mat

Abstract

This mat offers excellent abrasion resistance and water absorption in its pile yarn. [Solution] The mat 1 comprises pile yarn 10 and a base fabric 20 to which the pile yarn 10 is tufted. The pile yarn 10 has a BCF yarn composed of a plurality of BCF single yarns and an ultrafine fiber yarn composed of a plurality of ultrafine fiber single yarns having a diameter of 50 nm or more and less than 1000 nm.

Description

Technical Field

[0001] This disclosure relates to mats.

Background Art

[0002] Patent Document 1 discloses a water-absorbent mat having a pile yarn containing rayon.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] According to the description of Patent Document 1, since the pile yarn contains rayon which is excellent in water absorption, the water-absorbent mat can obtain high water absorption. On the other hand, rayon has poor abrasion resistance. Therefore, when the water-absorbent mat described in Patent Document 1 is used for a long time, the abrasion of the pile yarn progresses, and as a result, the function as a water-absorbent mat may be impaired.

[0005] An object of this disclosure is to provide a mat in which both the abrasion resistance and water absorption of the pile yarn are excellent.

Means for Solving the Problems

[0006] This disclosure provides a BCF raw yarn composed of a plurality of BCF single filaments, a microfiber raw yarn composed of a plurality of microfiber single filaments having a diameter of 50 nm or more and less than 1000 nm and a pile yarn having the same, a base fabric on which a plurality of the pile yarns are tufted and provides a mat.

[0007] According to the mat disclosed herein, the pile yarn has BCF filaments composed of BCF single filaments with excellent abrasion resistance. Furthermore, the ultrafine fiber filaments, composed of ultrafine single filaments with a diameter of 50 nm or more and less than 1000 nm, i.e., on the order of nanometers, draw up moisture through the gaps between the single filaments by capillary action. For this reason, the ultrafine fiber filaments have excellent water absorption. Therefore, a mat with both excellent abrasion resistance and water absorption can be provided by using pile yarn having BCF filaments and ultrafine fiber filaments. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic longitudinal cross-sectional view of the mat according to this embodiment. [Figure 2] This diagram schematically shows the structure of the pile yarn according to the first embodiment. [Figure 3] This figure schematically shows the structure of the pile yarn according to the second embodiment. [Figure 4] The graph shows the test results for the pile yarn alone. [Figure 5] The graph shows the test results for the pile yarn alone. [Modes for carrying out the invention]

[0009] The embodiments of this disclosure will be described below with reference to the attached drawings.

[0010] [First Embodiment] Figure 1 shows a schematic longitudinal cross-sectional view of the mat 1 according to this embodiment. The mat 1 of this embodiment is a dust-absorbing and water-absorbing mat that is laid in entrances and kitchen doorways where people frequently enter and exit, capturing dust from the soles of shoes and absorbing water. The mat 1 may also be used for other purposes, such as in kitchens, bathrooms, and toilets in homes.

[0011] Mat 1 comprises a mat base 2 that is stepped on by the user and a mat base material 3 that comes into contact with the floor. Mat base 2 has a plurality of pile yarns 10 and a base fabric 20 to which the plurality of pile yarns 10 are tufted. Mat base 2 is bonded onto mat base material 3. Mat base material 3 is, for example, a rubber sheet. Base fabric 20 is, for example, a nonwoven fabric containing polyester.

[0012] Figure 2 schematically shows the structure of the pile yarn 10 according to the first embodiment. The pile yarn 10 includes a first yarn 11, a second yarn 12, and a fusion yarn 13 for fusing the first yarn 11 and the second yarn 12. The pile yarn 10 is constructed by twisting the first yarn 11, the second yarn 12, and the fusion yarn 13 together.

[0013] The first filament 11 comprises a BCF filament 100 composed of multiple BCF single filaments, an ultrafine fiber filament 101 composed of multiple ultrafine fiber single filaments, and a monofilament 102. The first filament 11 is constructed by under-twisting the BCF filament 100, the ultrafine fiber filament 101, and the monofilament 102. In the first embodiment, the structure of the second filament 12 is the same as that of the first filament 11.

[0014] BCF yarn 100 is formed by aligning multiple BCF single yarns. BCF (Bulked Continuous Filaments) yarn is a yarn that has high bulkiness due to crimping of multifilaments. BCF yarn generally has high abrasion resistance, but its water absorption is inferior to that of rayon. As BCF yarn 100, for example, BCF nylon (registered trademark) manufactured by Toray Industries, Inc. can be used. A BCF single yarn refers to one yarn that makes up BCF yarn 100.

[0015] In this embodiment, in order to improve the water absorption of the pile yarn 10, the fineness of the BCF single yarn is set to 30 denier (D) or less. Furthermore, in order to avoid reducing washability, the fineness of the BCF single yarn is set to 1D or more. That is, the fineness of the BCF single yarn is set between 1D and 30D. The fineness of the BCF raw yarn 100 is set between 1000D and 1300D. For example, a BCF raw yarn 100 with a fineness of 1000D is formed by drawing together 100 BCF single yarns with a fineness of 10D.

[0016] The ultrafine fiber filament 101 is formed by aligning and sizing multiple ultrafine fiber single filaments. An ultrafine fiber single filament is a single thread with a diameter of 50 nm or more and less than 1000 nm (in other words, a fineness of 0.0001 D or more and less than 0.05 D). The diameters of the individual ultrafine fiber single filaments included in the ultrafine fiber filament 101 do not have to be the same. That is, individual ultrafine fiber single filaments having various diameters within the range of 50 nm or more and less than 1000 nm may be included in the ultrafine fiber filament 101. The ultrafine fiber single filaments are made of polyester, for example. Numerous voids exist between the multiple ultrafine fiber single filaments that make up the ultrafine fiber filament 101. The ultrafine fiber filament 101 has high water absorption due to the capillary action caused by these voids.

[0017] In this embodiment, in order to enhance the water absorption of the pile yarn 10, the fineness of the ultrafine fiber filament 101 is set to 130D or higher. Furthermore, in order to avoid reducing washability and to suppress an increase in the cost of the pile yarn 10, the fineness of the ultrafine fiber filament 101 is set to 520D or lower. That is, the fineness of the ultrafine fiber filament 101 is set between 130D and 520D. The number of ultrafine fiber single filaments constituting the ultrafine fiber filament 101 is set, for example, within the range of 2600 to 80000 so that the ultrafine fiber filament 101 has such fineness.

[0018] The ultrafine fiber yarn 101 of this embodiment has higher water absorption than a so-called microfiber filament composed of a plurality of single yarns with a diameter of 1 μm to 10 μm. For example, the content rate of the ultrafine fiber yarn 101 required to ensure water absorption equivalent to that of a pile yarn containing microfiber filaments at a predetermined content rate (the ratio of the fineness of the filaments to the fineness of the pile yarn) is lower than the content rate of the microfiber filaments.

[0019] In order to further enhance the water absorption of the pile yarn 10, in the first yarn 11 (or the second yarn 12), the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 is set to 10% (130D / 1300D) or more. Also, in order to ensure the washability of the pile yarn 10, in the first yarn 11 (or the second yarn 12), the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 is set to 52% (520D / 1000D) or less.

[0020] Furthermore, in order to enhance the water absorption of the pile yarn 10, in the pile yarn 10, the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 is set to 5% (130D / 2600D) or more. Also, in order to ensure the washability of the pile yarn 10, in the pile yarn 10, the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 is set to 52% (1040D / 2000D) or less. <​​​​​Furthermore, in order to maintain the water absorption of the pile yarn 10, it is preferable that the ratio of the fineness of the ultrafine fiber filament 101 to the fineness of the pile yarn 10 be 1.7% or more. That is, in this embodiment, it is preferable that the ratio of the fineness of the ultrafine fiber filament 101 to the total fineness of the BCF filament 100, the ultrafine fiber filament 101, the monofilament 102, and the fused yarn 13 be 1.7% or more.

[0023] The monofilament 102 is, for example, a single fiber containing a polyamide resin. By including the monofilament 102 in the pile yarn 10, the rigidity of the pile yarn 10 is improved, and the pile yarn 10 becomes easier to stand upright. As a result, when shoes are stepped on the mat 1, dirt such as mud attached to the soles of the shoes is more easily removed by the pile yarn 10.

[0024] The first yarn 11 may have further fibers. For example, the first yarn 11 may further have water-absorbing fibers that contain polyester, are crimped with a high crimping rate, and have voids between the single fibers. In this case, the first yarn 11 may be composed of BCF yarn 100, ultrafine fiber yarn 101, monofilament 102, and the water-absorbing fibers, which are under-twisted together. The water-absorbing fibers have water absorption properties such that the water absorption height measured according to the Baylec method specified in JIS L 1907 is 20 mm or more.

[0025] The fused yarn 13 is, for example, a fiber containing a polyamide resin, a polyester resin, or an olefin resin. By including the fused yarn 13 in the pile yarn 10, the abrasion resistance and washability of the pile yarn 10 are improved, and the pile yarn 10 is more likely to stand upright in the mat base 2. The melting point of the fused yarn 13 is preferably 80°C to 140°C. If the melting point of the fused yarn 13 is 80°C or higher, it is possible to prevent the fused yarn 13 from remelting when the mat 1 is washed. If the melting point of the fused yarn 13 is 140°C or lower, it is possible to prevent other fibers 100, 101, and 102 from being damaged by thermal deformation during the process of melting the fused yarn 13 when manufacturing the pile yarn 10.

[0026] To maintain the washability of the pile yarn 10, the ratio of the fineness of the fused yarn 13 to the fineness of the pile yarn 10 is set to 1.7% or more. By setting this ratio to 1.7% or more, the unraveling of the pile yarn 10 after washing the mat 1 can be suppressed. Furthermore, in order to improve the water absorption of the pile yarn 10, the ratio of the fineness of the fused yarn 13 to the fineness of the pile yarn 10 is set to 14.8% or less. By setting this ratio to 14.8% or less, space for retaining moisture can be secured in the gaps between the first yarn 11 and the second yarn 12, and between each yarn constituting each yarn 11 and 12. For example, the fineness of the fused yarn 13 is set to 60D or more and 600D or less.

[0027] The first yarn 11 and the second yarn 12 are formed by under-twisting each of the fibers 100, 101, and 102 constituting the yarn with a predetermined number of twists. The pile yarn 10 is formed by over-twisting the first yarn 11, the second yarn 12, and the fused yarn 13 with the same number of twists as the under-twist, and heating at a temperature in the range of 80°C to 120°C. The twist direction of the under-twist is opposite to the twist direction of the over-twist.

[0028] To maintain the washability of the pile yarn 10, the number of twists in the upper and lower twists is set to 80 times / m or more. By setting the number of twists to 80 times / m or more, the unraveling of the pile yarn 10 after washing the mat 1 can be suppressed. To maintain the water absorption of the pile yarn 10, the number of twists in the upper and lower twists is set to 240 times / m or less. By setting the number of twists to 240 times / m or less, space for retaining moisture can be secured in the gaps between the first yarn 11 and the second yarn 12, and between each yarn constituting each yarn 11, 12.

[0029] The mat base 2 is formed by tufting the pile yarns 10 described above onto the base fabric 20 at a predetermined tuft density. The height H of the pile yarns 10 in the mat base 2 (see Figure 1), that is, the length of the pile yarns 10 extending from the surface of the base fabric 20, is set to be between 5 mm and 15 mm. By setting the height H of the pile yarns 10 to be between 5 mm and 15 mm, the pile yarns 10 can stand upright in the mat base 2, effectively removing mud and other debris from the soles of shoes.

[0030] Mat 1 is formed by pressing an unvulcanized rubber sheet, which is a precursor to the mat base material 3, against the side of the mat roll 2 opposite to the side on which the pile yarns 10 extend, and then vulcanizing it.

[0031] The pile yarn 10 of this embodiment may be used for purposes other than mats. For example, the pile yarn 10 may be used for carpets, towels, or pot holders. Even when the pile yarn 10 is used for carpets, towels, or pot holders, excellent water absorption and abrasion resistance can be provided.

[0032] According to the mat 1 of the first embodiment, the following effects are achieved.

[0033] (1) Mat 1 is BCF yarn 100 composed of multiple BCF single yarns, An ultrafine fiber filament 101 composed of multiple ultrafine fiber single filaments having a diameter of 50 nm or more and less than 1000 nm, Pile yarn 10 having, A base fabric 20 to which multiple pile threads 10 are tufted and It is equipped with.

[0034] As a result, by using pile yarn having BCF yarn 100 with excellent abrasion resistance and ultrafine fiber yarn 101 with excellent water absorption, a mat with excellent abrasion resistance and water absorption can be provided.

[0035] (2) The fineness of the ultrafine fiber yarn 101 is between 130 denier and 520 denier. By setting the fineness of the ultrafine fiber yarn 101 to 130D or higher, the water absorption of the pile yarn 10 can be further increased. Furthermore, by setting the fineness of the ultrafine fiber yarn 101 to 520D or lower, a decrease in washability and an increase in the cost of the pile yarn 10 can be suppressed.

[0036] (3) In the pile yarn 10, the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 is 5% or more and 52% or less.

[0037] By setting this ratio to 5% or more, the water absorption of the pile yarn 10 can be further increased. Furthermore, by setting this ratio to 52% or less, the decrease in the washability of the pile yarn 10 can be suppressed.

[0038] (4) The fineness of the BCF single yarn is between 1 denier and 30 denier. By setting the fineness of the BCF single yarn to 1D or higher, the decrease in the washability of the pile yarn 10 can be suppressed. By setting the fineness of the BCF single yarn to 30D or lower, the water absorption of the pile yarn 10 can be further increased.

[0039] (5) The pile yarn 10 includes a first yarn 11 which is made by pre-twisting at least BCF yarn 100 and ultrafine fiber yarn 101, a second yarn 12 which is made by pre-twisting at least BCF yarn 100 and ultrafine fiber yarn 101, and a fusion yarn 13 for fusing the first yarn 11 and the second yarn 12. The pile yarn 10 is composed of a first yarn 11, a second yarn 12, and a fused yarn 13 that are twisted together.

[0040] As a result, the pile yarns 10 tend to stand upright in the mat base 2, effectively removing mud and other debris from the soles of shoes. Furthermore, the fused yarns 13 can further improve the abrasion resistance and washability of the pile yarns 10.

[0041] [Second Embodiment] Figure 3 shows the pile yarn 10 according to the second embodiment. In the second embodiment, the composition of the second yarn 12a differs from that of the first yarn 11. Specifically, the second yarn 12a does not contain the ultrafine fiber yarn 101. That is, the second yarn 12a is composed of BCF yarn 100 and monofilament 102.

[0042] In the second embodiment, when the fineness of the BCF yarn 100 is 1300D and the fineness of the ultrafine fiber yarn 101 is 130D, the ratio of the fineness of the ultrafine fiber yarn 101 to the fineness of the BCF yarn 100 in the pile yarn 10 is 5% (130D / 2600D). That is, in the second embodiment as well, the pile yarn 10 can have excellent water absorption. Furthermore, since the second yarn 12a does not contain the ultrafine fiber yarn 101, the increase in the cost of the pile yarn 10 can be further suppressed.

[0043] If the second yarn 12a contains only BCF yarn 100, the second yarn 12a does not need to be pre-twisted.

[0044] According to mat 1 of the second embodiment, The pile yarn 10 includes a first yarn 11 which is made by pre-twisting at least BCF yarn 100 and ultrafine fiber yarn 101, a second yarn 12 which includes at least BCF yarn 100, and a fusion yarn 13 for fusing the first yarn 11 and the second yarn 12. The pile yarn 10 is composed of a first yarn 11, a second yarn 12, and a fused yarn 13 that are twisted together.

[0045] As a result, the water absorption capacity of the pile yarn 10 can be maintained while further suppressing the increase in the cost of the pile yarn 10.

[0046] Next, we will describe the test results conducted to verify the water absorption, abrasion resistance, and washability of the pile yarn 10 of this embodiment.

[0047] [Water absorption test of pile yarn alone] Based on the Baylek method specified in JIS L 1907, one end of the prepared pile yarn was immersed in water, and the water absorption height was measured every minute.

[0048] [Test 1-1] In Test 1-1, water absorption tests were conducted by varying the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn. Table 1 shows the specifications of each example and comparative example.

[0049] [Table 1]

[0050] The pile yarn according to Example 1 is formed by twisting together a first yarn containing ultrafine fiber yarn, a second yarn not containing ultrafine fiber yarn, and a fused yarn. In other words, the pile yarn according to Example 1 corresponds to the pile yarn 10 according to the second embodiment.

[0051] The pile yarns according to Examples 2 to 4 are formed by twisting together a first yarn containing ultrafine fiber filaments, a second yarn having the same configuration as the first yarn, and a fused yarn. In other words, the pile yarns according to Examples 2 to 4 correspond to the pile yarn 10 according to the first embodiment.

[0052] In Examples 1 to 4, the fineness of the BCF single yarn constituting the BCF yarn is 4D. The percentages in Table 1 represent the ratio of ultrafine fiber yarn to the fineness of the BCF yarn. Furthermore, the ratio of the fineness of ultrafine fiber yarn to the fineness of the BCF yarn in the pile yarns of Examples 1, 2, 3, and 4 is 6.5%, 13%, 26%, and 52%, respectively.

[0053] The pile yarn according to Comparative Example 1 is formed by twisting together a first yarn, which does not contain ultrafine fiber yarn and is composed of BCF yarn with a fineness of 1000D, a second yarn with the same composition as the first yarn, and a fused yarn. The fineness of the BCF single yarn that makes up the BCF yarn is 20D.

[0054] The pile yarn in Comparative Example 2 is formed by twisting together a first yarn made of a blended yarn with a fineness of 970D, a second yarn having the same composition as the first yarn, and a fused yarn. The blended yarn contains rayon and polyester.

[0055] Figure 4 shows the test results. In Figure 4, the horizontal axis represents the measurement time after the pile yarn was immersed, and the vertical axis represents the water absorption height at each measurement time.

[0056] In Figure 4, the water absorption height of Examples 1-4, which contain ultrafine fiber filaments, is higher than that of Comparative Example 1, which does not contain ultrafine fiber filaments, and Comparative Example 2, which contains rayon. Furthermore, the water absorption height of Examples 2-4, which have a higher proportion of ultrafine fiber filaments than Example 1, is comparable.

[0057] From the above test results, it was found that the water absorption of pile yarn containing ultrafine fiber filaments is higher than that of pile yarn composed of BCF filaments without ultrafine fiber filaments, and also higher than that of pile yarn containing rayon. Furthermore, it was found that increasing the proportion of ultrafine fiber filaments by more than 13% did not significantly change the water absorption of the pile yarn.

[0058] [Test 1-2] In Test 1-2, water absorption tests were conducted by varying the fineness of the BCF monofilament. Table 2 shows the specifications of each example and comparative example.

[0059] [Table 2]

[0060] The pile yarns in Examples 5 to 9 are formed by twisting together a first yarn containing ultrafine fiber filaments, a second yarn having the same configuration as the first yarn, and a fused yarn. In other words, the pile yarns in Examples 5 to 9 correspond to the pile yarn 10 according to the first embodiment. The fineness of the ultrafine fiber filaments included in the pile yarns in Examples 5 to 9 is 130D in all cases. The fineness of the BCF single yarns included in the pile yarns in Examples 5, 6, 7, 8, and 9 is 1D, 4D, 10D, 20D, and 30D, respectively. Note that the pile yarn in Example 6 is the same as the pile yarn in Example 2.

[0061] The pile yarns in Comparative Examples 3 to 7 are the same as the pile yarns in Examples 5 to 9, except that the pile yarns do not contain ultrafine fiber filaments.

[0062] The pile yarn used in Comparative Example 8 is the same as the pile yarn used in Comparative Example 2, that is, it is a pile yarn containing rayon.

[0063] Table 3 shows the test results. Please also refer to Figure 5, which graphs some of the test results in a similar format to Figure 4.

[0064] [Table 3]

[0065] The water absorption heights of each of Examples 5-9 are higher than those of the corresponding Comparative Examples 3-7. As the fineness of the BCF single yarn decreased, the water absorption of the pile yarn improved. Furthermore, comparing Example 9 and Comparative Example 7 in Figure 5 (both with a BCF single yarn fineness of 30D), the water absorption rate of Example 9, i.e., the ratio of the change in water absorption height to the change in measurement time, is greater than that of Comparative Example 7. Moreover, the water absorption height of Example 9 (BCF single yarn fineness of 30D) is equivalent to that of Comparative Example 8, which contains rayon.

[0066] From the above test results, it was found that the water absorption of the pile yarn improves as the fineness of the BCF single yarn decreases, and that if the fineness of the BCF single yarn is around 30D, it can achieve the same water absorption as pile yarn containing rayon. It is thought that as the fineness of the BCF single yarn decreases, the surface area of ​​the BCF filament increases, allowing it to adsorb more moisture. Furthermore, it was found that the water absorption rate increases when the pile yarn contains ultrafine fiber filaments.

[0067] [Mat wear test] Based on the abrasion test method using a Taber-type abrasion tester specified in JIS L 1021, mat test specimens tufted with various pile yarns were prepared and abrasion tests were conducted. The rotation speed of the test stand in this abrasion test was set to 70 rpm. The amount of abrasion and the abrasion rate were calculated by measuring the weight of the mat test specimen before the test and the weight of the mat test specimen after rotating the test stand 5000 times. The abrasion rate is the ratio of the amount of abrasion to the weight of the mat test specimen before the test. Table 4 shows the specifications and test results of the examples and comparative examples of mat test specimens.

[0068] [Table 4]

[0069] Example 10 is a mat test specimen tufted with pile yarn that does not contain fused yarn. Example 11 is a mat test specimen tufted with pile yarn that includes fused yarn. In Examples 10 and 11, the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn is 52%. Comparative Example 9 is a mat test specimen tufted with pile yarn composed solely of BCF yarn. Comparative Example 10 is a mat test specimen tufted with pile yarn composed solely of blended yarn containing rayon.

[0070] The abrasion rates of Examples 10 and 11 are lower than those of Comparative Example 10, which contains rayon. The abrasion rate of Example 11, which contains fused yarn, is lower than that of Example 10, which does not contain fused yarn, and is equivalent to that of Comparative Example 9, which is composed solely of BCF yarn.

[0071] The above test results show that even a mat made by adding ultrafine fiber filaments to BCF filaments, which have excellent abrasion resistance, exhibits superior abrasion resistance compared to a mat made of rayon. Furthermore, it was found that abrasion resistance can be further improved by adding fused yarns.

[0072] [Water absorption test and wash resistance test of the mat] Mats were prepared using various pile yarns tufted together, and water absorption and washability tests were conducted on the mats. First, the methods for each test will be explained.

[0073] (Water absorption test) The prepared mat is cut with scissors into 20cm x 30cm pieces, and these cut mat test pieces are left overnight in an environment of 20°C and 65% humidity.

[0074] Next, the weight of the mat test piece and the weight of the pre-prepared cotton cloth were measured. Then, the sole of the shoe was immersed in a tray of water for 2 seconds, and then the sole was stepped on twice to ensure that the amount of water adhering to the sole was constant (e.g., 1.4g to 1.8g). Next, the mat test piece was stepped on for 2 seconds, and then the cotton cloth was stepped on 5 times to wipe off any remaining water from the sole. The weight of the mat test piece and the cotton cloth were then measured. This process was repeated twice, and the amount of water wiped from the sole by the mat test piece was evaluated. A good result (○) was given if the amount of water wiped from the sole by the mat test piece exceeded 90% of the amount of water that was adhering to the sole.

[0075] The change in weight of the mat test piece corresponds to the amount of moisture the mat piece wiped from the sole of the shoe. Furthermore, the combined change in weight of the mat test piece and the cotton cloth corresponds to the amount of moisture adhering to the sole of the shoe.

[0076] (Washable) The mat was washed and dried under the following conditions, and the opening of the pile yarn tips was visually evaluated. If no opening of the pile yarn tips was observed, the mat was considered to have good washability (○). • Washing machine: Turgot meter • Washing conditions: 60℃, 30 minutes, 120rpm • Dryer: Household tumble dryer Drying conditions: Until dry

[0077] [Exam 3-1] In Test 3-1, the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn was varied during the test. Table 5 shows the specifications and test results for each example.

[0078] [Table 5]

[0079] In Table 5, the fineness of each yarn refers to the total fineness of each yarn in a single pile yarn. The percentages in Table 5 refer to the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn.

[0080] Based on the above test results, it was confirmed that when the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn is within the range of 5% to 52%, the water absorption and washability are good.

[0081] [Exam 3-2] In Test 3-2, the tests were conducted using absorbent mats that are expected to be used in actual applications. Specifically, the pile yarns tufted onto the mat in Test 3-2 included BCF filament yarn, ultrafine filament yarn, and fused yarn, as well as monofilaments and other arbitrary fibers (e.g., polyester fibers with high crimp and voids between the single filaments). In Test 3-2, the tests were conducted by varying the fineness of the ultrafine filament yarn in relation to the fineness of various pile yarns. Table 6 shows the specifications and test results for each example.

[0082] [Table 6]

[0083] In Table 6, the fineness of the pile yarn refers to the sum of the fineness of all the fibers that make up the pile yarn. The percentage in Table 6 refers to the ratio of the fineness of the ultrafine fiber filament to the fineness of the pile yarn.

[0084] From the above test results, it was confirmed that good water absorption and washability are achieved when the ratio of the fineness of the ultrafine fiber yarn to the fineness of the pile yarn is at least 1.7%.

[0085] [Exam 3-3] In Test 3-3, tests were conducted using absorbent mats that are expected to be used in actual applications. Specifically, the pile yarns tufted onto the mat in Test 3-3 included BCF yarn, ultrafine fiber yarn, and fused yarn, as well as monofilaments and other arbitrary fibers (e.g., polyester fibers with high crimp and voids between the single fibers). In Test 3-3, tests were conducted by varying the fineness of the fused yarn in relation to the fineness of various pile yarns. Table 7 shows the specifications and test results for each example.

[0086] [Table 7]

[0087] The percentages in Table 7 represent the ratio of the fineness of the fused yarn to the fineness of the pile yarn.

[0088] From the above test results, it was confirmed that good water absorption and washability were achieved when the ratio of the fineness of the fused yarn to the fineness of the pile yarn was within the range of 1.7% to 14.8%. In addition, in Example 31, where the ratio was 0.9%, it was confirmed that the tips of the pile yarns were open after the test.

[0089] [Exam 3-4] In Test 3-4, the number of twists in the upper and lower twists of pile yarn containing BCF yarn and ultrafine fiber yarn were varied during the test. Table 8 shows the specifications and test results for each example.

[0090] [Table 8]

[0091] The twist counts in Table 8 represent the twist counts for the upper and lower twists of the pile yarn; that is, the twist counts for the upper and lower twists are the same. The fineness of the BCF yarn and the ultrafine fiber yarn in the pile yarns of Examples 38 to 43 are 1000D and 130D, respectively.

[0092] From the above test results, it was found that good water absorption and washability were achieved when the twist count was in the range of 80 turns / m to 240 turns / m.

[0093] Furthermore, the mat 1 relating to this disclosure is not limited to the configuration of the above embodiment, and various modifications are possible.

[0094] The pile yarn does not necessarily have to be composed of a first yarn that is initially twisted, a second yarn that is initially twisted, and a fused yarn that is then twisted together. For example, the pile yarn may be composed of a BCF yarn, an ultrafine fiber yarn, and a fused yarn that is then twisted together.

[0095] [Note] The mat relating to this disclosure provides the following aspects.

[0096] [Aspect 1] BCF yarn composed of multiple BCF single yarns, Ultrafine fiber filament composed of multiple ultrafine single fibers with a diameter of 50 nm or more and less than 1000 nm, and Pile yarn having, A base fabric to which multiple pile yarns are tufted and A mat equipped with [unclear] features.

[0097] [Aspect 2] The fineness of the aforementioned ultrafine fiber yarn is between 130 denier and 520 denier. The mat described in Embodiment 1.

[0098] [Aspect 3] In the pile yarn, the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn is 5% or more and 52% or less. The mat according to embodiment 1 or 2.

[0099] [Aspect 4] The fineness of the BCF single yarn is between 1 denier and 30 denier. A mat as described in any one of the embodiments 1 to 3.

[0100] [Aspect 5] The pile yarn comprises a first yarn formed by pre-twisting at least the BCF yarn and the ultrafine fiber yarn, a second yarn formed by pre-twisting at least the BCF yarn and the ultrafine fiber yarn, and a fusion yarn for fusing the first yarn and the second yarn together. The pile yarn is formed by twisting the first yarn, the second yarn, and the fused yarn together. A mat as described in any one of the embodiments 1 to 4.

[0101] [Aspect 6] The pile yarn comprises a first yarn in which at least the BCF yarn and the ultrafine fiber yarn are under-twisted, a second yarn containing at least the BCF yarn, and a fusion yarn for fusing the first yarn and the second yarn together. The pile yarn is formed by twisting the first yarn, the second yarn, and the fused yarn together. A mat as described in any one of the embodiments 1 to 4. [Explanation of Symbols]

[0102] 1: Matt 2: Mat raw material 3: Matte base material 10: Pile yarn 11: First yarn 12: Second yarn 13: Fused yarn 100: BCF yarn 101: Ultrafine fiber yarn 102: Monofilament 20: Base fabric

Claims

1. BCF yarn composed of multiple BCF single yarns, An ultrafine fiber filament composed of multiple ultrafine single filaments with a diameter of 50 nm or more and less than 1000 nm, and Pile yarn having, A base fabric to which multiple pile yarns are tufted and A mat equipped with [unclear] features.

2. The fineness of the aforementioned ultrafine fiber yarn is between 130 denier and 520 denier. The mat according to claim 1.

3. In the pile yarn, the ratio of the fineness of the ultrafine fiber yarn to the fineness of the BCF yarn is 5% or more and 52% or less. The mat according to claim 1 or 2.

4. The fineness of the BCF single yarn is between 1 denier and 30 denier. The mat according to claim 1 or 2.

5. The pile yarn comprises a first yarn formed by pre-twisting at least the BCF yarn and the ultrafine fiber yarn, a second yarn formed by pre-twisting at least the BCF yarn and the ultrafine fiber yarn, and a fusion yarn for fusing the first yarn and the second yarn together. The pile yarn is formed by twisting the first yarn, the second yarn, and the fused yarn together. The mat according to claim 1 or 2.

6. The pile yarn comprises a first yarn in which at least the BCF yarn and the ultrafine fiber yarn are under-twisted, a second yarn containing at least the BCF yarn, and a fusion yarn for fusing the first yarn and the second yarn together. The pile yarn is formed by twisting the first yarn, the second yarn, and the fused yarn together. The mat according to claim 1 or 2.

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