Rugs and methods for manufacturing rugs

Abstract

To provide a rug having sufficient anti-slip performance and excellent durability and lightweight properties.SOLUTION: Provided is a rug used as a floor pad or a bed pad, comprising an outer material 1 and a lining material made up of a three-dimensional knitted fabric 5, the three-dimensional knitted fabric 5 being provided with a pair of fabrics 51, 51 having a plurality of mesh cells and connecting fibers 52 connecting the fabrics 51, 51 to each other. A fiber diameter of fibers that make up the fabric 51 is 20 to 1,000 denier. A fiber diameter of fibers that make up the connecting fibers 52 is 10 to 1,200 denier. A back surface of the lining material has an anti-slip layer 6 made up of a thermoplastic adhesive. A ratio of the anti-slip layer 6 to the back surface of the lining material is 80 to 100%. The thermoplastic adhesive is a resin whose main component is SEBS (styrene-ethylene-butylene-styrene copolymer). A coating amount of the thermoplastic adhesive is 10 to 100 g / m2. A static friction coefficient of the back surface of the lining material is 1.5 to 1.8.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a rug having an anti-slip structure, and in particular to a mattress pad and a bed pad. [Background technology]

[0002] Conventionally, many mats such as mattress pads and bed pads have elastic rubber cords at the four corners to prevent them from slipping out of place during use, and the elastic rubber cords are attached to mattresses, futons, etc. However, elastic rubber cords are troublesome to attach and remove, and if the rubber bands stretch, they lose their effectiveness, etc. For this reason, anti-slip products that do not require elastic rubber cords have been developed in recent years.

[0003] On the other hand, for bedding such as mattress pads and bed pads, breathability is required, and three-dimensional knitted fabrics having a honeycomb structure, for example, have been used.

[0004] Patent Document 1 discloses a rug such as a mattress pad or bed pad that has a non-slip surface having a coating layer containing polyvinyl chloride or silicone on a three-dimensional or two-dimensional knitted fabric.

[0005] Patent Document 2 discloses a method for manufacturing a mat in which uneven anti-slip portions are easily provided in stripes on a substrate, the method comprising melting an anti-slip material, transporting the substrate with a transport roller, extruding the molten anti-slip material in the form of multiple stripes onto the surface of the transported substrate with an extrusion molding machine, and sandwiching each of the extruded stripes of anti-slip material and the substrate between the transport roller and an embossing roller while embossing each anti-slip material, thereby adhering the anti-slip material to the surface of the substrate.

[0006] Patent document 3 discloses an anti-slip mat comprising a mat layer made of a functional material and a back layer in which an anti-slip resin is backed by the mat layer and adheres to the floor surface, the mat being characterized in that a mesh fabric is interposed between the mat layer and the back layer, and the anti-slip resin is impregnated into the mesh fabric.

[0007] Patent Document 4 discloses a mat comprising an absorbent pad formed from knitted or nonwoven fabric made of absorbent fibers, and a breathable pad made of three-dimensional knitted fabric bonded to the back side of the absorbent pad directly or via another layer, the back side of the breathable pad being treated with an anti-slip coating or having an anti-slip sheet disposed thereon. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Utility Model Registration No. 3227068 [Patent Document 2] JP 2018-68624 A [Patent Document 3] JP 2018-93972 A [Patent Document 4] JP 2012-187380 A DISCLOSURE OF THEINVENTION [Problem to be solved by the invention]

[0009] The rug described in Patent Document 1 has an anti-slip layer containing polyvinyl chloride or silicon on the back of the three-dimensional knitted fabric, but polyvinyl chloride has durability problems because the layer is easily peeled off due to aging, and coatings containing silicon have the risk of the components dissolving during use and staining the fabric or structure that they come into contact with. The mats described in Patent Documents 2 and 3 have an anti-slip layer provided in stripes, i.e., partially, and have insufficient anti-slip performance. The mats described in Patent Documents 3 and 4 are impregnated with anti-slip liquid inside, and the anti-slip material cannot be sufficiently retained on the surface where it is most effective, so the anti-slip performance is insufficient, and there is a problem that if you try to retain enough anti-slip liquid on the surface, the amount of application is large, which increases costs and makes the mat heavy.

[0010] Therefore, an object of the present invention is to provide a carpet that has sufficient anti-slip performance over almost the entire back surface, and is excellent in durability and light weight. [Means for solving the problem]

[0011] The present invention relates to a rug for use in a mattress pad or bed pad, comprising a surface and a lining made of a three-dimensional knitted fabric, the three-dimensional knitted fabric comprising a pair of knitted fabrics having a plurality of meshes and connecting fibers connecting these knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier, the back surface of the lining has an anti-slip layer made of a thermoplastic adhesive, the ratio of the area of ​​the anti-slip layer to the area of ​​the knitted fabric on the back surface of the lining is 80 to 100%, the thermoplastic adhesive is a resin mainly composed of SEBS (styrene-ethylene-butylene-styrene copolymer), and the application amount of the thermoplastic adhesive is 10 to 100 g / m 2 and The thermoplastic adhesive has a viscosity of 3000 to 6000 mPa·s at 180° C., and a viscosity δ 1 Viscosity δ at 160°C for 2 The ratio δ 2 / δ 1 But it is 3 to 7,The thermoplastic adhesive does not penetrate inward through the openings in the knitted fabric, but solidifies while being retained on the back surface of the knitted fabric, and the static friction coefficient of the back surface of the lining is 1.5 to 1.8.

[0012] The term "main component" means that the component constitutes 50% by mass or more, 80% by mass or more, and preferably 90% by mass or more of the components forming the phase.

[0013] A "mattress pad" is a thin, flat mat or cushion that a person places under the body to sit or sleep on.

[0014] A "bed pad" is a thin, flat mat or cushion that a person places under the body to sleep.

[0015] A "rug" is something that a person places under something to sit or sleep on.

[0017] The present invention also relates to a method for producing a rug that is used for a mattress pad or a bed pad and has a static friction coefficient of 1.5 to 1.8 on the back surface, the rug having a front surface and a back surface made of a three-dimensional knitted fabric, the three-dimensional knitted fabric having a pair of knitted fabrics with a plurality of meshes and connecting fibers connecting the knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier, the method further comprising the steps of: a sewing process for quilting the front surface and the back surface; and after the sewing process, applying a thermoplastic adhesive melt-extruded in stripes to the back surface of the knitted fabric on the back side through a roller heated to a predetermined temperature in an amount of 10 to 100 g / m. 2 and a cooling step of cooling the applied thermoplastic adhesive, the thermoplastic adhesive being a resin containing SEBS (styrene-ethylene-butylene-styrene copolymer) as a main component. The thermoplastic adhesive has a viscosity of 3000 to 6000 mPa·s at 180° C., and a viscosity δ 1 Viscosity δ at 160°C for 2 The ratio δ 2 / δ 1 But it is 3 to 7,In the cooling step, the thermoplastic adhesive does not permeate inward through the openings in the knitted fabric, but solidifies while being retained on the back surface of the knitted fabric.

[0018] In the coating step, the thermoplastic adhesive in a molten state at the predetermined temperature of the roller preferably has a viscosity of 2000 to 6000 mPa·s. Effect of the Invention

[0019] According to the present invention, the anti-slip layer mainly composed of SEBS is applied almost uniformly to the back surface of the three-dimensional knitted fabric of the lining and remains on the surface, so that the anti-slip effect can be obtained efficiently with a light weight. The breathability of the three-dimensional knitted fabric is not impaired by the anti-slip layer, and high breathability can be maintained. [Brief description of the drawings]

[0020] [Figure 1] FIG. 2 is a cross-sectional view of the rug of the present embodiment. [Diagram 2] FIG. 2 is a surface view of the carpet of the present embodiment. [Diagram 3] FIG. 2 is a rear view of the rug of the present embodiment. [Figure 4] FIG. 2 is an enlarged view of the underside of the rug of this embodiment. [Diagram 5] FIG. 2 is an enlarged view of the underside of the rug of this embodiment. [Figure 6] 1 is a roller coating apparatus for carpets according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The inventors have discovered that by applying a predetermined amount of a thermoplastic adhesive whose main component is a SEBS (styrene-ethylene-butylene-styrene) copolymer to almost the entire surface of the lining fabric at a temperature that results in a predetermined viscosity range and then quickly solidifying it, the thermoplastic adhesive is more likely to remain on the surface of the backing fabric, resulting in a high static friction coefficient.

[0022] A rug 1 according to an embodiment of the present invention will be described with reference to Figs. 1 to 5. The rug 1 according to this embodiment is used for a mattress pad or a bed pad. As shown in Fig. 1, the rug 1 comprises a surface 2, a cushion layer 3, a nonwoven fabric 4, and a lining composed of a three-dimensional knitted fabric 5. The three-dimensional knitted fabric 5 comprises a pair of knitted fabrics 51, 51 having a plurality of meshes, and a connecting fiber 52 connecting these knitted fabrics. As shown in Figs. 2 to 5, the rug 1 is provided with quilting 7 that forms regular wavy lines using sewing thread. The lining composed of the surface 2, the cushion layer 3, the nonwoven fabric 4, and the three-dimensional knitted fabric 5 is sewn together at a seam 11 at its periphery.

[0023] In this embodiment, the three-dimensional knitted fabric 5 has a honeycomb structure, and the knitted fabrics 51, 51 and the connecting fibers 52 are both made of polyester resin. The fiber diameter of the fibers constituting the knitted fabrics 51, 51 is preferably 20 to 1000 denier, more preferably 50 to 400 denier. The fiber diameter of the fibers constituting the connecting fibers 52 is preferably 10 to 1200 denier, more preferably 20 to 300 denier.

[0024] The three-dimensional knitted fabric 5 is commercialized by various textile manufacturers, and examples of such products include FUSION (registered trademark) by Asahi Kasei, "Cubic Eye (registered trademark)" by Unitika Co., Ltd., "Swing Net (registered trademark)" by Suminoe Textile Co., Ltd., and "Fusion (registered trademark)" by Asahi Kasei Fibers Co., Ltd. In the present invention, the three-dimensional knitted fabrics of the above companies can be used.

[0025] Examples of the three-dimensional knitted fabric 5 include those described in Nos. 4972080, 5551890, 3943011, 4001890, 4646821, JP-A-10-102363, JP-A-2002-138352, JP-A-02-74648, etc., but are not limited thereto. The thickness is preferably 2 mm to 12 mm, more preferably 3 mm to 8 mm. The air permeability is 50 cc / cm 2 / sec or more, weight is 100~2000g / cm 2, density is 0.02~0.2g / cm 3 The compressive elastic modulus is preferably 20 to 200 N / mm.

[0026] The area ratio of the knitted fabric 51 on the back side of the three-dimensional knitted fabric 5 to the entire area, i.e., the ratio of the area of ​​the knitted fabric 51 to the combined area of ​​the knitted fabric 51 and the openings 53 surrounded by the knitted fabric 51, is preferably 10 to 90%, and more preferably 10 to 30%, in consideration of breathability, etc. The three-dimensional knitted fabric 5 has high breathability, elasticity, and shape retention due to its structure.

[0027] An anti-slip layer 6 of generally uniform thickness is provided over the entire back surface of the knitted fabric 51 on the back side of the three-dimensional knitted fabric 5. The thickness of the anti-slip layer 6 is preferably 10 to 110 μm. The three-dimensional knitted fabric 5 maintains high breathability, while the anti-slip layer 6 held on its back surface and the three-dimensional structure of the three-dimensional knitted fabric 5 provide a high anti-slip effect.

[0028] The anti-slip layer 6 is a thermoplastic adhesive material (hereinafter also referred to as SEBS resin) whose main component is SEBS (styrene-ethylene-butylene-styrene block copolymer), and contains mineral oil as a softener. An antioxidant may also be added to the SEBS resin. As will be described in detail later, the anti-slip layer 6 is formed by applying the SEBS resin to the back surface of the three-dimensional knitted fabric 5 with a roller, and the amount of SEBS resin applied is 10 to 100 g / m. 2 is preferable, and 10 to 60 g / m 2 If the amount of application is less than the above range, the anti-slip performance becomes insufficient, whereas if the amount of application is more than the above range, it takes a long time to cool and dry, resulting in a problem that the coating is difficult to remain on the surface of the knitted fabric 51.

[0029] The softening point of the SEBS resin used in this embodiment is preferably 110 to 140° C., and more preferably 120 to 130° C. The softening point is measured by the test method defined by ASTM-E28. The viscosity of the SEBS resin in a molten state is preferably 2000 to 33000 mPa s at 120 to 205° C.

[0030] The viscosity of the SEBS resin in a molten state is preferably 3000 to 6000 mPa·s at 180°C, and 10000 to 33000 mPa·s at 160°C. If the viscosity is low at high temperatures, the extruded SEBS resin is likely to spread between the rollers and on the fabric in the roller application process described below. After application from the roller to the fabric, that is, at low temperatures, the higher the viscosity, the more likely the resin will remain on the surface of the knitted fabric 51 of the three-dimensional knitted fabric 5 and will not penetrate into the interior through the openings 53. Therefore, the temperature dependency of the viscosity is important, and the ratio δ2 / δ1 of the viscosity at 160°C to the viscosity δ1 at 180°C is preferably 3 to 7. The viscosity can be measured using a Brookfield viscometer LVF (manufactured by Brookfield) at an appropriate speed using a No. 34 spindle.

[0031] The area ratio of the anti-slip layer 6 to the entire back surface of the back knitted fabric, i.e., the surface that comes into contact with a mattress, futon, or the like placed underneath, per unit area is preferably 80% or more, and more preferably 90 to 100%. In other words, it is preferable that the anti-slip layer is provided on substantially the entire surface of the knitted fabric 51.

[0032] The static friction coefficient of the underside of the carpet according to the present invention is preferably 1.5 to 1.8, and more preferably 1.6 to 1.7. It is measured by the method for measuring the static friction coefficient described below. If the static friction coefficient is less than 1.5, the anti-slip effect is insufficient.

[0033] The nonwoven fabric 4 is a short fiber nonwoven fabric made of polyester fibers, and is provided to prevent the filling from the cushion layer 3 from coming out.

[0034] The cushion layer 3 is intended to enhance cushioning properties and is made of polyester fibers.

[0035] Next, a method for manufacturing the floor covering 1 according to the present invention will be described with reference to FIG.

[0036] (Sewing and quilting process) First, the outer fabric 2, the cushion layer 3, the nonwoven fabric 4, and the three-dimensional knitted fabric 5 are prepared and sewn together. Specifically, first, the edges on both sides parallel to the direction of application of the anti-slip layer (described later) are sewn together and quilted. It is preferable to perform the quilting process before applying the anti-slip layer. This is because if the quilting process is performed after the anti-slip layer application process, resin will adhere to the needles and interfere with the quilting process.

[0037] (Anti-slip layer coating process) Next, the SEBS resin is roller-coated. FIG. 6 is a diagram for explaining the roller coating device 8. The fabric after the quilting process is held as a roll 81, and is pulled and moved on a conveyor 82. On the conveyor 82, the lining, i.e., the back knitted fabric 51 of the three-dimensional knitted fabric 5, moves on the upper side. A resin extrusion device 83 is disposed above the conveyor area. The resin extrusion device 83 extrudes molten SEBS resin in stripes from a plurality of discharge ports 831 provided at the lower part thereof at a discharge temperature of 180 to 205°C, more preferably 200 to 205°C. If the discharge temperature exceeds 205°C, yellowing or charring is likely to occur, which is not preferable.

[0038] Below the discharge port 831 of the resin extrusion device 83, there are a main roller 84 and an auxiliary roller 85, which are maintained at a predetermined roller temperature. The surface temperatures of the main roller 84 and the auxiliary roller 85 are each preferably 160 to 180°C, and are set to about 180°C in this embodiment. The viscosity of SEBS resin at 180°C is 3000 to 6000 mPa·s, and a plurality of SEBS resin stripes extruded from the discharge port 831 of the resin extrusion device 83 are spread between the main roller 84 and the auxiliary roller 85, and are applied in a planar manner to the entire back surface of the knitted fabric 51 via the main roller 84 and the auxiliary roller 85. The fabric passes between the rubber roller 87 and the main roller 84, so that the SEBS resin is adhered to the entire fabric.

[0039] (cooling process) The temperature of the SEBS resin immediately after it is applied to the fabric is 160°C, and thereafter, pressure is applied between cooling roller 88 and rubber roller 87, and then it is rapidly cooled and solidified by cooling fan 89. Here, the viscosity of SEBS resin at 160°C is 10,000 to 33,000 mPa·s, and the time it takes to cool and solidify after application to the fabric is 2 to 10 seconds, preferably 2 to 5 seconds, so that the SEBS resin applied to the back surface of knitted fabric 51 solidifies without penetrating inward through openings 53, and remains solidified while being held over the entire back surface of knitted fabric 51.

[0040] (cutting process) The cooled fabric is cut to length and the edges are sewn together.

[0041] In this way, in the present invention, the anti-slip layer does not penetrate into the knitted fabric, but remains sufficiently on the most important surface, thereby realizing a high coefficient of friction. To achieve this, the SEBS resin in a molten state is heated at a temperature of 10 to 100 g / m2 with a roller set at a temperature where the SEBS resin has a predetermined viscosity range (preferably 2000 to 6000 mPa s). 2 Since the viscosity of the SEBS resin at the roller temperature is within the above range, the resin extruded in stripes tends to spread out over the entire surface, and is less likely to penetrate into and permeate the openings 53 of the three-dimensional knitted fabric 5, and tends to remain on the surface of the back knitted fabric 51. EXAMPLES

[0042] Examples of the present invention will be described in detail below, but the present invention is not limited to these Examples. The static friction coefficients in the examples were measured as follows.

[0043] (Measurement of static friction coefficient) The sample (20cm x 30cm) is placed on the futon mattress with the lining facing downwards. A load of 8kg is evenly applied on top of it, and it is pulled with a push-pull gauge. The force at which it starts to move is measured, and the coefficient of friction is calculated. The test is performed five times, and the average value is used as the measured value. The futon mattress used is made of polyester fiber, and specifically, a futon mattress made by Cainz Corporation ("Compactly storable futon mattress single", product code 4549509507871, outer fabric: 100% polyester, inner material: 100% polyester) was used.

[0044] Example 1 The outer layer, cushion layer, nonwoven fabric, and honeycomb mesh structure were sewn and quilted together to create a 6mm thick three-dimensional knitted fabric. The SEBS-based resin was then applied by roller coating to produce a mattress pad. The amount of resin applied was 30g / m2. 2 The resin, whose main component is SEBS, had a softening point of 125°C, a viscosity of 3300 mPa·s at 180°C, and a viscosity of 10000 mPa·s at 160°C. The discharge temperature was 200-205°C, and the temperatures of the main roller and auxiliary roller were 180°C. Measurements of the static friction coefficient of the manufactured mattress pad showed that the start-up force was 139.6 N (average value of n=5 test results: 143.8 N, 135.9 N, 139.0 N, 138.5 N, 140.6 N), and the static friction coefficient was 1.7.

[0045] Comparative Example 1 A test was conducted to measure the static friction coefficient of a non-slip pad made by another company. The non-slip treatment was done by processing silicone resin into dots. The static friction coefficient of the pad of Comparative Example 1 was measured, and the force required to start slipping was 78.3N (average value of 76.4N, 77.0N, 79.9N, 78.0N, and 80.0N for n=5 tests), and the static friction coefficient was 1.0.

[0046] Comparative Example 2 A test was conducted to measure the static friction coefficient for a non-slip bed pad made by another company other than Comparative Example 1. The non-slip treatment was done by processing acrylic resin into dots. The static friction coefficient of the bed pad of Comparative Example 2 was measured, and the force required to start slipping was 101.6N (average value of n=5 test results: 106.8N, 102.6N, 103.4N, 96.5N, 98.5N), and the static friction coefficient was 1.3. [Explanation of symbols]

[0047] 1. Rugs 2. Outer material 3. Cushion layer 4. Nonwoven fabric 5. Three-dimensional knitting 51... Knitted fabric 52... Interlocking Fibers 6. Anti-slip layer 7. Quilting 8. Roller coating device 11...suture area 82...Conveyor 83 Resin extrusion device 831...Discharge port 84 Main roller 85 Auxiliary roller 88. Laura 89...Cooling fan

Claims

1. A rug having a surface and a lining made of a three-dimensional knitted fabric, the rug being used as a mattress pad or a bed pad, The three-dimensional knitted fabric comprises a pair of knitted fabrics having a plurality of meshes and connecting fibers connecting these knitted fabrics, the fiber diameter of the fibers constituting the knitted fabrics is 20 to 1000 denier, and the fiber diameter of the fibers constituting the connecting fibers is 10 to 1200 denier, The back surface of the backing has an anti-slip layer made of a thermoplastic adhesive material, The ratio of the area of ​​the anti-slip layer to the area of ​​the knitted fabric on the back surface of the lining is 80 to 100%; The thermoplastic adhesive is a resin mainly composed of SEBS (styrene-ethylene-butylene-styrene copolymer), The amount of the thermoplastic adhesive applied is 10 to 100 g / m ２ and The thermoplastic adhesive has a viscosity at 180° C. of 3000 to 6000 mPa·s, and a ratio δ 2 / δ 1 of the viscosity δ 2 at 160° C. to the viscosity δ 1 at 180° C. is 3 to 7; The thermoplastic adhesive does not permeate inward through the openings of the knitted fabric, but is solidified while being held on the back surface of the knitted fabric; The static friction coefficient of the back surface of the backing is 1.5 to 1.

8.

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

3. In the application step, the viscosity of the thermoplastic adhesive in a molten state at the predetermined temperature of the roller is 2000 to 6000 mPa·s. A method for producing the carpet of claim 2.

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