JP2016087050A - mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a mat excellent in non-slip performance and cushioning properties.SOLUTION: A mat is obtained by using a fiber structure including a fixing point formed by heat-sealing thermally-adhesive composite short fibers in which a heat-seal component composed of a thermoplastic elastomer is arranged on its surface.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a mat excellent in anti-slip performance and cushioning properties.

Conventionally, mats such as a rug mat, a kitchen mat, a bath mat, and an entrance mat are often used on the floor such as a flooring of a house. Further, these mats are often provided with a non-slip function (for example, see Patent Document 1 and Patent Document 2).
However, when these mats are laid for a long time, there is a problem that rubber or adhesive used for preventing slipping is transferred to the flooring or the surface of the flooring may be peeled off in some cases.

  Further, among mats, a thick rug mat having a thickness of 1.5 cm or more has recently been gaining popularity for reasons such as being able to sleep around and having good comfort. Such mats are often made of urethane for reasons of cushioning. However, if the mat made of urethane is used throughout the year, there is a problem that it is difficult to warm in winter when it is laid on a floor heating or hot carpet, and heat tends to be accumulated when sleeping in the summer, and washing is impossible.

JP-A-8-215131 JP 2002-282116 A

  This invention is made | formed in view of said background, The objective is to provide the mat | matte excellent in anti-slip performance and cushioning properties.

  As a result of diligent study to achieve the above-mentioned problems, the present inventor has found a fixing point formed by heat-sealing a heat-adhesive composite short fiber having a heat-fusion component made of a thermoplastic elastomer disposed on the surface thereof. When the mat is constituted by using the fibrous structure containing the mat, it has been found that a mat satisfying both the anti-slip performance and the cushioning property can be obtained by the action of the thermoplastic elastomer, and the present invention has been completed by further earnest studies. It was.

Thus, according to the present invention, “including a fiber structure including a fixing point formed by heat-bonding a heat-adhesive composite short fiber having a heat-bonding component made of a thermoplastic elastomer disposed on its surface. A mat characterized by: "is provided.
In that case, it is preferable that the said fiber structure contains a crimped short fiber further. Moreover, in the said fiber structure, it is preferable that the said heat bondable composite staple fiber and / or a crimped staple fiber are arranged in the thickness direction of a fiber structure. Moreover, it is preferable that the said thermoplastic elastomer is a polyester-type elastomer. Moreover, it is preferable that heat treatment is performed on any surface of the fiber structure. In that case, it is preferable that it is in the range of 25-60 in Asker rubber hardness meter F type in the surface to which the heat processing of the said fiber structure was given. Moreover, it is preferable to arrange | position so that the surface where the heat processing of the said fiber structure was performed contact | connects a floor. Moreover, it is preferable that the cloth is laminated on a surface opposite to the surface on which the heat treatment of the fiber structure is performed. Moreover, it is preferable that the frictional force at the time of a load of 10 g / cm < ² > exists in the range of 900-3000g. Moreover, it is preferable that 25% compressive stress exists in the range of 30-300N.
In addition, according to the present invention, there is provided a mat that is any one selected from the group consisting of a rug mat, a kitchen mat, a bath mat, and an entrance mat.

  According to the present invention, a mat having excellent anti-slip performance and cushioning properties can be obtained.

It is a figure which shows typically the fiber structure used by this invention. It is a figure for demonstrating the measuring method of T / W.

Hereinafter, embodiments of the present invention will be described in detail.
In the present invention, it is important that a heat fusion component made of a thermoplastic elastomer is disposed on the surface of the heat-adhesive composite short fiber. Such a thermoplastic elastomer achieves both anti-slip performance and cushioning properties.

  Here, it is preferable that the thermoplastic elastomer has a melting point of 190 ° C. or less (preferably 120 to 190 ° C.). The heat-fusion component is melted by heating, and the intersection between the heat-adhesive composite staple fibers or the crimped short fiber as described later is fused at the intersection between the heat-adhesive composite staple fibers and the crimped staple fibers. To wear. At that time, if the melting point is higher than 190 ° C., the adhesion is insufficient, and there is a possibility that the fiber structure is not loose and difficult to handle. In addition, fine control of the heat treatment temperature is required, resulting in poor productivity.

  As such a thermoplastic elastomer, a polyester elastomer having heat resistance and capable of high temperature thermoforming is particularly preferable. Polyester ester copolymer is a polyetherester copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically terephthalic acid, isophthalic acid, phthalic acid, naphthalene. -2,6-dicarboxylic acid, naphthalene-2,7-dicarboxylic acid, diphenyl-4,4'-dicarboxylic acid, alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, adipic acid , At least one dicarboxylic acid selected from aliphatic dicarboxylic acids such as sebacic acid, dodecanedioic acid and dimer acid, or ester-forming derivatives thereof, 1,4-butanediol, ethylene glycol trimethylene glycol, tetramethylene Glycol, penta Aliphatic diols such as tylene glycol, hexamethylene glycol neopentyl glycol, decamethylene glycol, or alicyclic diols such as 1,1-cyclohexanedimethanol, 1,4-cyclohexanedimethanol, tricyclodecane methanol, or esters thereof Polyethylene glycol, poly (1,2- and 1,3-polypropylene oxide) glycol, poly (tetramethylene oxide) having at least one diol component selected from formable derivatives and the like, and an average molecular weight of about 400 to 5000 A ternary copolymer composed of at least one of poly (alkylene oxide) glycols such as glycols, copolymers of ethylene oxide and propylene oxide, copolymers of ethylene oxide and tetrahydrofuran, etc. It can be mentioned coalescence.

  In particular, a block copolymer polyether ester having polybutylene terephthalate as a hard component and polyoxybutylene glycol as a soft segment is preferable. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component, and a part of the glycol component (usually 30 mol% or less) is butylene. It may be substituted with a dioxy component other than the glycol component. Further, the polyether portion constituting the soft segment may be a polyether substituted with a dioxy component other than butylene glycol.

In the heat-adhesive composite short fiber, the counterpart component of the heat-fusion component is not particularly limited, but a polyester-based polymer is preferable. For example, polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethine terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polypivalolactone or a copolymer ester thereof is preferably used. it can.
In addition, various stabilizers, ultraviolet absorbers, thickening branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended in the above-described polymer as necessary.

In the heat-bondable composite short fiber, it is preferable that the heat-sealing component occupies at least a half surface area. The weight ratio of the heat fusion component and the counterpart component is suitably in the range of 20/80 to 80/20 in this order of composite ratio. If the ratio of the heat fusion component is smaller than this ratio, there is a possibility that good anti-slip performance cannot be obtained. On the other hand, if the proportion of the heat-sealing component is larger than this proportion, there is a possibility that sticking or the like occurs during spinning and good spinnability cannot be obtained.
Although it does not specifically limit as a form of a heat bondable composite staple fiber, It is preferable that a heat-fusion component and the other party component are a side-by-side and a core-sheath type, More preferably, it is a core-sheath type. In the core-sheath-type heat-adhesive composite short fiber, the heat fusion component is the sheath portion, and the counterpart component is the core portion. The core may be concentric or eccentric, and is preferably eccentric.

In the above heat-adhesive composite short fiber, the single fiber fineness is preferably 2.0 to 100.0 dtex (more preferably 2.0 to 15.0 dtex, particularly preferably 2.0 to 10.0 dtex). . Further, the fiber length of the heat-adhesive composite short fiber is preferably cut to 38 to 255 mm. The number of crimps is preferably in the range of 4 to 70 pieces / 2.54 cm. If it is out of this range, the process stability such as blended cotton and web formation may be deteriorated. Moreover, there exists a possibility that cushioning properties may fall.
The fiber length of the heat-adhesive composite short fiber is preferably cut to 10 to 100 mm.

In the above-mentioned heat-adhesive composite short fiber, the number of crimps is preferably 3 to 40 / 2.54 cm (preferably 5 to 15 / 2.54 cm), and the crimp rate is 20 to 35%. Preferably there is. When the number of crimps and the crimp rate are smaller than these ranges, the entanglement between short fibers is insufficient, the bulkiness is lowered, and the cushioning property may be lowered. On the contrary, when the number of crimps exceeds 40 pieces / 2.54 cm, the entanglement of the short fibers is too large, and there is a possibility that sufficient carding cannot be performed in the opening process of the card or the like.
As a method of imparting crimps to the fibers, spiral crimps are imparted using composite fibers obtained by bonding polymers having different heat shrinkage rates to side-by-side types, and spiral crimps are imparted by anisotropic cooling. Various methods such as imparting mechanical crimping by a method may be used.

  In the present invention, it is preferable that crimped short fibers are further contained in the fiber structure. Such crimped short fibers are not particularly limited, but natural fibers such as cotton and wool, inorganic fibers such as carbon fibers, acrylic fibers, cellulose fibers, aramid (para-type or meta-type), polyolefin-type, nylon Examples thereof include synthetic fibers such as polyesters and polyesters, and recycled fibers called miscellaneous cotton or anti-wrists. Of these, synthetic fibers are preferable in terms of handleability, discardability, and recyclability.

  Examples of the polyester fiber include polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly-1,4-dimethylcyclohexane terephthalate, polyethylene naphthalate, polypivalolactone, polylactic acid. (PLA), polyesters such as stereocomplex polylactic acid, short fibers made of these copolymers or mixed cotton of these short fibers, or composite short fibers made of two or more of the above polymer components, etc. it can. In addition, polyester that has been material-recycled or chemically recycled, polyethylene terephthalate that uses a monomer component obtained from biomass, that is, a biologically-derived substance, described in JP2009-01694, The short fiber which consists of polyester etc. which were obtained using the catalyst containing a specific phosphorus compound and a titanium compound as described in Unexamined-Japanese-Patent No. 2004-270097 and 2004-21268 may be sufficient. Among these short fibers, short fibers made of polyethylene terephthalate, polytrimethylene terephthalate, or polybutylene terephthalate are particularly preferable from the viewpoint of fiber formation and the like.

In the crimped short fiber, the cross-sectional shape of the single fiber may be any of ordinary round shape, flat shape, flat shape with constriction such as flattened shape, triangular shape, square polygon shape, hollow shape such as round hollow shape and triangular hollow shape.
In the above-described crimped short fibers, the single fiber fineness is preferably 2.0 to 100.0 dtex (more preferably 5.0 to 50.0 dtex. If the single fiber fineness is smaller than 2.0 dtex, the mat On the other hand, if the single fiber fineness is larger than 100.0 dtex, the handleability and web formability are reduced, or the number of constituents is too small to make it difficult to express elasticity. At the same time, there is a possibility that problems such as the durability being easily lowered and the texture becoming coarse and hard may occur.
Moreover, as a fiber length of a crimped short fiber, it is preferable that the fiber length is cut | judged to 10-100 mm.

In the above-mentioned crimped short fibers, the number of crimps is preferably 3 to 40 / 2.54 cm (preferably 5 to 15 / 2.54 cm), and the crimp rate is 20 to 35%. preferable. When the number of crimps and the crimp rate are smaller than these ranges, the entanglement between short fibers is insufficient, the bulkiness is lowered, and the cushioning property may be lowered. On the contrary, when the number of crimps exceeds 40 pieces / 2.54 cm, the entanglement of the short fibers is too large, and there is a possibility that sufficient carding cannot be performed in the opening process of the card or the like.
As a method of imparting crimps to the fibers, spiral crimps are imparted using composite fibers obtained by bonding polymers having different heat shrinkage rates to side-by-side types, and spiral crimps are imparted by anisotropic cooling. Various methods such as imparting mechanical crimping by a method may be used.

  In the present invention, the heat-adhesive composite staple fibers are mixed with the crimped staple fibers as necessary, and heat-treated, so that the heat-adhesive composite staple fibers are heat-sealed in a crossed state. And / or the fiber structure in which the fixing points heat-sealed in a state where the heat-adhesive composite short fiber and the crimped short fiber intersect with each other are scattered. Under the present circumstances, it is preferable that the weight ratio of a crimped staple fiber and a thermobonding composite staple fiber is 70 / 30-0 / 100 in this order. When the ratio of the heat-bonding composite short fibers is less than this range, there is a possibility that good anti-slip performance cannot be obtained.

  In the fiber structure, in order to obtain a good cushioning property and anti-slip performance, as schematically shown in FIG. 1, the heat-adhesive composite short fiber and / or the crimped short fiber has a thickness of the fiber structure. It is preferable to arrange in the direction. Here, “arranged in the thickness direction” means that the total number of fibers arranged in parallel to the thickness direction of the fiber structure is (T) as shown in FIG. When the total number of fibers arranged perpendicular to the body thickness direction is (W), T / W is 1.5 or more.

In the fiber structure, the density is preferably in the range of 10 to 40 kg / m ³ . If it is smaller than this range, the settling is large, and if it is larger than this range, there is a risk that the stepping comfort suitable as a mat may be impaired.
In addition, the thickness of the fiber structure is preferably in the range of 3 to 30 mm from the viewpoint of anti-slip performance and cushioning properties.

  The mat of the present invention may be composed of the fiber structure alone, but it is preferable to laminate the fabric on any one side of the fiber structure (preferably one side opposite to the floor). If necessary, the periphery may be trimmed such as hem processing. The dough is not particularly limited as long as it is appropriately selected depending on the desired texture and function. The fabric and the fiber structure part may be integrated with an adhesive or a heat bonding sheet, or may be joined together by quilting.

In the mat of the present invention, it is preferable that the floor side surface of the fiber structure has an appropriate hardness to prevent tearing or perforation. Specifically, the floor side surface is preferably an Asker rubber hardness tester F type having a hardness of 25-60.
As a method for imparting such hardness, it is preferable to heat-treat the floor side surface of the fiber structure at a temperature in the range of 160 to 210 ° C. for 5 to 120 seconds. More preferably, the fiber structure is made thicker by about 1 to 20 mm than the thickness of the target mat, and heat treatment is performed by a method of curing the floor side surface of the fiber structure by hot pressing.

The mat of the present invention is excellent in anti-slip performance and cushioning properties due to the heat-adhesive composite short fibers that are included in the fiber structure and on which the heat-fusion component made of thermoplastic elastomer is arranged.
Here, it is preferable that the anti-slip performance has a frictional force of 900 to 3000 g at a load of 10 g / cm ² . This is also a property of the heat-adhesive composite short fiber, but the property can be further enhanced by heat-treating the floor-side surface described above.

  Moreover, as cushioning property, it is preferable that 25% compressive stress is 30-300N. When the 25% compressive stress is larger than 300N, the softness becomes insufficient, and a preferable stepping feeling cannot be obtained. If it is 30 N or less, it is too soft, and there is a risk of stickiness. However, the 25% compressive stress referred to in the present invention is measured according to JIS K6400-2 using a perfect pressure plate having a diameter of 200 mm.

  The mat of the present invention can be used for any purpose as a rug, and is particularly preferably used on a floor such as a flooring or a tatami mat in a house as a rug mat, a kitchen mat, a bath mat, an entrance mat or the like. Of course, you may use for other uses, such as a floor mat for cars.

  EXAMPLES Hereinafter, although an Example is given and this invention is demonstrated in detail, this invention is not limited at all by these.

(1) Melting point Using a differential thermal analyzer 990 manufactured by Du Pont, measured at a temperature increase of 20 ° C./min, and obtained a melting peak. If the melting temperature is not clearly observed, the melting point is the temperature at which the polymer softens and starts to flow (softening point) using a trace melting point measuring device (manufactured by Yanagimoto Seisakusho). In addition, the average value was calculated | required by n number 5.
(2) Number of crimps and crimp rate Measured by the method described in JIS L 1015. In addition, the average value was calculated | required by n number 5.
(3) T / W
The fiber structure is cut in the thickness direction, and in the cross section, the inelastic crimped short fibers and the heat-adhesive composite short fibers (0 ° ≦ θ ≦ 45 in FIG. 2) are arranged parallel to the thickness direction. (T), the inelastic crimped short fibers and the heat-adhesive composite short fibers arranged in a direction perpendicular to the thickness direction of the fiber structure (45 ° <θ ≦ 90 ° in FIG. 2) T / W was calculated with the total number of In addition, the measurement of the number was carried out by observing 30 fibers for each of 10 arbitrary positions with a transmission optical microscope, and counting the number.
(4) Surface hardness It measured using the Asker rubber hardness meter F type (manufactured by Kobunshi Keiki Co., Ltd.). In addition, the average value was calculated | required by n number 5.
(5) Friction force (g)
A rug mat was cut into a size of 20 cm × 15 cm, placed on the flooring, and the force when pressed at a speed of 36 cm / min was measured.
(6) 25% hardness (N)
A perfect pressure plate having a diameter of 200 mm was used, and measurement was performed according to JIS K6400-2.
(7) Thickness Measured according to JIS K6400.

[Example 1]
An acid component obtained by mixing terephthalic acid and isophthalic acid at 80/20 (mol%) and butylene glycol are polymerized, and the obtained polybutylene terephthalate 38 wt% is further added with polytetramethylene glycol (molecular weight 2000) 62 wt%. A block copolymerized polyether polyester elastomer was obtained by heating reaction. The melting point of this thermoplastic elastomer was 155 ° C. The thermoplastic elastomer is used as a sheath, and polyethylene terephthalate (melting point: 256 ° C.) is used as a core, and the sheath / core is spun so that the weight ratio of the sheath / core is 40/60. Obtained. The obtained composite fiber was stretched 2.0 times, dried at 80 ° C. to develop crimps, then applied with an oil agent and cut into 51 mm to obtain heat-adhesive short fibers. In the heat-bondable short fibers, the single yarn fineness was 6.6 dtex, the number of crimps was 13 / 2.54 cm, and the crimp rate was 30%.

Subsequently, the heat-adhesive short fiber and a polyethylene terephthalate short fiber obtained by a conventional method as a crimped short fiber (single yarn fineness 15 dtex, fiber length 64 mm, number of crimps 9 / 2.54 cm, crimp rate 34% The cross-sectional shape is round hollow, melting point is 256 ° C., blended at a ratio of 50/50, a web is produced with a normal card machine, and a struto equipment manufactured by Struto Co., Ltd. (special table 2002-516932 gazette) Folds into an accordion type by pushing into a hot-air suction heat treatment machine (heat treatment zone length 5 m, moving speed 1 m / min) with a roller having a roller surface speed of 2.5 m / min. In a state in which hot air is treated at 200 ° C. for 5 minutes and the heat-adhesive composite staple fibers are heat-sealed in a state where the heat-adhesive composite short fibers intersect with each other, and the heat-adhesive composite staple fibers and the crimped short fibers intersect. And the fused fixed point to obtain a fiber structure interspersed. T / W was 1.5 or more, and the heat-adhesive composite short fiber and the crimped short fiber were arranged in the thickness direction of the fiber structure. The weight was 500 g / m ² and the thickness was 25 mm.

One side of the obtained fiber structure was pressed with a hot press machine at 190 ° C. to a thickness of 20 m. Next, using a multifilament (total fineness 400 dtex) made of polyethylene terephthalate for the warp and the weft on the side opposite to the pressed surface, the warp density is 90 / 2.54 cm, the weft density is 40 / 2.54 cm, and the air permeability Is laminated with a hot-melt non-woven fabric (Valtech International fabric weight 24 g / m ² ), and the periphery is further hemmed, and the length is 195 cm, horizontal width is 35 cm ³ / cm ² · sec and fabric weight is 400 g / m ² A rug mat having a thickness of 195 cm and a thickness of 20 mm was obtained.
On the pressed surface of the resulting rug mat, the surface hardness was 45, the frictional force was 1500 g, and the 25% hardness was 100N.

[Comparative Example 1]
Urethane cushion material obtained in a conventional manner 17 mm on one side, the same fabric as Example 1 on the other side, the weight of 100 g / m ² basis weight 2 mm polyester needle punched nonwoven fabric bonded with adhesive Hem processing was performed to obtain a rug mat of 195 cm × 195 cm and a thickness of 20 mm.
The surface hardness of the obtained rug mat on the side of the cushion material cured was 50, the frictional force was 700 g, and the 25% hardness was 150 N.

[Comparative Example 2]
Cross-ray nonwoven fabric of reethylene terephthalate short fiber (single yarn fineness 15 dtex, fiber length 64 mm, crimp number 9 / 2.54 cm, crimp rate 34%, cross-sectional shape is round hollow, melting point 256 ° C.) obtained by a conventional method The same fabric as in Example 1 was used on one side, multifilaments (total fineness 100 dtex) consisting of warp and weft on the other side, with a warp density of 150 / 2.54 cm and a weft density of 100 / 2.54 cm. A 195 × 195 cm rug mat having a thickness of 10 mm was obtained, in which a woven fabric having an air permeability of 20 cm ³ / cm ² · sec and a basis weight of 100 g / m ² was arranged and quilted at intervals of 20 cm.
The surface hardness of the resulting rug mat on the cured side of the cushion material was 20, the frictional force was 500 g, and the 25% hardness was 50N.

  ADVANTAGE OF THE INVENTION According to this invention, the mat | matte excellent in anti-slip performance and cushioning properties is provided, The industrial value is very large.

1: Thermal adhesive composite short fiber or inelastic crimped short fiber 2: Thickness direction of fiber structure 3: Arrangement direction of thermal adhesive composite short fiber or inelastic crimped short fiber 4: Fiber structure

Claims (11)

  A mat comprising a fiber structure including a fixing point formed by heat-sealing a heat-adhesive composite short fiber having a heat-bonding component made of a thermoplastic elastomer disposed on a surface thereof.   The mat according to claim 1, wherein the fiber structure further includes crimped short fibers.   The mat according to claim 1 or 2, wherein in the fiber structure, the heat-adhesive composite short fibers and / or crimped short fibers are arranged in the thickness direction of the fiber structure.   The mat according to any one of claims 1 to 3, wherein the thermoplastic elastomer is a polyester elastomer.   The mat according to any one of claims 1 to 4, wherein heat treatment is performed on any surface of the fiber structure.   The mat according to claim 5, wherein the surface of the fiber structure subjected to heat treatment is in the range of 25 to 60 with an Asker rubber hardness meter F type.   The mat according to claim 5 or 6, wherein a surface of the fiber structure subjected to heat treatment is disposed so as to be in contact with a floor.   The mat according to any one of claims 5 to 7, wherein a fabric is laminated on a surface opposite to the surface on which the heat treatment of the fiber structure is performed. Frictional force at the time of a load of 10 g / cm ² is within the range of 900～3000G, mat according to claim 1.   The mat according to any one of claims 1 to 9, wherein the 25% compressive stress is in the range of 30 to 300N.   The mat according to any one of claims 1 to 10, wherein the mat is any one selected from the group consisting of a rug mat, a kitchen mat, a bath mat, and an entrance mat.

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