Mat

Abstract

To provide a mat capable of obtaining a good stepping feeling, suppressing the entanglement of fur on the surface and facilitating the removal of the fur.SOLUTION: The mat comprises a surface layer part composed of cut pile yarns erected on one side of a base fabric and a back layer part provided with an antislip material for a floor face on the other side of the base fabric, wherein the cut pile yarns are subjected to false twisting, interlacing or Taslan (registered trade mark) processing and are bulky in the direction crossing the erected direction and contain a granular deodorant and / or deodorizing agent.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a mat. [Background technology]

[0002] A pet mat is known that includes a substrate and an adhesive layer provided on one surface of the substrate, and the maximum static friction coefficient on the other surface of the substrate is 0.3 to 0.8, preferably 0.4 to 0.7 (Patent Document 1).

[0003] A Taslan-textured yarn having a total fineness of 500 to 4000 dtex and multiple bulky portions each having a height of 0.3 to 3.0 cm is also known (Patent Document 2), in which the Taslan-textured yarn is a Taslan composite yarn in which float yarns are fixed around a core yarn by interlacing the fibers through Taslan processing, and the sheath yarn is fixed by interlacing the fibers through Taslan processing, and the core yarn is a false-twisted multifilament yarn A made up of multiple thermoplastic fibers a, the float yarn is a false-twisted multifilament yarn B made up of multiple thermoplastic fibers b, and the sheath yarn is a false-twisted multifilament yarn C made up of multiple thermoplastic fibers c. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-50860 [Patent Document 2] Japanese Patent Application Laid-Open No. 2017-82349 Summary of the Invention [Problem to be solved by the invention]

[0005] To provide a mat that provides a good feeling of stepping on, prevents fur from entangling on the surface, and makes it easy to remove fur. [Means for solving the problem]

[0006] In order to solve the above problem, the mat according to claim 1 is The cushion comprises a surface layer made of cut pile yarns erected on one surface of a base fabric, and a back layer provided on the other surface of the base fabric with an anti-slip surface for use against a floor surface, The cut pile yarn is composed of a textured yarn that is bulky in a direction intersecting the standing direction. It is characterized by:

[0007] The invention described in claim 2 is the mat described in claim 1, The textured yarn is false twisted, interlaced or Taslan (registered trademark) textured. It is characterized by:

[0008] The invention described in claim 3 is the mat described in claim 1 or 2, The cut pile yarn contains a deodorizing agent and / or a deodorizing agent. It is characterized by: [Effects of the Invention]

[0009] According to the invention of claim 1, a good feeling of stepping on the floor can be obtained, and entanglement of fur on the surface can be suppressed, making it easier to remove the fur.

[0010] According to the invention as set forth in claim 2, it becomes difficult for fur to get between the cut pile yarns.

[0011] According to the invention described in claim 3, a deodorizing effect can be obtained. [Brief explanation of the drawings]

[0012] [Figure 1] 1 is a perspective view showing the overall configuration of a mat according to an embodiment of the present invention. [Figure 2] (a) is a cross-sectional view showing the structure of the mat, (b) is a plan view showing the surface layer, and (c) is a bottom view showing the back layer. [Figure 3] FIG. 1 is a cross-sectional schematic diagram showing cut pile fabric made of textured yarn. [Figure 4] 3A to 3C are schematic diagrams showing the manufacturing process of the surface layer portion of the mat according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0013] Next, the present invention will be described in more detail below with reference to the drawings, showing embodiments and specific examples, but the present invention is not limited to these embodiments and specific examples. Furthermore, in the following explanation using the drawings, it should be noted that the drawings are schematic and the ratios of the dimensions, etc. may differ from those of the actual product, and in order to facilitate understanding, illustrations of components other than those necessary for the explanation have been omitted as appropriate.

[0014] (1) Mat composition FIG. 1 is a perspective view showing the overall structure of the mat 1 according to this embodiment, FIG. 2(a) is a cross-sectional schematic diagram showing the structure of the mat 1, (b) is a plan view schematic diagram showing the surface layer 20, (c) is a bottom view schematic diagram showing the back layer 30, and FIG. 3 is a cross-sectional schematic diagram showing cut pile yarn 21 made of processed yarn. The structure and function of the mat 1 will be described below with reference to the drawings.

[0015] As shown in Figure 1, the mat 1 comprises a sheet-like base fabric 10, a surface layer 20 that is made up of a plurality of cut pile yarns 21 that are erected on one surface 10a of the base fabric 10 (see Figures 3 and 4) and that protrudes from the base fabric 10, and a back layer 30 that has an anti-slip surface 31 for use with floor surfaces on the other surface 10b of the base fabric 10 (see Figures 2 and 3). The surface layer 20 of the mat 1 according to this embodiment is made of cut pile yarn 21, which makes it difficult for the fur of pets such as dogs and cats to become entangled in the surface layer 20 and makes it easy to remove any adhering fur with a vacuum cleaner, for example. In addition, the claws of pets are less likely to get caught in the surface layer 20 compared to loop pile yarn.

[0016] (1.1) Composition of the base fabric The base fabric 10 is formed by weaving warp threads 11 and weft threads 12 extending in a direction intersecting the direction in which the warp threads 11 extend so that they intersect with each other. The warp yarns 11 and weft yarns 12 constituting the base fabric 10 are made of filament yarns, spun yarns, or the like, which are made of fibers that are excellent in durability and flexibility. Examples of such fibers include regenerated fibers such as rayon fiber and cupra fiber, and synthetic fibers made of nylon, acrylic, polypropylene, polyester, and the like. In this embodiment, polyester fiber, which is highly durable and flexible, is used.

[0017] The fineness of each of the warp yarns 11 and the weft yarns 12 can be appropriately selected depending on the intended use of the mat 1. As the fineness increases, the flexibility of the base fabric 10 decreases, which may result in a poorer fit to the floor surface. Also, as the fineness decreases, the strength of the base fabric 10 decreases, which may result in the base end of the cut pile yarns 21 becoming unable to be fastened. For this purpose, the base fabric 10 has a basis weight of 70 to 280 g / m 2 Preferably, the lower limit is 90 g / m 2 Above 180g / m 2 It is better to use the following:

[0018] (1.2) Surface structure As shown schematically in FIG. 2( a ), the surface layer 20 is configured by weaving a plurality of cut pile yarns 21 into the weft yarns 12 of the base fabric 10 . The polymer material of the cut pile yarns 21 is not particularly limited, but is preferably polyamide, polyester, or polypropylene. Polyamide is preferred in terms of its high resilience, durability, and dyeability. Polyester is also preferred in terms of versatility and ease of handling, and specific examples include polyethylene terephthalate, polypropylene terephthalate, and polybutylene terephthalate.

[0019] In this embodiment, as shown in Fig. 3, the cut pile yarns 21 are made of textured yarns 21a that are bulky in a direction intersecting the standing direction. Specifically, the cut pile yarns 21 are false-twisted, interlaced, or Taslan (registered trademark) textured.

[0020] False twisting is a process in which a straight yarn is first twisted, then heated to set it, and then the twist is restored. False twisted multifilament yarns have fine crimps, which improves their bulkiness and dyeability. The cut pile yarn 21 knitted from the multifilament yarn thus subjected to false twisting processing makes it difficult for pet hair to get inside, and any hair adhering to the surface layer 20 can be easily removed with a vacuum cleaner or the like.

[0021] Interlacing is a processing method in which the filaments are entangled by applying air pressure perpendicular to the direction of travel of the multifilament yarn (the direction of the fiber length), thereby improving the bulkiness of the filament yarn.

[0022] Taslan processing is a processing method that uses a fluid (generally air) to generate loop-shaped fluff and impart bulkiness. The yarn is supplied to a fluid agitation chamber, where the filaments are opened and mixed by the high-pressure turbulent fluid. The yarn is discharged from the nozzle together with the fluid, and by pulling the yarn almost perpendicular to the direction of the fluid, the open-mixed yarn moves violently in the vortex of the fluid at the point where its course changes, causing it to become entrained and tangled. Then, when the yarn leaves the fluid, it is pulled by the fluid and false twisted, resulting in a strongly tangled yarn similar to spun yarn. In this embodiment, bulkiness is improved by subjecting the multifilament yarn to taslan processing.

[0023] In this embodiment, the textured yarn 21a used for the cut pile yarns 21 preferably has a single yarn fineness of 1T (decitex) or more and 7T (decitex) or less. If the single yarn fineness is less than 1T (decitex), the yarn is prone to wear and has poor durability, and there is a risk that the fine crimp of the cut pile yarns 21 will not be sufficiently developed on the surface of the surface layer 20, which is undesirable. On the other hand, if the single yarn fineness is more than 7T (decitex), there is a risk that the crimp and crimp will be too strong, resulting in a stiff feel.

[0024] The total fineness is preferably 400T (decitex) or more and 800T (decitex) or less. When the total fineness is 400T (decitex) or more, sufficient volume and excellent texture can be obtained when a mat is produced using the resulting textured yarn. Furthermore, when the total fineness is 800T (decitex) or less, handling during the production process is easy and production costs can be reduced.

[0025] In this embodiment, the pile height of the cut pile yarns 21 is preferably 3 mm or more and 5 mm or less. If the pile height is less than 3 mm, the comfort of walking on the floor may be poor. If the pile height is greater than 5 mm, the resistance to settling may be reduced. The pile density of cut pile yarn 21 is 800 bundles / inch 2 More than 1100 bundles / inch 2 It is preferable that the pile density is 800 bundles / inch or less. 2 If the pile density is less than 1100 bundles / inch, the mat will feel hard to walk on and the texture of the mat will be poor. 2 If the temperature exceeds this range, the settling resistance of the mat may be deteriorated.

[0026] In this embodiment, the textured yarn 21a used for the cut pile yarn 21 preferably contains a deodorant and / or a deodorizing agent. The deodorant or deodorizing agent is preferably a material that becomes granular at least at room temperature (e.g., 0°C to 40°C). A method for applying a granular deodorant or deodorizing agent to the textured yarn 21a is to disperse granular material having a deodorizing or deodorizing effect in an aqueous solvent, immerse the textured yarn 21a in this dispersion, and then dry it to remove the moisture, resulting in the particles adhering to the surface of 21a. The granular deodorant or deodorizing agent applied to the textured yarn 21a in this way remains on the surface of the textured yarn 21a, thereby achieving a higher deodorizing or deodorizing effect.

[0027] The deodorizing agent may be an inorganic deodorizing agent, a polyphenol compound deodorizing agent, a nitrogen compound deodorizing agent, etc. The deodorizing agent may be activated carbon, zeolite, etc. The textured yarn 21a used for the cut pile yarn 21 may contain one or both of these deodorizing agents and deodorizing agents.

[0028] The particle size of the deodorant or deodorizer is preferably 1 nm or more and 0.5 mm or less. If the particle size of the deodorant or deodorizer is small, the yield of the deodorant or deodorizer will decrease during the processing stage, making it difficult to incorporate the desired amount of deodorant or deodorizer into the cut pile yarn 21. On the other hand, if the particle size of the deodorant or deodorizer is large, the cohesiveness will decrease, and the textured yarn will not be able to hold the deodorant or deodorizer with sufficient strength, which may result in the deodorant or deodorizer falling off. Examples of such deodorants or deodorizers include hybrid deodorants (TioTioPREMIUM (registered trademark)), inorganic deodorants (Kesmon (registered trademark)), and mineral deodorants (zeolite).

[0029] (1.3) Composition of the back layer The back layer 30 is configured by forming anti-slip surfaces 31 for use on floor surfaces, made of a resin composition or a rubber composition, on the other surface 10b of the base fabric 10. As shown in Fig. 2(c), the anti-slip surfaces 31 are formed in stripes with a width of 2 mm to 5 mm.

[0030] In this embodiment, the non-slip surface 31 is made of an acrylic resin material, and for example, the other surface 10b of the base fabric 10 is impregnated with foamed acrylic resin latex using a coating press, and then dried to form the non-slip surface 31 with vacuum adsorption properties. The back layer 30 of the mat 1, on which the anti-slip surface 31 is formed, has vacuum suction or adhesive properties, so that a good anti-slip effect can be obtained by contacting the back layer 30 with the floor surface and applying light pressure. On the other hand, it also has good releasability, so it can be easily removed from the floor.

[0031] (2) Mat manufacturing method FIG. 4 is a schematic diagram showing the manufacturing process of the surface layer 20 of the mat 1. To form the surface layer 20, first, two base fabrics 10 are arranged so that their surfaces 10a face each other, as shown in Fig. 4. The pile height of the cut pile yarns 21 varies depending on the distance between the two opposing base fabrics 10.

[0032] Next, textured yarn 21a that will become cut pile yarn 21 is woven so that it alternately overlaps the weft yarns 12 of the two base fabrics 10. Next, the center of textured yarn 21a that has overlapped the two base fabrics 10 is cut (see dashed line AA in Figure 4), and the fibers that make up textured yarn 21a spread out to form a surface layer 20 made of cut pile yarn 21. As a result, two surface layers 20 in a cut pile form are simultaneously formed, each consisting of the base fabric 10 and the textured yarn 21a cut to a predetermined height.

[0033] Then, the other surface 10b (back layer 30) of the base fabric 10 of the obtained surface layer 20 is impregnated with foamed acrylic resin latex using a coating press and dried, thereby forming an anti-slip surface 31 on the back layer 30 for use on floor surfaces.

[0034] (3) Functions of the mat The mat 1 according to this embodiment comprises a sheet-like base fabric 10, a surface layer 20 made of a plurality of cut pile yarns 21 standing on one surface 10a of the base fabric 10 and exposed to the outside, and a back layer 30 on the other surface 10b of the base fabric 10, on which an anti-slip surface 31 for use with floor surfaces is provided. As a result, compared to mats having a surface layer with standing loop pile yarns, the surface layer 20 is less likely to become entangled with the fur of pets such as dogs and cats, and any fur that does get stuck can be easily removed with a vacuum cleaner, for example. Furthermore, cut pile yarns are less likely to get caught on the claws of pets than loop pile yarns, and the mat has superior durability. For this reason, the mat 1 according to this embodiment can be suitably used as a pet-compatible mat to be placed on the floor of a room where both people and pets (dogs and cats) live together.

[0035] In this embodiment, the cut pile yarn 21 has a single yarn fineness of 1T (decitex) to 7T (decitex) and a total fineness of 400T (decitex) to 800T (decitex), and is composed of textured yarn 21a that is bulky in the direction intersecting with the vertical laying direction, thereby achieving sufficient volume and a dense, excellent texture.

[0036] In this embodiment, the cut pile yarn 21 has a pile height of 3 mm or more and 5 mm or less, and a pile density of 800 bundles / inch. 2 More than 1100 bundles / inch 2 This makes it possible to obtain a good pedal feel while suppressing wear.

[0037] In this embodiment, the textured yarn 21a used for the cut pile yarn 21 contains a deodorizing agent and / or a deodorizing agent such as a hybrid deodorizing agent (TioTioPREMIUM (registered trademark)), an inorganic deodorizing agent (Kesmon (registered trademark)), or a mineral deodorizing agent (zeolite), thereby achieving a deodorizing effect. [Explanation of symbols]

[0038] 1. Mat 10...Base fabric 11....warp thread, 12....weft thread 20...surface layer 21···Pile yarn, 21a···Textured yarn 30. Back layer 31. Anti-slip

Claims

1. The cushion comprises a surface layer made of cut pile yarns erected on one surface of a base fabric, and a back layer provided on the other surface of the base fabric with an anti-slip surface for use against a floor surface, The cut pile yarn is composed of a textured yarn that is bulky in a direction intersecting the standing direction. A mat characterized by:

2. The textured yarn is false twisted, interlaced or Taslan (registered trademark) textured.

2. The mat of claim 1.

3. The cut pile yarn contains a deodorizing agent and / or a deodorizing agent.

3. The mat according to claim 1 or 2.

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