JP2551759Y2 - mat - Google Patents

Description

[Detailed description of the invention]

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a mat, and more specifically, a matt tufted pile layer surface has a soft and gentle feel, and is excellent in dust collection and oil absorption. And has excellent durability,
The present invention relates to a mat in which pile yarns do not easily come off or fall off even under severe conditions such as repeated recycling.

[0002]

2. Description of the Related Art Conventionally, mainly at entrances of stores, offices, etc.,
In order to prevent dust from being brought into a room, mats for collecting dust are laid and used. When these mats are used and contaminated, they are usually collected, cleaned, regenerated, and then reused. In recent years, mats rented by a so-called rental system have often been laid and used. In the rental system, delivery of the mat to each user store, use in the store,
The cycle of collection, washing, regeneration of dust collection function, and delivery to each user store is repeated, and mats used for rental are not only in use but also subjected to severe cleaning and reprocessing etc. Exposed to conditions.

[0003] In any case, the mats are repeatedly cleaned and reprocessed many times during use, and during that time, fibers such as mat piles fall off, and the color and pattern of the pile surface become unclear. As a result, the life is relatively short. Such inconvenience is particularly noticeable in mats that use thin staple fibers as pile yarns in order to give a soft texture to the pile surface, and this type of mat with excellent durability performance including washing durability The emergence of has long been desired.

[0004]

[Problems to be Solved by the Invention] Therefore, an object of the present invention is to have a soft texture, excellent dust collecting property and oil absorption at the time of use, and to repeat washing and regeneration. Another object of the present invention is to provide a rental mat which is remarkably excellent in durability performance including washing durability, in which fibers such as a mat pile do not fall off or come off.

[0005]

According to the present invention, in a mat comprising a base cloth, a pile yarn tufted on the base cloth, and a backing provided on the back side of the base cloth, the pile yarns are substantially formed. The staple fiber bundle is formed by alternately twisting a plurality of twisted yarns with a part of the untwisted staple fiber bundle sandwiched therebetween, and the staple fiber bundle is mixed with a low melting point fusible staple. A mat is provided in which the staple fiber bundle is fixed between the twisted yarns by twisting and fusion with the fusible staple.

[0006]

According to the present invention, the pile yarn to be tufted on the base fabric is a cotton yarn-like untwisted staple fiber bundle sandwiched between the twisted yarns when a plurality of twisted yarns are intertwisted. The first feature is that the twisted staple fiber bundle is partially fixed between the intertwisted yarns.

The second feature of the present invention is that the cotton-like untwisted staple fiber bundle is mixed with a fusible staple having a low melting point. That is, a pile layer is formed on the base fabric by driving the pile yarn having such a structure onto the base fabric to form a tuft. By doing so, the untwisted staple fiber bundle is bonded and fixed to the twisted yarn by the interleaving of the twisted yarn and the fusion of the low-melting-point fusible staple. In the present invention, a mat is prepared by forming a rubber backing layer on the back surface of the base fabric with a pile layer formed in this manner by a conventional method.

[0008] The pile layer of the mat of the present invention not only has the untwisted staple fiber bundles constituting the pile yarns interposed and fixed between the twisted and twisted yarns as described above, but also has a structure in the staple fiber bundles. Since the fibers are bonded and fixed to the twisted yarn by fusing the mixed low melting point fusible fibers, the fibers fall off even when exposed to severe conditions such as washing and regenerating processes as well as when using the mat. It has characteristics that it hardly falls off and has remarkably excellent durability, especially cleaning durability.

Further, the pile yarn of the present invention can absorb and hold a large amount of dust and oils in a cotton-like untwisted staple fiber bundle, so that it is excellent in dust-capturing property, holding property and oil-absorbing property. . In addition, the pile yarn of the present invention is formed by twisting a cotton-like untwisted staple fiber bundle, so that the mat surface of the present invention formed by the pile yarn has a soft and gentle feeling. doing.

[0010]

Preferred embodiments of the present invention will be described in more detail with reference to the accompanying drawings. FIG. 1 is a perspective view showing an example of the rental mat of the present invention.
Represents a base fabric layer, and 3 represents a backing rubber layer. FIG. 2 is a partial schematic view schematically showing the structure of the pile yarn of the present invention.
Reference numeral 4 represents a twisted yarn, and reference numeral 5 represents a non-combustible staple fiber bundle.

In the pile yarn shown in FIG. 2, when a plurality of twisted yarns 4 are intertwisted, a cotton-like staple fiber bundle 5 is sandwiched between the intertwisted yarns and partially fixed. In addition, in this pile yarn, a low-melting-point fusible staple fiber is mixed in the untwisted staple fiber, and the pile yarn is formed into a base fabric. Then, the twisted yarn of the pile yarns adheres and fixes the untwisted staple fiber bundle at the sandwiched portion thereof by softening the low melting point fusible fiber present in the sandwiched untwisted staple fiber bundle. Therefore, the twisted staple fiber bundle is not only fixed by pinching,
It is in a state of being firmly bonded to the twisted yarn.

The twist yarn for the pile yarn used in the present invention is a twist yarn of a natural fiber such as cotton, a twist yarn of an artificial fiber such as rayon, a twist yarn of a synthetic fiber such as polyester, acrylic or vinylon, or a blend yarn of these. Twisted yarn or the like can be used. As the untwisted staple fiber bundle for pile yarn, a cotton-like staple fiber bundle made of fibers of cotton, fine rayon, polyester, acrylic, vinylon or the like is used.

Further, as the low melting point fusible staple,
Staple fibers such as low melting point copolyester and copolyamide are used, and the softening and fusing temperature of the fibers is 90 to 14.
A fiber made of a polyester copolymer or a polyamide copolymer at about 0 ° C. is preferably used.

In the present invention, it is preferable to use a low melting point copolyamide fiber as the fusible fiber in view of the fusibility.
Examples include a plurality of types of polyamide fiber-forming monomers, that is, copolymer polyamide fibers comprising a combination of an ω-aminocarboxylic acid component or a dicarboxylic acid component and a diamine acid component.

[0015] Such fibers are generally available in the form of multifilament yarns of low fineness, the fineness of which is generally 3
It is in the range of 0 to 300 denier. Suitable low-melting polyamide fibers are available under the trade name Elder from Toray Industries, Inc.
Also, it can be obtained from Unitika Co., Ltd. under the trade name of Flowru M.

In the present invention, the pile yarns are formed by driving the pile yarns into the base fabric using the pile yarns described above. The pile shape may be either a cut pile or a loop pile, and the pile length and the basis weight may be within the range of a mat conventionally used for dust control (dust prevention and dust removal). Generally, the pile length and the pile length are 3 to 40 mm. A basis weight of 300 to 4000 g / m ² is used.

In the present invention, the base fabric on which the pile layer 1 is formed is heat-set to soften and fuse the low melting point staples. The heat setting is preferably performed at a temperature from the softening temperature of the low melting point staple to about 20 ° C. higher than the temperature, and it can be carried out by any method of wet heat setting and dry heat setting. When a polyamide copolymer fiber is used as the conductive fiber, heat setting under wet heat is preferable from the viewpoint that heat setting can be performed at a relatively low temperature and the fusibility.

In the present invention, the heat-setting treatment is applied to the base fabric having the pile layer thus formed, and then the rubber backing layer 3 is formed on the back surface of the base fabric by a conventional method.

The rubber used for the backing is acrylonitrile-butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), chloroprene rubber, ethylene-propylene-diene copolymer rubber, isoprene rubber, isobutylene rubber. Rubber, polyurethane and the like can be mentioned.

[0020]

EXAMPLE A twisted yarn obtained by twisting 120 3-denier vinylon single yarns, a 90% untwisted polyester staple, a fusible polyamide spun yarn (trade name: Unimelt, manufactured by Unitika Ltd., 2 denier x 38 mm, melting point 110) ℃) 10%
Using the mixed cotton-like mixed twisted staples, the above-mentioned cotton-like mixed untwisted staples were mixed and twisted together with the vinylon twisted yarn when the above-mentioned four vinylon twisted yarns were twisted, to obtain pile yarns.

The pile yarn was driven into a base fabric made of a polyester woven fabric and tufted to form a tufted pile.
The pile-forming base fabric was twisted and set at a temperature of 120 ° C. in a steam atmosphere, and the mixed untwisted staple cotton was partially fused and fixed to the twisted yarn. In addition, the tuft is 8 gauges / inc.
h, 8 stitches / inch and a pile length of 12 mm.

On the back surface of the base fabric after setting, a mixture of NBR latex and an appropriate amount of a vulcanizing agent is applied (400 g).
/ M ² solid part), and after application, dried at 160 ° C. for 10 minutes to form a backing layer to produce a mat having a mat effective surface of 75 × 80 cm.

[0023] The number of people passing through the mat is 1,000 for 1 person.
After laying for 0 days, it was washed and laid under the same conditions, and this cycle was repeated 20 times. The state of the mat after 20 cycles was visually observed, and almost no pile yarn coming off, fraying, etc. were observed, and the pile color did not change. In the case of a conventional mat containing untwisted polyester cotton as a pile yarn, the above cycle number is 5 to 5.
Product value is lost in about 10 times.

[0024]

[Effects of the Invention] Since the mat of the present invention has the above-described structure, it has a soft texture and is excellent not only in dust collecting property and oil absorbing property, but also in washing, regenerating and so on. Even when the treatment under severe conditions is repeated, pile yarns and the like do not fall off and have excellent durability, especially excellent washing durability.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of the mat of the present invention.

FIG. 2 is a partial schematic view schematically showing a structure of a pile yarn used for the mat of the present invention.

[Explanation of symbols]

 Reference Signs List 1 pile layer 2 base fabric layer 3 backing rubber layer 4 twisted yarn 5 non-combustible staple fiber bundle

 ──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-62-62941 (JP, A) JP-A-1-97229 (JP, A) Jiko 58-42462 (JP, Y2)

Claims (1)

(57) [Scope of request for utility model registration] 1. A mat comprising a base fabric, a pile yarn tufted into the base fabric, and a backing applied to the back surface of the base fabric, wherein the pile yarns sandwich a part of a substantially untwisted staple fiber bundle therebetween. The staple fiber bundle is formed by mixing and twisting a plurality of twisted yarns, and a fusible staple having a low melting point is mixed in the staple fiber bundle. Wherein the staple fiber bundle is fixed between the twisted yarns.