JPS6347612B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a laminate product, and in particular to a laminate product such as an indoor carpet mat, an entrance carpet mat, an automobile floor mat, etc., in which a vulcanized backing rubber is laminated on the back side of the carpet to reinforce the lining. The present invention relates to a method for manufacturing a laminate product that can improve the performance of the product and provide it at a low cost.

Conventionally, there are the following methods for manufacturing a laminate product in which a vulcanized rubber sheet or the like is laminated on the back side of a carpet.

Conventional method (1): The most commonly used method is to apply an adhesive to the back side of the carpet and the surface of the vulcanized rubber sheet, dry it, stick them together, and then press them together to laminate them. However, in this method, the back surface of the carpet is extremely uneven and the adhesive permeates into the fibers to a large extent, making it difficult to obtain a smooth coating surface and having the disadvantage of point adhesion to the surface of the vulcanized rubber sheet. To prevent this, the back side of the carpet is often treated with a so-called backing treatment using rubber latex or synthetic resin emulsion, which has the drawback of increasing costs. Furthermore, the vulcanized rubber surface has the disadvantage that it will not adhere to the adhesive unless it is buffed or treated with halogen. There are also occupational health problems when using adhesives. However, since there is no suitable manufacturing method, this is the most practically used method.

Conventional method (2): A carpet and an unvulcanized rubber sheet are placed one on top of the other in a vulcanization mold that has a pressurized chamber using air pressure, and the carpet and unvulcanized rubber sheet are pressed together using air pressure from the carpet surface. A method of laminating by pressing and heating the mold surface and vulcanization molding is also useful, but if the mold surface has a deep engraved pattern, there is a drawback that the pressure is insufficient and the shape is insufficiently lifted. Furthermore, it is rarely put into practical use due to drawbacks such as the fact that the carpet and rubber sheet need to be wider than necessary in order to prevent air leakage.

Conventional method (3): In some cases, unvulcanized rubber sheets are layered on the back side of the carpet using a current rubber vulcanization press, and then laminated and vulcanized at the same time by applying pressure and heating. However, since it is compressed at high temperature and high pressure for a relatively long time of 3 to 10 minutes, it is rarely put to practical use because the nap on the carpet surface is compressed and deformed, impairing its commercial value.

The present invention improves the shortcomings of such conventional methods, and as a result of studying a method for manufacturing a laminate product of carpet and vulcanized rubber with excellent functionality at low cost, we have developed the conditions for manufacturing a laminate product by pressurizing and heating. I thought as follows.

(1) The temperature at which the napping is not damaged by heating from the carpet surface is preferably 30 to 80°C, and even the napping of stiff nylon fibers is 120°C or less.

(2) The pressing force that does not damage the nap during the vulcanization time of about 10 minutes is preferably a lamination surface pressure of 0 to 2 kg/
cm ² , and even napping of nylon fibers is less than 6 Kg/cm ² . In particular, no pressure will less likely damage the nap.

(3) The pressure to obtain good adhesion of the vulcanized rubber sheet to the back side of the carpet is a lamination surface pressure of 1 kg/ ^cm2 or more, provided that the following operations (4) and (5) are performed first. Good adhesion is obtained even after vulcanization without pressure.

(4) When vulcanizing is performed for approximately 20 seconds at a lamination surface pressure of 20 to 50 kg/ ^cm2 , the unvulcanized rubber reaches the deep part of the pattern engraved on the rubber mold without damaging the nap of the carpet. It flows in and fills up. It also firmly adheres to the back of the carpet.

(5) Even if the application of lamination surface pressure of 20 to 50 kg/cm ² is repeated for about 10 seconds 2 to 4 times, the nap of the carpet will not be damaged and even the deep parts of the pattern engraved on the rubber molding mold will not be damaged. Vulcanized rubber flows in and fills up. It also has strong adhesion to the back of the carpet.

(6) The heating temperature from the back side of the unvulcanized rubber sheet is 140
Good results are obtained between ℃ and 165℃. The shorter the vulcanization molding time, the less damage to the nap of the carpet.

It has been discovered that by appropriately combining the above conditions, it is possible to produce products in which carpet and vulcanized rubber are laminated at low cost and with excellent functionality, and one of these is the method for producing a laminate product of the present invention.

As shown in the drawings, the method for manufacturing the laminate 1 of the present invention is to superimpose a vulcanizable unvulcanized rubber sheet 5 on the back side of a carpet 2, and heat the laminate at a temperature of 20 to 120°C from the front side of the carpet 2. A lamination surface pressure of 6 to 50 Kg/cm ² is achieved by using a pressure plate with a temperature of 120 to 180°C from the back side of the unvulcanized rubber sheet 5 or a mold attached to this pressure and heat plate. After applying pressure for both times one or more times, the unvulcanized rubber is heated with no pressure using the laminated surface pressure with the five sides of the unvulcanized rubber in close contact with the pressure heating plate or the molding die, The method is characterized in that an unvulcanized rubber sheet 5 is fused to the back surface of the carpet, laminated, and vulcanized at the same time. To explain in more detail, a vulcanizable unvulcanized rubber sheet 5 is superimposed on the back side of the carpet 2, and this is attached to the lower heating plate 10 or the lower heating plate 10 of the press-type laminated vulcanization molding machine 8. Place the unvulcanized rubber sheet 5 in contact with the mold, adjust the temperature of the upper plate 9 to 20 to 120°C, and adjust the temperature of the lower heating plate to 120 to 180°C.
Using a press-type lamination vulcanization molding machine 8 adjusted to ℃,
Pressure is applied repeatedly one or more times for a short time at a lamination surface pressure of 6 to 50 kg/cm ² , and thereafter, the 5 unvulcanized rubber surfaces are placed under no pressure on the lower heating plate 10 or the molding mold. The unvulcanized rubber sheet 5 is heated and fused and laminated on the back surface of the carpet 2 while being in close contact with the carpet 2, and at the same time, vulcanization molding is performed.

The rubber material used in the present invention can be any of natural rubber, synthetic rubber, and recycled rubber.

This is kneaded with a vulcanizing agent, a vulcanization accelerator, a vulcanization aid, an anti-aging agent, a reinforcing agent, a filler, a softener, and other rubber chemicals, and then rolled.

Further, the carpet 2 used in the present invention may be a tufted carpet made of natural fibers or synthetic fibers, a needle punch carpet, or any other method of manufacturing the carpet 2.

Although it is also possible to use a carpet 2 whose back surface is backed with rubber latex or synthetic resin emulsion, a major feature and advantage of the present invention is that good results can be obtained even when the carpet 2 is not backed. It is.
Furthermore, in the present invention, adhesive can be applied to the back side of the carpet and dried, but it has the feature and advantage that strong lamination can be made without using adhesive on both the carpet side and the rubber side.

As shown in FIG. 3, the laminated vulcanization molding machine 8 used in the present invention has a pressure plate 9 on the carpet 2 side whose temperature can be adjusted appropriately between 10°C and 120°C by water cooling, etc. The pressure plate 10 on the side has a temperature of 120
It is a heating plate 10 that can be adjusted appropriately between ℃ and 180℃.
The pressure per unit area of the laminated surface, that is, the laminated surface pressure, is 0.
A press-type lamination vulcanization molding machine 8 is required, which has a mechanism that can be set appropriately over a wide range of ~50 kg/cm ² .

The work can also be carried out by interposing a heat insulating material, a cushioning material, etc. between the pressure plate 9 on the carpet 2 side and the carpet 2. A molding die engraved with an appropriate pattern or a flat molding die is attached to the heating plate 10.

The present invention will be further explained below with reference to Examples.

Example formulation (parts by weight) Natural rubber 100 Sulfur 2 Vulcanization accelerator CZ (N-cyclohexyl-2-benzothiazolylsulfenamide) 1.5 Vulcanization accelerator TT (tetramethylthiuram disulfide) 0.1 Acetylation Zinc 5 Stearic acid 1 Carbon black (FEF) 40 Light calcium carbonate 40 Hakuenka CC (fine activated calcium carbonate) 40 CML#31 (main component calcium oxide) 8 The above mixture was kneaded and rolled into a 4 mm thick sheet, 615 Unvulcanized rubber 5 cut into ×615mm and the second
A tufted carpet made of brushed nylon that has not been subjected to backing treatment as shown in Fig. a is cut into 615 x 615 mm and overlapped with carpet 2, and placed in a press-type lamination vulcanization molding machine 8 as shown in Fig. 3. Then, the upper plate 9 was set to 60 to 80℃, the lower heating plate 10 was set to 160℃, and crimping was carried out for 8 seconds at a lamination pressure of 25 kg/cm ² .
After repeating the process several times, the lamination surface pressure is set to no pressure,
The unvulcanized rubber sheet 5 is heated with the surface of the unvulcanized rubber 5 in close contact with the lower heating plate 10, and the unvulcanized rubber sheet 5 is fused and laminated to the back surface of the carpet 2, and at the same time, vulcanization molding is performed.
A laminate 1 of a carpet 2 and a vulcanized rubber backing 3 as shown in FIG.
The carpet was cut to a size of 600 mm to manufacture a carpet to be placed inside a golf course.

As shown in the embodiments, the present invention does not require backing treatment on the back side of the carpet 2, and there is no need for applying, drying, or pasting an adhesive. The unvulcanized rubber sheet 3 is infiltrated and vulcanized and bonded to form the material, so it has high adhesive strength and excellent heat resistance and water resistance, so it can be used for golf course carpets and mats using conventional adhesive methods. Thus, it is possible to manufacture an excellent carpet mat to be placed inside a golf course without failures such as peeling of the adhesive from the vulcanized rubber surface due to the repeated stress of the golf shoe spike nails.

As described above, the present invention is a manufacturing method that provides a laminate product of carpet and vulcanized rubber, such as an indoor carpet mat, an entrance carpet mat, and an automobile floor mat, which is inexpensive and has excellent performance.

The laminate manufactured by the method of the present invention has an excellent appearance because the nap of the carpet 2 is not impaired. However, since the unvulcanized rubber sheet 2 is heated and vulcanized under no pressure, it is desirable to take antifoaming measures such as adding a foaming inhibitor such as calcium oxide to prevent the unvulcanized rubber sheet 2 from foaming.

As described above, the present invention has many advantages as follows.

(1) No adhesive is used, so there is no need for adhesive costs. Further, there is an advantage that there are no adverse effects on occupational health caused by organic solvents.

(2) Since no adhesive is used, there is no risk of the adhesive penetrating too much into the carpet and causing the carpet to harden.
Will not stain carpet surface.

Since the adhesive does not penetrate too much, backing is not required and the cost of carpet materials is significantly reduced.

(3) Man-hours for applying adhesives are no longer required, and no man-hours are required for bonding and bonding.

(4) Unvulcanized rubber sheets are infiltrated and intertwined on the back side of the carpet to create a laminated vulcanization molding, which has strong adhesive strength and excellent heat resistance, water resistance, oil resistance, and detergent resistance, making it suitable for many uses. wide.

As described above, the present invention makes it possible to manufacture the laminate 1 of the carpet 2 and vulcanized rubber backing 3 which is inexpensive and has excellent quality and appearance with low material costs and man-hours.

[Brief explanation of drawings]

FIG. 1a is a perspective view showing a laminated product of carpet and vulcanized rubber according to an embodiment of the present invention;
Figure b is a partially enlarged sectional view of Figure 1a, and Figure 1c is a partially enlarged sectional view of Figure 1a.
The figure is another partially enlarged sectional view of Figure 1a, and the second
Figure a is a cross-sectional view of a tufted carpet, Figure 2b is a cross-sectional view of a tufted carpet that has been subjected to backing treatment, and Figure 3 is a cross-sectional view of a carpet and rubber according to an embodiment of the present invention. It is a cross-sectional explanatory schematic diagram showing one manufacturing process of a laminate product. 1...Laminated product of carpet and vulcanized rubber, 2...
Carpet, 3... Vulcanized back rubber, 4... Convex pattern portion of vulcanized back rubber, 5... Unvulcanized rubber sheet, 6...
...Base fabric of tufted carpet, 7...Backing of tufted carpet, 8...Press type lamination vulcanization molding machine, 9...Top plate of press type lamination vulcanization molding machine, 10...Press type lamination vulcanization molding machine Lower heating plate of vulcanization molding machine,
11...Cooling water inlet, 12...Cooling water outlet,
13...Steam inlet, 14...Steam outlet.

Claims (1)

[Claims] 1 Lay a vulcanizable unvulcanized rubber sheet on the back side of the carpet, and
A lamination surface pressure of 6 to 60°C is achieved using a pressure platen with a temperature of 20 to 120℃ and a pressure platen with a temperature of 120 to 180℃ from the back side of the unvulcanized rubber sheet, or a mold attached to this pressurization platen. After applying pressure at 50Kg/ ^cm2 for a short time one or more times, the laminated surface pressure is set to no pressure, and the unvulcanized rubber surface is heated in close contact with the pressure platen or molding die. A method for manufacturing a laminate product, which is characterized in that an unvulcanized rubber sheet is fused to the back side of the carpet, laminated, and vulcanized at the same time.