JPH08302556A - Loop pile sheet - Google Patents

Abstract

PURPOSE: To provide a loop pile sheet which has a pile layer having excellent performances for removing or absorbing and holding stains such as earth and sand. CONSTITUTION: This loop pile sheet comprises a sheet-like substrate and a pile layer comprising the groups of synthetic resin crimped monofilament bundle loop piles planted on at least one side of the substrate. Therein, the monofilaments composing each bundle form loops having random shapes and random directions and interlacing with the adjacent bundle monofilament loops. The monofilaments has a fineness of at least 800 denier.

Description

Detailed Description of the Invention

The present invention relates to a loop pile sheet, and more particularly to a loop pile sheet having a pile layer excellent in the ability to remove or absorb dirt such as earth and sand and the ability to carry it.

[0002]

2. Description of the Related Art Pile cloth is made of synthetic fibers such as nylon.
Due to its excellent abrasion resistance, it is often used for floor coverings such as floor mats and artificial grass. A pile mat for floors has a shape-retaining property that can withstand frequent step load pressures, and has the ability to wipe off the soil and sand adhering to the back of shoes, etc., and temporarily carry the wiped soil and sand into the pile structure of the mat. Required to be present. In Japanese Utility Model Publication No. 2-122092, the thickness is 800
An artificial turf in which a loop pile of a filament bundle made of synthetic resin monofilament having a denier or less is tufted to a base sheet is described, and the pile layer is formed in a structure that can withstand considerably frequent steps. However, since the artificial turf described in this publication has a structure in which the pile layer is regularly planted, it is possible to satisfy the required soil wiping performance, soil loading performance, and anti-stepping machine performance required for floor mats. Not of level.

US Pat. Nos. 4,351,683 and 3,
No. 837,988 describes a web for a mat having a large void ratio, which has three-dimensionally bonded and fixed groups of synthetic resin filaments having a diameter of 0.1 to 3 mm and has impact resilience and compression resistance. However, this web does not mention a pile layer having random spaces formed by tufting groups of crimped filaments. U.S. Pat. Nos. 4,893,439 and 4,820,566 describe mats using thick denier fibers, but for durable high void tufting pile layers consisting of 800 denier or more filaments. Not suggested.

On the other hand, floor covering materials such as carpets, rugs and mats made of synthetic fibers are disclosed, for example, in JP-A-63-288262, US Pat. Nos. 4,893,439 and 4,8.
As described in Japanese Patent Publication No. 20,566, crimped yarns are generally used as pile yarns. The pile yarns that have been used in the known floor covering materials use filaments of at most about 500 denier, and most of them are crimped by various processing methods such as push-type crimping processing and air jet crimping processing. As a result, the crimps are finely formed into a pile having a structure in which crimped yarns are bundled. However, the known crimped pile yarn is inferior in the crimp fastness and is not suitable for forming a pile layer of a mat which requires the above-mentioned performance. Further, conventionally, only the synthetic resin monofilament having a denier of 800 denier or less can be crimped in the random direction.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a pile layer having an excellent performance of removing or absorbing dirt such as earth and sand and carrying it, and further having a void structure capable of withstanding frequent impact and step load. It is to provide a pile sheet having. A further specific object of the present invention is to provide a floor mat that is excellent in the ability to remove dirt such as earth and sand and to be carried, and that can endure frequent walking pressure. Another object of the present invention is to provide a loop pile sheet suitable for effectively receiving and holding scattered hydrous soil.

[0006]

SUMMARY OF THE INVENTION In a broad sense, the object of the present invention is to provide a synthetic resin monofilant in which a sheet base material is provided with bending (hereinafter referred to as crimping) along a longitudinal direction of at least 800 denier. This is achieved by a loop pile sheet provided with a pile layer composed of groups of randomly oriented unit loops formed by tufting a plurality of bundles.

That is, the present invention comprises a sheet-like base material and a group of loop piles of a synthetic resin crimped monofilament bundle tufted on at least one surface side of the base material, each constituent monofilament having a shape, A pile layer formed by randomly intersecting with loops of constituent filaments of adjacent bundles to form a loop with random orientation and spreading, and the monofilament has a fineness of at least 800 denier. It is a loop pile sheet.

Here, the pile layer is formed by crimping monofilaments having a monofilament shape and directions in which random loops are randomly intersected, and moreover, it is formed of a crimped monofilament having a rigidity of 800 denier or more, so that it can withstand frequent stepping pressure. Soil and other dirt can be removed without sagging, and a loop pile sheet with high soil and sand carrying performance can be obtained. The pile layer is
The thickness and structure density can be arbitrarily changed depending on the level of removal of dirt such as earth and sand and the desired level of carrying performance. When the loop pile sheet is used for a floor mat, the thickness of the pile layer is about 5 mm or more, preferably 5 to 5 mm.
It is preferable to set it to 15 mm. The ratio of the space volume in the pile layer is related to the excellent removal of dirt such as earth and sand and the ability to carry it. That is, it was found that there is a correlation between the volume of the pile layer minus the filament volume and the removal performance of dirt such as earth and sand, and the carrying performance. The porosity of the pile layer (defined later) is 50-80.
%, Preferably 60 to 80%, it is possible to obtain a pile structure which is excellent in the ability to carry earth and sand and can withstand frequent step load pressures without sagging.

The pile layer is a monofilament of the above-mentioned fineness obtained by crimping a backing cloth (backing cloth) such as a woven fabric of natural fibers such as jute and cotton, synthetic fibers such as polyolefin such as polyester and polypropylene.
It is formed by bundling dozens, preferably four to ten, of tufting pile loops by, for example, a general-purpose tufting machine. The tufting density and pile height of the pile loop are preferably selected so that the pile layer satisfies the above-mentioned void ratio conditions. The pile layer having a desired porosity may be prepared by setting the tufting gauge and stitch in consideration of the fineness of the monofilament, the number of crimps, and the number of filaments in the bundle.

FIG. 1 is a schematic explanatory view of the outer appearance of the pile layer surface of the loop pile sheet of the present invention. As shown in FIG. 1, the upper surface (10) of the pile layer is formed by a loop (1) of a synthetic resin monofilament having a fineness of 800 denier or more, random in both shape and direction, intersecting with similar loops of adjacent filaments. 3 is an upper surface of a random array of rigid monofilament loops. Each filament forms a pile layer with a gently bent crimp, which makes the crossing of the filaments on the upper surface (10) of the pile layer more random.
FIG. 2 shows a loop pile sheet of the present invention, in which a loop of a bundle (2) of synthetic resin monofilaments having a predetermined fineness is tufted, is cut perpendicular to the plane of the substrate sheet (3) along the tufting direction. The structure of the cross section is shown. FIG. 3 shows a cross section of the loop pile sheet in a direction perpendicular to the cross section of FIG. In the figure, (4) is a backing resin layer. As shown in FIGS. 2 and 3, most of the monofilaments constituting the bundle are formed from the loops of the bundle of synthetic resin crimped monofilaments tufted on the base material sheet (3), and the loops (1) having random shapes and directions are formed. Formed and spread, interlaced with similar filament loops of adjacent bundle loops, a random array of monofilament loops forms a pile layer of thickness (T). The random array of monofilament loops forms voids of random shape, and the rigidity of the filaments forms a pile structure that is resistant to step load pressure as a whole.

The monofilament used in the loop pile sheet of the present invention is a monofilament of a fiber-forming thermoplastic synthetic resin such as polyolefin such as nylon or polypropylene, polyester such as polyethylene terephthalate, polycarbonate, polystyrene or the like, and has a fineness. At least 800 denier, preferably 200
Monofilament materials of 0 denier or less, most preferably 1000 to 1300 denier. The fineness of the filaments is important in making the pile structure resistant to frequent loading pressures, and in making the crimps of the filaments as rigid as necessary to wipe soil. Therefore, the cross-sectional shape of the filament is preferably a circular, polygonal, or elliptical cross-section, avoiding a cross-sectional shape that causes anisotropy in rigidity, for example, a flat cross section. Due to the ease of application of the crimping process, the use of fineness above 2000 denier is generally not advantageous.

As described in detail above, the loop pile sheet of the present invention has a tough, impact-resilient random pile layer structure rich in voids. This pile layer structure provides a pile sheet with a high degree of gait resistance, improved soil removal and sediment retention. Such a function of the pile layer is useful as a mat for outdoor use, an entrance mat, and a mud spatter preventing mat member for a vehicle mudguard fender. When the loop pile sheet of the present invention is used as a mud splash prevention mat for a vehicle fender, the sheep pile sheet is cut into a mat having an area sufficient to cover the inner surface of the fender (wheel arch), and the mat is fixed. . Thus, the mud splashed by the wheels can be absorbed and retained by the mat, and the splash of mud can be prevented.

Any known method can be applied to the method of crimping the monofilament. For example, a twisting-heating method, a twisting-heating-untwisting method, an air jet crimping method, a knit denitting method, a rubbing method, a gear crimping method and the like can be mentioned. The crimping is that filament loops tufted on the base sheet easily spread in random directions,
It is important to adopt the crimping method that facilitates formation of the random loop array structure. An example of the crimp imparting method by the combination of the twisting-heating method and the knit denit method is as follows. Several monofilaments are bundled and twisted at a rate of several tens of times / m, heated to a temperature of 100 ° C. to the softening point, and then fed to a knitting machine to knit, deknit, and deknit a bundle of filaments. When fed to a tufting machine and tufted, the tufted loops can easily spread into random filament loops to prepare the pile structure described above. In this case, the twist imparted to the bundle of filaments is more likely to be randomly spread when a single twist is adopted, and a loop pile structure rich in irregularity in shape is easily formed.

The present invention will be more specifically described below with reference to examples.

[0015]

EXAMPLES The evaluation method of the loop pile used in the following examples is as follows. (1) Sediment removal test: 6 steps (3 steps for one leg) rubber on a test mat (width 900 mm, length 3600 mm test piece) that an adult passes through a dish containing dry earth and sand (sand that has passed through a 600 μ mesh) The user wore soles shoes and walked, and this was repeated 500 times to weigh the amount of earth and sand (g) left on the mat. The greater the amount of sediment, the better the soil removal. (2) Measurement of thickness reduction rate due to dynamic load: JIS L-
The thickness reduction rate was measured according to the 1021-1979 A method (rotary method). As the test conditions, an impact rotor (load 1 kg / one arm) and a test bench rotation speed of 10,000 were used. (3) Measurement of porosity (%) of the pile layer: parallelogram (area [S] is 100c of 10 cm each in the warp and weft directions)
The weight (W ₀ ) of the test piece of m ² ) is measured. The pile layer of the mat is filled with dry sand having a bulk specific gravity of 1.4 g / cm ³ until the surface is just covered, and the weight (Wg) is measured. The thickness (Tcm) of the pile layer was measured, and the porosity (K%) was calculated by the following formula.

K (%) = [(W-W ₀ ) / (1.4
× S × T)] × 100

Example 1 A bundle of 6 nylon monofilaments with a circular cross section of 1300 denier was prepared, and a bundle of 40 times / m Z was prepared.
Directional twist was applied. This bundle of monofilaments was supplied to a weft knitting machine (1 piece / cm) to form a knit, and this knit was heated (130 ° C) and then unknitted to obtain a bundle of crimped filaments. The bundle of crimped filaments was supplied to a tufting machine (5/32 gauge) to tuft a loop basis pile having a stitch length of 3.2 mm and a pile length of 14 mm on a polyester fiber woven fabric base material. A pile layer having a thickness (T) of 9 mm was formed. After tufting, vinyl chloride plastisol was applied to a thickness of 2 mm to add a backing material.

The resulting loop pile sheet is formed by interlacing similar loops of tufted filaments with random loops adjacent in shape and direction of the constituent monofilaments of the tufted bundle on the surface of the substrate. It had a pile layer with a structure having random void spaces. The structure and performance of the pile layer of this loop pile sheet are shown in Table 1 in comparison with the conventional floor mat. It can be seen that the loop pile sheet according to this example has a structure that can withstand frequent walking, has a high sediment removal property and a high sand loading capability, and is an excellent material as a floor mat material.

Example 2 A bundle of three nylon monofilaments having a circular cross section of 1000 denier was prepared and aligned, and a twist of 60 times / m in the S direction was applied to the bundle. This monofilament bundle was combined and twisted in the Z direction at 60 turns / m to form one yarn.
This bundle of monofilaments was supplied to a weft knitting machine (1 / cm) to make a knit, and this knit was heated (130 ° C.) and then unknitted to obtain a bundle of crimped filaments. The bundle of crimped filaments was supplied to a tufting machine (5/32 gauge) and tufted to a polyester fiber woven base sheet. The tufting is stitch 3.2mm,
The pile length was 14 mm, and a pile layer having a thickness of 9 mm was formed. After tufting, vinyl chloride plastisol was applied to a thickness of 2 mm to add a backing material. This loop pile sheet is formed by forming monofilaments forming a loop of a tufted bundle on the surface of a base material, forming random loops in shape and direction, and interlacing with similar loops of adjacent tufted filaments. It had a pile layer with a structure having random void spaces. Table 1 shows the structure and performance of the pile layer of this loop pile sheet.

Example 3 A bundle of six 1800 denier nylon monofilaments having a circular cross section was prepared, and a twist of 40 times / m in the Z direction was imparted to the bundle. This bundle of monofilaments was supplied to a weft knitting machine (1 piece / cm) to form a knit, the knit was heated (130 ° C.), and then unknitted to obtain a bundle of crimped filaments. This bundle of crimped filaments was supplied to a tufting machine (5/32 gauge), and a polyester fiber woven fabric base sheet was tufted with a loop pile having a length of 7 mm. The tufting was performed by stitching for 3.2 mm to form a pile layer having a thickness of 6 mm. After tufting, vinyl chloride plastisol was applied to a thickness of 2 mm to add a backing material.

The obtained loop pile sheet is formed by the monofilaments forming the loops of the bundle forming random loops in shape and direction and intersecting with similar loops of crimped filaments which are tufted adjacent to each other. It had a pile layer with a structure with random void spaces.
Table 1 shows the structure and performance of the pile layer of this loop pile sheet.
Shown in

Comparative Examples 1 to 3 The following three mats were tested for the pile layer thickness reduction rate, porosity, and amount of debris removal by the test method described above. Each of these floor mats has a pile of crimped yarns planted on a woven fabric base material and has a backing resin sheet layer. The test results are shown in Table 1. (1) Indented crimped round cross-section nylon yarn (75 d / f) with a pile length of 6 mm and a cut pile carpet lined with 3 mm thick vinyl chloride. (2) Flat cross-section yarn of crimped polypropylene (200d /
f) A loop pile artificial grass mat with a pile length of 5 mm,
Lined with 1 mm thick foamed vinyl chloride. (3) Minnesota Mining and Manufacturing Carpet Mat "Enhance # 50
0 ”. Separate piles of the crimped propylene yarn (300 d / f) and the flat polypropylene yarn (30 d / f) are formed.

As can be seen from Table 1, the mats of Comparative Examples 1 to 3 have a large reduction rate of the pile layer thickness as compared with the mats of Examples 1-3, and obviously the resistance to repeated stepping is high. The sex is inferior. On the other hand, regarding the porosity of the pile layer, the mat of the comparative example is half that of Example 1-3. Further, the amount of soil removal of the known mat of Comparative Example 1-3 is significantly smaller than that of the mat of Example 1-3.

When the known mat of Comparative Example 1-3 is used for a long period of time (performance of removing soil) (wipe performance of soil),
Also, it is clear that the ability to carry soil and sand is significantly inferior.

[0025]

In the loop pile sheet of the present invention, the pile layer is formed by forming the synthetic resin crimped monofilament having a denier of 800 denier or more into randomly oriented toughened loops of various shapes. INDUSTRIAL APPLICABILITY The pile layer structure of the present invention has load-pressure resistance and is excellent in earth and sand removal and earth and sand carrying ability, and therefore has both the ability to remove earth and sand adhering to the sole and the ability to carry earth and sand. It is a suitable material for floor mats. The loop pile sheet of the present invention is attached to the inner surface of the wheel arch of a vehicle by utilizing its excellent mechanical and tough multi-void structure to absorb and carry earth and sand containing water, and to splash water on the wheel arch. It can also be used as a suitable material for a blocking material and the like.

[0026]

[Table 1]

[Brief description of drawings]

FIG. 1 shows a top surface appearance of a pile layer of a loop pile sheet of the present invention.

FIG. 2 shows a structure of a vertical cross section of a pile layer of a loop pile sheet of the present invention.

FIG. 3 shows a cross section of the pile layer in a direction perpendicular to the cross section of FIG.

Claims (9)

[Claims] 1. A sheet-like base material and a group of loop piles of a synthetic resin crimped monofilament bundle tufted on at least one surface side of the base material, wherein each constituent monofilament of the bundle has a random shape and orientation. A loop pile sheet comprising a pile layer formed by forming loops and expanding and randomly intersecting loops of constituent filaments of adjacent bundles, and the monofilament has a fineness of at least 800 denier. 2. The loop pile sheet according to claim 1, wherein the pile layer has a thickness of at least 5 to 15 mm, and the porosity is 50 to 80%. 3. The loop pile sheet according to claim 1, wherein the synthetic resin monofilament is a thermoplastic synthetic resin filament. 4. A sheet-shaped base material and a group of loop piles of a synthetic resin crimped monofilament bundle tufted on at least one surface side of the base material, wherein each constituent monofilament of the bundle has a random shape and orientation. A pile layer formed by randomly intersecting with the loops of the constituent filaments of the adjacent bundle to form and spread,
And the monofilament has a fineness of at least 8
A floor mat that is 00 denier. 5. The floor mat according to claim 4, wherein the pile layer has a thickness of at least 5 to 15 mm and a porosity of 50 to 80%. 6. The floor mat according to claim 4, wherein the synthetic resin monofilament is a thermoplastic synthetic resin filament. 7. A sheet-shaped base material and a group of loop piles of a synthetic resin crimped monofilament bundle tufted on at least one side of the base material, wherein each constituent monofilament of the bundle has a random shape and orientation. A pile layer formed by randomly intersecting with the loops of the constituent filaments of the adjacent bundle to form and spread,
And the monofilament has a fineness of at least 8
A water-repellent, sand-absorption carrier for vehicle wheel arches of 00 denier. 8. The water splash / sand absorbent carrier for vehicle wheel arches according to claim 7, wherein the pile layer has a thickness of at least 5 to 15 mm and a porosity of 50 to 80%. 9. A step of heating a plurality of monofilaments having a fineness of at least 800 denier, a step of twisting the bundle of monofilaments, a step of applying crimping means to the monofilament bundle which has undergone the above steps, and a sheet base material. A method for producing a loop pile sheet, which comprises a step of tufting a loop of a bundle of monofilaments crimped on a sheet.