KR100354372B1 - Dust-removing mat with excellent dimensional stability and manufacturing method of the same - Google Patents

Abstract

The present invention relates to a dust-removing mat and a method for producing the same, which have excellent dimensional stability during processing, good pile-upstanding characteristics, and excellent pattern representation.

Dust-removing mats with good dimensional stability include substrates in which the base fabric consists of woven or nonwoven fabrics and a floss-like nonwoven fibrous layer is bonded to the substrate, wherein the floss-like amulet fiber layer has a low melting point The fiber is included and a pile yarn is inserted thereon and then thermally fixed. The present invention further provides a method of making a dust-removing mat.

Description

Dust-removing mat with excellent dimensional stability and manufacturing method of the same

The present invention relates to a dust-removing mat and a method of manufacturing the same. More specifically, the present invention relates to a dust-removing mat and a method for manufacturing the same, which have excellent dimensional stability during processing, good pile-upstanding characteristics, and excellent pattern representation. In the present specification, the dust-removing mat is a mat located at the entrance and entrance of shops, hotels, hospitals, offices and homes where people enter and exit, which is attached to the bottom of the shoes to prevent dust and dirt from entering the building. Means a mat to remove dust and dirt.

Dust-removing mats are taffeting mats having a front surface made of almost textile material and a back surface made of rubber or resin.

To date, the mat is manufactured by implanting a pile onto a base fabric, applying latex on a non-pile surface as needed, and then applying heat and pressure to attach the solid rubber to the non-pile surface. The method has been used.

As the base fabric, a woven or nonwoven fabric used as a carpet is generally used.

Any type of latex can be used such as SBR, NBR and the like. However, NBR is known to be particularly preferred in terms of oil resistance and wash resistance.

Files are inserted in the usual way, such as typing and hooking.

The pile to be inserted can be of any type or spun type, such as filaments of nylon, acrylic, polyester, cotton, rayon or vinylon.

Often a solid rubber (single form) is attached depending on the type of mat; That is, the solid rubber is cut into regular sizes and the uncured solid rubber is attached to the non-pile surface under heat and pressure to cure.

In the manufacture of the mat, up to now, when the wound starting fabric obtained by inserting a pile onto a base fabric is treated with latex, cut or attached with solid rubber, the mat deforms due to the external force applied to the starting fiber, Bends and folds permanently. In the dust-removing mat of the letter pattern or the straight pattern, remaining warping or deformation degrades the appearance and quality of the product. Thus, the modified mat produces a force that acts to exhibit the original straight pattern after repeated use, washing and drying. As a result, the entire mat becomes crooked (i.e., undulating) and distorted, shortening its lifetime (due to rent).

To illustrate this in more detail, starting fabrics obtained by inserting piles on a base fabric are preferably as long as possible in terms of working efficiency, so that starting fabrics of substantially long length have been used. In that case the long starting fabric should be wound up or piled up folded on a pallet. However, this causes the starting fabric to deform or permanently fold.

When the starting fabric is coated with latex, normal tension is applied to the starting fabric in the width direction using a pin-like tenter, the starting fabric is continuously coated with latex using a coating roll, and then dried to diffuse water into the latex. Is used. In this case, however, a deformation of about 5 cm / m in the width direction cannot be overcome due to the external force applied, a small variation in speed and tension on the right and left sides in the width direction, a deviation and an error in the starting fabric-starting fabric joint. .

Therefore, the object of the present invention is not only the above-mentioned defects inherent in the conventional dust-removing mat, but also a dust-removing mat having excellent dimensional stability during processing, good pile-standing characteristics, and excellent pattern expressing ability, It is to provide a method for producing the same.

According to the present invention, there is provided a dust-removing mat comprising a base fabric, a pile inserted on one surface of the base fabric, and an elastomer backing applied to a non-pile surface of the base fabric, wherein the base fabric is a woven fabric. Or a layer of floss-like nonwoven fibers bonded to the nonwoven fabric and the substrate. Wherein the floss-like nonwoven fiber layer contains low melting fibers and is thermally fixed after the pile yarns are inserted.

According to the present invention, a step of preparing a base fabric by bonding a layer of floss-like nonwoven fibers containing staple fibers or filament fibers, wherein the low melting fibers are methods such as needle punching or dot-like thermal bonding. Uniformly dispersed in a substrate made of a woven or nonwoven fabric);

Preparing a starting fabric by inserting a pile onto a base fabric by tapping or hooking;

Heat treating the starting fabric to partially melt-bond the pile and the base fabric and the fibers in the base fabric to melt or soften the low melting point fibers; And

There is further provided a method of making a good dimensional stability dust-removing mat comprising forming an elastomeric backing on the non-pile surface of the starting fabric.

According to the present invention, when a floss-like nonwoven layer of a staple or filament type in which low melting point fibers are uniformly dispersed is bonded to a substrate made of a woven or nonwoven fabric and a pile is inserted, thermal curing is performed. Distinct features are shown that can greatly improve stability, pile-upright characteristics, and pattern representation.

First, the floss-like nonwoven fibrous layer formed on the substrate does not interfere with the insertion of the pile on the substrate fabric at all, but rather serves to improve the pile-standing characteristics of the pile being inserted. The inserted structure by inserting the pile onto the base fabric and then thermally fixing the floss-like nonwoven fiber layer to melt or soften the low-melting fibers contained in the floss-like nonwoven fiber layer to thermally bond them. And stabilize to contribute to improving the numerical stability, pile-standing characteristics and pattern representation of the mat, independent of subsequent processing.

That is, according to the present invention, a staple- or filament-type floss-like nonwoven layer in which low-melting fibers (hereinafter sometimes referred to as melt-adhesive components) are uniformly dispersed may be prepared by a process such as planting or dot-like thermal bonding. To a substrate made of woven or nonwoven fabric, so that the low melting fibers can be uniformly dispersed and adhered onto the surface of the substrate fabric. Thereafter, the pile is inserted onto the base fabric and then heat treated to melt and soften the hot melt-adhesive component to effectively effect adhesion between the pile and the base fabric and the fibers in the base fabric. At this point, it is possible to impart dimensional stability to the base fabric and in particular to impart resistance to external forces such as wound wrapping or bending of the starting fabric.

In addition, the adhesion can be performed between the inserted pile and the base fabric to increase the resistance to the pulling of the pile, so that the base fabric and the pile are melt bonded together to obtain a starting fabric exhibiting flexible and elastic-recovery properties. Can be.

The base fabric is a dual structure consisting of a base made of woven or nonwoven fabric and a layer of floss-like nonwoven fiber. Using the melt-adhesive component dispersed in the floss-like nonwoven fiber layer, it was found that there was little difference in the flexibility of the starting fabric being melt-treated before or after heating.

This suggests a fundamental difference from the nonwovens in which conventional hot melt-bonding components are mixed. In nonwoven fabrics, the melt-bonding component is uniformly dispersed throughout the entire base fabric, and the starting fabric after melt-gluing is of high hardness. When the starting fabric is used as the base fabric for the dust-removing mat, the stress is concentrated into the starting fabric due to the folding due to repeated washing and drying, resulting in rupture and the like, leading to a shortened life. However, the dust-removing mat of the present invention does not have the above drawbacks. It is difficult to achieve a great adhesion enough to bond the pile and the base fabric using conventional nonwoven fabrics in which the melt-bonding components are uniformly dispersed and, in part, low concentrations of low melting fibers. When attempting to increase the adhesion by increasing the ratio of the melt-adhesive component, the life of the starting fabric tends to be shortened because the stiffness of the base fabric increases. However, as described later, the present invention makes it possible to obtain excellent adhesion even though the melt-adhesive component is present at low concentrations.

According to the invention, it is advantageously possible to use the case where the base fabric consists of a nonwoven or a woven fabric. When the melt-adhesive component is added to the fabric, the loose component (substrate fabric component compared to the outer periphery of the base fabric) in the outer periphery of the base fabric is melt-bonded to prevent wear even after the mat is repeatedly washed.

The special effect obtained by this invention is as mentioned later. In dust-removing mats expressing characters such as " welcome " and multi-color pile mats expressing the design designed by the consumer himself, the pile-upper characteristics are remarkably improved, and the pattern expression ability is the dust produced by the prior art. It is very improved compared to the mat for removal. In other words, in the mat of the present invention, files of different colors hardly violate the boundary, and the boundary is very clear.

In conventional mats, in particular tapered cut-pile mats, in which files of different colors have been inserted, the files penetrate into parts of different colors because of the external force of the subsequent step, resulting in poor appearance of the hue. The piles invade different parts not only during the manufacturing process but also during cleaning and regeneration.

According to the invention, the substrate is provided with a layer of floss-like nonwoven fibre, wherein the low melting point component is melted and softened by a heat melt-gluing step after the pile has been inserted, thereby carrying out the fixing by thermal bonding. Create properties and stabilize.

The detailed mechanism is as follows. That is, if the base fabric has a layer of floss-like nonwoven fibres containing low melting point fibers and the pile is inserted, the piles inserted onto the substrate leave the low melting point fibers. As a result, the concentration of low-melting fibers in the outer periphery of the pile increases in an amount corresponding to the volume of the inserted pile.

Then, due to the subsequent heat treatment, the outer periphery of the pile is firmly fixed to enhance the pile-standing characteristics. In spite of the subsequent processing steps, the boundary is not obscured, and as a result, a dust-removing mat having good pattern representation is obtained.

Any known hot melt-bonding component such as polyester, polyolefin, polyamide, polyurethane type, such as filament, core-coated structure, etc. may be used as the melt-adhesive component. The mixing ratio in the floss-like nonwoven fibrous layer (sometimes-cotton cotton-like fibrous layer) is preferably 1 to 80% by weight.

Referring to FIG. 1, which illustrates the dust-removing mat of the present invention, the mat is applied to the base fabric 1, the mat pile 2 taped onto the base fabric 1 and the non-pile surface of the base fabric. Rubber support 4 to be applied.

Referring to FIG. 2, which illustrates the structure of the substrate fabric in cross section, the substrate 1 is a fabric treated with a substrate treated with a substrate 1 made of woven or nonwoven fabric and containing a filamentary or spun filament. A low melting fiber uniformly dispersed in the floss-like nonwoven layer 6, comprising a composite in the floss-like nonwoven layer 6; The piles 2 are heat-bonded together.

The substrate may be any of woven, nonwoven or knitted fabrics, and the fibers constituting the substrate may be any synthetic fiber, such as polyester fibers, polyamide fibers, acrylic fibers or ultra high molecular polyolefin fibers. The fibers are preferably primarily polymeric thermoplastic polyesters, with polyethylene terephthalate or ethylene terephthalate being particularly preferred.

The polyester fibrous constituting the base fabric can use a film-like yarn obtained by strongly drawing a polyester film to increase its tensile strength and dividing it into a predetermined width.

In the case of woven fabrics, there are no special restrictions in the woven structure, plain weave is sufficient. However, it is possible to use serpentine or other modified fabrics as needed. For nonwovens, spun-bonded nonwovens, melt-expanded nonwovens or combinations thereof can be used.

In general, the substrate weight is not changeable depending on the weight of the mat, but preferably 50 to 500 g / m ² .

The floss-like nonwoven layer is preferably composed of any synthetic fibers, such as polyester fibers, polyamide fibers, acrylic fibers or ultra high molecular polyolefin fibers, in the same manner as described above. However, the floss-like nonwoven layer is most preferably composed of polymeric thermoplastic polyester, in particular thermoplastic copolyester consisting mainly of polyethylene terephthalate or ethylene terephthalate.

As the low melting fiber included in the floss-like nonwoven fiber layer, any known melt-bonding yarn of low melting polyester, polyolefin, polyamide or polyurethane can be used. It is lower than the melting point of the low melting fiber, and the melting point of the general low melting fiber is 60 ℃ to 200 ℃.

Typically, low melting melt-adhesive fibers are obtained by incorporating copolymerizable components into a fiber-forming polymer. Preferred examples of low melting fibers can be represented by low melting copolymers, in particular poly (ethylene terephthalate / isophthalate). Other preferred examples of low melting fibers can be represented by low melting copolymers polyamides.

The low melting point fibers may be composed of the low melting point copolymers described above alone or may be a composite of low melting point copolymer fibers and other common fiber-forming polymers, such as synthetic fibers of core-shell structure or bimetal (side-by-side) structure. have.

The low melting fiber is preferably mixed in the floss-like nonwoven fiber layer in an amount of 1 to 80% by weight, in particular 5 to 50% by weight. That is, when the amount is less than the above range, the dimensional stabilizing effect is worse than when the amount is within the above range. On the other hand, when the amount exceeds the above range, the low melting fiber loses flexibility.

One or more layers of the web for forming the floss-like nonwoven fibrous layer are located on at least an upper surface (pile side), or on both sides of a substrate consisting of a woven or nonwoven fabric, the substrate and the floss-like nonwoven layer They are bonded together as a single structure by a planting process based on well known methods. The web remains in a very bulky state that is maintained even after the planting process.

The fibers constituting the floss-like nonwoven layer preferably have a size of 0.1 to 50 denier, in particular 1 to 20 denier, of a single yarn, and the single yarn may be referred to as so-called filament, or staple yarn. The floss-like nonwoven layer is preferably a protective web but may be a spun-bonded web. The weight of the floss-like nonwoven layer is usually 20 to 500 g / m ² , with a range of 5 to 200% of the substrate being preferred. The concentration of the hair dressing process is usually preferably 1000 punch / m ² or more.

The pile yarns derived into the base fabric may be one or two or more spun yarns of cotton fibers, rayon fibers, polyvinyl alcohol fibers, acrylic fibers, nylon fibers or other synthetic fibers, or may be multi-filament yarns. The length of the tapped pile is usually in the range of 3 to 20 mm. The file may be a cut file, a loop file, and may be further crimped or non-crimped. In addition, the file length may be constant or different, for example high cut-low loops and the like. The total thickness of the pile can vary greatly within the range of 300 to 10000 denier. The pile may be derived under known conditions and the number of gauges may be 3-20 and the number of stitches may be 3-20 or more per inch.

The starting fabric obtained by inserting the pile onto the base fabric is heat fixed (heat treated). The heat treatment is for melting the low melting fiber and can be carried out by heating the starting fabric at a temperature higher than the melting point of the low melting fiber. The starting fabric is heat treated to ensure no residual deformation during subsequent processing. Therefore, it is important to heat the starting fabric in a glass state to remove the clamping force acting on the starting fabric. The heating is preferably carried out using a hot-air circuit, infrared heating or steam heating. Copolymerized polyamides and copolymerized polyesters have a wet melting point lower than the dry melting point. Therefore, steam heating is performed as an effective heat treatment means.

Rubber sheets that act as backings include nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR), chloroprene rubber (CR), polybutadiene rubber (BR), polyisoprene (IIB), butyl rubber and ethylene-propylene rubber ( EPR), natural rubber, ethylene-propylene-diene rubber (EPDM), polyurethane, chlorinated polyethylene, chlorinated polypropylene, vinyl chloride soft resins and the like can be used. However, nitrile-butadiene rubber (NBR) is preferred in view of oil resistance and weather resistance.

The rubber sheet formed can be mixed with known amounts of sulfur or organic curing agents, curing accelerators, emollients, anti-aging agents, fillers, dispersants, plasticizers, colorants and the like.

In forming the mat as a unitary structure, the rubber composition is mixed using a roll, a Bumbury mixer or the like. The composition is then molded into sheets and placed on a tappeted mat. Thereafter, the laminate is heated and pressed in a compression mold to simultaneously perform adhesion and curing.

In order to increase the adhesion between the rubber sheet and the base fabric, the non-pile surface of the base fabric can be coated with the same kind of rubber latex as the rubber sheet. Alternatively, an adhesive such as ethylene acetate / vinyl copolymer or an adhesion promoter may be applied before.

The weight of the rubber sheet is preferably 500 to 4000 g / m ² , and the rubber sheet and the base fabric are bonded together in a unitary structure by slightly protruding the edge of the base sheet outwards beyond the edge of the base fabric.

Adhesion by curing is preferably carried out at a pressure of 0.1 to 20 Kg / mm ² and a temperature of 100 to 200 ℃.

The present invention is applicable not only to mats obtained by adhering a rubber sheet to a starting fabric in a single structure but also to so-called detachable mats in which the mat to be used is placed on a separate rubber sheet substrate.

In this case, the latex of the elastomer is cured after application to the non-pile surface of the starting fabric. The amount of the latex (solid component) is preferably 50 to 3000 g / m ² .

The pile yarn of the mat of the present invention functions to absorb and retain dust and dirt attached to the bottom of the shoe. To further enhance this working effect, it is possible to coat the pile yarns or to permeate the dust-absorbing oil. As the dust-absorbing liquid, fluidized paraffin, spindle oil, alkyl benzene oil, diester oil and castor oil, synthetic oil or vegetable fiber or aqueous dust-absorbing agents disclosed in Japanese Patent Publication Nos. 1019/1978 and 37471/1978 The same mineral oil can be used. In general, the absorbent is applied in an amount of 0.01 to 200 g / m ² .

Example

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

(Example 1)

File: BCF Nile

6 stitches / inch, gauge 5/32

Pile length 9 mm, weight 880 g / m ² , cut pile

Latex: NBR Latex 300 g / m ² (Solid content: 46%)

Using the following base fabrics A and B, samples were prepared and considered Examples 1-A and 1-B.

Substrate fabrics A and B were tappeted using the pile construction described above, and Example 1-B was continuously heat treated at 180 ° C. for 5 minutes.

The starting fabric was coated with latex, dried at 175 ° C. for 15 minutes, cut into pieces of 70 × 85 cm size and then heated and 10 Kg / with uncured rubber sheet having a thickness of 1.8 mm. Curing for 15 minutes at a pressure of cm ² and a temperature of 170 ℃.

Base fabric A: Polyester plain fabric 200 g / m ²

Base fabric B: Polyester plain fabric 150 g / m ²

Polyester 100 g / m ²

(Weight ratio of low melting floss-like fibers: 25%)

Polyester cotton was punched using a needle.

The mat was cut and the strain was measured in the stitch and gauge directions for 50 samples (Table 1).

The mat was placed in a place where 2000 people entered and left for 3 days and then washed. This was repeated 40 times. After 10 times, the pattern change was measured based on the number of files infiltrated (Table 2).

The change in the pattern was measured based on the number of black piles penetrating the white pile.

(result)

From Table 1, the effect was clearly recognized by the degree of deformation of the starting fabric pattern. From Table 2, the difference was clearly recognized by the number of files invaded. Even after 40 uses, there was no ups and downs on the mat B.

In Mat A, a relief of about 2 mm to 5 mm was observed at about three positions on one side. As mentioned above, the pattern of the starting fabric in Mat B was not deformed, good pile-standing properties were maintained, and no ups and downs occurred.

According to the present invention, a staple- or filament-like floss-like nonwoven layer in which the low melting point fibers are uniformly dispersed is bonded to a substrate made of a woven or nonwoven fabric and thermally fixed after the pile is inserted, It can greatly improve the dimensional stability, pile-upright characteristics and pattern representation.

1 is a view showing a cross section of the dust-removing mat of the present invention.

2 is an enlarged cross-sectional structure of the base fabric.

* Description of Major Symbols in Drawings *

1: base fabric 2: mat pile

3: non-pile surface 4, 5: rubber support

6 floss-like support 7 hair

Claims (6)

A dust-removing mat having excellent dimensional stability comprising a base fabric, a pile inserted on one surface of the base fabric and an elastomer backing applied to a non-pile surface of the base fabric, The base fabric comprises a substrate made of a woven or nonwoven fabric, and a floss-like nonwoven fibrous layer bonded to the base, wherein the floss-like nonwoven fibrous layer contains low melting fibers, and after inserting pile yarns And a floss-like nonwoven fibrous layer bonded to the substrate to thermally fix. The method of claim 1, A dust-removing mat wherein the floss-like nonwoven fibrous layer contains low melting fibers in an amount of 5 to 50% by weight. The method of claim 1, The low-melting fiber is a low-melting copolymerized polyester fiber, a low-melting copolymerized polyamide fiber or a copolymerized polyolefin fiber. The method of claim 1, A dust-removing mat, wherein the floss-like nonwoven fibrous layer is a staple- or filament-like fibrous layer, and is bonded to the substrate by needle punching. The method of claim 1, A dust-removing mat wherein the weight of the substrate is 30 to 300 g / m ² and the weight of the floss-like nonwoven fiber layer is 50 to 90% of the weight of the substrate. The base fabric is bonded by combining a layer of floss-like nonwoven fibers comprising staple fibers or filament fibers dispersed uniformly in a substrate made of a woven or nonwoven fabric, such as by a weaving process or dot-like thermal bonding. Manufacturing step; Inserting a pile onto the base fabric by tapping or hooking to produce a starting fabric; Heat treating the starting fabric to partially melt-bond the fibers in the pile, the base fabric and the base fabric to melt and soften the low melting point fibers; And Forming a elastomeric backing on the exit-pile surface.