JP4356082B1 - Dust control mat - Google Patents

Abstract

An object of the present invention is to smooth the back stitch surface of tufted fabric, firmly bond a secondary base fabric with a small amount of adhesive for bonding, and laminate thin unvulcanized rubber sheets to make it light and easy to carry. No dust appears on the surface of the rubber sheet, and a good-looking dust control mat is obtained.
SOLUTION: The top 15 of a back stitch 14 protruding from a primary base fabric 11 of a tufted fabric 13 formed by applying a backing adhesive to the back surface of a tufted raw machine is crushed and parallel to the primary base fabric 11. The secondary base fabric is firmly bonded to the flat surface 16, and a thin unvulcanized rubber sheet 18 is laminated on the flat back stitch surface. The unvulcanized rubber sheet 18 laminated on the back stitch surface is pressurized, heated and vulcanized to form a dust control mat 19 integrated with the tufted fabric 13.
[Selection] Figure 1

Description

  The present invention relates to a dust control mat formed by stacking an unvulcanized rubber sheet on a back stitch surface of a tufted fabric, pressurizing and heating and vulcanizing.

Tufted production machines may be used as they are for carpets, mats, sheets, bed covers, etc. without applying a backing adhesive. In loop pile tufted production machines, the back stitches on the loop pile surface and back side are used. Each surface may be brushed and used for blankets. Tufted raw machines used for carpets, mats and other rugs are finished by applying a backing adhesive to the back of the pile to firmly lock the pile to the primary base fabric. Pile yarn having a single fiber fineness of 5 dtex or less and a soft touch is used for the raised blanket and the rug.
The dust control mat is a kind of cleaning tool that is placed on the doorway and used to capture the dust adhering to the bottom of the footwear. A relatively stiff pile yarn having a single fiber fineness and generally 10 to 35 dtex is used.
Tufted living machines are also used as artificial lawns, and tape monofilaments having a single fiber fineness of 100 dtex or more and a flat cross-sectional shape are used for the pile yarn.

  The pile yarn for dust control mat is thicker and more rigid than the pile yarn for brushed blankets and rugs, even if it is not as thick as that for artificial lawn. The back stitch 14, which is greatly raised from the primary base fabric 11 and coated with the backing adhesive, becomes a porous ridge reinforced by the soaked backing adhesive.

  The dust control mat 19 is finished by superimposing an unvulcanized rubber sheet on the back stitch surface of the tufted fabric coated with the backing adhesive, heating and pressurizing, and vulcanizing the unvulcanized rubber sheet (for example, Patent Document 1).

JP-A-01-139253

  On the back stitch surface of the tufted fabric 13 for the dust control mat, the back stitch 14 is raised as a hard porous bulge, and an unadded thickness necessary to fill the valleys 17 between the back stitches 14 and 14 is added. A vulcanized rubber sheet is required, and the dust control mat becomes heavier depending on the thickness of the unvulcanized rubber sheet.

  However, if the unvulcanized rubber sheet is made thinner, the dust control mat will be lighter and easier to carry, but the rubber sheet will sink into the valleys 17 between the back stitches along the back stitch irregularities. As a result, the appearance of the back surface of the dust control mat is damaged, and the protrusions formed on the rubber sheet surface are rubbed and worn by the back stitch 14, and the fibers of the back stitch 14 are worn. As a result, the durability of the dust control mat is impaired.

Therefore, the present invention smoothes the back stitch surface of the tufted fabric so that even if a thin unvulcanized rubber sheet is used, the traces of unevenness of the back stitch do not appear on the surface of the rubber sheet, thereby obtaining a dust control mat that is light and easy to carry This is the first purpose.
The second object of the present invention is to reduce the cost of the dust control mat by thinning the unvulcanized rubber sheet.

  The dust control mat of the present invention has a back stitch surface of a tufted fabric 13 covered with an unvulcanized rubber sheet 18 that is pressed and heated and vulcanized, and the tufted fabric 13 uses pile yarn as a primary base fabric. 11 is formed by applying a backing adhesive to the back stitch surface of a tufted living machine in which a pile 12 is implanted, and in the back stitch 14 the fibers of the pile yarn and the resin component of the backing adhesive are integrated. The top portion 15 of the back stitch 14 in which the fibers and the resin component are integrated is crushed to form a flat surface 16 parallel to the primary base fabric 11, and the unvulcanized rubber sheet 18 is The flat surface 1 of the top portion 15 of the back stitch 14 is press-fitted into the valley portion 17 between the back stitches 14 and 14 of the adjacent stitch rows to fill the valley portion 17. The thickness t of the rubber sheet 18 from to the first, characterized in that aligned to a constant.

  In the second feature of the dust control mat of the present invention, in addition to the first feature, the back stitch 14 in which the fiber and the resin component are integrated is crushed and deformed into a flat plate, and deformed into the flat plate. The width w of the back stitch 14 is that it is wider than the thickness d of the base of the pile 12 fitted into the insertion hole 20 that can be made into a primary base fabric by inserting pile yarn.

  The third feature of the dust control mat of the present invention is that, in addition to any of the first and second features, the resin component of the backing adhesive that is applied to the tufted raw machine and integrated with the fibers of the pile yarn Is the same quality as the resin component of the rubber sheet 18.

  The fourth feature of the dust control mat of the present invention is that, in addition to any of the first, second, and third features, a bonding adhesive having the same quality as the resin component of the rubber sheet 18 is pressed by the top portion 15. It is applied on the back stitch 14 which is crushed and forms a flat surface 16 parallel to the primary base fabric 11, and an unvulcanized rubber sheet 18 is superimposed on the coating film of the adhesive for bonding. There is in point.

  The fifth feature of the dust control mat of the present invention is that, in addition to any of the first, second, third and fourth features, the thickness of the unvulcanized rubber sheet 18 is 1.3 mm or less. The thickness t from the flat surface 16 of the top 15 of the back stitch 14 after vulcanization to the surface of the rubber sheet 18 is 0.8 mm or less.

  The sixth feature of the dust control mat of the present invention is that, in addition to any of the first, second, third, fourth and fifth features, the pile yarn has a single fiber fineness of 10 to 35 dtex, and a total fineness. Is 1000 to 5000 dtex, and the number of fibers present in the cross section of the yarn is 50 or more.

  The back stitch of the tufted machine has a bulky bulge, and the fibers constituting the back stitch are not a little elastic. Therefore, the back stitch 14 of the tufted fabric 13 to which the backing adhesive is applied is the backing adhesive. It is a porous bulge in which the resin component and fiber are integrated. The resin component and the fiber are easily plastically deformed at a high temperature, and when the back stitch 14 is heated and pressed, it is crushed and deformed into a flat plate. Even if the pile yarn is not made of thermoplastic synthetic fibers such as nylon or polyester fibers, but also cellulose fibers such as rayon or cotton with poor thermoplasticity, wool or other animal fibers are included in the back stitch 14. The resin component is a resin component of a backing adhesive having adhesiveness, and the back stitch 14 has a porous bulge, so when it is heated and pressed, it is crushed and deformed into a flat plate.

  As described above, the top portions 15 of all the back stitches 14 of the tufted fabric 13 of the present invention (Claim 1) are crushed into the flat surface 16, and the flat surfaces 16 of the top portions of all the back stitches from the primary fabric 11 Since the heights h are uniformly low and the valleys 17 between the back stitches are shallow, even if the unvulcanized rubber sheet 18 to be pressed over the back stitch surface is thinned, the uneven traces of the back stitches 14 are rubber. The dust control mat 19 is reduced in weight by thinning the unvulcanized rubber sheet 18 without appearing on the surface of the sheet 18 and without causing only the portion corresponding to the back stitch 14 of the rubber sheet 18 to be rubbed strongly. It becomes easy to carry.

  In the dust control mat 19 of the present invention (Claim 2), the back stitch 14 is crushed so that the resin component of the backing adhesive and the fibers of the pile yarn are integrated and become dense, and the pile yarn is inserted into the primary. Since it becomes a hard plate shape like a nail head having a width d wider than the insertion hole 20 that can be made in the base cloth, the pile 12 is the primary base cloth like a nail that is hooked to the primary base cloth when the nail head is caught. Thus, the pulling strength of the pile 12 is increased, and the abrasion resistance of the pile surface is improved.

  In the present invention (Claim 3), since the resin component of the backing adhesive applied to the tufted raw machine is the same as the resin component of the rubber sheet 18, the unvulcanized rubber sheet 18 is pressed against the back stitch surface and heated. In addition, the backing adhesive can be vulcanized simultaneously with the unvulcanized rubber sheet 18.

  In the present invention (Claim 4), the adhesive for bonding is applied to the back stitch 14 forming the flat surface 16, and the back stitch 14 to be crushed to the flat plate by the adhesive for bonding is the nail head. Thus, the pile 12 is securely locked to the primary base fabric 11, the yarn removal strength of the pile 12 is increased, and the abrasion resistance of the pile surface is improved.

The pile fabric weight of the tufted fabric 13 with the backing adhesive used for the dust control mat 19 is generally 400 to 800 g / m ² although some of the pile fabric weights are around 1200 g / m ² . The basis weight of the primary base fabric 11 is generally about 100 g / m ² , and the dry coating amount of the backing adhesive is generally about 200 g / m ² . The specific gravity of the unvulcanized rubber sheet 18 is generally around 1.2, and the basis weight of the unvulcanized rubber sheet 18 having a thickness of 0.9 to 1.3 mm is generally 1080 to 1560 g / m ² .
Therefore, for example, an unvulcanized rubber sheet having a thickness of 1.1 mm used for tufted fabric 13 having a pile basis weight of about 420 g / m ² and a total basis weight of about 700 g / m ² including the primary base fabric and the backing adhesive. When the thickness 18 is changed to 0.9 mm, and the thickness t from the flat surface 16 of the top 15 of the back stitch 14 to the surface of the rubber sheet 18 is 0.8 mm or less, the primary base fabric and the backing adhesive The weight of the dust control mat 19 including the rubber sheet 18 is reduced by about 20% and the cost of the dust control mat 19 is reduced.
According to the present invention (Claim 5), such a thin and light weight can be achieved, so that the number of dust control mats 19 carried at a time can be increased.
Therefore, when the present invention is applied to the dust control mat 19 for rental business, it can be efficiently recovered, washed and re-lent easily.

  In the present invention (Claim 6), a multifilament yarn having a single fiber fineness of 10 to 35 dtex, a total fineness of 1000 to 5000 dtex, and 50 or more fibers interposed in the yarn cross section is used for the pile yarn. Thus, a tufted product that can be used as the dust control mat 19 is obtained.

  As described above, according to the present invention, the rubber sheet 18 is thin and light and easy to carry. Thus, a dust control mat 19 suitable for rental business that is frequently collected and re-rented for washing can be obtained.

FIG. 2 is a partial rear perspective view of the dust control mat of the present invention, and a part of the dust control mat is shown by enlarging it with a circle. It is the partial back surface perspective view of the conventional dust control mat, The part is enclosed and encircled and shown in figure.

The adhesive for backing applied to the back stitch surface of the tufted raw machine includes a rubber adhesive containing the same vulcanizing agent, vulcanization accelerator, anti-aging agent, stabilizer and the like as the unvulcanized rubber sheet 18. It is used and vulcanized simultaneously with the unvulcanized rubber sheet 18 when the unvulcanized rubber sheet 18 is pressed against the back stitch surface and heated. Therefore, the drying after the application of the backing adhesive can be performed in a low temperature range lower than the vulcanization temperature of the unvulcanized rubber sheet 18.
In order to achieve penetration into the back stitch 14, it is better not to add a filler to calcium carbonate or the like in the backing adhesive applied to the back stitch surface of the tufted raw machine.

Since the unvulcanized rubber sheet 18 is prepared to be viscous and has adhesiveness, an adhesive for bonding is not necessarily required when the unvulcanized rubber sheet 18 is superimposed on the back stitch surface, in unvulcanized rubber sheet and the same quality of the tufted fabric 13 coated backing adhesive, applying a lamination adhesive it is not necessarily required.

  The unvulcanized rubber sheet 18 is prepared so as to be viscous so that it can be press-fitted into the valleys 17 between the back stitches 14 and 14 when it is pressed on the back stitch surface. The thickness of the unvulcanized rubber sheet 18 is about 1 mm, and after being superimposed on the back stitch surface of the tufted fabric 13, the unvulcanized rubber sheet 18 is pressed by a pressing plate and pressed into the valleys 17 between the back stitches, and the flat surface of the back stitch 14. The thickness t from 16 should be less than 1 mm.

  Even if the unvulcanized rubber sheet 18 is thinned in this way, the top 15 of the back stitch 14 is the flat surface 16, so that when a part of the fibers of the back stitch 14 is pressed, the unvulcanized rubber sheet 18. Don't stick out on the surface. The back stitch 14 is pressed and deformed into a flat plate, and the valleys 17 between the back stitches 14 and 14 are shallow, so that a part of the unvulcanized rubber sheet 18 easily enters the valleys 17.

  Therefore, even if it is superimposed on the back stitch surface of the tufted fabric 13 and pressed by the pressing plate, the pressure can be lowered and the process of vulcanizing the unvulcanized rubber sheet 18 by heating while pressing with the pressing plate. In this case, the pile 12 is not easily crushed, and the dust control mat 19 having a good standing property of the pile 12 is obtained.

  Further, the back stitch 14 is pressed and deformed into a flat plate, and the valley portion 17 between the back stitches 14 and 14 is shallow, and the amount of unvulcanized rubber that is press-fitted into the valley portion 17 is also reduced. Even if the vulcanized rubber sheet 18 is made thin, the back and forth traces of the back stitch 14 do not appear on the surface of the rubber sheet 18, and the back surface of the dust control mat 19 is finished cleanly.

  Even when the rubber sheet 18 after vulcanization is worn by using the dust control mat 19, the fibers of the back stitch 14 are hardly exposed on the surface, and the dust control mat 19 having excellent durability can be obtained.

  The dust control mat 19 of the present invention lined with a rubber sheet 18 can be diverted to a floor mat for an automobile floor or a water mat for a kitchen or bathroom.

11: Primary base fabric 12: Pile 13: Tufted fabric 14: Back stitch 15: Top 16: Flat surface 17: Valley 18: Rubber sheet 19: Dust control mat 20: Insertion hole b: Pile root thickness h: Back Stitch height t: Rubber sheet thickness w: Back stitch width

Claims (6)

The unvulcanized rubber sheet (18) is stacked on the back stitch surface of the tufted fabric (13), and the rubber sheet (18) heated and vulcanized is lined.
The tufted fabric (13) is configured by applying a backing adhesive to the back stitch surface of the tufted raw machine in which the pile yarn (12) is implanted by inserting the pile yarn into the primary base fabric (11),
In the back stitch (14), the pile yarn fiber and the resin component of the backing adhesive are integrated,
The top (15) of the back stitch (14) in which the fibers and the resin component are integrated is crushed to form a flat surface (16) parallel to the primary base fabric (11),
The unvulcanized rubber sheet (18) is press-fitted into the valleys (17) between the back stitches (14, 14) of the adjacent stitch rows, and fills the valleys (17).
A dust control mat in which the thickness (t) of the rubber sheet (18) from the flat surface (16) of the top (15) of the back stitch (14) is uniform. The back stitch (14) in which the fiber and the resin component are integrated is crushed and deformed into a flat plate,
The width (w) of the back stitch (14) transformed into the flat plate is the thickness (d) of the base of the pile (12) fitted into the insertion hole (20) that can be made into the primary base fabric by inserting the pile yarn. The dust control mat according to claim 1, wherein the dust control mat is wider than.   The dust control mat according to any one of claims 1 and 2, wherein the resin component of the backing adhesive applied to the tufted raw machine and integrated with the fiber of the pile yarn is the same as the resin component of the rubber sheet (18). . The back stitch (14) in which the adhesive for bonding of the same quality as the resin component of the rubber sheet (18) forms a flat surface (16) parallel to the primary base fabric (11) by crushing the top (15). )
The dust control mat according to any one of claims 1, 2 and 3, wherein an unvulcanized rubber sheet (18) is superposed on the coating film of the bonding adhesive.   The thickness of the unvulcanized rubber sheet (18) is 1.3 mm or less, and from the flat surface (16) of the top (15) of the back stitch (14) after the vulcanization to the surface of the rubber sheet (18) The dust control mat according to any one of claims 1, 2, 3, and 4, wherein the thickness (t) is 0.8 mm or less.   Claims 1, 2, 3, 4, and 5 in which the pile yarn is a multifilament having a single fiber fineness of 10 to 35 dtex, a total fineness of 1000 to 5000 dtex, and 50 or more fibers interposed in the cross section of the yarn. The dust control mat according to any one of the above.

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