JP2000282339A - Water-absorbing mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a water-absorbing mat resistant to the lowering of the water-absorbing performance and dust-removing performance and keeping the appearance after the repeated application of external force by stamping. SOLUTION: The objective water-absorbing mat is composed of pile yarns tufted to a base cloth and at least a part of the pile shape is cut pile. The pile yarn to be used in the above mat is produced by twisting a pile stock yarn 1 composed of a water-absorbing fiber and a single nylon monofilament yarn 2 as the first twist, twisting a pair of the above first-twist yarns 3 and a single fusing yarn 4 placed between the first-twist yarns as the final twist and melting the fusing yarn 4 to bond the first-twist yarns 3 with each other.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat used mainly for absorbing water.

[0002]

2. Description of the Related Art Generally, the following structure is considered as a mechanism having high water absorption in a mat. The surface of the substance constituting each fiber is hydrophilic and has a structure that is easily wetted by contact with water. The internal structure of each fiber is a structure that easily absorbs water. Each fiber must be as thin as possible, and the surface tension between fibers must be strong. The structure must have a lot of space inside as a thread.

[0003] (i) a yarn obtained by twisting cotton or rayon;
i) Threads obtained by subjecting a single thread, such as polyester, acrylic, or nylon, having a fineness of 1.0 to 3.0 denier to a surface hydrophilic treatment, are often used. In addition, as a single fiber shape, to increase the space inside the yarn,
The spun type is most often used, and a filament yarn obtained by previously imparting crimpability to a synthetic fiber may be used. From the viewpoint of raw material cost and performance, cotton is the best, and is used as a main component.

[0004]

The mat using the pile yarn having the above-mentioned structure has the following features (1) and (2) in a situation where a large number of people walk and the external force due to stepping is repeatedly applied. Because of such a problem, it was unsuitable for long-term use. (1) The ability to remove water and earth and sand and to retain water tended to decrease. This is considered for the following reason. That is, (i) since the pile yarn is formed of a thin denier yarn and has low elasticity recovery, the height of the three-dimensional structure of the entire mat is reduced by the external force due to stepping. (ii) The space volume between the pile yarns and the space volume inside the pile yarns are reduced by the external force caused by stepping on the pile yarns. (2) Since the space volume between the pile yarns and the space volume inside the pile yarns are reduced by the external force caused by stepping on the pile yarns, it becomes difficult for soil to enter between the pile yarns or into the pile yarns. The probability of adhering to the surface is increased and the mat appearance is impaired.

Incidentally, Utility Model Registration Publication No. 25764.
No. 33 discloses a pile yarn obtained by bonding a plastic monofilament and a water-absorbing multifilament. However, in this pile yarn, since the monofilament is continuously adhered to the water-absorbent multifilament in the longitudinal direction, the entire pile yarn has a smaller elastic recovery force than the monofilament, and the fusion yarn and the water-absorbent multifilament have a smaller elastic recovery force. It was significantly affected by the physical properties of the filament and lost the physical properties of the monofilament. Therefore, in the mat using the pile yarn, the elastic recovery force and the water absorption performance were insufficient.

SUMMARY OF THE INVENTION An object of the present invention is to provide a water-absorbing mat in which the water-absorbing performance and dust-removing performance do not decrease and the appearance is not impaired even when an external force due to stepping is repeatedly applied.

[0007]

According to the first aspect of the present invention,
In a mat, in which a pile yarn is tufted to a base fabric and all or a part of the pile shape is a cut pile, at least one pile raw yarn made of water-absorbing fiber and at least one monofilament yarn are twisted. The plurality of lower twisted yarns and at least one fusion yarn are firstly twisted, and the fusion yarns are melted to bond the lower twisted yarns to each other, wherein the yarn is used as the pile yarn. It is a water absorption mat.

According to a second aspect of the present invention, in the first aspect of the present invention, at least one pile raw yarn and one monofilament yarn are sub-twisted, and the two sub-twisted yarns are interposed therebetween. Is twisted with the single spliced yarn, and the spliced yarn is melted and the lower twisted yarns are adhered to each other.

According to a third aspect of the present invention, in the first aspect of the present invention, the monofilament yarn is of a polyamide type.

According to a fourth aspect of the present invention, in the first aspect of the present invention, the melting point of the fused yarn is 90 ° C. or more.

According to a fifth aspect of the present invention, in the first aspect of the invention, the pile yarn is made of cotton and rayon.
It is contained in a proportion of 0% by weight or more.

The water-absorbing fibers that constitute the pile yarn include:
Cotton, rayon, vinylon, polyester, polypropylene, polyamide, acrylic and the like are used. The thickness is preferably from 0.1 to 10 denier. The number of the water-absorbing fibers used is the number required to obtain the required thickness as the pile yarn. When higher water absorption is required, cotton and rayon are preferable. If the content ratio of cotton and rayon in the pile yarn is less than 20% by weight, it becomes difficult to obtain high water absorption.

The water-absorbing fibers may be colored by a known method. In this case, from the viewpoints of washing durability, abrasion resistance, weather resistance and the like, it is preferable to use a known stock solution coloring method in which a fiber solution in which a pigment is dispersed is spun. The undiluted colored yarn may be used alone, or may be mixed with another type of white yarn so as to exhibit an arbitrary color.

The pile raw yarn may be either a spun type or a filament type. In the case of using a span type, usually, twisting is performed during spinning.

As the material of the monofilament yarn, polypropylene, polyamide, polyester and the like are used. The thickness of the single yarn is preferably 40 to 500 denier.
00-400 denier is preferred. From the viewpoint of elastic recovery force, polyamide is preferred.

As the fused yarn, a known polypropylene, polyamide, polyester or the like is used.
Since the fused yarn is exposed to heat and pressure in the subsequent process for performing thermal bonding and vulcanization of the rubber constituting the mat base material, the piled yarn is not adversely affected under such conditions. It is preferable to set the melting point. Specifically, since the thermal bonding and vulcanization of rubber are usually performed at 140 ° C. or higher, the melting point of the fused yarn is preferably 90 ° C. or higher.

A preferred pile yarn is obtained as follows. FIG. 1 shows one process. That is, first, the pile raw yarn 1 including a number of water-absorbing fibers is prepared. In the case of the span type, twisting is performed in one direction during spinning. Next, one pile original yarn 1 and one monofilament yarn 2 are combined and twisted to produce a twisted yarn 3.
The direction of the lower twist is opposite to the direction of the twist in the case of the span type. Next, the two twisted yarns 3 and the single fused yarn 4 disposed therebetween are twisted together to produce a twisted yarn. Then, the twisted yarn is heat-set to melt the fused yarn.

The heat setting may be performed with either dry heat or wet heat as long as the temperature is equal to or higher than the temperature at which the fused yarn is melted. For more stable processing, moist heat is preferable, and the condition is preferably 90 to 150 ° C. for 1 to 30 minutes.

In the mat of the present invention, since the monofilament yarn is located on the outer peripheral surface of the pile yarn composed of the water-absorbing fiber, the internal space of the pile yarn is maintained by the monofilament yarn. Therefore, even when an external force due to stepping is repeatedly applied, the internal space of the pile yarn is maintained for a long period of time, and the water absorption performance and the dust removal performance do not decrease.

In addition, since the monofilament yarn has a spiral shape, it exhibits a spring action. Therefore, even if the pile yarn is compressed by repeatedly applying an external force due to stepping, the monofilament yarn promotes the elastic recovery force of the pile yarn and further works to expand the internal space of the pile original yarn. Accordingly, the ability of the pile yarn to retain water and dust increases.

The monofilament yarn is partially adhered to the pile yarn in accordance with the number of twists. Therefore, the physical properties of the monofilament yarn are hardly hindered by the fusion yarn or the pile original yarn. Therefore, the action of the monofilament yarn described above is effectively exhibited.

Further, in the pile yarn, the adhesion between the monofilament yarn and the monofilament yarn, the adhesion between the monofilament yarn and the pile yarn, and the adhesion between the pile yarn and the pile yarn are all performed uniformly. Therefore, the adhesive force of the entire pile yarn becomes stable and strong.

Further, since the pile yarn is surrounded by the monofilament yarn on the outer periphery and the entire pile yarn has a uniform adhesive structure, the pile yarn is of a spun type or a filament type. Both can be used.

[0024]

(Embodiment 1) First, a pile raw yarn having a thickness of 1100 denier was produced by twisting in one direction at 320 times / m with the materials and mixing ratios shown in Table 1.

[0025]

[Table 1]

Next, by combining the two pile yarns and one polyamide monofilament having a thickness of 300 denier, the twist direction at the time of spinning of the pile yarn is reduced by 20 mm.
By performing 0 times / m lower twist, a lower twist yarn was produced.

Next, two ply-twisted yarns and one having a melting point of 130 ° C.
The polyamide-based fused yarn was combined and twisted at 100 times / m to produce a twisted yarn. At this time, the fused yarn was subjected to the upper twist while being arranged between the two lower twist yarns.

Then, the twisted yarn is humidified by a humidifying heater.
Heat set at 130 ° C. for 1 minute. Thus, a pile yarn was obtained.

Next, this pile yarn was tufted under the following conditions to prepare a raw mat. Base fabric: Polyester non-woven fabric: 120 g / m ² Tuft density: Gauge direction: 8 cores / inch Stitch direction: 7 cores / inch Pile length: High cut: 11 mm (50%) Low loop: 5 mm (50%) Pile weight: 950 g / m ²

Then, the original mat is 90 cm × 75 cm.
, And the following rubber sheet was bonded thereto under the following conditions to prepare a mat in which a mat substrate was bonded to a raw mat. Rubber sheet: unvulcanized NBR rubber (containing vulcanizing agent),
1.5 mm thickness Pressing condition: 3 kg / cm ² Heating condition: 170 ° C x 12 minutes

Comparative Example 1 A mat was prepared in the same manner as in Example 1 except that the polyamide monofilament and the polyamide-based fused yarn were not used.

(Performance Test) The mat of the first embodiment
Used repeatedly for cycles. In addition, one cycle was a process of laying at a place where the number of people passing by 2000 / day for 5 days, and then collecting and performing a washing process and a drying process. Comparative form 1
Mat was also used. Washing and drying
It was as follows.

Then, after confirming the appearance after use of the mats of Embodiment 1 and Comparative Embodiment 1, water retention performance, dust removal performance, and water removal performance were examined. The mat area used for the performance evaluation was 260 cm ² .

With respect to the mat of Embodiment 1, no change in appearance was observed. That is, the deformation and opening of the pile yarn, the falling off and peeling of the monofilament, and the like were not recognized, and the pile yarn was supported by the monofilament at the center and maintained a napped feeling. However, in the mat of Comparative Example 1, the pile yarn was shrunk due to repeated washing and drying, and the single fibers of the pile yarn were entangled with each other, and a decrease in the thickness direction of the pile yarn was observed.

The water retention performance was evaluated by applying water to the mat and examining how much the applied water adheres to the shoes per step. As shown in Table 2 and FIG. 2, in both the mats of Embodiment 1 and Comparative Embodiment 1, as the amount of water applied to the mat increases, the amount of adhesion to shoes increases. Compared to the mat of the form 1, the amount of adhesion to the shoes was considerably smaller. That is, the mat of Embodiment 1 can maintain a space holding a large amount of moisture between the pile yarns by the elastic recovery force of the pile yarn itself, and has a higher water retention performance than the mat of Comparative Embodiment 1. It was good.

[0036]

[Table 2]

The dust removal performance was evaluated by examining how much dust was removed from shoes according to the number of steps. As shown in Table 3 and FIG. 3, in both the mats of Embodiment 1 and Comparative Embodiment 1, the dust removal amount increases as the number of steps increases, but the mat of Embodiment 1 differs from that of Comparative Embodiment 1.
The amount of dust removed was considerably higher than that of the mat. That is, even when the pile yarn is compressed by the repeated application of the external force due to stepping, the space of the pile yarn does not decrease, and the mat of the first embodiment has a good dust removal performance as compared with the mat of the first embodiment. Was.

[0038]

[Table 3]

The water removal performance was evaluated by examining how much water was removed from the shoes according to the number of steps. Table 4
As shown in FIG. 4 and FIG. 4, in both the mats of Embodiment 1 and Comparative Embodiment 1, the amount of water removed increases as the number of steps increases, but the mat of Embodiment 1 has a higher water removal rate than the mat of Comparative Embodiment 1. The removal amount was quite large. That is, the mat of Embodiment 1 can maintain a space holding a large amount of moisture between the pile yarns, and the pile yarn space does not decrease even if the pile yarn is compressed by repeatedly applying an external force due to stepping. The water removal performance was better than that of the mat of Comparative Example 1.

[0040]

[Table 4]

In the first embodiment, two pile yarns and one nylon monofilament yarn are used. However, one or three or more pile yarns may be used. And two or more of them may be used.

[0042]

According to the water-absorbing mat according to the first or second aspect, it is possible to prevent the water-absorbing performance and dust-removing performance from deteriorating even when an external force due to stepping is repeatedly applied.
The appearance can be prevented from being impaired.

According to the water absorbing mat of the third aspect, the elastic recovery force of the pile yarn can be particularly promoted.

According to the water-absorbing mat of the present invention, the pile yarn has no adverse effect even under the heat and pressure conditions for performing the thermal bonding and vulcanization of the rubber constituting the mat base material. .

According to the water-absorbing mat of the fifth aspect, higher water-absorbing properties can be obtained.

[Brief description of the drawings]

FIG. 1 is a partial view showing one manufacturing process of a pile yarn used for a mat of the present invention.

FIG. 2 is a diagram showing the water retention performance of the mats of Embodiment 1 and Comparative Embodiment 1.

FIG. 3 is a diagram showing dust removal performance of the mats of Embodiment 1 and Comparative Embodiment 1.

FIG. 4 is a view showing the water removal performance of the mats of Embodiment 1 and Comparative Embodiment 1.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Pile original yarn 2 Nylon monofilament yarn 3 Under twist yarn 4 Fused yarn

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) D03D 27/00 D03D 27/00 A (72) Inventor Yoshihisa Fujiwara 1-33 Toyotsu-cho, Suita-shi, Osaka Stock (72) Inventor Seiji Ochi 1-33, Toyotsu-cho, Suita-shi, Osaka F-term in Daskin Co., Ltd. UA25 4L048 AA08 AA13 AA20 AA24 AA34 AB10 AB12 AB20 AC12 AC15 BA30 CA07 DA15

Claims (5)

[Claims] 1. A mat in which a pile yarn is tufted on a base fabric and a whole or a part of the pile shape is a cut pile, wherein at least one pile original yarn and at least one monofilament yarn made of water-absorbing fibers are provided. Is ply-twisted, and the plurality of ply-twisted yarns and at least one fused yarn are ply-twisted,
A water-absorbent mat, wherein the yarn obtained by fusing the fused yarn and bonding the twisted yarns together is used as the pile yarn. 2. The yarn according to claim 1, wherein at least one pile yarn and one monofilament yarn are under-twisted, and two of the under-twisted yarns and one of the fused yarns disposed therebetween are over-twisted. 2. The water-absorbing mat according to claim 1, wherein the fused yarn is melted and the twisted yarns are bonded to each other. 3. The water-absorbent mat according to claim 1, wherein the monofilament yarn is of a polyamide type. 4. The water-absorbent mat according to claim 1, wherein the fusion yarn has a melting point of 90 ° C. or more. 5. The water-absorbent mat according to claim 1, wherein the pile raw yarn contains cotton and rayon in a proportion of 20% by weight or more.