Method for manufacturing colored palm mat

Abstract

A method for manufacturing a colored palm mat according to exemplary embodiments of the present invention may comprise the steps of: decolorizing coconut fibers with a first mixture solution containing an oxygen-based oxidizer, a hydroxide salt, a silicate, a synthetic detergent, and water; dyeing the decolorized coconut fibers with a second mixture solution containing dye, vegetable oil, and water; forming a colored rope by twisting the dyed coconut fibers; and forming a colored palm mat by alternately weaving the warp and weft formed of the colored rope.

Description

Colored palm mat manufacturing method

[0001] The present invention relates to a method for manufacturing a colored palm mat.

[0002] The coconut palm is a tropical and subtropical plant, an evergreen tree belonging to the palm family, growing up to 30 meters tall. Native to the Malay Archipelago, the coconut palm is an important economic plant in tropical regions, serving a variety of purposes. Its leaves are commonly used as fuel, flooring, roofing, and hat material, while its trunk is used for various building materials. Its bark is used for resin, and its young shoots are used in salads.

[0003] Coconuts, the fruit of the coconut palm, have a variety of uses in food and industry. The outer husk is used to extract coir, a type of coconut fiber, and the coconut water inside the fruit is used as drinking water or beverages to replenish moisture. Coconut meat is processed into various products, such as coconut milk, coconut oil, shredded coconut, and coconut flour, which are used as ingredients in cooking, margarine, soap, candles, and cosmetics.

[0004] Coconut husks are made of two different fibers, making them highly elastic and, like cotton, possess excellent moisture absorption, moisture-wicking, and sound-absorbing properties. They are also environmentally friendly. Recently, they have been used in various ways in everyday life, such as as eco-friendly flooring for hiking trails and walking paths, and for providing acupressure when installed on barefoot walkways.

[0005] For example, in the related technology, Korean Patent No. 10-2355040 relates to an anti-slip walking mat, and is characterized by forming an anti-slip structure on the surface of the base mat to prevent slipping when walking.

[0006] As mentioned above, mats made from coconut fiber, derived from the husk of the coconut fruit, offer a wide range of applications. However, coconut fiber discolors easily and has limitations, such as difficulty in design modification. Therefore, the development of technologies for pretreatment (e.g., dyeing) of coconut fiber is needed to more effectively utilize it.

[0007] One object of the present invention is to manufacture a colored palm mat.

[0008] A method for manufacturing a colored coconut mat according to exemplary embodiments of the present invention may include the steps of: bleaching coconut fibers with a first mixture containing an oxygen-based oxidizing agent, a hydroxide salt, a silicate, a synthetic detergent, and water; dyeing the bleached coconut fibers with a second mixture containing a dye, vegetable oil, and water; twisting the dyed coconut fibers to form a colored rope; and interweaving warp and weft yarns formed from the colored rope to form a colored coconut mat.

[0009] In one embodiment, in the decolorizing step, the first mixed solution may include 10 to 30 parts by weight of the oxidizing agent, 1 to 20 parts by weight of the hydroxide salt, 1 to 20 parts by weight of the silicate, and 1 to 20 parts by weight of the synthetic detergent, with respect to 100 parts by weight of water.

[0010] In one embodiment, in the dyeing step, the second mixture may include 1 to 20 parts by weight of the dye and 1 to 10 parts by weight of the vegetable oil, based on 100 parts by weight of water.

[0011] In one embodiment, the step of forming the colored rope may include the steps of: forming fiber strands by twisting the dyed coconut fibers together; arranging the fiber strands in an outer portion and arranging cotton fibers in a central portion of the outer portion; forming a primary rope by twisting the fiber strands and the cotton fibers; and forming a secondary rope by twisting four strands of the primary rope together.

[0012] In one embodiment, in the step of manufacturing the colored palm mat, the warp yarn may extend in the length direction of the mat in two rows forming one set, and the weft yarn may extend in the width direction of the mat in two rows forming one set.

[0013] The method for manufacturing a colored palm mat according to an exemplary embodiment of the present invention is environmentally friendly and economical by utilizing coconut fiber.

[0014] A method for manufacturing a colored coconut mat according to an exemplary embodiment of the present invention can solve the problem of discoloration of existing coconut mats by dyeing coconut fibers in various colors.

[0015] The colored palm mat manufactured according to an exemplary embodiment of the present invention can be utilized in a variety of ways. For example, it can be used as an eco-friendly colored flooring material for hiking trails and walking paths, or as a colored protective strip for protecting trees.

[0016] Figure 1 briefly illustrates a method for manufacturing a colored palm mat according to an exemplary embodiment.

[0017] Figure 2 briefly illustrates a method for manufacturing a color rope according to one embodiment.

[0018] Figure 3 illustrates a color palm mat according to one embodiment.

[0019] Figure 4 illustrates a fixed pin that can be combined with a color palm mat according to one embodiment.

[0020] FIG. 5 is a plan view showing a fixed pin attached to a color palm mat according to one embodiment.

[0021] Fig. 6 is a cross-sectional view showing a colored palm mat and fixed pins installed on the ground according to one embodiment.

[0022] Figure 7 is an enlarged view of a colored palm mat and fixed pins installed on the ground according to one embodiment.

[0023] Fig. 8 shows an example of a colored palm mat constructed as a walking mat according to one embodiment.

[0024] According to exemplary embodiments of the present invention, a method for manufacturing a colored palm mat utilizing coconut fibers is provided, which is environmentally friendly, economical, and prevents discoloration. The resulting colored palm mat can be utilized for a variety of purposes.

[0025] Hereinafter, embodiments of the present invention will be described in more detail. However, since the drawings and embodiments attached to this specification serve to further understand the technical concept of the present invention, the present invention should not be interpreted as being limited to the matters described in such drawings and embodiments.

[0026] The term 'fiber' used in the present invention means 'fiber', 'fiber', 'fiber', and 'coconut fiber' means 'coir'.

[0027] A method for manufacturing a colored coconut mat according to exemplary embodiments may include the steps of: bleaching coconut fibers with a first mixture containing an oxygen-based oxidizing agent, a hydroxide salt, a silicate, a synthetic detergent, and water; dyeing the bleached coconut fibers with a second mixture containing a dye, vegetable oil, and water; twisting the dyed coconut fibers to form a colored rope; and interweaving warp and weft yarns formed from the colored rope to form a colored coconut mat.

[0028] Referring to FIG. 1, a method for manufacturing a colored palm mat according to an exemplary embodiment can be provided as follows.

[0029] First, coconut fibers can be pretreated before bleaching. For example, coconuts can be prepared to separate fibers from the coconut shell. For example, coconuts weighing approximately 1 to 2 kg can be sorted, the coconut water or flesh inside the coconut can be utilized for various purposes, and the discarded coconut shell can be prepared. Fibers can be separated from the prepared coconut shell. For example, dense fibers formed inside the coconut shell, 2 to 5 cm thick, can be separated from the coconut shell. The separated fiber length can be approximately 100 to 500 mm. The coconut shell can be pressed and crushed to separate the fibers. For example, the pressing and crushing can be performed using a separate crushing device or manually. Preferably, the crushing can be performed with longitudinal directionality to form fibers of a certain length.

[0030] Afterwards, foreign matter can be removed from the separated fibers. For example, the foreign matter can be removed by continuously rotating the fibers on a roller and applying impact, or by centrifugation. If necessary, the fibers can be washed with clean water. The foreign matter removal step can be repeated multiple times, as it can affect the quality of the fibers.

[0031] Thereafter, the separated fibers can be pre-dried. For example, the pre-drying can be performed at 10 to 35°C for 5 to 12 hours. For example, the pre-drying can be performed at 10 to 35°C, 10 to 30°C, or 15 to 30°C. For example, the pre-drying can be performed for 5 to 12 hours, 7 to 12 hours, or 7 to 10 hours. When drying within the above range, foreign substances bound to the fibers can be removed while drying together, and the color of the fibers can naturally fade from dark brown.

[0032] Next, the coconut fibers can be bleached with a first mixture containing an oxygen-based oxidizer, a hydroxide, a silicate, a synthetic detergent, and water (e.g., S-10).

[0033] For example, a first mixture can be prepared by adding an oxygen-based oxidizing agent, a hydroxide salt, a silicate, and a synthetic detergent to water. The dried fibers can be decolorized by first immersing them in the first mixture. The immersion can be performed for, for example, 7 to 15 hours, 10 to 15 hours, or 10 to 12 hours.

[0034] The mass ratio of the first mixed solution to the separated fibers may be 10 to 50, preferably 10 to 30. Within the above range, the separated fibers may be sufficiently immersed in the first mixed solution, allowing decolorization to proceed smoothly.

[0035] In one embodiment, the first mixed solution may include 10 to 30 parts by weight of the oxygen-based oxidizing agent, 1 to 20 parts by weight of the hydroxide salt, 1 to 20 parts by weight of the silicate, and 1 to 20 parts by weight of the synthetic detergent, per 100 parts by weight of water.

[0036] For example, the first mixed solution may contain 15 to 30 parts by weight of the oxygen-based oxidizing agent, 5 to 20 parts by weight of the hydroxide salt, 5 to 20 parts by weight of the silicate, and 5 to 20 parts by weight of the synthetic detergent, per 100 parts by weight of water.

[0037] For example, the first mixed solution may contain 20 to 30 parts by weight of the oxygen-based oxidizing agent, 10 to 20 parts by weight of the hydroxide salt, 10 to 20 parts by weight of the silicate, and 10 to 20 parts by weight of the synthetic detergent, per 100 parts by weight of water.

[0038] For example, the first mixed solution may include 20 to 25 parts by weight of the oxygen-based oxidizing agent, 10 to 15 parts by weight of the hydroxide salt, 10 to 15 parts by weight of the silicate, and 10 to 15 parts by weight of the synthetic detergent, per 100 parts by weight of water.

[0039] Within the above range, the decolorization effect of coconut fiber can be optimized, and the post-processing (e.g., dyeing) effect can also be maximized. For example, when decolorized coconut fiber is dyed, the dyeability (e.g., dyeing concentration) is excellent.

[0040] In some embodiments, the contents of the hydroxide salt, the silicate salt, and the synthetic detergent may be the same. When the contents of the hydroxide salt, the silicate salt, and the synthetic detergent are the same, the post-treatment effect can be maximized. For example, the dyeing concentration is excellent.

[0041] The oxygen-based oxidizing agent may include at least one selected from hydrogen peroxide, sodium percarbonate, ozone, and oxygen. The oxygen-based oxidizing agent may provide a bleaching or whitening effect by decomposing under alkaline conditions. Preferably, the oxygen-based oxidizing agent may be hydrogen peroxide or sodium percarbonate.

[0042] The above hydroxide salt may include at least one selected from sodium hydroxide, calcium hydroxide, potassium hydroxide, magnesium hydroxide, and aluminum hydroxide. The hydroxide salt may remove dye particles present in the fiber, provide cleaning power through bleaching activation, and serve as an acidity regulator.

[0043] The silicate may include at least one selected from sodium silicate, calcium silicate, potassium silicate, and lithium silicate. The silicate may bind to heavy metals that decompose oxygen-based oxidizing agents (e.g., hydrogen peroxide) to inhibit the decomposition of the oxygen-based oxidizing agent, thereby enhancing the bleaching and decolorizing effects. Preferably, the silicate may be sodium silicate.

[0044] The above synthetic detergent may be a mildly alkaline detergent. For example, it may be a mildly alkaline synthetic detergent used for laundry. The synthetic detergent can enhance the cleaning effect of coconut fibers and evenly discolor them.

[0045] The above synthetic detergent may include a surfactant, an alkaline builder, a binding coagulant, and a flow aid.

[0046] Surfactants can be used without particular limitations as long as they are ingredients applicable to synthetic detergents. For example, cationic surfactants, nonionic surfactants, or anionic surfactants can be used. For example, nonionic surfactants including α-olefin sulfonates, alkyl sulfates, alkenyl sulfates, alkylbenzene sulfonates, alkane sulfonates, alcohols having 6 to 18 carbon atoms, ethylene oxide, propylene oxide, and butylene oxide can be used. For example, the surfactant can be included in an amount of 10 to 50 wt% of the total detergent composition.

[0047] Alkaline builders can enhance cleaning power by assisting the surfactant in removing stains. For example, they can help the surfactant fully function by removing hardness ions. Examples of the alkali builder include polymeric phosphates such as sodium pyrophosphate, tetrasodium phosphate, tripolysodium phosphate, and hexametasodium phosphate; potassium carbonate; sodium gluconate; or mixtures thereof. The alkali builder may include an alkali builder commonly used in synthetic detergents. For example, the alkali builder may be present in an amount of 10 to 50 wt% of the total detergent composition.

[0048] A coagulant can be used to promote the bonding of surfactants and increase the bonding strength or strength of particles. For example, polyethylene glycol, polypropylene glycol, etc. can be used. The average molecular weight of the polyethylene glycol or polypropylene glycol can be 1,000 to 30,000. For example, the coagulant can be included in an amount of 0.1 to 10 wt% of the total detergent composition.

[0049] A flow aid helps to uniformly mix the surfactant and builder, and can also provide a fabric softening effect. For example, zeolite can be used as the flow aid. For example, the flow aid can be comprised of 10 to 50 wt% of the total detergent composition.

[0050] The above synthetic detergent may further include additives such as water, enzymes, and foam control agents as needed. For example, the additives may be included in an amount of 0.1 to 5 wt% of the total detergent composition.

[0051] The decolorized fibers can be dehydrated and dried by sufficiently immersing them in the first mixed solution. For example, if the decolorization of the fibers immersed in the first mixed solution has sufficiently progressed, the decolorized fibers can be first dehydrated and then first dried.

[0052] The above primary dehydration can be performed by pressing and dehydrating the fibers in a compressor. For example, the primary drying can be performed at 15 to 35°C for 12 to 48 hours. Preferably, the drying can be performed at 15 to 35°C, 15 to 30°C, or 15 to 25°C for 12 to 48 hours, 12 to 42 hours, or 12 to 36 hours. When drying within the above range, the moisture content of the decolored fibers can be appropriately controlled, and decolored coconut fibers that are easy to post-process can be obtained.

[0053] If necessary, the above primary dehydration and primary drying may be performed more than twice. This can enhance the decolorization effect and adjust the moisture content to the required level.

[0054] The pre-drying time and primary drying time may differ. For example, the pre-drying time may be shorter than the primary drying time. By allowing the primary drying to proceed for a longer period of time, the moisture content of the final coconut fiber can be controlled, allowing for the application of necessary post-processing.

[0055] Next, the bleached fibers can be dyed with a second mixture containing dye, vegetable oil and water (e.g., S-20).

[0056] The dye may be a conventional ingredient required for coloring fibers or fabrics. For example, any dye capable of coloring cellulosic natural fibers (e.g., cellulose, hemicellulose, lignin, pectin, etc.) may be used without limitation.

[0057] The dyes mentioned above may be, for example, acid dyes, azoic dyes, basic dyes, direct dyes, disperse dyes, metal-containing dyes, reactive dyes, synthetic sulfur dyes, vat dyes, and other synthetic dyes, or natural dyes extracted from plants or animals. However, dyes capable of dyeing keratin fibers may be excluded.

[0058] The vegetable oil may include, for example, at least one selected from coconut oil, sunflower oil, olive oil, macadamia oil, avocado oil, grapeseed oil, and apricot oil. Coconut oil is preferred. Coconut oil helps the dye penetrate well into the coconut fiber and aids in color development.

[0059] The water may be, for example, tap water, purified water, groundwater, distilled water, etc., and the temperature of the water may be 40 to 50°C. Preferably, it may be 40 to 45°C. The temperature of the water affects the dyeing speed and concentration. If the temperature exceeds the above temperature, the dyeing speed may increase, causing stains, and if the temperature is lower than the above temperature, the dyeing may not proceed sufficiently.

[0060] The mass ratio of the second mixture to the bleached fiber may be 10 to 50, preferably 15 to 30. Within the above range, coloring can proceed sufficiently without deteriorating the physical properties of the coconut fiber.

[0061] In one embodiment, the second mixture may include 10 to 20 parts by weight of the dye and 1 to 10 parts by weight of vegetable oil per 100 parts by weight of water.

[0062] For example, the second mixed solution may contain 5 to 15 parts by weight of the dye and 2 to 8 parts by weight of vegetable oil per 100 parts by weight of water.

[0063] For example, the second mixture may contain 10 to 15 parts by weight of the dye and 3 to 7 parts by weight of vegetable oil per 100 parts by weight of water.

[0064] Within the above range, the dyeability (e.g., dyeing concentration) of coconut fiber can be optimized to resolve the discoloration problem of coconut fiber. In addition, it can also help improve the physical properties (e.g., wear resistance) of coconut fiber.

[0065] The dyed fibers can be dehydrated and dried by sufficiently immersing them in the second mixture. For example, when the dyeing of the fibers immersed in the second mixture has sufficiently progressed, the dyed fibers can be dehydrated a second time and dried a second time.

[0066] The secondary dehydration can be performed by pressing and dehydrating the coconut fibers in a compressor. For example, the secondary drying can be performed at a temperature of 15 to 35°C for 12 to 48 hours. Preferably, the secondary drying can be performed at a temperature of 15 to 35°C, 15 to 30°C, or 15 to 25°C for 12 to 48 hours, 12 to 42 hours, or 12 to 36 hours. Within the above range, the dye component is firmly fixed to the coconut fibers, and the unfixed dye component is removed, thereby improving the color fastness.

[0067] Next, the dyed coconut fibers can be twisted to form a colored rope (e.g., S-30).

[0068] In one embodiment, the step of forming the colored rope may include the steps of: forming fiber strands by twisting the dyed coconut fibers together; arranging the fiber strands in an outer portion and arranging cotton fibers in a central portion of the outer portion; forming a primary rope by twisting the fiber strands and the cotton fibers; and forming a secondary rope by twisting four strands of the primary rope together.

[0069] Referring to FIG. 2, to form a color rope, the dyed coconut fibers can first be twisted together to form fiber strands (e.g., S-31).

[0070] For example, coconut fibers dyed with the second mixture can be twisted together to form fiber strands having a constant thickness. The fiber strand refers to a fiber bundle in which multiple strands of coconut fibers are twisted together. A twisting method in which two or more fiber strands are twisted together can be applied. The fiber strand can be formed by stranding multiple strands of dyed coconut fibers in a clockwise direction (Z-twist) or counterclockwise direction (S-twist). The thickness (average diameter) of the strand can be, for example, 1 mm to 5 mm.

[0071] The average moisture content of the dyed coconut fiber may be 10 to 40%. For example, the average moisture content of the dyed coconut fiber may be 10 to 40%, 15 to 35%, or 20 to 30%. Within the above range, breakage of the coconut fiber during twisting can be minimized, and the physical properties of the rope (e.g., tensile strength, wear resistance) can also be improved.

[0072] If necessary, an adhesive may be used to ensure that the coconut fibers adhere well to each other during the strand formation. The adhesive can be a natural adhesive, such as agar or latex, to maintain the intertwined coconut fibers in a twisted state without unraveling.

[0073] Thereafter, the fiber strands can be placed on the outer portion and cotton fibers can be placed on the center of the outer portion (e.g., S-32).

[0074] For example, six fiber strands can be arranged in the outer part, and one natural fiber (e.g., cotton fiber) can be arranged in the center. Coconut fiber has superior tensile strength compared to natural fibers, but its surface is not smooth, so if a rope is made of only coconut fiber, it is not aesthetically pleasing. Therefore, natural fibers such as cotton fiber, hemp fiber, wool fiber, silk fiber, etc. can be arranged in the center. Cotton fiber can be preferably arranged. For example, by arranging natural fibers in the center and dyed coconut fiber strands in the outer part, discoloration can be prevented, while also increasing the tensile strength, thereby improving wear resistance.

[0075] Thereafter, the fiber strands and the cotton fibers can be twisted to form a primary rope (e.g., S-33).

[0076] For example, the fiber strands and the cotton fibers can be twisted clockwise (Z-twist) or counterclockwise (S-twist). Twisting can be performed using a separate rope manufacturing device, and a twisting method typically used in rope manufacturing can be applied. For example, the thickness (average diameter) of the cotton fibers can be 1 mm to 5 mm. For example, the thickness (average diameter) of the primary rope can be 3 mm to 15 mm.

[0077] Thereafter, the four strands of the primary rope can be twisted together to form a secondary rope, ultimately forming a color rope (e.g., S-34). The color rope can be further strengthened by being formed from the secondary rope. For example, the thickness (average diameter) of the secondary rope can be between 5 mm and 30 mm.

[0078] Referring again to Figure 1, the warp and weft yarns formed by the above-mentioned color rope can be woven crosswise to form a color palm mat (e.g., S-40).

[0079] Fig. 3 illustrates a colored palm mat (100) according to one embodiment. Referring to Fig. 3, the colored palm mat (100) can be woven by weaving warp yarns (110) and weft yarns (120) in a vertical cross pattern. The warp yarns (110) and weft yarns (120) can be woven using a conventional weaving device, and the colored ropes arranged in the longitudinal and transverse directions of the colored palm mat (100) can be woven into a plain weave structure by crossing them at right angles.

[0080] In one embodiment, the warp yarn (110) may extend in the length direction of the mat in two rows forming a single group, and the weft yarn (120) may extend in the width direction of the mat in two rows forming a single group. Accordingly, the warp yarn (110) and the weft yarn (120) may intersect at right angles at two-row intervals to form a plain weave structure.

[0081] In some embodiments, the thickness of the colored palm mat (200) may be 20 mm to 60 mm. For example, it may be 20 mm to 60 mm, 20 mm to 50 mm, 30 mm to 50 mm, or 30 mm to 40 mm. Within the above range, the mat can be prevented from flowing down or moving, and accessories (e.g., fixing pins, connecting rings) can be firmly connected when installing the mat.

[0082] In some embodiments, the width (W) of the colored palm mat (200) may be 50 mm to 3,000 mm, and the length (L1) may be 1 m to 20 m. However, it is understood that the width and length are not limited and may be used according to the intended use.

[0083] The woven colored palm mat (100) can be used on its own, or can be fixed using a fixing pin (200) that can be combined with the colored palm mat (100) of FIG. 4. The fixing pin body length (L2) can be 20 to 25 cm. The fixing pin connecting portion (L3) can be 5 to 7 cm in length, and the fixing pin fixing portion (L4) can be 5 to 8 cm in length.

[0084] Figures 5 to 8 are examples showing a method for constructing the color palm mat (100) described above.

[0085] Referring to Fig. 5, when extending a plurality of color palm mats (100), they can be connected using fixing pins (200), and the fixing pins (200) can also be fixed to the ground.

[0086] Referring to Fig. 6, a colored palm mat (100) can be fixed to the ground (300) with a fixing pin (200). Referring to Fig. 7, two rows of warp yarns (110) and two rows of weft yarns (120) that cross each other vertically can be fixed by being tied together with a single fixing pin (200). Accordingly, slipping can be prevented when pedestrians walk, and other safety accidents can be prevented in advance.

[0087] Figure 8 illustrates an example of a colored (red) palm mat (100) constructed as a walking mat according to one embodiment. The color of the colored palm mat (100) can be varied to suit the intended purpose by using dyes used during dyeing. By providing a variety of colors to the mat compared to existing mats, discoloration can be prevented and both aesthetic appeal and visibility can be improved.

[0088] In some embodiments, the colored palm mat (100) can be used as a walking mat, a plant protection mat, or a plant protection belt.

[0089] Hereinafter, preferred embodiments are presented to help understand the present invention, but these embodiments are only illustrative of the present invention and do not limit the scope of the appended claims. It is obvious to those skilled in the art that various changes and modifications to the embodiments are possible within the scope and technical idea of ​​the present invention, and it is also natural that such changes and modifications fall within the scope of the appended claims.

[0090] Example 1

[0091] 1) Preprocessing

[0092] Coconut shells were fed into a compression roller to separate fibers from the coconut shells. The separated fibers were vibrated by the roller to remove foreign substances and pre-dried at approximately 20°C for approximately 8 hours.

[0093] 2) Bleaching treatment

[0094] A first mixture containing 20 parts by weight of hydrogen peroxide, 10 parts by weight of sodium hydroxide, 10 parts by weight of sodium silicate, and 10 parts by weight of a synthetic detergent per 100 parts by weight of water was prepared in a water tank. The synthetic detergent was prepared by including 15 wt% of a nonionic surfactant (trade name AE-7, Ilchil Chemical), 15 wt% of a cationic surfactant (Arosurf TA101, Sherex, 25 wt% of an alkali builder (potassium carbonate), 7 wt% of a binding coagulant (PEG, average molecular weight 10,000), 35 wt% of a flow aid (zeolite), and 3 wt% of water, based on the total detergent content.

[0095] The pre-dried fibers were immersed in a tank containing the first mixture for approximately 10 hours. The mass ratio of the first mixture to the fibers was 20. The immersed fibers were first dehydrated and then dried at approximately 25°C for 24 hours. The first dehydration and first drying were repeated once more to obtain decolored coconut fibers.

[0096] 3) Dyeing treatment

[0097] A second mixture containing 12 parts by weight of the dye Sunfix Red S3B 150% and 6 parts by weight of coconut oil per 100 parts by weight of water at approximately 45°C was prepared in a water bath. The bleached fiber was immersed in the water bath containing the second mixture for approximately 8 hours to dye it. The mass ratio of the second mixture to the fiber was 20. The dyed fiber was dehydrated a second time and then dried a second time at approximately 25°C for 24 hours. The second dehydration and second drying were repeated once more to finally obtain dyed coconut fiber.

[0098] 4) Color rope formation stage

[0099] The moisture content of the obtained coconut fibers was adjusted to 25%. Several coconut fibers were twisted together to produce fiber strands with a diameter of approximately 3 mm. One cotton fiber strand with a diameter of approximately 5 mm was placed in the center, and six fiber strands with a diameter of approximately 3 mm were placed around the center and then twisted clockwise to produce a primary rope (diameter of approximately 9 mm). Four strands of the primary rope were twisted together clockwise to produce a secondary rope (diameter of approximately 18 mm).

[0100] 5) Color palm mat formation stage

[0101] The above secondary ropes were used as warp (two rows per set) and weft (two rows per set), respectively, and a color palm mat (thickness 35 mm) with a plain weave structure of 60 mm width and 10 m length was woven using a loom (Phoenix V.2, Wooshin AMT).

[0102] Example 2

[0103] 2) In the above decolorization treatment, the same procedure as Example 1 was followed, except that the first mixture contained 100 parts by weight of water, 30 parts by weight of hydrogen peroxide, 20 parts by weight of sodium hydroxide, 20 parts by weight of sodium silicate, and 20 parts by weight of synthetic detergent.

[0104] Example 3

[0105] 3) In the dyeing treatment described above, the same procedure as Example 1 was followed, except that olive oil was used instead of coconut oil when preparing the second mixture.

[0106] Comparative Example 1

[0107] The procedure was the same as Example 1 except that the decolorization treatment was omitted (2).

[0108] Comparative Example 2

[0109] 2) The decolorization treatment was carried out in the same manner as Example 1, except that a solution containing 100 parts by weight of water and 4 parts by weight of hypochlorous acid was used instead of the first mixed solution.

[0110] Comparative Example 3

[0111] The procedure was the same as Example 1 except that the dyeing process (3) above was omitted.

[0112] Comparative Example 4

[0113] The dyeing process was carried out in the same manner as Example 1, except that the coconut fibers were dyed by directly applying the dye instead of immersing them in the second mixture.

[0114] Experimental Example 1: Dye Concentration Evaluation

[0115] Some specimens of colored palm mats were prepared according to the examples and comparative examples in Table 1, and the dyeing concentration was measured. The surface reflectance (R) of the dyed fabric was measured at the maximum absorption wavelength using a spectrophotometer (X-Rite, Model SP-B8, USA), and the dyeing concentration (K / S) was calculated according to the Kubelka-Munk equation, and the dyeing concentration of the dyed fabric according to each condition was compared. The results are shown in Table 1.

[0116] K / S=(1-R) 2 / 2R (K: absorption coefficient, S: scattering coefficient)

[0117] Experimental Example 2: Evaluation of Light Fastness

[0118] Some specimens of colored palm mats prepared according to the examples and comparative examples in Table 1 were tested for light fastness. Light fastness is a test to evaluate the degree of color change due to the influence of an artificial light source, and was measured according to the KS K ISO 105 B02 standard. The results are shown in Table 1.

[0119] Experimental Example 3: Evaluation of friction fastness

[0120] Some specimens of colored palm mats according to the examples and comparative examples in Table 1 were prepared and their friction fastness was measured. This test was conducted to evaluate the degree of color transfer to other materials due to friction, and the measurement was performed according to the KS K ISO 105-X12 standard. The results are shown in Table 1.

[0121] Experimental Example 4: Wear Resistance Evaluation

[0122] Some specimens of colored palm mats, according to the examples and comparative examples in Table 2, were prepared and their abrasion resistance was evaluated. Visual evaluation was performed using a Martindale Abrasion and Pilling Tester in accordance with ASTM-D 4966-98. The results are presented in Table 2.

[0123] Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Dyeing Concentration 53.64 8.64 9.23 2.73 3.54 0.8 Light Fastness 54-54-53 34 Rubbing Fastness Dry 54-54-53-43-44-5 Wet 444 334

[0124] Example 1 Comparative Example 3 Abrasion Resistance 313 points: Almost no fibers removed 2 points: Some fibers removed 1 point: Most fibers removed

[0125] Referring to Table 1, the examples demonstrate superior dyeability, as both dyeing density and friction fastness are superior to the comparative examples. The examples also demonstrate superior light fastness, suggesting that they can address the discoloration issues of existing palm mats.

[0126] Referring to Table 2, it can be seen that the wear resistance of Example 1 can be improved by dyeing according to the example of the comparative example 3, which has superior wear resistance.

Claims

1. A step of decolorizing coconut fiber with a first mixture containing an oxygen-based oxidizing agent, a hydroxide salt, a silicate, a synthetic detergent, and water; A step of dyeing the bleached coconut fiber with a second mixture containing a dye, vegetable oil and water; A step of forming a colored rope by twisting the dyed coconut fibers; and A method for manufacturing a colored palm mat, comprising a step of forming a colored palm mat by interweaving warp and weft yarns formed with the above-mentioned colored rope.

2. In claim 1, in the decolorizing step, A method for manufacturing a colored palm mat, wherein the first mixed solution comprises 10 to 30 parts by weight of the oxidizing agent, 1 to 20 parts by weight of the hydroxide salt, 1 to 20 parts by weight of the silicate, and 1 to 20 parts by weight of the synthetic detergent, relative to 100 parts by weight of water.

3. In claim 1, in the dyeing step, A method for manufacturing a colored palm mat, wherein the second mixed solution contains 1 to 20 parts by weight of the dye and 1 to 10 parts by weight of the vegetable oil, based on 100 parts by weight of water.

4. In claim 1, the step of forming the color rope comprises: A step of forming a fiber strand by twisting the dyed coconut fibers together; A step of arranging the above fiber strands in the outer portion and arranging cotton fibers in the center of the outer portion; A step of forming a primary rope by twisting the above fiber strands and the above cotton fibers; and A method for manufacturing a colored palm mat, comprising the step of forming a secondary rope by twisting the four strands of the primary rope together.

5. In claim 1, in the step of manufacturing the colored palm mat, A method for manufacturing a colored palm mat, wherein the above two lines form one group and extend in the length direction of the mat, and the above two lines form one group and extend in the width direction of the mat.

Images