Mat antimicrobial finishing method

Abstract

To provide a mat antimicrobial finishing method capable of easily imparting antibacterial properties to a new mat and a rental mat and imparting the antibacterial properties to the whole pile.SOLUTION: A method for antibacterial finishing for a mat 1 in which a mat substrate tufting pile to a base fabric is bonded to a surface of a mat base material composed of a rubber material has: a rinsing step rinsing the mat 1 with water; and a dehydration drying step which dehydrates the mat 1 and dries it up in this order. In the middle of the rinsing step, an antibacterial agent just for an amount at a prescribed ratio with respect to the mat 1 weight is administered in the water.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a processing method for imparting antibacterial properties to a mat.

Background Art

[0002] Due to the influence of infectious diseases, high hygiene is required for mats as well. By the way, the following methods are known for imparting antibacterial properties to mats, for example. (a) Knead an antibacterial agent into the pile. (b) Apply an antibacterial agent to the surface of the pile.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, with the method (a) above, it is impossible to re-impart antibacterial properties to rental mats. Note that rental mats refer to mats that are collected after being used for an arbitrary predetermined period. Also, with the method (b) above, antibacterial properties are imparted to the surface of the tip of the pile of the mat, but it is difficult to impart antibacterial properties to the surface of the base end of the pile. Therefore, there is a risk that sufficient antibacterial properties cannot be imparted. In addition, since the coating operation needs to be performed for each mat, the operation of imparting antibacterial properties is troublesome.

[0005] An object of the present invention is to provide an antibacterial processing method for mats that can easily impart antibacterial properties to both new and rental mats and can impart antibacterial properties to the entire pile.

Means for Solving the Problems

[0006] The present invention relates to a method for applying an antibacterial treatment to a mat, which is constructed by bonding a mat base roll, in which a pile tufted onto a base fabric, to the surface of a mat substrate made of rubber material. The process of rinsing the mat with water, A dewatering and drying step is performed to dewater and dry the aforementioned mat, It has them in this order, During the rinsing process, an antibacterial agent is added to the water in an amount that is a predetermined ratio to the weight of the mat. It is characterized by the following. [Effects of the Invention]

[0007] According to the present invention, antibacterial properties can be easily imparted to both new and rental mats, and moreover, antibacterial properties can be imparted to the entire pile. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic cross-sectional view of the mat that is the subject of this invention. [Figure 2] This is a schematic diagram showing the implementation of the antibacterial treatment method for mats according to the present invention. [Modes for carrying out the invention]

[0009] This invention relates to an antibacterial processing method for imparting antibacterial properties to a mat.

[0010] The mats covered by this invention may be new mats or rental mats collected from the market.

[0011] The mat targeted by the present invention is a mat 1 configured by joining a mat web 2 formed by tufting a pile 21 on a base fabric 22, as shown in FIG. 1 which is a schematic cross-sectional view, to the surface 31 of a mat base material 3 made of a rubber material. Note that the pile 21 is not limited to only the cut pile shown in FIG. 1, and may partially or entirely include loop piles. As the fiber material constituting the pile, for example, nylon, rayon, polyester, acrylic, etc. can be used. The rubber material is, for example, NBR.

[0012] When the mat is new, the antibacterial processing method of the present invention has a washing step of washing the mat with water and a dehydration drying step of dehydrating and drying the mat in this order, and during the washing step, an antibacterial agent is administered into water in an amount corresponding to a predetermined ratio to the weight of the mat.

[0013] When the mat is a rental product recovered from the market, the antibacterial processing method of the present invention has a cleaning step of cleaning the mat, a washing step of washing the mat with water, and a dehydration drying step of dehydrating and drying the mat in this order, and during the washing step, an antibacterial agent is administered into water in an amount corresponding to a predetermined ratio to the weight of the mat.

[0014] FIG. 2 is a schematic view showing the implementation state of the antibacterial processing method of the mat of the present invention. In FIG. 2, the cleaning step and the washing step are carried out by a batch washing machine 5. The washing machine 5 has a horizontally opening and closing door 52 for putting the mat 1 of new or rental product into the washing tub 51, and an opening and closing inlet 53 for putting chemicals such as detergents and antibacterial agents into the washing tub 51. In the antibacterial processing method of the present invention, when the mat 1 is being washed in the washing tub 51, an antibacterial agent is put in from the inlet 53 and the washing operation is continued.

[0015] As the antibacterial agent to be administered, a didecyldimethylammonium salt can be used.

[0016] The predetermined ratio of the antibacterial agent to be administered is 0.05 - 2.0% owf.

[0017] According to the antibacterial processing method of the present invention, the following operational effects can be exhibited. (1) Since the antibacterial agent adheres not only to the surface of the tip of the pile but also to the surface of the base end, antibacterial properties can be imparted to the entire pile of the mat raw fabric. Therefore, sufficient antibacterial properties can be imparted to the mat.

[0018] (2) Since it is only necessary to administer the antibacterial agent during the rinsing process, antibacterial properties can be easily imparted to both new mats and rental mats.

[0019] (3) Since it is only necessary to administer the antibacterial agent during the rinsing process, another device for imparting antibacterial properties can be made unnecessary.

[0020] (4) Since the antibacterial agent does not adhere to the mat base material made of a rubber material, it is possible to prevent the floor surface from being contaminated by the antibacterial agent when the mat is laid on the floor surface.

[0021] Furthermore, when imparting dust adsorption properties to a new mat, or when imparting dust adsorption properties again to a rental mat recovered from the market, the antibacterial processing method of the present invention has a coating step of applying a dust adsorbent to the pile after the dehydration drying step. As the dust adsorbent, for example, an acrylic-based adhesive, an oil-based adsorbent, etc. can be used. The coating can be carried out by a spray method, a roll coater method, etc.

[0022] According to the antibacterial processing method of the present invention, the antibacterial properties imparted to the pile can be maintained even after applying the dust adsorbent.

Example

[0023] <1> Mats A and B were produced, and the antibacterial processing method of the present invention was implemented for each of these new mats A and B. These are taken as Example 1 and Example 2. Then, an antibacterial property test was carried out on the mats after antibacterial processing in Example 1 and Example 2.

[0024] [Mat A] Specifically, it was produced as follows.

[0025] (Pile yarn) BCF nylon • Yarn: 1600 dtex / 68 filaments (Filament fineness: 23.5 decitex) Pile yarn Thickness: 3200 decitex (2 strands of yarn) • Twist: 240 twists (bottom twist) / 180 twists (top twist)

[0026] (Mat raw material) • Base fabric: Polyester nonwoven fabric: 120g / m 2 • Tuft conditions • Gauge direction: 5 / 32 (inches / number of needles) • Stitch direction: 7.0 (stitches per inch) • Pile length: 10.5mm • Pile weight: 750g / m 2

[0027] (Mat preparation) The above-mentioned mat roll was cut to a size of 90cm x 75cm, and the following rubber sheet was bonded to it under the following conditions to produce a mat in which the mat base material was bonded to the mat roll. Rubber sheet: Unvulcanized NBR rubber (with vulcanizing agent), 1.5mm thick Pressurization conditions: 3 kg / cm² 2 Vulcanization conditions: 170°C x 12 minutes

[0028] [Mat B] Specifically, it was manufactured as follows:

[0029] (Pile yarn) Nine strands of 290 denier (320 dt) 6,6-nylon monofilament yarn were prepared and bundled together. Two of these bundles were prepared. Next, these two bundles were crimped and then twisted together at 50 turns / meter to create a twisted yarn. This twisted yarn was then heat-set by heating it at 130°C for 15 minutes under humid conditions. In this way, pile yarn was obtained.

[0030] (Mat raw material) • Base fabric: Polyester nonwoven fabric: 120g / m 2 • Tuft conditions • Gauge direction: 6.4 pieces / inch • Stitch direction: 8 stitches / inch • Pile length: 12mm • Pile weight: 900g / m 2 • Pile shape • Cut pile (50%) • Loop pile (50%)

[0031] (Mat preparation) The above-mentioned mat roll was cut to a size of 90cm x 75cm, and the following rubber sheet was bonded to it under the following conditions to produce a mat in which the mat base material was bonded to the mat roll. Rubber sheet: Unvulcanized NBR rubber (with vulcanizing agent), 1.5mm thick Pressurization conditions: 3 kg / cm² 2 Vulcanization conditions: 170°C x 12 minutes

[0032] [Example 1] - 50 kg of mat A and 250 liters of water were placed in the washing tub 11, and a rinse cycle was performed at room temperature for 1 minute twice. Then, 0.05% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and a further rinse cycle was performed for 5 minutes, followed by spin-drying. After that, mat A was removed from the washing tub 11 and dried.

[0033] [Example 2] The antibacterial treatment method was applied to mat B in the same manner as in Example 1.

[0034] [Antibacterial test] (Exam content) • Test method: JIS L1902 (bacterial solution absorption method) • Target bacterial species: Staphylococcus aureus

[0035] (Test results) The antibacterial activity values ​​of the piles of mats A and B after antibacterial treatment in Examples 1 and 2 are shown in Table 1.

[0036] [Table 1]

[0037] As shown in Table 1, mats A and B after antibacterial treatment have an antibacterial activity value of 2.0 or higher, indicating sufficient antibacterial properties. Therefore, the antibacterial treatment methods of Examples 1 and 2 easily imparted sufficient antibacterial properties to new mats.

[0038] <2> Mats A and B were rented and used under the same conditions for a certain period (in this case, 3 years). After that, they were collected, and the antibacterial treatment method of the present invention was applied to each of these rented mats A and B. These are designated as Examples 3 and 4. Then, antibacterial tests were conducted on the mats from Examples 3 and 4 after antibacterial treatment.

[0039] [Example 3] - 50 kg of mat A and 250 liters of water were placed in the washing tub 11, and then a detergent was added. The washing process was carried out at 60°C for 15 minutes under a pH of 11. Next, rinsing was performed three times for 1 minute each. After that, 0.05% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and after another 5 minutes of rinsing, the tub was spun dry. Then, mat A was removed from the washing tub 11 and dried at 90°C for 30 minutes.

[0040] [Example 4] The antibacterial treatment method was applied to mat B in the same manner as in Example 3.

[0041] [Antibacterial test] (Exam content) It is the same as above.

[0042] (Test results) The antibacterial activity values ​​of the piles of mats A and B after antibacterial treatment in Examples 3 and 4 are shown in Table 2.

[0043] [Table 2]

[0044] As shown in Table 2, mats A and B after antibacterial treatment have an antibacterial activity value of 2.0 or higher, indicating sufficient antibacterial properties. Therefore, the antibacterial treatment methods of Examples 3 and 4 easily imparted sufficient antibacterial properties to rental mats.

[0045] <3> Mat A was prepared, and the antibacterial treatment method of the present invention was applied to this new mat A. However, six cases were set for the amount of antibacterial agent used: 0.05, 0.10, 0.30, 0.50, 1.00, and 2.00% owf. These are designated as Examples 5 to 10. Then, antibacterial tests were performed on the mats from Examples 5 to 10 after antibacterial treatment.

[0046] [Example 5] - 50 kg of mat A and 250 liters of water were placed in the washing tub 11, and a rinse cycle was performed at room temperature for 1 minute twice. Then, 0.05% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and a further rinse cycle was performed for 5 minutes, followed by spin-drying. After that, mat A was removed from the washing tub 11 and dried.

[0047] [Example 6] The amount of antibacterial agent was set to 0.10% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 5.

[0048] [Example 7] The amount of antibacterial agent was set to 0.30% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 5.

[0049] [Example 8] The amount of antibacterial agent was set to 0.50% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 5.

[0050] [Example 9] The amount of antibacterial agent was set to 1.00% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 5.

[0051] [Example 10] The amount of antibacterial agent was set to 2.00% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 5.

[0052] [Antibacterial test] (Exam content) It is the same as above.

[0053] (Test results) The antibacterial activity values ​​of the pile of mat A after antibacterial treatment in Examples 5 to 10 are shown in Table 3.

[0054] [Table 3]

[0055] As shown in Table 3, when the amount of antibacterial agent is 0.05 to 2.00% owf, mat A after antibacterial treatment has an antibacterial activity value of 2.0 or higher. Therefore, the antibacterial treatment method of the present invention can exhibit the desired effect when the amount of antibacterial agent used is 0.05 to 2.00% owf.

[0056] <4> The antibacterial processing method of the present invention was applied to mat B. However, two cases were set for the amount of antibacterial agent used on mat B: 0.1% and 0.3% owf. In addition, after dewatering and drying, a dust adsorbent was applied to the surface of the pile. These are designated as Examples 11 and 12. Then, an antibacterial test was performed on the antibacterial processed mats of Examples 11 and 12.

[0057] [Example 11] - 50 kg of mat B and 250 liters of water were placed in the washing tub 11, and rinsing was performed twice for 1 minute each at room temperature. Then, 0.1% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and after another 5 minutes of rinsing, the tub was spun dry. Next, mat B was removed from the washing tub 11 and dried. After that, an acrylic adhesive, a dust adsorbent, was applied to the surface of the pile of mat B in aqueous solution by spraying.

[0058] [Example 12] The amount of antibacterial agent was set to 0.3% owf, and the antibacterial treatment method was carried out on mat B in the same manner as in Example 11.

[0059] [Antibacterial test] (Exam content) It is the same as above.

[0060] (Test results) The antibacterial activity values ​​of the pile of mat B after antibacterial treatment in Examples 11 and 12 are shown in Table 4.

[0061] [Table 4]

[0062] As shown in Table 4, mat B after antibacterial treatment, i.e., after application of the dust adsorbent, has an antibacterial activity value of 2.0 or higher, indicating sufficient antibacterial properties. Therefore, according to the antibacterial treatment methods of Examples 11 and 12, it was possible to obtain a mat that exhibits sufficient antibacterial properties even when dust adsorbent is attached to it.

[0063] <5> The adhesion of antibacterial agents to the rubber mat base material was investigated using new mats A and B. Specifically, the adhesion of antibacterial agents to the pile of mat A, the pile of mat B, and the mat base material of mat A was examined. These are designated as Examples 13 to 15.

[0064] [Example 13] The antibacterial agent was added to 0.35% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 11. Then, 0.050 to 0.055 g of pile from mat A was taken and placed in a vial. Next, 10 ml of methanol was added to the vial, and the extraction of the antibacterial agent adhering to the pile was carried out for 2 hours in a heated shaker set to 55°C. The extract was then diluted with a methanol:water = 1:1 solution, and the concentration of the antibacterial agent in the extract was measured using a high-performance liquid chromatography-mass spectrometer.

[0065] [Example 14] The antibacterial agent was added at a concentration of 0.35% owf, and the antibacterial treatment method was carried out on mat B in the same manner as in Example 11. Then, the pile of mat B was taken and treated in the same manner as in Example 13.

[0066] [Example 15] The antibacterial agent was added at a concentration of 0.35% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 11. Then, 0.050 to 0.055 g of mat substrate was taken from mat A and placed in a vial. Next, 10 ml of methanol was added to the vial, and the extraction of the antibacterial agent adhering to the mat substrate was carried out for 2 hours in a heated shaker set to 55°C. The extract was then diluted with a methanol:water = 1:1 solution, and the concentration of the antibacterial agent in the extract was measured using a high-performance liquid chromatography-mass spectrometer.

[0067] The measurement results are shown in Table 5.

[0068] [Table 5]

[0069] As is clear from Table 5, the majority of the antibacterial agents adhered to the pile, while only a very small amount adhered to the mat base material.

[0070] <6> Mats A and B were prepared, and the antibacterial processing method of the present invention was applied to these new mats A and B, followed by special cleaning. However, three different amounts of antibacterial agent were set for the antibacterial processing method: 0.30, 0.50, and 1.00% owf. Antibacterial tests were then conducted on the mats after antibacterial processing and after special cleaning. These are referred to as Examples 16 to 21.

[0071] [Example 16] (Antibacterial treatment) - 50 kg of mat A and 250 liters of water were placed in the washing tub 11, and a rinse cycle was performed at room temperature for 1 minute twice. Then, 0.30% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and a further rinse cycle was performed for 5 minutes, followed by spin-drying. After that, mat A was removed from the washing tub 11 and dried.

[0072] (Special cleaning) A 50kg antibacterial treated mat A and 250 liters of water were placed in the washing machine tub 11. Then, 1.00% ows of sodium percarbonate bleach was added, and the bleaching process was carried out at 70°C for 20 minutes. After that, the mat was rinsed twice at room temperature for 1 minute each, and then spun dry. After that, the mat A was removed from the washing machine tub 11 and dried.

[0073] [Example 17] (Antibacterial treatment) The amount of antibacterial agent was set to 0.50% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 16. (Special cleaning) • Mat A, after antibacterial treatment, was subjected to special cleaning in the same manner as in Example 16.

[0074] [Example 18] (Antibacterial treatment) The amount of antibacterial agent was set to 1.00% owf, and the antibacterial treatment method was carried out on mat A in the same manner as in Example 16. (Special cleaning) • Mat A, after antibacterial treatment, was subjected to special cleaning in the same manner as in Example 16.

[0075] [Example 19] (Antibacterial treatment) The amount of antibacterial agent was set to 0.30% owf, and the antibacterial treatment method was carried out on mat B in the same manner as in Example 16. (Special cleaning) • Mat B, after antibacterial treatment, was subjected to special cleaning in the same manner as in Example 16.

[0076] [Example 20] (Antibacterial treatment) The amount of antibacterial agent was set to 0.50% owf, and the antibacterial treatment method was carried out on mat B in the same manner as in Example 16. (Special cleaning) • Mat B, after antibacterial treatment, was subjected to special cleaning in the same manner as in Example 16.

[0077] [Example 21] (Antibacterial treatment) The amount of antibacterial agent was set to 1.00% owf, and the antibacterial treatment method was carried out on mat B in the same manner as in Example 16. (Special cleaning) • Mat B, after antibacterial treatment, was subjected to special cleaning in the same manner as in Example 16.

[0078] [Antibacterial test] (Exam content) It is the same as above.

[0079] (Test results) The antibacterial activity values ​​of the piles of mats A and B after antibacterial treatment and special cleaning in Examples 16-21 are shown in Table 6.

[0080] [Table 6]

[0081] As is clear from Table 6, even when mats A and B are subjected to special cleaning such as bleaching after antibacterial treatment, the antibacterial activity value does not decrease. Therefore, according to the antibacterial treatment method of the present invention, the antibacterial properties of the mats can be maintained even when special cleaning is performed after antibacterial treatment.

[0082] <7> Mats A and B were rented and used under the same conditions for a certain period (in this case, 3 years). After that, they were collected, and the antibacterial processing method of the present invention was applied to each of the rented mats A and B, followed by special cleaning. These are referred to as Examples 22 and 23.

[0083] [Example 22] (Antibacterial treatment) - 50 kg of mat A and 250 liters of water were placed in the washing tub 11, and then detergent was added. The washing process was carried out at 60°C for 15 minutes under a pH of 11. Next, rinsing was performed three times for 1 minute each at room temperature. After that, 0.30% owf of didecyldimethylammonium salt, an antibacterial agent, was added to the washing tub 11, and after another 5 minutes of rinsing, the tub was spun dry. Then, mat A was removed from the washing tub 11 and dried.

[0084] (Special cleaning) A 50kg antibacterial treated mat A and 250 liters of water were placed in the washing machine tub 11. Then, 1.00% ows of sodium percarbonate bleach was added, and the bleaching process was carried out at 70°C for 20 minutes. After that, the mat was rinsed twice at room temperature for 1 minute each, and then spun dry. After that, the mat A was removed from the washing machine tub 11 and dried.

[0085] [Example 23] Mat B was subjected to antibacterial treatment and special cleaning in the same manner as in Example 22.

[0086] [Antibacterial test] (Exam content) It is the same as above.

[0087] (Test results) The antibacterial activity values ​​of the piles of mats A and B after antibacterial treatment and special cleaning in Examples 22 and 23 are shown in Table 7.

[0088] [Table 7]

[0089] As is clear from Table 7, even after applying antibacterial treatment to rental mats A and B and then performing special cleaning such as bleaching, the antibacterial activity value did not decrease. Therefore, according to the antibacterial treatment method of the present invention, the antibacterial properties of rental mats can be maintained even when special cleaning is performed after antibacterial treatment.

[0090] Furthermore, the bleach used for special cleaning is not limited to sodium percarbonate; other bleaches may also be used, with oxygen-based bleaches being particularly preferred. [Industrial applicability]

[0091] The antibacterial treatment method for mats according to the present invention has great industrial value because it can easily impart antibacterial properties to mats. [Explanation of symbols]

[0092] 1 mat 2. Mat raw material 21 pile 22 Base fabric 3. Matte base material 31 Surface

Claims

1. A method for antibacterial treatment of a mat, which is constructed by bonding a raw mat fabric having pile tufted into a base fabric to a surface of a mat substrate made of a rubber material, comprising: a rinsing step of rinsing the mat with water; a dehydration and drying step of dehydrating and drying the mat; in this order, During the rinsing step, an antibacterial agent is added to the water in an amount corresponding to a predetermined ratio to the weight of the mat. A method for antibacterial treatment of a mat, comprising:

2. A cleaning step of cleaning the mat is included before the rinsing step. The method for antibacterial treatment of a mat according to claim 1.

3. After the dehydration and drying step, a coating step is performed to coat the pile with a dust adsorbent. A method for antibacterial treatment of a mat according to claim 1 or 2.

4. The antibacterial agent is a didecyldimethylammonium salt. A method for antibacterial treatment of a mat according to claim 1 or 2.

5. The amount of the predetermined proportion is 0.05 to 2.00% owf; A method for antibacterial treatment of a mat according to claim 1 or 2.

Images