JP4493370B2 - Water absorption mat - Google Patents

Description

  The present invention relates to a water absorbent mat mainly used for water absorption.

Patent Document 1 discloses a water absorbing mat.
JP 2000-282339 A

  The water absorption mat of Patent Document 1 can exhibit water absorption performance that satisfies the demands of consumers to some extent. However, in order to further improve the water-absorbing performance of the water-absorbing mat, the customer has been demanding further improvement of the wiping performance for wiping off moisture adhering to the shoe sole.

  An object of this invention is to provide the water absorbing mat which can exhibit the outstanding wiping performance and, as a result, can exhibit the outstanding water absorbing performance.

The invention according to claim 1 is a water absorbent mat having a mat raw fabric in which pile yarn is tufted on a base fabric, wherein the first pile raw yarn and the second pile raw yarn are arranged between them. Is used as the pile yarn , and the first pile yarn is a single water-absorbing yarn. And a single BCF yarn are twisted together, and one water-absorbing yarn is composed of a large number of water-absorbing fibers, and one BCF yarn is composed of a large number of BCF fibers. The second pile raw yarn is also produced in the same manner as the first pile raw yarn, and the fused yarn has a melting point of 120 ° C. or higher .

The invention according to claim 2 is the invention according to claim 1, wherein the BCF fiber is a BCF nylon fiber and the fused yarn is made of a polyamide resin.

The invention according to claim 3 is the invention according to claim 1, wherein all or part of the water-absorbing fibers are colored by a stock solution coloring method.

The invention according to claim 4 is the invention according to claim 1, wherein all or part of the BCF fiber is colored by a stock solution coloring method.

  In general, many BCF fibers have a fiber thickness of 10 to 100 dtex. And the BCF thread | yarn which consists of many BCF fibers is bulky, has many clearance gaps between single fibers, and has high uprightness. Further, when the BCF yarn is a pile yarn, the BCF yarn shows a large volume, and even if it is stepped on, it hardly shows a decrease in the volume, but on the other hand, the fiber density is low. Therefore, when the mat yarn pile yarn is composed only of BCF fibers, the maximum water retention capacity is excellent because the fiber density is low. On the other hand, the water absorption capacity due to capillary action is low, and the fiber surface is hydrophobic. Therefore, it is difficult to say that the water wiping performance from the shoe sole is good.

  On the other hand, most of the water-absorbing fibers have a fiber thickness of about 0.05 to 10 dtex, and are thinner than BCF fibers. Moreover, since the water absorption fiber is a linear shape, the water absorption thread | yarn consisting of many water absorption fibers exhibits a high-density structure. However, as a result of the material, thickness, and shape of the water-absorbing fibers, the elastic recovery property of the water-absorbing yarn composed of a large number of water-absorbing fibers is low. Therefore, when the mat fabric pile yarn is composed only of water-absorbing fibers, the pile yarn tends to sag when it is stepped on, and therefore the maximum water retention capability is inferior. In addition, since the fiber surface is hydrophilic, the wettability is high, and the wiping performance of moisture from the shoe sole is good.

  According to the first aspect of the present invention, since the pile yarn includes both the water-absorbing fiber and the BCF fiber, the uprightness of the pile yarn can be maintained by the BCF fiber, and the water-wetting property of the pile yarn can be kept high by the water-absorbing fiber. it can. Therefore, high wiping performance and high water retention performance can be exhibited, and therefore, high water absorption performance can be exhibited as compared with the case of using pile yarns made only of water-absorbing fibers and pile yarns made only of BCF fibers.

  Moreover, since the water-absorbing fiber and the BCF fiber are fixed with the fusion yarn, it is possible to prevent the capillary phenomenon from being lowered due to the opening of the tip of the pile yarn, thus maintaining high water absorption performance. it can.

Furthermore, even if the pile yarn shrinks due to heat, moisture, etc., the first pile raw yarn and the second pile raw yarn have the same composition, so the shrinkage in the pile yarn becomes uniform and the pile yarn is deformed. Can be prevented. Therefore, the uprightness can be maintained well, and therefore high wiping performance can be exhibited. In addition, the melted fused yarn can be prevented from remelting during the rubber backing of the mat manufacturing operation, and therefore, the pile yarn once bonded can be prevented from being unraveled, and the pile yarn can be kept upright. Can be maintained.

According to the second aspect of the present invention, since the fused yarn and the BCF fiber are made of the same material, the adhesiveness between the two can be improved, and thus the uprightness of the pile yarn can be further improved.

According to the invention described in claim 3 or 4 , it is possible to improve the washing durability, wear resistance, weather resistance and the like in the colored pile yarn.

  The constituent materials of the pile yarn used for the mat original fabric of the water absorbent mat of the present invention are the first pile raw yarn, the second pile raw yarn, and the fusion yarn. When possible combinations of the first pile raw yarn and the second pile raw yarn in the present invention are shown based on the constituent fibers of each pile raw yarn, the combinations of “◯” and “「 ”in Table 1 are obtained. “◎” is the most preferable combination.

  As the water absorbing fiber, cotton, rayon, vinylon, polyester, polypropylene, nylon, acrylic, or a mixture thereof is used. The thickness is preferably 0.05 to 5 dtex. The water-absorbing fibers are used in the number necessary to obtain the thickness necessary for the pile yarn. When higher water absorption is required, it is preferable to use cotton and rayon.

  The water-absorbing yarn made of water-absorbing fibers may be either a span type or a filament type. When the span type is used, it is usually twisted during spinning.

  As the BCF fiber, BCF nylon fiber, BCF ester fiber, BCF polypropylene fiber or the like is used. The fiber thickness is preferably 10 to 100 dtex from the viewpoints of brushing function and tufting. Nylon is preferred from the viewpoint of elastic recovery.

  Both water-absorbing fibers and BCF fibers may be colored by known methods. In this case, from the viewpoint of washing durability, abrasion resistance, weather resistance, etc., it is preferable to use a known stock solution coloring method of spinning a fiber solution in which a pigment is dispersed. In addition, this undiluted | stock solution colored thread | yarn may be used independently or may be used so that it may mix with another type of white thread | yarn, and may exhibit arbitrary colors.

  As the fused yarn, known polypropylene, polyamide, polyester, and the like are used. The fusing yarn is exposed to heat and pressure conditions for backing (thermal bonding and vulcanization) of the rubber constituting the mat base material in the post-process, so that the pile yarn is adversely affected under these conditions. It is preferable that the melting point is set to a level that does not exist. Specifically, since the heat bonding and vulcanization of rubber is usually performed at 140 ° C. or higher, the melting point of the fused yarn is preferably 120 ° C. or higher.

  A preferred pile yarn is obtained as follows. That is, first, a water absorbent yarn composed of a large number of water absorbent fibers is produced. In the case of a span type, the yarn is twisted in one direction during spinning. On the other hand, a BCF yarn composed of a large number of BCF fibers is prepared. Next, one water-absorbing yarn and one BCF yarn are combined and subjected to a lower twist to produce a lower twist yarn (first pile raw yarn). This bottom twist direction is opposite to the twist direction in the case of the span type. Next, the same second pile raw yarn as the first pile raw yarn is produced. Next, the first pile raw yarn, the second pile raw yarn, and the fusion yarn disposed therebetween are combined and twisted to produce an upper twisted yarn. Then, the upper twisted yarn is heat set to melt the fused yarn. Thereby, a pile yarn is obtained.

  The heat setting may be performed by either dry heat or wet heat as long as the temperature is equal to or higher than the temperature at which the fused yarn melts. In order to perform more stable processing, wet heat is preferable, and the condition is preferably 90 to 150 ° C. and 1 to 30 minutes.

(Embodiment 1)
[Production of pile yarn]
First, a water absorbing yarn having a thickness of 1000 dtex and made of water absorbing fibers was produced by twisting in one direction at 80 times / m with the materials and mixing ratios shown in Table 2.

  Meanwhile, a BCF yarn comprising 34 BCF fibers and having a thickness of 720 dtex was prepared.

  Then, the one water-absorbing yarn and the one BCF yarn are combined and twisted 100 times / m in the direction opposite to the twisting direction of the water-absorbing yarn to form a lower twisted yarn (first pile raw yarn). Produced.

  Another lower twist yarn (second pile raw yarn) was prepared.

  One polyamide monofilament having a thickness of 200 dtex is disposed as a fusion yarn between the two lower twisted yarns, that is, between the first pile raw yarn and the second pile raw yarn. In addition, the upper twisted yarn was produced by twisting 100 times / m. The upper twisted yarn was heat-set at 130 ° C. for 20 minutes with a humidifying heater to obtain a pile yarn.

[Preparation of mat material]
The pile yarn was tufted under the following conditions to produce a mat original fabric.
Base fabric: polyester nonwoven fabric: 120 g / m ²
Tuft density ... ・ Gauge direction: 8 co / inch
-Stitch direction: 10 / inch
・ Pile shape: Cut pile
・ Pile length: 10mm
-Pile basis weight: 1130 g / m ²

[Production of mat]
The mat original fabric was cut into a size of 90 cm × 75 cm, and the following rubber sheets were bonded to each other under the following conditions to produce a mat in which the mat base material was bonded to the mat original fabric.
Rubber sheet: unvulcanized NBR rubber (containing vulcanized chemical), 1.5 mm thickness Pressurizing condition: 3 kg / cm ²
Heating conditions: 170 ° C x 15 minutes

(Embodiment 2)
The matting was made in the same manner as in Embodiment 1 except that tufting conditions in the production of the mat original fabric were set as follows.
Base fabric: polyester nonwoven fabric: 120 g / m ²
Tuft density ... ・ Gauge direction: 8 co / inch
-Stitch direction: 7 / inch
・ Pile shape: cut pile and loop pile
・ Pile length… ・ Cut: 10mm
・ Loop part: 5mm
-Pile basis weight: 990 g / m ²

(Comparative form 1)
[Production of pile yarn]
A BCF yarn composed of 34 BCF fibers and having a thickness of 720 dtex was twisted 100 times / m to prepare a twisted yarn.

  Another lower twisted yarn was prepared.

  The two above-mentioned lower twisted yarns were combined and twisted 100 times / m to produce an upper twisted yarn. The upper twisted yarn was heat-set at 130 ° C. for 20 minutes with a humidifying heater to obtain a pile yarn.

[Preparation of mat material]
The pile yarn was tufted under the following conditions to produce a mat original fabric.
Base fabric: polyester nonwoven fabric: 120 g / m ²
Tuft density ... ・ Gauge direction: 8 co / inch
-Stitch direction: 10 / inch
・ Pile shape: Cut pile
・ Pile length: 10mm
-Pile basis weight: 1040 g / m ²

[Production of mat]
A mat was produced in the same manner as in the first embodiment.

(Comparative form 2)
[Production of pile yarn]
The same water absorbing yarn as that of Embodiment 1 was produced. The two water-absorbing yarns were combined and twisted 100 times / m in a direction opposite to the twisting direction of the water-absorbing yarn to produce a lower twisted yarn.

  Another lower twisted yarn was prepared.

  Between the two above-mentioned lower twisted yarns, the same fused yarn as that in Embodiment 1 was placed, and these were combined and twisted 100 times / m to produce an upper twisted yarn. The upper twisted yarn was heat-set at 130 ° C. for 20 minutes with a humidifying heater to obtain a pile yarn.

[Preparation of mat material]
The pile yarn was tufted under the following conditions to produce a mat original fabric.
Base fabric: polyester nonwoven fabric: 120 g / m ²
Tuft density ... ・ Gauge direction: 8 co / inch
-Stitch direction: 10 / inch
・ Pile shape: Cut pile
・ Pile length: 10mm
-Pile basis weight: 1460 g / m ²

[Production of mat]
A mat was produced in the same manner as in the first embodiment.

(Water absorption performance)
About the mat | matte of Embodiment 1 and Comparative Examples 1 and 2, the following water absorption tests were done and water absorption performance was investigated.

[Water absorption test]
Immerse the sole in a tray filled with water with a depth of about 1 cm, then lift the sole, and lightly step on the floor three times with the sole, then step on the mat for 5 seconds, thereby applying it to the mat. The shoe sole was wiped off, and then the shoe sole was removed by stepping on the shoe sole. This operation was repeated 50 times. Every 5 times, the weight change of the mat and the weight change of the waste were measured. The results are shown in Tables 3-5.

  The amount of change in the weight of the mat corresponds to the amount of moisture that the mat wiped off from the shoe sole, and this was referred to as the “mat removal amount”. The amount of change in the weight of the waste corresponds to the amount of moisture that the mat could not wipe off from the shoe sole, and this was referred to as the “shoe sole residual amount”. Further, the total amount of the water attached to the shoe sole was defined as the sum of the “mat removal amount” and the “shoe sole residual amount”. Then, the ratio of “mat removal amount” to “total amount” was determined as “mat removal rate”, and the ratio of “shoe bottom residual amount” to “total amount” was determined as “shoe bottom residual rate”.

  As is apparent from Tables 3 to 5, the water-absorbing mat of Embodiment 1 has a larger “mat removal amount” and a higher “mat removal rate” than the mats of Comparative Examples 1 and 2. That is, the water-absorbing mat of the present invention has better wiping performance than the mat using pile yarns consisting entirely of water-absorbing fibers, i.e., the mat of Comparative Example 2, and therefore has superior water-absorbing performance. .

  Next, the water absorption performance durability test as follows was conducted on the water absorption mat of Embodiment 2 to examine the water absorption performance and the durability of the appearance.

(Water absorption performance durability test)
The mat of Embodiment 2 was used repeatedly for 20 cycles. In addition, 1 cycle was set as the process of collect | recovering after laying in the place of the number of passing persons 2000 persons / day for 5 days, and performing a washing process and a drying process. The mat of comparative form 1 was used in the same manner. The washing process and the drying process were as follows.
・ Cleaning treatment ... ・ Cleaning ... 60 ℃, 15 minutes
・ Rinsing: normal temperature, 1 minute x 3 times
・ Cleaning solution: pH 11
・ Drying conditions ... 90 ℃, 30 minutes

  And about the mat | matte of Embodiment 1 and the comparative form 1, after confirming the external appearance after use, the water absorption test mentioned above was done and water absorption performance was investigated.

  For the mat of Embodiment 2, no change in appearance was observed. That is, the pile yarn was not deformed or opened, the water absorbing yarn or the BCF yarn was not dropped or peeled off, and the pile yarn maintained a feeling of napping. However, for the mat of Comparative Example 1, the pile yarn contracted or dropped out by repeated washing and drying.

  The water absorption performance of the mat of Embodiment 2 did not change even after 20 cycles.

(Another embodiment)
In the first and second embodiments, one fused yarn is used, but a plurality of fused yarns may be used.

Since the water absorbing mat of the present invention can exhibit excellent wiping performance, the industrial utility value is great.

Claims (4)

In a water absorbent mat having a mat fabric in which pile yarn is tufted on a base fabric,
The first pile raw yarn and the second pile raw yarn are twisted together with one or more fusion yarns arranged therebetween, the fusion yarn is melted, and both pile raw yarns are bonded to each other. The
Used as the above pile yarn ,
The first pile raw yarn is produced by twisting together one water absorbing yarn and one BCF yarn,
One water-absorbing yarn consists of many water-absorbing fibers,
One BCF yarn consists of many BCF fibers,
The second pile yarn is made in the same manner as the first pile yarn,
A water-absorbing mat , wherein the fused yarn has a melting point of 120 ° C or higher .   The water absorbent mat according to claim 1, wherein the BCF fiber is a BCF nylon fiber, and the fused yarn is made of a polyamide-based resin.   The water absorbing mat according to claim 1, wherein all or part of the water absorbing fibers are colored by a stock solution coloring method.   The water absorbent mat according to claim 1, wherein all or part of the BCF fiber is colored by a stock solution coloring method.