JPH085153B2 - mat - Google Patents

Description

Detailed Description of the Invention [Industrial applications]

INDUSTRIAL APPLICABILITY The present invention provides a mat to be laid at a front door, an office, a restaurant or a bathhouse entrance, a car, a kitchen, etc., as well as a mat for removing oil and the like adhering to shoes in a factory, and a kitchen, a kennel, etc. It is about mats that can be used.

[Prior art]

As a conventional mat, there is used a so-called tufted carpet in which roving is driven into a base cloth, which is lined with a synthetic resin such as rubber. However, such a mat has a high manufacturing cost, and it is difficult to clean the mat when it is dirty, resulting in a high cleaning cost. In particular, when the mats laid at the entrances and exits of restaurants and offices are soiled, the procedure is to collect the mats once, and after cleaning or delivery, the delivery cost is added. The present inventors proposed a disposable mat, which is composed of a water-permeable layer, a liquid-retaining layer, and a water-impermeable layer, in Japanese Utility Model Laid-Open No. 1-170182.

[Problems to be Solved by the Invention]

An object of the present invention is to provide an inexpensive, disposable mat which is excellent in appearance, liquid absorbency, stain removability and durability.

[Means for Solving the Problems]

According to the present invention, the following mats (a), (b) and (e) are laminated in this order, and all the layers are fused and integrated in an area of 0.05 to 20%, (a) ) Layer: Apparent density 0.05g / cm ³ or more, permeability 1 × 1
Woven / knitted fabric or non-woven fabric that is 0 ^-3 or more and pilling grade ³ or more (b) layer: a thickness of 0.2 mm or more and a non-woven fabric with a water absorption ratio of 2 or more (e) layer: an apparent density of 0.05 g / cm ³ or more A non-woven fabric having a 10% modulus of 0.5 kg / 2.5 cm or more and a water resistance of 30 cm or more, and the following layers (a) to (d) are laminated in this order, and all layers are in the area of 0.05 to 20%. A mat characterized by being fused and integrated, (a) layer: apparent density of 0.05 g / cm ³ or more, water permeability of 1 × 1
Woven / knitted fabric or non-woven fabric having 0 ^-3 or more and pilling grade ³ or more, (b) layer ... 0.2 mm or more in thickness, non-woven fabric having a water absorption ratio of 2 times or more, (c) layer ... apparent density 0.05 g / cm ^A non-woven fabric having a modulus of ³ or more and a 10% modulus of 0.5 kg / 2.5 cm or more, a layer (d) ... a thermoplastic synthetic resin film. The layer (a) in the present invention forms the surface layer of the mat and has an apparent density of 0.05 g / cm ³ or more, preferably 0.1
To 0.6 g / cm ³ , water permeability is 1 × 10 ^-3 or more, preferably 1 × 10 ^-2 or more and pilling is grade 3 or more, and basis weight is 10 to 500 g / m
² , preferably 20 to 100 g / m ² of woven or knitted fabric or non-woven fabric. Here, the permeability coefficient is in accordance with JIS A 1218 and the permeability area is 1c.
It is a value measured by stacking one sample with m ² , permeation time of 60 seconds and water level of 10 cm, and pilling is an evaluation including surface fluff when tested for 5 hours by JIS L 1076 A method. If the apparent density is less than 0.05 g / cm ³ , the strength and durability are generally poor, and the removability of dirt adhering to the sole is not sufficient. When the coefficient of water permeability is low, water droplets and the like adhering to the surface do not rapidly move to the (b) layer and the surface is in a wet state forever, which is not preferable. If the pilling is less than the third grade, the appearance of the surface is deteriorated in a short period of time due to friction such as the sole of the shoe. The layer (b) is a layer that imparts liquid absorption and cushioning properties to the mat, and has a pressure according to JIS L 1085 of 0.2 mm or more, preferably 1.0 mm or more, cut into 10 cm squares, and immersed in water for 1 minute. It is a non-woven fabric that has a water absorption capacity of 2 times or more with respect to its own weight when a drop is suspended for about 30 seconds with one corner just below. If the thickness is less than 0.2 mm, the cushioning property and the amount of water absorption are not sufficient, and the stain removing effect in the layer (a) is also reduced. If the water absorption ratio is less than 2, a mat having sufficient liquid absorbency cannot be obtained. The density of the non-woven fabric is preferably 0.1 g / cm ³ or less in order to increase the cushioning property and the water absorption capacity. Further, the basis weight of the non-woven fabric is 10 to 900 g / m ² , preferably 50 to 500 g / m ² , and when the basis weight is small, the liquid absorption amount is not sufficient, and when the basis weight is large, the liquid absorption amount is not a problem, but it is sublime. Too much or poor handling. The layer (c) is a protective layer for preventing the layer (d) from being damaged and leaking during use, and the apparent density is 0.05 g / cm ³
Or more, preferably 0.1 to 0.5 g / cm ³ , the modulus at 10% elongation is 0.5 kg / 2.5 cm or more, preferably 2.0 kg / 2.5 cm or more,
A non-woven fabric having a basis weight of 10 to 300 g / m ² , preferably 20 to 100 g / m ² . If the apparent density is too small, it becomes too sublime and the protective effect becomes insufficient. Also, 10% modulus is 0.5kg / 2.5cm
If it is smaller than the above range, excessive force is applied to the (d) layer during use, and the (d) layer is easily damaged. The layer (d) is a layer for preventing dust and liquid collected by the mat from permeating to the back surface, and is made of a thermoplastic synthetic resin film. Thickness is 10 ~ 300μm, preferably 20 ~ 100μm
Range. If the thickness is thin, it will be easily damaged, and if it is thick, the handling will be poor and the cost will be high. Like the layer (d), the layer (e) is a layer for preventing dust and liquid collected by the mat from permeating to the back surface, and has a 10% modulus of 0.5 kg / 2.5 cm or more, preferably 2.0 kg / 2.5 cm or more.
Water resistance according to JIS L 1092A method 30 cm or more, preferably 50 cm
It is the above non-woven fabric. If the 10% modulus is small, the layer (e) tends to stretch during use and the edges of the mat tend to warp, and if the water resistance is low, a sufficient waterproof effect cannot be obtained. Next, each layer will be described in more detail. The fibers constituting the layer (a) may be natural fibers, regenerated fibers or synthetic fibers, but spunbonded nonwoven fabrics of thermoplastic resins such as polyester, polyamide and polyolefin are available due to their low price and smooth surface. It is preferably used. In the case of spunbonded non-woven fabric, various patterns and letters can be printed clearly due to the smoothness of the surface.
It can be used as a poster or advertising medium, which is preferable. Also,
It also has the effect that dirt is not noticeable due to the printed patterns and characters. When a highly hydrophobic fiber such as a polyolefin is used, it is preferable to knead or surface-treat the fiber to make it hydrophilic, in order to increase the coefficient of water permeation. The non-woven fabric of the layer (b) is obtained by subjecting short fibers of natural fibers, regenerated fibers or hydrophilic synthetic fibers to cards, random webrs, webs obtained by cross layers, etc. by needle punching, heat fusion or resin processing. It is a nonwoven fabric obtained by. Mixing highly crimped fibers is preferable in order to improve cushioning properties. Also,
Those containing PP cloth or a woven or knitted fabric inside the nonwoven fabric have good morphological stability and are preferably used. The fiber material constituting the non-woven fabric of the (c) layer is not particularly limited, but a non-woven fabric having one or more layers of polypropylene or polyethylene melt blown web can provide a non-woven fabric having high water resistance, and the point of preventing liquid leakage from the (d) layer. Are particularly preferred. The film of the layer (d) is a non-water-permeable film, and films made of polyethylene, polypropylene, polyvinyl chloride, polyester, etc. are used. However, polyethylene, polypropylene,
Films such as polyester are preferred. The non-woven fabric of the layer (e) may be a water repellent non-woven fabric, but a melt blown web of a polyolefin such as polypropylene or polyethylene is preferable because a non-woven fabric having high water resistance can be obtained and there is almost no drop with time. . Since it is difficult to obtain a sufficient strength with the melt-blown nonwoven fabric alone, it is preferable to use it by combining it with a spunbonded nonwoven fabric or another nonwoven fabric having high strength by a method such as hot embossing. Since the mat of the present invention can be obtained by fusion-bonding integration, thermoplastic fusion fibers that can be heat-fused in each of the above layers except the layer (d), for example, polyolefin fibers such as polyethylene,
It is necessary to contain 20% or more, preferably 30% or more of polyester fibers such as polyethylene terephthalate, polyamide fibers such as 6-nylon and 6,6 nylon, or composite fibers made of these materials. When the amount of the thermoplastic synthetic fiber is less than 20%, the peel strength of the fusion-bonded portion is low and peeling occurs during use to cause a morphological change. In the mat of the present invention, the layers (a), (b), (c) and (d) or the layers (a), (b) and (e) are laminated in this order (or reverse order), and heat is applied. It is obtained by fusing and integrating all layers by fusing. The fusing method includes fusing by a hot embossing roller or fusing by ultrasonic processing. However, ultrasonic processing is preferable in that the influence of heat on the non-fusing portion can be reduced and various fusing patterns can be selected. In the case of ultrasonic processing, continuous processing with the (a) layer side as the horn (vibrator) side and the (d) or (e) layer side as the embossing (engraving) roll side prevents liquid leakage to the back surface of the mat. It is preferable to The shape of the fusion-bonded portion may be dot-shaped, linear-shaped, or pattern-shaped. As a whole, it may be arranged in parallel linear shapes, lattice-shaped, simple repeating patterns such as wavy patterns, or arranged in letters or large patterns as advertising media. May be. The ratio of the fused area to the total area is 0.05 to 20%, preferably 0.1 to 10%. Area of fused part is 0.05
When it is less than%, stress concentration occurs in the fusion-bonded portion, the layer (d) is easily damaged, and liquid leakage occurs. In addition, the area of the fused portion is
If it exceeds 20%, the liquid absorbency is lowered and the texture becomes hard, resulting in poor handleability. If necessary, an anti-slip resin or the like may be adhered to the back surface of the mat before or after the fusion and integration to prevent slippage. The mat raw material for fusion-integrated mat of the present invention is cut into an appropriate size and shape to obtain a mat. The edges of the mat are arranged by a fusion process or a sewing process. It is also possible to omit the step of arranging the edges by fusing in a strip shape in accordance with the cut shape when fusing and integrating.

【Example】

Next, embodiments of the present invention will be described with reference to specific examples. In the examples, parts and% are by weight unless otherwise specified. Example 1 As a layer (a), a unit weight of 40 g / m ² , a thickness of 0.15 mm, an apparent density of 0.27 g / cm ³ , a pilling grade 4, a partially thermally embossed hydrophilic permeability of 2.5 × 10 ^-2. A non-woven fabric in which a poster design was flexographically printed on the surface of the treated 6-nylon spunbonded non-woven fabric was used. The pattern contained letters of 3mm x 5mm and was clearly printed. As the layer (b), a needle punched non-woven fabric having a fineness of 6 denier, a fiber length of 64 mm and a rayon of 50% each having a basis weight of 250 g / m ² , a thickness of 2 mm and a water permeability of 3 times was used. (C) Layer has a basis weight of 30 g / m ² , a thickness of 0.12 mm and an apparent density of 0.25 g / cm ³ , 10
A polypropylene spunbond non-woven fabric having a% modulus of 3.0 kg / 2.5 cm and not treated with an oil was used. A polyethylene film having a thickness of 50 μm was used as the layer (d). The above (a) to (d) layers are superposed in this order, and the (a) layer side is ultrasonically processed as a horn side and the (d) layer side is an embossing roll side having a pattern as shown in FIG. The layers were fused together. The length of one side of the grid pattern shown in FIG. 1 is 40 mm. The obtained laminated sheet is 75
The mat according to the present invention was cut into a size of 90 cm × 90 cm and overedged. The obtained mat was light in weight, the printing on the surface exhibited the advertising effect, and the liquid absorption and the dust removal were excellent. In addition, even after about 1 month of use, no water leakage on the back surface of the mat or damage to the back surface of the mat was observed. Example 2 A (a) layer is a polypropylene spunbonded nonwoven fabric treated with a hydrophilizing oil having a basis weight of 50 g / m ² , a thickness of 0.2 mm, an apparent density of 0.25 g / cm ³ , a pilling grade 5, and a water permeability of 2.6 × 10 ^−1. did.
The (b) layer has polyethylene terephthalate as a core component, polyethylene as a sheath component, and is treated with a durable hydrophilizing oil agent to obtain a carded web of staples having a fineness of 3 denier and a fiber length of 51 mm by hot air treatment at 130 ° C. Unit weight 60g / m ² ,
A nonwoven fabric having a thickness of 1.0 mm and a water absorption ratio of 3 was used. The layer (c) has a basis weight of 25 g / m ² , a thickness of 0.08 mm, an apparent density of 0.31 g / cm ³ , a 10% modulus of 2.0 kg / 2.5 cm, and a water resistance, which are obtained by processing a polypropylene melt-blown web with a flat heat calender. A 65 cm non-woven fabric was used. A 40-micron-thick vinyl chloride film was used for the layer (d). These four layers were laminated and fused and integrated in the same manner as in Example 1 using the fusion pattern shown in FIG. The dimension of the pattern is 50 mm for A and 8 mm for B in FIG. The obtained mat was excellent in handleability, cushioning property, and dust removing property, and did not cause liquid leakage to the back surface and tear of the back surface film. Example 3 3 denier rayon staple 30%, polypropylene core, polyethylene sheath fineness 3 denier composite fiber
Random web is made from 70% and heat-calendered to have a basis weight of 60 g / m ² , thickness of 0.15 mm, and apparent density of 0.40 g / c.
A non-woven fabric having m ³ , pilling grade 4, and water permeability of 1.5 × 10 ^-1 was prepared and used as layer (a). Next, 4 denier polyester short fibers 60%, 3 denier rayon staple 40% were mixed and sprayed with acrylic resin as a card web, dried and heat treated to give a basis weight.
300g / m ² , thickness 2.5mm, non-woven fabric with water permeability 3.5 times,
The layer (b) was used. (E) layer has a basis weight of 70 g / m ² , thickness of 0.3 mm
Heat-embossed fusion of polypropylene spunbonded non-woven fabric with polypropylene melt blown non-woven fabric with unit weight of 35g / m ² 0.4mm thickness, 10% modulus 3.5kg / 2.5cm, water resistance 70cm
The laminated non-woven fabric of was used. These three layers were laminated and fused and integrated in the same manner as in Example 1 using the embossing roll having the pattern shown in FIG.
The layer (e) was laminated so that the spunbond side was the outer side. Further, in FIG. 3, C is 20 mm and D is 4 mm. The obtained mat had no liquid leakage on the back surface and was as excellent as Example 2. Example 4 A rubber-based resin was further printed in dots on the back surface of the mat of Example 3 to prevent slippage. In addition to the effect of Example 3, this product was a practically extremely useful mat with less slippage and deviation from the floor surface.

【The invention's effect】

According to the present invention, a mat which is lightweight, has excellent appearance, handleability, dust-removing property, liquid absorbing property, and has no damage on the back surface of the mat or liquid leakage can be easily obtained and can be supplied at low cost.

[Brief description of drawings]

FIG. 1 is an example of the fusion pattern of the mat of the present invention.
2 and 3 are views showing another embodiment of the fusion pattern of the mat of the present invention.

Claims (2)

[Claims] 1. A mat characterized in that the following layers (a), (b) and (e) are laminated in this order, and all layers are fused and integrated in an area of 0.05 to 20%. (A) Layer: Apparent density of 0.05 g / cm ³ or more, Permeability coefficient of 1 × 1
Woven / knitted fabric or non-woven fabric that is 0 ^-3 or more and pilling grade ³ or more (b) layer: a thickness of 0.2 mm or more and a non-woven fabric with a water absorption ratio of 2 or more (e) layer: an apparent density of 0.05 g / cm ³ or more Non-woven fabric with 10% modulus 0.5kg / 2.5cm or more and water resistance 30cm or more 2. A mat characterized in that the following layers (a) to (d) are laminated in this order, and all layers are fused and integrated in an area of 0.05 to 20%. (A) Layer: Apparent density of 0.05 g / cm ³ or more, Permeability coefficient of 1 × 1
Woven / knitted fabric or non-woven fabric that is 0 ^-3 or higher and pilling grade ³ or higher (b) layer: a thickness of 0.2 mm or more and a water absorption capacity of 2 or more (c) layer: an apparent density of 0.05 g / cm ³ or more , Non-woven fabric with 10% modulus of 0.5 kg / 2.5 cm or more (d) layer ...... thermoplastic synthetic resin film