Mat and manufacturing method of mat

Abstract

To provide a mat capable of improving shape retention and durability, and a manufacturing method of the mat.SOLUTION: A mat comprises a nonwoven-fabric mat body formed by interlacing resin fibers 31 and 32 with each other, and an anti-slip layer formed on one surface of the mat body A. The mat body includes a plurality of first resin fibers 31, and a plurality of second resin fibers 32 different from the first resin fibers 31, where each first resin fiber 31 includes a fiber body 311 made of a synthetic resin and a coating layer 312 made of a thermoplastic resin and covering the peripheral surface of the fiber body 311. The first and second resin fibers 31 and 32 or the first resin fibers 31 are partially bonded to each other by the coating layers 312.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to mats and methods for making mats. [Background technology]

[0002] Conventionally, mats that are laid on floors or stairs have been widely used. The mat described in Patent Document 1 (hereinafter referred to as "staircase mat") comprises a mat body (hereinafter referred to as "staircase mat body") and an anti-slip layer. The mat body is made of nonwoven fabric. The anti-slip layer is formed on one surface of the mat body. When the mat is in use, the anti-slip layer comes into contact with the floor or stairs, etc., to prevent the mat from slipping out of position. The user or a pet, etc., steps on the mat body. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 10-88760 Summary of the Invention [Problem to be solved by the invention]

[0004] Generally, a nonwoven mat body has high flexibility, so if the anti-slip layer is soft, the mat is easily deformed. A mat that is easily deformed is difficult to lay accurately in the designated position on a floor or stairs. In particular, since staircase mats are laid one by one on multiple steps, if it is difficult to lay them accurately in the designated position, it takes a long time to finish laying all the mats. There is also a demand for further improving the durability of the mat against long-term use, repeated washing, and the like.

[0005] An object of the present disclosure is to provide a mat and a method for manufacturing a mat that can improve shape retention and durability. [Means for solving the problem]

[0006] The mat according to the present disclosure comprises a mat body made of nonwoven fabric formed by intertwining resin fibers, and an anti-slip layer formed on one surface of the mat body, wherein the mat body includes a plurality of first resin fibers and a plurality of second resin fibers different from the first resin fibers, the first resin fibers have a fiber body made of synthetic resin and a coating layer made of thermoplastic resin covering the circumferential surface of the fiber body, and the first and second resin fibers, or the first resin fibers themselves, are partially bonded to each other by the coating layer.

[0007] In the present disclosure, an anti-slip layer is formed on one surface of the mat body. The mat body is made of a nonwoven fabric, and is formed by intertwining (entangling) each resin fiber with other resin fibers. The mat body includes a plurality of first and second resin fibers. Each of the first resin fibers has a fiber body made of synthetic resin and a coating layer made of thermoplastic resin. The coating layer covers the circumferential surface of the fiber body. That is, the first resin fibers are so-called sheath-core fibers. Each of the second resin fibers is different from the first resin fibers.

[0008] The first resin fibers and the second resin fibers are partially bonded to each other by the coating layer, or the first resin fibers are partially bonded to each other by the coating layer. Since the resin fibers are intertwined and bonded to each other, the shape retention of the mat body (and therefore the mat) can be improved. Since the mat has high shape retention, it is easy to lay the mat accurately in a specified position on a floor, staircase, etc. A mat with high shape retention is a mat with strong stiffness.

[0009] Since the resin fibers that are bonded to each other do not separate from each other, fraying of the resin fibers from the mat body is unlikely to occur. Furthermore, the resin fibers that are bonded to each other reinforce each other. As a result of the above, the durability of the mat body (and therefore the mat) against long-term use or repeated washing can be improved. Here, durability refers to abrasion resistance, long-term shape retention, etc. Such a mat is resistant to abrasion, and maintains its stiffness for a long period of time.

[0010] The mat of the present disclosure is characterized in that the anti-slip layer has a plurality of suction portions arranged in one direction at a pitch P [mm] (3≦P<15.8), each suction portion has an adhesive force and forms a convex stripe extending in a direction intersecting the one direction, and the width W [mm] of each suction portion is 1.8≦W<3.3.

[0011] In the present disclosure, the anti-slip layer has a plurality of adsorption portions, each of which has an adsorption force. The multiple suction parts are arranged in parallel in one direction at a pitch P [mm]. Each suction part is a convex stripe with a width W [mm] and extends in a direction intersecting the one direction.

[0012] The smaller the pitch P, the greater the number of suction parts per unit area, making it less likely that the mat will shift from its designated position. Also, the greater the width W, the greater the suction force of each suction part, making it less likely that the mat will shift from its designated position. On the other hand, the smaller the pitch P or the larger the width W, the greater the amount of synthetic resin used to form the anti-slip layer, resulting in increased costs, and there is also the concern that it may be difficult for users to remove the mat from floors, stairs, etc. It has been experimentally shown that when the pitch P [mm] is a specified value of 3≦P<15.8 and the width W [mm] is a specified value of 1.8≦W<3.3, it is possible to prevent the mat from shifting out of position while reducing the amount of synthetic resin used and making the mat easier to remove.

[0013] The method for manufacturing a mat according to the present disclosure is a method for manufacturing a mat comprising a nonwoven mat body formed by entangling resin fibers, and an anti-slip layer formed on one surface of the mat body, and is characterized in that a first resin fiber having a synthetic resin fiber body and a thermoplastic resin coating layer covering the peripheral surface of the fiber body, and a second resin fiber different from the first resin fiber are mixed together in groups of several fibers, and the mixed resin fibers are entangled to form the mat body, the anti-slip layer is formed on one surface of the formed mat body, and the first and second resin fibers, or the first resin fibers themselves, are partially bonded to each other by the coating layer by heating the mat body at a temperature equal to or higher than the softening point of the coating layer before or during the formation of the anti-slip layer.

[0014] In the present disclosure, a nonwoven mat body is formed by mixing a plurality of first resin fibers and a plurality of second resin fibers and entangling the mixed resin fibers with each other. An anti-slip layer is formed on one side of the formed mat body. Each of the first resin fibers has a fiber body made of synthetic resin and a coating layer made of thermoplastic resin. The coating layer covers the circumferential surface of the fiber body. That is, the first resin fibers are so-called sheath-core fibers. The second resin fibers are different from the first resin fibers.

[0015] The mat body is heated before or during the formation of the anti-slip layer. The temperature during heating is equal to or higher than the softening point of the coating layer of the first resin fiber, so that at least a part of the coating layer softens or melts and functions as a thermoplastic resin adhesive. When the softened or melted coating layer hardens, the first resin fiber and the second resin fiber are partially bonded to each other by the coating layer. Alternatively, the first resin fibers are partially bonded to each other by the coating layer. As a result of the above, a mat according to the present disclosure can be manufactured.

[0016] Since the coating layer of the first resin fiber functions as a type of hot melt material, the hot melt material can be properly interposed between the resin fibers more easily than when a non-fibrous (e.g., powder) hot melt material or a liquid adhesive is used. The higher the mixing ratio of the first resin fiber, the more the number of resin fibers bonded together. Also, the higher the temperature at which the mat body is heated, the more times it is heated, or the longer it is heated, the more the coating layer softens or melts, and the greater the adhesive strength between the resin fibers. Therefore, by appropriately setting the mixing ratio of the first resin fiber or the conditions for heating the mat body, a mat having the desired stiffness can be manufactured.

[0017] Since the resin fibers are entangled with each other and are also bonded to each other, the shape retention of the mat body can be improved. When the mat body is heated before the formation of the anti-slip layer, the anti-slip layer can be formed on one side of the mat body, which has high shape retention, thereby preventing distortion, fraying, etc. of the mat body when the anti-slip layer is formed. When the mat body is heated during the formation of the anti-slip layer, the step of melting the coating layer does not need to be carried out separately from the step of forming the anti-slip layer.

[0018] The manufacturing method of the mat according to the present disclosure is characterized in that after the formation of the mat body, a fluid material is applied to one surface of the mat body, and the applied material is heated and dried to form the anti-slip layer on the one surface, and the temperature at which the material is heated is set to a temperature higher than the melting point of the coating layer, thereby melting the coating layer during the formation of the anti-slip layer.

[0019] In the present disclosure, after the mat body is formed, a fluid material is applied to one side of the mat body, and the applied material is heated and dried to form an anti-slip layer on one side of the mat body. The temperature at which the material is heated is higher than the melting point of the coating layer. Therefore, the coating layer of the first resin fiber melts during the formation of the anti-slip layer. As a result, the process of forming the anti-slip layer and the process of melting the coating layer can be combined. Furthermore, the melted coating layer can improve the adhesive strength between the resin fibers compared to a coating layer that is merely softened.

[0020] The method for manufacturing a mat according to the present disclosure is characterized in that the anti-slip layer is formed using a synthetic resin containing acrylic resin or polyurethane, the formed anti-slip layer is covered with a protective sheet made of a synthetic resin containing polypropylene, polyethylene, or polyester, the anti-slip layer covered with the protective sheet and the mat body are folded at a predetermined angle with the anti-slip layer facing inward, and during the folding process, the folding position is heated at a temperature equal to or higher than the softening point of the covering layer.

[0021] In the present disclosure, a non-slip layer is formed using a synthetic resin including an acrylic resin or a polyurethane. The formed non-slip layer is covered with a protective sheet made of a synthetic resin including polypropylene, polyethylene, or polyester. The protective sheet protects the non-slip layer when the mat is sold, for example, and is peeled off from the non-slip layer before the mat is used. The anti-slip layer and the mat body covered with the protective sheet are folded. During the folding process, the anti-slip layer and the mat body covered with the protective sheet are folded at a predetermined angle with the anti-slip layer facing inward. At this time, the folding position is heated intensively at a temperature equal to or higher than the softening point of the coating layer of the first resin fiber, so that the coating layer at the folding position softens or melts again or anew, and the resin fibers are further bonded to each other.

[0022] As a result, a mat is manufactured that is folded at a predetermined angle with the anti-slip layer on the inside. The coating layer further bonds the resin fibers together during the folding process, so that the corners of the folded mat can be reliably and long-term maintained at the predetermined angle. Since the anti-slip layer is covered with a protective sheet before folding, the troublesome work of covering the anti-slip layer with a protective sheet after folding is not required.

[0023] It is desirable for the protective sheet to have both heat resistance against heating during folding processing and ease of peeling from the anti-slip layer (releasability for the synthetic resin contained in the anti-slip layer). Protective sheets made of synthetic resins including polypropylene, polyethylene, or polyester have the above-mentioned heat resistance and releasability. Effect of the Invention

[0024] According to the mat and the method for producing a mat of the present disclosure, shape retention and durability can be improved. [Brief description of the drawings]

[0025] [Figure 1] FIG. 1 is a perspective view showing a mat according to an embodiment. [Diagram 2] FIG. 2 is a schematic side view of a mat. [Diagram 3] FIG. 2 is a schematic cross-sectional view of a mat. [Figure 4] FIG. 2 is a schematic perspective view of resin fibers constituting a mat body. [Diagram 5] FIG. 2 is a schematic bottom view of the mat. [Figure 6] 1 is a flowchart for explaining a method for manufacturing a mat. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Hereinafter, embodiments of the present disclosure will be described.

[0027] FIG. 1 is a perspective view showing a mat according to an embodiment. In the figure, reference numeral 1 denotes a mat, and the mat 1 is attached to a step 21 of a staircase 2. The mat 1 has a rectangular shape that is long in one direction. The mat 1 is folded to cover both the upper surface and the tip surface of the step 21, and has a fold 10. The fold 10 extends over the entire length of the mat 1 in the longitudinal direction. Here, the tip surface of the step 21 is the surface that faces a user ascending the staircase 2.

[0028] With the fold 10 as the boundary, one side in the short direction of the mat 1 is a first covering part 11 that covers the upper surface of the step 21, and the other side in the short direction of the mat 1 is a second covering part 12 that covers the tip surface of the step 21. The first covering part 11 has a rectangular shape that is long in the longitudinal direction of the mat 1, and the second covering part 12 has a strip shape that is long in the longitudinal direction of the mat 1. The mat 1 has a degree of flexibility that allows the shape of the mat 1 to follow the shape of the steps 21 .

[0029] Fig. 2 is a schematic side view of the mat 1. Fig. 2 shows the vicinity of the fold 10. The mat 1 comprises a mat body 3 and an anti-slip layer 4. The mat body 3 is made of nonwoven fabric. The anti-slip layer 4 is made of synthetic resin, for example, acrylic resin. The anti-slip layer 4 is formed on one surface of the mat body 3. The mat 1 includes the mat body 3 and the anti-slip layer 4 in each of the fold 10, the first covering portion 11, and the second covering portion 12.

[0030] FIG. 3 is a schematic cross-sectional view of the mat 1. As shown in FIG. The mat body 3 contains a large number of first resin fibers 31 and a large number of second resin fibers 32. In the following, the first resin fibers 31 and the second resin fibers 32 will be referred to as resin fibers 31, 32 when there is no need to distinguish between them. The mat body 3 is formed by intertwining the resin fibers 31 and 32 with each other.

[0031] FIG. 4 is a schematic perspective view of the resin fibers 31 and 32 that form the mat body 3. As shown in FIG. Each of the first resin fibers 31 has a fiber body 311 and a coating layer 312. The coating layer 312 covers the peripheral surface of the fiber body 311. That is, the first resin fibers 31 are so-called core-sheath fibers. The weight ratio of the fiber body 311 to the coating layer 312 is, for example, 1:1. The length of the first resin fiber 31 is, for example, 51 mm to 76 mm. The thickness of the first resin fiber 31 is, for example, 4 denier.

[0032] The fiber body 311 is made of a synthetic resin, for example, polyester. The fiber body 311 has a circular cross section. The softening point and melting point of the fiber body 311 are, for example, 235°C and 255°C. The covering layer 312 is made of a thermoplastic resin, for example, a low melting point polyester. The softening point and melting point of the covering layer 312 are lower than the softening point of the fiber body 311, for example, 80°C and 110°C.

[0033] Unlike the first resin fibers 31, each second resin fiber 32 does not have a portion corresponding to the coating layer 312. The second resin fibers 32 are made of a synthetic resin, for example, polyester. The softening point and melting point of the second resin fibers 32 are approximately the same as those of the fiber body 311. The length of the second resin fibers 32 is approximately the same as that of the first resin fibers 31. The second resin fibers 32 have a circular cross section and are thicker than the first resin fibers 31 (for example, 6 to 7 denier). The first resin fibers 31 and the second resin fibers 32 are partially bonded to each other by the coating layer 312 of the first resin fibers 31. Similarly, the first resin fibers 31 are partially bonded to each other by their respective coating layers 312.

[0034] Fig. 5 is a schematic bottom view of the mat 1. Fig. 5 shows the first covering portion 11 as viewed from the anti-slip layer 4 side. As shown in FIGS. 3 and 5, the anti-slip layer 4 has a base portion 41 and a plurality of adsorption portions 42. The base 41 is in a layer shape and covers one surface of the mat body 3 entirely. Each suction portion 42 is provided on one surface (the surface opposite to the mat main body 3) of the base portion 41. Each suction portion 42 has a convex stripe shape and extends over the entire length of the mat 1 in the longitudinal direction. Each suction portion 42 has elasticity.

[0035] 3, the anti-slip layer 4 contains a large number of air bubbles 40. Some of the air bubbles 40 are open on the surface of the adsorbing portion . Since the air bubbles 40 are open on the surface of the suction portion 42, the suction portion 42 has a vacuum suction force. When the suction portion 42 is pressed against the object to which the mat 1 is to be attached (for example, the steps 21), the suction portion 42 deforms and the air inside the air bubbles 40 is expelled to the outside of the air bubbles 40, causing the air pressure inside the air bubbles 40 to fall below atmospheric pressure. As a result, the suction portion 42 adheres to the object to which the mat 1 is to be attached.

[0036] The width of the suction portion 42 (the length in the direction along one surface of the base portion 41 and perpendicular to the longitudinal direction of the suction portion 42) is W [mm]. The width W is a predetermined value of 1.8≦W<3.3, and is preferably 3 mm (tolerance ±0.2 mm). The suction portions 42 are arranged side by side at a pitch P [mm] in the short side direction of the mat 1 (a direction along one surface of the mat 1 and perpendicular to the longitudinal direction of the mat 1). The pitch P is a predetermined value of 3≦P<15.8, and is preferably 10 mm (tolerance ±0.2 mm). The width B between two adjacent suction portions 42 is 1.2≦B<10.8, and is preferably 7 mm (tolerance ±0.2 mm).

[0037] The smaller the pitch P, the greater the number of suction parts 42 per unit area, making it less likely that the mat 1 will shift from its designated position. Also, the greater the width W, the greater the suction force of each suction part 42, making it less likely that the mat 1 will shift from its designated position. On the other hand, the smaller the pitch P or the larger the width W, the greater the amount of synthetic resin used to form the anti-slip layer 4, resulting in increased costs. In addition, there is a concern that the adhesive force may be too strong, making it difficult for the user to remove the mat 1 from the steps 21. It has been experimentally shown that when the pitch P [mm] is a specified value of 3≦P<15.8 and the width W [mm] is a specified value of 1.8≦W<3.3, it is possible to prevent the mat 1 from shifting out of position while reducing the amount of synthetic resin used and making the mat 1 easy to remove.

[0038] In the figures, reference numeral 5 denotes a protective sheet, which completely covers and protects the anti-slip layer 4, for example, when the mat 1 is sold (see Figs. 2 and 3). At this time, the adhesive portion 42 adheres to the protective sheet 5, so that the protective sheet 5 does not peel off naturally. Before using the mat 1, the user peels the protective sheet 5 off the anti-slip layer 4 to expose the anti-slip layer 4. The protective sheet 5 is made of a synthetic resin, for example, an oriented polypropylene film.

[0039] 2, when the mat 1 is not attached to the step 21, the angle between the first covering part 11 and the second covering part 12 is less than 90° (for example, 60°), which is smaller than the angle between the top surface and the tip surface of the step 21. 1, when the mat 1 is attached to the step 21, both surfaces of the first covering part 11 face up and down, and the fold 10 is located at the corner between the top surface and the tip surface of the step 21. The second covering part 12 hangs down from the fold 10.

[0040] When the mat 1 is attached to the step 21, the first covering part 11 is naturally pressed against the upper surface of the step 21 by its own weight (or by a user or a pet stepping on the first covering part 11 when going up and down the stairs 2). The angle between the first covering part 11 and the second covering part 12 is equal to the angle between the upper surface and the tip surface of the step 21 (generally 90°). Since the angle between the first covering part 11 and the second covering part 12 increases when the mat 1 is attached to the step 21, the second covering part 12 is naturally pressed against the tip surface of the step 21. As a result of the above, it is not necessary for the user to press the mat 1 against the step 21 in order to cause the suction part 42 to stick to the step 21.

[0041] When the mat 1 is in use, the anti-slip layer 4 adheres to the steps 21 to prevent the mat 1 from shifting position. A user or a pet steps on the mat body 3 that constitutes the first covering portion 11. In the present embodiment, one end of the mat 1 in the short direction is folded to cover the top surface and the tip surface of the step 21, but is not limited to this. For example, both ends of the mat 1 in the long direction may be folded to cover the top surface of the step of an open staircase and both end surfaces in the long direction of the step. The mat 1 may be configured not to be folded (ie, not to have the second covering portion 12). The mat 1 is not limited to being attached to the stairs 2, but may also be attached to, for example, the stepping rail at the entrance or the floor of a kitchen.

[0042] According to the above-described mat 1, the resin fibers 31, 32 are entangled with each other and are also bonded to each other, so that the shape retention of the mat body 3 (and therefore the mat 1) can be improved. Because the mat 1 has high shape retention, it is easy to lay the mat 1 accurately at a predetermined position on the steps 21. A mat 1 with high shape retention is one that has a strong backbone. Since it is easy to lay the mat 1 accurately at a predetermined position on the step 21, a plurality of mats 1 can be laid one by one on each of the steps 21 of the staircase 2 in a short time.

[0043] Since the resin fibers 31, 32 bonded to each other do not separate from each other, fraying of the resin fibers 31, 32 from the mat main body 3 is unlikely to occur. Furthermore, the resin fibers 31, 32 bonded to each other reinforce each other. As a result of the above, the durability of the mat main body 3 (and therefore the mat 1) against long-term use or repeated washing can be improved. Here, durability refers to abrasion resistance, long-term shape retention, etc. Such a mat 1 is resistant to abrasion, and maintains its stiffness for a long period of time. The resin fibers 31 and 32 are partially bonded to each other. In particular, the second resin fibers 32 are not bonded to each other without the interposition of the coating layer 312. Therefore, the mat body 3 is porous and has sufficient air permeability, water permeability, and elasticity.

[0044] The inventors conducted a sensory test to compare the mat 1 with another mat in which the resin fibers 31, 32 were not bonded together by the coating layer 312 (hereinafter, simply referred to as the other mat). Before use, the mat 1 has tension in both the first covering portion 11 and the second covering portion 12. When one end of the mat 1 in the longitudinal direction is supported by hand, the amount of curvature of the mat 1 is small. Before use, the other mat has low tension in the portions corresponding to the first covering portion 11 and the second covering portion 12. When one end of the other mat in the longitudinal direction is supported by hand, the other mat bends significantly. In other words, Mat 1 is stronger and less likely to deform than the other mats.

[0045] When mat 1 and other washable mats were washed multiple times (e.g., six times), mat 1 remained taut after washing and did not lose its shape. Furthermore, there was no problem in which the anti-slip layer 4 became more easily detached from the object to which it was attached than before washing. On the other hand, the other mats became less taut after washing and also lost their shape in a wavy manner. As a result, the other mats became more easily detached from the object to which they were attached than before washing. In other words, Mat 1 is more durable against repeated washing than the other mats.

[0046] FIG. 6 is a flow chart for explaining the method for manufacturing the mat 1. As shown in FIG. The manufacturer mixes a large number of first resin fibers 31 and a large number of second resin fibers 32 together (S11). The mixing ratio R [wt %] of the first resin fibers 31 is, for example, 10≦R≦50, and preferably 15≦R≦17.

[0047] The manufacturer entangles the mixed resin fibers 31, 32 with each other to form a nonwoven fabric that will become the mat body 3 (hereinafter simply referred to as the mat body 3) (S12). In S12, the mixed resin fibers 31, 32 are entangled to become cotton-like to form a thin sheet-like first web, and a plurality of the first webs are stacked to form a thick sheet-like second web. The second web is needle-punched to entangle the resin fibers 31, 32 contained in adjacent first webs, thereby forming the mat body 3.

[0048] The manufacturer also foams the fluid material containing acrylic resin and silicone resin by stirring (S13). The fluid material is, for example, an emulsion of 50% resin and 50% water. The acrylic resin is the main material of the anti-slip layer 4. The silicone resin is an additive to promote foaming of the material. If the weight ratio of the silicone resin is too small, the fluid material is difficult to foam, and the adhesive force of the anti-slip layer 4 decreases. If the weight ratio of the silicone resin is too large, the releasability (ease of peeling) of the anti-slip layer 4 from the attached body deteriorates. After forming the mat body 3, the manufacturer applies a foamed fluid material to one surface of the mat body 3 (S14).

[0049] The manufacturer heats and dries the synthetic resin applied to one surface of the mat body 3, thereby forming the anti-slip layer 4 on one surface of the mat body 3 (S15). In S15, the mat body 3 is also heated while the anti-slip layer 4 is being formed. The heating temperature is a predetermined temperature that is equal to or higher than the softening point (80°C) of the coating layer 312 and lower than the softening points (235°C) of the fiber body 311 and the second resin fiber 32. The temperature of the drying device for thermally drying the anti-slip layer 4 is preferably set to 160°C to 200°C. The heating time is, for example, 7 minutes, and the heating temperature may be changed during heating within the range of 160°C to 200°C.

[0050] When the mat body 3 is heated, at least a part of the coating layer 312 softens or melts and functions as a thermoplastic resin adhesive. The softened or melted coating layer 312 deforms and extends between the adjacent first resin fibers 31 and second resin fibers 32 (or between adjacent first resin fibers 31). The deformed coating layer 312 spreads, for example, in a web-like (film-like) shape at the intersections of the resin fibers 31, 32. As the softened or melted coating layer 312 cools and hardens, the first resin fibers 31 and the second resin fibers 32 are partially bonded to each other by the coating layer 312. Alternatively, the first resin fibers 31 are partially bonded to each other by the coating layer 312. As a result, the step of forming the anti-slip layer 4 and the step of melting the covering layer 312 can be combined.

[0051] Since the coating layer 312 of the first resin fiber 31 functions as a kind of hot melt material, if the resin fibers 31, 32 are mixed uniformly in S11, the hot melt material can be appropriately dispersed between the resin fibers 31, 32. Since the fiber body 311 and the second resin fiber 32 do not soften or melt, there is no risk of the amount of hot melt material being too large and completely solidifying the mat body 3. Therefore, the air permeability and water permeability of the mat body 3 are not impaired by the adhesion between the resin fibers 31 and 32.

[0052] The manufacturer covers the formed anti-slip layer 4 with a protective sheet 5 (S16), and cuts the laminate of the mat body 3, the anti-slip layer 4, and the protective sheet 5 into a rectangular shape (S17). The manufacturer performs a folding process on the anti-slip layer 4 and the mat body 3 covered with the protective sheet 5 (S18). Through this folding process, the anti-slip layer 4 and the mat body 3 covered with the protective sheet 5 are folded at a predetermined angle with the anti-slip layer 4 facing inward.

[0053] In S18, the bending position (the position that will become the fold 10) is heated intensively at a predetermined temperature that is equal to or higher than the softening point of the coating layer 312 and lower than the softening points of the fiber body 311 and the second resin fiber 32. The temperature setting of the processing device used for the bending process is preferably 220°C to 230°C. The heating time is, for example, 5 seconds. At this time, the coating layer 312 at the bending position softens or melts again or anew, and the resin fibers 31, 32 are further bonded together. Since the heating range during the bending process is limited, the heating temperature during the bending process is set higher than the heating temperature during the formation of the anti-slip layer 4 in order to improve the shape retention of the fold 10.

[0054] According to the manufacturing method of the mat 1 as described above, the mat 1 of the present embodiment can be manufactured. The higher the mixing ratio of the first resin fibers 31 in S11, the greater the number of resin fibers 31, 32 bonded together in S15. Furthermore, the higher the temperature at which the mat body 3 is heated, the more times it is heated, or the longer it is heated, the greater the amount of the coating layer 312 that is softened or melted, and the greater the adhesive strength between the resin fibers 31, 32. Therefore, by appropriately setting the mixing ratio of the first resin fibers 31 or the conditions for heating the mat body 3, the mat 1 having the desired stiffness can be manufactured.

[0055] The heating temperature in S15 or S18 is desirably the melting point of the coating layer 312. The molten coating layer 312 can improve the adhesive strength between the resin fibers 31, 32 compared to the coating layer 312 that is merely softened. Both the first resin fiber 31 and the second resin fiber 32 are made of polyester. Since they are made of the same type of synthetic resin, the adhesive strength is improved compared to when different types of synthetic resins are used, and the stiffness of the mat 1 is increased. Therefore, the mixing ratio of the first resin fiber 31, which is generally more expensive than the second resin fiber 32, can be reduced.

[0056] During the folding process in S18, the covering layer 312 further bonds the resin fibers 31, 32 together, so that the corners of the folded mat 1 are reliably maintained at a predetermined angle for a long period of time. Furthermore, since the anti-slip layer 4 is covered with the protective sheet 5 before folding, the troublesome task of covering the anti-slip layer 4 with the protective sheet 5 after folding is not required.

[0057] Since the protective sheet 5 has both heat resistance against heating during folding and releasability against the synthetic resin contained in the anti-slip layer 4, there is no risk that the protective sheet 5 will melt and adhere to the anti-slip layer 4 during folding, or that it will thermally shrink during folding and impair the aesthetic appearance. However, the fold 10 of the protective sheet 5 may partially tear. However, there is no risk that the tear on the fold 10 will adversely affect the protection of the anti-slip layer 4 by the protective sheet 5. Furthermore, the tear on the fold 10 is not noticeable, so there is no risk that it will impair the aesthetic appearance.

[0058] In this embodiment, the mat body 3 is heated during the formation of the anti-slip layer 4, but the mat body 3 may be heated before the formation of the anti-slip layer 4. In this case, the anti-slip layer 4 can be formed on one surface of the mat body 3, which has high shape retention, and therefore, distortion, fraying, etc. of the mat body 3 can be prevented when the anti-slip layer 4 is formed.

[0059] In addition, each of the resin fibers 31 and 32 may be a modified cross-section fiber. The combination of the synthetic resin constituting the fiber body 311 and the thermoplastic resin constituting the coating layer 312 is not limited to the combination of polyester and low melting point polyester. The second resin fiber 32 is not limited to polyethylene. The anti-slip layer 4 is preferably made of a synthetic resin containing at least one of an acrylic resin and a polyurethane. When the anti-slip layer 4 contains an acrylic resin, the anti-slip layer 4 is particularly excellent in heat resistance, light resistance, water resistance, and corrosion resistance. When the anti-slip layer 4 contains polyurethane, the mechanical strength of the anti-slip layer 4 is improved.

[0060] The adsorption portion 42 is not limited to a convex stripe shape. For example, the adsorption portion may be dot-shaped and scattered on one surface of the base 41. The anti-slip layer 4 may not have the adsorption portion 42. In this case, the anti-slip layer 4 may have only the base 41, or may have a groove, hole, or the like formed on one surface of the base 41. The anti-slip layer 4 is not limited to a structure having an adhesive force, but may be a structure having an adhesive force that allows the layer to be attached and detached to an object to which the layer is attached. The protective sheet 5 is not limited to a stretched polypropylene film, but is preferably made of a synthetic resin including polypropylene, polyethylene (stretched polyethylene), or polyester.

[0061] The embodiments disclosed herein are illustrative in all respects and should not be considered as limiting. The scope of the present invention is intended to include not only the above-mentioned meaning, but also the meaning equivalent to the claims and all modifications within the scope of the claims. The independent claims and dependent claims described in the claims can be combined with each other in any combination, regardless of the reference format. Furthermore, the claims use a format in which a claim references two or more other claims (multiple claim format), but this is not limited to this format. The claims may also be written in a format in which a multiple claim references at least one other claim (multiple multiple claim format). [Explanation of symbols]

[0062] 1 Matt 3 Mat body 31 First resin fiber 311 Textile body 312 Covering layer 32 Second resin fiber 4 Anti-slip layer 42 Adsorption part 5 Protective Sheet

Claims

1. A nonwoven fabric mat body formed by intertwining resin fibers; An anti-slip layer formed on one surface of the mat body; A mat comprising: The mat body includes a plurality of first resin fibers and a plurality of second resin fibers different from the first resin fibers, The first resin fiber is A synthetic resin fiber body; a coating layer made of a thermoplastic resin that covers the peripheral surface of the fiber body; having A mat, characterized in that the first and second resin fibers, or the first resin fibers themselves, are partially bonded to each other by the coating layer.

2. The anti-slip layer has a plurality of suction portions arranged in parallel at a pitch P [mm] (3≦P<15.8) in one direction, Each of the suction portions has an adhesive force and is formed in a convex shape extending in a direction intersecting the one direction, 2. The mat according to claim 1, wherein the width W [mm] of each suction portion satisfies 1.8≦W<3.

3.

3. A nonwoven fabric mat body formed by intertwining resin fibers; An anti-slip layer formed on one surface of the mat body; A method for producing a mat comprising: A first resin fiber having a fiber body made of a synthetic resin and a coating layer made of a thermoplastic resin covering the circumferential surface of the fiber body and a second resin fiber different from the first resin fiber are mixed together in a plurality of fibers, The mixed resin fibers are entangled to form the mat body; The anti-slip layer is formed on the one surface of the formed mat body, A method for manufacturing a mat, characterized in that the mat body is heated at a temperature equal to or higher than the softening point of the coating layer before or during formation of the anti-slip layer, thereby partially bonding the first and second resin fibers, or the first resin fibers together, to each other by the coating layer.

4. After the mat body is formed, a fluid material is applied to the one surface of the mat body; The applied material is heated and dried to form the anti-slip layer on the one surface; The method for manufacturing a mat according to claim 3, characterized in that the temperature at which the material is heated is higher than the melting point of the coating layer, thereby melting the coating layer during the formation of the anti-slip layer.

5. The anti-slip layer is formed using a synthetic resin including an acrylic resin or a polyurethane, The formed anti-slip layer is covered with a protective sheet made of a synthetic resin including polypropylene, polyethylene, or polyester; The anti-slip layer and the mat body covered with the protective sheet are folded at a predetermined angle so that the anti-slip layer is on the inside, 5. The method for manufacturing a mat according to claim 3, wherein during the folding process, the folding positions are heated to a temperature equal to or higher than the softening point of the covering layer.

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