JP3004572U - Dust control mat - Google Patents

Abstract

(57) [Abstract] [Purpose] To provide a dust control mat which has a good feel, a good texture, little "sagging" and fluffing, and a large stain removal property. [Structure] In a dust control mat that uses polyamide-based long-fiber crimped yarn as pile yarn, two types of processed yarns with different single yarn fineness are used, both processed yarns are inserted into the base fabric to form a loop pile, and the back side is rubber When forming a tuft mat in which a material layer is arranged, tufts formed by the respective processing threads and having a side of 1 to 5 cm are adjacent to each other, and when the adjoining object is a unit, the tufts alternate vertically and horizontally. Dust control mat formed so as to be arranged in a row, and at that time,
Of the two types of processed yarns with different single-filament fineness, the processed yarn with large single-filament fineness has a triangular fiber cross section. [Effect] A dust control mat having excellent texture and feel, rigidity, abrasion resistance, and stain-removing property, and a shade pattern formed was obtained.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a dust control mat for removing dirt adhered to the soles and soles of shoes, dust, sand, mud, etc., especially when entering indoors from the outdoors at home, offices, hotels, etc. Regarding wiping mat (entrance).

[0002]

[Prior art]

 Traditionally, dust control mats have used natural fibers such as cotton and wool, recycled fibers such as human silk and cupra, and synthetic fibers such as polyamide, polyester, and polypropylene. Carpet in which a backing layer is formed by weaving (rugs, carpets, mattresses) or flocking (hooked rugs, tufted carpets) on a non-woven fabric, etc. Matters and mats are used.

Among them, tufting is a method of planting piles on a base cloth using a tufting machine, which is a flocking machine. The productivity is extremely high, and the production cost is higher than that of an ordinary mechanical woven carpet. Since it is cheap and the price is low, the demand is rapidly increasing with the westernization of lifestyle in recent years.

As the fibers forming the tufted pile, various fibers as described above are used, but synthetic fibers are used because of the uniformity of the material and easy handling, and among them, polyamide-based fibers are often used. . This is because polyester fibers have poor impact resistance and recontamination property (recontamination after washing), and polypropylene fibers have lipophilicity, poor oil stain resistance and re-staining property, which are not preferable. This is because polyamide fibers have excellent stain resistance, weather resistance, and recontamination properties. When a fiber bundle of polyamide fibers is used as a tufted pile, it is used as a polyamide fiber crimped yarn after being subjected to crimping processing such as jetting, pushing, false twisting, and knitting / deniting. Usually, tufts are formed that are rich in bulkiness (bulkyness). Further, the piles formed include cut piles, loop piles, and composite piles of cut and loops, but the loop piles are preferable from the viewpoint of durability for stain removal and pile shape retention.

However, when tufted is manufactured using a polyamide-based fiber bundle, the fineness (fiber thickness) of the single yarn that constitutes the pile greatly affects the performance of the manufactured dust control mat, and Is small (thin), the pile is flexible, and it is good for feeling the feeling when treading, feeling and fine dust with a particle size of less than 0.5 mm. A large amount of fluffing, etc., caused by single yarn breakage due to abrasion, leads to the destruction of the mat, and the dirt removal effect (dirt removal performance) is also reduced, and large dust particles (earth and sand etc.) of 0.5 mm or more are piled on the pile surface. Will be deposited on. Also, if the fineness is large (thick), there is no "sagging" or fluffing, the dirt removal property is large, and dust with a large particle size is also taken well, but the rigidity becomes too large and the original matte feel and texture are impaired. Becomes Therefore, in the past, piles of various fineness have been prepared and manufactured according to the purpose of use and the place of use.

[0006]

[Problems to be solved by the device]

 The present invention has the above-mentioned two contradictory effects of the single yarn fineness of the fibers constituting the pile on the dust control mat, that is, the feeling and the texture are good, and the "sagging" and the fluffing are small and the particle size is small. The present invention provides a dust control mat that has the ability to remove small to large dust and to have great dirt removal performance.

[0007]

[Means for Solving the Problems]

 As a result of diligent studies, the present inventors have used two types of long-fiber crimped yarns having different single yarn fineness as pile yarns, and the tufts formed by the pile yarns are arranged adjacent to each other to improve the feel and texture. It was found that a dust control mat having good properties, good "removal" and less fluffing, and having a large dust removal property with a small to large particle size was obtained, and completed the present invention. did.

That is, the first aspect of the present invention is a dust control mat using polyamide long-fiber crimped processed yarn as pile yarn, using two types of processed yarns having different single yarn fineness, and using both processed yarns as a base fabric. When forming a tuft mat in which the insertion pile is formed and the rubber material layer is arranged on the back surface, tufts with one side of 1 to 5 cm formed by each processed yarn are adjacent, and the adjacent object is one unit , A dust control mat characterized in that each unit is formed so that tufts are arranged alternately in the vertical and horizontal directions, and the second is a single yarn of two types of processed yarns with different single yarn fineness. The processed yarn having a high fineness is a dust control mat whose fiber cross section is triangular, and the third is a single yarn fineness of 200 to 400 denier on the one hand and 50 to 150 denier on the other hand. Dust control mat.

Hereinafter, the present invention will be described in detail. The polyamide-based long fibers constituting the pile yarn of the dust control mat of the present invention are long fibers made of an aliphatic polyamide such as nylon 6, nylon 66, nylon 11, nylon 12, nylon 610, nylon 612 or a copolymer thereof. In particular, long fibers made of nylon 66 are preferable from the viewpoint of rigidity, weather resistance, wear resistance and the like. As means for crimping polyamide long fibers, there are injection, indentation, false twisting, knit / denit, etc., and any means may be used. Among these means, the jetting is particularly preferable in terms of productivity. desirable.

In the present invention, the two types having different single yarn finenesses preferably have a single yarn fineness in the range of 200 to 400 denier and the other in the range of 50 to 150 denier. The thickness of both fiber bundles composed of single yarns is in the range of 1,600 to 16,000 in total denier, and if the single yarn fineness is too thin, it becomes too soft and "sagging" single yarn breakage easily occurs. Dust (earth and sand) with a particle size of 0.5 mm or more is accumulated on the pile surface, and if it is too thick, it becomes too hard and is not suitable as a dust control mat, and if the total denier is too thin, it is not suitable for mats. It is suitable, and if it is too thick, it will be difficult to hit the tufting machine. As the base fabric for flocking pile yarn, a plain woven fabric such as a natural fiber, a regenerated fiber, a synthetic fiber or a non-woven fabric obtained by subjecting a spun fabric to needle punching or the like is used, and particularly, spunbond, polypropylene or polyester. A non-woven fabric or plain woven fabric is preferred.

The rubber material as the backing layer is provided to prevent the pile yarns from slipping out and to prevent the mat from slipping. Natural rubber (NR), styrene butadiene rubber (SBR), nitrile rubber Various rubber materials such as butyl rubber, butyl rubber, chloroprene rubber (CR), and nitrile butadiene rubber (NBR) are used. Nitrile rubber is preferable from the viewpoint of oil resistance, and NBR is preferable from the viewpoint of durability. Gum latex may be applied, or a rubber sheet manufactured in advance may be attached with an adhesive.

As shown in FIG. 1, the mat is manufactured by forming pile piles (4) with pile yarns (1) on a base fabric (2) by using an implanting needle (3). Regarding the obtained tufts, the number of needles in the needle implantation direction (a) is called a gauge, and the number of needles in the pile arrangement direction (b) is called a stitch. Generally, the gauge is 4 to 15 / Inch, the number of stitches is 5 to 15 / inch, and the pile height (c) is in the range of 4 to 30 mm.

The pile to be formed may be a cut pile, a loop pile or a composite pile of cut and loop, but a loop pile is preferable from the viewpoint of durability of stain removal and pile shape retention. In the present invention, two types of pile yarns (1) and (1 ') having different single yarn fineness are inserted so that they are adjacent to each other in the range of 1 to 5 cm in the needle implantation direction (a, gauge direction), and then the pile is piled up. 1 to 5 cm in the arrangement direction (b, stitch direction) so that they are adjacent to each other.

In the present invention, the tufts each having a side length of 1 to 5 cm, which are formed of the processed yarns, mean that the individual piles formed of the pile yarns (1) and (1 ′) are arranged in the needle direction and arrangement. The tufts are inserted in each direction so that each side is in the range of 1 to 5 cm, and each side is in the range of 1 to 5 cm. For example, the tufts are (A) and (B) in Fig. 2, and each side is (C) and (D). Each side may be inclined, for example, in the needle implantation direction or the arrangement direction as shown in FIG. 3, and need not be a straight line, and may be a curve as shown in FIGS. 4 and 5, for example.

When the tufts are adjacent to each other and the adjoining object is one unit, the units are formed so as to alternate vertically and horizontally, that is, the pile yarns (1) and (1 ′) are formed. When tufts such as (A) and (B) are planted so that they are adjacent to each other and the adjacent products (A) and (B) are one unit (E), the unit (E ′) adjacent to the unit is a tuft. The upper and lower sides and the left and right sides are alternately formed, that is, the tufts (A) are adjacent to the tufts (B) in the upper, lower, left and right directions as shown in FIG.

The two types of pile yarns (1) and (1 ′) may be twisted with each other or may be arranged alternately and tufted. However, when the width is 1 to 5 cm, the feel, texture, It is preferable because the characteristics such as settling, abrasion resistance, and dust removal with different particle diameters are mutually shared. The cross section of the single yarn has various shapes, for example, a circular shape, an elliptical shape, a polygonal shape, a flat shape and the like, and is usually a circular shape. However, in the second aspect of the present invention, a triangular single thread is particularly used. Yes, the corners of the triangles scrape off dirt such as dust and mud adhering to the soles and soles of the shoes, which is extremely effective in removing dirt. The triangular shape in the present invention includes various shapes as shown in (1) to (3) of FIG. 6, and is preferably a swollen triangle (1). It is manufactured by spinning using a spinneret of a regular shape, and when a regular spinneret is used, a single yarn having a bulged triangular cross section is obtained by necking or the like.

[0017]

[Action]

 According to the present invention, tufts having a large single yarn fineness and tufts having a small single yarn fineness are alternately formed on the upper, lower, left and right sides, so that the feel, the texture are excellent, and at the same time the rigidity, abrasion resistance and particle size are small. It is possible to obtain a dust control mat that is also excellent in removing dust and dirt, and by using a single yarn with a triangular cross section, a dust control mat that is even more excellent in stain removal is obtained.

Further, in the case of synthetic fibers used for carpets, mats, etc., the coloring is generally based on so-called soaking, in which a colored spinning dope prepared by adding a dye, a pigment and the like to a spinning dope is spun. Even single yarns spun from the same colored spinning dope have dark tufts from thick single yarns and light tufts from thin single yarns. Therefore, in the present invention, even with single yarns obtained from the same spinning dope, the shades of tufts (A) and (B) are different, and beautiful patterns such as a checkerboard pattern as shown in FIG. Patterns such as those shown in FIGS. 3 to 5 are formed.

[0019]

【Example】

 Examples and comparative examples are shown below, but the present invention is not limited to these examples. The evaluation of each example and comparative example was performed by the following methods. Cleanability by a 100,000-person practical test: A sample (100 × 25 cm surrounded by a metal frame) was constructed on stairs with many passersby, and the number of passing people was measured at the counter, and every 10,000 people were for home use. Vacuum clean with a vacuum cleaner for 1 minute, replace the sample based on the random number table, repeat 10 times for each sample, sieving the dust after a practical test with a 0.5 mm mesh sieve to remove dust solids. The total amount was measured and evaluated according to the following 5 grades.

5th grade 4th grade 3rd grade 2nd grade 1st grade Less than 0.5 mm 50 to 49 to 26 25 to 15 14 to 6 5 0.5 mm or more 150 to 149 to 76 75 to 40 39 to 21 to 20 (g / 0.25 m ² ) Compressibility (%), compressive elastic modulus (%), thickness reduction rate (%) due to compression: Measured by JIS L1021 / 1979, 6.10A method Thickness reduction rate (%) due to dynamic load : Measured 10,000 times by JIS L1021, 1979, 6.11A method Wear strength (mg): Measured by JIS L1021, 1979, 6.12 method (wear wheel; H38, wear count; 10,000 times)

(Example 1) Single yarn fineness 325 denier x 12 nylon 66 long fiber crimped yarn (total denier 3,900) was used as one pile yarn, and single yarn fineness 75 denier x 40 Niro 5/32 gauge by using Tebak (trade name) manufactured by Teikoku Sangyo Co., Ltd., which is made of polypropylene as a base fabric, using a 66-fiber long-fiber crimped yarn (total denier 3,000) as the other pile yarn. Using a tufting machine (having 32 needles in a width of 5 inches), 7 stitches (insert a needle 7 times into a length of 1 inch), a loop pile with a pile height of 6 mm was implanted, and 3 × as shown in FIG. 1.6 cm tufts (A) and (B) are formed so that the top, bottom, left and right alternate, and then Nitrile Butadiene Rubber Latex (Takeda Pharmaceutical Co., Ltd. for synthetic rubber mats) is applied to the back surface, A dust control mat was obtained. The obtained mat was excellent in texture and feel, and at the same time, excellent in rigidity, abrasion resistance and stain removal. Various evaluations were made on the obtained mat, and the results are shown in Table 1.

Example 2 As one pile yarn, the cross-sectional shape was a swollen triangular shape as shown in FIG. 6 (1), and the single yarn fineness was 325 denier × 12 nylon 66 long fiber crimped A dust control mat was obtained in the same manner as in Example 1 except that the yarn (all denier 3,900) was used. The resulting mat had the same performance as in Example 1 except that it was superior to Example 1 in terms of stain removal. Various evaluations were made on the obtained mat, and the results are shown in Table 1.

Comparative Example 1 Dust control mat in the same manner as in Example 1 except that single yarn fineness 325 denier x 12 nylon 66 long fiber crimped yarn (total denier 4,000) is used as pile yarn. Got Various evaluations were made on the obtained mats, and the measurement results are shown in Table 1. (Comparative Example 2) A dust control mat was obtained in the same manner as in Example 1 except that single-filament fineness 75 denier x 40 nylon 66 long fiber crimped yarn (total denier 3,000) was used as the pile yarn. . Various evaluations were performed on the obtained mat, and the results are shown in Table 1.

[0024]

[Table 1]

[0025]

[Effect of device]

 A dust control mat having excellent texture and feel, rigidity, abrasion resistance, and stain-removing property, and a shade pattern formed was obtained.

[Submission date] June 8, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0004

[Correction method] Change

[Correction content]

[0004] Fibers forming the pile tufted, although the various fibers such as are used, the uniformity of the material, the handling synthetic fibers easiness is used, is used inter alia polyamide textiles is rather multi There is. Polyester fiber has poor impact resistance and recontamination property (recontamination after washing), polypropylene fiber has lipophilicity, poor oil stain resistance and recontamination property. This is because the system fibers are excellent in stain resistance, weather resistance and recontamination property. When a fiber bundle of polyamide fibers is used as a tufted pile, it is used as a polyamide fiber crimped yarn by subjecting it to crimping processing such as jetting, pushing, false twisting, and knitting / deniting. Usually, tufts having a high bulkiness are formed. Further, the piles formed include cut piles, loop piles, and composite piles of cut and loops, but the loop piles are preferable from the viewpoint of durability for stain removal and pile shape retention.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0010

[Correction method] Change

[Correction content]

In the present invention, the two types having different single yarn finenesses preferably have a single yarn fineness in the range of 200 to 400 denier and the other in the range of 50 to 150 denier. The thickness of both fiber bundles composed of single yarns is in the range of 1,600 to 16,000 in total denier, and if the single yarn fineness is too thin, it becomes too soft and "sagging" single yarn breakage easily occurs. Dust (earth and sand) with a particle size of 0.5 mm or more is accumulated on the pile surface, and if it is too thick, it becomes too hard and is not suitable as a dust control mat, and if the total denier is too thin, it is not suitable for mats. It is suitable, and if it is too thick, it will be difficult to hit the tufting machine. The base fabric for planting a pile yarn, natural fibers, regenerated fibers, flat woven fabrics such as synthetic fibers, although non-woven fabric having been subjected to processing by two Dorupanchi like are used, in particular, positive descriptors propylene, non-woven fabric made of polyester, Plain woven cloth is preferred.

[Procedure 3]

[Document name to be amended] Statement

[Correction target item name] 0018

[Correction method] Change

[Correction content]

Further, in the case of synthetic fibers used for carpets, mats, etc., the coloring is generally based on so-called soaking, in which a colored spinning dope prepared by adding a dye, a pigment or the like to a spinning dope is spun. Even single yarns spun from the same colored spinning dope have dark tufts from thick single yarns and light tufts from thin single yarns. Therefore, in the present invention, even with single yarns obtained from the same spinning dope, the shades of tufts (A) and (B) are different, and beautiful patterns such as a checkerboard pattern as shown in FIG. Patterns such as those shown in FIGS. 3 to 5 are formed.

[Procedure amendment 4]

[Document name to be amended] Statement

[Name of item to be corrected] 0022

[Correction method] Change

[Correction content]

Example 2 As one pile yarn, the cross-sectional shape was a swollen triangular shape as shown in FIG. 6 (1), and the single yarn fineness was 325 denier × 12 nylon 66 long fiber crimped A dust control mat was obtained in the same manner as in Example 1 except that the yarn (total denier 4,000 ) was used. The resulting mat had the same performance as in Example 1 except that it was superior to Example 1 in terms of stain removal. Various evaluations were made on the obtained mat, and the results are shown in Table 1.

[Submission date] June 13, 1994

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] 0022

[Correction method] Change

[Correction content]

Example 2 As one pile yarn, the cross-sectional shape was a swollen triangular shape as shown in FIG. 6 (1), and the single yarn fineness was 325 denier × 12 nylon 66 long fiber crimped A dust control mat was obtained in the same manner as in Example 1 except that the yarn (all denier 3,900 ) was used. The resulting mat had the same performance as in Example 1 except that it was superior to Example 1 in terms of stain removal. Various evaluations were made on the obtained mat, and the results are shown in Table 1.

[Procedure Amendment 2]

[Document name to be amended] Statement

[Name of item to be corrected] 0023

[Correction method] Change

[Correction content]

Comparative Example 1 Dust control mat in the same manner as in Example 1 except that single yarn fineness 325 denier × 12 nylon 66 long fiber crimped yarns (total denier 3,900 ) are used as pile yarns. Got Various evaluations were made on the obtained mats, and the measurement results are shown in Table 1. (Comparative Example 2) A dust control mat was obtained in the same manner as in Example 1 except that single-filament fineness 75 denier x 40 nylon 66 long fiber crimped yarn (total denier 3,000) was used as the pile yarn. . Various evaluations were performed on the obtained mat, and the results are shown in Table 1.

[Brief description of drawings]

FIG. 1 is a sectional view of a dust control mat according to the present invention.

FIG. 2 is a schematic view of an example of a dust control mat according to the present invention.

FIG. 3 is a schematic view of an example of a dust control mat according to the present invention.

FIG. 4 is a schematic view of an example of a dust control mat according to the present invention.

FIG. 5 is a schematic view of an example of a dust control mat according to the present invention.

FIG. 6 is a cross-sectional view of one single yarn in the present invention.

[Explanation of symbols]

 1: Pile yarn 1 ': Pile yarn composed of other type single yarn 2: Base fabric 3: Implanting needle 4: Loop pile 5: Rubber material layer a: Implanting direction b: Array direction c: Pile height A: Tuft B: Tufts made of other kinds of single yarns C: One side of tufts D: Other side of tufts E: One unit of tufts E ': Other unit of tufts

Claims (3)

[Scope of utility model registration request] 1. A dust control mat using polyamide long-fiber crimped yarn as pile yarn, using two types of textured yarn having different single yarn fineness, inserting both textured yarns into a base fabric to form a pile, and forming a pile on the back surface. To form a tuft mat in which a rubber material layer is arranged, one side formed by each processing yarn is 1
A dust control mat, wherein tufts of up to 5 cm are adjacent to each other, and when the adjoining object is one unit, the units are formed so that the tufts are alternately arranged vertically and horizontally. 2. The dust control mat according to claim 1, wherein, of the two types of processed yarns having different single yarn fineness, the processed yarn having a large single yarn fineness has a triangular fiber cross section. 3. A single yarn fineness of two types of processed yarns having different single yarn fineness, one of which is 200 to 400 denier, and the other of which is 50.
The dust control mat according to claim 1 or 2, which has a denier of about 150 to 150 denier.