JP5209519B2 - Method for manufacturing tatami mats with excellent friction resistance - Google Patents

Description

  The present invention relates to a method for producing a tatami mat having excellent friction resistance.

  The applicant has been researching and developing a tatami mat using a fiber-making yarn in which paper is twisted instead of rush and has been commercialized (see, for example, Patent Document 1).

  According to the tatami mat according to Patent Document 1, since the fiber-making yarn that can be industrially produced is used as a material instead of the natural material rush, it is possible to produce a more uniform tatami mat with less variation in quality. It becomes possible.

  By the way, in the tatami mat of patent document 1, since the fiber-making yarn rich in water absorption is used as a material, even if a general water repellent is applied to the surface of the fiber-making yarn, tea or coffee is spilled. If left untreated for a long time, there was a problem that it remained as a spot on the surface of the tatami mat.

  Therefore, the applicant has devised a tatami mat subjected to a water-repellent treatment by two-layer coating as a means for making these tatami mats more excellent in water resistance and stain resistance (see, for example, Patent Document 2). . In this prior art, since the water- and oil-repellent layer having water repellency is firmly formed on the surface of the fiber-making yarn, it is possible to provide a tatami mat that is less likely to be stained even when tea or the like is spilled.

Japanese Patent No. 2885658 Japanese Patent No. 4167846

  However, in a tatami mat surface that has been subjected to conventional water repellent treatment, the surface of the water / oil repellent layer is scratched and whitened if the surface is rubbed strongly with a rag or the like in either a dry state or a wet state. There is a drawback that it looks shining. This is presumably because the water- and oil-repellent layer formed on the surface of the fiber-making yarn peels off from the surface of the fiber-making yarn in the form of scratches.

  The present invention has been made in view of such a conventional problem, and an object of the present invention is to provide a tatami mat that makes it difficult for a water / oil repellent layer to peel off from the surface of a fibermaking yarn.

  The invention described in claim 1 is “(a) an aqueous resin emulsion, a water / oil repellent, and an organic silane coupling agent on the surface of a fiber 12 obtained by twisting paper made from wood fibers. After forming the first water / oil repellent layer 16 by coating the first resin composition 22 containing, (b) the second resin composition 24 containing the water / oil repellent on the surface of the first water / oil repellent layer 16. The surface of the fiber yarn 12 was subjected to water / oil repellent treatment by forming a second water / oil repellent layer 18 by coating, and then (c) the water-repellent / oil-repellent treated fiber yarn 14 was woven. It is a method for producing a tatami mat with excellent friction resistance.

  Invention of Claim 2 is the manufacturing method of the tatami surface excellent in friction resistance characterized by "The 2nd resin composition 24 further contains the aqueous resin emulsion."

  The invention according to claim 3 is the invention according to claim 1 or 2, wherein “the first resin composition 22 comprises a water / oil repellent agent having a solid content of 0.6 with respect to 100 parts by mass of the solid content of the aqueous resin emulsion. ˜30 parts by mass, containing 0.5 to 50 parts by mass of an organic silane coupling agent ”.

  The invention described in claim 4 is characterized in that “the water and oil repellents of the first resin composition 22 and the second resin composition 24 are fluororesins”.

  According to these inventions, when the first water / oil repellent layer is formed, the organic silane coupling agent contained in the first resin composition crosslinks with the cellulose component constituting the fiber-making yarn. The adhesive strength between the first water / oil repellent layer and the fiber yarn is improved. Therefore, the surface strength of the fibermaking yarn is enhanced, and a tatami mat with excellent friction resistance can be obtained.

It is a figure which shows the fiber-making yarn which has been subjected to water / oil repellent treatment. It is a figure which shows the water-repellent | oil-repellent treatment process of fibermaking yarn.

  The method for producing a tatami mat according to the present invention includes a “water / oil repellent treatment step” in which a water-repellent / oil-repellent treated fiber-formed yarn 14 is formed by subjecting the fiber-made yarn 12 to a water / oil / oil repellent treatment, It is generally composed of a “knitting process” in which the fiber knitted yarn 14 subjected to the oil repellent treatment is knitted to form a target tatami surface.

  In the water / oil repellent treatment step, the surface of the fiber making yarn 12 is subjected to water / oil repellent treatment. More specifically, the first water / oil repellent layer 16 and the second water / oil repellent layer 16 are applied to the surface of the fiber making yarn 12. This is a step of forming a water-repellent / oil-repellent layer 20 formed with the oil layer 18 to form a water-repellent / oil-repellent treated fiber-making yarn 14 as shown in FIG.

  Here, the fiber-making yarn 12 (before the water and oil-repellent treatment) is obtained by twisting paper-making paper mainly composed of softwood wood fibers. In this embodiment, the outer diameter is 0.7 to 1. It is set to about 5 mm, and a cavity with a diameter of about 0.2 to 0.8 mm is provided in the center part as necessary (of course, twist the paper-making paper so that there is no cavity in the center part. Thus, the fiber yarn 12 may be formed.)

The type and number of turns of papermaking paper papermaking sheet constituting the抄繊yarn 12 is not particularly limited, in this embodiment, the pine pulp at a basis weight 15 to 35 g / m ² approximately as papermaking paper papermaking The tape-shaped thing about 15-40 mm in width was used, and the number of turns is set to about 4-15.

  The first water / oil repellent layer 16 constituting the water / oil repellent layer 20 is formed by coating the first resin composition 22 on the surface of the fiber yarn 12.

  Here, the first resin composition 22 is configured by mixing an aqueous resin emulsion, a water / oil repellent, an organic silane coupling agent, a reaction catalyst, and water.

  The aqueous resin emulsion is for fixing a water / oil repellent described later on the surface of the fibermaking yarn 12. In this embodiment, an acrylic resin is used as the aqueous resin emulsion. However, the present invention is not limited to this. For example, vinyl acetate, acrylic-styrene copolymer, ethylene-vinyl acetate copolymer, etc. can be used. is there.

  The water / oil repellent agent imparts water / oil repellency to the fiber 12 and is a fluorine resin, more specifically, a nonionic fluorine surfactant having a perfluoroalkyl group in the molecule. Is preferably used because of its high affinity with aqueous resin emulsions.

  The addition amount of the water / oil repellent is desirably 0.6 to 30 parts by mass with respect to 100 parts by mass of the solid content of the aqueous resin emulsion. When the addition amount is less than 0.6 parts by mass, a satisfactory water / oil repellency effect cannot be obtained. Conversely, when the addition amount is more than 30 parts by mass, the aqueous resin emulsion There arise problems such as a decrease in film forming performance due to a relative decrease in the ratio and a decrease in antifouling property and friction resistance.

  The organic silane coupling agent is used to reinforce the surface of the fiber 12 and using an organosilicon compound having a glycidyl group in the molecule such as epoxy silane has a high effect of improving the friction resistance. preferable.

  The addition amount of the organic silane coupling agent is desirably 0.5 to 50 parts by mass with respect to 100 parts by mass of the solid content of the aqueous resin emulsion. If the amount is less than 0.5 parts by mass, the surface of the fiber-making yarn 12 cannot be sufficiently reinforced, so that the friction resistance is lowered. Conversely, if the amount is more than 50 parts by mass, the aqueous resin Since the proportion of the emulsion is relatively lowered, the film forming performance is lowered, resulting in a problem that the antifouling property and the friction resistance are lowered.

  The reaction catalyst is for accelerating the curing rate of the aqueous resin emulsion, and an organic compound having a carboxylic acid in the molecule such as maleic acid or lactic acid is used.

  As for the addition amount of a reaction catalyst, it is desirable to add 0.5-10 mass parts with respect to 100 mass parts of solid content of an aqueous resin emulsion.

  The second water / oil repellent layer 18 constituting the water / oil repellent layer 20 is formed by coating the surface of the first water / oil repellent layer 16 with the second resin composition 24.

  Here, the second resin composition 24 is constituted by mixing an aqueous resin emulsion, a water / oil repellent and water.

  In this example, an acrylic resin is used as the aqueous resin emulsion, but it is not limited to this as described above. For example, vinyl acetate, acrylic-styrene copolymer, ethylene-vinyl acetate copolymer, etc. Is available.

  In this embodiment, the same water / oil repellent as that used in the first resin composition 22 is used as the water / oil repellent (for example, polyvinyl alcohol as the water / oil repellent of the first resin composition 22). Is used, the polyvinyl alcohol is used as the water and oil repellent agent of the second resin composition 24.) It is also possible to use different materials.

  As in the above, the addition amount of the water / oil repellent is desirably 0.6 to 30 parts by mass with respect to 100 parts by mass of the solid content of the aqueous resin emulsion.

  In the second resin composition 24, the water-based resin emulsion is not necessarily added and may be omitted. However, by adding the water-based resin emulsion, the first water / oil repellent layer 16 and the second water repellent layer 16 are added. The affinity with the water / oil repellent layer 18 is enhanced, and the effect of improving the water / oil repellent performance is obtained.

  When the surface of the fiber thread 12 is subjected to water / oil repellent treatment, a water / oil repellent treatment apparatus 30 as shown in FIG. 2 is used.

  The water / oil repellent treatment apparatus 30 includes a transport path 34 constituted by a plurality of guide rollers 32. A supply device 36 for supplying the fiber yarn 12 to the conveyance path 34 is disposed at the start point of the conveyance path 34, and the fibermaking yarn 14 after the water / oil repellent treatment is disposed at the end of the conveyance path 34. A winding device 38 for winding is disposed. In addition, the fiber-making yarn 14 after the water / oil repellent treatment may be cut into a certain length and piled up like a grass without being wound up. Not cutting machine is arranged. Further, a first immersion tank 40, a primary heating device 42, a second immersion tank 44, and a secondary heating device 46 are disposed in the middle of the conveyance path 34.

  The first immersion tank 40 contains a first resin composition 22 in which an aqueous resin emulsion, a water / oil repellent, an organic silane coupling agent, a reaction catalyst, and fresh water are mixed.

  The second immersion tank 44 contains a second resin composition 24 in which an aqueous resin emulsion, a water / oil repellent, and fresh water are mixed.

  When the water-repellent / oil-repellent treatment of the fiber-making yarn 12 is performed using the water / oil-repellent treatment device 30, the fiber-making yarn 12 is supplied from the supply device 36 to the conveying path 34. It is immersed in the first immersion tank 40. And in the 1st immersion tank 40, the 1st resin composition 22 adheres to the surface of the fiber yarn 12. FIG. Part of the first resin composition 22 adhering to the surface of the fibermaking yarn 12 soaks up to the surface layer of the fibermaking yarn 12 (about 4 layers below the surface indicated by A in the circle in FIG. 1). Yes.

  The fiber yarn 12 that has passed through the first dipping tank 40 is given to a primary heating device 42, and the surface of the first resin composition 22 that adheres to the surface of the fiber yarn 12 is dried by heating. A first water / oil repellent layer 16 is formed on the surface.

  The drying conditions (drying temperature and drying time) in the primary heating device 42 are appropriately set depending on the type of resin constituting the first resin composition 22 and the drying method.

  The fiber yarn 12 that has passed through the primary heating device 42 is conveyed to the second immersion tank 44 while being naturally cooled. In the second immersion tank 44, the second resin composition 24 adheres to the surface of the first water / oil repellent layer 16, and the surface is heated and dried by the secondary heating device 46, whereby the first water / oil repellent layer. A second water- and oil-repellent layer 18 is formed on the surface 16, and the fibermaking yarn 14 that has been subjected to the water- and oil-repellent treatment is obtained.

  The drying conditions (drying temperature and drying time) in the secondary heating device 46 are appropriately set depending on the type of resin constituting the second resin composition 24 and the drying method.

  In addition, as a method of forming the first water / oil repellent layer 16 and the second water / oil repellent layer 18 on the fiber yarn 12, in addition to the dipping method as in the above-described embodiment, a spraying method, a flow coating method, or the like is used. It may be used.

  The knitting process is a process of obtaining a desired tatami surface by knitting the water- and oil-repellent treated fibermaking yarn 14 obtained as described above with a knitting machine (not shown).

  The inventors tested the water repellency and oil repellency of the tatami surface obtained by the above-mentioned method, and verified its practicality. Hereinafter, the test method and test results will be described.

[Preparation of sample and comparative sample]
(Sample 1)
As the fiber-making yarn 12, a 20-mm wide tape-like paper-making paper made from pine pulp with a basis weight of 18 g / m ² was prepared by twisting it with 10 windings.

  An acrylic resin was prepared as an aqueous resin emulsion, a fluorosurfactant as a water and oil repellent, an epoxy silane as an organic silane coupling agent, and maleic acid as a reaction catalyst.

  Then, with respect to 100 parts by mass of the solid content of the aqueous resin emulsion, 5 parts by mass of the water / oil repellent is used as the solid, 4.3 parts by mass of the organic silane coupling agent as the solid, and 1 as the solid of the reaction catalyst. Preparation of first resin composition 22 by mixing 1 part by weight and 126 parts by weight of fresh water, applying this to the surface of fiber yarn 12, and drying the surface at 80 ° C. for 2 minutes Thus, the first water / oil repellent layer 16 was formed.

  Also, by mixing the acrylic resin as the aqueous resin emulsion with a solid content of 100 parts by mass, the fluorine-based surfactant as the water and oil repellent is mixed with the solid content of 22 parts by mass and fresh water at a ratio of 2325 parts by mass. The second resin composition 24 was prepared. Then, this second resin composition 24 is applied to the surface of the first water / oil repellent layer 16, and the surface is dried at 180 ° C. for 1 minute, whereby the second water / oil repellent layer 16 is applied to the surface of the first water / oil repellent layer 16. An oil layer 18 was formed, and a fibermaking yarn 14 having been subjected to water / oil repellent treatment was obtained.

And the sample 1 (tatami mat) was obtained by knitting the fiber yarn 14 after the water- and oil-repellent treatment thus obtained at a weaving density of 0.85 kg / m ² .

(Sample 2)
A stack of four 10 cm square paper made of pine pulp with a basis weight of 18 g / m ² was prepared.

  First resin composition 22 and second resin composition 24 having the same composition as used in sample 1 were prepared, and water repellent was applied to the surface of the 10 cm square paper-making paper in the same manner as sample 1 was prepared. Sample 2 (papermaking paper) was obtained by applying an oil repellent treatment.

(Comparative sample 1)
Comparative Sample 1 (Tatami Table) was obtained in the same manner as Sample 1 except that no organic silane coupling agent was added as the first resin composition 22.

(Comparative sample 2)
Comparative sample 2 (papermaking paper) was obtained in the same manner as the preparation of sample 2, except that no organic silane coupling agent was added as first resin composition 22.

[Method of contamination resistance test]
On sample 1 and comparative sample 1, about 1 ml each of two types of contaminants (1) Japanese tea at 80 ° C. and (2) coffee with sugar and milk were dropped. Then, after elapse of a predetermined time, each of these contaminants is wiped off with alkaline ionized water, and the level of stain after wiping is visually observed in three stages (○: no stain mark, Δ: light stain mark, ×: dirt mark) Evaluated. The results are as shown in [Table 1]. The number of samples of Sample 1 was 8, and the number of samples of Comparative Sample 1 was 1.

[Method of light resistance test]
Sample 1 and comparative sample 1 were each irradiated with artificial light, and the color difference after 48 hours was evaluated with a color difference meter. A light resistance tester (manufactured by Suga Test Instruments Co., Ltd.) was used for the artificial light irradiation. In the evaluation, a color difference of 0.5 or less was accepted (◯), and the results are shown in [Table 2]. The number of samples of Sample 1 was 8, and the number of samples of Comparative Sample 1 was 1.

[Abrasion resistance (cleaning resistance) test]
According to the JIS L-1096 Gakushin-type wear test, the surfaces of Sample 2 and Comparative Sample 2 are rubbed, and the surface conditions are visually in three stages (○: no change, Δ: fuzzy, ×: with tear) evaluated. The results are as shown in [Table 3]. In addition, the sample number of the sample 2 was eight, and the sample number of the comparative sample 2 was one.

  From the results of [Table 1] to [Table 2], no deterioration in quality due to the addition of an organic silane coupling agent was observed with respect to stain resistance and light resistance.

  From the results of [Table 3], it can be seen that the wear resistance is improved by adding an organic silane coupling agent. Although the reason why such an effect is obtained is not known in detail, when the first water / oil repellent layer 16 is formed, a part of the first resin composition 22 adhering to the surface of the fiber yarn 12 is made. It soaks up to the surface of the thread 12. The organic silane coupling agent added to the first resin composition 22 and the cellulose constituting the fiber yarn 12 are cross-linked near the surface of the fiber yarn 12 and near the surface layer thereof. It is considered that the adhesive strength between the water / oil repellent layer 16 and the fiber yarn 12 is improved, and the surface strength of the fiber yarn 12 is improved.

12 ... Fibermaking yarn 14 (before water / oil repellent treatment) ... Fibermaking yarn 16 after water / oil repellent treatment ... First water / oil repellent layer 18 ... Second water / oil repellent layer 20 ... Water / oil repellent layer 22 ... First resin composition 24 ... second resin composition 30 ... water / oil repellent treatment device 32 ... guide roller 34 ... conveying path 36 ... feed device 38 ... winding device 40 ... first immersion tank 42 ... primary heating device 44 ... Second immersion tank 46 ... secondary heating device

Claims (4)

(A) The surface of the fiber-making yarn obtained by twisting paper made from wood fiber is coated with a first resin composition containing an aqueous resin emulsion, a water / oil repellent and an organic silane coupling agent. After forming the first water / oil repellent layer,
(B) The surface of the first water / oil repellent layer is coated with a second resin composition containing a water / oil repellent to form a second water / oil repellent layer, thereby forming a water / oil repellent finish on the surface of the fiber. And (c) a method for producing a tatami surface having excellent friction resistance, characterized in that a water- and oil-repellent treated fiber-making yarn is machine-woven.   The method for producing a tatami surface excellent in friction resistance according to claim 1, wherein the second resin composition further contains an aqueous resin emulsion.   The first resin composition has a solid content of 0.6 to 30 parts by mass and an organic silane coupling agent of 0.5 to 50 parts by mass with respect to 100 parts by mass of the solid content of the aqueous resin emulsion. The method for producing a tatami mat having excellent friction resistance according to claim 1 or 2, wherein the tatami mat is contained. The method for producing a tatami mat with excellent friction resistance according to any one of claims 1 to 3, wherein the water and oil repellent of the first resin composition and the second resin composition is a fluororesin. .

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