JP3032717B2 - Waterproof thermal barrier rug - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to sea bathing, athletic meet,
This is a rug used to sit down on the ground during picnics and various events, and more specifically, a laminated sheet of fibrous nonwoven fabric and synthetic resin film that has a cushioning property and fits the ground. It relates to an excellent rug.

[0002]

2. Description of the Related Art This kind of rug, called a leisure sheet, is used by simply laying it on the ground or the like in order to prevent the adhesion of soil, moisture, and dirt. Generally, a film or a synthetic resin sheet alone or a cloth woven from a tape of a synthetic resin film is subjected to lamination processing.

When a synthetic resin film or sheet alone is used as a rug, a thin film tends to have pinholes and has a problem of waterproofness, and a thick film tends to be curled or creased, and both have insufficient strength. Limited to completely disposable items. On the other hand, cloth-based laminate sheets, which are durable and diversified in design, have high commercial value and are the most popular type, but lack flexibility and elasticity, and have good fit and stability to the ground However, they are not satisfactory in terms of the feel and touch. Further, when the rug is laid on a sandy land where the temperature becomes high in summer or on a frosty lawn in winter, for example, the temperature is directly transmitted to the surface of the rug, causing a discomfort to a person sitting on the rug.

[0004]

Therefore, in the present invention, in addition to various characteristics such as low cost, high durability, repetitive use and sufficient waterproofness, as well as the conventional rug, appropriate flexibility and cushioning are provided. It is an object of the present invention to provide a waterproof and heat-insulating rug that has excellent heat resistance and good fit and stability to the ground, and that can be used as an underlay of a kotatsu futon or a hot carpet indoors by having a heat-insulating property.

[0005]

According to the present invention, there is provided a web having a synthetic fiber containing 5 to 40% by weight of a thermoadhesive fiber deposited thereon, and heat-fixed by a needle punch to form a basis weight of 150 to 350 g / g.
A waterproof and heat-insulating rug characterized in that a synthetic resin film layer is laminated on both surfaces of a fibrous nonwoven fabric having an m ² and an apparent fiber density of 0.1 to 0.3 g / cm ³ .

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 1, the basic structure of a rug 1 of the present invention is a three-layer laminate in which a synthetic resin film layer 3 is laminated on both sides of a fibrous nonwoven fabric 2. is there.

[0007] The fibrous nonwoven fabric 2 used in the present invention is made of various synthetic fibers such as polypropylene, polyester, polyamide, polyacrylonitrile, polyvinyl chloride, and polyvinylidene chloride based spinning fibers as the main fiber material. Adopted.

[0008] A predetermined amount of the heat-adhesive fiber is mixed into the synthetic fiber. As the heat-adhesive fiber, the raw material resin is a material having a lower melting point or softening point than the fiber material,
Those having good adhesiveness with the film resin to be laminated later with the nonwoven fabric are preferable, for example, fibers using an adhesive resin such as a low-melting-point polyolefin type, a low-melting-point copolyester-type, or a low-melting-point copolyamide type, or these adhesive resins have a surface. And conjugate fibers having a cross-sectional shape such as a core-sheath type, a laminated type, and a side-by-side type that are present in a part of the composite fiber.

This heat-adhesive fiber is added for the purpose of fixing the fiber by a needle punch in a later step to maintain the non-woven fabric state and to improve the adhesiveness between the non-woven fabric and the synthetic resin film. From 5 to 40 to the synthetic fiber
It is important that the content be contained by weight. That is, if the heat-bondable fiber is less than 5% by weight, the nonwoven fabric will have poor shape stability and adhesiveness to the film, while if it exceeds 50% by weight, the nonwoven fabric will have poor flexibility and cushioning properties. It tends to come and becomes a problem.

[0010] A fibrous nonwoven fabric 2 formed from such fibers
Has a basis weight of 150 to 350 g / m ² and an apparent fiber density of 0.1 to
It is important to satisfy 0.3 g / cm ³ . In other words, basis weight 15
If it is less than 0 g / m ² , it tends to be insufficient in terms of strength and heat shielding effect, and it is necessary to strongly pressurize to improve strength, and it is assumed that the apparent fiber density will fall below the preferred range On the other hand, if the grammage exceeds 350 g / m ² , it is difficult to fold and bulky, resulting in poor handling properties. The apparent fiber density calculated from the basis weight and the apparent thickness is 0.1 to 0.3 g as a range having an appropriate buffering property as a base material of the rug, and a range in which the heat shielding effect can be sufficiently expected. / cm ³ is set.

These fibers may be in the form of staples or filaments, but preferably have a single fiber fineness of 1 to 20 dr, more preferably 3 to 10 dr, in the nonwoven fabric having the apparent fiber density. Is suitable and the production efficiency is good.

In forming the fibrous nonwoven fabric 2, these fibers are opened and irregularly deposited, and then turned into a fibrous nonwoven fabric through a needle punching step of fixing the fibers with a group of heated needles. This needle punching method is a method suitable for producing a relatively bulky nonwoven fabric, and in a nonwoven fabric satisfying the apparent fiber density and the basis weight range described above, a plurality of times such as coarse pre-punching and dense finishing are performed. It is preferable to perform punching. That is, if the punching is performed in a state similar to the roll embossing, the pressure between the fibers is strongly increased, and it is difficult to obtain a bulky nonwoven fabric.

Further, since the fibrous nonwoven fabric 2 is used as a base material of a rug, it preferably has predetermined mechanical properties. Specifically, it satisfies a tensile strength of 20 kgf / 5 cm or more, a tensile elongation of 100% or less, and a tear strength of 10 kgf or more. In other words, the tensile strength and tear strength are indications that can sufficiently withstand the use of the rug as a rug, and the tensile elongation is determined by the appearance of the rug, such as the rug being wavy without the subsequent laminate coating following the elongation of the base material. It is a problem factor.

Next, a synthetic resin film layer 3 is formed on both sides of the fibrous nonwoven fabric 2 for the purpose of imparting waterproofness. The synthetic resin forming the film layer is preferably a resin having a relatively low melting point having good adhesion to a nonwoven fabric, and examples thereof include a low-melting-point polyolefin resin, a low-melting-point copolyester-based resin, and a low-melting-point copolyamide-based resin. In addition, the rug 1 of the present invention
When used as an underlay of a kotatsu futon or a hot carpet from its thermal barrier properties, it is preferable that the film layer has anti-slip properties, ethylene-vinyl acetate copolymer, ethylene-acrylic acid copolymer, acrylate resin,
Examples of such resins include polyurethane resins and styrene-butadiene copolymers which form films and have a high friction coefficient.
Here, the thickness of the synthetic resin film layer is preferably about 10 to 80 μm from the viewpoint of durability and the like.

The synthetic resin film layer 3 can be formed by a melt extrusion lamination method in which the fibrous nonwoven fabric 2 is directly coated with a synthetic resin to form a film layer, or a dry lamination in which a preformed synthetic resin film is bonded to the nonwoven fabric. Law,
A known method such as a thermocompression lamination method can be employed, but a melt extrusion lamination method in which the adhesion between members is good, the processing speed is high, and the productivity is good is most preferable. The synthetic resin used in the case of the melt extrusion lamination method has a melt flow rate (MFR) of 1 to 50 g / 10 min., More preferably 5 to 20 g / 10 min. In terms of film formability and laminating processability. Range.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The waterproof and heat-insulating rug of the present invention will be described in detail below with reference to examples, and its effectiveness will be clarified by comparison with conventional products.

Example 1 A low-melting-point ethylene resin was used as a heat-adhesive fiber in a sheath layer.
Composite fiber (5dr,
51mm length), and this thermal adhesive fiber is 20% by weight,
In addition, polypropylene fiber (3dr, 51mm length) 25% by weight, polypropylene fiber (7dr, 64mm length) 20% by weight,
A web obtained by opening and depositing a fiber containing 35% by weight of a polyester fiber (7dr, 64 mm length) is subjected to a needle punching process (23 pre-punches / cm ² , 141 first punches / cm ² , 2nd punch 1
34 fibers / cm ² ), basis weight 265g / m ² , apparent fiber density 0.15g / c
It was obtained m ³ of non-woven fabric. On both sides of this fibrous nonwoven fabric, a laminate formed by coating a 35 μm-thick ethylene-vinyl acetate copolymer (MFR = 6.0 g / 10 min.) With a thickness of 35 μm by melt extrusion lamination to form a synthetic resin film layer was formed. × 270cm
The rug of Example 1 was formed by performing edge processing on the periphery.

COMPARATIVE EXAMPLE 1 A web on which polypropylene long fibers were deposited was bonded by hot embossing (50 points / cm ² ) to obtain a basis weight of 150 g / m ² and an apparent fiber density of 0.30 g / cm ³ . Using a spread non-woven fabric as a base material, a linear low-density polyethylene (MFR = 5.0 g / 1
(0 min.) Was coated to a thickness of 35 μm to form a synthetic resin film layer, and the laminate was cut into 180 × 270 cm, and the periphery was edged to form a rug of Comparative Example 1.

Comparative Example 2 A flat yarn having a fineness of 500 dr formed from high-density polyethylene (MFRI = 1.0 g / 10 min.) Was used as a base material with a cloth woven in a plain weave structure at a driving density of 8 × 8 yarns / inch. On both sides, a low-density polyethylene (MFR = 8.0 g / 10 min.) Was coated at 35 μm thickness to form a synthetic resin film layer on both sides by melt extrusion lamination, and the laminate was cut to 180 × 270 cm. The rug of Comparative Example 2 was formed by performing edge processing.

The rugs of the examples and comparative examples were evaluated according to the following measuring methods, and the results are summarized in Table 1.

Measurement method 1. Tensile strength, tensile elongation, tear strength: JIS-L1085
Compliant. 2. Heat shielding effect: As shown in FIG. 2, the inside of a tank A made of stainless steel whose back and four sides are covered with a heat insulating material B is 45 ° C.
Is circulated through a circulating thermostatic water bath C, a sample of the rug 1 cut into a square having a side length of 20 cm is placed on the surface of the tank, a temperature sensor E is attached to the sample surface, and a 50 g load F ( Apply a contact area of 5 cm ² ). A stable temperature was recorded about 5 minutes after the start of the measurement. 3. Observation of appearance: Observation of the state after hand-massaging by hand with appropriate force. ○: No change in state, X: Wavy or peeling of film layer. . 4. Sit comfort: The number of persons who responded to the questionnaire "20 were the most comfortable" using the three types of rugs of the examples and the comparative examples, respectively, is expressed as a percentage.

[0022]

[Table 1]

[0023]

As described above, the waterproof and heat-insulating rug of the present invention is a sheet that is durable enough to be used repeatedly and is easy to handle, and has high waterproofness and moderate flexibility and cushioning properties. It has excellent fit and stability on the ground because it has a ground, and it can be used not only as an outdoor padding but also as an underlay for kotatsu futons and hot carpets indoors because of its heat shielding properties. For example, since it is difficult to dissipate heat and can block cold air, it can be expected to have an effect of improving heat retention and contributing to energy saving, and it can be effective in that the use as a rug is expanded.

[Brief description of the drawings]

FIG. 1 is a partially enlarged sectional view showing a configuration of a waterproof and heat-insulating rug of the present invention.

FIG. 2 is an explanatory diagram of a measurement method of a heat shielding effect test.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Rug 2 Fibrous nonwoven fabric 3 Synthetic resin film layer

Claims (1)

(57) [Claims] 1. A web on which synthetic fibers containing 5 to 40% by weight of heat-adhesive fibers are deposited is heat-fixed by needle punch to form a basis weight of 150 to 350 g / m ² and an apparent fiber density of 0.1 to 0.3.
A waterproof and heat-insulating rug characterized by laminating synthetic resin film layers on both sides of a fibrous nonwoven fabric of g / cm ³ .