GB2338412A

GB2338412A - Dust control mat

Info

Publication number: GB2338412A
Application number: GB9812985A
Authority: GB
Inventors: Terence Michael Hedley
Original assignee: Walk Off Mats Ltd
Current assignee: Walk Off Mats Ltd
Priority date: 1998-06-17
Filing date: 1998-06-17
Publication date: 1999-12-22
Also published as: EP0965300A1; GB9812985D0

Abstract

A dust control mat has a tufted fibre layer (2) including a substrate (8) and tufts of a first yarn (10) and a second yarn (12). The first yarn (10) is a twisted synthetic yarn and the second yarn (12) is a twisted yam that includes a synthetic monofilament (14) and a third yarn (16) having good moisture absorbing characteristics, e.g. being a cotton yarn.

Description

2338412 1 DUST CONTROL MATS This invention relates to dust control and in

particular, but not exclusively, to washable dust control mats, in which a rubber backing sheet is cured and heat-bonded under pressure to the back of a fabric layer. It also relates to a process for manufacturing dust control mats.

The term "washable" means washable by immersion and agitation in water or other cleaning fluid usually followed by spin extraction and tumble drying. The term "mat" is used hereinafter in a wide sense to include rugs and carpets.

Manufacturers of washable rubber backed dust control mats sell their mats to the textile rental industry who then rent or sell the mats to the end users such as shops, factories, hospitals etc. The mats are placed at the entrances of buildings and serve to remove dirt and moisture from the feet of pedestrians entering the buildings. On a weekly, two weekly or monthly cycle the dirty mats are collected and returned to the laundry for washing and replaced with clean mats.

It is normal for a laundry to purchase a number of types of mats to deal with the variety of soiling types and end users. The common types of mat are as follows:

A. Cotton Mats: In general, these are mats of low aesthetic appeal but with very good moisture, grease and oil absorbing properties. The mats have low particulate soil absorption properties as the dense closed structure of the pile only allows the dirt to remain on the surface. This type of mat is usually seen in industrial locations and in entrances other than the main high profile entrances of shops, offices, factories etc.

B - High Twist Nylon Mats: These mats utilise a high twist nylon pile and are harder wearing and generally more aesthetically pleasing than cotton pile mats. The mats are therefore usually placed at the high profile entrances to premises and can be colour co-ordinated with the decoration and may have a message or advertisement written on them. The mats have very good particulate soiling absorption properties and maintain 2 their appearance longer than other mat types, as the soiling is absorbed into and hidden within the pile. These mats only have limited moisture and oil absorption properties.

C. Scraper Mats: These mats have a pile that is manufactured from 100% nylon or polyester monofilament, or a combination of monofilament and high twist nylon pile. This type of mat can be placed outside the entrance to enable people entering the building to wipe their feet to remove particulate soiling. The mats have little or no moisture absorbing properties and are usually complemented by a second mat of cotton or High Twist Nylon immediately inside the entrance to remove moisture from the shoes of pedestrians.

It is an object of the invention to provide a dust control mat that mitigates at least some of the disadvantages of the aforesaid mat types.

According to the present invention there is provided a dust control mat having a tufted fibre layer including a substrate and tufts of a first yarn and a second yarn, wherein the first yarn is a twisted synthetic yarn and the second yarn is a twisted yarn that includes a synthetic monofilament and a third yarn having good moisture absorbing characteristics.

The inclusion in the second yarn of a synthetic monofilament and a third yarn having good moisture absorbing characteristics gives the mat good dirt removing and moisture absorbing properties, while first yarn of twisted synthetic yarn gives the mat good particulate soil absorption and a smart and durable appearance. Twisting the synthetic monofilament and the third yarn together gives the second yarn a similar stiffness to that of the first yarn, which gives the mat a uniform appearance and improves its durability.

Advantageously, the first yarn is a high twist nylon yam and preferably a two ply yarn, the count of the first yam being in the range 1000 to 5000 decitex, preferably 3 approximately 1300 decitex. High twist nylon yarn has been found to give the mat very good particulate soil absorption and a smart appearance.

Advantageously, the second yarn includes a nylon or polyester monofilament of diameter 0.025mm to 0.5mm, preferably approximately 0.2mm. The monofilaments provide a scraping effect that removes dirt very efficiently from pedestrians' shoes.

They also cause an audible scraping sound when the mat is stepped upon, which encourages people to wipe their feet.

Advantageously, the third yarn includes from one to six plies, preferably two plies, of cotton yam of cotton count 10 to cotton count 1, preferably cotton count 2. The cotton yarn gives the mat very good moisture absorbing properties.

The third yarn may include a blend of cotton and polyester and the second yarn may 15 be a twisted, heat set yarn. The inclusion of low melting point polyester allows the second yarn to be twisted and heat set. Alternatively, the second yarn may be heat set by partially melting the synthetic monofilament. Heat setting the second yarn gives it better abrasion resistance and improves adhesion between the third yarn and the monofilament.

Advantageously, the ratio of first yam tufts to second yam tufts in the fibre layer is in the range 1: 1 to 6: 1, preferably 3: 1. These ratios have been found to give a good balance of properties: i.e., a good scraping effect, good moisture absorption, good particulate soil absorption and good appearance and durability.

Advantageously, the substrate includes a layer of non-woven polyester.

Advantageously, the tufted fibre layer is bonded to a rubber bacidng layer of natural or synthetic rubber.

The mat is preferably a washable dust control mat.

4 According to a further aspect of the invention there is provided a process for manufacturing dust control mats, in which a first yarn and a second yarn are tufted onto a substrate to produce a tufted fibre layer having tufts of said first and second yarns, wherein the first yarn is a twisted synthetic yarn and the second yarn is a twisted yarn that includes a synthetic monofilament and a third yarn having good moisture absorbing characteristics.

An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawing, in which:

Fig. 1 is a side cross-section through a portion of a dust control mat.

The mat shown in Fig. 1 has a fabric layer 2 and a rubber bacIcing 4. The fabric layer 2 includes a tufted pile 6, which can be cut, looped or both, and typically consists of cut pile. The pile 6 is tufted onto a substrate 8 (or primary bacldng), for example of woven or non-woven polyester or polypropylene of density between 70 and 300 gms/m. In the preferred example we use a non-woven polyester substrate of density 100 gmslml. The fabric layer 2 is bonded to the bacIdng 4 of nitrile rubber in a heated press, for example at a temperature of 170 0 C and a pressure of 30 pounds per square inch, applied for a cycle time of six minutes.

The pile is made up of two yarn types, these being: A: a first yarn 10 of high twist nylon, and B: a second yarn 12 including a nylon monofilament 14 and two cotton plies 16.

The fibre layer 2 is produced by creeling the tufting machine as follows: A A A B A A A B A A A B etc., where A = high twist nylon yarn 10 and B = 3 ply cotton/nylon monofilament 12.

This produces a 1 in 4 tufted pile with three tufts of high twist nylon yarn 10 for each tuft of 3 ply cotton/nylon monofilament yarn 12 (i.e. a ratio of 3: 1).

By combining the three pile types, it is possible to create a mat with the following properties:

1 increased scraping effect compared to a cotton or high twist nylon pile, increased moisture absorption compared to a high twist nylon or scraper mat, 3. increased particulate soil absorption compared to a cotton mat.

2.

In this example, the high twist nylon yarn 10 is a two ply yarn of 1300 Decitex with an inserted twist level of 195 twists per metre and heat set. However other 1, 2, 3 or 4 ply yarns ranging in count from 1000 to 4500 denier with single filament counts of the order 15 to 100 denier per filament may also be used.

In this example, the 3 ply cotton/nylon monofilament yarn 12 consists of one ply of nylon monofilament 14 and two plies of cotton 16. The nylon monofilament has a diameter of 0.2mm: however polyester monofilament varying in diameter from 0.025nim to 0.5mm would also be suitable. The two plies of cotton 16 are of count 2's cotton count and are twisted with the monofilament 14. Counts of 10's to I's cotton count would also be suitable in 1, 2, 3, 4, 5 or 6 ply.

Blends of cotton and polyester up to 50% would also be suitable. The addition of a low melting point polyester may be advantageous in that the yarn would then be heat set during the pressing process and the polyester would melt into the cotton, giving better abrasion resistance and improved adhesion to the monofilament. It would also be possible to achieve the same effect by melting the nylon monofilament either by heat setting, microwaving or heating by some other suitable means.

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Claims

1. A dust control mat having a tufted fibre layer including a substrate and tufts of a first yarn and a second yam, wherein the first yam is a twisted synthetic yam and the second yarn is a twisted yam that includes a synthetic monofilament and a third yarn having good moisture absorbing characteristics.

2. A mat according to claim 1, wherein the first yarn is a high twist nylon yarn.

3. A mat according to claim 1 or claim 2, wherein the first yam is a two ply yarn.

4. A mat according to any one of the preceding claims, wherein the count of the first yarn is in the range 1000 to 5000 decitex, preferably approximately 1300 decitex.

5. A mat according to any one of the preceding claims, wherein the second yarn includes a nylon or polyester monofilament of diameter 0.025mm to 0. 5mm, preferably approximately 0.2mm.

6. A mat according to any one of the preceding claims, wherein the third yarn includes from one to six plies, preferably two plies, of cotton yarn of cotton count 10 to cotton count 1, preferably cotton count 2.

7. A mat according to any one of the preceding claims, wherein the third yarn 25 includes a blend of cotton and polyester.

8. A mat according to any one of the preceding claims, wherein the second yarn is a twisted, heat set yarn.

9. A mat according to any one of the preceding claims, wherein the ratio of first yarn tufts to second yarn tufts in the fibre layer is in the range 1: 1 to 6: 1, preferably 3A.

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10. A mat according to any one of the preceding claims, wherein the substrate includes a layer of non-woven polyester.

11. A mat according to any one of the preceding claims, wherein the tufted fibre 5 layer is bonded to a rubber backing layer.

12. A mat according to any one of the preceding claims, wherein the mat is a washable dust control mat.

13. A dust control mat substantially as described herein with reference to and as illustrated by the accompanying drawings.

14. A process for manufacturing dust control mats, in which a first yarn and a second yarn are tufted onto a substrate to produce a tufted fibre layer having tufts of said first and second yarns, wherein the first yarn is a twisted synthetic yarn and the second yarn is a twisted yarn that includes a synthetic monofilament and a third yarn having good moisture absorbing characteristics.

15. A process according to claim 14, wherein the first yarn is a high twist nylon yarn.

16. A process according to claim 14 or claim 15, wherein the first yarn is a two ply yarn.

17. A process according to any one of the preceding claims, wherein the count of the first yarn is in the range 1000 to 5000 decitex, preferably approximately 1300 decitex.

18. A process according to any one of the preceding claims, wherein the second 30 yarn includes a nylon or polyester monofilament of diameter 0. 025mm to 0.5mm, preferably approximately 0.2mm.

8 1

19. A process according to any one of the preceding claims, wherein the third yam includes from one to six plies, preferably two plies, of cotton yarn of cotton count 10 to cotton count 1, preferably cotton count 2.

20. A process according to any one of the preceding claims, wherein the third yarn includes a blend of cotton and polyester.

21. A process according to any one of the preceding claims, wherein the second yarn is a twisted, heat set yarn.

22. A process according to any one of the preceding claims, wherein the ratio of first yarn tufts to second yarn tufts in the fibre layer is in the range 1: 1 to 6: 1, preferably 3A.

23. A process according to any one of the preceding claims, wherein the substrate includes a layer of non-woven polyester.

24. A process according to any one of the preceding claims, wherein the tufted fibre layer is bonded to a rubber backing layer.

25. A process according to any one of the preceding claims, wherein the mat is a washable dust control mat.

26. A process for manufacturing mats, the process being substantially as described 25 herein with reference to and as illustrated by the accompanying drawings.