CN1767783A - 控尘垫 - Google Patents

控尘垫 Download PDF

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Publication number
CN1767783A
CN1767783A CNA2004800089363A CN200480008936A CN1767783A CN 1767783 A CN1767783 A CN 1767783A CN A2004800089363 A CNA2004800089363 A CN A2004800089363A CN 200480008936 A CN200480008936 A CN 200480008936A CN 1767783 A CN1767783 A CN 1767783A
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Prior art keywords
dust control
tissue layer
control mat
mat
layer
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T·M·赫德利
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Milliken Industrials Ltd
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Milliken Industrials Ltd
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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47L—DOMESTIC WASHING OR CLEANING; SUCTION CLEANERS IN GENERAL
    • A47L23/00—Cleaning footwear
    • A47L23/22—Devices or implements resting on the floor for removing mud, dirt, or dust from footwear
    • A47L23/26—Mats or gratings combined with brushes ; Mats
    • A47L23/266—Mats
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/026—Knitted fabric
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    • B32B25/10—Layered products comprising a layer of natural or synthetic rubber next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B25/14—Layered products comprising a layer of natural or synthetic rubber comprising synthetic rubber copolymers
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D—TEXTILES; PAPER
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    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
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    • B32B2471/04—Mats
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    • D06N2203/02—Natural macromolecular compounds or derivatives thereof
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  • Carpets (AREA)
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  • Filtering Of Dispersed Particles In Gases (AREA)
  • Laminated Bodies (AREA)
  • Woven Fabrics (AREA)

Abstract

本发明提供一种可洗涤的地板垫，其具有纺织层(1)和背衬层(2)。该纺织层(1)包括隔离织物，该隔离织物具有第一织物层(3)、第二织物层(4)、以及将第一和第二织物层连接并隔开的中间绒毛层(5)。

Description

控尘垫
技术领域
本发明涉及一种控尘垫，特别是涉及具有高粉尘容量的控尘垫。本发明还涉及制造该控尘垫的方法。
背景技术
控尘垫通常放置在商店、办公室和工厂的入口，以除去进入建筑物的行人脚上的粉尘和水分。我们用术语“粉尘”指各种固体颗粒污物，包括沙子、砂粒和其它污垢。
普通的控尘垫包括具有良好的吸湿和吸尘性能的簇绒纺织顶面，其粘合在硫化橡胶背衬层上。可以使用各种不同的织物材料，包括例如高捻度尼龙的合成材料和例如棉的天然纤维。这些纺织品具有不同的性能特征。例如，尼龙垫具有很好的控尘性能并且耐磨，但是它们没有很好的吸湿性能。另一方面，棉垫具有很好的吸湿性能，但是控尘性能较次，并且倾向于不如尼龙垫耐用。两种类型的垫子均仅具有有限的粉尘容量(即它们仅能够吸收有限量的粉尘)并且因此必须对其定期清洗。
上述类型的控尘垫通常可以通过在水中浸泡和搅动来清洗。许多这样的垫子用于工业和租用市场部门。这些垫子倾向于由洗衣店持有，洗衣店把垫子租给其客户，并定期用干净的垫子更换脏垫子，将脏垫子返回洗衣店进行清洗。相同类型的一些垫子也用于商业和零售部门，在这种情况下通常是终端用户持有垫子。由于持有者通常没有适当的洗涤设备，这些垫子经常得不到定期清洗。
当控尘垫用于较多尘的或肮脏的环境时，它可能很快便被粉尘弄得非常脏，因此降低了其效用并不利地影响其外观。对于用于工业和租用市场部门的垫子，这导致了高的清洗费用，而对于用于商业和零售部门的垫子，则可能很少或从来没有彻底的清洗。因此需要一种具有高粉尘容量并相对易于清洗的垫子。
控尘垫有时可以带有标识或图像。通过镶嵌不同颜色的簇绒材料而形成织物表面，可以制成简单的标识。另外可选地，通过在织物表面上印花可以将更为复杂的图案或图像应用于垫子。但是，由于簇绒能够在印花期间及之后移动，印花图像的可见分辨率很低。实际上，可以达到的最大可见分辨率不超过约20dpi(点/英寸)。因此可以印在垫子上的图像限于相对简单的图案和标识。
已知制造一种地板垫，其表面能够带有较高分辨率的图像，例如摄影图像或广告信息。这样的垫子有时称为招贴垫或广告垫。由于较长的绒毛不能支持高可见分辨率的图像，这些垫子的织物表面通常没有绒毛或仅有很短的绒毛。因此，它们通常具有较差的控尘性能。因此还需要一种能够支持高分辨率图像(例如可见分辨率为75dpi或更高)并且具有良好控尘性能的垫子。
还已知提供一种高弹性抗疲劳垫，以供必须在一个位置长期站立的劳动者使用。这样的垫子通常加入泡沫橡胶以提供必要的弹性。WO01/74206中描述了一个例子。
发明内容
本发明提供了一种具有纺织层和背衬层的控尘垫，其中纺织层包括隔离织物，其具有形成垫子上表面的第一织物层、形成纺织层下表面的第二织物层、以及将第一和第二织物层连接并隔开的中间绒毛层。
隔离织物是三维织物，其厚度典型地为2到20mm，包括两个平面底织物层和将两个底织物层连接并隔开的中间绒毛层。隔离织物可以在双针床Rachel机上经编制成。中间绒毛层含有弹性绒毛纱，其通常为合成的单丝纤维，基本垂直于织物面在底织物层之间伸展。中间绒毛层在底织物层之间维持着基本均一的间隔，但是具有弹性，使得隔离织物可以被压缩。已知许多类型的隔离织物，US5385036、US2001/11442、US5817391、US6037035和US5896758中描述了一些例子。
我们己发现隔离织物提供了高度有效的控尘纺织物，其具有良好的除尘性能和极大的粉尘容量。因此加入隔离织物的控尘垫特别适用于较多尘的环境。该垫子还可以使用机械干洗方法(例如拍打清洗、真空清洗或干式翻转)很容易地清洗。此外，如果需要洗涤，我们已发现该垫子排水很好，因此可以用最小的翻转或不经翻转而干燥。因此清洗费用很低。
由于隔离织物表面平坦并且基本无绒毛，该垫子还适于印花并能够支持高分辨率的印花图像。因此可能提供具有良好的控尘性能的招贴垫。
该垫子还是高弹性的，提供了良好的抗疲劳性能，因此适于必须在一个位置长期站立的劳动者使用。
有利地，第一织物层包括具有多个孔的网眼，粉尘和污物可以通过这些孔落入纺织层内部。孔的宽度可以为0.5-10mm，优选1-4mm，更优选2-3mm。本文所用的术语“宽度”是指将通过孔的球体的直径。有利地，第一织物层是隔距近似为11的针织物。
第一织物层可以由例如复丝纱制成，优选提供很好的印花表面的聚酯纱，或任何其它合适的纱线。
有利地，第一织物层由100-200分特的纱线制成，优选136-167，更优选近似为150。
第二织物层优选具有基本闭合的结构，其构造比第一织物层更为紧密，从而在将纺织层粘合到背衬层时，防止橡胶或粘合剂进入隔离织物。有利地，第二织物层是隔距近似为22或更高的针织物。
有利地，第二织物层由复丝纱制成，优选聚酯纱。有利地，第二织物层由100-200分特的纱线制成，优选136-167，更优选近似为150。
中间绒毛层的厚度为2-10mm，优选近似为4-6mm，以提供良好的粉尘容量和适当的弹性度。
有利地，中间绒毛层由单丝纱制成，其直径在0.04-3mm范围内，优选0.05-0.3mm，更优选0.1-0.2mm。我们已发现这为地板垫提供了适当的弹性度。
有利地，中间绒毛层由合成的单丝纱制成，优选聚酯纱。
纺织层可以是经编织物，优选Raschel针织物。
有利地，背衬层粘合在第二织物层上。
背衬层可以由橡胶制成，优选丁腈橡胶。这便提供了很好的稳定性并且抵抗垫子的滑动、缓慢移动和卷曲。橡胶背衬层的厚度可以从0.5mm到5mm，优选0.8mm到3mm。橡胶背衬层可以硬化在第二织物层上。
纺织层可以印花，优选用热转移墨印花。我们已发现使用该方法可以将高分辨率的图像转移到垫子上。有利地，纺织层印有可见分辨率至少为75dpi的图像。通常，纺织层具有至少为0.2m2(例如40cm×50cm)的面积，并且优选至少1m2或更大。
本发明另一方面提供了制造控尘垫的方法，该方法包括将背衬层粘合到纺织层上的步骤，该纺织层包括具有第一织物层、第二织物层、以及将第一和第二织物层连接并隔开的中间绒毛层的隔离织物。
隔离织物可以是针织物，优选经编织物，更优选Rachel针织物。有利地，第一织物层包括具有多个孔的网眼，第二织物层具有基本闭合的结构。
橡胶背衬层优选在热压机中硬化到纺织层上。
纺织层有利地用热转移印花法来印花，优选在背衬过程期间。
本发明的另一个方面提供了一种具有纺织层的控尘垫，该纺织层含有隔离织物，该隔离织物具有形成垫子上表面的第一织物层、形成纺织层下表面的第二织物层、以及将第一和第二织物层连接并隔开的中间绒毛层。有利地，第一织物层包括具有多个孔的网眼，粉尘和污物可以通过这些孔落入纺织层内部。
附图说明
现参考所附的附图，通过实施例的方式描述本发明的实施方式，其中：
图1是隔离织物的等角视图。
图2是根据本发明的垫子的等角视图。
图3是搁置于热压机中的垫子组件的侧视图。
具体实施方式
图2所示的垫子包括上面的纺织层1，它粘合在下面的例如硫化丁腈橡胶的背衬层2上。任选地，背衬层可以稍大于纺织层，以提供橡胶边缘(未显示)。垫子的整体大小典型地为85cm×150cm。
独立地示于图1的纺织层1包括三维隔离织物。这样的织物是公知的，例如US5385036、WO96/32526、US5817391和US2001/0011442中描述了一些例子，在此引入其全部内容作为参考。
通过使用例如Raschel型的双针床经编机编织三维隔离织物来编制纺织层1。这便制造了双面隔离织物，其包括用于形成垫子上表面的第一织物层3、形成纺织层下表面并粘合到背衬层2上的第二织物层4、以及将第一和第二织物层3、4彼此连接并隔开的包含弹性绒毛纱的中间绒毛层5。中间层5是弹性的，使得纺织层1在一定程度上可压缩，但是当变形力撤走时便恢复了第一与第二织物层3、4的分隔。
第一织物层3优选具有开放的网眼或类网状结构，具有多个孔6，使得粉尘可以通过该层落入第一与第二层之间的空间。孔6在形状上，例如可以粗略地是正方形的，或者它们可以粗略地是六角形或圆形的，宽度在0.5-10mm范围内，典型地为1-4mm，优选2-3mm。第一织物层3的上表面相对光滑，非常稳定，使得它能够支持高可见分辨率的印花图像。第一织物层可以例如由Raschel经编织物组成，用线圈横列和隔距设置(gauge setting)使得它能够提供相对开放的结构。例如，第一织物层3的构造可以是11隔距下6线圈横列的缎纹织物，由150分特的聚酯复丝纱制成。
第二织物层4优选具有致密的和基本封闭的结构，以提供适于粘合在背衬层2上的粘着基础。在织物层上不应当有任何显著的孔，以避免在背衬过程中任何橡胶、胶或其它粘合物质显著地进入纺织层中。例如，第二织物层4的构造可以是2梳栉，全穿经22隔距，钩编组织，由150分特的聚酯复丝纱制成。
中间绒毛层5可以由单丝纱、复丝纱或者单丝和复丝纱的组合制成。优选地，其由直径为0.1-0.2mm的聚酯或尼龙单丝制成。例如，中间绒毛层的构造可以典型地为半穿经22隔距，单梳栉，5针V，采用0.15mm的单丝。中间层5的厚度通常是2-10mm，典型地是4-6mm。中间层5具有相对开放的结构，以提供大的粉尘容量。
背衬层2由为垫子提供必要稳定性的任何合适材料制成：即，它在行人走在上面时防止垫子的滑动及过多的缓慢移动，并使垫子平放在地板上。优选地，背衬层由厚度为0.5-5mm的丁腈橡胶制成，优选0.8-3mm。背衬层可以由固体或泡沫橡胶制成，或者由粘合的橡胶颗粒薄片制成。另外可选地，它可以由任何其它合适的材料制成，例如PVC或乳胶。
通过将纺织层1粘合在背衬层2上来制造垫子。如果背衬薄片由橡胶制成，可以通过将未硫化的橡胶薄片在热压机中硬化到纺织层上来制造该垫子。在图3所示的方法中，将包括纺织层1和背衬层2的未硫化橡胶薄片的垫子组件搁置在底部释放薄板7上，其由例如PTFE涂层的玻璃织物制成。可以将使用热转移染料印染图像的印花转移薄板8，任选地面向下放置在纺织层1之上。顶部释放薄板9置于垫子组件之上，然后将其置于包括加热的金属压板10和固定在顶板12上的可膨胀隔膜11的压力机中。
将搁置的垫子组件在热压机中压制，例如在170℃温度下和每平方英寸30磅的压力下，应用达到二十分钟的周期时间。来自压力机的热使得橡胶软化并硫化，将其粘合在纺织层1的底面上。同时，如果使用了印花转移薄板，热量使热转移染料汽化，将印花图像转移到纺织层的上表面上。
这个过程一完成，便将垫子从压力机中取出，将释放薄板7、9取出，并且如果必要的话修整背衬层的边缘。任选地，可以将背衬层2打孔，以使得旋转干燥过程中的水通过。
另外可选的制造方法包括用粘合剂将织物层粘合到例如颗粒橡胶或PVC的背衬层上，以及用例如乳胶的合适背衬材料来涂覆纺织品的底面。
我们发现根据本发明的具有由隔离织物制成的纺织层的控尘垫，提供了听得见的刮垢效应，促使人们擦拭他们的脚，并且高度有效地从行人脚上除去粉尘。粉尘透过第一织物层中的孔掉落，保存在中间绒毛层的丝之间。
我们还发现该垫子的粉尘容量比传统的簇绒尼龙控尘垫要高得多。例如，在一个测试中，通过用沙子填充100cm2的样品然后将样品称重，测定垫子的粉尘容量，我们比较了新型垫子与传统簇绒尼龙控尘垫的吸收性。结果如下：
常规簇绒尼龙割绒垫：4.17kg/m2
橡胶背衬上的隔离织物：8.13kg/m2
因此从这个测试中显出新型垫子的粉尘容量是传统簇绒控尘垫的将近2倍。
此外，我们发现该垫子相对易于清洗。垫子中保留的大部分粉尘可以简单地通过拍打、摇动或干燥翻转垫子、或者通过用真空清洗机清洗来除去。如果必要的话，随后可以通过洗涤或应用表面清洁剂来恢复表面外观。如果洗涤了垫子，我们发现它很快且很容易干燥，因此可能避免对翻转干燥的需求，或者至少大大降低了干燥垫子所需要的能量。
我们还发现由于隔离织物的上层稳定且平滑，实际上没有绒毛，第一织物层的上表面能够支持高可见分辨率的图像。
当然可能对本发明进行各种修改，现描述其中的一些修改。
可以使用许多不同类的隔离织物，采用不同的纱线。中间绒毛层可以由例如多种合成的单丝纱制成，包括聚丙烯、聚乙烯、聚酯和聚酰胺纱线。单丝的厚度将取决于垫子要求的厚度：例如厚度为0.05-0.1mm的纱线可以用于厚度为4-5mm的织物。单丝纱可以是同样的材料和厚度，或者在一些情况下，可以使用不同材料和厚度的纱线。另外可选地，可以使用复丝纱或单丝和复丝纱的组合。至少一些做成中间层的纱线可以是弯曲的，以提高纺织品的弹性。
对于隔离织物的第一和第二外层，通常可以采用复丝纱。这些可以是细纱或者例如包芯纱、捻合纱或技术纱的复合纱。可以采用多种天然和合成的材料，包括例如黄麻、棉、聚酯和玻璃。这些纱线并非必须是同样的类型：可以使用各材料和各直径的混合物来提供不同的特征。另外，第一和第二层以及中间层的纱线可以是全部相同的，或全部不同的。
纱线可以是白色的，使得垫子能够进行印花或染色，或者可以使用彩色纱线来制造单色或多色垫子。如果需要印花的垫子，可以通过任何不同的合适印花方法，在将纺织品粘合到背衬层之前、期间或之后进行印花。
在纺织层与背衬层之间可以提供例如编织或非编织聚酯的基底层。可以任选地将纺织层的边缘封口。垫子可以具有橡胶边缘或印花“光学”边缘，或者可以是无边的。垫子可以包括一个或多个其它织物区，例如簇绒织物或针织、编织或非编织织物。纺织品表面的上表面可以是磨光的、拉绒的或起毛的，以修饰它的外观、触感和控尘/湿性能。纺织层可以用亲水剂或去污剂处理。
背衬层可以由固体或泡沫橡胶、颗粒橡胶、PVC、乳胶或任何其它合适的材料制成。另外可选地，可以省去背衬层并通过其它方式将垫子固定在位置上，例如将它附在地板或支撑结构上，或者对于下部的织物层使用涂层纤维。

Claims (29)

1.一种具有纺织层和背衬层的控尘垫，其中所述纺织层包括隔离织物，所述隔离织物具有形成垫子上表面的第一织物层、形成所述纺织层下表面的第二织物层、以及将所述第一和第二织物层连接并隔开的中间绒毛层。
2.根据权利要求1所述的控尘垫，其中所述第一织物层包括具有多个孔的网眼。
3.根据权利要求2所述的控尘垫，其中所述孔的宽度为0.5-10mm，优选1-4mm，更优选2-3mm。
4.根据前述权利要求中的任何一项所述的控尘垫，其中所述第一织物层是隔距近似为11的针织物。
5.根据前述权利要求中的任何一项所述的控尘垫，其中所述第一织物层由复丝纱制成，优选由聚酯纱制成。
6.根据权利要求5所述的控尘垫，其中所述第一织物层由100-200分特的纱线制成，优选136-167，更优选近似为150。
7.根据前述权利要求中的任何一项所述的控尘垫，其中所述第二织物层具有基本闭合的结构。
8.根据前述权利要求中的任何一项所述的控尘垫，其中所述第二织物层是隔距近似为22或更高的针织物。
9.根据前述权利要求中的任何一项所述的控尘垫，其中所述第二织物层由复丝纱制成，优选由聚酯纱制成。
10.根据权利要求9所述的控尘垫，其中所述第二织物层由100-200分特的纱线制成，优选136-167，更优选近似为150。
11.根据前述权利要求中的任何一项所述的控尘垫，其中所述中间绒毛层的厚度为2-10mm，优选近似为4-6mm。
12.根据前述权利要求中的任何一项所述的控尘垫，其中所述中间绒毛层由直径在0.04-3mm范围内的单丝纱制成，优选0.05-0.3mm，更优选0.1-0.2mm。
13.根据前述权利要求中的任何一项所述的控尘垫，其中所述中间绒毛层由合成的单丝纱制成，优选由聚酯纱制成。
14.根据前述权利要求中的任何一项所述的控尘垫，其中所述纺织层是经编织物，优选Raschel编织物。
15.根据前述权利要求中的任何一项所述的控尘垫，其中所述背衬层粘合在所述第二织物层上。
16.根据前述权利要求中的任何一项所述的控尘垫，其中所述背衬层由橡胶制成，优选由丁腈橡胶制成。
17.根据权利要求16所述的控尘垫，其中橡胶背衬层的厚度为0.5mm-5mm，优选0.8mm-3mm。
18.根据权利要求16或权利要求17所述的控尘垫，其中所述橡胶背衬层硫化到所述第二织物层上。
19.根据前述权利要求中的任何一项所述的控尘垫，其中所述纺织层是印花的。
20.根据权利要求19所述的控尘垫，其中所述纺织层印有可见分辨率至少为75dpi的图像。
21.根据前述权利要求中的任何一项所述的控尘垫，其中所述纺织层的面积至少为0.2m2，优选至少为1m2。
22.一种制造控尘垫的方法，所述方法包括将背衬层粘合到纺织层的步骤，所述纺织层包括隔离织物，所述隔离织物具有第一织物层、第二织物层、以及将所述第一和第二织物层连接并隔开的中间绒毛层。
23.根据权利要求22所述的方法，其中所述隔离织物是针织物，优选经编织物，更优选Rachel编织物。
24.根据权利要求22或权利要求23所述的方法，其中所述第一织物层包括具有多个孔的网眼。
25.根据权利要求24所述的方法，其中所述第二织物层具有基本闭合的结构。
26.根据权利要求22-25中的任何一项所述的方法，其中将橡胶背衬层在热压机中硫化到纺织层上。
27.根据权利要求22-26中的任何一项所述的方法，其中所述纺织层使用热转移印花法印花。
28.根据从属于权利要求26的权利要求27所述的方法，其中所述纺织层在背衬过程期间进行印花。
29.一种具有纺织层的控尘垫，所述纺织层包括隔离织物，所述隔离织物具有形成垫子上表面的第一织物层、形成所述纺织层下表面的第二织物层、以及将所述第一和第二织物层连接并隔开的中间绒毛层。
CNA2004800089363A 2003-04-04 2004-03-26 控尘垫 Pending CN1767783A (zh)

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CN102139654B (zh) * 2010-02-02 2013-11-06 通用汽车环球科技运作有限责任公司 地板垫

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ATE341270T1 (de) 2006-10-15
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US20060188689A1 (en) 2006-08-24

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