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JP6560021B2 - Non-slip mat manufacturing method - Google Patents

Non-slip mat manufacturing method Download PDF

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Publication number
JP6560021B2
JP6560021B2 JP2015095840A JP2015095840A JP6560021B2 JP 6560021 B2 JP6560021 B2 JP 6560021B2 JP 2015095840 A JP2015095840 A JP 2015095840A JP 2015095840 A JP2015095840 A JP 2015095840A JP 6560021 B2 JP6560021 B2 JP 6560021B2
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mat
melt material
hot melt
adhesive member
hot
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JP2016209304A (en
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豊 赤松
豊 赤松
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Oka Co Ltd
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Oka Co Ltd
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • AHUMAN NECESSITIES
    • A47FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47GHOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00Floor fabrics; Fastenings therefor
    • A47G27/02Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0212Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207Heat-activated adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207Heat-activated adhesive
    • B32B2037/1215Hot-melt adhesive
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/70Other properties
    • B32B2307/744Non-slip, anti-slip
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00Floor coverings
    • B32B2471/04Mats

Landscapes

  • Carpets (AREA)
  • Adhesives Or Adhesive Processes (AREA)

Description

本発明は、滑り止め付きマット(例えば、玄関マット、キッチンマット、トイレマット、バスマット等)の製法に関する。   The present invention relates to a method for producing a mat with a non-slip (for example, an entrance mat, a kitchen mat, a toilet mat, a bath mat, etc.).

居室、廊下、台所、洗面所、脱衣場、便所等の床面に、防音、保温、装飾等を目的としてマットを敷くことがある。そのようなマットの裏面には滑り止め加工を施すのが普通である。   Mats may be placed on the floors of living rooms, hallways, kitchens, washrooms, dressing rooms, toilets, etc. for the purposes of sound insulation, heat insulation, decoration, etc. It is common to apply a non-slip process to the back surface of such a mat.

例えば特開平10―272049によれば、塩素含有ビニル系樹脂とエステル系化合物からなる組成物を紐状若しくは帯状に形成した樹脂部材が加熱処理されてマットの裏面に圧着されている。 For example, according to Japanese Patent Laid-Open No. 10-272049, a resin member in which a composition made of a chlorine-containing vinyl resin and an ester compound is formed in a string shape or a band shape is heat-treated and pressed onto the back surface of the mat.

別の従来技術として、粘着力のある発泡材からなる滑り止めシートをマット裏面の一部分に貼り付けて、摩擦係数を高めることも広く行われている。そのような滑り止めシートとして、例えば特開平7―247663号(特許第2841018号)が知られている。 As another conventional technique, a non-slip sheet made of an adhesive foam material is attached to a part of the back surface of the mat to increase the friction coefficient. As such an anti-slip sheet, for example, JP-A-7-247663 (Patent No. 2841018) is known.

特開平10―272049号公報Japanese Patent Laid-Open No. 10-272049 特開平7―247663号公報JP-A-7-247663

上記特開平10―272049のような滑り止め加工は、長尺の原反に対して行われる連続加工であるため、1枚ずつ製造されるマットの加工としては不適当である。また、連続加工であり、裏面全体に対する加工となるため、大きなサイズではマットの配置、位置合わせが困難となる。 The anti-slip processing as described in JP-A-10-272049 is a continuous processing performed on a long original fabric, and is therefore unsuitable for processing mats manufactured one by one. Moreover, since it is a continuous process and the process is performed on the entire back surface, it is difficult to place and align the mats with a large size.

さらにそのようにした加工したマットは、人が足を載せて静止している状態では効果があるが、人の歩行による踏み付けや蹴り出しにより微動するし、掃除機、特にロボット掃除機により横方向から力が加わると容易に動いてしまう。 Furthermore, such a processed mat is effective in a state where a person rests on a foot, but it moves finely by stepping on or kicking out by a person walking, and is laterally moved by a vacuum cleaner, particularly a robot cleaner. It moves easily when force is applied.

上記特開平7―247663号のような滑り止めシートを貼り付けた従来のマットは、洗濯するたびにシートの付着力が減衰し、数回の洗濯後にはもはやマット裏面に再付着できなくなって、シートの買い替えを余儀なくされていた。   The conventional mat to which the non-slip sheet such as the above-mentioned JP-A-7-247663 is attached, the adhesion of the sheet is attenuated every time it is washed, and it can no longer be reattached to the back of the mat after several washings. I had to buy a new seat.

本発明はこのような事情に鑑みてなされたものであり、強力な滑り止め効果を有し、度重なる洗濯にも耐久性のある滑り止め付きマットの製法を提供することを目的とする。 The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for producing a mat with a non-slip which has a strong anti-slip effect and is durable for repeated washing.

上記課題を解決する本発明請求項1の発明は、滑り止めマットの製法であって、第1基布にパイル糸をタフティングした前記マット裏面をロールコーターにより第1ホットメルト材で固定し、乾燥させる工程と、第2基布に吸着材を設け粘着部材を形成する工程と、前記マットの中で、前記粘着部材を設ける部分において、前記第1ホットメルト材に対して、第2ホットメルト材をコーティングガンで塗布する工程と、前記第2ホットメルト材に対して前記第2基布を圧着固定する工程を有することを特徴とする。
The present invention invention according to claim 1 for solving the aforementioned problems is a sliding stop Mema Tsu City of preparation, the first hot-melt material the back surface of the mat where the pile yarn is tufted into the first foundation fabric by a roll coater In the step of fixing and drying with, the step of forming an adhesive member by providing an adsorbent on the second base fabric, and the portion of the mat where the adhesive member is provided, with respect to the first hot melt material The method further comprises a step of applying the second hot melt material with a coating gun and a step of pressure-bonding and fixing the second base fabric to the second hot melt material.

同請求項2の発明は、滑り止めマットの製法であって、パイル糸で地組織を形成した前記マット裏面を第1ホットメルト材で固定し、乾燥させる工程と、第2基布に吸着材を設け粘着部材を形成する工程と、前記マットの中で、前記粘着部材を設ける部分において、前記第1ホットメルト材に対して、第2ホットメルト材をコーティングガンで塗布する工程と、前記第2ホットメルト材に対して前記第2基布を圧着固定する工程を有することを特徴とする。 Invention of the claim 2 is the slip stop Mema Tsu preparative production method, the back surface of the mat forming the ground structure with the pile yarn is fixed in the first hot-melt material, and drying, the second group Applying a second hot melt material to the first hot melt material with a coating gun in the step of forming an adhesive member by providing an adsorbent on the cloth and in the portion of the mat where the adhesive member is provided And a step of crimping and fixing the second base fabric to the second hot melt material.

好ましくは、粘着部材を取り付ける所定個所はマットの裏面の4隅である(請求項3)。   Preferably, the predetermined places where the adhesive member is attached are the four corners on the back surface of the mat.

本発明によれば、マットと粘着部材は、マット裏側の第1ホットメルト材の所定個所に対して、第2ホットメルト材をコーティングガンで塗布し、この第2ホットメルト材に対して前記第2基布を圧着固定するので、特定の個所に粘着部材を取り付けるのが容易である。また、第1ホットメルト材と第2ホットメルト材がホットメルト結合体を形成するので、マットと粘着部材は強固に固定される。その結果、度重なる洗濯に対しても粘着部材が剥がれ落ちるようなことはなくなった。   According to the present invention, the mat and the adhesive member are coated with the second hot melt material with a coating gun on a predetermined portion of the first hot melt material on the back side of the mat, and the second hot melt material is applied to the second hot melt material. Since the two base fabrics are pressure-fixed, it is easy to attach the adhesive member to a specific location. Further, since the first hot melt material and the second hot melt material form a hot melt bonded body, the mat and the adhesive member are firmly fixed. As a result, the adhesive member does not peel off even after repeated washing.

以下、添付の図面に基づき本発明の実施例を説明する。   Embodiments of the present invention will be described below with reference to the accompanying drawings.

総合実施例に係る玄関マットの(a)平面図と、(b)背面図である。It is (a) top view and (b) back view of the doormat concerning a comprehensive example. (a)加工前のマットの一部拡大断面図、(b)第2ホットメルト材の側面図、(c)加工前の粘着材の断面図、(d)粘着材貼り付け加工後のマット(実施例1)の一部拡大断面図である。(A) Partial enlarged cross-sectional view of the mat before processing, (b) Side view of the second hot melt material, (c) Cross-sectional view of the adhesive material before processing, (d) Mat after adhesive material pasting processing ( It is a partial expanded sectional view of Example 1). (a)加工前のマットの一部拡大断面図、(b)第2ホットメルト材の側面図、(c)加工前の粘着材の断面図、(d)粘着材貼り付け加工後のマット(実施例2)の一部拡大断面図である。(A) Partial enlarged cross-sectional view of the mat before processing, (b) Side view of the second hot melt material, (c) Cross-sectional view of the adhesive material before processing, (d) Mat after adhesive material pasting processing ( It is a partially expanded sectional view of Example 2).

実施例1のマットは、図2(c)に示すように、40cm×60cmの玄関マット1で、裏面の4隅に粘着部材2が固着されている。   The mat of Example 1 is a 40 cm × 60 cm entrance mat 1 as shown in FIG. 2C, and adhesive members 2 are fixed to the four corners of the back surface.

粘着部材2を貼り付ける前のマットは、図2(a)に示すように、基布11にパイル糸12がタフティングされ、基布11の裏面でバッキングされているものである。基布11としては不織布が使用され、パイル糸12としてはアクリル、ポリエステル、綿などが使用されている。バッキングは、EVA系(エチレン酢酸ビニル)、SEBS(ポリスチレン―block―ポリ(エチレン―co―ブチレン)―block―ポリスチレン)などの合成ゴム系、ポリオレフィン系などのホットメルト材13aである。バッキングはパイル糸が抜け落ちるのを防止すると共にそれ自体滑り止め効果を有する。 As shown in FIG. 2A, the mat before attaching the adhesive member 2 is one in which the pile yarn 12 is tufted on the base fabric 11 and is backed on the back surface of the base fabric 11. Nonwoven fabric is used as the base fabric 11, and acrylic, polyester, cotton, or the like is used as the pile yarn 12. The backing is a hot-melt material 13a made of synthetic rubber such as EVA (ethylene vinyl acetate) or SEBS (polystyrene-block-poly (ethylene-co-butylene) -block-polystyrene) or polyolefin. The backing prevents the pile yarn from falling off and has a non-slip effect in itself.

このようなマットを製造するには、基布11にパイル糸12をタフティングした後、マット裏面に対して溶融したホットメルト材13a(例えばEVA樹脂)をロールコーターで均一な膜厚に塗布して乾燥させる。この例では、マット表面は、シャーリングによるパイル表面カットを施している。 In order to manufacture such a mat, after pile yarn 12 is tufted on the base fabric 11, a hot melt material 13a (for example, EVA resin) melted on the back surface of the mat is applied to a uniform film thickness by a roll coater. And dry. In this example, the mat surface is subjected to pile surface cutting by shearing.

粘着部材2は、7cm×7cmの大きさで、図2(b)に示すように、基布21に吸着材22を設けたものである。基布21としては不織布が使用され、吸着材22としてはアクリル発泡樹脂又はウレタン発泡樹脂が使用されている。 The adhesive member 2 has a size of 7 cm × 7 cm and is provided with an adsorbent 22 on a base fabric 21 as shown in FIG. Nonwoven fabric is used as the base fabric 21, and acrylic foam resin or urethane foam resin is used as the adsorbent 22.

図2(a)のマット1に対して、図2(b)の粘着部材2を貼り付けるには、まずマットの所定の4隅に対して、溶融したホットメルト材13b(例えばEVA樹脂)をコーティングガンで再び塗布し、その後、その4隅に粘着部材2を置き、加圧一体化させ、乾燥させる。コーティングガンは断続運転が可能であるので、特定位置での塗布が容易に可能である。   To attach the adhesive member 2 of FIG. 2B to the mat 1 of FIG. 2A, first, a molten hot melt material 13b (for example, EVA resin) is applied to predetermined four corners of the mat. It is applied again with a coating gun, and then the adhesive member 2 is placed at the four corners thereof, integrated with pressure, and dried. Since the coating gun can be intermittently operated, it can be easily applied at a specific position.

このようにして、粘着部材2が4隅に付着した図2(c)のマット1が得られる。なお、実際の使用に供されるまでは、吸着材22の表面を離型シート又は保護フィルム(図示せず)を貼り付けておく。   In this way, the mat 1 shown in FIG. 2C in which the adhesive member 2 is attached to the four corners is obtained. In addition, a release sheet or a protective film (not shown) is pasted on the surface of the adsorbent 22 until it is actually used.

このマット1は、マット裏面に1回目に塗布したホットメルト材13aと、粘着部材の貼り付け用に塗布した2回目のホットメルト材13bが結合体13となるので、マット1裏面に対して粘着部材2が非常に強固に貼り付けられている。この粘着部材2は、度重なる洗濯にもはがれることがなく、マット1本体とほぼ同じ長さの製品寿命があるものとなった。 The mat 1 is bonded to the back surface of the mat 1 because the hot melt material 13a applied for the first time on the back surface of the mat and the second hot melt material 13b applied for adhering the adhesive member are combined 13. The member 2 is affixed very firmly. The pressure-sensitive adhesive member 2 did not peel off after repeated washing, and had a product life of almost the same length as the mat 1 main body.

実施例2のマットは、図3(c)に示すように、40cm×60cmの玄関マット1Aで、裏面の4隅に粘着部材2Aが固着されている。 As shown in FIG. 3C, the mat of Example 2 is a 40 cm × 60 cm entrance mat 1A, and adhesive members 2A are fixed to the four corners of the back surface.

実施例1と異なるのは、基布11がなく、パイル糸自身が地組織を形成しており、その地組織がバッキングされていることである(いわゆるウィルトン織りマット)。パイル糸12Aとしてはアクリル、ポリエステル、綿などが使用されている。バッキングは、EVA系(エチレン酢酸ビニル)、SEBS(ポリスチレン―block―ポリ(エチレン―co―ブチレン)―block―ポリスチレン)などの合成ゴム系、ポリオレフィン系などのホットメルト材13Aaである。バッキングはパイル糸が抜け落ちるのを防止すると共にそれ自体滑り止め効果を有する。   The difference from Example 1 is that there is no base fabric 11, the pile yarn itself forms a ground structure, and the ground structure is backed (so-called Wilton woven mat). Acrylic, polyester, cotton or the like is used as the pile yarn 12A. The backing is a hot-melt material 13Aa made of synthetic rubber such as EVA (ethylene vinyl acetate) or SEBS (polystyrene-block-poly (ethylene-co-butylene) -block-polystyrene) or polyolefin. The backing prevents the pile yarn from falling off and has a non-slip effect in itself.

このようなマットを製造するには、パイル糸12で地組織を形成した後、マット裏面に対して溶融したホットメルト材13Aa(例えばEVA樹脂)をロールコーターで均一な膜厚に塗布して乾燥させる。この例では、マット表面は、シャーリングによるパイル表面カットを施している。 In order to manufacture such a mat, after forming a ground structure with the pile yarn 12, a hot melt material 13Aa (for example, EVA resin) melted on the back surface of the mat is applied to a uniform film thickness with a roll coater and dried. Let In this example, the mat surface is subjected to pile surface cutting by shearing.

粘着部材2Aは実施例1と同様である。マット1Aに部材2Aを取り付ける方法も実施例1と同様である。 The adhesive member 2A is the same as that in the first embodiment. The method for attaching the member 2A to the mat 1A is the same as that in the first embodiment.

このようにして、粘着部材2Aが4隅に付着した図3(c)のマット1Aが得られる。なお、実際の使用に供されるまでは、吸着材22Aの表面を離型紙又は保護フィルム(図示せず)を貼り付けておく。   In this way, the mat 1A shown in FIG. 3C in which the adhesive member 2A is attached to the four corners is obtained. Note that a release paper or a protective film (not shown) is pasted on the surface of the adsorbent 22A until it is actually used.

このマット1Aは、マット裏面に1回目に塗布したホットメルト材13Aaと、粘着部材の貼り付け用に塗布した2回目のホットメルト材13Abが結合体13Aとなるので、マット1A裏面に対して粘着部材2Aが非常に強固に貼り付けられている。この粘着部材2Aは、度重なる洗濯にもはがれることがなく、マット1A本体とほぼ同じ長さの製品寿命があるものとなった。 In this mat 1A, the hot melt material 13Aa applied to the back surface of the mat for the first time and the second hot melt material 13Ab applied for attaching the adhesive member become a combined body 13A. The member 2A is affixed very firmly. The pressure-sensitive adhesive member 2A did not peel off after repeated washing, and had a product life of almost the same length as the mat 1A main body.

1,1A マット
11 基布
12,12A パイル糸
13,13A ホットメルト結合体
13a 第1ホットメルト材
13b 第2ホットメルト材
13Aa 第1ホットメルト材
13Ab 第2ホットメルト材
2,2A 粘着部材
21,21A 基布
22,22A 吸着材
1, 1A Mat 11 Base fabric 12, 12A Pile yarn 13, 13A Hot melt bonded body 13a First hot melt material 13b Second hot melt material 13Aa First hot melt material 13Ab Second hot melt material 2, 2A Adhesive member 21, 21A base fabric 22, 22A adsorbent

Claims (3)

滑り止めマット(1)の製法であって、
第1基布(11)にパイル糸(12)をタフティングした前記マット裏面をロール コーターにより第1ホットメルト材(13a)で固定し、乾燥させる工程と
第2基布(21)に吸着材(22)を設け粘着部材(2)を形成する工程と、
前記マット(1)の中で、前記粘着部材(2)を設ける部分において、前記第1ホットメルト材(13a)に対して、第2ホットメルト材(13b)をコーティングガンで塗布する工程と、
前記第2ホットメルト材(13b)に対して前記第2基布(21)を圧着固定する工程
を有することを特徴とする滑り止めマットの製法。
There is provided a process for the preparation of non-slip Mema Tsu door (1),
The back surface of the mat pile yarn to a first base cloth (11) to (12) and tufted fixed with the first hot-melt material using a roll coater (13a), a step of drying,
Forming an adhesive member (2) with adsorbent (22) provided in the second base fabric (21),
Applying a second hot melt material (13b) to the first hot melt material (13a) with a coating gun in the mat (1) where the adhesive member (2) is provided ;
Slip Mema Tsu City of method characterized by having a step of crimped fabric (21) the second group to the second hot-melt material (13b).
滑り止めマット(1A)の製法であって、
パイル糸(12A)で地組織を形成した前記マット(1A)の裏面を第1ホットメルト材(13Aa)で固定し、乾燥させる工程と
第2基布(21A)に吸着材(22A)を設け粘着部材(2A)を形成する工程と、
前記マット(1A)の中で、前記粘着部材(2A)を設ける部分において、前記第1ホットメルト材(13Aa)に対して、第2ホットメルト材(13Ab)をコーティングガンで塗布する工程と、
前記第2ホットメルト材(13Ab)に対して前記第2基布(21A)を圧着固定する工程
を有することを特徴とする滑り止めマットの製法。
There is provided a process for the preparation of non-slip Mema Tsu door (1A),
The back surface of the mat forming the ground structure with the pile yarns (12A) (1A) fixed with the first hot-melt material (13Aa), and drying,
Forming an adhesive member (2A) and adsorbents (22A) provided in the second base fabric (21A),
Applying a second hot melt material (13Ab) with a coating gun to the first hot melt material (13Aa) in a portion of the mat (1A) where the adhesive member (2A) is provided ;
Slip Mema Tsu City of method characterized by having a step of crimping fixing the second base fabric (21A) to said second hot-melt material (13Ab).
前記粘着部材(2,2A)を設ける部分がマットの裏面の4隅である請求項1または2記載の製法。
The manufacturing method according to claim 1 or 2, wherein the portions where the adhesive members (2, 2A) are provided are the four corners of the back surface of the mat.
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