JP3059415U - Waterproof rug - Google Patents

Abstract

(57) [Abstract] [Problem] It is possible to wash repeatedly (washable), it can be washed at home, the waterproof performance does not decrease even after repeated washing, the back surface is not slippery, the overall thickness is thin, the end face portion Provide a waterproof rug that does not turn over. SOLUTION: A waterproof rug (50) in which a raised hair knitting layer (51) on the front surface and a synthetic rubber backing layer (53) on the back surface are integrated, wherein the fiber (51) of the raised portion has synthetic fibers. The backing layer (53) on the back side is embossed, retains waterproofness even after repeated washing, and the raised hair knitting layer and the backing layer are around the end portion while being shrunk and entangled. Sewing (52) is performed with a sewing thread (54).

Description

[Detailed description of the invention]

[0001]

[Technical field to which the invention belongs]

 The present invention relates to a waterproof rug mainly used for indoor toilet rugs for nursing care for the elderly or for the physically handicapped.

[0002]

[Prior art]

 Elderly or physically handicapped people who need nursing care and who cannot walk freely to the restroom need to use a simple toilet in their room. In addition, there are some people who have physical disabilities who, even with a simple toilet, can obstruct and leak small water out of the toilet. In this case, it is difficult to wash the tatami floor, flooring, or ordinary carpet. Therefore, it is desirable to lay a rug under the toilet and wash it when it gets dirty.

[0003] However, the conventional rugs are not completely waterproof, and have problems such as leaking water when washing and being unable to freely wash at home. In addition, there was an accident that the back side was slippery and the user fell down. Furthermore, there were accidents in which the entire body was thick and the end face was easily turned up, and the user crashed and fell. As the prior art, Japanese Patent Application Laid-Open Nos. 59-129023 and 6-181836 have been proposed, but the above problem has not been solved yet.

[0004]

[Problems to be solved by the invention]

 In order to solve the above-mentioned conventional problems, the present invention can be repeatedly washed (washable), can be washed at home, does not deteriorate in waterproof performance even after repeated washing, the back surface is less slippery, and The purpose is to provide a waterproof rug that is thin and does not turn up at the end.

[0005]

[Means for Solving the Problems]

 In order to achieve the above object, the waterproof rug of the present invention is a waterproof rug in which a raised knitted knitting layer on the front surface and a synthetic rubber backing layer on the back surface are integrated. The backing layer on the back side is embossed and retains waterproofness even after repeated washing, and the raised hair knitted layer and the backing layer are sewn around the ends. It is characterized by the following.

According to the present invention, since the surface is made of knitted fabric, the thickness is small and the basis weight is light. Also, since the synthetic fibers of the nap fibers are shrunk and entangled, the fiber density on the surface is relatively high and the water absorption is large. Secondly, since the front surface is made of synthetic fiber knit and the back surface is covered with a synthetic rubber backing layer, it can be washed repeatedly (washable), and can be washed at home. . Since the backing layer on the back side is embossed, the back side is not slippery and the end face does not turn up. Further, since the raised hair knitting layer and the backing layer are sewn around the end, the end face is prevented from fraying, and the appearance is also good.

In the rug, it is preferable that the raised knitted knitted fabric is prevented from being stretched in the weft direction by inserting a weft. This is because dimensional stability is excellent. Further, in the rug, it is preferable that the nap portion is made of a fiber mainly composed of an acrylic fiber, and is shrunk and entangled by sheep processing using steam. Acrylic fibers have a warm feel, good wash resistance, and can be easily shrunk and entangled by steam treatment. Further, even when washing is repeated, there is little change in the surface shape. This is because shrinking and entanglement by steam treatment make it difficult to understand the so-called pilling that occurs with repeated washing. The knitted fabric may be made of polyester fiber or cotton fiber in addition to acrylic fiber, or a mixture of these fibers.

In the rug, the synthetic rubber of the backing layer is preferably a styrene-based synthetic rubber or an olefin-based synthetic rubber. Examples of the styrene-based synthetic rubber include butadiene-styrene copolymer (SBR), and examples of the olefin-based synthetic rubber include ethylene-propylene copolymer (EPM) and ethylene-propylene-non-conjugated diene copolymer. (EPDM). The thickness of the synthetic rubber backing layer is preferably about 0.5 to 1.0 mm. In the rug, it is preferable that the waterproof rug is a rug for an indoor toilet for nursing care for the elderly or a disabled person. Other uses include household toilet rugs and pet toilet rugs.

[0009]

[Embodiment of the invention]

 Next, an example of a method for manufacturing the waterproof rug of the present invention will be described with reference to the drawings. The present invention is not construed as being limited by the following embodiment.

[0010] (1) Formation of a circular knitted raised boa knitting using a milling knitting apparatus Fig. 1 is an enlarged explanatory view of a main part of cut pile forming means. In FIG. 1, reference numeral 1 denotes a ground tissue thread, 2 denotes a knitting needle (dial needle), 3 denotes a vera portion located below a hook portion of the knitting needle 2 and capable of opening and closing, 4 denotes a bee which holds a dial loop, and 5 denotes a pile thread. Reference numeral 6 denotes a sickle hook that forms a loop of a pile thread and controls the length of the loop, 7 denotes a blade section that cuts off the pile thread loop by raising the sickle hook, and 8 denotes a pile thread loop section. A holding disk 9 for facilitating the cutting of the loop portion of the pile yarn by raising the sickle hook 6 and a weft yarn 9. Further, P is a pile yarn supply section, G is a ground texture yarn supply section, C is a cut section for cutting a loop section of the pile yarn, and N is a weft operating section.

The operation of the apparatus according to the embodiment configured as described above will be described below. First, in the pile thread supply section P, the pile thread 5 is supplied to the hook portion of the dial needle 2. At the same time, the thread is hooked on the hook of the sickle hook 6 that is rising. Next, the ground yarn 1 is supplied to the hook of the dial needle 2 in the ground tissue yarn supplying section G, and a loop is formed by the reciprocating operation of the dial needle 2. Next, in the pile thread cutting section C, the pile thread is cut by the blade 7 attached to the hook side of the needle by raising the sickle hook 6. The cut may be pulled off using a sickle hook with a blade at the hook.

Next, FIG. 2 is a diagram illustrating the configuration and operation of the knitting needle 2 and the sickle hook 6 used in the present embodiment. In FIG. 2, the knitting needle 2 is shown in the vertical direction for the purpose of illustration, but actually the knitting needle 2 is arranged on the dial in the horizontal direction along the gauge of the circular knitting machine. For example, three knitting needles a, b, and c are used. Knitting needle a has one high protrusion 11, knitting needle b has two protrusions 13 and 14, knitting needle c has one low protrusion 12, and protrusions 11, 12, 13 at a common position. Reciprocating movement before and after creates a ground structure. 11 and 14 are used as projecting portions for feeding the pile yarn 5 to the hook portion of the dial needle 2.

Next, in the pile yarn supply section P, the protrusion 11 of the knitting needle a reciprocates back and forth by the cams 20 and 21. The sickle hook A corresponding to the knitting needle a has protrusions 15 and 16. The protrusion 16 is pushed up by the cam 23, and the protrusion 15 is pulled down by the cam 24. The protrusions 14 and 13 of the knitting needle b reciprocate back and forth by the cams 22 and 21. The sickle hook B corresponding to the knitting needle b has protrusions 15 and 17. The protrusion 17 is pushed up by the cam 25, and the protrusion 15 is pulled down by the cam 26. As a result, the knitting needle a and the sickle hook A are advanced so as to be orthogonal to each other at the pile thread supply section P, and the pile thread is hooked on each hook section. Similarly, the knitting needle b and the sickle hook B perform the same operation.

Next, FIG. 3 is a diagram of one embodiment for explaining the knitting order for each course. First, in 1 course pile yarn supplying portion P ₁ of to advance Kamakagihari A and knitting needles a, pile yarns were subjected feeding, in the ground structure yarns supply unit G _1, to the yarn feeding the ground threads. In the pile cut portion C _1, and at the same time hold the pile yarn presser disc 8, by pushing up the protruding portion 15 of the Kamakagihari, cutting the pile yarn edge portion 7. Similarly, in two courses of pile yarn supply section P _2, to advance the Kamakagihari B and knitting needles b, pile yarn supplies, in the ground structure yarns supply unit G _2, cutting the pile yarns. Three courses perform the same operation as one course, and four courses perform the same operation as two courses. Knitting is performed as described above. In the above description, one pattern has been described. However, three kinds of knitting needles (bella needles) of dials, two kinds of knife sickle hooks A and B of cylinders, and arrangements of lifting cams allow various organizational changes. it can.

Next, FIG. 4 shows the relationship between the knitting needles (dial needles) a, b, and c and the sickle hooks A and B of the cylinder needles. In FIG. 4, 27 indicates a knitting needle, 28 indicates an arrangement of a sickle hook, and 5 indicates knitting of a pile yarn. The knitting needle 27 and the sickle hook 28 are alternately operated on the same gauge line, indicating that the knitting needle a and the sickle needle A, and the knitting needle b and the sickle hook B, rise when the pile yarn is fed.

FIG. 5 shows an example of the fabric obtained in the present embodiment, in which the ground structure and the weft yarn are supplied and the pile yarn is knitted. In FIG. 5, 29 is a ground texture loop, 31 and 32 are pile yarns, and 30 is a weft yarn. By inserting the weft, elongation in the weft direction is stopped. Each pile loop is cut near the center. However, since this cut is made with a sickle, there is a difference in the length of the left and right hair legs of the cut loop. This variation is corrected and commercialized by post-processing shearing. FIG. 6 shows the napped bore knitted fabric 40 obtained as described above. A nap 41 exists on the front surface, and a knitted ground 42 is formed on the back surface. FIG. 7 shows the state of the defibrated pilus fiber 41a and the knitted structure. 43a is a needle loop yarn, and 43b is a needle wale yarn.

In the above embodiment, the pile yarn is 85% by weight of acrylic fiber and 15% by weight of acrylate fiber (manufactured by Toyobo Co., Ltd., ammonia deodorant fiber “Dismel”), and is 2/32 wool count (double yarn). 45% by weight of acrylic fiber (spun yarn using 1/52 wool count single yarn), 45% by weight of polyester fiber (150 denier filament yarn), 10% by weight of cotton fiber % (20 / -spun yarn). The basis weight (weight per unit area) of the obtained knitted fabric was 400 g / m ² .

(2) Prevention of pile removal on the back surface of the raised knitted knit Next, removal treatment of the pile on the back surface of the raised knitted knit was performed. That is, the knitted ground was fixed by spray-coating a vinyl acetate solution on the knitted ground 42 on the back surface in FIG.

(3) Depilation / Shearing Cut of the Surface of the Napped Bore Knit Next, the napped fibers on the surface were depilated and sheared. As a result, a surface as shown in FIG. 8 was obtained. The pile length was adjusted to about 5 mm.

(4) Shrinkage / entanglement of nap fibers by steam treatment Next, shrinkage / entanglement treatment was performed by applying steam to the nap fibers on the surface. The steam jet nozzle was vibrated vertically and horizontally (beating) to apply steam uniformly. This process is common as sheep processing when making women's coats.

(5) Intermediate Setting A vinyl acetate solution was again spray-coated on the entire knitted fabric, held by a tenter, dried with a drier, and wrinkled to set the intermediate setting. The condition of the intermediate set was a drying condition at 200 ° C. for 3 minutes. This intermediate set is necessary for smooth backing processing in the next step.

(6) Backing treatment Styrene rubber was applied to the back surface of the napped bore knitted fabric with a thickness of 0.5 mm using a doctor blade, and immediately thereafter, embossed using an embossing roll.

(7) Final Finish The sheet was cut into a length of 80 cm and a width of 90 cm (however, four corners were cut round), and the periphery was sewn with a sewing machine. As a result, it was possible to prevent the end of the woven fabric from fraying and to improve the appearance. The total weight was 430 g. The size can be cut at will according to the customer's request. FIG. 9 shows an overall perspective view of the obtained waterproof rug. In FIG. 9, reference numeral 50 denotes a waterproof rug, reference numeral 51 denotes a raised portion (however, the raised fibers are contracted and entangled), and reference numeral 52 denotes a surrounding sewing portion. FIG. 10 shows a cross-sectional view of the end portion. In FIG. 10, 53 is a backing layer, and 54 is a thread at a sewing portion.

The waterproof rug prepared as described above was actually used in a nursing home. In this platform, the user laid a waterproof rug beneath the toilet when using the toilet indoors. As a result, the following effects were confirmed. Good washing resistance, no water leakage after washing several times. In the case of nursing homes, it is necessary to wash once every two to three days or once a week, but this was applicable. Since the backing part (back side) did not slip and the edge did not turn up, there was no accident that the user slipped or stumbled with his feet. Since the main fibers of the knitted fabric are synthetic fibers, washing was easy, contaminants were easily removed, and drying was easy. The main fiber of the nap portion is an acrylic synthetic fiber, so the touch was warm and users could use it. The appearance was good, the appearance was excellent, and the user could like to use it. The portable toilet can be used with confidence.

[0025]

[Effect of the invention]

 As described above, the present invention is a waterproof rug in which a raised knitted knitting layer on the front surface and a synthetic rubber backing layer on the back surface are integrated, and the fibers of the raised portion are made of synthetic fibers contracted and entangled, The backing layer on the back side is embossed, retains waterproofness even after repeated washing, and the raised hair knitted layer and the backing layer are sewn around the ends, so that repeated washing is possible. It is possible (washable) and can be washed at home. Waterproof performance does not decrease even after repeated washing, the back side is not slippery, the overall thickness is thin, and a waterproof rug that does not turn over at the end can be realized. .

[Brief description of the drawings]

FIG. 1 is an enlarged explanatory view of a main part of a cut pile forming means according to an embodiment of the present invention.

FIG. 2 is a diagram illustrating the configuration and operation of a knitting needle and a sickle hook.

FIG. 3 is a diagram for explaining the knitting order for each course.

FIG. 4 is a view for explaining the relationship between a knitting needle and a sickle hook.

FIG. 5 schematically shows the ground structure, the weft insertion yarn, and the pile of the fabric obtained in this example.

FIG. 6 is a perspective view of the bore knitted fabric obtained in the embodiment.

FIG. 7 is a perspective view of a raised portion of the bored knitted fabric obtained in the embodiment.

FIG. 8 is a perspective view in which fibers of the nap portion of the bored knitted fabric obtained in this example are defibrated.

FIG. 9 is an overall perspective view of the waterproof rug obtained in the embodiment.

FIG. 10 is a sectional view of an end portion of the waterproof rug obtained in the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Ground tissue thread 2 Knitting needle (dial needle) 3 Vera part 4 Bee 5 Pile thread 6 Sickle hook 7 Blade part 8 Holding disc 9 Weft 29 Ground tissue loop 30, 31 Pile thread 32 Weft 40 Standing bore knitting 41 Standing thread 41a Disintegrated nap fiber 42 Back knitted ground 43a Needle loop thread 43b Needle wool thread 50 Waterproof rug 51 Napped section 52 Sewing section 53 Backing layer 54 Sewing section thread P Pile thread supply section G Ground tissue thread supply section C pile Thread cutting section

Claims (5)

[Utility model registration claims] 1. A waterproof rug in which a raised knitted knitted layer on the front side and a synthetic rubber backing layer on the back side are integrated, wherein the fibers of the raised part are made of synthetic fibers contracted and entangled,
A waterproof rug, wherein the backing layer on the back side is embossed and retains waterproofness even after repeated washing, and wherein the raised hair knitted layer and the backing layer are sewn around the ends. 2. The waterproof rug according to claim 1, wherein the upright bored knitted fabric is prevented from being stretched in the weft direction by weft insertion. 3. The waterproof rug according to claim 1, wherein the nap portion is made of a fiber mainly composed of an acrylic fiber, and is shrunk and entangled by sheep processing using steam. 4. The waterproof rug according to claim 1, wherein the synthetic rubber of the backing layer is a styrene or olefin synthetic rubber. 5. The waterproof rug according to claim 1, wherein the waterproof rug is an indoor toilet rug for nursing the elderly or a physically handicapped person.