Mat and method for manufacturing the same

Abstract

To provide a mat having sufficient strength, while maintaining flameproofness and capable of exerting antiviral properties, and manufacturing method of the mat.SOLUTION: A mat is formed by attaching a plaster component to a nonwoven web containing polyester fibers, where a needle punch density of the polyester fiber is 80 kg / m3 or more and 120 kg / m3 or less, and a basis weight of at least one of calcium hydroxide and calcium carbonate derived from the plaster component per 1 m2 of the nonwoven web is 50 g / m2 or more and 400 g / m2 or less.SELECTED DRAWING: None

Description

Technical Field

[0001] The present invention relates to a mat installed at the entrance of a building, the entrance of a hospital room, etc., and a method for manufacturing the same.

Background Art

[0002] Conventionally, various proposals have been made regarding techniques for imparting deodorizing properties and antibacterial properties to fiber materials such as non-woven fabrics. For example, Patent Document 1 discloses a method for manufacturing a deodorizing fabric in which a deodorant A containing a metal hydroxide and an amine compound is attached to a fabric containing organic fibers via a synthetic resin binder B having an acid value of 5 mgKOH / solid content g to 600 mgKOH / solid content g. The deodorizing fabric obtained by this manufacturing method exhibits excellent deodorizing properties against acetic acid and acetaldehydes, which are the main components of tobacco odor. Further, Patent Document 2 discloses a polyester-based fiber fabric coated with a plaster obtained by adding and mixing sodium polyborate to a plaster composition mainly composed of calcium hydroxide and containing a thickener, a fibrous substance, and a dispersant. This polyester-based fiber fabric has flame retardancy and non-combustibility in addition to antibacterial and deodorizing properties.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0004] In Patent Document 1, although the deodorizing properties of the fabric have been studied, the strength, flame retardancy, and antiviral properties of the fabric have not been studied. Further, in Patent Document 2, although the deodorizing properties, flame retardancy, and non-combustibility of the polyester-based fiber fabric have been studied, the strength and antiviral properties of the polyester-based fiber fabric have not been studied.

[0005] For the fabric as described above, sufficient strength has been required in order to stably exhibit anti-inflammatory properties after installation and to withstand long-term use. Further, for the fabric as described above, antiviral properties have been required in order not to be mediated by viruses.

[0006] The present invention has been made in view of the above circumstances, and an object thereof is to provide a mat that retains anti-inflammatory properties, has sufficient strength, and can exhibit antiviral properties, and a method for manufacturing the same.

Means for Solving the Problems

[0007] In order to solve the above problems, the present invention has the following aspects. [1] A mat formed by attaching a plaster component to a nonwoven web containing polyester fibers, wherein the needle punch density of the polyester fibers is 80 kg / m 3 or more and 120 kg / m 3 or less, and the basis weight of at least one of calcium hydroxide and calcium carbonate derived from the plaster component per 1 m 2 of the nonwoven web is 50 g / m 2 or more and 400 g / m 2 or less. [2] Having a base fabric joined to the nonwoven web, wherein the base fabric is composed of a fiber woven fabric, the mat according to [1]. [3] Having a flame retardant-containing resin layer between the nonwoven web and the base fabric, the mat according to [2]. [4] A method for manufacturing the mat according to any one of [1] to [3], comprising a step of applying a paint containing a plaster component to a nonwoven web, and a step of drying the nonwoven web to which the paint has been applied. [5] The method for manufacturing the matte according to [4], wherein the paint is an aqueous paint containing at least one of calcium hydroxide and calcium carbonate, a carboxy group-containing dispersion resin, an alkali metal compound, a compound having an amino group and an acid group, and water. [6] The method for manufacturing the matte according to claim [4] or [5], wherein the paint contains at least one of a thickener and a binder resin. [Advantages of the Invention]

[0008] According to the present invention, it is possible to provide a matte having sufficient strength while retaining anti-inflammatory properties and capable of exhibiting antiviral properties, and a method for manufacturing the same. [Embodiments for Carrying Out the Invention]

[0009] Embodiments of the matte of the present invention will be described. It should be noted that this embodiment is specifically described to better understand the gist of the invention, and does not limit the present invention unless otherwise specified.

[0010] [Matte] The matte of this embodiment is a matte in which a plaster component adheres to a nonwoven web. The nonwoven web contains polyester fibers.

[0011] The shape of the matte of this embodiment is not particularly limited. For example, in a plan view, a square shape, a rectangular shape, etc. can be mentioned. It should be noted that in the matte of this embodiment, the longitudinal direction refers to the flow direction of the web, and the transverse direction refers to the direction perpendicular to the flow of the web. Also, the longitudinal direction of the nonwoven web included in the matte of this embodiment is the same as the longitudinal direction of the matte, and the transverse direction of the nonwoven web is the same as the transverse direction of the matte.

[0012] In the mat of the present embodiment, as the form in which the plastering component adheres to the nonwoven web, examples include a form in which the plastering component is impregnated between the polyester fibers contained in the nonwoven web, a form in which the plastering component adheres to the surface of the polyester fibers contained in the nonwoven web, and the like.

[0013] The mat of the present embodiment preferably has a basis weight of 600 g / m 2 or more and 720 g / m 2 or less, more preferably 630 g / m 2 or more and 690 g / m 2 or less. When the basis weight is at least the lower limit value, the quality as an underlay such as cushioning properties and immobility is stabilized. When the basis weight is at most the upper limit value, it can have a weight suitable for installation and carrying.

[0014] The mat of the present embodiment preferably has a thickness of 3.0 mm or more and 3.6 mm or less, more preferably 3.2 mm or more and 3.4 mm or less. When the thickness is at least the lower limit value, leakage of the plaster paint can be prevented. When the thickness is at most the upper limit value, the plaster paint can be uniformly impregnated.

[0015] "Nonwoven web" The nonwoven web is a felt-like fabric obtained by mixing multiple types of polyester fiber wools, carding them to form a web, further laminating 8 or more and 10 or less of the webs with a cross-layer device, and entangling them by needle punching. When producing the nonwoven web by compressing the stacked webs, the load (pressure) is represented by the needle punch density (kg / m 3 ).

[0016] The needle punch density of the polyester fibers contained in the nonwoven web is 80 kg / m 3 or more and 120 kg / m 3 or less, preferably 90 kg / m 3 or more and 120 kg / m 3 or less, more preferably 90 kg / m 3 or more and 110 kg / m 3The following are more preferable. If the needle punch density is less than the lower limit value, there is a possibility that the plaster paint leaks out to the lower part of the matte. If the needle punch density exceeds the upper limit value, there is a possibility that the plaster paint is not uniformly impregnated.

[0017] Examples of the polyester constituting the polyester fiber contained in the nonwoven web include polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polybutylene naphthalate (PBN), and the like. Among these, from the viewpoint of the shape retention of the matte of the present embodiment, polyethylene terephthalate (PET) is preferable.

[0018] The polyester fiber may be a monofilament yarn or a multifilament yarn. The thickness of the polyester fiber is not particularly limited, but for example, it is preferably 3.3 dtex or more and 20 dtex or less, and more preferably 4.4 dtex or more and 17 dtex or less. If the thickness of the polyester fiber is equal to or more than the lower limit value, the bond between the fibers can be strengthened and the strength can be stabilized. If the thickness of the polyester fiber is less than the lower limit value, the gaps between the fibers do not become sparse, so that leakage of the plaster paint can be prevented. If the thickness of the polyester fiber is within the above range, the shape retention of the matte of the present embodiment is further improved.

[0019] The polyester fiber contained in the nonwoven web may be either raw yarn or processed yarn. From the viewpoint of the shape retention of the matte of the present embodiment, the polyester fiber is preferably raw yarn or processed yarn subjected to coloring processing or the like.

[0020] "Plaster component" The plaster component is mainly composed of at least one of calcium hydroxide and calcium carbonate. The plaster component adheres to the nonwoven web by applying the paint described later to the nonwoven web. A non-woven web of at least one of calcium hydroxide and calcium carbonate derived from a lime plaster component, 1 m 2 with a basis weight per unit area of 50 g / m 2 or more and 400 g / m 2 or less. Particularly from the viewpoint of improving the anti-inflammatory property, the basis weight is preferably 200 g / m 2 or more and 400 g / m 2 or less, more preferably 250 g / m 2 or more and 350 g / m 2 or less. If the basis weight is less than the lower limit, the pH of the mat will be 10 or less, the mat will not exhibit alkalinity, and the mat will not be able to exhibit antiviral properties. If the basis weight exceeds the upper limit, the finishability will deteriorate.

[0021] The mat of this embodiment may contain, in addition to the lime plaster component, a coloring pigment, a extender pigment, a flame retardant, a formaldehyde catcher, etc.

[0022] "Base fabric" The mat of this embodiment preferably has a base fabric joined to the non-woven web. The base fabric is mechanically joined in the middle of the non-woven web by a needle punching method. Since the base fabric is present, for example, in the middle of the non-woven web, the lime plaster component also adheres to the fibers contained in the base fabric.

[0023] As the base fabric, one composed of a fibrous woven fabric is used. Examples of the fibers constituting the fibrous woven fabric include synthetic fibers, natural fibers, semi-synthetic fibers, inorganic fibers, etc. Examples of the synthetic fibers include polypropylene fibers, polyethylene fibers, polyester fibers, nylon fibers, vinylon fibers, etc. Examples of the natural fibers include cotton, hemp, etc. Examples of the semi-synthetic fibers include acetate, etc. Examples of the inorganic fibers include glass fibers, silica fibers, alumina fibers, etc. These fibers may be used alone or in combination of two or more.

[0024] The mat of this embodiment has a base fabric joined to the nonwoven web, thereby further improving the strength.

[0025] The mat of this embodiment preferably has a flame retardant-containing resin layer between the nonwoven web and the base fabric. When the base fabric exists in the middle of the nonwoven web, the nonwoven web and the base fabric are joined via a flame retardant-containing resin layer.

[0026] The flame retardant-containing resin layer contains a resin as the main component and a flame retardant dispersed in the resin. Examples of the resin contained in the flame retardant-containing resin layer include flame retardant urethane rubber and the like. Among these, from the viewpoint of excellent flame retardancy, SBR (modified styrene-butadiene copolymer) is preferable. Examples of the flame retardant include halogen-based compounds. Among these, from the viewpoint of excellent flame retardancy, TBBPA (tetrabromobisphenol A) is preferable.

[0027] When the total amount of the flame retardant-containing resin layer is 100% by mass, the content of the flame retardant in the flame retardant-containing resin layer is preferably 10% by mass or more and 80% by mass or less, more preferably 20% by mass or more and 70% by mass or less, and still more preferably 30% by mass or more and 60% by mass or less. If the content of the flame retardant is at least the lower limit value, the flame retardant-containing resin layer exhibits sufficient flame retardancy. If the content of the flame retardant is at most the upper limit value, it is possible to suppress the flame retardant-containing resin layer from becoming brittle and the strength from decreasing.

[0028] The mat of this embodiment may be subjected to processing for imparting water repellency, waterproofness, antibacterial and deodorizing properties, antibacterial properties, antiviral properties, pollen adhesion prevention properties, anti-allergy properties, water absorption properties, ultraviolet shielding properties, antifouling properties, antistatic properties, etc.

[0029] From the perspective of maintaining the durability of the mat, the tensile elongation rate in the vertical direction of the mat according to this embodiment is preferably 60% or less, and more preferably 50% or less. If the tensile elongation rate in the vertical direction is equal to or less than the above upper limit value, the shape can be maintained during use. Also, from the perspective of the stability during processing, the tensile elongation rate in the vertical direction of the mat according to this embodiment is preferably 10% or more, and more preferably 15% or more. If the tensile elongation rate in the vertical direction is equal to or more than the above lower limit value, even if wrinkles occur during processing, they will automatically recover, so the processability is excellent.

[0030] From the perspective of maintaining the durability of the mat, the tensile elongation rate in the horizontal direction of the mat according to this embodiment is preferably 85% or less, and more preferably 80% or less. If the tensile elongation rate in the horizontal direction is equal to or less than the above upper limit value, the shape can be maintained during use. Also, from the perspective of the stability during processing, the tensile elongation rate in the horizontal direction of the mat according to this embodiment is preferably 20% or more, and more preferably 25% or more. If the tensile elongation rate in the horizontal direction is equal to or more than the above lower limit value, even if wrinkles occur during processing, they will automatically recover, so the processability is excellent.

[0031] From the perspective of maintaining the durability of the mat, the tensile strength in the vertical direction of the mat according to this embodiment is preferably 330 N or more, and more preferably 360 N or more. If the tensile strength in the vertical direction is equal to or more than the above lower limit value, the shape can be maintained during use. Also, from the perspective of hardness, the tensile strength in the vertical direction of the mat according to this embodiment is preferably 600 N or less, and more preferably 500 N or less. If the tensile strength in the vertical direction is equal to or less than the above upper limit value, excessive hardness can be prevented.

[0032] From the perspective of maintaining the durability of the mat, the tensile strength in the horizontal direction of the mat according to this embodiment is preferably 430 N or more, and more preferably 440 N or more. If the tensile strength in the horizontal direction is equal to or more than the above lower limit value, the shape can be maintained during use. In addition, from the perspective of hardness, the mat of the present embodiment preferably has a tensile strength in the transverse direction of 700 N or less, and more preferably 600 N or less. If the tensile strength in the transverse direction is equal to or less than the above upper limit value, excessive hardness can be prevented.

[0033] The tensile elongation rate and tensile strength of the mat were measured in accordance with JIS L 1913:1998 using a constant speed elongation type tensile testing machine. For each of the longitudinal and transverse directions, three pieces (specimens) with a width of 40 mm and a length of 300 mm were prepared, and when measured under the conditions of a clamp interval of 200 mm and a tensile speed of 100 mm / min, the maximum tensile load was measured, and the average value was calculated for each of the longitudinal and transverse directions.

[0034] From the perspective of maintaining the durability of the mat, the mat of the present embodiment preferably has a tear strength in the longitudinal direction of 200 N or more, and more preferably 220 N or more. If the tear strength in the longitudinal direction is equal to or more than the above lower limit value, breakage can be suppressed when a tear occurs in the mat.

[0035] From the perspective of maintaining the durability of the mat, the mat of the present embodiment preferably has a tear strength in the transverse direction of 240 N or more, and more preferably 250 N or more. If the tear strength in the transverse direction is equal to or more than the above lower limit value, breakage can be suppressed when a tear occurs in the mat.

[0036] The tear strength of the mat was measured in accordance with JIS L 1913:1998 using a constant speed elongation type tensile testing machine by the single tongue method. For each of the longitudinal and transverse directions, three pieces (specimens) with a width of 40 mm and a length of 300 mm were prepared, a cut with a depth of 10 mm was made in the transverse direction from the center, and when measured under the condition of a tensile speed of 100 mm / min, the maximum tear load was measured, and the average value was calculated for each of the longitudinal and transverse directions.

[0037] The mat of the present embodiment may be subjected to processing to impart water repellency, waterproofness, antibacterial and deodorizing properties, bacteriostatic properties, antiviral properties, pollen adhesion prevention properties, anti-allergy properties, water absorption properties, ultraviolet shielding properties, antifouling properties, antistatic properties, etc.

[0038] According to the mat of this embodiment, the needle punch density of the polyester fibers contained in the nonwoven web is 80 kg / m 3 or more and 120 kg / m 3 or less. At least one of calcium hydroxide and calcium carbonate derived from the plaster component adhering to the nonwoven web is 50 g / m 2 or more and 400 g / m 2 or less per 1 m of the nonwoven web. Therefore, it has sufficient strength without reducing the flame retardancy and can exhibit antiviral properties. 2

[0039] [Manufacturing method of mat] The manufacturing method of the mat of this embodiment includes a step of producing a nonwoven web (hereinafter referred to as the "nonwoven web production step"), a step of applying a paint containing a plaster component to the nonwoven web (hereinafter referred to as the "coating step"), and a step of drying the nonwoven web to which the paint has been applied (hereinafter referred to as the "drying step").

[0040] "Nonwoven web production step" Mix a plurality of types of polyester fiber wools, card them to form a web, further stack 8 or more and 10 or less of the webs with a cross-layer device, and entangle them by needle punching to produce a nonwoven web.

[0041] In the nonwoven web production step, when entangling the 8 or more and 10 or less stacked webs with each other by needle punching, the needle punch density is 80 kg / m 3 or more and 120 kg / m 3 or less, preferably 90 kg / m 3 or more and 120 kg / m 3 or less, preferably 90 kg / m 3 or more and 110 kg / m 3 ​The following are more preferable. If the needle punch density is less than the lower limit value, there is a possibility that the plaster paint leaks out to the lower part of the matte. If the needle punch density exceeds the upper limit value, there is a possibility that the plaster paint is not uniformly impregnated.

[0042] "Coating process" The method of coating the nonwoven web with the paint is not particularly limited, and a known method is used. As a method of coating the nonwoven web with the paint, a method of impregnating the nonwoven web with the paint is usually used.

[0043] (Paint) The paint is an aqueous paint containing a plaster component as a main component, a resin component, an additive component, and water. The plaster component contains at least one of calcium hydroxide and calcium carbonate as a main component. The paint preferably contains at least one of calcium hydroxide and calcium carbonate, a carboxy group-containing dispersion resin, an alkali metal compound, a compound having an amino group and an acid group, and water.

[0044] When the total amount of the paint is 100% by mass, the content of at least one of calcium hydroxide and calcium carbonate in the paint is preferably 20% by mass or more and 30% by mass or less, more preferably 22% by mass or more and 25% by mass or less, and even more preferably 23% by mass or more and 24% by mass or less. If the content of at least one of calcium hydroxide and calcium carbonate is equal to or more than the lower limit value, the alkalinity increases and a high antibacterial and sterilizing effect is exhibited against viruses and bacteria. If the content of at least one of calcium hydroxide and calcium carbonate is equal to or less than the upper limit value, a sufficient antibacterial and sterilizing effect is not imparted.

[0045] The carboxy group-containing dispersion resin is not particularly limited, and conventionally known resins can be used. For example, an acrylic resin, a polyolefin resin, and a polyurethane resin having an acid value of 4 mgKOH / g or more and 400 mgKOH / g or less, preferably 8 mgKOH / g or more and 300 mgKOH / g or less, are preferably at least one selected.

[0046] Examples of the acrylic resin having an acid value of 4 mgKOH / g or more and 400 mgKOH / g or less include acrylic resins obtained by polymerizing a carboxy-containing polymerizable unsaturated monomer and other polymerizable unsaturated monomers copolymerizable with the carboxy group-containing polymerizable unsaturated monomer by a method known per se.

[0047] Examples of the polyolefin resin having an acid value of 4 mgKOH / g or more and 400 mgKOH / g or less include copolymers of ethylene and (meth)acrylic acid, and polyolefin resins obtained by modifying a polyolefin resin produced by a known method with maleic anhydride.

[0048] Examples of the polyurethane resin having an acid value of 4 mgKOH / g or more and 400 mgKOH / g or less include polyurethane resins obtained by dispersing a urethane prepolymer obtained by reacting a polyisocyanate, a polyol, and a carboxyl group-containing diol in water, and polyurethane resins obtained by further reacting the urethane prepolymer with a chain extender to cause a chain extension reaction using the chain extender.

[0049] Among the above carboxy group-containing dispersion resins, acrylic resins are preferred from the viewpoints of dispersibility, storage stability, and the like.

[0050] When the total amount of the paint is 100% by mass, the content of the carboxy group-containing dispersion resin in the paint is preferably 0.5% by mass or more and 10% by mass or less, and more preferably 1.0% by mass or more and 5.0% by mass or less. When the content of the carboxy group-containing dispersion resin is at least the lower limit value, dispersibility can be ensured. When the content of the carboxy group-containing dispersion resin is at most the upper limit value, a paint having an appropriate viscosity can be obtained.

[0051] Examples of the alkali metal compound include hydroxides, alkoxides, oxides, halides, etc. of alkali metals such as lithium, sodium, potassium, rubidium, cesium, and francium. Among these, from the viewpoint of storage stability, hydroxides of the above metals are preferred.

[0052] When the total amount of the paint is 100% by mass, the content of the alkali metal compound in the paint is preferably 0.1% by mass or more and 3% by mass or less, more preferably 0.1% by mass or more and 2.5% by mass or less, and even more preferably 0.2% by mass or more and 2% by mass or less. If the content of the alkali metal compound is at least the lower limit value, the storage stability of the paint can be ensured. If the content of the alkali metal compound is at most the upper limit value, it will not have an adverse effect on the adhesion and water resistance.

[0053] Examples of the compound having an amino group and an acid group include compounds having an acid group such as a carboxy group, a sulfonic acid group, a sulfinic acid group, a phosphonic acid group, and a phosphinic acid group. Among these, from the viewpoint of storage stability of the paint, a compound having a carboxy group as the acid group is preferred.

[0054] When the total amount of the paint is 100% by mass, the content of the compound having an amino group and an acid group in the paint is preferably 0.05% by mass or more and 3% by mass or less, more preferably 0.1% by mass or more and 2.5% by mass or less, and even more preferably 0.1% by mass or more and 2% by mass or less. If the content of the compound having an amino group and an acid group is at least the lower limit value, the storage stability of the paint can be ensured. If the content of the compound having an amino group and an acid group is at most the upper limit value, it will not have an adverse effect on the water resistance.

[0055] When the total amount of the coating material is 100% by mass, the water content in the coating material is preferably 25% by mass or more and 60% by mass or less, more preferably 27% by mass or more and 55% by mass or less, and even more preferably 29% by mass or more and 50% by mass or less. If the water content is at least the lower limit value, the coating material can uniformly penetrate into the mat because the viscosity can be kept low. If the water content is at most the upper limit value, the antibacterial and antiviral functions can be exhibited without being impaired.

[0056] The coating material preferably contains at least one of a thickener and a binder resin.

[0057] The coating material can appropriately contain additives for coating materials such as coloring pigments, extender pigments, chelating agents, organic solvents, plasticizers, emulsifiers, defoaming agents, flame retardants, formalin catchers, etc., as necessary.

[0058] When impregnating the non-woven fabric web with the coating material, it is preferable to add a foaming agent to the coating material. As the foaming agent, for example, sodium linear alkylbenzene sulfonate or the like is used.

[0059] The foaming ratio of the coating material is preferably 1.5 times or more and 5 times or less, and more preferably 2 times or more and 4 times or less. If the foaming ratio of the coating material is within the above range, the basis weight of at least one of calcium hydroxide and calcium carbonate in the mat of the present embodiment can be within the above range. If the foaming ratio of the coating material is at least the lower limit value, the coating basis weight can be at most the upper limit value. If the foaming ratio of the coating material is at most the upper limit value, the coating basis weight can be at least the lower limit value.

[0060] The foaming ratio of the coating material can be measured by the cup method.

[0061] The foam viscosity of the paint during foaming is preferably 1000 mPa·s or more and 6000 mPa·s or less, more preferably 2500 mPa·s or more and 4000 mPa·s or less. If the foam viscosity of the paint during foaming is within the above range, the basis weight of at least one of calcium hydroxide and calcium carbonate in the mat of the present embodiment can be within the above range. If the foam viscosity of the paint is equal to or higher than the lower limit value, the coating basis weight can be equal to or higher than the lower limit value. If the foam viscosity of the paint is equal to or lower than the upper limit value, the coating basis weight can be equal to or lower than the upper limit value.

[0062] The foam viscosity of the paint during foaming can be measured under the conditions of rotor N04 (30 rpm, 25 °C) of a BM type viscometer.

[0063] "Drying process" The temperature for drying the nonwoven web coated with the paint is preferably 140 °C or more and 160 °C or less, more preferably 150 °C or more and 155 °C or less. If the temperature for drying the nonwoven web is within the above range, it is possible to suppress the nonwoven web from deteriorating due to heat. By drying the nonwoven web coated with the paint, water as a solvent evaporates, and the lime component, resin component, and additive component adhere to and remain on the nonwoven web, obtaining the mat of the present embodiment.

[0064] In addition, when the mat of the present embodiment has a flame retardant-containing resin layer between the nonwoven web and the base fabric as described above, a resin liquid containing a flame retardant is applied to at least one of the nonwoven web and the base fabric and dried by heating, whereby the flame retardant-containing resin layer can be formed.

[0065] According to the method for manufacturing the mat of the present embodiment, by applying a paint containing a lime component to a nonwoven web and drying the nonwoven web coated with the paint, a mat having sufficient strength and exhibiting antiviral properties can be obtained without reducing the flame retardancy.

Examples

[0066] Hereinafter, the present invention will be described more specifically with reference to Examples and Comparative Examples, but the present invention is not limited to the following Examples. Here, "parts" and "%" mean "parts by mass" and "mass %", respectively. In the following Production Examples, Examples and Comparative Examples, the parts by mass of the raw materials represent the parts by mass of the solid content (which may also be referred to as the active ingredient) of the raw materials.

[0067] "Production of an aqueous paint containing a plaster component" An aqueous paint containing a plaster component was produced as follows. 100 parts of calcium hydroxide, 5.0 parts of a carboxyl group-containing resin, 1.13 parts of potassium hydroxide, 1.50 parts of glycine, 116.7 parts of a binder resin aqueous dispersion with a solid content of 30%, 100 parts of titanium white, 1 part of ammonium polyoxyethylene polycyclic phenyl ether sulfate (trade name: Newcol 707, manufactured by Nippon Emulsifier Co., Ltd.), 2 parts of an antifoaming agent (trade name: SN Defoamer 777, manufactured by San Nopco Ltd.), 1 part of a thickener (hydroxyethyl cellulose, trade name: HEC AL-15F, manufactured by Sumitomo Seika Chemicals Co., Ltd.), and water were dispersed and mixed in a container equipped with a stirrer to obtain an aqueous paint A with a solid content of 52%.

[0068] "Production of a carboxyl group-containing dispersed resin" A carboxyl group-containing dispersed resin was produced as follows. Into a 1000 mL pressure reaction vessel equipped with a heating device, 100 parts of propylene glycol monomethyl ether was charged under atmospheric pressure. Then, the pressure reaction vessel was sealed, and while stirring at 200 rpm, the internal liquid phase temperature was maintained at 200 °C. In this state, a monomer mixture containing 30 parts of styrene, 44 parts of 2-ethylhexyl acrylate, 26 parts of acrylic acid, and 1 part of di-t-amyl peroxide was supplied into the pressure reaction vessel over 5 hours. After the supply of the monomer mixture was completed, the internal liquid phase temperature was maintained at 200 °C for 1 hour, and then cooled to room temperature. The content was transferred to another pressure reaction vessel, and while stirring, the volatile substances inside the pressure reaction vessel were distilled off under reduced pressure at a temperature of about 120 °C to 170 °C to obtain a carboxyl group-containing dispersion resin. The weight average molecular weight (hereinafter referred to as "Mw") of the obtained carboxyl group-containing dispersion resin was 7000, and the acid value was 200 mgKOH / g.

[0069] "Production of a binder resin aqueous dispersion with a solid content of 30%" A binder resin aqueous dispersion with a solid content of 30% was produced as follows. Into a reaction vessel equipped with a thermometer, a thermostat, a stirring device, a reflux condenser, a nitrogen inlet tube, and a dropping device, 128 parts of deionized water and 2 parts of an emulsifier (active ingredient 25%, trade name: ADEKA LIA SOAP SR-1025, manufactured by ADEKA Corporation) were charged, stirred and mixed in a nitrogen stream, and heated to 80 °C. Next, 1% of the total amount of the following core part monomer emulsion (40 parts of deionized water, 2.8 parts of "ADEKA LIA SOAP SR-1025", 2.1 parts of methylenebisacrylamide, 2.8 parts of styrene, 16.1 parts of methyl methacrylate, 28 parts of ethyl acrylate, and 21 parts of n-butyl acrylate) and 5.3 parts of a 6% aqueous ammonium persulfate solution were introduced into the reaction vessel and held at 80 °C for 15 minutes. Then, the remainder of the core part monomer emulsion was added dropwise into the reaction vessel maintained at 80 °C over 3 hours, and aging was carried out for 1 hour after the completion of the dropping. Next, the following shell part monomer emulsion (17 parts of deionized water, 1.2 parts of "ADEKA LIA SOAP SR-1025", 0.03 part of ammonium persulfate, 3 parts of styrene, 5.1 parts of 2-hydroxyethyl acrylate, 3.1 parts of methacrylic acid, 8.0 parts of methyl methacrylate, 1.8 parts of ethyl acrylate, and 9.0 parts of n-butyl acrylate) was added dropwise over 1 hour and aged for 1 hour. Then, while gradually adding 40 parts of a 5% aqueous solution of 2-(dimethylamino)ethanol to the reaction vessel, it was cooled to 30 °C and discharged while filtering through a 100-mesh nylon cloth to obtain an acrylic resin aqueous dispersion having an average particle diameter of 100 nm and a solid content of 30%. The obtained acrylic resin aqueous dispersion had an acid value of 20 mgKOH / g and a hydroxyl value of 25 mgKOH / g.

[0070] [Production of Mat] (Examples 1 to 4 and Comparative Examples 1 to 5) 60 parts of polyester fiber white cotton (Semi-dull, 7.8 dtex, manufactured by Toray Industries), 20 parts of polyester fiber colored cotton (Brown, 17 dtex, manufactured by Takagi Chemical Co., Ltd.), and 20 parts of polyester heat-sealing fiber cotton (4.4 dtex, manufactured by Toyobo Co., Ltd.) were mixed, carded to form a web, and the web was laminated in 9 layers using a cross-layer device and entangled by needle punching to obtain a non-woven fabric web with a needle punching density of 100 kg / m 3 . A foaming agent mainly composed of sodium linear alkylbenzene sulfonate was added to the above aqueous paint A, and the foaming ratio of the aqueous paint A was adjusted to 1.5 to 5 times, and the foam viscosity during foaming was adjusted to 1000 mPa·s to 6000 mPa·s. The nonwoven web was impregnated with the aqueous paint A whose foaming ratio and foam viscosity were adjusted so that the basis weight of at least one of calcium hydroxide and calcium carbonate became the amount shown in Table 1. Thereafter, the nonwoven web impregnated with the aqueous paint A was heated and dried at 150 °C to obtain the mats of Examples 1 to 4 and Comparative Examples 1 to 5. Table 1 shows the tensile elongation rate in the longitudinal direction, the tensile elongation rate in the transverse direction, the tensile strength in the longitudinal direction, the tensile strength in the transverse direction, the tear strength in the longitudinal direction, and the tear strength in the transverse direction of each obtained mat.

[0071] "Evaluation of Durability" (Measurement of Tensile Elongation Rate and Tensile Strength) In the measurement of the tensile elongation rate and tensile strength of the mat, three pieces (samples) with a width of 40 mm and a length of 300 mm were prepared for each of the longitudinal and transverse directions of the mat. For each piece, when measuring the tensile strength using a constant speed elongation type tensile testing machine under the conditions of a clamp interval of 200 mm and a tensile speed of 100 mm / min, the maximum tensile load was measured, and the average value of the tensile strength was calculated for each of the longitudinal and transverse directions. Also, the tensile elongation rate at the maximum tensile load was measured, and the average value of the tensile elongation rate was calculated for each of the longitudinal and transverse directions.

[0072] (Measurement of Tear Strength) In the measurement of the tear strength of the mat, three pieces (samples) with a width of 40 mm and a length of 300 mm were prepared for each of the longitudinal and transverse directions of the mat. For each piece, a cut with a depth of 10 mm was made in the transverse direction from the center, and when measuring the tear strength using a constant speed elongation type tensile testing machine under the condition of a tensile speed of 100 mm / min, the maximum tear load was measured, and the average value of the tear strength was calculated for each of the longitudinal and transverse directions.

[0073] The evaluation criteria for durability were as follows. ◎: All of the following conditions are satisfied. · Tensile elongation rate: 55% or less in the vertical direction and 80% or less in the horizontal direction · Tensile strength: 335 N or more in the vertical direction and 435 N or more in the horizontal direction · Tear strength: 205 N or more in the vertical direction and 245 N or more in the horizontal direction

[0074] 〇: The following conditions are satisfied. · Tensile elongation rate: 55% or more and 60% or less in the vertical direction, 80% or more and 85% or less in the horizontal direction · Tensile strength: 330 N or more and 335 N or less in the vertical direction, 430 N or more and 435 N or less in the horizontal direction · Tear strength: 200 N or more and 205 N or less in the vertical direction, 240 N or more and 245 N or less in the horizontal direction

[0075] ×: None of the following conditions are satisfied. · Tensile elongation rate: 60% or less in the vertical direction, 85% or less in the horizontal direction · Tensile strength: 330 N or more in the vertical direction, 430 N or more in the horizontal direction · Tear strength: 200 N or more in the vertical direction, 240 N or more in the horizontal direction

[0076] "Evaluation of anti-inflammatory property" In the evaluation of anti-inflammatory performance, the 45° air mix burner method was used. In the evaluation of anti-inflammatory performance, for each of the vertical and horizontal directions of the mat, three pieces (samples) with a width of 22 cm and a length of 40 cm were prepared. For each piece, it was attached to the combustion test box at an angle of 45°, and the afterflame time (the time during which the flame continues to occur from the test piece) and the char length were measured when heated with a burner for 30 seconds at a distance of 1 mm from the surface of the test piece. The evaluation criteria for anti-inflammatory property were as follows. ◎: Afterflame time is 20 seconds or less and char length is 10 cm or less ×: Afterflame time is 20 seconds or more or char length is 10 cm or more

[0077] "Evaluation of antiviral property (expression of strong alkali)" A pH test paper was pressed against the surface of the mat, water was dropped, and the time until the pH reached 10 or higher was evaluated based on the degree of color development. The higher the strong alkali expressivity, the higher the antiviral property. The evaluation criteria for the antiviral property (strong alkali expressivity) were as follows. ◎: Within 1 minute 〇: Exceeding 1 minute and within 5 minutes △: Exceeding 5 minutes and within 15 minutes ×: Exceeding 15 minutes

[0078] "Evaluation of finish quality" The finish quality of the surface of the mat was visually evaluated. The evaluation criteria for the finish quality were as follows. ◎: No coating unevenness is observed. 〇: Slight coating unevenness is observed. △: Some coating unevenness is observed. ×: Coating unevenness is prominent.

[0079]

Table 1

[0080] From the results in Table 1, it was confirmed that the mats of Examples 1 to 4 are excellent in durability (strength), flame retardancy, and antiviral property.

Industrial applicability

[0081] Since the mat of the present invention can maintain flame retardancy, has sufficient strength, and can exhibit antiviral property, it can be installed at the entrance of a building, the entrance of a hospital room, etc., and can exhibit antiviral property and flame retardancy.

Claims

1. A mat in which a plaster ingredient adheres to a non-woven fabric web containing polyester fibers, The needle punch density of the polyester fiber is 80 kg / m ３ or more and 120 kg / m ３ or less. The basis weight per 1 m of the nonwoven web of at least one of calcium hydroxide and calcium carbonate derived from the plaster ingredient ２ is 50 g / m ２ or more and 400 g / m ２ or less, a mat.

2. having a base fabric joined to the non-woven fabric web, The mat according to claim 1, wherein the base fabric is composed of a fiber woven fabric.

3. The mat according to claim 2, having a flame retardant-containing resin layer between the non-woven fabric web and the base fabric.

4. A method for manufacturing the mat according to any one of claims 1 to 3, comprising a step of applying a paint containing a plaster ingredient to a non-woven fabric web and a step of drying the non-woven fabric web to which the paint has been applied.

5. The method for manufacturing a mat according to claim 4, wherein the paint is an aqueous paint containing at least one of calcium hydroxide and calcium carbonate, a carboxy group-containing dispersion resin, an alkali metal compound, a compound having an amino group and an acid group, and water.

6. The method for manufacturing a mat according to claim 4 or 5, wherein the paint contains at least one of a thickener and a binder resin.

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