JPH05309065A - Pile mat - Google Patents

Abstract

PURPOSE:To provide the pile mat having the gloss of deep and good color tones, excellent form stability and quality without having fallen hair by mainly forming fibers constituting pile yarn of composite fibers composed of the saponified matter of an ethylene-vinyl acetate copolymer and polyamide. CONSTITUTION:The fibers constituting the pile yarn are mainly formed of the composite fibers (saponified Et.VAc/Pa composite fiber) composed of the saponified matter of the ethylene-vinyl acetate (saponified Et-VAc copolymer) and the polyamide. The ratio of the ethylene unit in the saponified Et-VAc copolymer is specified to 25 to 70mol% and >=95mol% of the vinyl acetate unit is preferably saponified. The compounding ratio of the saponified Et-VAc copolymer and the polyamide in the composite fibers is preferably specified to the saponified Et-VAc copolymer: the polyamide =20:80 to 80:20 by weight.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION This invention relates to pile mats.
Specifically, the present invention has excellent color development, good color tone and luster with depth, is flexible and has excellent bulkiness and morphological stability, and further recontamination during washing, and during use and during washing. The present invention relates to a pile mat of good quality without hair loss.

[0002]

2. Description of the Related Art In order to remove dirt and dust adhering to footwear such as shoes, so-called dust-removing mats made of wire mesh, palms, plastic sheets having many irregularities and openings have been widely used. Although these dust removal mats can remove relatively large dirt such as mud, they cannot smoothly remove fine dust and the like.

Therefore, for the purpose of removing fine dust and dust, and preventing static electricity in mats and footwear, a pile mat is produced by using spun yarns composed mainly of cotton, cellulose fibers or polyvinyl alcohol fibers as pile yarns. The one that is impregnated with a wetting agent or the like is used. Furthermore, for the purpose of further improving the dust removal performance of the pile mat,
Underwater softening point is 80 ° C or higher and acetalization degree is 25 to 34
% Undiluted dyed polyvinyl alcohol-based synthetic fiber or mixed fiber of this fiber and other fibers to make a spun yarn, which is twisted into a twisted yarn, and the pile portion is formed from the twisted yarn, and then the surface has dust retention A dust removing mat to which an oil agent is attached has been proposed (Japanese Patent Publication No. 60-2292).
No. 9).

However, in the above-mentioned conventional pile mats, the stiffness of the pile fibers is weak, and particularly when wet, the stiffness of the pile fibers is remarkably lost and the pile falls asleep, resulting in a loss of bulkiness. There is a drawback in that the dust removal effect and the feel are greatly reduced. Moreover, since the spun yarn formed from staple fibers such as staples is used as the pile yarn, there is a lot of idle hair, hair loss occurs during washing and use, and the hair removal easily causes secondary pollution in the room or the like. It has the drawback of

Furthermore, in the case of the above-mentioned polyvinyl alcohol-based synthetic fibers, it takes time and labor to dissolve polyvinyl alcohol in an appropriate solvent to prepare a spinning dope and send it to a wet spinning machine containing a coagulating medium for spinning. A spinning process is required, and the fiber cannot be directly produced by a simple spinning operation such as melt spinning.

Attempts have also been made to fabricate a dust removing mat using synthetic fibers such as polyamide fibers or polyester fibers.
It has the disadvantage that it has poor light fastness and easily turns yellow, and it produces a whitish luster, and that a product with a clear and deep color tone cannot be obtained. There is a problem of recontamination that it is adsorbed and becomes dark.

[0007]

SUMMARY OF THE INVENTION The object of the present invention is not to have the above-mentioned drawbacks of conventional mats, to be easily manufactured, and to have a good color tone and a good color tone and gloss. To provide a pile mat of good quality, which is elastic and does not fall asleep particularly when wet, has excellent bulkiness and morphological stability, and is free from recontamination during washing and without hair loss during use or washing. Is.

[0008]

Means for Solving the Problems The present inventors have conducted research to solve the above problems. As a result, the inventors have found that the above problems can be solved by using a yarn mainly composed of a composite fiber of an ethylene-vinyl acetate copolymer saponified product and a polyamide as a pile yarn in a pile mat, and completed the present invention.

That is, the present invention is a pile mat characterized in that the fibers constituting the pile yarn are mainly composed of composite fibers of saponified ethylene-vinyl acetate copolymer and polyamide.

In the present invention, the expression "the fibers constituting the pile yarn are mainly composed of composite fibers of saponified ethylene-vinyl acetate copolymer and polyamide" means 50 of the fibers constituting the pile yarn. It means that at least 50% by weight, preferably 60 to 100% by weight, is composed of composite fibers of saponified ethylene-vinyl acetate copolymer and polyamide.

A composite fiber of a saponified ethylene-vinyl acetate copolymer and a polyamide (hereinafter referred to as "saponified Et.
Vac / PA composite fiber ") is one of the polymer components, which is a saponified ethylene-vinyl acetate copolymer (hereinafter referred to as" saponified Et.VAc copolymer ") is an ethylene / vinyl acetate copolymer. It means a copolymer obtained by hydrolyzing the vinyl acetate unit of the copolymer by saponification to give a vinyl alcohol unit.

The proportion of ethylene units in the saponified Et.VAc type copolymer is preferably 25 to 70 mol%, particularly preferably 30 to 70 mol%. If the proportion of ethylene units in the copolymer is less than 25 mol%, the spinnability at the time of fiber formation becomes poor, and the number of single yarn breaks and yarn breakages during spinning and drawing increases, and the flexibility is lacking. It becomes a thing. Moreover, the saponified Et.VAc-based copolymer is usually used together with the polyamide in an amount of 250
When a melt-spun composite fiber is produced at a temperature of ℃ or higher, the heat resistance of the saponified Et.VAc-based copolymer becomes inferior, and the spinning cannot be performed smoothly. On the other hand, when the proportion of ethylene units exceeds 70%, the proportion of saponified vinyl acetate units (that is, vinyl alcohol units) inevitably decreases, and the redeposition resistance during washing of the pile mat and the pile yarn elasticity are reduced. Strength, dust-removing effect, colorability, luster, etc. are deteriorated, and the appearance is inferior.

Further, in the saponified Et.VAc type copolymer,
It is preferred that 95 mol% or more of the vinyl acetate units are saponified. When the saponification degree of the vinyl acetate unit is lower than 95 mol%, the crystallinity of the saponified Et.VAc-based copolymer is lowered, the fiber physical properties such as strength are lowered, and the copolymer is easily softened. Therefore, troubles are likely to occur in the processing step, and the pile mat obtained is likely to have a poor texture.

The saponified Et.VAc type copolymer is commercially available from Kuraray Co., Ltd. under the trade name of EVAL ^R and from Nippon Synthetic Chemical Industry Co., Ltd. under the trade name of SORAR ^R , and is easily available. Is. However, a commercially available copolymer of ethylene and vinyl acetate is purchased and saponified, or an ethylene / vinyl acetate copolymer is produced from ethylene and vinyl acetate by radical polymerization or the like and saponified and used. You may.

In any case, when saponified Et.VAc-based copolymer contains metal ions such as alkali metal ions such as sodium ions and potassium ions and alkaline earth metal ions such as calcium and magnesium, saponified E / VAc copolymer
Excessive cross-linking, main chain scission, side chain desorption, etc. occur in the t ・ VAc-based copolymer, and the gelation of the copolymer is likely to occur, or the thermal stability becomes poor, resulting in melting. The heat resistance during composite spinning tends to decrease. Therefore, saponified Et.VAc
In order to spin the PA / PA composite fibers continuously and stably for a long time, it is desirable to keep the content of the metal ions in the saponified Et.VAc-based copolymer below a predetermined amount, particularly saponification. The content of each metal ion in the Et.VAc-based copolymer is preferably 100 ppm or less.

In order to improve the softening point, heat resistance, hot water resistance, etc. of the saponified Et.VAc copolymer, the saponified Et.VAc copolymer in the composite fiber is optionally crosslinked. You may stay. As the cross-linking method, any method known as a cross-linking method for a vinyl alcohol unit-containing copolymer can be adopted. For example, divinyl compounds, monoaldehyde represented by formaldehyde, aldehyde compounds such as dialdehyde, diisocyanate, etc. Examples thereof include cross-linking with an organic cross-linking agent such as polyisocyanate, cross-linking with an inorganic cross-linking agent such as a boron compound, and cross-linking with radiation or light such as γ-ray or electron beam. For example, when the crosslinking treatment is performed with dialdehyde, it is preferable to use a strong acid such as sulfuric acid or hydrochloric acid. If unreacted aldehyde remains after the cross-linking treatment, it may cause discoloration of the dyed product, so it is desirable to oxidize the dye with an oxidizing agent to form the carboxylic acid or its salt. Such a cross-linking treatment is performed by saponification Et.VAc / P
Processability is obtained after the pile mat of the present invention is produced by using a yarn mainly composed of A composite fiber as a pile yarn,
It is desirable in terms of workability.

In the pile mat of the present invention, as the pile yarn, a yarn mainly composed of the above-mentioned saponified Et.VAc copolymer and the composite fiber of polyamide is used. Polyamide has good bonding properties with saponified Et.VAc copolymers, and saponified Et.VAc in various composite forms.
Even when composite spinning is performed with the copolymer, the interfacial peeling at the joint surface between the saponified Et.VAc copolymer and the polyamide does not occur, and the processability of fiber formation is good. Moreover, even after being formed into a pile mat, there is no trouble due to peeling at the joint surface between the saponified Et.VAc copolymer and the polyamide.
Moreover, like saponified Et.VAc-based copolymers, polyamide has relatively good resistance to recontamination during washing and there is little problem of recontamination during washing such as polyester, so saponification In combination with the extremely excellent redeposition resistance of the Et.VAc-based copolymer, it is possible to obtain a pile mat having an extremely excellent redeposition resistance during washing.

Since polyamide has a relatively high refractive index, the colored fiber of polyamide alone tends to have whitish luster, but it is colored by forming a composite fiber with a saponified Et.VAc copolymer having a small refractive index. As a result, it is possible to obtain a color tone having a good gloss and a good gloss. In that case, but not limited to, saponified Et.V
Saponified E obtained by compounding with a polyamide using a copolymer having a refractive index of 1.55 or less as an Ac-based copolymer
The color tone and gloss of the t · VAc / PA composite fiber are further improved.

As the polyamide, it is preferable to use nylon 6, nylon 66, nylon 12 or a mixture of two or three of them, from the viewpoint of fiber forming processability. In addition, a small amount of a polyamide obtained by copolymerizing another third component may be used together with these polyamides, if necessary.

The composite ratio of the saponified Et.VAc copolymer and the polyamide in the composite fiber is, by weight, saponified Et.
-VAc-based copolymer: polyamide = 20:80 to 80: 2
It is preferably 0, and particularly preferably 30:70 to 70:30. Saponified Et.VAc in composite fiber
When the proportion of the system copolymer is less than 20% by weight, the proportion of alcoholic hydroxyl groups in the composite fiber decreases,
The redeposition resistance of the obtained pile mat at the time of washing or the like is lowered, and the gloss and the color development state are poor. On the other hand, when the proportion of the saponified Et.VAc-based copolymer exceeds 80% by weight, the processability such as spinning, stretching and entanglement treatment tends to be poor, and the fiber physical properties such as fiber strength are deteriorated, resulting in poor resistance. It becomes difficult to obtain a pile mat having excellent friction properties.

The composite form of the saponified Et.VAc / PA composite fiber may be any form such as a core-sheath type, a sea-island type, a laminating type, and a mixed type thereof. 2 for core-sheath type
Either a core-sheath type or a multilayer core-sheath type having three or more layers may be used. In the case of the sea-island type, the shape, number and dispersion state of the islands can be arbitrarily selected, and a part of the islands may be exposed on the fiber surface. Further, in the case of the bonding type, in the fiber cross section perpendicular to the length direction of the fiber, the bonding surface may be linear, arcuate, or any other random curved shape, and further a plurality of bonding portions May be parallel to each other, may be radial, or may have any other shape.

As described above, saponified Et.VAc / PA
In the conjugate fiber, the saponified Et.VAc-based copolymer and the polyamide are preferably compounded in a weight ratio of 20:80 to 80:20. Among them, the saponified Et.・ The area ratio occupied by VAc-based copolymer is 6
It is desirable to set it to 0% or more. As a result, the obtained pile mat is given sufficient resistance to redeposition during washing, and its gloss and color development are further improved. In particular, when a polyamide having a high refractive index is covered with a saponified Et.VAc copolymer having a low refractive index,
It is possible to obtain a product which is not whitish and has a good gloss and color with a depth that is wet.

The cross-sectional shape of the saponified Et.VAc / PA composite fiber may be any shape, and may be circular or irregular. In the case of an irregular cross section, for example, a flat shape, a polygon such as a triangle to an octagon, a T-shape, a multilobe shape,
It can be an arbitrary shape such as an ellipse. Although not limited, the saponified Et.VAc / P used in the present invention
Specific examples of the A composite fiber include the composite form and cross-sectional shape shown in FIGS. 1 to 8, for example. 1 to 8, A represents a saponified Et.VAc-based copolymer and B represents a polyamide. Further, the above-mentioned conjugate fiber can optionally contain optional additives such as a fluorescent whitening agent, a stabilizer, a flame retardant and a colorant which are usually used in the fiber-forming polymer.

The above-mentioned saponified Et.VAc / PA composite fiber is produced by melt-composite spinning using a saponified Et.VAc copolymer and polyamide, and subjecting it to stretching treatment, heat treatment, etc., if necessary. be able to. The conditions such as the spinning temperature, the take-up speed, the drawing temperature, the draw ratio, and the heat treatment temperature are determined by the composition of the saponified Et / VAc copolymer, the saponification degree, the type of polyamide, and the composite ratio of both polymers. It is preferable to appropriately select it according to the composite form or the like. As the melt spinning method at that time, any of the conventional melt composite spinning techniques for producing a composite fiber from two kinds of thermoplastic polymers can be used. For example, each of the saponified Et.VAc-based copolymer and the polyamide is melted by a separate extruder to form each molten polymer stream, and the molten polymer stream is introduced into a spinning device having a composite spinning pack. A composite fiber can be produced by combining and spinning in a spinning pack and spinning.
Although not limited, a melting temperature of each polymer at that time is usually 285 ° C. or lower, and a spinning temperature is 250 to 285 ° C.

The method for producing a pile yarn for a pile mat from the saponified Et.VAc / PA composite fiber obtained above is not particularly limited, and for example, a large number of saponified Et.VAc / PA may be used.
The filaments of the composite fiber are combined to form a multifilament yarn, and a plurality of the multifilament yarns may be combined to form a pile yarn having a predetermined thickness by, for example, ply twisting, air processing, or fiber mixing, or Interlacing, stuffing, and conventional BCF (Bulked Continuous Filament)
Pile yarn may be obtained by performing bulking by applying crimps by the ment method), and then combining a plurality of the bulky processed yarns and performing ply twisting, air processing, mixed fiber, and the like.

When a plurality of multifilament yarns are combined to produce a pile yarn by carrying out twisting, air processing, mixed fiber, etc., even if the same multifilament yarns are combined, saponified Et.VAc / PA composite fiber You may combine the multifilament yarn of and the multifilament yarn of other fibers. When the multifilament yarn of the saponified Et.VAc / PA composite fiber and the multifilament yarn of another fiber are combined, the multifilament yarn of the other fiber is selected from aromatic polyamide fiber, aliphatic polyamide fiber, polyester fiber, etc. Can be used. In that case, the ratio of the other multifilament yarns should be 5% of the fibers constituting the pile yarn.
It is necessary to keep it below 0% by weight, and particularly preferably 40% by weight or less.

It is preferable that the pile yarn is formed of long fibers such as the above-mentioned multifilament yarn because the idle yarn in the pile yarn is eliminated and hair loss or hair loss does not occur when the pile mat is formed. However, in some cases,
A staple is formed from the above-mentioned saponified Et.VAc / PA composite fiber, which is used alone or by mixing with less than 50% by weight of other natural and / or synthetic fibers to form a spun yarn. Pile threads may be formed and used in the pile mat of the present invention. Regardless of whether the pile yarn is made of filament yarn or spun yarn, the thickness of one pile yarn is usually about 500 to 6000 denier.

The pile yarn is colored by saponification Et.VAc / P
At the time of manufacturing the A composite fiber, before manufacturing the pile yarn after manufacturing the composite fiber, after manufacturing the pile yarn from the composite fiber,
Alternatively, it can be performed at any stage after manufacturing the pile mat. In the case of directly producing a colored composite fiber by composite spinning, the colorant is mixed with one or both of a saponified Et.VAc copolymer and a polyamide in the form of a masterbatch, and then melt composite spinning is performed. Good. As the colorant, for example, an inorganic pigment typified by titanium oxide, carbon black, ultramarine, dark blue, phthalocyanine, or other organic pigment may be appropriately used depending on the color tone to be exhibited in the pile yarn. It is preferable to use a colorant that is capable of producing a light and has good light resistance.

The pile yarn obtained as described above is then embedded in a substrate made of cloth such as woven cloth, knitted cloth, and non-woven cloth. There are no particular limitations on the type of base material, the method for implanting pile yarns, the apparatus used therefor, and the like, and any of the base materials, methods, and manufacturing apparatuses used in the conventional manufacture of pile mats can be used. It is preferable that the pile thread is embedded in the base material so that the gauge interval is usually in the range of 1/5 to 1/12 and the stitch is in the range of 5 to 13.
If the pile yarn is too densely planted, dust will increase on the pile surface, and fine dust will scatter when it is stepped on, leading to recontamination of the surrounding area. On the other hand, if the pile thread density is too low, the dust removal function will decrease,
In addition, dust enters the eyes of the base material, making cleaning and removal thereof difficult. If necessary, saponified Et.VAc /
A pile yarn mainly made of PA composite fiber and a pile yarn mainly made of other fiber may be implanted together in a base material,
As a result, it is possible to obtain a pile mat having the above-mentioned various excellent properties based on the saponified Et.VAc / PA composite fiber and the properties based on other fibers. And, in that case, the ratio of the pile yarn composed of other fibers is 40%.
The following is preferable.

When the pile yarn implanted is hard to come off from the base material, the base material in which the pile yarn is embedded may be used as it is as a pile mat, but generally, a backing material such as rubber or resin is applied to the back surface of the base material. It is desirable to fix the pile yarn that has been implanted and prevent it from coming off and to stabilize it. As the backing material, it is possible to use any of those used in this type of pile mat, for example, styrene butazine rubber, acrylonitrile rubber, butadiene rubber, chloroprene rubber, isoprene rubber,
Examples thereof include synthetic rubber such as polyurethane rubber, natural rubber, polyvinyl chloride and the like. The backing with these polymers is usually a suspension, emulsion, latex, solution or melt of those polymers containing additives such as colorants, flame retardants, cross-linking agents and stabilizers as required. Etc. are applied to the back surface of the base material and dried or solidified by other means. In the pile mat of the present invention, if necessary, another cloth or the like may be laminated on the backing material made of a polymer.

The pile yarn implanted in the base material may be used as a loop pile without being cut as it is, or may be cut into a tufted cut pile for use. The pile yarn length (length) is generally about 5 to 20 mm, preferably about 8 to 15 mm.

The pile mat of the present invention obtained as described above may be dyed, if necessary, by an appropriate dyeing method such as a dip dyeing method and a textile printing method. Further, the pile mat may be treated with any agent such as a treating agent, a wetting agent, an antistatic agent, a flame retardant, a fungicide, a bactericide / insecticide, and a light stabilizer for enhancing the dust removing effect of the pile mat.

The pile mat of the present invention has a wide range of applications, such as entrance mats, room entrance mats, bathroom mats, kitchen mats, corridor mats, indoor mats, vehicle mats for automobiles, railroads, aircrafts, and the like. It can be used for various purposes, and in particular, it can be effectively used in a place where dust-removing property, antistatic property, water absorbing property, and hygroscopic property are required. And especially the degree of recontamination (DS) at the time of washing (DS:
The pile mat of the present invention having a ratio of (described below) of 10% or less does not have a dark color due to a small amount of dirt adsorbed at the time of washing and can keep a good color tone forever.

The present invention will be specifically described below with reference to examples and the like, but the present invention is not limited thereto. In the following examples, the degree of recontamination (DS) when washing the pile mat,
The loss of fibers (hair loss) in the pile mat and the appearance of the pile mat were measured or evaluated as follows.

[0035]

【Example】

[Measurement of Decontamination Degree (DS) During Washing] (a) Pretreatment: The pile mat is washed once under the conditions shown below to be pretreated. Washing conditions : Washing machine: National Automatic NA-5050 Washing liquid: Temperature 40 ° C ± 2 ° C, Detergent (Monogen) 0.25% Bath ratio 1: 100 Washing time: 10 minutes Rinse: 40 ° C × 1 minute 3 times ( b) Recontamination treatment: 6 pieces of 5 × 5 cm test pieces are taken from the pile mat which has been subjected to the above-mentioned pretreatment, and they are set as one set. La
Contaminated liquid in a cup with an under-O-meter type washing machine (3 g of the artificial oily soil component and the solid soil component below mixed in a ratio of 3: 1 and 7 g of detergent monogen paste, and water to add 4
After adding 150 ml and 10 Steel balls to preheat to 40 ± 2 ° C, put the test piece into a washing machine and rotate it for 20 minutes to contaminate it. After the contamination, the test piece is taken out of the washing machine, washed with about 3 liters of water for 1 minute, repeated twice, and then dried at 50 to 60 ° C.

Artificial oily stain component : stearic acid 12.5% oleic acid 12.5% hardened coconut oil 12.5% olive oil 12.5% cetyl alcohol 8.5% solid paraffin (melting point 60 to 61 ° C.) 21.5 % Cholesterol 5.0% Carbon Black (Tamagawa Carbon #LBC) 15.0%

Solid dirt component : Clay dirt 55% (dry cleaning residue diatomaceous earth adsorbate) SiO ₂ (erol) 17% Fe ₂ O ₃ 0.5% cement 17% n-lower hydrocarbon (heptane) 8.75 % Carbon Black (Tamagawa Carbon #LBC) 1.75%

(C) Measurement: Four test pieces obtained above were piled up, and the reflectance (%) was calculated by using an RC-II type Shimadzu Corporation automatic recording spectrophotometer with MgO as 100. Measured three times, take the average value, and use the following formula 1 to determine the degree of contamination.
(DS) (Degree of Soiling) is calculated.

[0039]

## EQU1 ## DS (%) = {(Ro-Rs) / Ro} × 100 where Ro = reflectance of mat before recontamination (original mat) Rs = reflectance of recontamination mat

[Evaluation of Hair Loss of Pile Mat] Diameter 1
Along the length of a 00 mm cylinder, four brushes of about 30 mm width made of palm fibers are fixed at opposite positions, and they are contacted with a motor of 75 rpm to rotate them to form a pile mat. After brushing for a minute, the state of fiber loss (hair loss) and the cut state at that time were relatively evaluated by the following. Criteria for evaluation of hair loss ; ○: Almost no fiber fibers are cut off or cut Δ: Slight fiber loss or breakage occurs ×: Fiber loss or breakage occurs significantly

[Evaluation of Appearance of Pile Mat] The evaluation was performed according to the following evaluation criteria. ○: Good appearance without change in appearance after DS measurement △: Slight contamination after DS measurement and slight hair loss ×: Severe contamination after DS measurement and significant hair loss and fiber cutting Occurrence

Example 1 Using methanol as a polymerization solvent and azobis-4-methyloxy-2,4-dimethylvaleronitrile as a polymerization initiator, 60
Ethylene and vinyl acetate are radically polymerized under pressure at ℃, ethylene content is ethylene in the ratio shown in Table 1 below.
Vinyl acetate random copolymer (number average degree of polymerization about 350)
Was manufactured. Next, the ethylene / vinyl acetate random copolymer was saponified in a methanol solution containing caustic soda, and the saponification degree of vinyl acetate units in the copolymer was in the wet state having the values shown in Table 1. A modified Et.VAc-based copolymer was produced. This saponified Et.VAc-based copolymer was repeatedly washed with a large excess of pure water to which a small amount of acetic acid was added, and then washed with a large excess of pure water to obtain the alkali in the copolymer. The content of each of metal ion and alkaline earth metal ion is set to about 10 ppm or less, and then water is separated from the copolymer by a dehydrator, and then sufficiently dried by vacuum drying at a temperature of 100 ° C. or less to saponify Et.・ V
An Ac-based copolymer (refractive index 1.53) was obtained.

The saponified Et.VAc type copolymer obtained above and nylon 6 [1013BK manufactured by Ube Industries, Ltd.] are melt extruded at 250 ° C. by separate extruders and supplied to a spinning pack of a composite spinning device. And spinning from a spinneret at a spinning temperature of 260 ° C. to spin out a composite fiber having a composite weight ratio, a composite morphology and a cross-sectional shape shown in Table 1, and adhering a non-aqueous spinning oil agent to 1500 m / min. I wound it up. The obtained spun raw yarn is drawn 2.0 times by a usual roller plate type drawing machine and then combined to form a multifilament of 1500 denier / 100 filaments, and the multifilament is crimped by a hot air fluid treatment method. It was processed into crimped yarn. The total fineness of the crimped yarn is 300
A 0-denier / thread, 100T / MZ plied yarn was prepared and used as a pile yarn.

On the other hand, as a substrate, an average basis weight 1 obtained by impregnating a fiber-entangled nonwoven fabric of polyester fibers with a binder resin
Using a non-woven fabric of 60 g / m ² , the pile yarn produced above was planted at a pile implantation density of 8 × 8 yarns / inch ² . Next, after trimming the pile length to 9 mm and performing hair styling, a nitrile synthetic rubber latex solution is applied to the back surface of the base material at a rate of 900 g / m ² , dried and cured at 160 ° C. and lined with rubber. The pile mat of the present invention was prepared. The degree of washing redeposition (DS) of the obtained pile mat was measured by the above-mentioned method, and the hair loss property and the mat appearance were also evaluated by the above-mentioned method. The results are shown in Table 1 below.

[0045]

[Table 1]

From the results shown in Table 1 above, saponified Et.VAc /
A pile yarn made of PA composite fiber, in which the copolymerization ratio of ethylene is 25 to 70 mol%, the saponification degree of vinyl acetate units is 95 mol% or more, and the saponified Et / VAc copolymer is used. And the composite ratio of polyamide is 2
Saponified Et.VAc / in the range of 0:80 to 80:20
It can be seen that the pile mat of the present invention produced by using the pile yarn made of PA composite fiber has extremely high redeposition resistance during washing, less hair loss, and good appearance.

Example 2 Polymerization and saponification were carried out in the same manner as in Experiment No. 5 of Example 1 to give a saponified Et.VAc copolymer having an ethylene content of 44 mol% and a saponification degree of 99%. Made. The saponified Et / VAc copolymer was subjected to composite spinning, stretching and crimping treatment in the same manner as in Example 1 to give a saponified Et / VAc copolymer / polyamide composite weight ratio of 1 A 1: 1 crimped composite filament was made. This filament is cut into staple fibers (fiber length 51 mm, fineness 6 denier),
Using this, a spun yarn with an average fineness of 750 denier was produced, and four spun yarns were twisted together to produce a pile yarn with a total fineness of 3000 denier / line.

Using this pile yarn, a pile mat was produced in the same manner as in Example 1, and the degree of redeposition during washing (D
S), hair loss and matte appearance were measured or evaluated by the methods described above. As a result, as shown in Table 2 below, the hair loss property is Δ and slightly inferior, but the DS is 2.5.
%, The anti-soil resistance during washing was excellent, and the appearance of the mat was also good.

Example 3 The same crimped multifilament yarn (1 as produced in Experiment No. 5 of Example 1)
A pile yarn with a total fineness of about 2100 denier and 100 T / MZ was prepared by twisting false-twisted yarn (600 denier / 48 filament) of blue-dyed nylon 6 filament yarn) with 500 denier / 100 filament). The pile yarn was embedded in a base material made of a nylon spunbonded nonwoven fabric impregnated with a binder resin containing a flame retardant at a pile implanting density of 10 × 10 yarns / inch ² to form a loop pile having a pile length of 6 mm. Next, 200 g / m 2 of synthetic rubber latex liquid containing a flame retardant on the back surface of the base material.
^It was applied at a ratio of ² and then dried and then cured at 160 ° C. to fix the pile, and a pile mat having a loop pile was manufactured. The degree of redeposition on washing (DS), hair loss and mat appearance of this pile mat were measured or evaluated by the methods described above. The results are shown in Table 2 below, and the DS was as low as 7.0% and the redeposition resistance during washing was excellent, and the hair loss resistance and the appearance were also good.

Example 4 The same crimped multifilament yarn (1 as produced in Experiment No. 5 of Example 1)
500 denier / 100 filament) and false twisted polyester filament yarn false twisted yarn (600 denier / 48 filament) are combined and twisted at a weight ratio of 70:30 to obtain a total fineness of about 3,000 denier, 100 T / MZ.
I made a pile thread. Using this pile yarn, a pile mat was manufactured in the same manner as in Example 1. When the soil redeposition degree (DS), hair loss property and mat appearance of this pile mat were measured or evaluated by the above-mentioned methods,
The results are shown in Table 2 below, and DS was 4.
It was as low as 5%, was excellent in redeposition resistance during washing, and had good hair loss resistance and good appearance.

Comparative Example 1 A polyester multifilament having about 1500 denier / 100 filaments was prepared by a conventional method, and the multifilament was treated by a hot air fluid treatment method to produce a crimped yarn, and then two crimped yarns were produced. The yarns were twisted together to make a pile yarn having a total fineness of about 3000 denier and 100 T / MZ. Using this pile yarn, Example 1
A pile mat was manufactured in the same manner as in. This pile mat was measured or evaluated for the degree of recontamination at washing (DS), the hair loss property and the mat appearance, and the results are shown in Table 2 below, and the DS was 45.
It was extremely high at 0% and was inferior in redeposition resistance.

Comparative Example 2 In the above-mentioned Example 4,
Example 4 except that the ply twist ratio of the same crimped multifilament yarn produced in Experiment No. 5 of Example 1) and the false twisted yarn of the blue-dyed polyester filament yarn was set to 30:70. A pile mat was manufactured in the same manner as in. As shown in Table 2 below, the redeposition degree (DS) at the time of washing of this pile mat was as high as 25.0%, and the redeposition resistance was poor.

[0053]

[Table 2]

[0054]

The pile mat of the present invention is not re-contaminated at the time of washing and therefore does not darken for a long period of time, and can maintain a good color tone and luster with a feeling of cleanliness and depth. Further, in the pile mat of the present invention, since the pile is elastic and does not fall asleep when wet, it is excellent in bulkiness and shape stability, and can maintain a good appearance and dust removal performance. Further, the pile mat of the present invention,
In particular, in a pile mat using a multi-filament yarn of saponified Et.VAc / PA composite fiber as a pile yarn, there is no hair removal during use or washing, and there is no secondary pollution of the surrounding environment due to hair removal. Moreover, the pile yarn in the pile mat of the present invention can be produced extremely easily and smoothly by melt-composite spinning.

[Brief description of drawings]

1 is a saponified Et. Used in the pile mat of the present invention.
It is a figure which shows an example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 2 Saponified Et · used in the pile mat of the present invention
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 3 is a saponified Et. Used in the pile mat of the present invention.
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 4 is a saponified Et. Used in the pile mat of the present invention.
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 5: Saponified Et. Used in the pile mat of the present invention
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 6 is a saponified Et. Used in the pile mat of the present invention.
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 7: Saponified Et. Used in the pile mat of the present invention
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

FIG. 8: Saponified Et. Used in the pile mat of the present invention
It is a figure which shows another example of the cross-sectional shape of VAc / PA conjugate fiber.

[Explanation of symbols]

 A Saponified Et / VAc copolymer B Polyamide

 ─────────────────────────────────────────────────── ─── Continued Front Page (72) Inventor Hiroaki Morioka 1-1239 Umeda, Kita-ku, Osaka Kuraray Co., Ltd. (72) Inventor Kiyoshi Hirakawa 1621 Sakata, Kurashiki-shi, Okayama Kuraray Co., Ltd.

Claims (5)

[Claims] 1. The fiber constituting the pile yarn is ethylene-
A pile mat which is mainly composed of a composite fiber of a saponified vinyl acetate-based copolymer and a polyamide. 2. The pile mat according to claim 1, wherein the saponification product of the ethylene-vinyl acetate copolymer has a saponification degree of 95% or more. 3. The pile mat according to claim 1, wherein the ethylene copolymerization ratio in the saponified ethylene-vinyl acetate copolymer is 25 to 70 mol%. 4. The pile mat according to claim 1, wherein the composite ratio of saponified ethylene-vinyl acetate copolymer: polyamide in the composite fiber is 20:80 to 80:20 by weight. .. 5. The pollution degree DS is 10% or less.
The pile mat according to any one of items 1 to 4.