EP2014814B1 - Floor mat made from fluid-absorbing non-woven material - Google Patents

Description

Field of the invention

The invention relates to a liquid absorbent nonwoven floor mat (pad) for receiving and storing liquids that can be used in toilets and placed on urinals or toilet bowls to catch urine drops, and the use of such a mat in sanitary areas. Common feature is that in public toilets or toilets with a high degree of use, cleaning often does not keep pace with use and thus the toilets always smell unpleasant and look dirty. With the floor mat of liquid-absorbent nonwoven fabric according to the invention, this circumstance is eliminated, since the floor mat is placed in front of or under urinals or toilet bowls and the invariably occurring urine drops, which fall next to the collecting bowl, are invisibly taken up by the latter.

State of the art

So far, no suitable for the intended use products are known.

The method used for the surface formation of the nonwoven fabric of the floor mat according to the invention is known and corresponds to the prior art. This method uses the mechanical needling with the help of special needles and in a through the Faseraustrag in a co-rotating brush belt compared to the classic principle of non-woven fabric consolidation modified form.

The use of nonwoven fabrics with a formed on a surface continuous Faserpolschicht on an industrial scale is previously known only as a textile flooring in the commercial and private sector, as well as textile lining and Kaschiermaterial in the automotive industry.

The DD-PS 39 819 describes a single-ply fleece-stitched fabric in which the fibers of the nonwoven fabric are incorporated in the form of loops in a prefabricated carrier web. The structured surface according to the invention is achieved here by roughing and shearing.

In the DD-PS 85141 becomes the compound training after the DD-PS 39 819 describes the use of a carrier web, which consists of a nonwoven stitching knitted together by knitting needles, from which also fibers can contribute to the formation of a fluffy surface.

From the DD-PS 159 353 a product is known in which from pile or pile fabric by barb needles fibers from the existing pile or pile are discharged through a textile carrier web and train on the back of this carrier web also a Polschicht.

In the DD 101 39 842 a loop member for Velcro is described in which by applying a part of the present invention on the underlying mechanical finishing process on a fiber or thread stitch bonded nonwoven fabric by the discharge of a Faserpolschicht a velor-like surface in high density, parallelism and uniform height is formed.

The DD 101 39 841 describes the production of a textile backing for carpets, in the same way a fibrous pile layer of high density and height uniformity is formed on a nonwoven fabric solidified by fiber or thread stitch.

Presentation of the invention

The invention has for its object to provide a floor mat of a novel nonwoven fabric, which is due to their structure and composition of materials for the uptake and storage of liquids, in particular accidentally leaked body fluids on floors in sanitary areas, suitable and can be produced by a simple method ,

This object is achieved by a floor mat having the features of claim 1 and by the use of such a mat having the features of claim 14. Advantageous embodiments follow from the remaining claims.

The object is achieved by the invention in that the floor mat of liquid-absorbent, preferably by needling consolidated nonwoven fabric having on a surface facing away from the bottom a Polschicht of fiber parts consists, wherein the nonwoven fabric contains fibers with a high absorption capacity, only in the interior of the nonwoven fabric are contained. As used herein, the term "high absorbency fibers" refers to fibers capable of receiving many times (preferably more than 5 times, more preferably more than 10 times, more preferably more than 15 times) their own weight of aqueous liquid , Liquid (such as urine) is taken up via the pile layer of the nonwoven fabric, which can be formed with a defined density and structure and firmly bonded to the nonwoven fabric, and stored in the nonwoven fabric, primarily in the high absorbency fibers. The high absorbency fibers may be synthetic fibers or natural fibers, especially viscose, cotton or sheep wool fibers. Since the floor mat of the invention can be made and processed by conventional textile processing methods, production is simple and inexpensive.

Preferably, the high-absorbency fibers are superabsorbent fibers. Superabsorbents, also called absorbent gelling materials (AGMs), are known in the art. Their most important feature is that they can absorb many times their own weight in liquid and do not give it off even under pressure. Ingested liquid is transformed into a superabsorbent gel and thus bound. This ensures that even when using the floor mat, d. H. For example, if a user is wholly or partially standing on the floor mat, with considerable pressure being exerted on the mat, no liquid will escape from the mat. Furthermore, the high absorbent capacity of the superabsorbents allows for reduced thickness and / or extended service life (i.e., duration until the nonwoven fabric is saturated with liquid) of the floor mat. Superabsorbents may be in various forms, such as flakes or beads, with superabsorbent fibers being used in a preferred embodiment of the invention because they can be forcibly knitted in the fiber composite of the nonwoven fabric, particularly by needlepunching. This ensures that the superabsorbent do not shift even when using the floor mat, so that a uniform fluid intake and storage is permanently enabled. Thus, a robust floor mat is created, which can absorb liquid and store it reliably even under increased stress.

The high-absorbency fibers are contained only inside the nonwoven fabric. The Polschicht can in this case mainly or even exclusively from liquid-receiving and be formed liquid-conveying fiber parts, so that liquid absorbed via the pole layer is transported into the interior of the nonwoven fabric and there is stored by the fibers with high absorption capacity. This ensures that the surface of the floor mat facing the user remains at least substantially dry, which is desirable for hygienic reasons, especially when using the mat on floors in sanitary areas. Such a structure of the floor mat can be easily achieved in the formation of the pole layer. In the pile forming process described further below (velorizing), the nonwoven fabric is pierced with a plurality of indented needles perpendicular to its surface, thereby discharging the pile forming fiber portions from the fabric. By a suitable choice of the diameter of the superabsorbent fibers and the dimensions of the Nadeleinkerbungen can be ensured that no high-absorbency fibers are discharged in this method and the Polschicht is thus formed exclusively by other fibers contained in the nonwoven fabric.

In a preferred embodiment of the invention, the nonwoven fabric contains between 10% and 30% superabsorbent fibers, preferably about 20% superabsorbent fibers. In this way, on the one hand, a high liquid absorption capacity and thus a long service life of the floor mat is guaranteed. On the other hand, since superabsorbent fibers saturated with liquid have low mechanical stability, for example, the addition of other, more physically robust synthetic and / or natural fibers can achieve the mat strength required for the high demands on use. Furthermore, especially the fibers of the fiber layer forming the pile layer can be chosen so that they have good liquid absorption and liquid transport properties. In addition, it is possible to use a combination of superabsorbent fibers and others High absorbency fibers (synthetic or natural fibers, especially viscose, cotton or sheep wool fibers) for liquid storage in the floor mat. As already mentioned above, the various fibers of the nonwoven fabric can be knitted together, preferably by needling, resulting in a homogeneous and robust floor mat.

In a preferred embodiment, the nonwoven fabric further contains synthetic fibers, preferably polyester fibers. As such fibers are generally more robust and durable than natural fibers, this can increase the stability and service life of the mat. Furthermore, synthetic fibers are available in any desired colors, so that with a suitable choice of the fiber colors and targeted fiber discharge into the pile layer, a desired appearance of the mat surface corresponding to the intended use can be achieved.

In a further preferred embodiment, the nonwoven fabric contains natural fibers, preferably viscose fibers. These fibers can preferably be used for liquid absorption in the pile layer, for liquid transport from the pile layer into the nonwoven fabric interior, and for liquid storage in the nonwoven fabric interior. In a preferred embodiment, the floor mat of the invention can be made entirely of rotting natural fibers, which enables environmentally friendly disposal of the mat, possibly via the organic waste.

Furthermore, a surface of the nonwoven fabric facing the bottom may be provided with an adhesive coating, preferably a rubber coating. Thus, a slippage of the mat is prevented during use and ensures a secure footing of the user.
In a further embodiment, the pile layer of the nonwoven fabric preferably a point or strip-shaped pattern of selectively discharged from the fiber non-woven fabric fiber parts that can protrude from the pile layer in the direction of the user. The structuring of such a surface can be achieved, for example, by a two or more stage fiber discharge process using the same or different types of needles (needle shape, needle size, dimensions and shape of the needle notches, etc.). In particular, this process can be carried out so that only fibers of a certain thickness (or a certain thickness range) form the specifically discharged fiber parts of the pattern. If these discharged fibers are selected in a certain color different from the color of the other fibers (in the production of the nonwoven fabric), then a color matching of the surface of the mat coordinated with the field of application of the floor mat can be achieved. On the other hand, when using fibers of the same color, a structural patterning (ie a controlled change in the surface morphology) of the mat is possible by discharging certain fiber parts out of the polar layer. The surface structure of the pole layer can be made rough, for example, so that unintentional slipping of a standing on the mat user is prevented. Of course, by combination of these two approaches, both a structurally and color patterned floor mat can be produced.

For example, the pile layer of the floor mat may be patterned to have a yellow / black mottled appearance. Such a coloring is ideal for use of the mat on floors in sanitary areas, as contamination of the polar layer caused by trapped drops of urine and hair is not visible to the user.

Preferably, the nonwoven fabric with an antiviral and / or antibacterial and / or a antiparasitic and / or antifungal agents. Here, for example, a plurality of different agents or a single agent having one, several or even all of these effects may be used, wherein the agent or agents are preferably taken up and stored in the high-absorbency fibers. Such a pretreatment of the mat is advantageous in particular for its use in sanitary areas for hygienic and health reasons.

Preferably, the nonwoven fabric is provided with a perfume. In this way, for example, can be covered by leaked body fluids, such as urine, evoked bad odors and ensure a pleasant smell of the mat.

Preferably, the floor mat includes a display device that indicates the degree of saturation of the absorbent nonwoven fabric with absorbed liquid. Thus, when the nonwoven fabric is completely saturated and can not accept any more liquid, the mat can be replaced. The display guarantees here that the mat exchange takes place at the right time. On the one hand, such an economic use of the floor mat is made possible because it is disposed of only when the nonwoven fabric is soaked with liquid. On the other hand, too long use of the mat, which could result in leakage of liquid from the saturated or supersaturated nonwoven fabric, is prevented.

Preferably, the floor mat has a length of 30 to 40 cm and a width of 30 to 40 cm. Such a size of the floor mat is sufficient to reliably absorb escaped body fluids (for example, urine droplets) from a user standing on or immediately adjacent to it. On the other hand, the mat is small enough to hold one to guarantee trouble-free transport and cost-effective production.

Preferably, the floor mat of the invention is suitable for receiving inadvertently leaked body fluids on floors in sanitary areas. For example, the mat may be placed directly below or in front of a urinal (or toilet bowl), with a user standing in front of the mat or in whole or in part on the mat depending on the mat placement. In the case of the user standing on the floor mat, the use of superabsorbent fibers is particularly advantageous since they ensure reliable storage of liquids even under pressure applied to the mat. Further advantages of the invention when used as floor mat in sanitary areas have already been described in detail above.

Furthermore, the invention relates to the use of a floor mat of liquid absorbent, preferably by needling solidified, nonwoven fabric having on a surface facing away from the bottom a Polschicht of fiber parts, wherein the nonwoven fabric contains fibers with a high absorption capacity, for receiving accidentally leaked body fluids on floors in sanitary areas.

Preferably, a floor mat of the preferred embodiments described above is used to accommodate inadvertently leaked body fluids on floors in sanitary areas.

Brief description of the drawings

Fig. 1

einen schematischen Querschnitt einer Vliesstoffstruktur aus einer einzelnen Vliesstoffkomponente mit einer vollflächigen Polschicht einheitlicher Höhe gemäß einer ersten Ausführungsform der Erfindung zeigt;

Fig. 2

einen schematischen Querschnitt einer Vliesstoffstruktur aus einer einzelnen Vliesstoffkomponente mit partiell ausgebildeten, hervorstehenden Faserpolkomponenten gemäß einer zweiten Ausführungsform der Erfindung zeigt;

Fig. 3

einen schematischen Querschnitt einer Vliesstoffstruktur aus einer einzelnen Vliesstoffkomponente mit einer vollflächigen Polschicht einheitlicher Höhe und einer haftfähigen Rückenschicht gemäß einer dritten Ausführungsform der Erfindung zeigt; und

Fig. 4

eine mögliche Anordnung der erfindungsgemäßen Bodenmatte auf dem Boden vor einem Urinal zeigt.

The invention will now be described purely by way of example with reference to the accompanying drawings, in which:

Fig. 1

shows a schematic cross section of a nonwoven fabric structure of a single nonwoven fabric component with a full-height pole layer of uniform height according to a first embodiment of the invention;

Fig. 2

Figure 3 shows a schematic cross-section of a nonwoven fabric structure of a single nonwoven component with partially formed protruding fiber pile components according to a second embodiment of the invention;

Fig. 3

Figure 12 shows a schematic cross section of a nonwoven fabric component nonwoven fabric structure with a uniform height, all-over pile layer and an adhesive backsheet according to a third embodiment of the invention; and

Fig. 4

shows a possible arrangement of the floor mat according to the invention on the floor in front of a urinal.

Ways to carry out the invention

FIG. 1 shows a schematic cross section of a nonwoven fabric structure of only one nonwoven fabric component 1 according to a first embodiment of the invention, in which moisture-transporting fibers and moisture-storing fibers are contained in defined proportions and are discharged from the fiber parts of all fiber components in equal parts in a full-surface pole layer 2 of uniform height.

The nonwoven fabric structure of the first embodiment is as in FIG Fig. 1 represented by a nonwoven fabric component 1, formed from a needle-punched non-woven fabric, previously from a Mixture of 63% viscose fibers 8.9 dtex, 15% viscose fibers 1.7 dtex, 20% superabsorbent fibers 10 dtex and 2% polyester fibers 13 dtex with a basis weight of 400 g / m ^{2 is} produced. Due to the black polyester fibers mixed in a proportion of 2%, a special appearance of the nonwoven surface is achieved.

The process used to form a Faserpolschicht 2 by the discharge of fiber parts of a nonwoven fabric 1 is referred to as Velourisieren. A multiplicity of needles pierces the nonwoven fabric 1 perpendicular thereto. Depending on the design, either needles with a round cross-section at the top are provided with a notch called a fork, or needles with a triangular or square cross-section are provided with a short distance from the needle point with barb-shaped notches introduced in all or selected edges. The size of the fork opening or notches is selected according to the diameter of the fibers used in the needle punched nonwoven fabric 1. This ensures that fibers located in the plane of the nonwoven fabric 1 are caught by the forks or the hooks of the piercing needles, are carried out of the nonwoven fabric 1 and form the pole components 5 projecting perpendicularly to the nonwoven fabric. The height of this discharge movement is chosen so that the fiber remains anchored with at least one end in the nonwoven fabric 1.

From fiber parts of all fibers contained in the nonwoven fabric component 1 is by their vertical discharge with fork needles of fineness 42 gg, the fork opening is tuned with a width of 0.05 mm and a depth of 0.05 mm to the diameter of the fibers of the nonwoven fabric 1, formed at a penetration depth of 6.0 mm on a surface, the Faserpolschicht 2 in full-surface manner. A high and dense fiber discharge into the pile layer is realized by the needles penetrating with a puncture density of 842 punctures per cm ² . While the needles are hers Running backward movement, the discharged fiber parts remain temporarily fixed in their vertical position in a brush belt, which moves with the material at the same feed rate of 3.00 m / min. The height of this Faserpolschicht 2 results with 4 mm.

At the in Fig. 2 In the illustrated nonwoven fabric structure of a second embodiment of the invention, a two-stage process using two needle machines arranged one behind the other is used. The composition of the nonwoven fabric 1 is the same as in the first embodiment. In the first process step as under Fig. 1 first described the Faserpolkomponenten 5 discharged from parts of all fibers of the nonwoven fabric component 1. For this fork needles of fineness 42 gg are used. The depth of the puncture is 6 mm and gives the height of Faserpolschicht 2 with 3 mm.

Subsequent to the first process stage, the nonwoven fabric component 1 with the already formed Faserpolschicht 2 is fed to a second needle machine wherein the Faserpolschicht 2 remains fixed over the entire process in the brush belt of the machine.
The second needle machine now bears with ringing needles of fineness 36 gg additional Faserpolkomponenten 3 partially from the nonwoven fabric 1 from. With the barbs having a depth of 0.01 mm attached at 3.18 mm from the tip on each of the three edges of the working part of the needle, only the fine viscose fibers 1.7 dtex are transported out of the nonwoven fabric component 1, so that they open the outside of the nonwoven fabric 1 already provided with the Faserpolschicht 2 form the consisting of the Faserpolkomponenten 3 Faserpolschicht 6 with a height of 4 mm. The wreath needle must protrude 9.5 mm deep from the surface of the nonwoven fabric 1 into the brush belt to realize a Faserpolhöne of 4 mm. By special design of the Benadelung and the Ratio between material feed and Nadelhubfrequenz (3.55 mm feed per stroke) in the needle machine used for the second process step, the graft and partial formation of the Faserpolkomponenten 3 is achieved. The result is a dot-shaped pattern, which is highlighted by the yellow color of the predominantly discharged viscose fibers 1.7 dtex.

FIG. 3 Fig. 10 shows the nonwoven fabric structure of a third embodiment of the invention whose nonwoven fabric composition and pile layer configuration are identical to those of the first embodiment. In addition, the nonwoven fabric structure of the third embodiment has a backing layer 4 applied by laminating a hot melt adhesive film or by coating, which serves as anti-slip equipment for positioning the structure in the desired area.

According to the above-described production of the nonwoven fabric structures of the first to third embodiments, the nonwoven fabrics are prepared by conventional cutting or punching methods into a suitable size for use as a floor mat size such. B. 40 × 40 cm ² , divided. The referring to Fig. 3 described application of an adhesive backing layer 4 in the structure of the third embodiment may be carried out before or after the dicing process. The thus-divided nonwoven fabric structure may then be used as a liquid receiving and storing floor mat with the mat placed so that the fiber pile layer 2 (or 6) lies on the user facing side.

FIG. 4 shows an arrangement of the liquid-absorbent floor mat 10 according to the invention, which is placed on the floor in front of a urinal 20. In this case, the mat 10 is arranged so that the user stands entirely on it when using the urinal 20. However, the mat 10 can be placed closer to the wall 30, so that the user is only partially or not at all. The arrangement of the mat 10 can be adapted to the structure of the given premises.

Claims (15)

1. Floor mat (10) made from liquid-absorbing fibre non-woven fabric (1) preferably solidified by needling and which has on one surface facing away from the floor a pile layer (2, 6) made from fibre parts (5, 3), characterised in that the fibre non-woven fabric (1) contains fibres having a high absorption capacity which are present only in the interior of the fibre non-woven fabric (1).
2. Floor mat (10) according to claim 1, in which the fibres having high absorption capacity are superabsorber fibres.
3. Floor mat (10) according to one of the preceding claims, in which the fibre non-woven fabric (1) contains between 10% and 30% of superabsorber fibres, preferably about 20% of superabsorber fibres.
4. Floor mat (10) according to one of the preceding claims, in which the fibre non-woven fabric (1) also contains artificial fibres, preferably polyester fibres.
5. Floor mat (10) according to one of the preceding claims, in which the fibre non-woven fabric (1) contains natural fibres, preferably viscose fibres.
6. Floor mat (10) according to one of the preceding claims, in which one surface of the fibre non-woven fabric (1) facing the floor is provided with an adhesive coating (4), preferably a rubber coating.
7. Floor mat (10) according to one of the preceding claims, in which the pile layer (2, 6) of the fibre non-woven fabric (1) has a preferably point-like or strip-like pattern of fibre parts (5, 3) removed specifically from the fibre non-woven fabric (1).
8. Floor mat (10) according to one of the preceding claims, in which the pile layer (2, 6) has a yellow/black blended appearance.
9. Floor mat (10) according to one of the preceding claims, in which the fibre non-woven fabric (1) is provided with an anti-viral and/or an anti-bacterial and/or an anti-parasitic and/or an anti-fungal agent.
10. Floor mat (10) according to one of the preceding claims, in which the fibre non-woven fabric (1) is provided with a fragrance.
11. Floor mat (10) according to one of the preceding claims, which also has a display device which displays the degree of saturation of the fibre non-woven fabric (1) with absorbed liquid.
12. Floor mat (10) according to one of the preceding claims, which has a length of 30 to 40 cm and a width of 30 to 40 cm.
13. Floor mat (10) according to one of the preceding claims, which is suitable for absorbing inadvertently expelled body fluids on floors in sanitary areas.
14. Use of a floor mat (10) made from liquid-absorbing fibre non-woven fabric (1) preferably solidified by needling and which has on one surface facing away from the floor a pile layer (2, 6) made from fibre parts (5, 3), wherein the fibre non-woven fabric (1) contains fibres having a high absorption capacity to absorb inadvertently expelled body fluids on floors in sanitary areas.
15. Use of a floor mat (10) according to one of claims 2 to 13 to absorb inadvertently expelled body fluids on floors in sanitary areas.

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