JPH0648572U - mat - Google Patents

Abstract

(57) [Summary] [Purpose] The matted tufted pile layer surface has a soft and gentle texture, and also has excellent dust collection properties and oil absorption properties, as well as excellent durability. Provided is a mat in which pile yarns do not come off or fall off even when subjected to severe conditions such as repeated washing and regeneration. A mat comprising a base fabric, a tufted pile on the base fabric, and a backing provided on the back face of the base fabric, wherein the pile comprises a plurality of twisted yarns, a substantially untwisted staple fiber bundle, and a low melting point melt. A mat comprising adhesive filaments or staples, wherein the staple fiber bundle is fixed between the twisted yarns by cross twisting by the twisting yarns and fusion by the fusible filaments or staples.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a mat, and more specifically, the tufted pile layer surface of the mat has a soft and gentle texture, and is excellent in dust collection and oil absorption, as well as durability. The present invention relates to a mat which is excellent, and in which pile yarns do not easily come off or fall off even when subjected to harsh conditions such as repeated washing of the mat and repeated regeneration.

[0002]

[Prior art]

 In the past, mats for dust collection have been laid and used mainly at the entrances of stores and offices to prevent dust from being brought into the room. When used and contaminated, these mats are usually collected, cleaned, regenerated, and reused later. In recent years, mats rented by a so-called rental system have been laid and used for these mats. In the rental system, the cycle of mat delivery to each user store, use at the store, collection, cleaning, regeneration of dust collection function, and delivery to each user store is repeated, and for rental The mat to be used in the above is exposed to severe conditions such as many times of cleaning and regeneration treatment as well as during use.

In any case, mats are repeatedly cleaned and regenerated during their use, so that fibers such as mat piles may fall out during that time and the color tone and pattern of the pile surface may become unclear. As a result, its life will be relatively short. Such inconvenience is particularly noticeable in mats that use fine staple fibers as pile yarns in order to give the pile surface a soft texture, and this type of excellent durability performance including cleaning durability. The appearance of Matt has long been strongly desired.

[0004]

[Problems to be Solved by the Invention] Therefore, the object of the present invention is to have a soft texture, excellent dust collecting property and oil absorbing property at the time of use, and repeated cleaning and regeneration. The purpose is to provide a rental mat that has outstanding durability performance, including cleaning durability, in which fibers such as mat pile do not fall off or fall out.

[0005]

[Means for solving problems]

 According to the present invention, in a mat comprising a base fabric, a tufted pile on the base fabric, and a backing provided on the back face of the base fabric, the pile comprises a plurality of twisted yarns, a bundle of substantially incombustible staple fibers, and a low-strength fiber bundle. A fusible filament or staple having a melting point, and the staple fiber bundle is fixed between the twisted yarns by intertwisting by the twisting yarns and fusion by the fusible filaments or staples. Matt is provided.

[0006]

[Action]

 The mat of the present invention uses a plurality of twisted yarns, a cotton-like non-combustible staple fiber bundle, and a low-melting fusible filament fiber or staple fiber as the pile yarn tufted on the base fabric. When the fusible fiber is a staple, the non-combustible staple in which the fusible staple is mixed between or inside the cross-twisted yarns when the fusible fiber is mixed in the non-combustible staple fiber bundle and the twisted yarns are twisted Use a partially fixed mixed staple fiber bundle that incorporates a fiber bundle, or arrange the low melting point fusible filament fiber together with the twisting yarn, and then twist the twisted yarn where this filament is placed. Non-combustible staple fiber bundles are partially fixed between the intertwisted yarns or inside thereof, or a combination of the above is used. That uses Le yarn is the first characteristic.

Next, in the present invention, the pile yarn having the above-mentioned structure is driven into a tuft to be tufted, and the tuft is further tufted to form a pile layer, and the base cloth is softened and fused to the low melting point fusion temperature. The second feature is that the heat-set is performed at the above temperature, and the intertwisted twisted yarn and the incombustible staple fiber bundle are further bonded and fixed by the fused fiber. In the present invention, a matte is produced by forming a rubber backing layer on the back surface of the base fabric with a pile layer thus formed by a conventional method.

The pile layer of the mat of the present invention is arranged not only by the non-combustible staple fiber bundle constituting the pile yarn being sandwiched between the intertwisted yarns as described above but also fixed in the pile yarn. Since it is bonded and fixed to the twisted yarn by fusing the low melting point fusible fiber, the fiber will not fall off or fall out not only when the mat is used but also when it is exposed to harsh conditions such as washing and regeneration processes. There is almost nothing, and it has a characteristic that it is remarkably excellent in durability, particularly cleaning durability.

Moreover, since the pile yarn of the present invention can absorb and hold a large amount of dust and oils in the cotton-like non-combustible staple fiber bundle, it has excellent dust trapping property, retention property and oil absorption property. Further, since the pile yarn of the present invention is a twisted yarn in which cotton-like non-combustible staple fiber bundles are arranged, the pile surface of the mat of the present invention formed by the pile yarn has a soft and gentle texture. ing.

[0010]

[Preferred Embodiment of the Invention]

 The mat 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 a rental mat of the present invention. Reference numeral 1 is a pile yarn layer, 2 is a base cloth layer, and 3 is a backing rubber layer. 2 to 4 are partial schematic views schematically showing the structure of the pile yarn of the present invention. Reference numeral 4 represents a twisted yarn, and reference numeral 5 represents an incombustible staple fiber bundle.

The pile yarn shown in FIG. 2 has a configuration in which, when the plural twisted yarns 4 are twisted, a cotton-like staple fiber bundle 5 is sandwiched between the twisted yarns and the portion is fixed. In this pile yarn, low melting point fusible staple fibers are mixed in non-combustible staple fibers, and when the pile yarn is cast into the base fabric and tufted, the base fabric on which the pile yarn layer is formed is heat set. The twisted and twisted yarn of the yarn serves to soften the low melting point fusible fibers present in the sandwiched portion of the incombustible staple fiber bundle to further bond the fixed portion of the twisted yarn and the incombustible staple fiber bundle. Therefore, the incombustible staple fiber bundle is not only fixed by sandwiching, but also firmly bonded to the twisted yarn at the fixing portion.

The pile yarn shown in FIG. 3 is substantially the same as the pile yarn of the embodiment shown in FIG. 2, except that the non-combustible staple fiber bundle is not mixed with the low melting point fusible staple, and instead, the twisted yarn is used. A bundle 6 of low-melting-point fusible filament fibers is arranged in the center of the interlaced strands. In the pile yarn of this aspect, the fixed portion sandwiched between the untwisted yarns of the non-combustible staple fiber bundle by the heat setting treatment is in a state of being bonded to the untwisted yarns by the fusible filament fibers.

In FIG. 4, a plurality of intertwisted yarns are used as a core yarn 7 and the periphery thereof is surrounded by a cotton-like non-combustible staple fiber bundle 5, and one twisted yarn 8 is wound from the outside as a wrapping yarn to form a non-combustible staple fiber. This is a mode in which the bundles are bound and fixed. In the pile yarn of this embodiment, the low melting point fusible fibers may be mixed as staples in the non-combustible staple fiber bundle, or may be arranged as filaments in the twisted yarn. Also, a combination of both of the above aspects may be used.

In the present invention, although not shown, a pile yarn of a mode in which non-combustible staple fibers are arranged so as to be wound around each of a plurality of twisted yarns, and these are bundled and fixed by another twisted yarn is used. Of course, it is possible.

As the twisted yarn for the pile yarn used in the present invention, twisted yarn of natural fiber such as cotton, twisted yarn of artificial fiber such as rayon, twisted yarn of synthetic fiber such as polyester, acrylic and vinylon, or a blended fiber thereof is used. Twisted yarn and the like can be used. As the non-combustible staple fiber bundle for pile yarn, a cotton-like staple fiber bundle made of fibers such as cotton, fine rayon, polyester, acrylic and vinylon is used.

Further, as the low melting point fusible staples or filaments, staple or filament fibers of low melting point copolyester, copolyamide, etc. are used, and the polyester softening temperature of the fibers is about 90 to 140 ° C. Fibers made of polymer or polyamide copolymer are preferably used.

In the present invention, it is preferable to use a low melting point copolyamide fiber as the fusible fiber from the viewpoint of the fusion property. Copolymer polyamide fibers composed of monomers, that is, a combination of w-aminocarboxylic acid component or dicarboxylic acid component and diamine acid component can be mentioned.

Such fibers are generally available in the form of low fineness multifilament yarns, the fineness of which is generally in the range of 30 to 300 denier. Suitable low melting point polyamide fibers are available from Toray Co., Ltd. under the trade name Elder and Unitika Co. under the trade name Floor M.

In the present invention, the pile yarn is used to form the pile layer 1 by driving the pile yarn into the base cloth. 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 the mat conventionally used for the purpose of dust control (dust prevention, dust removal). Generally, the pile length of 3 to 40 mm and 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 fusible filaments or staples. The heat setting is preferably performed at a softening temperature of the low melting point fusible filament or staple or at a temperature about 20 ° C. higher than the temperature, and it can be carried out by either a wet heat set or a dry heat set. Particularly when polyamide copolymer fibers are used as the low melting point fusible fibers, heat setting under moist heat is preferable from the viewpoint of heat setting at a relatively low temperature and the fusibility.

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

As the rubber used for the backing, acrylonitrile-butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), chloroprene rubber, ethylene-propylene-diene copolymer rubber, isoprene rubber, isobutyl rubber Examples thereof include ren rubber and polyurethane.

[0023]

【Example】

Twisted yarn obtained by twisting and twisting seven 3 denier vinylon single yarns, non-twisted polyester staple 90%, fusible polyamide spun yarn (trade name: Unimelt, Unitika Ltd., 2 denier × 38 mm, melting point) (110 ° C) 10% of mixed cotton-like untwisted staples are used, and when the four vinylon twisted yarns are twisted together, the cotton-like mixed untwisted staples are mixed and twisted with the vinylon twisted yarns to make a pile yarn. And

This pile yarn was driven into a base fabric made of polyester woven fabric and tufted to form a tuft pile. The pile-forming base fabric was twisted and set in a steam atmosphere at a temperature of 120 ° C., and the mixed untwisted staple cotton was partially fused and fixed to the intertwisted yarn. The tufts had a gauge of 8 pcs / inch, a stitch of 8 pcs / inch, and a pile length of 12 mm.

On the back surface of the base fabric after this setting, NBR latex with an appropriate amount of a vulcanizing agent was applied (400 g / m ² solid content), and after application, the backing layer was dried at 160 ° C. for 10 minutes. A mat having an effective surface of 75 × 80 cm was manufactured.

This mat was laid for 10 days with 1,000 passengers / day, washed, laid under the same conditions, and this cycle was repeated 20 times. The condition of the mat after the 20th cycle was visually observed, but the pile yarns did not fall off or break, and the pile color did not change. A conventional mat containing non-combustible polyester cotton as a pile yarn loses its commercial value after about 5 to 10 times of the above-mentioned silk.

[0028]

[Effect of device]

 Since the mat of the present invention has the above-mentioned structure, it has a soft texture, is not only excellent in dust collecting property and oil absorbing property, but also in washing, recycling and other severe conditions. It has the characteristic that pile yarns do not fall off even if the treatment is repeated and the durability, especially the cleaning durability, is extremely excellent.

[Brief description of drawings]

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

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

FIG. 3 is a partial schematic view schematically showing another example of the structure of the pile yarn used in the mat of the present invention.

FIG. 4 is a partial schematic view schematically showing still another example of the structure of the pile yarn used in the mat of the present invention.

[Explanation of symbols]

 1 Pile Layer 2 Base Fabric Layer 3 Backing Rubber Layer 4 Twisted Yarn 5 Nonflammable Staple Fiber Bundle 6 Low Melting Fusing Filament Bundle 7 Twisted Yarn (Core Yarn) 8 Twisted Yarn (Wrapping Yarn)

Claims (4)

[Scope of utility model registration request] 1. A mat comprising a base fabric, a tufted pile on the base fabric, and a backing provided on the back face of the base fabric, wherein the pile comprises a plurality of twisted yarns, a substantially incombustible staple fiber bundle, and a low melting point. A mat comprising fusible filaments or staples, wherein the staple fiber bundle is fixed between twisted yarns by intertwisting with the twisting yarns and fusion with the fusible filaments or staples. 2. The mat according to claim 1, wherein the fusible staple having a low melting point is mixed in a non-combustible staple fiber bundle. 3. The mat according to claim 1, wherein the low melting point fusible filaments are aligned and replaced together with the twisted yarn. 4. The mat according to claim 1, wherein at least one of the twisted yarns is present as a wrapping yarn and the rest of the twisted yarns is present as a core yarn.