rubber sheet must be preheated in the previous step or Alternatively, by keeping the heating at a relatively low temperature when applying pressure, even if carpet hair is temporarily strongly compressed, it will return to its original length after the pressure is released, preventing deformation and hardening, and improving product functionality. No damage to appearance.

[Brief explanation of the drawing]

The drawing is a schematic diagram showing the first step in an embodiment of the present invention. (1) Carpet, (3) Unvulcanized rubber sheet, (4) Cushion material, (5) Press mold.

Claims (1)

[Claims] (11) A laminate consisting of unvulcanized rubber sheet 1- is brought into contact with the back surface of a carpet, without heating or heated to such an extent that the hair of the carpet does not deform and harden, through a cushion layer. A method for manufacturing a mat, characterized in that the car vent and the unvulcanized rubber sheet are brought into close contact with each other by applying pressure, and then the unvulcanized rubber sheet is pressure-vulcanized. The method for manufacturing a cloak according to claim 11, wherein the pressure is applied by interposing cloth between the cushioning material and the cushioning material.