Mat and method for manufacturing the 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] FIELD OF THE DISCLOSURE The present disclosure relates to mats and methods for making mats. [Background technology]

[0002] Conventionally, mats that are laid on floors, stairs, etc. have been widely used. The mat described in Patent Document 1 (hereinafter referred to as "stair mat") comprises a mat body (hereinafter referred to as "stair 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, stairs, etc., preventing 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, nonwoven fabric mat bodies have 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 desired position on a floor or staircase. In particular, since staircase mats are laid one by one for multiple steps, if it is difficult to lay them accurately in the desired position, it takes a long time to finish laying all the mats. There is also a demand for further improvement in the durability of mats against long-term use or repeated washing.

[0005] An object of the present disclosure is to provide a mat and a method for manufacturing the 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 nonwoven fabric and is formed by entangling (intertwining) each resin fiber with other resin fibers. The mat body contains 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 second resin fiber is different from the first resin fiber.

[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 themselves are partially bonded to each other by the coating layer. The resin fibers are intertwined and bonded to each other, which improves the shape retention of the mat body (and therefore the mat itself). Because the mat has high shape retention, it is easy to lay the mat accurately in the desired position on the floor, stairs, etc. A mat with high shape retention is what we call a strong mat.

[0009] Since the resin fibers that are bonded together 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 together reinforce each other. As a result, the durability of the mat body (and therefore the mat) can be improved against long-term use, repeated washing, etc. Here, durability refers to abrasion resistance, long-term shape retention, etc. Such a mat is resistant to abrasion and maintains its strength 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 suction 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 suction portions, each of which has an adhesive force. The suction portions are arranged in a row in one direction at a pitch of P [mm]. Each suction portion is a convex stripe with a width of W [mm] and extends in a direction intersecting the one direction.

[0012] The smaller the pitch P, the greater the number of suction points 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 point, 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, which increases 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 predetermined value of 3≦P<15.8 and the width W [mm] is a predetermined value of 1.8≦W<3.3, it is possible to prevent the mat from shifting position, reduce the amount of synthetic resin used, and make the mat easier to remove.

[0013] The mat manufacturing method 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 the method comprises mixing a first resin fiber having a synthetic resin fiber body and a thermoplastic resin coating layer covering the circumferential surface of the fiber body with a second resin fiber different from the first resin fiber, in groups of two or more, and forming the mat body by entangling the mixed resin fibers, forming the anti-slip layer on one surface of the formed mat body, and 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, thereby partially bonding the first and second resin fibers, or the first resin fibers, to each other by the coating layer.

[0014] In the present disclosure, a nonwoven fabric 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, and an anti-slip layer is formed on one surface 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 core-sheath 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 heating temperature is equal to or higher than the softening point of the coating layer of the first resin fiber, so that at least a portion 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 using non-fibrous (e.g., powdery) hot melt materials or liquid adhesives. The higher the mixing ratio of the first resin fiber, the greater the number of resin fibers bonded together. Furthermore, the higher the temperature at which the mat body is heated, the more times it is heated, or the longer it is heated, the greater the amount of softening or melting of the coating layer, thereby improving 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 with 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 method for manufacturing a mat according to the present disclosure is characterized in that, after the mat body is formed, 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 surface of the mat body, and the applied material is heated and dried to form an anti-slip layer on one surface 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 subjected to a folding process in which the anti-slip layer is on the inside and the folding position is heated at a temperature equal to or higher than the softening point of the covering layer during the folding process.

[0021] In the present disclosure, a non-slip layer is formed using a synthetic resin including acrylic resin or 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 then 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, causing the coating layer at the folding position to soften or melt again or again, further bonding the resin fibers together.

[0022] As a result, a mat is produced that is folded at a predetermined angle with the anti-slip layer facing inward. The coating layer further bonds the resin fibers together during the folding process, ensuring that the corners of the folded mat maintain their shape at the predetermined angle for a long period of time. 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 to 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 aforementioned heat resistance and releasability. [Effects of the Invention]

[0024] According to the mat and the method for manufacturing the mat of the present disclosure, it is possible to improve shape retention and durability. [Brief explanation of the drawings]

[0025] [Figure 1] 1 is a perspective view showing a mat according to an embodiment. [Figure 2] FIG. 2 is a schematic side view of a mat. [Figure 3] FIG. 2 is a schematic cross-sectional view of a mat. [Figure 4] FIG. 2 is a schematic perspective view of resin fibers that form the mat body. [Figure 5] FIG. 2 is a schematic bottom view of the mat. [Figure 6] 10 is a flowchart illustrating a method for manufacturing a mat. DETAILED DESCRIPTION OF THE INVENTION

[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 is rectangular and long in one direction. The mat 1 is folded to cover both the top and tip surfaces of the steps 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 stairs 2.

[0028] With the fold 10 as the boundary, one side of the mat 1 in the short direction is a first covering part 11 that covers the top surface of the step 21, and the other side of the mat 1 in the short direction 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 flexibility to such an extent that the shape of the mat 1 can 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, such as acrylic resin. The anti-slip layer 4 is formed on one surface of the mat body 3. The mat 1 includes a fold 10, a first covering portion 11, and a second covering portion 12, each including the mat body 3 and the anti-slip layer 4.

[0030] FIG. 3 is a schematic cross-sectional view of the mat 1. The mat body 3 contains a large number of first resin fibers 31 and a large number of second resin fibers 32. Hereinafter, the first resin fibers 31 and the second resin fibers 32 will be referred to as resin fibers 31, 32 unless they are to be distinguished from each other. 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 resin fibers 31 and 32 that form the mat body 3. As shown in FIG. Each first resin fiber 31 has a fiber body 311 and a coating layer 312. The coating layer 312 covers the circumferential surface of the fiber body 311. That is, the first resin fiber 31 is a so-called core-sheath fiber. 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, such as polyester, and 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, such as a low-melting-point polyester. The softening point and melting point of the covering layer 312 are lower than those 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 synthetic resin, such as 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 suction portions 42. The base 41 is layered 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. The suction portions 42 are shaped like convex stripes and extend over the entire length of the mat 1 in the longitudinal direction. The suction portions 42 are elastic.

[0035] 3, the anti-slip layer 4 contains a large number of cells 40. Some of the cells 40 are open on the surface of the adsorbing portion . The suction portion 42 has a vacuum suction force because the air bubbles 40 are open on the surface of the suction portion 42. 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 it is attached.

[0036] The width of the suction portion 42 (the length along one surface of the base 41 and perpendicular to the longitudinal direction of the suction portion 42) is W [mm]. The width W is a predetermined value in the range 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 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 portions 42 per unit area, making it less likely that the mat 1 will shift from its predetermined position. Also, the greater the width W, the greater the suction force of each suction portion 42, making it less likely that the mat 1 will shift from its predetermined 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, which increases costs, and there is also the 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 predetermined value of 3≦P<15.8 and the width W [mm] is a predetermined value of 1.8≦W<3.3, it is possible to prevent the mat 1 from shifting out of position, reduce the amount of synthetic resin used, and make the mat 1 easy to remove.

[0038] In the figures, reference numeral 5 denotes a protective sheet, which completely covers and protects the non-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 the protective sheet 5 does not peel off naturally. Before using the mat 1, the user peels the protective sheet 5 off the non-slip layer 4 to expose the non-slip layer 4. The protective sheet 5 is made of a synthetic resin, such as an oriented polypropylene film.

[0039] 2, when the mat 1 is not attached to the step 21, the angle between the first covering portion 11 and the second covering portion 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. As shown in Figure 1, when mat 1 is attached to step 21, both surfaces of first covering portion 11 face up and down, and fold 10 is located at the corner between the top surface and the tip surface of step 21. Second covering portion 12 hangs down from fold 10.

[0040] When the mat 1 is attached to the step 21, the first covering portion 11 is naturally pressed against the upper surface of the step 21 by its own weight (or by a user or pet stepping on the first covering portion 11 when going up or down the stairs 2). The angle between the first covering portion 11 and the second covering portion 12 is equal to the angle between the upper surface and the tip surface of the step 21 (generally 90°). When the mat 1 is attached to the step 21, the angle between the first covering portion 11 and the second covering portion 12 increases, so that the second covering portion 12 is naturally pressed against the tip surface of the step 21. As a result of the above, the user does not need to press the mat 1 against the step 21 in order to make the suction portion 42 adhere 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 slipping out of position. A user or a pet steps on the mat body 3 that constitutes the first covering portion 11. In this embodiment, one end of the mat 1 in the short direction is bent to cover the top surface and tip end surface of the steps 21, but this is not limiting. For example, both longitudinal ends of the mat 1 may be bent to cover the top surface of the tread of an open staircase and both longitudinal end surfaces of the tread. The mat 1 may be configured as an unfolded mat (that is, without the second covering portion 12). The mat 1 is not limited to being attached to the stairs 2, but may also be attached to the step at the entrance or the kitchen floor, for example.

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

[0043] The resin fibers 31, 32 that are bonded to each other do not separate from each other, so the resin fibers 31, 32 are less likely to fray from the mat main body 3. Furthermore, the resin fibers 31, 32 that are bonded to each other reinforce each other. As a result, the durability of the mat main body 3 (and therefore the mat 1) can be improved against long-term use, repeated washing, etc. 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, 32 are only 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 are 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 longitudinal end of the mat 1 is supported by hand, the amount of curvature of the mat 1 is small. Before use, the other mat has weak tension in the portions corresponding to the first covering portion 11 and the second covering portion 12. When one longitudinal end of the other mat is supported by hand, the amount of bending of the other mat is large. 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 (for example, six times), mat 1 remained firm after washing and did not lose its shape. Furthermore, there was no problem with the anti-slip layer 4 becoming more easily detached from the object to which it was attached than before washing. On the other hand, the other mats lost their firmness after washing and began to lose their shape, causing them to ripple. 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 flowchart illustrating a method for manufacturing the mat 1. 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 form a cotton-like 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, so that the resin fibers 31, 32 contained in adjacent first webs are entangled with each other, thereby forming the mat body 3.

[0048] The manufacturer also foams a fluid material containing acrylic resin and silicone resin by stirring it (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 that promotes foaming of the material. If the weight ratio of the silicone resin is too small, the fluid material will not foam easily, and the adhesive force of the anti-slip layer 4 will decrease. If the weight ratio of the silicone resin is too large, the releasability (ease of peeling) of the anti-slip layer 4 from the substrate will decrease. 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. Preferably, the temperature set in the drying device for thermally drying the anti-slip layer 4 is 160°C to 200°C. The heating time is, for example, 7 minutes, and the heating temperature may be changed within the range of 160°C to 200°C during heating.

[0050] When the mat body 3 is heated, at least a portion 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 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 process of forming the anti-slip layer 4 and the process of melting the coating 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 and 32 are mixed uniformly in S11, the hot melt material can be dispersed appropriately between the resin fibers 31 and 32. Since the fiber body 311 and the second resin fiber 32 do not soften or melt, there is no risk of an excessive amount of hot melt material 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, 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, anti-slip layer 4, and 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). By 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 where the fold 10 will be formed) 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. Preferably, the temperature setting of the processing device used for the bending process is 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, further bonding the resin fibers 31, 32 together. Because the heating range during the bending process is limited, the heating temperature during the bending process is set higher than the heating temperature used to form 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 main 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 softens or melts, thereby improving 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 main body 3, it is possible to manufacture a mat 1 having the desired stiffness.

[0055] The heating temperature in S15 or S18 is preferably the melting point of the coating layer 312. The melted coating layer 312 can improve the adhesive strength between the resin fibers 31, 32 compared to a coating layer 312 that is merely softened. Both the first resin fiber 31 and the second resin fiber 32 are made of polyester. Because they are made of the same type of synthetic resin, the adhesive strength is improved compared to when different types of synthetic resin 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 coating 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 the folding process, the troublesome work of covering the anti-slip layer 4 with the protective sheet 5 after the folding process is not necessary.

[0057] Because protective sheet 5 is heat resistant to heating during folding and has releasability from the synthetic resin contained in anti-slip layer 4, there is no risk that protective sheet 5 will melt and adhere to anti-slip layer 4 during folding, or that it will heat shrink during folding and impair the aesthetic appearance. However, fold 10 of protective sheet 5 may partially tear. However, there is no risk that tears along fold 10 will adversely affect the protection of anti-slip layer 4 by protective sheet 5. Furthermore, tears along fold 10 are not noticeable, so there is no risk that they 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 also 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] The resin fibers 31 and 32 may each 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 suction portions 42 are not limited to being convex stripes. For example, dot-shaped suction portions may be scattered over one surface of the base 41. The anti-slip layer 4 may not have the suction portions 42. In this case, the anti-slip layer 4 may have only the base 41, or may have grooves, holes, 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 it to be attached and detached to an object to which it is attached. The protective sheet 5 is not limited to a stretched polypropylene film, but is preferably made of a synthetic resin containing polypropylene, polyethylene (stretched polyethylene), or polyester.

[0061] The embodiments disclosed herein are to be considered as illustrative in all respects and not restrictive. 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 and dependent claims described in the claims can be combined with each other in any combination, regardless of the reference format. Furthermore, although the claims use a format in which a claim references two or more other claims (multiple claim format), this is not limited to this format. Multiple claims that reference at least one other multiple claim (multi-multi claim format) can also be used. [Explanation of symbols]

[0062] 1 Matt 3 Mat body 31 First resin fiber 311 Fiber 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 circumferential surface of the fiber body; and The mat is 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 in one direction at a pitch P [mm] (3≦P<15.8), Each suction portion has an attraction force and is formed in a convex stripe 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 is in the range of 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; 1. A method for manufacturing a mat comprising: A first resin fiber having a fiber body made of synthetic resin and a coating layer made of 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 plurals, 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 above the softening point of the coating layer before or during the 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 forming the mat body, 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; 4. A method for manufacturing a mat as described in 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 with the anti-slip layer facing inward, 5. The method for manufacturing a mat according to claim 3, wherein the folding position is heated at a temperature equal to or higher than the softening point of the coating layer during the folding process.

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