JPH0194819A - Nylon pile mat wherein curling tendency is prevented - Google Patents

Abstract

PURPOSE: To prevent a mat from curling and from raising its end edges when this mat is wet with water by providing the backing layer of the mat with curling preventive layers consisting of a resin or rubber having flexibility at both end edges in the stitch direction of the backing layer of the mat or near the same along the end edges. CONSTITUTION: This mat comprises a base fabric 1, nylon piles 2 tufted to this base fabric 1 and the thin backing layer 3 of elastomer applied on the stitch surface of the base fabric 1. The backing layer 3 of the mat is provided with the curling preventive layers 4 of the resin or rubber having the flexibility at both end edges 3' in the stitch direction of this layer or near these edges along the end edges 3'. At this time, the mat is provided with the backing layer 3 at a coating weight of 200 to 1500g/m<2> and with the curling preventive layers 4 at Metsuke (a weight unit, 4,3560g/m<2> OF 5000 to 50000g/m<2> . Consequently, the mat does not curl and raise its end edges and is safely usable when the mat is wet with the water.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a nylon pile mat that is prevented from curling, and more specifically, the present invention relates to a nylon pile mat that is prevented from curling, and more specifically, its edge portions do not curl even when wet with water. Regarding pace set type nylon pile mat.

(Prior art and its problems) Conventionally, in order to prevent dust attached to the soles of shoes from being brought indoors, dust-collecting mats have been installed at the entrances and entrances of offices, stores, residences, etc. etc., and are used. This type of mat has a tufted pile as the base layer, the tips of the pile are trimmed to form a flat mat surface, and a thin backing layer of elastomer is formed on the back side (stitched side) of the base fabric. It is used. Such a mat is used by simply being placed on a frame-mounted stand called a base. Such mats are used for a long period of time by being repeatedly washed and regenerated when they become dirty due to use.In that case, it is sufficient to wash and regenerate only the mat, so it is necessary to attach the mat to the base, and It is necessary to frequently perform removal work from the base. Generally, the mats mentioned above are used as rental products, and cleaning and recycling of the mats requires special techniques, so cleaning and recycling of the mats is carried out intensively by specific companies. It is important for these companies to simplify the installation and removal of the base from the base. The easiest way to do this is to simply place the mat on the base.

As the pile of the mat, a nylon pile made of nylon fiber or a blended fiber containing nylon fiber is generally used from the viewpoint of mechanical strength, dyeability, durability, economic efficiency, and other aspects.

However, when the above-mentioned mat using nylon pile gets wet with water such as rainwater or splashing water during use (due to the nature of the above-mentioned mat, getting wet with water happens on a daily basis), the stitching direction of the mat may change. The ends tend to lift and curl toward the front side of the mat. As mentioned above, the mat is used simply by being placed on the base, so if the mat gets wet and its edges are raised, there is a danger of pedestrians tripping over it. Even if the amount of lift is small, the danger of traversing pedestrians is surprisingly large. The reason why the nylon pile mat curls toward the front side is not necessarily clear, but it is thought to be due to the high water absorption rate and high expansion coefficient of nylon when wet.

Therefore, there is a strong demand for a safe nylon pile mat that does not curl when wet.

(Object of the Invention) An object of the present invention is to provide a nylon pile mat that can be used safely without curling and lifting of the edges when wet with water.

Another object of the present invention is that it is easy to attach to and remove from the base, and maintains its ability to prevent curling for a long period of time even under extremely harsh usage conditions such as repeated rentals, washing and regeneration. It is an object of the present invention to provide a nylon pile mat that can

(Structure of the Invention) The present invention provides a mat comprising a base fabric, a tufted nylon pile on the base fabric, and a thin elastomer backing layer applied to the stitched surface of the base fabric, in which the stitching direction of the backing layer of the mat is This is a nylon pile mat that is prevented from curling, and is characterized by having a flexible resin or rubber anti-curl layer provided along both end edges or in the vicinity thereof.

(Preferred embodiment of the invention) The invention will now be described with reference to the accompanying drawings.

FIG. 1 is a plan view showing the surface of a backing layer of an embodiment of the mat of the present invention, and FIG. 2 is a sectional view schematically showing a cross section taken along the line A--A in FIG. 1.

In FIGS. 1 and 2, a base fabric 1 has a tufted nylon pile 2, and the tips of the nylon pile 2 are trimmed to form a flat surface to form a matte surface. Base fabric 1
A thin backing layer 3 made of elastomer is formed on the entire stitched surface. In the vicinity of both end edges 3' of the backing layer 3 in the pile stitch direction, an anti-curl layer 4 is provided at the end edges 3'.

As the base fabric 1, a woven fabric or a nonwoven fabric made of any synthetic fiber such as polyester is used.

As the pile 2, various fibers manufactured from nylon 6, nylon 66, nylon 6/66, and other nylons, especially crimped nylon fibers alone, or vinylon fibers, acrylic fibers, etc. mainly made of these nylon fibers, etc. Synthetic fibers and blended fibers with natural fibers such as cotton fibers are used. The length and basis weight of the pile 2 may be within the range of mats conventionally used for the purpose of dust control (dust prevention, dust removal), and generally the pile length is 3 to 40 mm and the basis weight is 300 to 4000 g/lx2. It's fine.

Elastomers used for the backing include acrylonitrile-butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), chloroprene rubber, butadiene rubber, ethylene-propylene copolymer rubber, and ethylene-propylene-diene rubber. copolymer rubber,
Examples include isoprene rubber, isobutylene rubber, polyurethane, and soft polyvinyl chloride. These elastomers are applied in latex form to the entire stitched surface of the base fabric 1, dried and then optionally vulcanized to form a thin backing layer 3 of elastomer. The backing layer is preferably provided in a coating amount of 200 to 1500 g7m2 in terms of solid matter.

The material forming the anti-curl layer 4 is a flexible resin or rubber. As flexible resin or rubber,
The elastomer used for the backing layer 3 is preferably used for the integration or adhesiveness of the backing layer 3 and anti-curl layer 4, but polyethylene, polypropylene,
Other resins such as iron, iron, acrylic resin, etc. can also be used if necessary by pre-treating them or by using them in combination with a plasticizer. The anti-curl layer further includes glass fiber,
Inorganic or organic fibers such as polyester fibers, calcium carbonate, talc, silica, carbon black or other powder fillers may be mixed.

The anti-curl layer 4.4 is provided near both end edges 3', 3' of the backing layer 3 in the pile stitch direction, as shown in FIG. The anti-curl layer 4 is generally in the form of a strip with a width of 1 to 15 cm, although it varies depending on the size of the mat, the material of the bail 2, and the basis weight.
It is preferable that the distance between the outer edge of the anti-curl layer 4 and the edge 3' of the mat is within 3 cm.Of course, the outer edge of the anti-curl layer 4 and the edge 3' of the mat should be aligned Good too. The anti-curl layer 4 may have any shape other than the strip shape shown in FIG. 1, such as a broken line strip, a wavy strip, or any other shape that enhances the Ikenuchi effect. Further, the cross-sectional shape of the curl prevention layer 4 is not limited to a rectangle as shown in FIG. 2, but may be a trapezoid or any other arbitrary shape. The weight per area of the anti-curl layer 4 varies depending on the size of the mat, the material and weight of the bail 2, the position of the anti-curl layer 4, etc., but is generally preferably from 5,000 to 50,000 g/m'.

The method for forming the anti-curl layer 4 is that when forming the backing layer, the backing material is applied and dried, and the material for the anti-curl layer is applied and dried on top of the backing material, and the backing layer material and the anti-curl layer material are simultaneously applied. Method of heating and vulcanizing under pressure, after vulcanizing to form a backing layer, applying and drying the anti-curl layer material, or stacking unvulcanized molded products, and then heating A method of vulcanization, a method of adhering an anti-curl layer member after forming a backing layer, etc. can be employed.

(Effects of the Invention) The mat of the present invention is provided with an anti-curl layer at both end edges of the backing layer of the mat or in the vicinity thereof, so even though it is a nylon pile mat, it can be used even when wet. Since it does not curl and its edges do not lift, it can be safely used as a dust control mat by laying it at a doorway, entrance, etc.

In addition, in the mat of the present invention, the anti-curl layer is fixed to the backing layer to such an extent that it does not cause any trouble during normal use, making it easy to attach and remove the mat from the base. Moreover, even after repeated rental, washing and regeneration, the curling tendency prevention function can be maintained for a long period of time.

Example 1 and Comparative Example 1 Fabric weight 2 Q Ogem 2 polyester fiber plain woven base fabric, crimped nylon (BCF nylon) stitched at 6/1 nch, gauge 5/32, and stitch size 560 g/m `` to form a matte surface by trimming the ends of the pile to a pile height of 8 mm, and applying NBR latex (solid content 46% by weight) to the stitched surface of the base fabric in an amount of 900 g/m' in terms of solid content. Apply with, dry,
A backing layer was formed by vulcanization at 150°C, and a nylon pile mat was created.

Cut this mat to 70cm (stitch direction) x 8
Two mat pieces having a size of 5cI11 (in the gauge direction) were prepared.

On top of one backing layer of this mat piece, a strip (5 cm) is placed near both edges in the stitching direction as shown in Figure 1.
Size: x83cm, distance from the edge of the mat: 1tC1
) was coated with a urethane resin coating liquid (approximately 40 g each in terms of solid matter) and dried to form an anti-curl layer. The obtained mat was designated as Example 1.

The remaining mat piece was used as Comparative Example 1 as it was.

The mats of Example 1 and Comparative Example 1 were placed in water at room temperature for 10 minutes.
After soaking for 1 minute, taking it out of the water and dehydrating it in a centrifugal dehydrator for 1 minute, immediately spread it on a horizontal place and leave it for 1 minute, curl height (height from the horizontal place to the edge of the matte backing layer, h) in FIG. 3, which shows a partial cross section of the curled mat, was measured. The results are shown in Table 1.

Table 1 Example 2 and Comparative Example 2 BCF nylon stitched 7.5/1 nc on a base fabric made of polyester fiber plain woven fabric with a basis weight of 200 g/m"
Tufted with a gauge of 5/32 and a basis weight of 690 g/m2, the tip of the pile was trimmed to a pile height of 8.5 mm to form a matte surface, and NBR was applied to the stitched surface of the base fabric.
Latex (solid content 46% by weight) converted to solid content 950
It was applied at a coating weight of g/m2, dried, and vulcanized to form a backing layer, thereby creating a nylon pile mat.

Cut this mat to 70cm + (stitch direction) x
Two mat pieces having a size of 85 cm (in the gauge direction) were prepared.

On top of one backing layer of this mat piece, as shown in FIG.
+ x 83cm x 1 arm (thickness)) unvulcanized NBR sheet from the edge of the mat ICll1! ! Place them on the table, sandwich them with Teflon-coated glass fiber cloth, and add 5g
Heating at 150°C for 15 minutes under a pressure of
The unvulcanized BR sheet was press-cured and simultaneously adhered to the backing layer to create a mat having an anti-curl layer. The resulting mat was designated as Example 2.

The remaining mat piece was used as Comparative Example 2 as it was.

The mats of Example 2 and Comparative Example 2 were treated in the same manner as in Example 1, and the curl height after the immersion dehydration treatment was measured. The results are shown in Table 2.

Table 2

[Brief explanation of the drawing]

1 is a plan view showing the backing layer surface of one embodiment of the mat of the present invention; FIG. 2 is a sectional view schematically showing the cross section taken along the line A-A in FIG. 1; The figure is a partial cross-sectional view showing a curled state of a mat that has been immersed in water and then dehydrated. 1 is the base fabric, 2 is the nylon pile, 3 is the backing layer, 3
' is an edge of the backing layer in the pile stitch direction, and 4 is an anti-curl layer. Figure 1 Figure 2 Figure 3

Claims (3)

[Claims] (1) In a mat consisting of a base fabric, tufted nylon pile on the base fabric, and a thin elastomer backing layer applied to the stitched surface of the base fabric, both edges of the backing layer of the mat in the stitching direction or the vicinity thereof A nylon pile mat that is prevented from curling, characterized in that a flexible resin or rubber anti-curl layer is provided along the edge. (2) The backing layer is 200 to 1500 g/m^
The anti-curl layer is applied at a coating weight of 5,000 to 5,000.
The mat according to claim 1, which is provided with a basis weight of 0,000 g/m^2. (3) The anti-curl layer has a width of 1 to 15 cm, and the distance between the outer edge of the anti-curl layer and the edge of the mat is 3 cm.
The mat according to claim 1, wherein the mat is provided such that