JP2005261798A - Air permeable and water impermeable mat with slip stopper - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a backing nonwoven fabric for imparting a slip stopping function to a mat, and an air permeable and water impermeable mat with a slip stopper to which the backing nonwoven fabric is joined. <P>SOLUTION: In this air permeable and water impermeable mat, the backing nonwoven fabric 10 is constituted such that latex containing a resin whose glass transition temperature is 0°C at highest and a water repellent resin selected from a fluorine-based resin, a silicon-based resin and a paraffin-based resin is applied by atomization and dried and the resin 2 after being dried is stuck in a granular shape at least on a lower surface. The upper surface of the backing nonwoven fabric 10 is joined to the ground fabric 6 of a carpet 12, and the air permeable and water sealing mat with the slip stopper is constituted. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a backing non-woven fabric for imparting a non-slip function to a mat having air permeability and water impermeability, and further relates to a non-slip vent water-impervious mat to which the backing non-woven fabric is joined.

  Car mats and room mats are required to have heat retention, touch, breathability, water shielding, sound absorption, etc. in order to improve comfort. In particular, automobile mats and the like are required to be lightweight in order to affect the driving fuel consumption of the automobile. Although these characteristics are primarily influenced by the fiber material constituting the mat and are directly linked to the cost, the matte structure can be improved even with a relatively inexpensive synthetic fiber mat.

  Conventionally, as a mat with such a structural contrivance, for example, a fibrous backing formed by a resin component is formed by interposing an adhesive layer on the back side of a fiber base as described in Patent Document 1 Carpets are known. Further, Patent Document 2 discloses an installation mat in which a part of the constituent fibers of a nonwoven fabric invades and entangles with a pile mat base fabric, and the nonwoven fabric is impregnated with a polymer adhesive.

JP 2003-19067 A JP 2003-245186 A

  Patent Document 2 describes that since the nonwoven fabric is impregnated with a polymer adhesive, the laying mat provides an anti-slip effect on the base surface. However, conventional mats do not provide a sufficient anti-slip effect.

  The present invention was made in order to solve the problem that a conventional mat is slippery on the floor, and is provided with a non-slip nonwoven fabric for imparting a non-slip function to the mat, and further with a non-slip to which the non-slip nonwoven fabric is joined. It aims at providing a ventilation impermeable mat.

  In order to achieve the above-mentioned object, the backing nonwoven fabric of the non-slip air-permeable impermeable mat according to claim 1, which is made of a resin having a glass transition temperature of at most 0 ° C. is formed on at least the lower surface. A latex containing a water-repellent resin selected from fluorine-based resin, silicon-based resin and paraffin-based resin is applied by spraying and dried, and the resin after drying is adhered in a granular form.

  In order to spray latex, mist particles adhere to and dry on the lower surface of the nonwoven fabric, and the resin solidifies into granules, forming irregularities on the nonwoven fabric. Moreover, since the glass transition temperature of the granular resin adhering to the lower surface of the nonwoven fabric is low and its hardness is relatively soft, the granular resin has flexibility.

  The non-slip lining nonwoven fabric with a non-skid air-permeable impermeable mat according to claim 2 has a glass transition temperature (Tg.) Of 0 ° C. at the highest in the air-permeable impermeable mat according to claim 1. The resin is an acrylic resin.

  An acrylic resin having a maximum Tg. Of 0 ° C. (low Tg.) Is extremely soft to medium. For example, a homopolymer of ethyl acrylate (Tg. = − 22 ° C.), n-butyl acrylate Homopolymer (Tg. = − 54 to −56 ° C.), homopolymer of isobutyl acrylate (Tg. = − 30 ° C.), homopolymer of 2-ethylhexyl acrylate (Tg. = − 55 to −76 ° C.) It is done.

  Of the water-repellent resins, the fluororesin is particularly preferable because it also exhibits oil repellency.

The nonwoven fabric lining the non-slip air-permeable and water-impermeable mat described in claim 3 is the amount of the latex applied to the air-permeable and water-impermeable mat according to claim 1 in a dry solid content of the resin. It is 5 to 100 g / m ² .

  If the amount of resin applied is less than this, the friction will be insufficient, and the waterproof property will be insufficient.If it is more than this, the cushioning will be poor, the air permeability will be insufficient, and other performance will not be improved and it will be economically wasteful. is there.

  A non-slip lining nonwoven fabric with a non-slip air-permeable impermeable mat described in claim 4 is a resin having a glass transition temperature of 0 ° C at the highest in the latex of the air-permeable impermeable mat according to claim 1. And the weight ratio of the water-repellent resin is 2: 1 to 100: 1.

  If the ratio of the low Tg.resin amount / water-repellent resin amount is smaller than this, the friction is insufficient, and if it is large, the water repellency and eventually the waterproof property is insufficient.

The backing nonwoven fabric of the air-permeable impermeable mat with slip according to claim 5 has a basis weight of 10 to 2000 g / m ² and an apparent thickness of 1 in the air-permeable impermeable mat according to claim 1. It is ˜30 mm.

  If the basis weight is less than this, water shielding and sound absorbing properties will be insufficient. If the weight per unit area and the apparent thickness are larger than this, the air permeability is insufficient, and it is bulky and inconvenient to handle.

  Moreover, in order to achieve the above object, the air-permeable and water-impervious mat with slip according to claim 6 has the upper surface of the backing nonwoven fabric according to any one of claims 1 to 5. It is characterized by being bonded to a carpet base fabric.

  The air-permeable and water-impervious mat with a non-slip according to claim 7 is characterized in that the joining of the carpet base fabric and the nonwoven fabric is needle punching or hot melt using a heat-meltable resin. To do.

  The backing nonwoven fabric of the present invention is non-slip by increasing the friction with the floor surface due to the unevenness and flexibility of the granular resin adhering to the lower surface. Therefore, the non-slip air-permeable and water-impermeable mat of the present invention, to which the backing nonwoven fabric is bonded, can eliminate displacement on the floor surface. The non-skid air-permeable and impermeable mat of the present invention can be used not only for automobile mats and room mats, but also for ordinary applications such as entrance mats, toilet mats, kitchen mats, bath mats, and aircraft mats. Not only water-proof and breathable properties.

  As shown in FIG. 1, the backing nonwoven fabric of the air-permeable and impermeable mat of the present invention has the resin 2 adhered to the lower surface of the nonwoven fabric 1 in a granular form. This backing nonwoven fabric 10 is manufactured as follows.

  A nonwoven fabric 1 is obtained by performing needle punching on a web in which short fibers of predetermined synthetic fibers have a predetermined basis weight. A latex of low glass transition temperature resin and water-repellent resin is sprayed on one side of the nonwoven fabric 1 by spraying and immediately heated and dried, so that the resin 2 solidifies and adheres to the fibers of the nonwoven fabric 1. At this time, it is gently treated so as not to break the latex mist adhering to the fibers of the nonwoven fabric 1. In this way, the backing nonwoven fabric 10 is obtained.

For example, a regular shape, a crown shape, a cross shape, or a fork shape can be adopted as the shape of the needle for needle punching. It is preferable to process to a density of 50 to 200 / cm ² and a depth of 6 to 15 mm with a needle of thickness 32 to 40.

  Further, the non-slip vented water-impervious mat of the present invention has a backing nonwoven fabric 10 joined to a base fabric 6 of a carpet 12 (see FIG. 1).

  This non-slip vented water-impervious mat is manufactured by hot melt as follows.

  On the base fabric 6 of the carpet 12 in which the pile 5 is driven into the base fabric 6, fine beads of a heat-meltable resin, for example, a polyester resin having a low melting point (mp = 100 ° C.) are sprinkled, and the lining nonwoven fabric 10 is granulated thereon. The surfaces without resin 2 are overlapped. The overlapping surface is pressurized while heating to a temperature equal to or higher than the melting point of the heat-meltable resin and lower than the melting point of the fiber material of the nonwoven fabric 1. When this is cooled, the carpet and the lining nonwoven fabric are joined at the pinpoints where the beads are melted, so that the air permeability is maintained and the non-slip vented water-impervious mat of the present invention is completed. Spider web spunbonds can be used instead of resin microbeads.

  Bonding by hot melt can also be performed by previously blending the nonwoven fabric 1 with binder fibers (low melting point fibers) and superposing them on the base fabric 6 of the carpet 12 to heat and melt the binder fibers. As the binder fiber, for example, a single fiber such as a low melting point polyester fiber, a polypropylene fiber, or a polyethylene fiber or a composite fiber can be used.

  The fibers of the pile 5 constituting the carpet 12 are not particularly limited. For example, animal fibers such as wool, plant fibers such as cotton and hemp, and synthetic fibers such as nylon (registered trademark), polyester fibers, and acrylic fibers. But you can. The material of the base fabric into which the pile is driven is preferably, for example, polyester fiber or nylon, and is not limited to a woven fabric, and may be a non-woven fabric. Polyester fibers and nylon spunbond nonwoven fabrics are preferred.

  Hereinafter, an example in which the backing nonwoven fabric of the present invention was prototyped and an example in which a non-slip vented water-impervious mat with the backing nonwoven fabric joined was prototyped will be described in detail. Furthermore, the performance evaluation of the prototyped backing nonwoven fabric will be explained.

Example 1
(Prototype of backing nonwoven fabric)
Polyester fiber (7 denier white 10%, 8 denier gray 20%, 10 denier black 62%) and low melting point polyester fiber having a melting point of 100 ° C. (4 denier white 8%) as the raw material cotton of the constituent fibers A 300 g / m ² web was needle punched into a density of 150 pieces / cm ² and a depth of 11 mm with a No. 40 regular needle to prepare a nonwoven fabric. To this nonwoven fabric, a homopolymer foamed resin of ethyl acrylate having a low glass transition temperature as a dry solid content of 20 g / m ² and a fluororesin having a perfluoroalkyl group as a water repellent resin as a dry solid content of 4 g / m ² are obtained. Spray with latex with m ² and spray. This was passed through a tunnel furnace at 80 ° C. and dried. A fine granular resin component was adhered to the obtained backing nonwoven fabric.

(Prototype of air-permeable impermeable mat)
The carpet was made by laying a nylon set yarn as a pile at a rate of 670 g / m ² into a polypropylene woven fabric having a basis weight of 100 g / m ² as a base fabric. A polyester-based low melting point (melting point: 120 ° C.) fiber sheet was overlaid on the carpet base fabric, and further, the surface of the backing non-woven fabric obtained in Example 1 that had not been processed was overlaid. The polyester-based low melting point resin was melted by applying hot air at a temperature of 180 ° C. and a wind speed of 8 m / min for 1 minute from the carpet side. At this time, no other press is performed. When this was naturally cooled, the polyester-based low melting point resin joined the carpet base fabric and the backing nonwoven fabric in a scattered manner. This was naturally cooled to obtain a prototype air-permeable and impermeable mat.

Comparative Example 1
A nonwoven fabric similar to that of Example 1 was constructed, and a backing nonwoven fabric was obtained without processing the latex. This backing nonwoven fabric was bonded to the same carpet as in Example 1 in a similar manner using a polyester low-melting point resin to obtain a prototype mat of a comparative example.

Examples 2-4
The carpet was the same as that in Example 1, and the basis weight of the lining nonwoven fabric was changed as shown in Table 1. Further, the amount of latex applied to the backing nonwoven fabric was changed, and the amount of dry solid content of the resin was as shown in Table 1. Table 1 shows the weight ratio of the low Tg resin and the water-repellent resin in the latex applied to the lining nonwoven fabric. Others were the same as in Example 1 to obtain a prototype waterproofing mat.

Comparative Examples 2-4
A prototype mat of a comparative example was obtained in the same manner as the corresponding Examples 2 to 4 except that the latex processing was not performed.

(Performance evaluation test)
Test 1: Non-slip performance evaluation Samples obtained by cutting the prototype mats obtained in Examples and Comparative Examples into A4 size (210 mm × 290 mm) were prepared. The bottom surface of the prototype mat (the side of the backing nonwoven fabric) is placed on a normal nonwoven fabric, and a 5Kg (150mm x 150mm) load plate is placed on top of it to place the sample in the normal direction and reverse direction of the designated carpet. The load (Kg) when pulled and slid was measured. Each sample was measured three times in the forward direction and the reverse direction.

Test 2: Evaluation of water shielding performance Samples obtained by cutting prototype mats obtained in Examples and Comparative Examples into 200 mm × 200 mm were prepared. This sample is placed over the opening of a glass beaker having a diameter of 60 mmφ, the center is recessed, and 200 cc of water is placed in the recess. The water falling through the sample is visually checked for 20 minutes.

Test 3: Evaluation of ventilation performance Three samples were prepared by cutting the prototype water mats obtained in Examples and Comparative Examples into 180 mm × 180 mm. This sample was attached to a cylindrical flange of a Frazier type aeration tester and clamped. The suction fan is adjusted so that the inclination type barometer exhibits a pressure of 12.7 mm of water column by the adjusting resistor, and the amount of air passing through the sample from the pressure indicated by the vertical barometer and the diameter of the air hole ( cm ³ / cm ² / Sec). The average of 3 samples is shown.

  Table 1 shows the test results of the non-slip performance evaluation, water shielding performance evaluation, ventilation performance evaluation, and sound absorption performance evaluation of the prototype mats obtained in the examples and comparative examples.

  As is apparent from Table 1, it is clear that the anti-slip performance and water shielding performance of the prototype mats of Examples 1 to 4 to which the present invention is applied are superior to that of the prototype mat of the comparative example. The ventilation performance is almost the same.

It is a side view which shows the middle of preparation of the air-permeable impermeable mat with a slip stopper to which the backing nonwoven fabric to which this invention is applied was joined.

Explanation of symbols

  1 is a nonwoven fabric, 2 is a granular resin, 5 is a pile, 6 is a base fabric, 10 is a backing nonwoven fabric, and 12 is a carpet.

Claims (7)

At least on the lower surface, a latex containing a resin having a maximum glass transition temperature of 0 ° C. and a water-repellent resin selected from a fluororesin, a silicon resin and a paraffin resin is applied by spraying and dried, and the resin after drying A non-slip lining nonwoven fabric with a non-slip air-permeable impermeable mat, characterized in that is adhered in a granular form. The non-slip nonwoven fabric with a non-skid air-permeable mat according to claim 1, wherein the resin having a maximum glass transition temperature of 0 ° C is an acrylic resin. The coating amount of the latex, anti-slip vented water barrier mat backing nonwoven fabric according to claim 1, characterized in that a 5 to 100 g / m ² in the dry solids of resin. The air-permeable impermeable mat with a non-slip according to claim 1, wherein the weight ratio of the resin having a maximum glass transition temperature of 0 ° C and the water-repellent resin in the latex is 2: 1 to 100: 1. Backed nonwoven fabric. The nonwoven fabric lining the air-permeable and water-impervious mat with non-slip according to claim 1, wherein the nonwoven fabric has a basis weight of 10 to 2000 g / m ² and an apparent thickness of 1 to 30 mm.   A ventilation impermeable mat with a non-slip, wherein the upper surface of the backing nonwoven fabric according to any one of claims 1 to 5 is bonded to a carpet base fabric.   The air-permeable and water-impervious mat with non-slip according to claim 6, wherein the carpet base fabric and the nonwoven fabric are joined by needle punching or hot melt using a heat-meltable resin.

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