Mat and mat-base assembly

(54) Name Composite construction of mats and substrates (56) Published publications: CH 526 291 (A47G 27/02), GB 1 546 901 (A47G 27/00) (57) Abstract: £_n a composite construction of a mat and a substrate is described which comprises a substrate (1) comprising a sheet (2) integrally made of a polymer elastomer, a board frame-like protruding portion (3) formed on the periphery of the sheet, and a mat containing portion (4) formed on the inside of the peripheral protruding portion, a dirt control mat (5) enclosed in a mat-containing portion and a temporary anchoring mechanism for detachable anchoring of the support and the mat at a plurality of points on the peripheral edge of the sheet, an anchoring element (11) comprising retaining pieces (10) embedded in a support material (9), which element is fixed to the substrate (1), a fiber loop member (12) which can be engaged with the retaining pieces is secured to the mat and the peripheral portion (14) of the anchor member is fused to the support sheet while retaining the retaining pieces as they are in the remaining portion of the anchor member.

In this composite construction of carpet and substrate, the durability of the anchoring mechanism is improved and good adaptability to the operation including fixing and loosening the dirt control mat is maintained for a long time. Furthermore, effective movement of the dirt control mat or roll-up of corner portions of the mat is prevented.

DB 603415

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The present invention relates to a composite construction of a mat and a substrate. More particularly, the invention relates to a composite construction of a mat and a substrate wherein the attachment and release of a dirt control mat is greatly facilitated and this property is maintained for a long time.

As a means of preventing dirt sticking to shoe soles from entering the room, a dirt control mat was used extensively. This dirt control mat is placed and held in a predetermined position, such as at the entrance, and must exhibit the property of not being easily moved even if it is rubbed heavily with the sole of a shoe or if many people walk in and out of the mat. Furthermore, the end portion or corner portion of the mat should not be peeled off or rolled up easily.

As a method for meeting these requirements, a composite structure of such a dirt control mat and a mat-supporting substrate is preferably used. Such a composite structure is disclosed in Japanese Utility Model No. 1601/74, wherein it is proposed that a composite structure comprises a sheet of a thermoplastic resin, such as a vinyl chloride resin, having an oblong, oval or other optional shape, and a mat detachably fitted within the frame frame-like retaining protrusion. on the periphery of the sheet.

However, if the mat is only fitted to such retention committees trained on the periphery of the substrate, the acceptable purpose is not to prevent the mat from moving or to prevent the corner portion of the mat from being folded up. In the case of a dirt control mat, a system is utilized in which a mat is rented to a user for a certain period of time, the used mat is washed and regenerated by an oil impregnation treatment or the like and the regenerated mat is re-rented to a user. When this cycle of use regeneration is repeated, the mat shrinks and it becomes difficult to maintain the size of the mat's perimeter in accordance with the size of the protruding retaining portions of the substrate. In view of this, it is preferred that a temporary anchoring mechanism is provided between the mat and the supporting support.

As such a temporary anchoring mechanism, so-called magic tape has been used, ie a combination of an anchoring element comprising retaining pieces.

8100353-5 in a support material and a fiber loop element. Acceptable results can be obtained with such soft tape if soft materials, such as fiber, are matched, but if this magic tape is applied to the aforementioned composite construction of mat and substrate, this anchoring mechanism has unacceptable durability and the usefulness of the operation for holding and loosening the mat soon deteriorates. time.

The present invention relates to a composite construction of a mat and a substrate thereby eliminating the disadvantages mentioned above.

More particularly, the invention relates to a composite structure of a mat and a substrate characterized by a substrate comprising a sheet integrally made of a polymer elastomer, a board frame-like protruding portion formed on the periphery of the sheet, and a mat-containing portion formed on the inside of the peripheral protruding protrusion portion, in the mat-containing portion and an anchorage mechanism for detachable anchoring of the substrate and mat; said anchoring mechanism comprising an element having retaining pieces embedded in a support material and fixed to the support and a fiber loop element which may be engaged with the retaining pieces and secured to the mat, a peripheral portion of the anchoring element being melt bonded to the support sheet being secured to the support sheet. the central portion of the anchor member, and wherein melt bonding of the peripheral portion and sheet is performed at a temperature higher than the softening point of the polymer constituting the sheet but lower than the melting point or softening point of the backing material of the anchoring member.

In the following, the invention is described with reference to the drawings, in which Fig. 1 shows a cross-section of a mat-supporting substrate; Fig. 2 shows a cross section illustrating a dirt control mat; and Fig. 3 is a partial perspective view illustrating a composite construction of mat and substrate in such a state as one end of a mat is peeled off.

The present invention is described in more detail below.

Figure 1 shows a mat-supporting substrate used in accordance with the invention, which substrate 1 comprises an elongated or oval sheet 2 and a panel frame-like protruding portion 3 formed on the periphery of the sheet 2. Sheet 2 and the protruding portion

8100353-5 are integrally formed of a polymer load and a concave vacant portion 4 for receiving the dirt control mat is formed on the inside of the protruding portion 3.

Examples of the polymer elastomer are a soft vinyl chloride resin composition, chlorinated polyethylene, chlorinated polypropylene, an ethylene-propylene gum, an ethylene-propylene dicngine, polyisobutylene, a butyl rubber, polybutadiene, a styrene-butadiene rubber, a nitrile-butadiene rubber. The sheet made of a polymer elastomer should exhibit heat sealability. From this point of view, the use of a soft vinyl chloride resin such as the polymer elastomer is preferred.

In Fig. 2, a dirt control mat is shown which is included in the composite construction of mat and backing according to the drawing, which mat 5 comprises a backing material 6, pile yarns 7 formed by bonding fibers in the form of tufts to the backing material 6 and trimming the top ends of the mat. the lugs 7, and a packing layer 8 for fixing the lugs 7 to the support material 6. The pile yarns 7 may consist of spun yarns or multi-thread yarns consisting of at least one of the following: Cotton fibers, rayon fibers, polyvinyl alcohol fibers, acrylic fibers and nylon fibers. The substrate material 6 may consist of a knitted or woven material, non-woven material or a web consisting of fibers, as stated above, or a plastic mesh or the like. The gasket layer 8 is formed by applying a coating of a synthetic rubber latex, such as a nitrile butadiene rubber latex on the back of the tuff-containing support material and drying the widespread latex.

The lug yarns 7 in the dirt control mat perform the function of adsorption of dirt that adheres to shoe soles by sliding contact with the shoe soles and retaining this dirt on the lug yarns 7. To enhance the dirt adsorption and retention action of the lug yarns 7, a dirt sorbents 7 may be impregnated with such liquid. Such as soil sorbents can be mentioned, for example, mineral oils, synthetic oils and vegetable oils, for example liquid paraffin, spindle oil, alkyl benzene oil, diester oil and castor oil, and aqueous soil sorbents such as are disclosed in Japanese Patents 10194/78 and 37471.

In accordance with the invention, instead of the aforementioned tufts containing mat, a mat made by electrically embedding fiber flocks in a substrate material can be used.

According to the invention, a temporary anchoring mechanism is provided for releasably anchoring the support 1 and the mat 5 to one another at a plurality of places on the peripheral edge of the mat 5.

As shown in Figures 1 and 3, this temporary anchoring mechanism comprises an anchoring element 11 comprising retaining pieces 10 having a shape similar to a hook or sponge embedded in a support material 9 and a fiber loop element 12 which can be engaged with the retaining pieces.

10th The combination of anchoring elements 11 and fiber loop elements is called magic tape and is marketed under, for example, the trade name Belclo Fastener. The retaining pieces 10 of the anchoring element 11 are formed of nylon or polypropylene and are embedded in a support material of nylon fibers or other thermoplastic fibers while the opposite side of the support material is coated with resin, for example polyurethane, thus preventing the retaining pieces from falling. The fiber eyelet element 12 is formed by embedding fibrous yarns with loop configuration. in a similar support material.

According to the invention, this loop element 12 is fixed to the support surface of the carpet 5 by stitch 13 and the anchoring element 11 is fixed to the sheet portion 2 of the support 1.

At this stage, as shown in Fig. 1, the peripheral portion 14 of the anchor member 11 is fused to the substrate sheet 2 while retaining the retaining pieces 11 in the remaining central portion of the retaining member 11 as they are.

According to the invention, by very bonding the peripheral portion of the anchoring element 11 to the backing sheet 2, a very high bond strength (scaling strength) can be obtained and a bonded structure can be obtained which can withstand a sufficiently long repetition of fixing and detaching, outdoor exposure and dipping in water or hot water.

However, in the peripheral portion 14 of the anchoring element 11, the retaining pieces 10 are crushed or pressed against the backing sheet since the anchoring member is fused to the backing sheet 2. However, in the remaining portion 15 of the anchoring element 11, the retaining pieces 10 are left in such an anchorage position as possible and a necessary anchorage 10 is provided. and the fiber loop element 11.

In fact, one reason is that a bound construct8100353-5 s

exhibiting excellent resistance properties are formed between the mat backing 1 and the anchoring element 11 so that the polymer constituting the backing sheet is fused to the backing material or retaining pieces of the anchoring element 11 or the gasket. However, another significant reason is believed to be that the polymer elastomer constituting the backing sheet penetrates into the backing material of the anchoring element 11 and the retaining pieces 10 of the anchoring element 11 penetrate the backing sheet 2 through the backing material of the anchoring element and the anchoring element 11

Melt bonding of the anchoring element 11 to the mat base 1 can be easily accomplished by stacking the anchoring element and the substrate on one another and pressing the stacked composite device under heat by means of a pair of hot sealing rods. The heating temperature varies from the softening point of the polymer constituting the backing sheet 2 to the melting point or the softening point of the backing material of the anchoring element. A pressure sufficient for crushing or pressing the retaining pieces 10 in the anchor member 11, for example 0.1-20 kp / cm (overpressure) can be applied. Heating is preferably carried out using a high frequency heating device.

When a polyurethane binder is provided between the anchoring element and the substrate to be bonded, the adhesion strength of the interface may be further increased. If the gasket of the anchoring element consists of polyurethane resin, an increase in adhesion strength is achieved through this polyurethane resin.

As polyurethane resin, a polyurethane resin having end-end groups blocked with an alcohol, phenol or amine is preferably used, i.e. a heat sensitive adhesive polyurethane resin.

According to a preferred embodiment of the invention, the blocked isocyanate and polyol such as a polyether polyol and a polyester polyol are mixed in a stoichiometric ratio, the mixture wherein each component is preferably solid and the mixture is also preferably solid at room temperature, applied in a solution or in a molten state. at a temperature not exceeding 95 ° C on the rear of the anchoring element, the anchoring element is arranged in a predetermined position on the substrate sheet such that the coated surface contacts the surface of the substrate sheet and the combination of the anchor element and the substrate sheet is heated at a temperature of 170-190 ° C for a period of time.

A pressure of 0.1-20 kp / cm (overpressure) by means of a high frequency heating device, whereby the blocked isocyanate is dissociated to a free isocyanate and the reaction between the reactivated isocyanate group and the coexisting polyol gives rise to a raised polyurethane resin in situ .

For example, Collonate® AP (Nippon Polyurethane Industries Co.) obtained by a reaction of tolylene diisocyanate and trimethylol propane is mixed followed by the addition of phenol for 10. blocking of remaining isocyanate groups, with Placcel '&lt;&gt; 220 (Daicel Chem Industries Co.), which consists of polyester polyol formed by ring-opening polymerization of caprolactan at a 1: 2 blend weight ratio and this mixture is mixed with 0.33% by weight cobalt octenoate and then melted at At about 95 ° C. This molten composition is applied to the back of the anchoring element to a coating thickness of 0.1-0.8 mm. This applied anchoring element is applied to the predetermined location on the substrate so that the coated surface contacts the substrate and is heated by high frequency heating for 5 seconds at about 185 ° C under a pressure of 2 kp / cm.

With. this method binds the anchoring element completely to the support surface and cannot be peeled off by a scaling force 2 of 20 kp / cm.

The application of blocked isocyanate and polyol to the back of the anchoring element can be carried out with a solution of tetrahydrofuran or methyl ethyl ketone and after application the solvent can be evaporated.

Like other blocked isocyanates, 4,4'-diisocyanate-diphenylmethane blocked with xylenols or methylethyl ketone oxime and trimethylolpropanol-tolylene diisocyanate addition product blocked with 2,4-dichlorophenol can be used.

Like other polyols, Desmophen 650 (Bayer GmbH) and Nippolan 4009 or 4010 (Nippon Polyurethane Industries Co.) can be used as polyester polyol and Pluronic Polyol (Wyandotte Chem. Corp.) can also be used as polyether polyol.

Such a polyol must be solid at room temperature to remain safe during all seasons.

In the composite construction of the mat and substrate of the present invention, the peripheral portion of the anchoring element is fused, which is of importance from the viewpoint of the

8100353-5 mechanical strength or preventing roll-up, to the substrate sheet in a state where it is embedded therein while retaining the retaining pieces in the central portion of the anchoring element as such. Accordingly, the composite construction of mat and substrate according to the invention is advantageous since the anchoring action is maintained stable for a long period of time even if the fixing and loosening operation is repeated many times.

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