EP3124692A1 - Recyclable non-slip mat - Google Patents

Recyclable non-slip mat Download PDF

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Publication number
EP3124692A1
EP3124692A1 EP16182174.9A EP16182174A EP3124692A1 EP 3124692 A1 EP3124692 A1 EP 3124692A1 EP 16182174 A EP16182174 A EP 16182174A EP 3124692 A1 EP3124692 A1 EP 3124692A1
Authority
EP
European Patent Office
Prior art keywords
mat
layer
yarn
polypropylene
eva
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16182174.9A
Other languages
German (de)
French (fr)
Inventor
Valter MICHELA
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Emmevi Mv SpA
Original Assignee
Emmevi Mv SpA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Emmevi Mv SpA filed Critical Emmevi Mv SpA
Publication of EP3124692A1 publication Critical patent/EP3124692A1/en
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D06N2209/108—Slipping, anti-blocking, low friction

Definitions

  • the present invention relates to a recyclable non-slip mat, in particular for domestic or automotive use, with improved properties.
  • mats for domestic or automotive use are made of various layers, mainly including a first layer typically comprising tufted-woven fibres on a polypropylene or polyamide support fabric (e.g. synthetic raffia) or jacquard-woven fibre tufts, which, in use, define a resting surface for the feet of the user or of a passenger of the motor vehicle, i.e. an upper side that, in use, faces the environment.
  • a first layer typically comprising tufted-woven fibres on a polypropylene or polyamide support fabric (e.g. synthetic raffia) or jacquard-woven fibre tufts, which, in use, define a resting surface for the feet of the user or of a passenger of the motor vehicle, i.e. an upper side that, in use, faces the environment.
  • this first layer of yarn is made of a polypropylene or polyamide fibre woven fabric.
  • the rubber backing is not compatible, in terms of recycling, with the products used, such as the polypropylene and polyamide used for the manufacture of the first layer of yarn, and therefore, both the processing waste and the finished product at the end of its life are difficult to dispose of and are not reusable, and thus, must go to the landfill with waste assimilable to urban waste.
  • mats made this way have greater thickness and stiffness, making them difficult to handle by the consumer and making the washing machine cleaning process difficult for mats with an upper surface greater than 0.70 m 2 .
  • the object of the present invention is to provide a mat which is fully recyclable, has less stiffness and good spring-back characteristics.
  • a mat for domestic or automotive use comprising a first layer of polypropylene or polyamide yarn which, in use, faces the environment and a second layer made of ethyl vinyl acetate (EVA) which, in use, rests on the floor.
  • EVA ethyl vinyl acetate
  • EVA is a bright, transparent or coloured copolymer, which, coupled to the layer of yarn, allows for obtaining a mat that is more textile to the touch and lighter, but nonetheless non-slip on the resting surface.
  • EVA being compatible with the polypropylene or polyamide yarn, makes the mat and the processing waste fully recyclable, avoiding landfilling.
  • the mat, as well as the processing waste, can be processed to be reused in the production of, for example, a new mat.
  • EVA gives the mat greater softness, lesser thickness, lower weight, high capacity of adhesion, malleability, good spring-back, and thus enhanced washing machine cleanability.
  • the inventive mat is obtained by applying, on the first layer of yarn of the product, EVA in a granular form by means of a powder distribution unit which consists of a hopper containing the EVA powder.
  • a motorised metering roller whose variable speed can be adjusted with an inverter, is mounted, which is coated with dimpled rubber or carding pins.
  • a doctor blade placed on the roller is used to adjust the output of the EVA powder.
  • the distribution of EVA on the yarn layer is effected by means of a brush that spreads the powder evenly on the underlying fabric, in an amount comprised between 300 grams per square metre and 700 grams per square metre of EVA on the reverse of the first layer of yarn.
  • the EVA powder is melted and treated with a heat source to allow for the formation of the backing layer.
  • This step is carried out at a temperature ranging from 60°C to 110°C.
  • the mat is rapidly cooled down on a rotary press cooled to a temperature ranging from -2°C to -12°C, in order to subject the melted EVA powder to a thermal shock and thereby make the backing layer even and compact.
  • a coating layer is formed on the mat, the former defining the face that, in use, will rest on the underlying surface.
  • the dynamic measurement between a marble floor and a 20x20 cm sample of the inventive mat was tested by bringing into contact the EVA layer with the marble floor. A weight of 1 Kg was placed on the sample which was then subjected to a traction force to make it slide on the floor.
  • the slip resistance measured is 0.830 g.
  • the slip resistance measured is 0.550 g.
  • test sample For the same amount of test sample, but with an EPDM or rubber latex backing, it is 870 grams per square metre.
  • the mat according to the invention once ground and powdered, can be reused in the manufacture of mat backings.
  • the thermal behaviour of a sample of the mat of the invention was evaluated and compared with the individual components.
  • thermogravimetric analyses a sample of the EVA powder, a sample of polypropylene yarn and a sample of the mat made with a first layer of polypropylene yarn and a second layer of EVA were analysed by thermogravimetric analyses.
  • Figure 1 represents the thermogravimetric analysis of the EVA powder
  • Figure 2 represents the thermogravimetric analysis of the polypropylene yarn
  • Figure 3 represents the thermogravimetric analysis of a sample of the inventive mat.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Carpets (AREA)

Abstract

The present invention relates to a mat for domestic or automotive use comprising a first layer of polypropylene or polyamide yarn which, in use, faces the environment and a second layer made of an ethyl vinyl acetate copolymer which, in use, rests on the floor.
It also relates to a method of manufacture of the mat.

Description

  • The present invention relates to a recyclable non-slip mat, in particular for domestic or automotive use, with improved properties.
  • Commonly, mats for domestic or automotive use are made of various layers, mainly including a first layer typically comprising tufted-woven fibres on a polypropylene or polyamide support fabric (e.g. synthetic raffia) or jacquard-woven fibre tufts, which, in use, define a resting surface for the feet of the user or of a passenger of the motor vehicle, i.e. an upper side that, in use, faces the environment.
  • Generally, this first layer of yarn is made of a polypropylene or polyamide fibre woven fabric.
  • Since, in use, it is typically positioned beneath the feet of the consumer or of the driver, it is particularly important that a mat for domestic or automotive use does not slip with respect to the floor surface, so as to ensure absolute stability and safety during the use thereof. Therefore, in this sector, coating the rear surface of the mats, i.e. the surface that, in use, rests directly on the floor, with a composition suitable for endowing the mat with non-slip qualities, and which has the function of blocking the weaving yarns on the back of the tufted or jacquard weaves, is a common practice. In particular, today, coating the rear surface of the mats with solid resins such as EPDM or rubber latexes, for example a styrene-butadiene copolymer, creating a second layer (or "backing") which guarantees the non-slip property, is known.
  • However, the majority of the known coating compositions for the rear surface of the mats has the disadvantage of making said mats heavier in terms of weight and of having limited spring-back characteristics.
  • In addition, the rubber backing is not compatible, in terms of recycling, with the products used, such as the polypropylene and polyamide used for the manufacture of the first layer of yarn, and therefore, both the processing waste and the finished product at the end of its life are difficult to dispose of and are not reusable, and thus, must go to the landfill with waste assimilable to urban waste.
  • Moreover, mats made this way have greater thickness and stiffness, making them difficult to handle by the consumer and making the washing machine cleaning process difficult for mats with an upper surface greater than 0.70 m2.
  • Therefore, in this field, there is a need to provide a new mat whose materials, compatible with each other, allow for recycling the final product, as well as the processing waste, without the disadvantages of the mats of the prior art.
  • Therefore, the object of the present invention is to provide a mat which is fully recyclable, has less stiffness and good spring-back characteristics.
  • This object is achieved by the present invention, insofar as it relates to a mat according to claim 1.
  • Further features and advantages of the present invention will be better understood by means of the following description of a preferred embodiment thereof, which is given by way of non-limiting example.
  • According to the present invention, there is provided a mat for domestic or automotive use comprising a first layer of polypropylene or polyamide yarn which, in use, faces the environment and a second layer made of ethyl vinyl acetate (EVA) which, in use, rests on the floor.
  • Advantageously, EVA is a bright, transparent or coloured copolymer, which, coupled to the layer of yarn, allows for obtaining a mat that is more textile to the touch and lighter, but nonetheless non-slip on the resting surface.
  • In addition, EVA, being compatible with the polypropylene or polyamide yarn, makes the mat and the processing waste fully recyclable, avoiding landfilling. In particular, the mat, as well as the processing waste, can be processed to be reused in the production of, for example, a new mat.
  • Furthermore, the use of EVA gives the mat greater softness, lesser thickness, lower weight, high capacity of adhesion, malleability, good spring-back, and thus enhanced washing machine cleanability.
  • The inventive mat is obtained by applying, on the first layer of yarn of the product, EVA in a granular form by means of a powder distribution unit which consists of a hopper containing the EVA powder.
  • At the base of the container, a motorised metering roller, whose variable speed can be adjusted with an inverter, is mounted, which is coated with dimpled rubber or carding pins.
  • A doctor blade placed on the roller is used to adjust the output of the EVA powder. The distribution of EVA on the yarn layer is effected by means of a brush that spreads the powder evenly on the underlying fabric, in an amount comprised between 300 grams per square metre and 700 grams per square metre of EVA on the reverse of the first layer of yarn.
  • After the distribution, the EVA powder is melted and treated with a heat source to allow for the formation of the backing layer.
  • This step is carried out at a temperature ranging from 60°C to 110°C.
  • Subsequently, the mat is rapidly cooled down on a rotary press cooled to a temperature ranging from -2°C to -12°C, in order to subject the melted EVA powder to a thermal shock and thereby make the backing layer even and compact.
  • In this way, a coating layer is formed on the mat, the former defining the face that, in use, will rest on the underlying surface.
  • Further features of the present invention will become apparent from the following description of a few merely illustrative and non-limiting examples.
    • Example 1 SLIP-SLIDING RESISTANCE
  • The dynamic measurement between a marble floor and a 20x20 cm sample of the inventive mat was tested by bringing into contact the EVA layer with the marble floor. A weight of 1 Kg was placed on the sample which was then subjected to a traction force to make it slide on the floor.
  • The load required for its dynamic displacement was then assessed; a spring dynamometer was used for the measurement.
  • The greater the friction between the surfaces, the more effective the slip resistance, i.e. the ability of the mat of staying in place, will be. In the case of the mat according to the invention, the slip resistance measured is 0.830 g.
  • Repeating the same test with a backing made of EPDM or rubber latex, the slip resistance measured is 0.550 g.
    • Example 2 GRAMMAGE
  • This is the weight of 1 square metre of the sample. In the case of the mat according to the invention, it is 400 grams per square metre for a tufted-woven fabric.
  • For the same amount of test sample, but with an EPDM or rubber latex backing, it is 870 grams per square metre.
    • Example 3 RECYCLABILITY
  • The mat according to the invention, once ground and powdered, can be reused in the manufacture of mat backings. In particular, in order to demonstrate the compatibility of the materials of which the mat of the invention is made, which allows for the reuse thereof, the thermal behaviour of a sample of the mat of the invention was evaluated and compared with the individual components.
  • In particular, for comparison, a sample of the EVA powder, a sample of polypropylene yarn and a sample of the mat made with a first layer of polypropylene yarn and a second layer of EVA were analysed by thermogravimetric analyses.
  • The results are shown in Figures 1-3, wherein Figure 1 represents the thermogravimetric analysis of the EVA powder, Figure 2 represents the thermogravimetric analysis of the polypropylene yarn, and Figure 3 represents the thermogravimetric analysis of a sample of the inventive mat.
  • It can be seen that up to 250°C the mixture of the two materials is stable in an inert environment, in particular, it is evident that, at processing temperatures, the coexistence of the two materials does not vary significantly the degradation of the two individual materials.

Claims (4)

  1. Mat for domestic or automotive use comprising a first layer of polypropylene or polyamide yarn which, in use, faces the environment and a second layer made of an ethyl vinyl acetate copolymer which, in use, rests on the floor.
  2. A method for preparing a mat according to claim 1, characterised in that it comprises the steps of:
    - providing a first layer of polypropylene or polyamide yarn having two faces,
    - applying on one face of said first layer of yarn an ethyl vinyl acetate copolymer in granules,
    - heating to melt the ethyl vinyl acetate,
    - cooling to obtain the mat.
  3. A method according to claim 2, characterised in that said heating step is conducted at a temperature ranging from 60 to 110°C.
  4. A method according to claim 2, characterised in that said cooling step is conducted at a temperature ranging from -2°C to -12°C.
EP16182174.9A 2015-07-31 2016-08-01 Recyclable non-slip mat Withdrawn EP3124692A1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
ITUB2015A002696A ITUB20152696A1 (en) 2015-07-31 2015-07-31 ANTI-SLIP RECYCLABLE CARPET

Publications (1)

Publication Number Publication Date
EP3124692A1 true EP3124692A1 (en) 2017-02-01

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EP16182174.9A Withdrawn EP3124692A1 (en) 2015-07-31 2016-08-01 Recyclable non-slip mat

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EP (1) EP3124692A1 (en)
IT (1) ITUB20152696A1 (en)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940525A (en) * 1974-12-30 1976-02-24 E. I. Du Pont De Nemours And Company Tufted carpet having a polyolefin film as the secondary backing
US3975562A (en) * 1974-02-08 1976-08-17 Veb Leuna-Werke "Walter Ulbricht" Textile floor covering with bottom of thermoplastic foam and a method of producing it
EP1076125A1 (en) * 1999-08-09 2001-02-14 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
EP1323577A2 (en) * 2001-12-27 2003-07-02 Suminoe Textile Co., Ltd. Carpet for vehicles and method for manufacturing the same

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3975562A (en) * 1974-02-08 1976-08-17 Veb Leuna-Werke "Walter Ulbricht" Textile floor covering with bottom of thermoplastic foam and a method of producing it
US3940525A (en) * 1974-12-30 1976-02-24 E. I. Du Pont De Nemours And Company Tufted carpet having a polyolefin film as the secondary backing
EP1076125A1 (en) * 1999-08-09 2001-02-14 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
EP1323577A2 (en) * 2001-12-27 2003-07-02 Suminoe Textile Co., Ltd. Carpet for vehicles and method for manufacturing the same

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Publication number Publication date
ITUB20152696A1 (en) 2017-01-31

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