JPH09313430A - Floor mat - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a floor mat which is equipped with a proper degree of cushioning property to give a good feeling of walking, does not allow the earth/ sand or water to remain on the mat surface, serves recovery of fatigue by means of stimulus of the soles when one stamps by bare feet, and ensures a comfortable sense in use. SOLUTION: A number of continuous wires 6 of synthetic polymerides of 0.5-2mm in diameter having an excellent elastic recovering property are intersected with one another while irregular loops are formed, and a number of ridge-form crests in the form of a circular arc and groove-shaped bottoms recessed between the crests are formed while curving is made in the direction across the thickness so that a mat surface 2 is produced in a bulky mesh form having a void rate of 60-98%, and flat tabs 5 are formed around the mat surface by these continuous wires 6, and an intended floor mat 1 is accomplished whose rate of deflection ranges 5-45% when a person gets on the mat 2 to ensure a fine cushion and walking characteristics and which is equipped with a sole stimulating function.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bedding mat laid on a floor such as a bathhouse, a changing room, a work place, an entrance, and a poolside.

[0002]

2. Description of the Related Art Conventionally, various bedding mats have been laid in order to remove water droplets and mud at the entrances and exits of bathhouses and buildings, or in the changing rooms and workplaces for the purpose of suppressing noise and mitigating fatigue caused by walking. ing. For example, mats with good water permeability formed of bristles such as palms and palm fibers are laid at the entrances and exits of bathhouses, and mud removal mats formed by coiling metal wires into the entrances and exits of buildings are old. The carpet is laid in the changing room and the workshop.

Further, in recent years, in order to make the feet more comfortable, a wide variety of mats using new materials have been proposed. For example, as described in Japanese Utility Model Laid-Open No. 60-133981, a mat formed by attaching a pile carpet to a base sheet formed of rubber or a polymer material, and a short fiber formed by three-dimensionally assembling and bonding. Shoe-wiping mats or bamboo mats for maintaining health as described in Japanese Utility Model Laid-Open No. Sho 63-185688 have come into practical use.

Further, in Japanese Patent Application Laid-Open No. 61-203933, instead of a conventional mud removing mat formed by coiling a metal wire, a loop is formed on a synthetic polymer continuous wire having a diameter of 1 to 3 mm. However, a mat for mud removal has been proposed which is integrated and arranged in a certain direction in parallel.

[0005]

However, the mat formed of palm fiber and palm has the excellent property as a natural fiber that it has good water absorption and cushioning property, but it is easily soiled by dirt and dust. Also, if bare feet are placed, water will ooze out, causing discomfort to the user, and a mat or short fibers that are made by sticking the pile carpet as described above to a base sheet made of rubber or a polymer material will be three-dimensionally formed. The mat formed by collectively bonding not only makes dirt and dirt stand out when the surface of the mat is walked on with bare feet, but also when water is contained, water seeps out to the user in the same manner as above. There is a drawback that it causes discomfort.

Such a problem is caused by the above-mentioned Japanese Patent Laid-Open No. 61-20.
As described in Japanese Patent No. 3933, it is improved by forming a mat by arranging loops of synthetic polymer continuous filaments having a diameter of 1 to 3 mm in parallel. However, since the mat is constructed by arranging the loops of continuous lines of synthetic polymer standing side by side like loop piles, the mat can withstand a vertical load sufficiently and undergo compressive deformation, and the load is removed. When the load acts laterally on the loop row direction, the loop tilts, and when such lateral loading is repeated, the continuous filament finally fatigues and elastically recovers to the standing state. Can not do. Moreover, since this mat was developed for removing mud on the soles of shoes, it is not suitable for other applications.For example, a bamboo mat formed by splitting a bamboo stake into halves can recover from fatigue by promoting blood circulation. Can not achieve the effect.

[0007] A bamboo mat formed by splitting the bamboo shoots into halves increases blood circulation due to the stimulating action of the soles of the feet due to unevenness, and is effective in recovering from fatigue, but lacks cushioning properties, so it is not suitable for changing rooms, It cannot be applied to a mat that stays on it for a long time, such as in a workplace, and if the bamboo deteriorates, it may lead to a situation in which spines are stuck.

According to the present invention, it is possible to walk comfortably on the mat surface with appropriate elasticity, the mat surface is excellent in water permeability, and there is no discomfort caused by water content, and the mat surface can be kept clean for a long time. The purpose of the present invention is to provide a bedding mat that has the function of a foot-operated health appliance such as a bamboo mat.

[0009]

According to the present invention, a large number of continuous filaments are entwined in a mesh to form a matte surface.
The above-mentioned problems were solved by forming peaks and troughs on the mat surface and imparting appropriate elasticity and load resistance to the mat surface.

That is, the bedding mat of the present invention has a diameter of 0.
Each of a large number of synthetic polymer continuous filaments of 5 to 2 mm intersects each other in an irregular loop and is curved in the thickness direction to extend from one side to the other, and the large number of continuous filaments at each intersection point. A number of ridge-shaped ridges, which are adhered to each other and have an arc-shaped cross section, and groove-shaped troughs, which are recessed between the ridges, are formed. Part and peak part to form a porosity of 60 to 98
%, A matte surface is constituted by a bulky net-like portion having a parallel light transmittance of 10 to 70%, and an ear portion is formed by the synthetic polymer continuous filaments extending in the horizontal direction around the matte surface. The deflection rate is 5 to 45%.

The above-mentioned load deflection rate is measured by using the following measurement formula in consideration of the load equivalent to the weight of an adult male. Deflection rate under load (%) = {(Y−X) / Y} × 100, where X = bottom area on mat surface is 150 mm × 150 m
m, a load weight consisting of a rectangular parallelepiped weighing 67.5 kg
Thickness (mm) of the mat surface under the condition that a weight is loaded after loading for a minute, and Y = thickness (mm) of the mat surface when no load is applied.

The synthetic polymer of continuous filaments forming the bedding mat of the present invention is not particularly limited, and synthetic polymers having a flexural modulus of 200 to 5000 kgf / cm ² , for example, polyolefins such as polypropylene and polyethylene. Polymers, terpolymers of propylene-ethylene-butene, elastic polymers such as styrene-butadiene rubber, or a mixture of two or more of these thermoplastic polymers, the flexural modulus, A mixture of a styrene-butadiene rubber and a propylene-ethylene-butene terpolymer is preferable in consideration of durability against repeated bending, friction fastness and the like.

The thickness of the synthetic polymer continuous filament forming the bedding mat is limited to a diameter of 0.5-2 mm. If the thickness of the continuous filament is smaller than 0.5 mm, unless the porosity is reduced, it is not possible to obtain appropriate flexural modulus, durability against repeated bending as a mat, and fastness to friction, and if it is thicker than 2 mm. However, it is advantageous in terms of load resistance and durability, but not only deteriorates cushioning properties, but is uneconomical.

Further, the reticulated matte surface has a porosity of 60.
%, And if the parallel light transmittance is less than 10%, the water permeability and the passage through the mud become poor and the cleanliness is impaired. In addition, the porosity exceeds 98% and the parallel light transmittance is 70%.
If it exceeds the limit, not only the load resistance and the durability are deteriorated, but also the walkability on the mat surface is deteriorated. Therefore, the porosity is limited to 60 to 98%, and the parallel light transmittance is limited to 10 to 70%. If the loading deflection rate is large, the bedding mat will be soft and the walking surface will not be sufficiently supported, making it difficult to walk. , 5 to 45%.

The height of a large number of ridge-shaped ridges having an arc-shaped cross section formed on the surface of the matte surface, that is, the apparent thickness of the matte surface is 5 to 30 mm and the width of the ridges is 15 to 60 mm. Is preferred. When the height of the mountain part is less than 5 mm and the width is less than 15 mm, not only the mat surface is flattened and the cushioning property is deteriorated, but also the foot health function like a bamboo mat is lost, and the height of the mountain part is high. When the width is over 30 mm and the width is over 60 mm, the mat surface is undulated and the sinking under load becomes large, so that the walking ability is impaired, and it is unsuitable for a mat used by many people.

The width of the flat ears formed around the matte surface having a bulky mesh shape may be set arbitrarily according to the size of the mat. The laid state can be maintained without slipping on the top.

In order to make the floor mat of the present invention in the form of a net into a more stable laid state, the ears around the mat surface are embedded in the frame made of the polymer material or an adhesive is used. It is advisable to form a frame-like edging by integrating them. The width of the edging is the same as the ear part of the above mat 1
The thickness is about 6 cm, and the thickness may be appropriately determined in a range larger than the thickness of the continuous filaments constituting the mat and smaller than the apparent thickness of the mat surface. As the polymeric material forming the edging, soft polyvinyl chloride, polyethylene, polypropylene, polyolefin-based polymers such as ethylene-vinyl acetate copolymer, natural rubber, synthetic rubber, etc. can be applied, but they are economical and have a unit area. In consideration of the weight per unit, soft polyvinyl chloride is preferable.

Further, during use, it is desirable to form a mat with synthetic polymer continuous filaments in which an antibacterial agent and a fungicide are kneaded in order to prevent the growth of bacteria and mold attached to the mat. As the antibacterial agent and antifungal agent, an inorganic antibacterial agent such as silver or zinc, or an organic nitrogen-based commercially available antibacterial agent or antifungal agent may be applied, and an antibacterial agent kneaded into the synthetic polymer,
The amount of the antifungal agent is preferably 0.1 to 1.0% by weight in the synthetic polymer. If it is less than 0.1% by weight, the chemical components present on the surface portion of the fiber cross section of the continuous filament will be too small to obtain sufficient functions to suppress the habitation and growth of microorganisms. When mixed, the function of suppressing the habitation and growth of microorganisms increases, but the manufacturing cost increases, and the flexural modulus of the synthetic polymer continuous filament decreases, which is not preferable.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described based on examples with reference to the drawings. FIG. 1 is a perspective view showing a part of a mat surface of a floor covering mat according to the present invention, and FIG. 2 is a mat. 3 is a cross-sectional view in the thickness direction of a bedding mat, where 1 is a bedding mat, 2 is a mat surface, and 3 is a mountain. Part 4 is a trough, and 5 is an ear.

Example 1 A resin obtained by mixing 60 parts by weight of a propylene-ethylene-butene terpolymer and 40 parts by weight of styrene-butadiene rubber was made into a molten state,
This melt has an inner diameter of 1 m, as schematically shown in FIG.
The spinning mat 11 spun from the spinneret 11 of the spinning machine 10 having a row of spinning holes of m as spinning filaments 6 and 6, and below the spinneret 11, on the surface as shown in FIG. The endless carrier 16 formed by connecting the molding plates 15 and 15 having the ridges 12 and the valleys 13 and the flat portions 14 and 14 similar to the matte surface 2 and the ear 5 of FIG. It is moved in the direction of the arrow at a slower speed than the falling speed, and while the spun continuous filaments 6 and 6 groups have not yet solidified, the spun continuous filament groups are allowed to spontaneously fall onto the carrier 16 and spun on the continuous filaments. Bending along the surface shape of the forming plate 15 while drawing an irregular loop on the groups of strips 6 and 6 and stacking them, and at the time of stacking, self-fusing the respective intersections of the continuous strips 6 and 6 and then cooling. While being transported, the flat formed in the width direction of the transport body 16 The central portion of the ear portion 5 which is formed on the central portion of the 14 were without the bedding mat 1 by cutting with a cutter 17.

The bedding mat 1 obtained was propylene-
Approximately 1 m in diameter composed of a mixed resin of ethylene-butene terpolymer elastomer and styrene-butadiene rubber
Each of the many continuous filaments 6, 6 of m intersects with each other in an irregular loop, and is curved in the thickness direction and extends from one to the other. Are united to each other at about 700g / m
² , composed of a bulky net with an apparent thickness of 6 mm,
As shown in FIG. 1, on the surface of the mat surface 1, a large number of ridge-shaped ridges 3 and 3 having an arc-shaped cross section and groove-like valleys depressed between the ridges 3 and 3. 4 and 4 are formed,
The peaks 3 and the valleys 4 are arcuate valleys 4A and peaks 3A on the back surface. As shown in FIG. 3, the mat surface 2 is provided with an ear portion 5 formed by the synthetic polymer continuous filaments 6 and 6 extending horizontally from the valley portion 4 as shown in FIG.

The width of the arc-shaped crests 3 of the mat surface 2 in the first embodiment is about 20 mm and the crest interval is about 25 m.
m and the porosity in the mesh portion of the matte surface 2 is 87.
%, The parallel light transmittance is 45%, the thickness of the ears 5 formed around the mat surface 2 is about 2 mm, and the width is about 20 m.
m, the overall size is a rectangle of 100 cm x 200 cm, and the loading deflection rate on the mat surface 2 is 25
%.

The load deflection rate described above was measured as follows. Deflection rate under load (%) = {(Y−X) / Y} × 100, where X = bottom area on mat surface is 150 mm × 150 m
m, a load weight consisting of a rectangular parallelepiped weighing 67.5 kg
Thickness (mm) of the mat surface under the condition that a weight is loaded after loading for a minute, and Y = thickness (mm) of the mat surface when no load is applied.

The many peaks 3 and troughs 4 on the surface of the mat surface 2 may be formed continuously in the lengthwise direction, but as shown in FIGS. About 1
Crossing valleys 4B are formed at intervals of 0 cm to divide the ridges of the ridges 3, and the ridges 4 are also formed at intervals with crossing ridges 3B to divide the groove portions of the ridges 4 to separate adjacent ridges. It is also a preferred embodiment that the portion 3 is a mat surface having a structure in which the portion 3 is connected by the cross mountain portion 3B. By connecting the adjacent ridges 3 and 3 with the transverse ridges 3B in this manner, the load resistance of the ridges 3 and 3 can be further improved, and the mat surface 2 can be moved in the lateral direction. Can be prevented from spreading.

When the floor mat 1 of Example 1 was laid on the front of the wash basin in the bath of the golf club, the surrounding ears 5
Touches the floor surface in a planar manner and the valley portion 4 of the mat surface 2
The back surface of the mat touches the floor surface to suppress the sliding movement of the bedding mat 1, and when the bare mat is placed, a comfortable feeling of footing, which is different from the conventional mat, can be obtained. When the above was repeated, the soles were elastically stimulated by the ridges 3 of the matte surface 2, and it was a feeling of use in which a fatigue recovery effect can be expected.

Example 2 A resin prepared by mixing 48 parts by weight of a propylene-ethylene-butene terpolymer and 32 parts by weight of styrene-butadiene rubber was added to an organic nitrogen-based antibacterial and antifungal agent (thiaventazole). 20 parts by weight were mixed and melt-molded to form an antibacterial and antifungal masterbatch.

Then, 2 parts by weight of the master batch containing the antibacterial and antifungal agent, 59 parts by weight of the propylene-ethylene-butene terpolymer and 39 parts by weight of styrene-butadiene rubber were mixed to prepare a mixture of Example 1. Continuous filaments 6 and 6 were spun with this mixed resin using a manufacturing apparatus to form a bedding mat 1. The bending rate of the mat surface 2 of this bedding mat 1 was 23%, and 0.4% by weight of an antibacterial and antifungal agent was mixed in each continuous filament 6 constituting the bedding mat 1. .

About 0.15 g of a sample piece obtained by cutting the continuous filament 2 into a length of 5 mm from the above-mentioned floor mat 1 was collected, and antibacterial
It was used as a sample (instep) for the mildew proof test.

In addition, as a comparative example, from the floor mat 1 of Example 1 in which antibacterial and antifungal agents are not kneaded, to the continuous filament 2
Approximately 0.15 g of a sample piece cut into a length of 5 mm was collected,
A sample (B) for antibacterial and antifungal tests was used.

An agar medium was prepared as an antibacterial and antifungal test culture medium. As the bacterial cells, a bacterial cell suspension was prepared by a usual method for each of Aspergillus niger, Blue mold, Red mold and Black mold. As a method for adjusting the bacterial cell suspension, the bacterial cells are put into sterilized water and stirred.

Two Petri dishes containing the above-mentioned culture medium were prepared, the above sample A was put in the central portion of one petri dish, and the above sample B was placed in the central portion of the other petri dish. Then, a bacterial cell suspension was inoculated on it and cultured, and after 24 hours, the presence or absence of growth of the inoculated bacteria was visually judged,
Propagation of the inoculum was observed for all molds in the sample Otsu's petri dish, but no inoculum growth was observed in the sample instep petri dish for all molds. It was confirmed that the mold was resistant.

[Example 3] A rectangular frame-shaped metal mold container having a width of 5 cm and a depth of 5 mm in which the outer peripheral ear portion 5 of the floor covering mat 1 obtained in Example 1 can be immersed was prepared. After injecting an emulsion sol of polyvinyl chloride adjusted to a viscosity of 10000 centipoise to a depth of 4 mm, the outer peripheral ear portion 5 of the floor mat 1 was immersed in the emulsion sol at 130 ° C. After curing with hot air for 5 minutes, cool to room temperature and take out.
As shown in FIG. 5, the ear part 5 around the mat surface 1 is a bedding mat with a rim 7 made of a polyvinyl chloride frame.

The obtained floor mat 1A has continuous linear strips 6
The outer peripheral ear portion 5 of the mat surface 2 formed in step 1 is embedded in and integrated with polyvinyl chloride having a thickness of 3 mm as shown in FIGS. Has an inseparable thickness of 3 mm and a width of 5 cm, and the mat surface 2 has an area of about 2 m ² and a total weight of 2.80 k.
It was g, and could be laid in a more stable state on the floor surface.

As the means for forming the bedding mat 1A having the edging 7 made of a polymer material, the embodiment 3 described above is used.
Although it is possible to coat only the ear portion 5 of the mat having a mesh shape with a polymeric material as shown in FIG. 9, as shown in FIG. Recess 21 with a large number of through holes 20 that can be accommodated
And an underlay mat 23 having a frame-shaped edge portion 22 is formed around the recess 21, and the recess 2 of the underlay mat 23 is formed.
The bedding mat 1 may be inserted into the interior of the base mat 1 and the bedding mat 1 inserted using an adhesive may be fixed to the underlay mat 23, if necessary.

[0035]

As described above, the bedding mat 1 of the present invention is
Each of a large number of synthetic polymer continuous filaments 6 having a diameter of 0.5 to 2 mm intersects with each other in an irregular loop and is curved in the thickness direction to extend from one to the other. 6 are adhered to each other at intersections, and a large number of ridge-shaped ridges 3 having an arc-shaped cross section and groove-shaped valleys 4 depressed between the ridges are formed on the surface. And the valley portion 4 has a valley portion 4A and a mountain portion 3A on the back surface, respectively.
To form a porosity of 60 to 98% and a parallel light transmittance of 10 to
The matte surface 2 is composed of a 70% bulky mesh portion,
Further, an ear portion 5 is formed by the synthetic polymer continuous filament 6 extending in the horizontal direction around the mat surface 2,
Since the deflection rate of loading is 5 to 45%, the following effects are obtained.

Since the matte surface 2 has an appropriate cushioning property, a soft feeling of stepping can be obtained, and by laying it on the floor surface for standing work, the worker can walk comfortably and help reduce fatigue. In addition, since the matte surface 2 has a high porosity and parallel light transmittance, soil and water do not stay on the matte surface 2 and the feet are kept clean at all times, and dirt is not brought into other departments. In addition, the presence of a large amount of air between the voids exerts a heat insulating effect, and prevents cooling from the floor surface in the winter season to make the working environment comfortable.

When the floor mat 1 of the present invention is laid on a floor surface where bare feet can be walked like in a bath, there is no discomfort due to good drainage, and a large number of ridges can be formed by stepping on the mat surface. The mountain 3 softly stimulates the soles of the feet to improve blood circulation and exert a fatigue recovery effect.

Continuous filaments 6 constituting the bedding mat 1
In addition, by using a soft polyolefin-based polymer having a flexural modulus of 200 to 5000 kgf / cm ² , the floor mat 1 has an anti-slip effect, and the floor has a mesh structure of synthetic polymer continuous filaments 6 It has excellent fixing power on the surface, and because it has smoothed ears, it does not slip indefinitely, and there is a phenomenon of sticking to the floor due to aging as seen with vinyl chloride material. Does not happen.

The crests 3 and troughs 4 of the matt surface 2 have a large number of synthetic polymer continuous filaments 6 each having a diameter of 0.5 to 2 mm, which intersect each other in an irregular loop and in the thickness direction. Curved from one side to the other side, and a large number of continuous filaments 6 are formed by being adhered to each other at intersections respectively, so that despite the bulky structure, they are excellent in load resistance and elastic restoring force of deflection, It can be used for a long time without losing its shape.

Further, in the bedding mat 1 formed by the continuous filaments 6 in which the antibacterial agent and the antifungal agent are kneaded and mixed in the synthetic polymer continuous filaments, the habit of microorganisms adhering to the mat surface 1 , The growth is suppressed and it becomes hygienic, and it is possible to prevent the generation of malodor due to mold.

Then, in the bedding mat 1A in which at least the portion of the ear portion 5 around the mat surface 2 of the above net-like bedding mat 1 is embedded in a frame made of a polymer material and trimmed, the floor surface is Can be laid in a stable form, the edge 7 is in close contact with the floor surface to prevent sliding of the mat, and further, when a load is applied to the mat surface 2, distortion of the mat is suppressed and form stability is maintained. It is suitable for cleaning shoes for entrances and exits of buildings and for laying by the pool.

[Brief description of drawings]

FIG. 1 is a perspective view showing a mat surface portion of a floor mat according to the present invention.

FIG. 2 is an explanatory view showing peaks and valleys of the matte surface of FIG.

FIG. 3 is a side view schematically showing a cross section in the thickness direction of the floor covering mat of the present invention.

FIG. 4 is a simplified explanatory diagram of a floor mat production apparatus of the present invention.

5 is a perspective view showing a molded plate of a carrier in the manufacturing apparatus of FIG.

FIG. 6 is a perspective view of a bedding mat with edging.

FIG. 7 is a side view schematically showing a cross section in the thickness direction of the floor covering mat of FIG.

FIG. 8 is an enlarged view of an edge portion of FIG.

FIG. 9 is a perspective view of an underlayment sheet for forming another bedding mat with edging.

[Explanation of symbols]

1. Bedding mat 2. Matte surface 3. Yamabe
4. Tanibe 5. Ear 6. Continuous line 7. Border

Claims (5)

[Claims] 1. A plurality of synthetic polymer continuous filaments each having a diameter of 0.5 to 2 mm intersect each other in an irregular loop and are curved in the thickness direction to extend from one to the other. The continuous filaments of are adhered to each other at the intersections, and a large number of ridge-shaped peaks with an arc-shaped cross section and recessed groove-shaped troughs are formed between the peaks. And the valleys form valleys and peaks on the back surface, respectively, to obtain a porosity of 60 to 98% and a parallel light transmittance of 10 to 70.
%, The matte surface is constituted by a bulky net-like portion, and further the ear portion is formed by the synthetic polymer continuous filaments extending horizontally around the matte surface, and the loading deflection rate of the matte surface is measured by the following measuring method. Is a floor mat of 5 to 45%. Note Deflection rate (%) = {(Y−X) / Y} × 100 where X = bottom area on mat surface is 150 mm × 150 m
m, a load weight consisting of a rectangular parallelepiped weighing 67.5 kg
Thickness (mm) of the mat surface under the condition that a weight is loaded after loading for a minute, and Y = thickness (mm) of the mat surface when no load is applied. 2. The bedding mat according to claim 1, wherein the continuous line of synthetic polymer comprises a mixture of styrene-butadiene rubber and a terpolymer of propylene-ethylene-butene. 3. The bedding mat according to claim 1, wherein an antibacterial agent and an antifungal agent are kneaded into the synthetic polymer continuous filament. 4. The floor mat according to claim 1, wherein the ears around the mat surface are embedded in a frame body made of a polymer material to be framed. 5. The bedding mat according to claim 4, wherein the polymeric material of the frame framing the ears around the mat surface is soft polyvinyl chloride.