RECYCLABLE NON-SLIP MAT

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

[0001] The present invention relates to a recyclable non-slip mat, in particular for domestic or automotive use, with improved properties.

[0002] 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.

[0003] Generally, this first layer of yarn is made of a polypropylene or polyamide fibre woven fabric.

[0004] 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.

[0005] 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.

[0006] 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.

[0007] 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.

[0008] 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.

[0009] Therefore, the object of the present invention is to provide a mat which is fully recyclable, has less stiffness and good spring-back characteristics.

[0010] This object is achieved by the present invention, insofar as it relates to a mat according to claim 1.

[0011] 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.

[0012] 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.

[0013] 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.

[0014] 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.

[0015] 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.

[0016] 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.

[0017] 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.

[0018] 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.

[0019] After the distribution, the EVA powder is melted and treated with a heat source to allow for the formation of the backing layer.

[0020] This step is carried out at a temperature ranging from 60°C to 110°C.

[0021] 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.

[0022] 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.

[0023] 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

[0024] 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.

[0025] The load required for its dynamic displacement was then assessed; a spring dynamometer was used for the measurement.

[0026] 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.

[0027] Repeating the same test with a backing made of EPDM or rubber latex, the slip resistance measured is 0.550 g.

Example 2

GRAMMAGE

[0028] 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.

[0029] 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

[0030] 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.

[0031] 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.

[0032] 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.

[0033] 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

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.

Drawing