CN1113629C - Dust-control mat having excellent dimensional stability and method of producing the same - Google Patents
Dust-control mat having excellent dimensional stability and method of producing the same Download PDFInfo
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- CN1113629C CN1113629C CN 95116945 CN95116945A CN1113629C CN 1113629 C CN1113629 C CN 1113629C CN 95116945 CN95116945 CN 95116945 CN 95116945 A CN95116945 A CN 95116945A CN 1113629 C CN1113629 C CN 1113629C
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Abstract
The present invention relates to a dust-proof cushion having excellent dimensional stability, fine velvet performance and an outstanding pattern showing effect in the process of treatment and a method for producing the dust-proof cushion. The dust-proof cushion having excellent dimensional stability comprises a base layer, wherein base fabric is woven fabric or nonwoven fabric. A fluffy non-textile fiber layer is connected to the base layer, wherein the fluffy non-textile fiber layer contains low-melting-point fibers. After pile yarn is implanted on the fibers, the fluffy non-textile fiber layer is thermoset. The present invention also further provides the method for producing the dust-proof cushion.
Description
The method that the present invention relates to a kind of dust-proof cushion and produce this pad, more particularly, the present invention relates to a kind of fabulous dimensional stability that in processing procedure, has, dustproof (footwear wiping) pad of good cut velvet performance and outstanding pattern expression effect, and the method for producing this pad.In this manual, dust-proof cushion relate to those be placed on people such as shop, hotel, hospital, office and dwelling house go out out into porch and the mat of porch, its effect is to remove dust and the foul that sole adheres to, so that prevent in dust and the foul inlet chamber.
Most of dust-proof cushions all are the pads of taffeta weave, and front and back made from rubber or resin of a fibrous material arranged.
So far, producing the method that doormat adopted is flocking on a base fabric, coats latex on lint-free surface if desired, and the method that adopts heating and pressurization is at lint-free surface adhesion one deck vulcanie.
Usually, base fabric or be woven fabric, or be adhesive-bonded fabric as carpet.
The latex of any kind of can use, as SBR, NBR or analog, yet, be only from oil resistant and washable angle NBR.
Can adopt conventional method such as taffeta weave, pinhock weave or the like method to come flocking.
Fine hair to be implanted can be the fine hair of any kind of, as: the long filament of nylon, propylene, polyester, cotton, staple fibre or vinylon, or spun yarn.
Kind according to mat often adheres to one deck vulcanie (single type), for example, vulcanie is cut into regular size, under heating and pressurized conditions, unhardened vulcanie is sticked to non-matte, makes its sclerosis.
Up to now, in the process of producing doormat, there is such problem, the initial fabric after the flocking on the base fabric handle with latex, cutting or adhere in the process of vulcanie, mat can be out of shape, crooked, owing to be applied to external force on the initial fabric, mat is always bent.In the dust-proof cushion that character or straight-line pattern are arranged, this distortion or distortion can damage the outward appearance of product, reduce the quality of product.Reuse at it, after washing and the drying, the pad of this distortion has produced the influential power of initial straight form, and the result makes whole mat Texturized, has shortened its life-span (renting the life-span).
This point will more detailed description.On the angle of operating efficiency, the initial fabric that obtains in the base fabric flocking is preferably long as much as possible, in practice, what use also is long initial fabric, like this, long initial fabric must be rolled or be deposited on the shelf foldedly, yet, in this case, initial fabric can deform or nonvolatil warpage.
Usually, when applying latex, adopt the pin tentering chance to produce tension force, also can coat latex continuously for initial fabric, carry out shed water in the latex of drying then with an applicator roll at the width of initial fabric to initial fabric.Yet, in this case, because the effect of external force, be inevitable in the distortion of the about 5cm/m of width, there are deviation in a small amount in speed and tension force in width right side and left side, and the junction between initial fabric and the initial fabric exists deviation and other error.
Therefore, the purpose of this invention is to provide a kind of dust-proof cushion that can overcome the above-mentioned defective of traditional dust-proof cushion, in processing procedure, it has dimensional stability, good cut velvet performance and outstanding pattern expression effect, the present invention also provides the method for producing this dust-proof cushion.
According to the present invention, a kind of dust-proof cushion with outstanding dimensional stability is provided, this pad comprises a base fabric, is implanted in the fine hair on base fabric one surface, and the elastic bottom plate that is added in the non-suede of base fabric surface, wherein, base fabric comprises that the basic unit of a woven fabric or adhesive-bonded fabric and one deck stick to the villous non-textile fiber layer in the basic unit, and above-mentioned fine hair shape non-textile fiber layer is a low-melting fiber, after pile yarns are implanted, fine hair shape non-textile fiber layer is carried out thermosetting handle.
In addition, according to the present invention, also provide a kind of method of dust-proof cushion of production excellent in dimensional stability, this method comprises; By needle point method or site thermal bonding, the villous non-textile fiber layer of one deck is bonded in the basic unit of a woven fabric or adhesive-bonded fabric, thereby prepare a kind of base fabric, above-mentioned villous non-textile fiber layer contains long fibre or short fiber, wherein is uniform-distribution with low-melting fiber in above-mentioned fine hair shape non-textile fiber layer; Prepare initial fabric by on base fabric, implanting fine hair with taffeta weave or pinhock weave; By initial fabric is heat-treated, make the pars fibrosa in fine hair and base fabric and the base fabric bonding, so that make low-melting fiber fusing or deliquescing; And add elastic bottom plate on the lint-free surface of initial fabric.
Distinguishing characteristics of the present invention is equally distributed short fiber of low-melting fiber or long stapled villous nonwoven fabric layer, stick in the basic unit of woven fabric or adhesive-bonded fabric, carrying out thermosetting after the flocking handles, thereby can greatly improve dimensional stability, cut velvet characteristic and pattern expression effect.
At first, at the fine hair shape non-textile fiber layer that forms in the basic unit is not in order to implant fine hair on base fabric, but in order to improve the piloerection characteristic of implanting fine hair, after flocking on the base fabric, carry out thermosetting to villous non-textile fiber layer handles, thereby make low-melting fiber fusing in the fine hair shape non-textile fiber layer or softening, so that carry out hot sticky attached, works after the flocking is cured and the stability processing, thereby no matter processing subsequently how, can both improve dimensional stability, cut velvet performance and the pattern expression effect of mat.
That is to say, according to the present invention, by adopting needle point method or the hot sticky connection in site, low-melting fiber (hereinafter often referring to the bond vitrified component) equally distributed short fiber or long fibre fine hair shape on-woven layer are bonded in the basic unit of woven fabric or adhesive-bonded fabric, thereby low-melting fiber is evenly distributed and are bonded in the base fabric surface.Then, flocking is heat treatment then on base fabric, thereby makes component fusing of heat fusing bonding and deliquescing, is boning effectively between fine hair and the base fabric and among the fiber at base fabric.At this moment, base fabric has dimensional stability, especially has the ability that external force resistance such as initial fabric warrping get up to pack or fold the external force that is produced.
Also between fine hair of being planted and base fabric, carry out bonding, increasing the possibility that anti-fine hair is run out of, thus obtain a kind of base fabric and fine hair together melting adhered, have the initial fabric of good pliability and rebound performance.
Base fabric has double-decker, the villous non-textile fiber layer of the basic unit of one deck woven fabric or adhesive-bonded fabric and one deck.Because the bond vitrified component is distributed on the villous non-textile fiber layer, its pliability of initial fabric of crossing melt process at the heating anteroposterior diameter does not almost have difference.
This is that the adhesive-bonded fabric that mixes has basic difference with traditional heat fusing bonding component, in adhesive-bonded fabric, the bond vitrified component is evenly distributed on the whole base fabric, initial fabric has very big hardness through after the bond vitrified, therefore, and when initial fabric is used as the base fabric of dust-proof cushion, because the bending that produces in repeated washing and the dry run, cause in initial fabric stress to concentrate, fracture or similar phenomenon have taken place in the result, have shortened service life.Therefore yet the present invention has overcome these defectives, and in traditional adhesive-bonded fabric, the bond vitrified component is equally distributed, and the concentration of low-melting fiber is low, is difficult to obtain a kind of cohesive force that fine hair and base fabric are bonded together of being enough to.If attempt to strengthen cohesive force, because the rigidity of base fabric will increase, will certainly shorten the life-span of initial fabric so by the ratio that increases the bond vitrified component.Yet just as the back will as described in, although the concentration of bond vitrified component is low, the present invention still can obtain fabulous cohesive force.
According to the present invention, the base fabric of being made up of adhesive-bonded fabric still is that the base fabric of being made up of woven fabric all is applicable to the present invention, especially when being added to the bond vitrified component on the woven fabric, unstuck component also can get up in bond vitrified in the base fabric neighboring, even mat can not wear and tear after by cyclic washing yet.
Outstanding effect of the present invention is described below, when character pattern being arranged on the dust-proof cushion, and when the self-designed pattern of client is arranged on the polychrome fine hair pad, can improve the cut velvet performance significantly as " welcome " with similarly during pattern, compare with the dust-proof cushion of prior art, improved the pattern expression effect greatly.That is to say that the fine hair of dust-proof cushion different colours of the present invention seldom passes its border, form line is very clear.
In being implanted with traditional dust-proof cushion of different colours fine hair, especially the clipping pad that is made into of taffeta weave because the external force that subsequent processing steps produces usually makes fine hair pour the zone of different colours fine hair into, makes the degraded appearance of dust-proof cushion.Fine hair is toppled over and is not occurred over just production process, but also occurs in washing and recuperation.
According to the present invention, be provided with the villous on-woven fiber layer of one deck in the basic unit, after flocking, make fusing of low melting point component and deliquescing, thereby by hot adhesion and fixed bit, produce thus and stablized the cut velvet performance by heating and melting bonding.
Below concrete mechanical part will be described, that is to say, after the flocking, the fine hair shape non-textile fiber layer that one deck contains low-melting fiber is set on base fabric, in basic unit, implant the low-melting fiber of telling, its result is increased in the concentration of fine hair outer peripheral areas low-melting fiber by correspondingly adjusting the amount of implanting fine hair.
Then, because heat treatment subsequently, the fine hair outer peripheral areas can firmly fix, thereby has strengthened the cut velvet performance.Even through treatment step subsequently, the border can be not chaotic yet, thereby obtained the good dust-proof cushion of a kind of pattern expression effect.
As the bond vitrified component, can use any known heat fusing bonding component, as polyester, polyolefin, polyamide, polyurethane or have the analog of silk, skin core structure or similar structures.In fine hair shape non-textile fiber layer (willow short-staple layer), preferably its mixing ratio is 1～80% percentage by weight.
Fig. 1 is the sectional drawing of dust-proof cushion of the present invention.
Fig. 2 is the profile of the base fabric section structure of amplification.
Referring to dust-proof cushion of the present invention shown in Figure 1, this pad comprises one deck base fabric 1, and the fine hair 2 that is made into the taffeta weave on base fabric 1 is attached to the rubber bottom plate 4 on the base fabric lint-free surperficial 3.
Section structure referring to base fabric shown in Figure 2, basic unit comprises that one deck woven fabric or adhesive-bonded fabric and one deck contain the fine hair shape non-textile fiber layer 6 of long fibre or short fiber, above-mentioned villous non-textile fiber layer 6 is to pass basic unit with acupuncture 7, low-melting fiber is evenly distributed in the fine hair shape non-textile fiber layer 6, and fiber in fine hair shape non-textile fiber layer and base fabric are in the same place with fine hair 2 hot adhesions.
Basic unit can be any woven fabric, adhesive-bonded fabric or braid, and the fiber that constitutes it can be any synthetic fibers, as polyester fiber, Fypro, acrylic fiber or supra polymer polyolefine fiber.Best, fiber is made of simple macromolecule thermoplastic polyester, especially polyethylene terephthalate or terephthaldehyde's acetoacetic ester.
Although can constitute basic unit's woven fabric with polyester fiber, can also use filmated silk, this silk be by the polyester film that stretches with strength increasing its hot strength, and it is divided into predetermined width makes.
When using woven fabric, fabric construction there is not special restriction, plain weave just can.Yet, can adopt twill weave or other any weave if desired.Using under the situation of adhesive-bonded fabric, can adopt spunbonded nonwoven, both uses that combine of melt-blown fabric or its.
Usually, the weight of basic unit 50～500g/m preferably
2But this depends on the weight of mat.
Preferably villous non-textle layers is made of any synthetic fibers, as polyester fiber, Fypro, acrylic fiber or the supra polymer polyolefine fiber that has same pattern as mentioned above.Yet preferably the non-textle layers of fine hair shape is made of the macromolecule thermoplastic polyester, especially mainly the thermoplastic copolymer that is made of polyethylene terephthalate or terephthaldehyde's acetoacetic ester.
As the low-melting fiber that is included in the fine hair shape non-textile fiber layer, can use the bond vitrified silk of any known low-melting point polyester, polyolefin, polyamide or polyurethane.The fusing point of low-melting fiber is lower than the fusing point that those common fusing points are 60 ℃～200 ℃ of fibers.
Usually, prepare the molten low melting point viscose fibre by in fiber forming polymer, mixing the copolymerization component.The preferred example of low-melting fiber is low-melting copolyester, especially polymerization (terephthaldehyde's acetoacetic ester/isophthalate).Another preferred example of low-melting fiber is low-melting copolyamide.
Low-melting fiber can be made of above-mentioned low melting point copolymer separately, perhaps is made up of jointly fiber and other common fiber forming polymer of low melting point copolymer, as comprises the fiber of core shell structure or bimetallic (edge-to-edge) structure.
Be preferably in and sneak into percentage by weight in the fine hair shape non-textile fiber layer and account for 1～80%, preferably 50% low-melting fiber.That is to say, when the amount of the LMP fiber of sneaking into than above-mentioned scope hour, the effect of stable dimensions is not as the effect of quantitative value in the above-mentioned scope.On the other hand, low-melting fiber can lose pliability.
At least being provided with at least on the upper side (matte side) of the base fabric that is made of woven fabric or adhesive-bonded fabric or two sides, one deck is used for the net that fine hair shape non-textile fiber layer is shaped, by widely used needle point method basic unit and fine hair shape non-textile fiber layer are fixed together as an overall structure, even after the acupuncture, net still keeps very bulk state.
The fiber that preferably constitutes fine hair shape non-textile fiber layer is the silk of single size, and normally 0.1～50, especially 1～20, monofilament can be so-called long filament or short silk.Preferably fine hair shape non-textile fiber layer has a catch net, and it can be the net of spunbond.Usually, the weight of the non-textle layers of fine hair shape is 20～500g/m
2, preferably this weight accounts for 5～200% of substrate weight.Usually wish that needling density is not less than 1000 perforation/m
2
The wool sliver of implanted base fabric can be the spun yarn of one or both or multiple cotton fiber, staple fibre, vinal, tacryl, nylon fiber or other synthetic fibers, or multifilament yarn.Best, the length of taffeta fine hair is generally 3～20mm, and this fine hair can be clipping, loop pile, can also be fine hair that curl or non-crimping.In addition, pile length can be constant or different, for example also can be that height cuts low lopping or the like.The gross thickness of fine hair changes in 300～10000 scope, carries out flocking under known condition, and the knitting needle number of each inch is 3～20, and the coil number of each inch is 3～20.
The initial fabric that implantation fine hair on base fabric obtains is carried out thermosetting processing (heat treatment), heat treatment is the fusion low-melting fiber, under the temperature of the fusing point that is higher than low-melting fiber initial fabric is carried out heat treated, it is in order not deform in processing subsequently that initial fabric is carried out such heat treatment.Therefore, the very important point is that initial fabric is heat-treated at free state, so that do not have shutting on initial fabric.Preferably adopt hot air circulate stove, Far-infrared Heating or Steam Heating to heat-treat.The wet fusing point of copolyamide and copolyester is lower than their dried fusing point, and therefore, Steam Heating is a kind of very effective heat treatment mode.
For rubber layer as base plate, can use various elastomeric polymers, as acrylonitrile-butadiene rubber (NBR), butadiene-styrene rubber (SBR), neoprene (CR), polybutadiene rubber (BR), polyisoprene (IIB), butyl rubber, natural rubber, EPM (EPR), tri poly ethylene-propylene rubber (EPDM), polyurethane, haloflex, chlorinated polypropylene, soft koroseal or the like.Yet,, preferably use acrylonitrile-butadiene rubber (NBR) from the angle of oil resistant and weather resisteant.
When forming rubber layer, can mix the admixture of known quantity, as sulfuration or organic sulfurizing agent, vulcanization accelerator, softening agent, age resister, filler, dispersant, plasticizer, colouring agent and similar additive.
When forming integrally-built mat, can adopt roller, Bumbury blender or similar equipment that above-mentioned rubber component is rubbed, then this mixture is molded into thin plate, then place the pad that a usefulness taffeta weave is made into thereon.Then, this laminate heating and pressurization in a pressure die cavity bond simultaneously and vulcanize.
In order to increase the adhesive strength between rubber and the base fabric, can be coated with the latex rubber that last layer and rubber slab belong to a class together on the non-suede surface of base fabric.Perhaps, coat binding agent on above-mentioned surface in advance, as the copolymer or the adhesive accelerant of diethyl oxalate/ethene.
Best, the weight of rubber slab is 500～4000g/m
2, by following mode rubber slab and base fabric are bonded together and to form an overall structure, that is, and the limit that makes the limit of rubber slab stretch out base fabric slightly.
Be preferably in 0.1～20Kg/mm
2Pressure under, in 100～200 ℃ temperature range, undertaken bonding by sclerosis.
The present invention not only can form an overall structure and obtains this mat by rubber slab being bonded on the initial fabric, but also can be used for obtaining the mat of so-called separate type, wherein, mat is placed on the independent rubber substrate.
In this case, can coat elasticity latex, be cured then at the non-matte of initial fabric.Best, the amount of the amount of latex (solid constituent) is 50～3000g/m
2
Pile yarns on the mat of the present invention can absorb and accommodate dust and the foul that adheres to sole, in order further to improve above-mentioned action effect, can coat dust palliative on dust palliative or the dipping on these pile yarns.As dust suction liquid, can use silicon thing oil, as liquid paraffin, spindle oil, alkylbenzene oil, diester oil, castor oil, or artificial oil or vegetable oil, perhaps those disclosed dust suction agent aqueous fusion liquid in the Japanese patent application publication No. 1019/1978 and 37471/1978.Usually, the use amount of absorbent is 0.01～200g/m
2
To describe the present invention by embodiment below.
Embodiment 1
Pile: BCF nylon
6 coil/inches, gauge 5/32
Pile length 9mm, heavy 880g/m
2, clipping
Latex: NBR latex 300g/cm
2(solids content 46%)
By adopting following base fabric A and B to prepare sample, be represented as sample 1-A and 1-B.
Base fabric A and B are made into the taffeta method, have above-mentioned fluff structures, under 180 ℃ temperature, sample 1-B are heated 5 minutes continuously.
Coat latex on above-mentioned initial fabric, drying is 15 minutes under 175 ℃ temperature, cuts into the piece of 70 * 85cm, it is heated, and at 10kg/cm
2Pressure under, under 170 ℃ temperature, with thickness be 1.8mm unhardened rubber slab by the sclerosis 15 minutes.
Base fabric A: polyester plain cloth 200g/m
2
Base fabric B: polyester plain cloth 150g/m
2
*Polyester cotton 100g/m
2
(percentage by weight of low melting point villus fiber is 25%)
Polyester cotton forms with pin acupuncture.
Cut above-mentioned mat, and 50 samples are carried out the measurement (table 1) of degree of deformation in stitch direction and line-spacing direction.
Above-mentioned pad is placed on the place that had 2000 walkings to pass in a day, placed altogether 3 days, clean then, repeat like this 40 times, after 10 times, the situation of change (table 2) of the takeoff pattern that passes through according to fine hair.
Table 1
Degree of deformation mm A B
Stitch direction 3mm 0mm
Line-spacing direction 34mm 0.5mm
Table 2
A B
55 piles, 5 piles once
83 piles, 4 piles after ten times
Traverse to quantitative measurement change in pattern situation in the white pile according to black pile.
Can see the distortion situation of initial fabric pattern significantly from table 1, can clearly see the difference of the pile number that passes through from table 2, even use after 40 times, curling or breaking can not appear in mat B yet.
Mat A curls nearly three the local about 2mm～5mm's of appearance of a side, and the pattern of the initial fabric of above-mentioned mat B does not deform, and has kept good cut velvet performance, does not take place Texturized.
According to the present invention, short type or the non-textle layers of elongated fine hair shape are bonded in the basic unit of a woven fabric or an adhesive-bonded fabric, in the non-textle layers of above-mentioned fine hair shape, be uniform-distribution with low-melting fiber, then through after implanting fine hair, carrying out thermosetting handles, thereby can improve the dimensional stability of mat significantly, cut velvet performance and pattern expression effect.
Claims (5)
1. dust-proof cushion, comprise a base fabric, be implanted in the fine hair on base fabric one surface, and the elastic bottom plate that is attached to the non-matte of base fabric, wherein, base fabric comprises the basic unit of a woven fabric or adhesive-bonded fabric, be bonded in fine hair shape non-textile fiber layer in the basic unit with one deck, it is 5～50% low-melting fiber that above-mentioned fine hair shape non-textile fiber layer contains percentage by weight, after pile yarns are implanted, fine hair shape non-textile fiber layer is carried out thermosetting handle.
2. dust-proof cushion as claimed in claim 1 is characterized in that low-melting fiber comprises low melting point copolymerization of polyester fiber, low melting point copolyamide fiber, or the copolymerization polyolefine fiber.
3. dust-proof cushion as claimed in claim 1 is characterized in that fine hair shape non-textile fiber layer is the fibrage of elongated or short type, is connected in the basic unit by needle point method.
4. dust-proof cushion as claimed in claim 1, the weight that it is characterized in that basic unit is 30～300g/m
2, fine hair shape non-textile fiber layer accounts for 50～90% of substrate weight.
5. method of producing dust-proof cushion comprises:
By adopting needle point method or site thermal bonding, fine hair shape non-textile fiber layer is bonded in the basic unit of a woven fabric or adhesive-bonded fabric, thereby preparation base fabric, above-mentioned villous non-textile fiber layer contains long fibre or short fiber, wherein, being uniform-distribution with percentage by weight in above-mentioned fine hair shape non-textile fiber layer is 5～50% low-melting fiber; Prepare initial fabric by on base fabric, implanting fine hair with taffeta weave or pinhock weave; By initial fabric is heat-treated, the pars fibrosa in fine hair, base fabric and the base fabric is bonded together, so that low-melting fiber fusing or deliquescing; Lint-free surface in initial fabric adds elastic bottom plate.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 95116945 CN1113629C (en) | 1995-09-14 | 1995-09-14 | Dust-control mat having excellent dimensional stability and method of producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN 95116945 CN1113629C (en) | 1995-09-14 | 1995-09-14 | Dust-control mat having excellent dimensional stability and method of producing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1145212A CN1145212A (en) | 1997-03-19 |
| CN1113629C true CN1113629C (en) | 2003-07-09 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN 95116945 Expired - Fee Related CN1113629C (en) | 1995-09-14 | 1995-09-14 | Dust-control mat having excellent dimensional stability and method of producing the same |
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| CN1696375B (en) * | 2004-05-13 | 2011-01-05 | 海南欣龙无纺股份有限公司 | Hyperfine structured base cloth material for imitating real leather |
| CN109402843A (en) * | 2018-11-08 | 2019-03-01 | 阳信诺瑞织品有限公司 | A kind of carpet this bright base fabric of encryption Acker and its production method |
| CN114795025A (en) * | 2022-03-17 | 2022-07-29 | 山东艺成复合材料有限公司 | Super-strong cleaning and decontaminating cleaning cloth for roller brush of cut pile electrical appliance and manufacturing method thereof |
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1995
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