JP7638711B2 - Rugs and methods for manufacturing rugs - Google Patents

Description

Article 30, paragraph 2 of the Patent Law applies. Cainz Co., Ltd. has released and sold the product on its website (the address below). https://www.cainz.com/shop/g/g4549509685340/

The present invention relates to a rug with an anti-slip structure, and in particular to a mattress pad and a bed pad.

Traditionally, many mats, such as mattress pads and bed pads, have elastic rubber cords at the four corners to prevent them from shifting during use, and the elastic rubber cords are attached to the mattress or futon. However, elastic rubber cords are problematic in that they are time-consuming to attach and remove, and are no longer effective if the rubber band stretches. For this reason, anti-slip products that do not require elastic rubber cords have been developed in recent years.

On the other hand, bedding used as bedding such as mattress pads and bed pads requires breathability, and three-dimensional knitted fabrics with a honeycomb structure, for example, have been used.

Patent Document 1 discloses a rug such as a mattress pad or bed pad that has a non-slip surface with a coating layer containing polyvinyl chloride or silicone on a three-dimensional or two-dimensional knitted fabric.

Patent Document 2 discloses a method for manufacturing a mat in which uneven anti-slip portions are easily provided in stripes on a substrate, which method includes melting an anti-slip material, transporting the substrate with a transport roller, extruding the molten anti-slip material in the form of multiple stripes onto the surface of the transported substrate with an extrusion molding machine, and sandwiching the extruded stripes of anti-slip material and the substrate between the transport roller and the embossing roller while embossing each anti-slip material, thereby adhering the anti-slip material to the surface of the substrate.

Patent document 3 discloses an anti-slip mat comprising a mat layer made of a functional material and a back layer with an anti-slip resin backed by the mat layer and adhering to the floor surface, characterized in that a mesh fabric is interposed between the mat layer and the back layer, and the anti-slip resin is impregnated into the mesh fabric.

Patent document 4 discloses a mat that includes an absorbent pad made of knitted fabric or nonwoven fabric made of absorbent fibers, and a breathable pad made of a three-dimensional knitted fabric that is bonded to the back side of the absorbent pad directly or via another layer, and that is characterized in that the back side of the breathable pad is treated with an anti-slip coating or has an anti-slip sheet disposed thereon.

Utility Model Registration No. 3227068 JP 2018-68624 A JP 2018-93972 A JP 2012-187380 A

The rug described in Patent Document 1 has an anti-slip layer containing polyvinyl chloride or silicone on the back of the three-dimensional knitted fabric, etc., but polyvinyl chloride has durability issues because the layer easily peels off due to aging, and coatings containing silicone have the risk of the components dissolving during use and staining fabrics and structures that come into contact with them. The mats described in Patent Documents 2 and 3 have an anti-slip layer provided in stripes, i.e., partially, and have insufficient anti-slip performance. The mats described in Patent Documents 3 and 4 are impregnated with anti-slip liquid inside, and the anti-slip material cannot remain sufficiently on the surface where it is most effective, so the anti-slip performance is insufficient, and there are also problems with the amount of anti-slip liquid required to be applied to retain sufficient anti-slip liquid on the surface, which increases costs and makes the mat heavy.

Therefore, the present invention aims to provide a carpet that has sufficient anti-slip performance over almost the entire back surface, and is durable and lightweight.

The present invention relates to a floor covering for use in a mattress pad or bed pad, comprising a surface and a lining made of a three-dimensional knitted fabric, the three-dimensional knitted fabric comprising a pair of knitted fabrics having a plurality of meshes and connecting fibers connecting the knitted fabrics together, the fiber diameter of the fibers constituting the knitted fabrics is 20-1000 denier, the fiber diameter of the fibers constituting the connecting fibers is 10-1200 denier, the back surface of the lining has an anti-slip layer made of a thermoplastic adhesive, the ratio of the area of the anti-slip layer to the area of the knitted fabric on the back surface of the lining is 80-100%, the thermoplastic adhesive is a resin mainly composed of SEBS (styrene-ethylene-butylene-styrene copolymer), the application amount of the thermoplastic adhesive is 10-100 g/m ² , the thermoplastic adhesive has a viscosity at 180° C. of 3000-6000 mPa·s, and the ratio δ ₂ /δ of the viscosity at 160° C. to the viscosity δ ₁ at ₁₈₀ ° C. The thermoplastic adhesive does not permeate inward through the openings in the knitted fabric but is solidified while being held on the back surface of the knitted fabric, and the static friction coefficient of the back surface of the lining is _1.5 to 1.8 .

"Main component" means that it constitutes 50% by mass or more, 80% by mass or more, and preferably 90% by mass or more of the components that form the phase.

A "mattress pad" is a thin, flat mat or cushion that is placed under a person's body to sit or sleep on.

A "bed pad" is a thin, flat mat or cushion that is placed under a person's body to sleep.

A "mat" is something that is laid down for someone to sit or sleep on.

The present invention also relates to a method for manufacturing a rug that is used for a mattress pad or bed pad and has a static friction coefficient of 1.5 to 1.8 on the back surface, the rug having a front surface and a back surface made of a three-dimensional knitted fabric, the three-dimensional knitted fabric having a pair of knitted fabrics with a plurality of meshes and connecting fibers connecting the knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier, the method further comprising the steps of: a sewing process for quilting the front surface and the back surface; and after the sewing process, applying a thermoplastic adhesive melt-extruded in stripes to the back surface of the knitted fabric on the back side through a roller heated to a predetermined temperature in an amount of 10 to 100 g/m. the thermoplastic adhesive is a resin whose main component is SEBS (styrene-ethylene-butylene-styrene copolymer), the thermoplastic adhesive has a viscosity of 3000-6000 mPa·s at 180°C and a ratio δ ₂ /δ ₁ of the viscosity δ ² at 160°C to the viscosity δ ₁ at ₁₈₀ °C of 3-7, and in the cooling step, the thermoplastic adhesive does not permeate inward through the openings in the knitted fabric but solidifies while being retained on the back surface of the knitted fabric.

In the application process, it is preferable that the viscosity of the thermoplastic adhesive in a molten state at the specified temperature of the roller is 2000 to 6000 mPa·s.

According to the present invention, the anti-slip layer, which is mainly composed of SEBS, is applied almost uniformly to the back surface of the three-dimensional knitted lining fabric and remains on the surface, so that the anti-slip effect can be obtained efficiently and lightly. The breathability of the three-dimensional knitted fabric is not impaired by the anti-slip layer, and high breathability can be maintained.

FIG. 2 is a cross-sectional view of the rug of the present embodiment. FIG. 2 is a surface view of the carpet of the present embodiment. FIG. 2 is a rear view of the rug of the present embodiment. FIG. 2 is an enlarged view of the underside of the rug of this embodiment. FIG. 2 is an enlarged view of the underside of the rug of this embodiment. 1 is a roller coating apparatus for carpets according to the present embodiment.

The inventors discovered that by applying a specified amount of a thermoplastic adhesive, whose main component is a SEBS (styrene-ethylene-butylene-styrene) copolymer, to almost the entire surface of the lining at a temperature that produces a specified viscosity range, and then quickly solidifying it, the thermoplastic adhesive tends to remain on the surface of the lining, achieving a high static friction coefficient.

A rug 1 according to an embodiment of the present invention will be described with reference to Figures 1 to 5. The rug 1 according to this embodiment is used as a mattress pad or bed pad. As shown in Figure 1, the rug 1 comprises a surface 2, a cushion layer 3, a nonwoven fabric 4, and a lining composed of a three-dimensional knitted fabric 5. The three-dimensional knitted fabric 5 comprises a pair of knitted fabrics 51, 51 having a plurality of meshes, and connecting fibers 52 connecting these knitted fabrics. As shown in Figures 2 to 5, the rug 1 is provided with quilting 7 that forms regular wavy lines using sewing thread. The lining composed of the surface 2, cushion layer 3, nonwoven fabric 4, and three-dimensional knitted fabric 5 is sewn together at seams 11 at its periphery.

In this embodiment, the three-dimensional knitted fabric 5 has a honeycomb structure, and the knitted fabrics 51, 51 and the connecting fibers 52 are both made of polyester resin. The fiber diameter of the fibers constituting the knitted fabrics 51, 51 is preferably 20 to 1000 denier, more preferably 50 to 400 denier. The fiber diameter of the fibers constituting the connecting fibers 52 is preferably 10 to 1200 denier, more preferably 20 to 300 denier.

Three-dimensional knitted fabrics 5 are commercialized by various textile manufacturers, and examples of such products include FUSION (registered trademark) by Asahi Kasei, Cubic Eye (registered trademark) by Unitika Ltd., Swing Net (registered trademark) by Suminoe Textile Co., Ltd., and Fusion (registered trademark) by Asahi Kasei Fibers Co., Ltd. This invention can use the three-dimensional knitted fabrics of the above companies.

Examples of the three-dimensional knitted fabric 5 include those described in Nos. 4972080, 5551890, 3943011, 4001890, 4646821, JP-A-10-102363, JP-A-2002-138352, JP-A-02-74648, etc., but are not limited thereto. The thickness is preferably 2 mm to 12 mm, more preferably 3 mm to 8 mm. The breathability is preferably 50 cc/ ^cm2 /sec or more, the weight is 100 to 2000 g/ ^cm2 , the density is 0.02 to 0.2 g/ ^cm3 , and the compressive elastic modulus is 20 to 200 N/mm.

The ratio of the area of the knitted fabric 51 on the back side of the three-dimensional knitted fabric 5 to the total area, i.e., the ratio of the area of the knitted fabric 51 to the combined area of the knitted fabric 51 and the opening 53 surrounded by the knitted fabric 51, is preferably 10 to 90%, and more preferably 10 to 30%, taking into consideration breathability, etc. The three-dimensional knitted fabric 5 has high breathability, elasticity, and shape retention due to its structure.

The back surface of the knitted fabric 51 on the back side of the three-dimensional knitted fabric 5 has an anti-slip layer 6 of generally uniform thickness over the entire surface. The thickness of the anti-slip layer 6 is preferably 10 to 110 μm. The three-dimensional knitted fabric 5 maintains high breathability, while the anti-slip layer 6 held on its back surface and the three-dimensional structure of the three-dimensional knitted fabric 5 provide a high anti-slip effect.

The anti-slip layer 6 is a thermoplastic adhesive (hereinafter also referred to as SEBS resin) whose main component is SEBS (styrene-ethylene-butylene-styrene block copolymer), and contains mineral oil as a softener. An antioxidant may also be added to the SEBS resin. As will be described in detail later, the anti-slip layer 6 is formed by roller coating on the back surface of the three-dimensional knitted fabric 5, and the coating amount of the SEBS resin is preferably 10 to 100 g/ ^m2 , and more preferably 10 to 60 g/ ^m2 . If the coating amount is below the above range, the anti-slip performance becomes insufficient, and if it exceeds the above range, it takes a long time to cool and dry, so that the resin is difficult to remain on the surface of the knitted fabric 51.

The softening point of the SEBS resin used in this embodiment is preferably 110 to 140°C, and more preferably 120 to 130°C. The softening point is measured by the test method defined by ASTM-E28. The viscosity of the SEBS resin in a molten state is preferably 2000 to 33000 mPa·s at 120 to 205°C.

The viscosity of the SEBS resin in a molten state is preferably 3000 to 6000 mPa·s at 180°C, and 10000 to 33000 mPa·s at 160°C. If the viscosity is low at high temperatures, the extruded SEBS resin will easily spread between the rollers and on the fabric in the roller application process described below. After application from the roller to the fabric, that is, at low temperatures, the higher the viscosity, the more the resin will remain on the surface of the knitted fabric 51 of the three-dimensional knitted fabric ₅ and the less it will penetrate into the interior through the openings 53. Therefore, the temperature dependency of the viscosity is important, and if the viscosity at 160°C is δ2 to the viscosity at 180°C _δ1 , the ratio _δ2 / _δ1 is preferably 3 to 7. The viscosity can be measured using a Brookfield viscometer LVF (manufactured by Brookfield) at an appropriate speed using a No. 34 spindle.

The anti-slip layer 6 preferably covers the entire back surface of the knitted fabric on the reverse side, i.e., the surface area of the anti-slip layer 6 per unit area of the surface that comes into contact with a mattress, futon, or the like placed underneath, and more preferably 80% or more, and 90 to 100% is even more preferable. In other words, it is preferable to have an anti-slip layer on almost the entire surface of the knitted fabric 51.

The static friction coefficient of the underside of the carpet of the present invention is preferably 1.5 to 1.8, and more preferably 1.6 to 1.7. It is measured by the method for measuring the static friction coefficient described below. If the static friction coefficient is less than 1.5, the anti-slip effect is insufficient.

The nonwoven fabric 4 is a short fiber nonwoven fabric made of polyester fibers, and is provided to prevent the filling from coming out of the cushion layer 3.

The cushion layer 3 is intended to enhance cushioning and is made of polyester fibers.

Next, the manufacturing method of the rug 1 according to the present invention will be described with reference to FIG.

(Sewing and quilting process)
First, the outer fabric 2, the cushion layer 3, the nonwoven fabric 4, and the three-dimensional knitted fabric 5 are prepared and sewn together. Specifically, first, the edges on both sides parallel to the direction of application of the anti-slip layer, which will be described later, are sewn together and quilted. It is preferable to perform the quilting process before applying the anti-slip layer. If the quilting process is performed after the anti-slip layer application process, resin will adhere to the needles, which will interfere with the quilting process.

(Anti-slip layer coating process)
Next, the SEBS resin is roller-coated. Fig. 6 is a diagram for explaining the roller coating device 8. The fabric after quilting is held as a roll 81, and is pulled and moved on a conveyor 82. On the conveyor 82, the fabric moves with the lining, i.e., the back knitted fabric 51 of the three-dimensional knitted fabric 5, facing upward. A resin extrusion device 83 is disposed above the conveyor area. The resin extrusion device 83 extrudes molten SEBS resin in stripes from a plurality of discharge ports 831 provided at the bottom thereof at a discharge temperature of 180 to 205°C, more preferably 200 to 205°C. If the discharge temperature exceeds 205°C, yellowing or charring is likely to occur, which is not preferable.

Below the discharge port 831 of the resin extrusion device 83 are the main roller 84 and the auxiliary roller 85, which are maintained at a predetermined roller temperature. The surface temperatures of the main roller 84 and the auxiliary roller 85 are preferably 160 to 180°C, and in this embodiment, they are set to around 180°C. The viscosity of SEBS resin at 180°C is 3000 to 6000 mPa·s, and the multiple SEBS resins extruded in stripes from the discharge port 831 of the resin extrusion device 83 are spread between the main roller 84 and the auxiliary roller 85, and are applied in a surface form to the entire back surface of the knitted fabric 51 via the main roller 84 and the auxiliary roller 85. The fabric passes between the rubber roller 87 and the main roller 84, so that the SEBS resin is applied to the entire fabric.

(Cooling process)
The temperature of the SEBS resin immediately after it is applied to the fabric is 160° C., and thereafter, pressure is applied between cooling roller 88 and rubber roller 87, and then it is rapidly cooled and solidified by cooling fan 89. Here, the viscosity of SEBS resin at 160° C. is 10,000 to 33,000 mPa·s, and the time it takes to cool and solidify after application to the fabric is 2 to 10 seconds, preferably 2 to 5 seconds, so that the SEBS resin applied to the back surface of knitted fabric 51 solidifies without penetrating inward from openings 53, and is solidified while being held over the entire back surface of knitted fabric 51.

(Cutting process)
The cooled fabric is cut to length and the edges are sewn shut.

In this way, in the present invention, the anti-slip layer is sufficiently retained on the most important surface without penetrating into the knitted fabric, thereby realizing a high friction coefficient. To achieve this, 10 to 100 g/m2 of molten SEBS resin is applied with a roller set at a temperature at which the SEBS resin reaches a predetermined viscosity range (preferably 2000 to 6000 mPa·s ⁾ , and then quickly solidified (preferably 2 to 10 seconds) by cooling. Since the viscosity of the SEBS resin at the roller temperature is within the above range, the resin extruded in stripes tends to spread over the entire surface, and is less likely to penetrate and permeate the openings 53 of the three-dimensional knitted fabric 5, and tends to remain on the surface of the back knitted fabric 51.

The following describes specific examples of the present invention, but the present invention is not limited to these examples. The static friction coefficients in the examples were measured as follows.

(Measurement of static friction coefficient)
A sample (20 cm x 30 cm) is placed on the mattress so that the lining is on the underside. A load of 8 kg is evenly applied on the sample, and the force at which it starts to move is measured using a push-pull gauge, and the friction coefficient is calculated. The test is performed five times, and the average value is taken as the measured value. The mattress used is made of polyester fiber, and specifically, a mattress made by Cainz Co., Ltd. ("Compactly storable mattress single", product code 4549509507871, outer fabric: 100% polyester, inner material: 100% polyester) was used.

Example 1
The outer layer, cushion layer, nonwoven fabric, and honeycomb mesh structure were sewn and quilted, and then a resin mainly composed of SEBS was applied by roller coating to produce a mattress pad. The amount of resin applied was 30 g/ ^m2 . The resin mainly composed of SEBS had a softening point of 125°C, a viscosity of 3300 mPa·s at 180°C, and a viscosity of 10000 mPa·s at 160°C. The discharge temperature was 200-205°C, and the temperatures of the main roller and auxiliary roller were 180°C. The static friction coefficient of the mattress pad produced was measured, and the slip force was 139.6 N (average value of 143.8 N, 135.9 N, 139.0 N, 138.5 N, and 140.6 N for n=5 tests), and the static friction coefficient was 1.7.

(Comparative Example 1)
A test was conducted to measure the static friction coefficient of a non-slip pad made by another company. The non-slip treatment was done by processing silicone resin into dots. The static friction coefficient of the pad of Comparative Example 1 was measured, and the force required to start slipping was 78.3N (average value of n=5 test results: 76.4N, 77.0N, 79.9N, 78.0N, 80.0N), and the static friction coefficient was 1.0.

(Comparative Example 2)
A test was conducted to measure the static friction coefficient for a non-slip pad made by another company, different from Comparative Example 1. The non-slip treatment was done by processing acrylic resin into dots. The static friction coefficient of the pad of Comparative Example 2 was measured, and the slip-out force was 101.6N (average value of n=5 test results: 106.8N, 102.6N, 103.4N, 96.5N, 98.5N), and the static friction coefficient was 1.3.

Reference Signs List 1: Rug 2: Outer material 3: Cushion layer 4: Nonwoven fabric 5: Three-dimensional knitted fabric 51: Knitted fabric 52: Connecting fibers 6: Anti-slip layer 7: Quilting 8: Roller application device 11: Stitching section 82: Conveyor 83: Resin extrusion device 831: Discharge port 84: Main roller 85: Auxiliary roller 88: Roller 89: Cooling fan

Claims (3)

A rug having a surface and a lining made of a three-dimensional knitted fabric, the rug being used as a mattress pad or a bed pad,
The three-dimensional knitted fabric comprises a pair of knitted fabrics having a plurality of meshes and connecting fibers connecting these knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, and the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier,
The back surface of the backing has an anti-slip layer made of a thermoplastic adhesive material,
The ratio of the area of the anti-slip layer to the area of the knitted fabric on the back surface of the lining is 80 to 100%;
The thermoplastic adhesive is a resin mainly composed of SEBS (styrene-ethylene-butylene-styrene copolymer),
The application amount of the thermoplastic adhesive is 10 to 100 g/ ^m2 ;
The thermoplastic adhesive has a viscosity at 180°C of 3000 to 6000 mPa·s, and a ratio δ ₂ /δ ₁ of the viscosity δ ₂ at 160°C to the viscosity δ ₁ at 180°C is 3 to 7;
The thermoplastic adhesive does not permeate into the knitted fabric through the openings, but is solidified while being held on the back surface of the knitted fabric;
The static friction coefficient of the back surface of the lining is 1.5 to 1.8. A method for manufacturing a rug having a surface and a lining made of a three-dimensional knitted fabric, the rug being used for a mattress pad or a bed pad, and the static friction coefficient of the back surface being 1.5 to 1.8,
The three-dimensional knitted fabric comprises a pair of knitted fabrics having a plurality of meshes and connecting fibers connecting these knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, and the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier,
a sewing process for quilting the outer fabric and the lining fabric;
After the sewing process, a coating process is performed in which a thermoplastic adhesive material melt-extruded in stripes is applied to the back surface of the knitted fabric on the back side by a roller heated to a predetermined temperature in an amount of 10 to 100 g/ ^m2 ;
A cooling step of cooling the applied thermoplastic adhesive material,
The thermoplastic adhesive is a resin mainly composed of SEBS (styrene-ethylene-butylene-styrene copolymer),
The thermoplastic adhesive has a viscosity at 180°C of 3000 to 6000 mPa·s, and a ratio δ ₂ /δ ₁ of the viscosity δ ₂ at 160°C to the viscosity δ ₁ at 180°C is 3 to 7;
In the cooling step, the thermoplastic adhesive does not permeate inward through the openings in the knitted fabric, but solidifies while being held on the back surface of the knitted fabric.
How rugs are made. In the application step, the viscosity of the thermoplastic adhesive in a molten state at the predetermined temperature of the roller is 2000 to 6000 mPa·s.
A method for producing the carpet of claim 2 .

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