DE102012007294A1 - Fluid-absorbent floor mat installed in foot space of driver or passenger side of motor car, has intermediate layer that is made of absorbent material, and absorber sheets are inserted between base layer and covering layer - Google Patents

Abstract

The fluid-absorbent floor mat has base layer, covering layer and intermediate layer. The intermediate layer is made of interchangeable absorbent material e.g. super absorber. The absorber sheets are inserted between the base layer and covering layer. The mat main portion is provided with slide fastener. The intermediate layer is made of plastic material and absorber sheet is made of super absorber material e.g. super absorber non-woven fabric.

Description

The present invention relates to a liquid-absorbing floor mat for automobiles, comprising a bottom layer, a planar intermediate layer with absorber material and at least one cover layer, wherein the intermediate layer or the part of the intermediate layer comprising the absorber material is exchangeable. The absorber material is preferably superabsorbent material.

Superabsorbent or superabsorber material is known. These are crosslinked hydrophilic polymers, in particular polymers of (co) polymerized hydrophilic monomers, graft (co) polymers of one or more hydrophilic monomers on a suitable graft, crosslinked cellulose or starch ethers, crosslinked carboxymethylcellulose, partially crosslinked polyalkylene oxide or in aqueous Liquid swellable natural products, such as guar derivatives, wherein water-absorbing polymers based on partially neutralized acrylic acid and optionally copolymers based on acrylic acid derivatives are the most widespread. The essential properties of superabsorbents are their ability to absorb many times their own weight in aqueous liquids and also to keep them under a certain pressure. The dry superabsorbent transforms into a hydrogel by the fluid intake. Superabsorbents are described in detail in "Modern Superabsorbent Polymer Technology", FL Buchholz and AT. Graham, Wiley-VCH, 1998, pages 69-117 , and this disclosure is also included in the content of this application.

It is known to provide superabsorbents in multi-layered floor mats for taking up liquid in the sanitary and hospital area. However, it is not known to design floor mats with absorber material, in particular superabsorbent material, for the footwell in automobiles and to make the absorber interchangeable.

Object of the present invention is to provide floor mats are available, which are suitable for the footwell in automobiles. Car-floor mats have a special requirement profile, which is fundamentally different from hygiene mats with superabsorbers, as used in the sanitary and hospital sector.

Car mat mats must rest against slipping in the footwell and must not fray or lead to detachment or displacement of the top layer when forces are applied at an acute angle to the surface of the car mat. Incidentally, car mats are expected to fit harmoniously into the interior of the automobile and have a higher quality appearance than simple cellulosic or pulp mats made of cellulose. Incidentally, the car mat should be more than just easy to use. These and other objects, the subject of the present invention solves surprisingly advantageous.

The subject of the present invention is a fluid-absorbing floor mat for the footwell of vehicles according to claim 1. Preferred embodiments are the subject of the dependent claims or described below.

The structure of the doormat is at least 3-ply comprising a bottom layer, an intermediate layer and a cover layer. The bottom layer and parts of the intermediate layer can be designed in one piece, for example by the separator layer forming the separate absorber material, the circumferential integral collar on the bottom layer, which surrounds the absorber material, wherein the top layer rests on the upper edge of the collar. The doormat is intended for the footwell of motor vehicles. The intermediate layer is at least partially formed by an absorber sheet or absorbs absorber material and the absorber sheet or the absorber material is interchangeable inserted between the bottom layer and top layer.

In order to ensure the necessary stability of the doormat, an absorber sheet or several absorber sheets adjacent to each other, in particular without mutual overlap, can be inserted by means of webs. For this purpose, the bottom layer and / or top layer on a flat receiving space for the absorber sheet to the intermediate position towards, for. B. in the form of cassettes. The webs ensure that the cover layer can not slip relative to the bottom layer when lateral forces are exerted on the cover layer. For this purpose, according to one embodiment webs engage from above the top layer and / or below from the bottom layer, for example in the form of a hook-and-loop fastener or by an offset according to the web recess principle, for example in the form of tongue and groove or pin and hole.

The further advantage of such an embodiment is that the inserted absorber sheets can each have a uniform shape, regardless of the shape of the doormat, ie whether it is z. B. is the passenger side or the driver's side. Particularly preferably, the recordings / cassettes each have the same size. In this way it is possible to provide the absorber sheets only in patches of uniform dimension. The user can then go to z. B. rectangular pieces of the same size (size and thickness) and engage in floor mats the passenger side, driver side or rear seat at the same time and then only needs Purchase and store absorbent panels of uniform size. This is also advantageous because depending on the frequency of occupation of the motor vehicle with occupants, the floor mats absorb water at different speeds.

The at least one arranged in the doormat superabsorbent sheet has the sum of a water absorption capacity of z. B. 1 to 10 liters of water.

In particular, the doormat has a size which corresponds with respect to the outer border with a conventional standard car mat of a certain type of vehicle, especially for driver and passenger side, and is placed on this or used instead. But it is also possible that a smaller format is selected that can be used simultaneously on the driver's and passenger's side and can also be used independently of the vehicle type.

The soil layer may be provided with spikes or a rubberized surface for better adhesion to the support surface or cooperate with the respective standard retaining devices of a motor vehicle.

In the front area of the driver, which extends around the pedals around the doormat may have no absorber sheet as an intermediate layer. The doormat has this on the driver's side in the front area (under the pedals) no absorber and is not hollow there. This applies to the driver and passenger side, which also means on the passenger side of the far away from the passenger area, where the footwell already bulges upwards.

Due to its "water-pulling" quality, the foot mat ensures that moisture in the shoes or melting snow and ice is absorbed, which also reduces rising (evaporating) water in the vehicle interior, thus avoiding excessive fogging of the window panes.

The floor mats can be provided as a sales set for the driver and front passenger side at the same time, and additionally extended by two or four floor mats for the rear seat row (s).

The doormat may be formed according to an embodiment as a pocket and record the absorber sheet inside the bag. The pocket then has at least one open or reversibly closable opening through which the superabsorbent sheet (s) is / are introduced and from which it can be removed again through the opening. The reversibly closable opening can, for. B. be realized by a Velcro, a zipper or on the tongue and groove principle. Preferably, the cover and bottom layer is permanently connected only on one side or corner and can be opened along an edge. The pocket then has an open or reversibly closable opening. Cover layer and bottom layer can be sewn together outside the opening, glued, pressed and / or interlinked. At least the cover layer is water permeable, z. B. by perforation or as a grid, possibly also the bottom layer.

The doormat may be formed according to another embodiment as a trough with an on-grid. The grid then forms the cover layer or a part thereof. The trough bottom is the bottom layer, while the trough walls together with the introduced absorber material form the intermediate layer.

• • Schlingenware Polypropylen, Rückseite Latex oder synthetische Jute
• • PVC
• • ein Teppich mit Hochfrequenzmaschine gewebt
• • Nadelfilz gerippt 100% Polypropylen (PP)
• • Nadelfilz Rippe 100% PP, Rückseite Gummigranulat beschichtet
• • Nadelfilz Velourd 100% PP, Rückseite Gummigranulat beschichtet
• • Nadelfilz Velours 60% Polyester, 40% PP, Rückseite thermoplastisches Elastomere, spikesbeschichtet
• • Nadelfilz Velours 60% PES, 40% PP, Rückseite PVC Spikes beschichtet
• • Nadelfilz Velours 100% PES, Rückseite PVC Spikes beschichtet
• • Lage aus Jutefasern.

Suitable materials for cover layer and / or bottom layer are

• • Polypropylene sling, latex latex or synthetic jute
• • PVC
• • woven a carpet with high-frequency machine
• • Needle felt ribbed 100% polypropylene (PP)
• • Needle felt rib 100% PP, back coated with rubber granules
• • Needle felt Velourd 100% PP, back rubber granules coated
• • Needle felt velor 60% polyester, 40% PP, backside thermoplastic elastomers, spike-coated
• • Needle felt velor 60% PES, 40% PP, backside coated PVC spikes
• • Needle felt velor 100% PES, back coated with PVC spikes
• • Layer of jute fibers.

The cover layer can thus z. As a needle felt, a velor or 100% PP. The back of the cover layer may be coated with rubber granules. Particularly preferred is a plastic top and bottom layer.

The absorber material or the absorber sheet is in particular a superabsorbent material or superabsorbent sheet. Other absorber materials are silica gel and / or clay minerals that can absorb a great deal of moisture through the porous structure, such as bentonite and sepiolite. On the other hand, it is also possible to use wood in the form of wood fibers or wood pellets or cellulose, such as shredded recycled paper chips pressed into pellets.

By using biodegradable absorbers and especially superabsorbents, the absorber sheet is biodegradable.

The superabsorbent may be incorporated in various forms in the superabsorbent sheet as an intermediate layer, e.g. B. loosely introduced between at least two surface materials as a top and bottom layer, the superabsorbent sheet has the function of a flat bag with at least one moisture-permeable layer. The superabsorbent can be distributed in a fiber composite in particle form or be polymerized as a layer on a sheet.

The superabsorbent sheet is preferably formed by a superabsorbent nonwoven as a single or multi-layer mat. In superabsorbent nonwovens, the superabsorber is introduced onto or into the nonwoven, it is produced, for example, by polymerization of a corresponding monomer solution or suspension applied to the nonwoven fabric or introduced as a finished powdered or fibrous superabsorber in the production of the nonwoven fabric or fixed to it with a binder.

• a) mindestens ein ethylenisch ungesättigtes, mindestens eine Säuregruppe tragendes Monomer, das wahlweise zumindest teilweise neutralisiert ist;
• b) mindestens einen Vernetzer;
• c) mindestens einen Initiator;
• d) wahlweise ein oder mehrere mit den unter a) genannten Monomeren copolymerisierbare ethylenisch ungesättigte Monomere;
• e) wahlweise ein oder mehrere wasserlösliche Polymere;
• f) ggf. mindestens ein Lösungsmittel; und
• g) wahlweise weitere Zusätze und/oder Hilfsstoffe.

The process for producing superabsorbents comprises the reaction of:

• a) at least one ethylenically unsaturated, at least one acid group-carrying monomer which is optionally at least partially neutralized;
• b) at least one crosslinker;
• c) at least one initiator;
• d) optionally one or more ethylenically unsaturated monomers copolymerizable with the monomers mentioned under a);
• e) optionally one or more water-soluble polymers;
• f) optionally at least one solvent; and
• g) optionally further additives and / or auxiliaries.

Suitable monomers a) are, for example, ethylenically unsaturated carboxylic acids, such as acrylic acid, methacrylic acid and itaconic acid. Particularly preferred monomers are acrylic acid and methacrylic acid. Very particular preference is given to acrylic acid. Further suitable monomers a) are, for example, ethylenically unsaturated sulfonic acids, such as styrenesulfonic acid and 2-acrylamido-2-methylpropanesulfonic acid (AMPS). Preferably, the monomer is partially neutralized. The degree of neutralization of the monomer is preferably at least 25 mol%, more preferably at least 50 mol% and more preferably at least 60 mol%, and generally at most 95 mol%, preferably at most 80 mol%, and most preferably at most 75 mol%, wherein the usual neutralizing agents can be used, preferably alkali metal hydroxides, alkali metal oxides, alkali metal carbonates or alkali metal bicarbonates and mixtures thereof. Instead of alkali metal salts and ammonium salts can be used. Sodium and potassium are particularly preferred as alkali metals, but most preferred are sodium hydroxide, sodium carbonate or sodium bicarbonate and mixtures thereof. The monomer solution preferably contains a stabilizer against undesirable early polymerization.

Suitable crosslinkers b) are compounds having at least two groups suitable for crosslinking. Such groups are, for example, ethylenically unsaturated groups which can be radically copolymerized into the polymer chain, and functional groups which can form bonds with the acid groups of the monomer. The crosslinkers b) are preferably compounds having at least two polymerisable groups which can be copolymerized into the polymer network in a free-radical manner.

Suitable crosslinkers b) are, for example, ethylene glycol dimethacrylate, diethylene glycol diacrylate, polyethylene glycol diacrylate, allyl methacrylate, trimethylolpropane triacrylate, triallylamine, tetraallylammonium chloride, tetraallyloxyethane, di- and triacrylates, mixed acrylates which, in addition to acrylate groups, contain further ethylenically unsaturated groups.

As initiators c) it is possible to use all compounds which generate free radicals under the polymerization conditions, for example thermal initiators, redox initiators or photoinitiators. Suitable redox initiators are sodium peroxodisulfate / ascorbic acid, hydrogen peroxide / ascorbic acid, sodium peroxodisulfate / sodium bisulfite and hydrogen peroxide / sodium bisulfite. Often mixtures of thermal initiators and redox initiators are used, such as sodium peroxodisulfate / hydrogen peroxide / ascorbic acid.

As water-soluble polymers e) it is possible to use polyvinyl alcohol, polyvinylpyrrolidone, starch, starch derivatives, modified cellulose, such as methylcellulose or hydroxyethylcellulose, gelatin, polyglycols or polyacrylic acids, preferably starch, starch derivatives and modified cellulose.

Any solvent or solvent mixture can be used which allows satisfactory application of the monomer solution to the web. Mostly and preferably, water is used. The water content of the monomer solution is generally at least 40% by weight, and generally at most 75% by weight. If the monomer solution is applied by spraying on the nonwoven, the amount of water is adjusted so that a good sprayable solution is obtained. Optionally, this can also be achieved by using thickeners.

To produce the superabsorber fleece, the monomer solution is first applied to the carrier material. The monomer solution is typically applied in amounts such that a final superabsorbent content after final drying of generally at least 20 g / m ^2, preferably at least 40 g / m ² and more preferably at least 40 g / m ² and generally at most 700 g / m ² preferably at most 500 g / m ² and in a particularly preferred form at most 400 g / m ^{2 is} achieved. Preferably is sprayed. After application of the monomer solution to the support material, it is subjected to conditions in which the monomers polymerize.

For example, depending on the initiator contained in the monomer solution, these conditions include the action of heat, ultraviolet rays, electron beams or their combination on the foam charged with the monomer solution. The polymerization may be carried out batchwise or continuously, for example by passing the carrier material charged with monomer solution through irradiation or heating sections on a conveyor belt. The thermal polymerization is typically carried out in a temperature range from 20 ° C to 150 ° C, and preferably from 40 ° C to 100 ° C. The polymerization time depends on the polymerization temperature, but is typically in the range of a few seconds to 2 hours, and preferably in the range of several seconds to 10 minutes. Upon initiation of polymerization by ultraviolet radiation, irradiation is carried out conventionally using conventional UV lamps.

If desired, the superabsorbent fleece can be aftertreated. Examples of possible post-treatments are the application of plasticizers, surfactants, other textile auxiliaries, the setting of a desired moisture content or the post-crosslinking of the superabsorbent. Suitable surface postcrosslinkers are compounds containing groups that can form covalent bonds with at least two carboxylate groups of the polymer particles. Suitable compounds are, for example, polyfunctional amines, polyfunctional amidoamines, polyfunctional epoxides. Preferred postcrosslinkers are ethylene carbonate, ethylene glycol diglycidyl ether, reaction products of polyamides with epichlorohydrin and mixtures of propylene glycol and 1,4-butanediol.

The superabsorbent web may optionally be laminated with one or more further layers of textile or non-textile fabrics to moisture-regulating composites or textiles. Examples of such further layers are foams, upholstery, nonwovens, woven fabrics, knitted fabrics, knitted or other sheet-like plastic structures. The lamination is done in the usual way. For the production of the desired cohesive connection, for example, is glued surface or with an adhesive network or by melting, welding (such as thermal or ultrasound) connected by fibers. However, it is also possible to laminate the layers by sewing or quilting. By "composite" is meant a multilayer sheet. Most composites are two- or three-ply, but depending on the application or desired properties, additional layers may be added.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited non-patent literature

• "Modern Superabsorbent Polymer Technology", FL Buchholz and AT. Graham, Wiley-VCH, 1998, pages 69 to 117 [0002]

Claims (13)

A liquid-absorbing footmat for the footwell of automobiles, comprising a bottom layer, a planar intermediate layer and at least one cover layer, wherein the intermediate layer comprises an absorber material and the absorber material is exchangeable. Floor mat according to claim 1, wherein the absorber material is in the form of one or more absorber sheets and interchangeably inserted between the bottom layer and the top layer. Floor mat according to claim 1 or 2, wherein between the bottom layer and top layer in or as part of the intermediate layer, a flat receiving space for the superabsorber material or the superabsorbent sheet is formed, for. B. in the form of cassettes. Floor mat according to one or more of the preceding claims, wherein a plurality of absorber sheets are inserted side by side without mutual overlap in the intermediate layer and these are separated by webs from each other. Floor mat according to claim 4, wherein the webs from above from the cover layer and / or below from the bottom layer as part of the intermediate layer interlock, in particular in the form of a hook and loop fastener, an offset according to the web-recess principle, and / or in the form of groove and pen or pen and hole. Floor mat according to one or more of the preceding claims, wherein the plurality of absorber sheets each have a uniform shape, regardless of the shape of the doormat. Doormat according to one or more of the preceding claims, wherein the doormat is designed as a pocket with a flat cavity or surface cavities, filled by the absorber material or Absorberflächengebilde, and has at least one open or reversibly closable opening through which the absorber material or absorber sheet and introduced can be exchanged. Doormat according to claim 7, wherein the doormat has a reversibly closable opening, in particular a Velcro fastener, a zipper or is realized by the tongue and groove principle or pin and hole. Floor mat according to one or more of the preceding claims, wherein the top and bottom layer, possibly over the intermediate layer, are permanently connected only on one side or corner and are folded along an edge. Floor mat according to one or more of the preceding claims, wherein the cover and bottom layer and intermediate layer is a trough with grid. Floor mat according to one or more of the preceding claims, wherein the cover and bottom layer and possibly also the intermediate layer consist of a plastic material. Floor mat according to one or more of the preceding claims, wherein the cover layer has a plurality of openings and in particular has a grid structure. Floor mat according to one or more of the preceding claims, wherein the absorber material or absorber sheet is superabsorbent material or a Superabsorberflächengebilde, in particular a superabsorbent nonwoven.