JP2008206802A - Deodorant antibacterial carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide the carpet which can adsorb the malodor component of the room air efficiently and remove it through natural air flow, and can control generation of bacterium or green mold. <P>SOLUTION: Air flows through inside the carpet by natural convection, by giving deodorizing and antibacterial functions to a highly expanded carpet backing agent to give ventilation function totally to the carpet, which in return reduces malodor effectively and gives antibacterial function to control the generation of the bacteria. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a carpet having both a deodorizing function capable of efficiently adsorbing and removing malodors such as formaldehyde, ammonia and acetic acid in the indoor air and an antibacterial function for suppressing the generation of bacteria, molds, etc. It is.

  In recent years, heat insulation and airtightness have been remarkably improved compared to conventional houses, and high-performance energy-saving houses have been developed. However, it is considered that the higher the airtightness of a house, the more likely it will be that unpleasant odors and house dust will be trapped in the room, which will cause allergies and cause discomfort. Therefore, in the carpet used in such a house, there has been a demand for a carpet provided with a function of removing unpleasant odors and a function of suppressing generation of bacteria, molds and the like. In addition, such a demand is not limited to a house, but a similar demand is also increasing in a carpet used in a room such as an aircraft, an automobile, and a railway vehicle.

  The main unpleasant odors in the room include food odors, pet odors, and tobacco odors. For example, various gases such as ammonia, hydrogen sulfide, methyl mercaptan, acetic acid, formaldehyde, etc. can be exemplified as the cause of bad odor components. The present invention provides a carpet having an antibacterial effect on bacteria that cause odor.

In Patent Document 1, a carpet having a deodorizing, antibacterial, and insect-repellent function is proposed. In Patent Document 1, a compounding agent composition having an additional function such as a flame retardant, a deodorant, an antibacterial agent, and an insect repellent, which does not contain a binder on the back surface of the carpet, is applied, and a binder is further formed thereon Carpets formed by applying a backing composition containing the same have been proposed, and carpets that can exhibit additional functions such as flame retardants, deodorants, antibacterial agents, insect repellents, etc. with very high efficiency are disclosed. . However, since this technique is applied with a compound composition having additional functions such as a flame retardant, deodorant, antibacterial agent, insect repellent and the like on the back side of the carpet without including a binder, the effect of the additional function agent However, since the backing composition cannot securely fix the pile yarn, the pull-out strength of the pile yarn is weak and the carpet has no basic performance.
Japanese Patent Laid-Open No. 10-328013

  The present invention has been made in view of such a technical background, and can efficiently adsorb and remove malodorous components of indoor air by the flow of natural air, and can suppress the generation of bacteria and mold. The purpose is to provide a carpet.

  As a result of intensive studies to solve such problems, the present inventors have given a defoaming function and an antibacterial function to a highly foamed carpet backing agent, thereby providing the entire carpet with breathability. As a result, the present inventors have found that air can flow inside the carpet by natural convection, effectively reducing malodor, and exhibiting an antibacterial action that suppresses the generation of bacteria. In order to achieve the above object, the present invention provides the following means.

[1] In a carpet including a skin layer comprising a pile yarn and a base fabric, and a sealing layer for fixing the pile yarn and the base fabric, a deodorant and an antibacterial agent are supported on the sealing layer. A carpet having an air permeability of 1 to 50 (cm ³ / cm ² · sec) as a whole.

  [2] The carpet according to item 1 above, wherein the sealing layer is made of foamed latex.

  [3] The item 1 or 2 above, wherein the deodorant comprises a hydrazine derivative and an inorganic substance, and the antibacterial agent is one or more metals selected from zinc, copper and silver, and compounds thereof. Carpet described in 2

[4] The carpet according to any one of items 1 to 3, wherein the deodorant is applied at ² to 50 g / m ² and the antibacterial agent is applied at 0.5 to 20 g / m ² .

According to the invention of [1], in a carpet including a skin layer comprising a pile yarn and a base fabric, and a sealing layer for fixing the pile yarn and the base fabric, a deodorant is provided on the sealing layer. And the antibacterial agent is supported, and the air permeability of the entire carpet is 1 to 50 (cm ³ / cm ² · sec), so that indoor air can pass through the interior of the carpet by natural convection, Deodorant and antibacterial action can be effectively exerted by the deodorant and antibacterial agent.

According to the invention of [2], since the sealing layer is made of foamed latex, it is easy to form continuous holes, and the air permeability of the entire carpet is ensured to be 1 to 50 (cm ³ / cm ² · sec). Therefore, good air permeability can be stably ensured, and the deodorant and antibacterial agent can effectively exert the deodorant and antibacterial action.

  According to the invention of [3], the deodorant comprises a hydrazine derivative and an inorganic substance, and the antibacterial agent is one or more metals selected from zinc, copper, and silver, and compounds thereof. A carpet capable of exhibiting sufficient deodorizing performance for gases such as formaldehyde, ammonia, hydrogen sulfide, methyl mercaptan, and acetic acid, and further suppressing the growth of bacteria such as staphylococci.

According to the invention of [4], the deodorant is ² to 50 g / m ² , and the antibacterial agent is 0.5 to 20 g / m ^2. Can be a pet.

Next, an embodiment of a carpet according to the present invention will be described with reference to the drawings. The carpet 1 of this embodiment includes a skin layer 4 (with air permeability) in which a pile yarn 2 and a base fabric 3 are sealed by a sealing layer 5, and a backing layer 6 is provided below the sealing layer 5. (Breathable) is bonded at the same time. A deodorant and an antibacterial agent are mixed in the sealing layer 5 to form a breathable layer, and the skin layer 4 (with air permeability) and the backing layer 6 (with air permeability) are bonded. (See FIG. 1) Since the carpet 1 has an air permeability of 1 to 50 (cm ³ / cm ² · sec), air gradually flows from the pile side to the backing layer side or from the backing layer side to the pile side. As a result, the chance of the malodorous component coming into contact with the deodorant increases and the deodorization is efficiently performed. Moreover, the generation of a rotting odor caused by the propagation of various germs attached to dirt that could not be removed such as food dropped on the carpet 1 and the propagation of the various germs are made into a carpet that is suppressed by an antibacterial agent.

In the present invention, the air permeability refers to the air permeability in the thickness direction of the entire carpet, and is a numerical value measured in a state where the pile yarn 2, the base fabric 3, the sealing layer 5 and the backing layer 6 are bonded and integrated. However, it substantially reflects the air permeability of the sealing layer 5 and is generally considered to be substantially equal to the air permeability of the sealing layer 5. It is preferable that the air permeability in the thickness direction of the entire carpet is designed to be in the range of 1 to 50 (cm ³ / cm ² · sec), more preferably 15 to 40 (cm ³ / cm ^2).・ Second) is good.

  The sealing layer 5 is preferably made of foamed latex. Examples of the resin component include resins such as acrylic, urethane, polyvinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber composition include SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber) MBR (methyl methacrylate-butadiene rubber), and natural rubber. Foaming is mechanical foaming, and it is preferable that the foaming ratio is 2 or more. Further, the foaming ratio is preferably 4 or more. By sufficiently foaming, open cells are easily formed when the foamed latex is applied and dried, and air permeability is ensured. A roll coating method is preferred as a method for applying the foamed latex. Further, since the deodorant and the antibacterial agent are kneaded in the sealing layer 5 and the deodorant and the antibacterial agent are in contact with the open cells, the air flowing gently through the continuous holes and The deodorant and the antibacterial agent come into contact with each other and can effectively exhibit the deodorant and antibacterial action.

The air permeability of the sealing layer 5 is designed to be in the range of about 1 to 50 (cm ³ / cm ² · sec), and the air permeability in the thickness direction of the entire carpet is 1 to 50 (cm ³ / It is preferable to design so that it may be in the range of cm ² · sec. When the air permeability is less than 1 (cm ³ / cm ² · sec), the air does not move easily in the carpet, and the deodorizing and antibacterial effects cannot be exhibited. Further, a carpet exceeding 50 (cm ³ / cm ² · sec) is not a carpet that can withstand practical use.

In the present invention, the material of the pile yarn 2 is not particularly limited, and materials made of polyester fiber, polyamide fiber, polypropylene fiber, acrylic fiber, rayon fiber, etc. can be suitably used. Those made of natural fibers such as cotton and wool can also be used. The pile may be a cut pile or a loop pile. The basis weight of the pile yarn 2 is preferably set to ²⁰⁰ to 2000 g / m ² . If it is less than 200 g / m ² , the function as a carpet is inferior, which is not preferable. If it exceeds 2000 g / m ² , air permeability cannot be obtained sufficiently, which is not preferable.

The base material as the base fabric 3 may be of any material and form. Examples of the material include thermoplastic fibers such as polyester fibers, polyamide fibers, and polyolefin fibers, and composite fibers of these fibers. Examples thereof include semi-synthetic fibers such as acetate, regenerated fibers such as rayon, natural fibers such as hemp and cotton, or a mixture thereof. Examples of the form of the base fabric include woven fabric, knitted fabric, and non-woven fabric, but a spunbonded non-woven fabric having good air permeability, cost, and performance is preferable. The basis weight of the base fabric 3 is preferably set to 80 to 150 g / m ² . If it is less than 80 g / m ^2, it is difficult to stably hold the pile yarn 2, which is not preferable. If it exceeds 150 g / m ² , air permeability cannot be obtained sufficiently, which is not preferable.

  As the deodorant, a deodorant composed of a hydrazine derivative and an inorganic substance is preferable. Examples of the hydrazine derivative include those obtained by reacting a hydrazine compound and a long-chain aliphatic compound, or those obtained by reacting a hydrazine compound and an aromatic compound. Among them, one or two compounds selected from the group consisting of hydrazine and semicarbazide, and a group consisting of monocarboxylic acid having 8 to 16 carbon atoms, dicarboxylic acid, aromatic monocarboxylic acid, and aromatic dicarboxylic acid are selected. A reaction product with one or more compounds, or one or two compounds selected from the group consisting of hydrazine and semicarbazide, and a group consisting of monoglycidyl derivatives and diglycidyl derivatives having 8 to 16 carbon atoms. Reaction products with one or more compounds are preferred. Specific examples of the reaction product include sebacic acid dihydrazide, dodecanoic acid dihydrazide, and isophthalic acid dihydrazide. However, the reaction product is not particularly limited to these exemplified compounds. By using such a hydrazine derivative, excellent malodor removal performance can be ensured. In particular, it exhibits an excellent effect on the chemical adsorption action of acetaldehyde, which is said to be contained in a large amount in tobacco odor.

  Examples of the inorganic substance include activated carbon, zeolite, barley stone, silica gel, and metal oxides such as alumina, titanium oxide, zinc oxide, and iron oxide, but are not particularly limited to these examples. Absent. By using such an inorganic substance in combination, it is possible to effectively deodorize malodor that passes through the interior of the carpet in combination with the action of the hydrazine derivative.

  In the present invention, a porous inorganic substance is preferably used as the inorganic substance. Since it is porous, it has a large surface area and an excellent ability to absorb malodors. For example, as such a porous inorganic substance, the above-mentioned activated carbon, zeolite, etc. are mentioned. Among these, it is preferable to use a zeolite having an excellent adsorption ability for acetic acid, ammonia and the like. Zeolite is white and is good because it does not look black and dirty like activated carbon.

The application amount of the deodorant is preferably ^{2 to} 50 g / m ² (dry weight). If it is less than 2 g / m ^2, it is not preferable because sufficient malodor removal performance cannot be obtained. Moreover, even if it exceeds 50 g / m < ² >, there is no big improvement in a deodorizing performance, and it will increase cost easily, and is unpreferable.

Moreover, in this invention, an antibacterial agent is mixed with foamed latex simultaneously with the said deodorizer. The antibacterial agent is preferably one or more metals selected from zinc, copper, and silver, and compounds thereof. Specific examples include silver zeolite, silver-supported diboron trioxide, silver-supported zirconium phosphate, silver oxide, zinc oxide, copper zeolite, and copper phosphate. Among these, silver compounds are preferably used because they have a large antibacterial effect and low toxicity to the human body. Moreover, in this invention, it is good to apply 0.5-20 g / m < ² > of an antibacterial agent. Less than 0.5 g / m ² is not preferable because sufficient antibacterial performance cannot be obtained. Moreover, even if it exceeds 20 g / m < ² >, there is no big improvement in antibacterial performance, and it will increase cost easily, and is not preferable.

  In the present invention, in addition to the deodorant and antibacterial agent, the foamed latex includes various additives such as a dispersant, a thickener, and a foaming agent for improving the properties of the foamed latex as necessary. And fillers such as calcium carbonate may be added, and additives such as flame retardants, antioxidants, and UV absorbers are appropriately added within the range that does not interfere with the present invention for the purpose of improving various properties of the carpet. Can be blended.

Further, as an example of the present invention, there can be mentioned a form of a carpet in which a backing layer 6 (with air permeability) is bonded to the lower side of the sealing layer 5. In this case, the backing layer serves to prevent the sealing layer 5 from coming into direct contact with the floor surface and protect the sealing layer 5 and the floor surface. The backing layer 6 is preferably a breathable nonwoven fabric such as a needle punched nonwoven fabric or a spunbonded nonwoven fabric. The basis weight of the backing layer 6 is preferably 50 to 1000 g / m ² , its thickness is set to 0.5 to 15 mm, and the fineness of the constituent fibers is preferably set to a range of 0.1 to 30 dtex. The basis weight of the backing layer 6 is less than 50 g / m ^2, which is not preferable because the function and quality of the carpet are inferior. If it exceeds 1000 g / m ² , air permeability cannot be sufficiently obtained, which is not preferable. The material is not particularly limited as in the case of pile yarn and base fabric, but it is desirable to unify polyester fiber from the viewpoint of recyclability.

  As described above, the backing layer 6 is laminated on the lower side of the sealing layer and then dried. The drying means is not particularly limited, but heat treatment is preferable from the viewpoint of drying efficiency. The heat treatment temperature is preferably 100 to 180 ° C. By heat treatment at this temperature, open cells are generated and a breathable sealing layer is formed. When the backing layer is laminated, a strong adhesive force can be obtained.

  In addition, the evaluation method of the deodorization test in this invention, the measuring method of antibacterial performance, and the measuring method of air permeability are as follows.

<Deodorization test>
(Ammonia deodorization performance)
After putting a test carpet piece (10 cm x 20 cm) in a bag with an internal volume of 500 ml, inject ammonia gas so that the concentration is 200 ppm in the bag, and measure the residual concentration of ammonia gas after 1 hour. Then, the total amount of ammonia gas removed was calculated from the measured value, and the ammonia gas removal rate (%) was calculated from this.

(Hydrogen sulfide deodorization performance)
The removal rate (%) of hydrogen sulfide was calculated in the same manner as in the ammonia deodorization performance measurement except that hydrogen sulfide gas was used instead of ammonia gas and the concentration was 20 ppm in the bag.

(Formaldehyde deodorization performance)
The formaldehyde gas was used instead of ammonia gas so that the concentration was 80 ppm in the bag, and the remaining concentration of formaldehyde gas was measured after 4 hours. The removal rate (%) was calculated.

  And, “◎” when the removal rate is 95% or more, “◯” when the removal rate is 80% or more and less than 95%, “△” when the removal rate is 70% or more and less than 80%, Those having a removal rate of less than 70% were evaluated as “x”, and the results shown in Table 1 were obtained.

<Measurement of antibacterial performance>
Antibacterial performance was evaluated in accordance with the JIS L1902 unified method for antibacterial testing of textile products. Staphylococcus aureus was used as the test cell. The test cells were poured into a sterilized test cloth, the number of viable bacteria after 18 hours of cultivation was counted, the number of viable bacteria relative to the number of propagated bacteria was determined, and the following criteria were followed. That is, the log (B / C)> 1.5 was defined as the bacteriostatic activity value, and the case where the log (B / C) was 1.5 or more was regarded as acceptable. However, A represents the number of bacteria dispersed and recovered immediately after inoculation of the untreated product, B represents the number of bacteria dispersed and collected after 18 hours of incubation of the unprocessed product, and C represents the number of bacteria dispersed and collected after 18 hours of incubation of the processed product. Antimicrobial performance was evaluated only for Examples 2 and 4 and Comparative Example 2.

<Measurement of air permeability>
It was measured by A method of 8.27.1 of JIS L1096-1999.

<Example 1>
First, pile yarn made of polyester fiber is implanted into the base fabric with a tufting machine on a spunbond nonwoven fabric made of polyester fiber (110 g / m ² basis weight) to create a skin layer with a pile length of 7 mm and a pile basis weight of 700 g / m ² Next, a foaming agent is added to the SBR latex (SBR content of 50% by weight) as the sealing layer, and after mechanical foaming (foaming ratio: 3.0), the sebacic acid dihydrazide and the zeolite are used as a deodorant. (Average particle size 8 μm, 4.0 wt% with respect to SBR), silver-supported silver diboron trioxide (0.6 wt% with respect to SBR) as an antibacterial agent, and carbonic acid as a filler (30% by weight relative to SBR) for the additional inclusion of calcium, immediately applied as a 400 g / ^{m 2} th stop layer by a roll coating, consisting of further polyester fiber d - dollar A punch nonwoven fabric (3.4 dtex, thickness 3 mm, basis weight 100 g / m ² ) was laminated as a backing layer on the sealing layer, and dried at 150 ° C. for 15 minutes to obtain a carpet. The carpet, ² deodorant 8.0 g / ^m, the antimicrobial agent is 1.2 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 20 cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluations are shown in Table 1, and good evaluations were obtained.

<Example 2>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that the backing layer was not laminated. The carpet, ² deodorant 8.0 g / ^m, the antimicrobial agent is 1.2 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 22 cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluations are shown in Table 1, and good evaluations were obtained. In addition, the antibacterial performance passed the bacteriostatic activity value of 4.8.

<Example 3>
A carpet was obtained in the same manner as in Example 1 except that the foaming ratio of SBR latex was changed to 6. A carpet, ² deodorant 8.0 g / ^m, the antimicrobial agent is 1.2 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 27cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluations are shown in Table 1, and good evaluations were obtained.

<Example 4>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that 200 g / m ^{2 was} applied as a sealing layer. The carpet, ² deodorant 4.0 g / ^m, the antimicrobial agent is 0.6 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 33cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluations are shown in Table 1, and good evaluations were obtained. Further, the antibacterial performance was a bacteriostatic activity value of 3.9 and passed.

<Example 5>
In Example 1, a composition (average particle size of 8 μm, 4.0% by weight with respect to SBR) in which sebacic acid dihydrazide, zeolite, and zinc oxide were mixed one-on-one as a deodorant, and silver zeolite as an antibacterial agent A carpet was obtained in the same manner as in Example 1 except that the amount was 0.6% by weight based on SBR. The carpet, ² deodorant 8.0 g / ^m, the antimicrobial agent is 1.2 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 20 cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluations are shown in Table 1, and good evaluations were obtained.

<Comparative Example 1>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that the SBR latex was processed without foaming. The carpet, ² deodorant 8.0 g / ^m, the antimicrobial agent is 1.2 g / ^{m 2} coating, mosquitoes - the air permeability of the entire pet was 0.7 cm ³ / cm ² · sec. Various deodorization tests were conducted and the evaluation is shown in Table 1. The air permeability was low and a good deodorizing effect was not obtained.

<Comparative example 2>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that the amount of deodorant applied was 1.5 g / m ² . The antibacterial agent was applied at 1.2 g / m ^{2, and} the air permeability of the entire carpet was 20 cm ³ / cm ² · sec. Various deodorization tests were conducted, and the evaluation is shown in Table 1. The amount of deodorant applied was small, and a good deodorizing effect was not obtained.

<Comparative Example 3>
A carpet was obtained in the same manner as in Example 1 except that the coating amount of silver as an antibacterial agent was 0 in Example 1. The deodorant was applied at 8.0 g / m ^{2, and} the air permeability of the entire carpet was 20 cm ³ / cm ² · sec. Since the antibacterial agent was not applied, the bacteriostatic activity value was 0.1, and the antibacterial effect was not obtained.

It is a schematic sectional drawing which shows the deodorizing carpet which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Deodorizing carpet 2 ... Pile thread 3 ... Base fabric 4 ... Skin layer 5 ... Sealing layer 6 ... Backing layer

Claims (4)

In a carpet including a skin layer comprising a pile yarn and a base fabric, and a sealing layer for fixing the pile yarn and the base fabric, a deodorant and an antibacterial agent are carried on the sealing layer, A carpet having an air permeability of 1 to 50 (cm ³ / cm ² · sec) as a whole pet.   2. The carpet according to claim 1, wherein the sealing layer is made of foamed latex.   The deodorizer comprises a hydrazine derivative and an inorganic substance, and the antibacterial agent is one or more metals selected from zinc, copper, and silver, and compounds thereof. Carpet described Mosquitoes according to the deodorant 2 to 50 g / ^{m 2,} either one of claims 1 to 3 characterized by the fact that the antimicrobial agent is 0.5 to 20 g / ^{m 2} coating - pet.

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