mat
The mat design with crimped and twisted filaments enhances mud removal by using protrusions and recesses, addressing the inefficiencies of existing mats in scraping dirt from shoe soles.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- DUSKIN CO LTD
- Filing Date
- 2024-11-07
- Publication Date
- 2026-05-19
AI Technical Summary
Existing shoe cleaning mats lack sufficient scraping properties to effectively remove dirt, particularly mud, from shoe soles.
A mat design featuring single filaments with a base portion and protrusions, and recesses between adjacent protrusions, tufted onto a base fabric, where the filaments are crimped and twisted to enhance scraping performance.
The mat effectively scrapes off mud from shoe soles and collects it in recesses, improving dirt removal efficiency and maintaining rigidity and durability through specific filament fineness and crimping methods.
Smart Images
Figure 2026082352000001_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to a mat.
Background Art
[0002] Patent Document 1 discloses a shoe cleaning mat.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] According to Patent Document 1, the shoe cleaning mat is composed of a base cloth and mat pile implanted in the base cloth. The mat pile consists of cut pile of a bundle of nylon monofilaments. The cut pile is loosened to individual monofilaments, and the tips of the monofilaments are directed in random directions. According to the shoe cleaning mat of Patent Document 1, the scraping property of dirt such as mud adhering to the shoe sole is good, but there is room for improvement from the viewpoint of further improving the scraping property.
[0005] An object of this disclosure is to provide a mat capable of improving the scraping property of dirt such as mud.
Means for Solving the Problems
[0006] This disclosure is [[ID=四十七]] a single filament having a fineness of 400 to 1200 decitex, and in a cross section orthogonal to the extension direction of the single filament, having a base portion and a plurality of protrusions protruding outward from the base portion of the single filament, and a recess is provided between adjacent protrusions, the single filament, a base cloth on which a plurality of the single filaments are tufted and has a mat stock We provide a mat equipped with the following features.
[0007] According to the mat disclosed herein, each single yarn has a base and a projection, with recesses provided between adjacent projections. Therefore, when the mat is stepped on with shoes, mud from the soles of the shoes can be scraped off by the projections of the single yarns and collected in the recesses. As a result, the ability to scrape off dirt such as mud can be improved compared to conventional shoe-wiping mats. [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 figure schematically shows the structure of a single yarn according to the first embodiment. [Figure 3a] This figure shows an example of the cross-sectional structure of a monofilament. [Figure 3b] This figure shows another example of the cross-sectional structure of a monofilament. [Figure 3c] This figure shows another example of the cross-sectional structure of a monofilament. [Figure 3d] This figure shows another example of the cross-sectional structure of a monofilament. [Figure 4] This figure schematically shows the structure of a single yarn according to the second embodiment. [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 in this embodiment is an exterior mat laid on the outside of a building entrance. The mat 1 may also be used for other purposes, such as at the entrance to a kitchen.
[0011] The mat 1 has a mat base 2 that is stepped on by the user and a mat base material 3 that is in contact with the floor surface. The mat base 2 has a plurality of twisted yarns 10 and a base fabric 20 to which the plurality of twisted yarns 10 are tufted. The mat base 2 is bonded onto the mat base material 3. In this embodiment, the mat base material 3 is a rubber sheet. The mat base material 3 may also be a plastic board. The base fabric 20 is, for example, a nonwoven fabric containing polyester.
[0012] Figure 2 schematically shows the structure of the twisted yarn 10 according to the first embodiment. The twisted yarn 10 is composed of four single yarns 100. At the tip end of the twisted yarn 10 (side A1 in Figure 2), the four single yarns 100 are separated from each other, while at the base end end of the twisted yarn 10 (side A2 in Figure 2), the four single yarns 100 are twisted together. The number of single yarns 100 constituting the twisted yarn 10 is not limited to four. The twisted yarn 10 can be composed of two or more single yarns 100 twisted together. For example, the number of single yarns 100 may be three, five, six, eight, or ten. In order for the single yarns 100 to be easily tufted onto the base fabric 20, it is preferable that the single yarns 100 be tufted onto the base fabric 20 as the twisted yarn 10.
[0013] The single yarn 100 is a so-called monofilament containing a resin such as nylon, polyester, acrylic, or polypropylene. By including the above materials in the single yarn 100, the mat 1 can advantageously scrape off mud and other debris from shoe soles. To withstand the heat generated during the manufacturing process of the mat 1, it is preferable that the single yarn 100 contains nylon, polyester, or acrylic. If the mat is to be used in heavy foot traffic applications or if it is expected to be washed, it is preferable that the single yarn 100 is nylon from the viewpoint of durability. More preferably, the single yarn 100 contains nylon 6 or nylon 66. Since nylon 6 or nylon 66 has weather resistance and chemical resistance, even if the mat is repeatedly washed, the single yarn 100 containing nylon 6 or nylon 66 is less likely to shrink and less likely to be damaged.
[0014] To ensure high scraping performance by maintaining the rigidity of the single yarn 100, the fineness of the single yarn 100 is preferably between 400 decitex (dt) and 1200 decitex (dt). Increasing the fineness of the single yarn 100 above 1200 dt is difficult from a manufacturing standpoint. To stably produce the single yarn 100, the fineness of the single yarn 100 is preferably 1100 dt or less.
[0015] As shown in Figure 2, the four single filaments 100 are each crimped so that they vibrate in a direction intersecting (for example, perpendicular to) the extension direction of the single filament 100 (direction A in Figure 2). The four single filaments 100 are crimped by a shaping method, specifically the knit-de-knit method, while the four single filaments 100 are twisted together. The shaping method (knit-de-knit method) is a known crimping method, disclosed, for example, in Japanese Patent Publication No. 53-024452. The four single filaments 100 crimped by the shaping method are crimped with similar regularity to one another. As shown in Figure 2, the vibration shape (i.e., wave shape) of the four single filaments 100 are similar to one another, and their phases are also similar.
[0016] In order for the twisted yarn 10 to be easily tufted onto the base fabric 20, the crimp rate of the single yarn 100 is preferably 2% or more. Furthermore, in order to maintain scrapability, the crimp rate of the single yarn 100 is preferably 15% or less. From the viewpoint of the crimp rate achieved by the crimping method and from the viewpoint of further improving scrapability, the crimp rate of the single yarn 100 is preferably 4% to 8%, with 6% being the most preferred. Note that the crimp rate in this specification is a value measured based on the chemical fiber staple test method specified in JIS L 1015.
[0017] Figure 3a shows a cross-sectional view in a direction orthogonal to the extension direction A of the single filament 100. As shown in Figure 3a, the cross-sectional shape of the single filament 100 is a star shape. The single filament 100 has a base portion 100a that forms the main body of the single filament 100, and a protrusion portion 100b that protrudes outward (in a direction orthogonal to direction A). In Figure 3a, five protrusion portions 100b are provided. The five protrusion portions 100b are provided at equal intervals in the circumferential direction (with direction A as the rotation axis). The arrangement of the protrusion portions 100b does not have to be at equal intervals. When the mat 1 is stepped on by a shoe, the mud on the sole of the shoe is scraped off by the protrusion portions 100b.
[0018] The width of the protrusion portion 100b (the dimension in the circumferential direction with direction A as the rotation axis) becomes smaller as it goes outward. In other words, the protrusion portion 100b has a tapered shape that tapers toward the outside. Thereby, the protrusion portion 100b can scrape off the mud adhering to the sole of the shoe more advantageously.
[0019] By providing a plurality of protrusion portions 100b, a recess 100c is provided between adjacent protrusion portions 100b. The recess 100c is defined by two adjacent protrusion portions 100b and the base portion 100a therebetween. The recess 100c can collect the mud scraped off by the protrusion portions 100b. Thereby, the scraping property of the mat 1 is further improved. The recess 100c in this specification means, for example, the space between two protrusion portions 100b provided when the angle between two adjacent protrusion portions 100b is less than 180°. However, when the shape of the protrusion portion 100b is a tapered shape that widens toward the outside, even if the angle between two adjacent protrusion portions 100b is 180°, a recess 100c can be defined in the space between the two protrusion portions 100b.
[0020] The cross-sectional shape of the single filament 100 is not limited to that shown in Figure 3a. The cross-sectional shape of the single filament 100 may be a shape having four protrusion portions 100b shown in Figure 3b, a shape having three protrusion portions 100b shown in Figure 3c, or a gear shape shown in Figure 3d. The number of the protrusion portions 100b only needs to be two or more as long as a recess 100c is formed between the protrusion portions 100b.
[0021] Next, the manufacturing method for mat 1 will be described. The single yarn 100 described above is crimped in a state in which multiple yarns are twisted together, that is, in the state of twisted yarn 10. The crimped twisted yarn 10 is tufted onto the base fabric 20 so as to form a cut pile in mat 1. Since the twisted yarn 10 (single yarn 100) is crimped, the tufting process can be easily carried out.
[0022] After a portion of the twisted yarn 10 is pressed, the unvulcanized rubber sheet, which is a precursor of the mat base material 3, is pressed onto the base fabric 20 and vulcanized to obtain the rubber sheet mat base material 3. In this process, the temperature of the mat 1 can rise to 190°C. In this embodiment, since the single yarn 100 contains nylon, polyester, or acrylic, the single yarn 100 is less susceptible to damage by this process.
[0023] According to the mat 1 of the first embodiment, the following effects are achieved.
[0024] (1) Mat 1 is A single yarn 100 having a fineness of 400 decitex or more and 1200 decitex or less, wherein in a cross section perpendicular to the extension direction A of the single yarn 100, it has a base portion 100a and a plurality of protrusions 100b projecting outward from the base portion 100a, and recesses 100c are provided between adjacent protrusions 100b, and A base fabric 20 to which multiple single yarns 100 are tufted and Mat raw material 2 It is equipped with.
[0025] As a result, the mud on the sole of the shoe is scraped off by the protrusions 100b and collected in the recesses 100c, thus improving the scraping ability of the mat 1. In addition, since the fineness of the single yarn 100 is between 400dt and 1200dt, the rigidity of the single yarn 100 is ensured, and as a result, the mud can be scraped off advantageously.
[0026] (2) The crimp rate of single yarn 100 is 2% or more and 15% or less. By setting the crimp rate of the single yarn 100 to 2% or more, the single yarn 100 can be easily tufted onto the base fabric 20. Furthermore, by setting the crimp rate of the single yarn 100 to 15% or less, the scraping properties of the mat 1 can be maintained.
[0027] (3) Single yarn 100 contains nylon, polyester, acrylic, or polypropylene.
[0028] As a result, mat 1 may have an advantage in scraping off the mud.
[0029] (4) Single yarn 100 contains nylon 6 or nylon 66. As a result, sufficient durability can be provided when the mat is used in heavy-duty applications or when it is expected to be washed.
[0030] (5) The mat roll 2 has a twisted yarn 10 made by twisting together two or more single yarns 100. As a result, the single yarn 100 can be easily tufted onto the base fabric 20 by being twisted together as a twisted yarn 10.
[0031] [Second Embodiment] Figure 4 shows a schematic configuration of the twisted yarn 11 according to the second embodiment. In the second embodiment, the shapes of the four single yarns 100 that make up the twisted yarn 11 are different from each other. The single yarns 100 according to the second embodiment are also crimped in the same way as the single yarns 100 according to the first embodiment, but the crimping method is different from that of the first embodiment.
[0032] In the second embodiment, the single yarn 100 is crimped by a pressing method, specifically an air jet method, while four single yarns 100 are twisted together. The pressing method (air jet method) is a known crimping method, disclosed, for example, in Japanese Patent Application Publication No. 48-054247. The four single yarns 100 crimped by the pressing method are crimped to have a random orientation. As shown in Figure 4, the wave shape (i.e., wave shape) and phase of the four single yarns 100 are different from each other.
[0033] Generally, to produce single yarns crimped with a relatively low crimping rate, crimping by the pressing method is preferable to crimping by the shaping method. Furthermore, regardless of the crimping method used, the single yarn 100 can be easily tufted onto the base fabric 20 and maintain its scrapability.
[0034] Next, we will describe the test results conducted to verify the scraping ability of the mat 1 of this embodiment.
[0035] First, three mats were prepared for each example (or comparative example). Each example and comparative example shared the same base fabric and mat substrate, but differed in the composition of the single yarns (see Table 1 below).
[0036] Next, the cylindrical clay is cut into 3 cm lengths, the cut circular cross-sections are polished, and the initial weight is measured. The clay has a hardness of 82 at a temperature of 25°C, as measured by an Asker C-type durometer in accordance with JIS K 7312. The clay is the test piece scraped onto the mat of the example (or comparative example) in this test.
[0037] Next, the clay was placed on the mat so that its polished circular cross-section was in contact with the single filaments on the mat, and a 1 kg weight was then placed on top of the clay. After that, the clay and weight were moved back and forth 10 times horizontally across a distance of 30 cm relative to the mat. The weight of the clay after the movement was measured, and the difference from the initial weight was calculated. This difference was defined as the amount scraped off.
[0038] The above test was conducted using three mats prepared for each example (or comparative example), and the average of the three scraped amounts was taken as the scraped amount for each example (or comparative example). Table 1 shows the specifications of the single yarns used in each example and comparative example and the test results.
[0039] [Table 1]
[0040] The single yarns in Examples 1 to 3 correspond to the single yarn 100 according to the second embodiment, which is crimped by the pressing method. The single yarns in Examples 4 to 6 correspond to the single yarn 100 according to the first embodiment, which is crimped by the shaping method. The cross-sectional shape of the single yarns in Examples 1 to 6 is the star shape shown in Figure 3a.
[0041] The mat in the comparative example is a conventional mat. The fineness of the single yarn in the comparative example is 300 dt, which is smaller than the fineness of the single yarns in Examples 1 to 6. The single yarn in the comparative example is crimped by a pressing method. Furthermore, the single yarn in the comparative example has a triangular cross-sectional shape, meaning it does not have the recesses provided in the single yarn of this embodiment.
[0042] The crimp rate in Table 1 represents the crimp rate measured according to the method described herein. The scraping rate represents the ratio of the amount scraped from the mat in each example to the amount scraped from the mat in the comparative example.
[0043] The scraping rates in Examples 1-6 were higher than those in the comparative example. Furthermore, magnified observation of the single filaments after conducting this test confirmed that the scraped clay was collected in the depressions of the single filaments in Examples 1-6.
[0044] Comparing Example 1 and Example 3, which use the same crimping method and have almost the same crimping rate, the scraping rate of Example 3, which has a higher single-fiber fineness, is higher than that of Example 1, which has a lower single-fiber fineness. Furthermore, comparing Example 1 and Example 2, which use the same crimping method and have the same fineness, the scraping rate of Example 1, which has a lower crimping rate, is higher than that of Example 2, which has a higher crimping rate.
[0045] From the above test results, it was found that scraping performance is improved by creating a recess in the cross-section of the single yarn, by increasing the fineness of the single yarn, by lowering the crimping rate of the single yarn, and that scraping performance can be maintained regardless of whether the crimping method or the shaping method is used.
[0046] Furthermore, the mat 1 relating to this disclosure is not limited to the configuration of the above embodiment, and various modifications are possible.
[0047] The twisted yarn 10 tufted onto the base fabric may form loop piles. The twisted yarn 10 may also form a combination of cut piles and loop piles.
[0048] The single yarn may be crimped by other crimping methods. For example, the single yarn may be crimped by a twisting crimping method such as the false twist method or the Kennel method, a non-twisting crimping method such as the abrasion method, the gear method or the mechanical method, a non-stretchable crimping method, or a non-bulky crimping method.
[0049] [Note] The mat relating to this disclosure provides the following aspects.
[0050] [Aspect 1] A single yarn having a fineness of 400 decitex or more and 1200 decitex or less, wherein in a cross section perpendicular to the extension direction of the single yarn, it has a base and a plurality of protrusions projecting outward from the base, and recesses are provided between adjacent protrusions, and the single yarn and A base fabric to which multiple single yarns are tufted Mat raw material having A mat equipped with [unclear] features.
[0051] [Aspect 2] The crimp rate of the aforementioned single yarn is between 2% and 15%. The mat described in Embodiment 1.
[0052] [Aspect 3] The aforementioned single yarn includes nylon, polyester, acrylic, or polypropylene. The mat according to embodiment 1 or 2.
[0053] [Aspect 4] The aforementioned single yarn includes nylon 6 or nylon 66. The mat described in aspect 3.
[0054] [Aspect 5] The aforementioned matting has a twisted yarn formed by twisting together two or more of the aforementioned single yarns. A mat as described in any one of the embodiments 1 to 4. [Explanation of Symbols]
[0055] 1: Matt 2: Mat raw material 3: Matte base material 10, 11: Twisted yarn 100: Single yarn 100a: Base 100b:Protrusion 100c: recess 20: Base fabric
Claims
1. A single yarn having a fineness of 400 decitex or more and 1200 decitex or less, wherein in a cross section perpendicular to the extension direction of the single yarn, it has a base and a plurality of protrusions projecting outward from the base, and recesses are provided between adjacent protrusions, and the single yarn and A base fabric to which multiple single yarns are tufted Mat raw material having A mat equipped with [unclear] features.
2. The crimp rate of the aforementioned single yarn is 2% or more and 15% or less. The mat according to claim 1.
3. The aforementioned single yarn includes nylon, polyester, acrylic, or polypropylene. The mat according to claim 1 or 2.
4. The aforementioned single yarn includes nylon 6 or nylon 66. The mat according to claim 3.
5. The aforementioned matting has a twisted yarn formed by twisting together two or more of the aforementioned single yarns. The mat according to claim 1.