JPS63270854A - Mat like fiber structure - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a mat-like fiber structure with excellent compression recovery properties and adhesive durability.
In particular, the present invention relates to a mat-like fiber structure having excellent performance as a floor mat, entrance mat, shoe-wiping mat, foot-wiping mat, etc.

(Prior Art) Various mat-like fiber structures have been known so far, but
As a method of reducing the cost of mat-like products made of so-called woven or knitted fabrics, m-fibers are created by entangling crimped fibers, forming the fiber entanglement into a mat shape, and joining the entangled points with an adhesive. Structures are often used, especially in areas such as floor mats.

The crimped fibers forming the above-mentioned mat-like fiber structure include, for example, vegetable fibers having fine natural crimps such as cotton, thick rigid linear vegetable fibers such as coconut fibers, and synthetic fibers. Examples include those that are twisted into a shape and heat-set to give a coil-like crimp, and synthetic fibers that are given sawtooth-like crimp by a push crimping method or the like.

Conventional mat-like fiber structures are produced by intertwining the above-mentioned crimped fibers in a two-dimensional manner using a card machine, forming a mat, and then physically applying adhesive or needle punching to form a mat. It is manufactured by strengthening entanglement.

(Problems to be Solved by the Invention) However, most of the above-mentioned conventional mat-like fiber structures have large crimps and are made of linear crimped fibers with gentle curves in order to achieve a bulky finish. However, in applications such as floor mats, it has poor compression recovery properties, tends to sag, and has poor durability. Ta.

In addition, if the crimps are strengthened by needle punching or the like to improve the sag, the crimped fibers become hard and plate-like, resulting in even poorer compression recovery (elasticity). Even if the entangled body is processed with a processing agent that has rubber elasticity such as rubber latex, the problem remains that because the entangled body originally has a planar fiber structure, it tends to collapse when a vertical force is applied. .

Furthermore, in conventional mat-like fiber structures, in order to strengthen the bonding at the entangled points, an adhesive is applied to the entangled body by a spraying method or an infiltration method to strengthen the bonding at the entangled points. However, with the above method, it is difficult to bond all entangled points uniformly, and the amount of adhesive applied is uneven, resulting in uneven bonding strength, and the durability of the bonding strength must also be satisfied. The problem was that it wasn't a kimono.

Therefore, conventional mat-like fiber structures have poor compression recovery properties and adhesive durability, and tend to sag.
It has been considered unsuitable for use in applications where force is applied in the vertical direction, such as floor mats, entrance mats, shoe-wiping mats, and foot-wiping mats.

Therefore, the present inventors conducted extensive studies with the aim of obtaining a mat-like fiber structure that has excellent compression recovery properties and adhesive durability, and is particularly suitable for applications where force is applied in the vertical direction, such as floor mats. A layer of heat-fusible adhesive is provided on the surface layer of the material monofilament, and the form of the crimped fibers is made into a three-dimensional lump-like crimped body made of the synthetic fiber monofilament, and this three-dimensional lump-like crimped body is formed into a mat-like shape. A mat-like 11i fiber structure constructed by entangling the entangled body, further heating the entangled body to melt the above-mentioned thermal a-adhesive adhesive, and joining the entangled points of the entangled body preferably meets the above purpose. We have discovered that this is the case, and have arrived at the present invention.

(Means for Solving the Problems) That is, the present invention provides a tertiary synthetic fiber monofilament having a heat-fusible adhesive layer on the surface layer and having a diameter of 0.1 to 2.0 cm and a length of 5 to 30 cm. The original lump-like crimped bodies are assembled into a mat-like entangled body, and the entangled body is further heated to a temperature higher than the melting point of the heat-fusible adhesive and lower than the melting point of the synthetic fiber monofilament to entangle the entangled body. The object of the present invention is to provide a mat-like fiber structure characterized in that the mating points are joined with the heat-fusible adhesive.

The mat-like fiber structure of the present invention uses a synthetic resin monofilament having a heat-fusible adhesive layer on the surface layer as a material, and is made by self-crimping one or more of the synthetic resin monofilaments. It is characterized by a collection of three-dimensional lump-like crimped bodies entangled in a mat shape.

The three-dimensional lumpy crimped body used in the present invention has a stronger residual crimp force than the crimped fibers having linear crimps constituting conventional mat-like fiber structures, and has excellent compression recovery properties itself. Therefore, the mat-like fiber structure of the present invention, which is made by aggregating these fibers and intertwining them into a mat-like shape, exhibits high compression recovery properties and does not buckle even when force is repeatedly applied in the vertical direction. It has excellent performance in that it is difficult to cause.

In addition, the mat-like fiber structure of the present invention uses a synthetic resin monofilament 1 having a heat-fusible adhesive layer on the surface layer as a material, and after forming an entangled body, the entangled body is heated to have the above-mentioned heat-fusible adhesive property. By melting the adhesive, the entangled points of the entangled body are bonded, so the bonded points are uniform and strong compared to mat-like fiber structures obtained by conventional adhesive spraying or dipping. Excellent adhesive durability.

The synthetic fiber monofilament used in the present invention is made by melt-extruding and spinning thermoplastic resins such as polyamide, polyester, polyolefin, polyvinyl helokenide, and polyvinylidene halide by a conventional method, and then stretching and heat-setting as necessary. It has a heat-fusible adhesive layer on its surface layer.

The heat-fusible adhesive here refers to the synthetic fiber monofilament forming the main body of the mat-like fiber structure.
It is selected from natural resins with low melting points, synthetic resins, natural rubber, synthetic rubber, and elastomers made by combining synthetic resin with synthetic rubber as a soft segment.
The ability to melt and bond to each other by heating to exhibit strong adhesive strength can be achieved through a simple process of heating and cooling.

Specific examples of heat-fusible adhesives that can be used for this purpose include polyisoprene, polybutadiene, butadiene-styrene copolymers, butadiene-acryloni-1-lyl copolymers, polychloroprene, ethylene-propylene copolymers, etc. Examples include synthetic rubbers such as polymers and chlorosulfonated polyethylene, and synthetic resins such as polyamides, polyesters, polyolefins, polyvinyl halides, polyvinylidene halides, polyurethanes, polysiloxanes, and copolymers thereof.

As a method for applying the heat-fusible adhesive layer to the surface layer of the synthetic fiber monofilament, when the heat-fusible adhesive is synthetic rubber, a rubber-based latex obtained by dispersing it in water with an appropriate emulsifier is used. Alternatively, a rubber adhesive is dissolved in a suitable solvent, and the above adhesive is sprayed onto the monofilament, or the monofilament is immersed in the above adhesive, and the monofilament is passed through a tank or die filled with the above adhesive. After applying the above-mentioned adhesive to the surface of the monofilament by a method such as drying and heat treatment, the rubber component is cured.

In addition, when the heat-fusible adhesive is a synthetic resin, a method of coating the monofilament 1 to the surface with molten synthetic resin and a normal composite spinning method can be used to create a synthetic resin with a low melting point using the monofilament as a core. Methods such as forming composite threads into sheaths are adopted.

If the surface of the synthetic fiber monofilament is treated with a primer in advance using a treatment agent compatible with the synthetic rubber or synthetic resin used, the bond between the monofilament surface and the heat-fusible adhesive layer will be strengthened, making it even stronger. We can expect excellent bonding.

There are no particular restrictions on the amount of heat-fusible adhesive to be applied to synthetic fiber monofilaments, but depending on the diameter of the monofilament used, the thickness of the intended mat-like fiber structure, etc. 400%
A range of can be suitably adopted.

The above-mentioned synthetic fiber monofilament having a heat-fusible adhesive layer on its surface has a diameter of 0.1 to 2.0 mm.
It is particularly desirable that the monofilament diameter is in the range of 0.2 to 1.7 m. If the monofilament diameter is less than 0.2 rra, the compression recovery properties of the mat-like fiber structure will be insufficient, and if it exceeds 2.0 m, the matte This is not preferable because the shaped fibrous structure becomes too hard.

Furthermore, the synthetic fiber monofilament forming one three-dimensional mass crimped body has a length of 5 to 30 cm, especially 10 to 2 cm.
It is preferable that the length of the monofilament is less than 5 ctn, and if the length of the monofilament is less than 5 ctn, a three-dimensional lump-like crimped body having a lump-like structure cannot be obtained, and the compression recovery properties of the mat-like fiber structure are inhibited. If the diameter exceeds 30 cm, the maximum diameter of the three-dimensional lumpy crimp becomes large,
This is undesirable because the entanglement points of the three-dimensional mass-like crimped body are reduced, and the mat-like fiber structure becomes easily flattened, resulting in a decrease in its durability.

Hereinafter, the structure of the mat-like fiber structure of the present invention will be explained with reference to the drawings.

FIG. 1 is a perspective view of a synthetic fiber monofilament having a heat-fusible adhesive layer on the surface used as a material for the mat-like fiber structure of the present invention, and FIG. 2 is an enlarged perspective view of the same three-dimensional lump-like crimped body. FIG. 3 is a perspective view of the appositional composite, and FIG. 4 is a surface structure diagram of the mat-like structure of the present invention.

As shown in FIG. 1, a synthetic fiber monofilament 1 having a heat-fusible adhesive layer used as a material for the mat-like fiber structure of the present invention has a heat-fusible adhesive layer 2 on its surface. ing.

The three-dimensional mass crimped body 3 made of the synthetic fiber monofilament 1 used in the present invention is a synthetic fiber monofilament having a diameter of 0.1 to 2.0 m and a length of 5 to 30 cm and having a heat-fusible adhesive layer on the surface. As shown in the enlarged perspective view in Fig. 2, the monofilament 1 having an adhesive layer 2 on its surface is formed into a three-dimensional cubic shape such as a sphere. They are intertwined and have a fixed shape.

The three-dimensional lump-like crimped body 3 is made by aligning a plurality of synthetic fiber monofilaments 1 with an adhesive layer 2 on the surface thereof so as to have a desired radius (radius of curvature) and double-twisting them to generate a so-called kink. It can be easily produced by heating until the material is heated until the material is crimped, cutting it into the required length to form the desired three-dimensional crimped mass, and then untwisting the material.

In addition, when performing the above-mentioned heating, it can also be heated to a temperature below the melting point of the above-mentioned heat-fusible adhesive.

Here, the maximum diameter of the obtained three-dimensional massive crimped body (for example, L shown in FIG. 2) is 5 to 40 m, particularly 10 to 30 m.
It is desirable that the length is within the range of m.If it is less than 5 m, the entanglement of the mat-like fiber structure will be inhibited and compression recovery properties will be reduced, and if it exceeds 40 m, the entanglement points of the three-dimensional lumpy crimped body will decrease. This is not preferable because the three-dimensional entangled blocks tend to peel off or become sag, reducing the durability of the mat-like fiber structure.

Next, the three-dimensional lump-like crimped bodies are assembled and entangled into a mat shape, and the entangled body is heated to a temperature above the melting point of the heat-fusible adhesive and below the melting point of the synthetic fiber monofilament 1. The mat-like fiber structure of the present invention can be obtained by heating and joining the entangled points of the entangled body with a heat-fusible adhesive.

The above-mentioned entangled body can be formed by defibrating and entangling at the same time using a card or the like, or by subjecting the three-dimensional block-like entangled body to a locking machine and entangling the three-dimensional block-like entangled bodies. Can be done.

Here, the same kind of three-dimensional crimped bodies can be collected and entangled, but three-dimensional crimped bodies of different sizes and natural fibers such as different types of synthetic fiber monofilament and coconut fiber can also be used. It is also possible to mix and assemble three-dimensional bulk crimped bodies or crimped bodies having linear crimps, and then subject them to entanglement.

The entangled body 4 obtained in this way is shown in a perspective view as shown in the third figure.
As shown in the figure, a plurality of three-dimensional lump-like crimps 3 are intertwined with each other, and the three-dimensional lump-like crimps 3 on the upper, lower, left, and right sides are connected together to form a mat-like object, and each three-dimensional lump-like crimper is The elasticity and compression recovery properties of the body 3 are fully exhibited.

Next, the entangled body 4 is heated to a temperature above the melting point of the heat-fusible adhesive and below the melting point of the synthetic fiber monofilament, and the entangled points are joined by the adhesive to form the mat-like fiber structure of the present invention. When the product is completed, according to the present invention, each entanglement point can be uniformly joined, the three-dimensional lump-like crimped body 3 can be effectively prevented from falling off, and the mat-like fiber structure can be further bonded. Provides strong compression recovery properties.

Moreover, the desired mat-like fiber structure can be created by passing the entangled body through a hot air zone and cooling it by blowing air immediately after heating, without requiring processes such as adhesive spraying or dipping. As a result, it is possible to positively simplify the process and reduce processing costs.

In the thus obtained mat-like fiber structure 5 of the present invention, as shown in the surface structure diagram in FIG. The entangled points are joined by a joining layer 2' made of the above-mentioned adhesive, and it is a bulky mat-like material with a porosity of usually about 60 to 99%.

The mat-like fiber structure of the present invention can be cut into a desired size and put to practical use as it is, but it can be further heat-pressed to flatten the surface, or embossed as desired. , densification of internal structure,
Even more favorable effects can be expected by reducing surface friction resistance, increasing surface strength, adding a design, and adding shape durability.

The effects of the present invention will be further explained with reference to Examples below.

(Example) Nylon 6 having a relative viscosity of 3.6 was melt-spun and drawn according to a conventional method to obtain a monofilament having a diameter of 0.44 m.

The above monofilament was subjected to a wire coating machine, and a soft vinyl chloride having the following composition was coated with a thickness of 0.
．． It was coated to a concentration of 15M.

Here, the weight ratio of the monofilament to the soft vinyl chloride of the obtained soft vinyl chloride-coated monofilament was 1:2.15.

32 miles of selection Heavy flooded part Vinyl chloride 100 Plasticizer (DOP> 60 Stabilizer 8 Lubricating agent 1 Filler, coloring agent 13 The limit heating temperature in the above composition was 172°C.

Forty pieces of the above-mentioned soft vinyl chloride-coated monofilament were twisted together in the right direction. The diameter of the fiber bundle at this time is about 5 seconds! Met.

Twist the above fiber bundle until it forms a double twist (kink), pass it through hot water at 100°C for about 20 seconds, and then cool it through cold water for 5 seconds. , the morphology was fixed.

Next, the fiber bundle was heated and untwisted in the left direction, and the fiber bundle was heated for 150 m.
By cutting, the average maximum diameter is 20m,
A three-dimensional lumpy crimped body (A) having a spherical shape as shown in FIG. 1 was obtained.

On the other hand, for comparison, nylon 6 monofilament (diameter 0.44s++) not coated with the above-mentioned soft vinyl chloride
From this, a three-dimensional massive crimped body (B) was created under the same conditions as above.

Next, the three-dimensional lump-like crimped body (A) obtained above was applied to a card machine to obtain a fabric weight of 12,480 g/m and a thickness of 30 I! 1f
A sheet-like entangled body as shown in FIG. 2 was obtained.

This sheet-like entangled body was placed in a heat exchanger at 140° C. for 15 minutes, and then cooled to obtain a mat-like structure with a thickness of 12M.

The thus obtained mat-like fibrous structure exhibited a state in which entangled points were firmly joined by thermal melting of the soft vinyl chloride, and its compression recovery properties were extremely excellent.

On the other hand, the three-dimensional lump-like crimped body (B) for comparison was applied to a card machine, and a second
A sheet-like entangled body as shown in the figure was obtained.

Styrene with a solid content of 50% by weight was added to the sheet-like entangled body.
Butadiene copolymer rubber latex (manufactured by Japan Synthetic Rubber)
A rubber-coated product weighing 2450 g/bottom was obtained by spraying on both sides with a spray gun, drying, and heating and vulcanizing.

Further, the rubber processed product was heated in a hot press at 140° C. for 20 minutes and then cooled to obtain a mat-like fiber structure with a thickness of 12 layers.

Samples with a width of 5 cm and a length of 10 cm were cut from the two types of mat-like fiber structures obtained in this way, and in order to evaluate their adhesive strength, they were subjected to a tensile tester model JCM500 manufactured by Shinko Tsushin Kogyo ■. The tensile strength and elongation were measured in the manufacturing direction of the mat (vertical) and in the direction perpendicular to this (horizontal).

In addition, in order to evaluate the adhesive durability of the mat, a repeated load of 1.0ffff/cd was applied to the mat with io, oo
The tensile strength and elongation were measured in the same manner as above.

These results are shown in Table 1.

As is clear from the results in Table 1, the mat-like structure of the present invention has higher tensile strength and elongation than conventional mat-like structures, and has excellent bonding strength. ing.

Furthermore, even when repeated loads are applied, the rate of decrease in tensile strength and elongation is small, and adhesive durability is excellent.

(Effects of the Invention) As explained above, the mat-like fiber structure of the present invention has
It has excellent compression recovery properties and adhesive durability, and
It is extremely durable and does not easily buckle even when force is applied repeatedly from the vertical direction, so it is especially suitable for floor mats, entrance mats, shoe-wiping mats, foot-wiping mats, etc. Suitable and necessary for added mat applications.

The mat-like fiber structure of the present invention has a lot of space inside and has good circulation from the surface layer to the lower layer.
For example, when used as an entrance mat where many people come and go, the dust from the soles of shoes can be easily removed from the surface layer to the lower layer, and there is no re-adhesion of the dust, effectively preventing contamination inside the building. You can also use it to clean the mat.
It has the advantage of being able to remove dust sufficiently by applying water to the culm.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a synthetic fiber monofilament having a heat-fusible adhesive layer on the surface used as a material for the mat-like fiber structure of the present invention, and FIG. 2 is an enlarged perspective view of the same three-dimensional lump-like crimped body. FIG. 3 is a perspective view of the appositional union, and FIG. 4 is a surface structure diagram of the mat-like structure of the present invention. 1...Synthetic fiber monofilament 2...
・Adhesive layer 2'...Joining layer (adhesive) 3...Three-dimensional lumpy crimped body 4...Entangled body

Claims (2)

[Claims] (1) Diameter 0.0mm with a heat-fusible adhesive layer on the surface layer.
Three-dimensional lump-like crimped bodies made of synthetic fiber monofilaments with a length of 1 to 2.0 mm and a length of 5 to 30 cm are assembled to form a mat-like entangled body, and the entangled body is further heated at a temperature higher than the melting point of the heat-fusible adhesive, A mat-like fiber structure, characterized in that it is heated to a temperature below the melting point of the synthetic fiber monofilament, and the entangled points of the entangled body are bonded using the heat-fusible adhesive. (2) The three-dimensional mass crimped body is formed by self-crimping one or more synthetic fiber monofilaments having a heat-fusible adhesive layer on the surface layer, and has a maximum diameter in the range of 5 to 40 mm. A mat-like fiber structure according to claim (1), characterized in that: