JPH0957883A - Water permeable carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To have good water permeability, drainage, stepping touch, and workability and to enable broad continuous processing by laminating a three dimensional reticulated body which is made from a thermoplastic resin and has specified porosity on the bottom surface of a carpet having water permeability. SOLUTION: A three dimensional reticulated body 2 is laminated on the bottom surface of a carpet 1 having water permeability. In artificial turf, for example, PP, which is hydrophobic and good in drainage, is preferable as a raw material for a pile. The porosity of the reticulated body is 30-95% preferably. EVA, elasticized polyvinyl chloride, etc., which have good flexibility and elasticity, are especially preferable as the thermoplastic resin. The contact area between the reticulated body and a floor surface is controlled to prevent the retention of water between the floor surface and the filaments of the reticulated body.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention has excellent water permeability, drainage function, cushioning properties, etc., and is used for outdoor applications such as balconies, poolsides, sidewalks, or shower rooms, bathrooms,
The present invention relates to a water-permeable rug used for indoor use around water such as toilets and kitchens.

[0002]

2. Description of the Related Art Heretofore, as a rug having a water permeable and drainage function, for example, a type in which a clogged resin plate is adhered to the bottom surface of a water permeable substrate is well known.

As another water-permeable rug, for example, a method of forming a resin layer having a protrusion on the back surface of the rug is well known.

[0004]

Among the rugs, the former is extremely excellent in water permeability and drainage function, but it cannot be flexibly adapted to the laying area because it is a standard size, and it is relatively hard, so There are many restrictions such as the fact that the surface is required to be completely smooth, and there are drawbacks such as high cost due to the high cost involved in the molding of the plate and the bonding process. In addition, the latter does not need to be a standard size and can be cut out to a desired size from a wide product, but the water permeation and drainage functions are considerably lower than those of the plate mounting type. As described above, in the conventional technique, a wide continuous type rug excellent in water permeability and drainage function has not been found so far.

The present invention does not provide a water-permeable rug which solves the above-mentioned problems of the prior art, has excellent water permeability and drainage property, and at the same time has excellent tread comfort and workability and can be continuously processed in a wide width. It is what

[0006]

The present application employs the following means in order to achieve such an object.
That is, the water-permeable rug of the present invention is characterized in that a three-dimensional net body made of a thermoplastic resin is laminated on the bottom surface of the water-permeable rug.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is a wide-width continuous type rug excellent in water permeability and drainage function, which has never been seen before. As the material forming the bottom,
By adopting a three-dimensional reticulate body made of thermoplastic resin filaments, it was surprisingly found that a rug satisfying all the required functions can be provided.

FIG. 1 shows the structure of the water permeable rug of the present invention. Although artificial turf, floor carpet or mat can be used as the surface material of the rug, it is important that the entire rug has vertical water permeability. Artificial grass is particularly preferably used as the surface material of such a water-permeable rug, but in order to achieve the above-mentioned vertical water permeability, a water-permeable type base cloth is used as the base cloth for driving the piles,
Alternatively, it is necessary to carry out water permeable processing such as drilling with a hot rod before or after backing with the three-dimensional net body.

As a material for such a pile of artificial turf, there is P
P or nylon is often used, but PP is more hydrophobic than nylon and therefore drains well. Considering the effect of walking with bare feet after getting wet, such a water permeable rug has durability and durability. Nylon artificial turf is often used because of its texture, but originally it has the drawback that excess water cannot be drained quickly due to the poor drainage due to its hydrophilicity. Therefore, PP artificial turf is used. This is preferable because it is rational for the water-permeable floor covering of the present invention and can quickly achieve excess water drainage.

A three-dimensional net body to be attached to the bottom surface of the surface material will be described. First, the optimum value of the porosity of the three-dimensional network body of the present invention varies depending on the resin used, but it is preferably 30 to 95%, more preferably 50 to 80%. This is because the voids between the filaments due to the loop structure peculiar to the reticulate body exhibit high water permeability in both vertical and horizontal directions and an appropriate cushioning property, resulting in a rug excellent in drainage function and tread feeling. If the porosity is too low, the water permeability will decrease and the pedal feel will be hard,
On the other hand, if it is too high, the comfort of walking will be unreliable and the walking ability will be hindered. The average diameter of the filaments constituting the three-dimensional network is preferably 0.2 to
3.0 mm, more preferably 0.5 to 2.0 mm,
The thickness of the three-dimensional net formed by the filament is
It is preferably 3 to 50 mm, more preferably 5 to 20 mm. If it deviates from these ranges, it becomes difficult to obtain an appropriate loop shape and void, and it becomes impossible to achieve both the high drainage function and the excellent tread feeling.

Further, the flexibility of such a three-dimensional network is greatly influenced by structural factors such as void ratio and filament diameter, but is greatly influenced by the rigidity of the resin itself used. That is, when the resin constituting the three-dimensional net body is expressed by the flexural rigidity according to JIS K-7106, it is 50
The resin is preferably 2,000 to 2000 kg / cm ² , more preferably 100 to 500 kg / cm ² . If the rigidity of the resin is too high, the cushioning property peculiar to the three-dimensional reticulate body will not be developed, and the resin will not be able to follow the unevenness, so that the workability will be deteriorated. On the contrary, if the rigidity is too low, the cushioning property is lost, and it becomes difficult to form voids, so that the water permeability is greatly impaired.

As the thermoplastic resin satisfying the above conditions, for example, polyethylene, polypropylene, ethylene-
The olefin resin such as vinyl acetate copolymer (hereinafter EVA), polyvinyl chloride, and various elastomers are not particularly limited as long as they are in the above-mentioned rigidity range, but are excellent in flexibility and elasticity. And soft polyvinyl chloride are particularly preferably used.

Further, when the rug of the present invention is laid on a smooth floor surface, it is preferable that the contact area between the three-dimensional net body and the floor surface is not too large. This is because even if the three-dimensional network has sufficient voids, if the floor surface and the three-dimensional network filament are completely sealed, water will be retained. This contact area is determined by the characteristics of the resin and the processing conditions (thread diameter, smoothness of the surface of the net, etc.), but, for example, by intentionally forming a continuous dent pattern on the net as shown in FIG. It is conveniently achieved. This continuous depression creates a space between the floor surface and the three-dimensional net, and this plays the role of a drainage groove, so that the drainage function is dramatically improved in rug applications such as balconies with a slight slope. So very effective.

Further, referring to the workability of the water-permeable rug of the present invention in terms of the Gurley stiffness of the three-dimensional net body, the Gurley stiffness of the three-dimensional net body must be 20,000 mg or less. Absent. If the bending resistance exceeds 20,000 mg, the rug cannot be transported or constructed in a roll shape and cannot follow the uneven portion. As described above, the flexibility of the water permeable rug of the present invention can be obtained only by appropriate structural design of the three-dimensional net body and selection of resin.

Further, by adding a foaming agent or an antibacterial / antifungal agent to the thermoplastic resin constituting the three-dimensional net body, it is possible to obtain a mat having further excellent functionality. For example, when a foaming agent is added to foam a three-dimensional reticulate body, it becomes possible to obtain a rug with more excellent cushioning properties, and with the addition of an antibacterial / antifungal agent, indoor water in shower rooms, bathrooms, toilets, kitchens, etc. It is possible to suppress discoloration, slimyness, malodor, etc., which are likely to occur when used for surrounding applications.

Next, the method for producing the water-permeable rug of the present invention will be described. FIG. 2 shows an outline of the manufacturing process of the three-dimensional network. First, the thermoplastic resin melted and kneaded by the melt extruder 3 is melt extruded from the multi-filament spinneret 4 into a large number of filaments 5, and the take-up roll surface set below the spinneret while the filaments are still in a molten state. Pick up at 6. Here, if the take-up speed is made sufficiently smaller than the linear discharge speed of the filament, the filament folds so as to draw a loop near the moving surface, and the cross-contacted portions are fused to obtain a three-dimensional net body. . There are two methods for joining the three-dimensional net body and the rug base material: adhesion with an adhesive or heat fusion. In the case of bonding with an adhesive, particularly when the rug is one that passes through the anchor coat process like artificial grass, it is possible to supply a three-dimensional net body as a secondary and backing it simultaneously with the anchor coat. Also in the case of heat fusion, if the rug base material is set in advance on the take-up roll 6 of FIG. 2, fusion with the base material occurs simultaneously with the formation of the three-dimensional net body, so that the backing is efficiently performed. It can be carried out. Further, while the three-dimensional network is still a semi-molten state, by nipping it with a roll having a continuous convex portion, a concave for efficient drainage is formed and at the same time, the base material and the three-dimensional network are more firmly heat-melted. Can be dressed.

The rug thus obtained is preferably used for outdoor applications such as balconies, poolsides and sidewalks, and indoor applications around water such as shower rooms, bathrooms, toilets and kitchens. Due to the nature of the product, it is particularly effective when used on a floor with a slight slope for drainage.

In the water-permeable rug of the present invention, the backing layer has a porosity of 30 to 30 made of a thermoplastic resin having a specific range of flexibility.
Since 95% three-dimensional mesh is used, water can be quickly drained vertically, horizontally, and in any direction regardless of where water seeps into the rug. It is preferably 1 x 10 ^{-2 in} any of the above directions.
Has a hydraulic conductivity of cm / sec or higher. Further, the water-permeable rug of the present invention preferably has a vertical direction of 1 × 10 ⁻¹ cm / sec.
It has the above water permeability. Permeability is JIS A-1
218 measured by the low water level test method. As a result, the cushioning characteristic of a three-dimensional mesh body provides a gentle pedaling comfort while maintaining drainage comparable to that of a rug with a conventional geta-shaped resin plate attached. Further, since the rug of the present invention is flexible, it can be transported in a roll shape or cut into a desired size, and it can flexibly follow even if the installation floor surface is not completely smooth, thereby satisfying the workability.

As a use, a veranda, a poolside,
It is preferably used around the water such as in a shower room or a bathroom, and particularly in the case of walking with bare feet, the effect can be more clearly realized due to its unique cushioning property and suppression of stickiness.

Briefly explaining the drawings, FIG. 1 shows a basic structure of a water-permeable rug according to the present invention, and is a schematic view of a state in which an artificial turf and a three-dimensional net are integrated. FIG. 2 shows an example of a backing process, in which a base material and a melt-extruded three-dimensional net body are partially nipped by a pressing roll having convex portions in a lattice pattern. FIG. 3 is a schematic view of the water-permeable rug integrated by the processing method of FIG. 2 when viewed from the back side, and shows a state in which a drainage groove having a lattice pattern is formed.

[0021]

The present invention will be described in more detail by the following examples.

Example 1 A permeable mat is prepared by the manufacturing process shown in FIG. JIS K-
EVA resin having a flexural rigidity of 300 kg / cm ² according to 7106 was melt-kneaded by a melt extruder 3 and 180 discharge holes having a diameter of 1 mm were arranged in a zigzag pattern in 180 rows in 3 rows. A large number of filaments 5 were spun on the surface of the take-up roll 6 immediately below the spinneret. Here, by setting the rotation speed of the take-up roll to be sufficiently lower than the discharge linear velocity of the filament, the filaments are folded so as to draw a loop, and the cross-contact portions are fused to form a three-dimensional net body. The obtained three-dimensional network has a filament diameter of 1.2 m.
m, basis weight 1000 g / m ² , thickness 10 mm, porosity 75%
Met.

Next, the anchor coat-treated artificial grass 7 is set on the take-up roll 6 so that the filament 5 falls on the back surface, and the three-dimensional net body is laminated. Here, since the filament 5 is still sufficiently hot and is in a semi-molten state, the filament 5 and the water-permeable artificial turf 7 that has been punched are thermally fused and integrated. In Example 1, the pressing roll 8 was not used. The vertical hydraulic conductivity of this rug was 3.5 × 10 ^-1 cm / sec.

Comparative Example 1 The same manufacturing method as in Example 1 was used, but a three-dimensional net body was nipped by a pressing roll 8 having convex portions in a lattice pattern. Thereby, as shown in FIG. 3, the drainage grooves 1 in a grid shape were provided on the bottom surface of the laminate. The drainage groove has a groove width of 8 mm, a groove interval of 50 mm, and a depth of 5
mm.

COMPARATIVE EXAMPLE 2 A water-permeable artificial turf for a veranda, to which a geta-shaped mount of ABS resin was adhered, was prepared.

For these three levels, with an average slope of 3 °,
In addition, Table 1 shows the results of evaluation of workability, drainage performance, and stepping comfort when walking with bare feet when 1.44 m ^{2 of} facility is installed on each concrete surface that is slightly uneven.

[0027]

[Table 1] In Example 1, the three-dimensional network structure having large voids and the flexibility of the resin itself are used to flexibly cope with the uneven portion, have a cushioning property, and have a good stepping comfort. The drainage condition was also at a satisfactory level.

In Comparative Example 1, the drainage groove was provided in the bottom portion, so that the drainage property was improved as compared with Example 1. In Comparative Example 2, the drainage property was good, but since the gantry was hard, it was not possible to follow even a slight uneven portion, rattling occurred, and construction was difficult. Furthermore, the feeling of pedaling was hard and the cushioning was applied.

[0029]

According to the water-permeable rug of the present invention, excellent permeability
It is possible to obtain a rug with excellent workability and treading comfort while maintaining drainage. Also, wide continuous processing is possible,
Since the processed product can be easily cut out, it is possible to flexibly adapt to the intended installation area.

[Brief description of drawings]

FIG. 1 shows a basic structure of a water-permeable rug according to the present invention.

FIG. 2 shows an example of a manufacturing process of a water permeable rug according to the present invention.

FIG. 3 shows the state of the bottom surface of the water-permeable rug obtained in Comparative Example 1.

[Explanation of symbols]

 1: Rug part 2: Three-dimensional reticulated body part 3: Melt extruder 4: Multi-thread spinneret 5: Filament 6: Take-up roll 7: Artificial turf 8: Pressing roll (with convex portion of lattice pattern) 9: Groove part 10 : 3D mesh part

Claims (15)

[Claims] 1. A water-permeable rug, wherein a three-dimensional net body made of a thermoplastic resin is laminated on the bottom surface of the water-permeable rug. 2. The water-permeable rug according to claim 1, wherein the three-dimensional network has a porosity of 30 to 95%. 3. The flexibility of the thermoplastic resin forming the three-dimensional network has a flexural rigidity of JIS K-7106 of 50 to 200.
The water-permeable rug according to claim 1, which has a weight of 0 kg / cm ² . 4. The three-dimensional reticulate body has a Gurley stiffness of 20,000 mg.
The water-permeable rug according to claim 1, wherein: 5. The water-permeable rug according to claim 1, wherein the rug is a water-permeable artificial turf. 6. The drainage groove according to claim 1, wherein the three-dimensional net-like body has a recess formed by being fused to the surface on the installation floor surface side.
The water-permeable rug described. 7. The water-permeable rug according to claim 1, wherein the drainage groove has a pattern formed continuously on the surface of the net-like body. 8. The water-permeable rug according to claim 5, wherein the drainage grooves are provided in a grid pattern. 9. The water-permeable rug according to claim 1, wherein the filament has an average diameter of 0.2 to 3.0 mm. 10. The water-permeable rug according to claim 1, wherein the three-dimensional net body has a thickness of 3 to 50 mm. 11. The water-permeable rug according to claim 1, wherein the three-dimensional network is a foam filament of a thermoplastic resin. 12. The water-permeable rug according to claim 1, wherein the three-dimensional reticulate body is blended with at least one of an antibacterial agent and an antifungal agent. 13. The rug has a vertical direction of 1 × 10 ^-1 cm /
The water-permeable rug according to claim 1, which has a water permeability coefficient of sec or more. 14. The water-permeable rug according to claim 1,
Water permeable rugs intended for laying on outdoor foundations selected from balconies, poolsides and walkways. 15. The water-permeable rug according to claim 1,
A permeable rug for laying on a water-indoor indoor base selected from shower rooms, bathrooms, toilets and kitchens.