CN104662223B - 地毯基底布和包括地毯基底布的簇绒地毯 - Google Patents

地毯基底布和包括地毯基底布的簇绒地毯 Download PDF

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CN104662223B
CN104662223B CN201380039183.1A CN201380039183A CN104662223B CN 104662223 B CN104662223 B CN 104662223B CN 201380039183 A CN201380039183 A CN 201380039183A CN 104662223 B CN104662223 B CN 104662223B
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carpet
carpet backings
primary carpet
primary
fiber
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CN104662223A (zh
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L·卢卡斯
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Lobona Co Ltd
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Abstract

本发明涉及一种包括至少一个非织造纤维层的地毯基底布，所述非织造纤维层具有包括较高熔点组分和较低熔点组分的纤维，其特征在于，所述纤维包括12～20％体积百分比的较低熔点组分，在簇绒后产生展示出一改善的针迹保持性能的簇绒地毯底布。

Description

地毯基底布和包括地毯基底布的簇绒地毯
技术领域
本发明涉及包括非织造纤维层的地毯基底布/主底布。本发明还涉及包括所述地毯基底布的簇绒地毯。
背景技术
许多年来已知包括非织造纤维层的用于簇绒地毯的地毯基底布。在簇绒地毯生产中采用的非织造基底布通常为包括聚酯(例如聚对苯二甲酸乙二醇酯(PET))纤维骨干的非织造织物或包括聚丙烯纤维骨干的非织造织物。在本文中术语“纤维”既指短纤维也指长丝/单丝。
总体上，聚丙烯纤维或聚酯纤维是在1dtex至25dtex范围内、优选在2dtex至20dtex范围内、最优选在5dtex至15dtex范围内的、提供所需的工艺稳定性的长丝。单位dtex所定义的长丝纤度为：每10000米长丝的重量克数。
非织造基底布的骨干纤维可由机械针刺和/或利用细的水射流的水力缠结来缠结并且可选地利用化学粘合剂粘合。
替代地，非织造基底布的骨干纤维可采用以纤维形式存在或者作为粉末或颗粒加入至非织造纤维层的较低熔点聚合物(即，在较低温度下熔化的聚合物)例如通过压延或热风粘合或类似技术而热粘合。当较低熔点聚合物以纤维形式存在时，较低熔点聚合物可作为单独的单组分纤维存在，或者较低熔点聚合物可与骨干聚合物一起以所谓的双组分或多组分纤维存在于相同的纤维中。双组分纤维在现有技术中是普遍已知的，例如半月型纤维、皮芯型纤维或橘瓣型纤维。替代地，包括单种聚合物但沿着纤维的长度具有变化的结晶度的纤维可作为双组分纤维而使用，因为变化的结晶度导致了由沿着纤维长度具有不同熔点的聚合物组成的纤维部段。
制造簇绒地毯的工艺方法包括如下步骤：将地毯基底布材料提供至簇绒机中，以簇绒纱线给基底布材料植绒以获得具有显示出绒头的正面和形成有回针针迹的背面的地毯原坯。绒头是簇绒纱线在原坯或地毯的正面上的可见部分。回针针迹是簇绒纱线在地毯原坯的背面上的可见部分。
许多年来，非织造地毯基底布时常被改进以便满足地毯制造商和消费者的日益严格的要求。新的簇绒技术如用于生产在单个地毯中具有高绒头和低绒头的地毯的高低簇绒法需要基底布具有改善的针迹保持能力以在簇绒工艺中将绒头保持在其位置中。特别重要的是，要改善制成的地毯的外观、促进可簇绒性即提供在簇绒期间低的簇绒针穿透阻力和减小的针偏移、避免背部污渍毛、增大针迹保持性能和减小在簇绒期间的噪音。
在地毯原坯中新形成的绒头由基底布材料的针迹保持能力保持在其位置中。针迹保持是从背面将绒圈从地毯原坯除去所需的力。针迹保持决定了在地毯原坯中地毯基底布和簇绒纱线之间的相互作用有多强。针迹保持决定了在簇绒后直至绒头锁定在其位置上为止的后续工艺步骤(例如，预涂层的涂敷)中失败的可能性有多大。这些工艺步骤可例如包括地毯原坯的染色、预涂覆、拉展、蒸烘和/或卷绕和/或地毯原坯卷的运输。地毯原坯的这些工艺步骤中的每一步均在与温度和/或所施加的张力有关的苛刻的条件下执行，这对地毯基底布材料提出了高要求。
预涂层的绒头结合性能主要决定绒头有多好地在预涂覆的地毯中保持在其位置中。在预涂覆后，一厚层可涂覆在预涂覆的地毯的背面上和/或第二层地毯底布可被施加以获得制成的簇绒地毯。
地毯基底布应当展示出良好的绒头保持能力。地毯基底布应当具有高的针迹保持能力以在簇绒的动态过程中使绒头保持在其位置中，以便获得高度基本相同的绒头以使地毯原坯中具有均匀的地毯表面。地毯基底布的针迹保持能力是指在簇绒过程期间使绒头就位在形成绒头的位置处并且在簇绒过程期间直接在形成绒头后将绒头在后续绒头形成期间保持在其位置中的能力。它决定了簇绒过程期间地毯原坯的正面外观和背部污渍毛。背部污渍毛是地毯原坯中的松脱的或不均匀的回针针迹，本质上就是先前位于地毯正面上的绒头现在(部分地)位于背面上。在随后的工艺步骤如染色和预涂覆期间，基底布的针迹保持应当高到足够使地毯表面保持和簇绒期间所产生的地毯表面一样。
为了将地毯原坯中的绒头锁定在其位置中，可将一预涂层涂敷至地毯原坯的背面。绒头结合是将一个绒头从正面从(预涂覆的或制成的)地毯完全除去所需的力。它决定了在簇绒纤维和涂敷至地毯原坯的粘合剂涂层之间的粘合力有多强。预涂层一般作为乳胶液或泡沫乳胶涂敷至地毯原坯的背面并且随后乳胶经干燥以在绒头的基部与地毯基底布之间形成结合。
发明内容
本发明的目的是提供具有改善的针迹保持能力的地毯基底布。
本发明的目的是由包括非织造纤维层的地毯基底布实现的，其中，非织造纤维层具有包括较高熔点组分和较低熔点组分的纤维，其突出之处在于，所述纤维包括12～20％体积百分比的较低熔点组分。
在本文中术语“纤维”既指短纤维也指长丝/单丝。优选地，所述纤维具有在1dtex至25dtex范围内、优选地在2dtex至20dtex范围内、最优选地在5dtex至15dtex范围内的线密度以提供足够的工艺稳定性。优选地，所述纤维是长丝以进一步改善地毯基底布的工艺稳定性。
地毯基底布的非织造纤维层的纤维的至少50％可包括12～20％体积百分比的较低熔点组分。优选地，地毯基底布的非织造纤维层的至少75％、更优选地至少85％、甚至更优选地至少95％的纤维、最优选地所有纤维包括12～20％体积百分比的较低熔点组分。
包括在地毯基底布的非织造纤维层中的纤维包括12～20％体积百分比的较低熔点组分。优选地，包括在地毯基底布的非织造纤维层中的纤维包括14～18％体积百分比、更优选地15～17％体积百分比、最优选地16％体积百分比的较低熔点组分。这种地毯基底布展示出改善的针迹保持能力和/或在簇绒后产生一展示出增大的针迹保持的簇绒地毯底布。
当包括在地毯基底布的非织造纤维层中的纤维包括少于12％体积百分比的较低熔点组分时，单个长丝在热粘合的基底布中的结合是不充分的。具有包括至少12％体积百分比的较低熔点组分的纤维的地毯基底布不具有或仅具有低的从地毯基底布延伸出来的纤维松脱的风险，松脱的纤维易于在簇绒期间造成问题。例如，松脱的纤维可能在基底布退绕期间和/或在进入簇绒机中期间卷绕在旋转的辊子上，或者松脱的纤维可能在簇绒工艺期间缠结在簇绒针中，这会造成簇绒工艺的中断和生产率的降低。
优选地，非织造纤维层具有统一的组成成分以在整个地毯基底布上并且在整个簇绒地毯上实现一致的针迹保持能力和针迹保持性能。在本文中所采用的术语“统一的组成成分”应当理解成整个非织造层上的纤维的类型和数量在在标准的非织造工艺中所遇到的限度内是不变的。
地毯基底布的非织造纤维层的纤维可为双组分纤维或多组分纤维。多组分纤维可例如为橘瓣型纤维、芯-内皮-外皮构型或并排式构型的形式。所述纤维可为中空的双组分纤维或中空的多组分纤维以减少重量比的性能。
优选地，地毯基底布的非织造纤维层的纤维为双组分纤维。双组分纤维可为任意类型的双组分纤维，例如半月型/并列型纤维、皮芯型纤维、橘瓣型纤维和/或海岛型纤维。更优选地，双组分纤维为皮芯双组分纤维。优选地，皮芯双组分纤维的皮层包括较低熔点组分。对于海岛型纤维，海相优选包括较低熔点组分。
较高熔点组分可为任何热塑性聚合物。然而，较高熔点组分优选包括聚酯(例如聚对苯二甲酸丙二醇酯(PTT)、聚萘二甲酸乙二酯(PEN)和/或聚对苯二甲酸乙二醇酯(PET))、共聚酯、聚酰胺(例如聚酰胺-6,6(PA6,6)和/或聚酰胺-6(PA6))、共聚酰胺、聚烯烃(例如聚丙烯)和/或以上这些的混合物。
较低熔点组分可以是熔点温度低于较高熔点组分的任何热塑性聚合物。较低熔点组分的熔点温度比较高熔点组分的熔点温度低至少5℃。优选地，较低熔点组分的熔点温度比较高熔点组分的熔点温度低至少10℃、更优选地低至少20℃、甚至更优选地低至少30℃、最优选地低至少50℃。
然而，较低熔点组分优选包括共聚酯例如聚对苯二甲酸丁二醇酯(PBT)、聚酰胺例如聚酰胺-6(PA6)、共聚酰胺、聚烯烃例如聚丙烯、或以上这些的混合物。
在一优选的实施例中，双组分纤维的较高熔点组分包括聚酯、更优选地包括聚对苯二甲酸乙二醇酯(PET)，而较低熔点组分包括聚烯烃、更优选地包括聚丙烯。地毯基底布的非织造纤维层中包括的PET/聚烯烃纤维包括12～20％体积百分比的较低熔点组分。优选地，纤维包括16～20％体积百分比、更优选18～20％体积百分比、最优选20％体积百分比的较低熔点组分以获得低的针迹保持能力值、平滑的回针针迹和/或改善的可修补性。
在另一优选的实施例中，双组分纤维的较高熔点组分包括聚酯、更优选地包括聚对苯二甲酸乙二醇酯(PET)，而较低熔点组分包括聚酰胺、更优选地包括聚酰胺-6(PA6)。地毯基底布的非织造纤维层中包括的PET/PA纤维包括12～20％体积百分比的较低熔点组分。优选地，地毯基底布的非织造纤维层中包括的纤维包括14～18％体积百分比、更优选地15～17％体积百分比、最优选地16％体积百分比的较低熔点组分以获得低的针迹保持能力值、平滑的回针针迹和/或改善的可修补性。
地毯基底布优选借助于双组分纤维的较低熔点组分来热粘合。热粘合可由任何已知的热粘合工艺(例如压延或热风粘合)来实现。
地毯原坯的断裂强度和断裂应变是重要的，特别是当簇绒地毯用作汽车地毯时。基于车身地板的几何形状，地毯在各个区域中须得大大地弯曲、即变形。特别显著的当然是汽车传动通道区域中的变形。为了适应大的局部变形，簇绒地毯的断裂强度和断裂伸长率必须是足够的。
地毯基底布可包括一个或多个附加纤维层。每个附加纤维层可从非织造纤维层、织造纤维层或稀松平纹棉麻织物/稀松窗帘用布中选择。例如，稀松平纹棉麻织物可合并入地毯基底布中以进一步改善地毯片的尺寸稳定性。织造纤维层可合并入地毯基底布中以例如提供在织造层的经、纬线方向上的附加的强度。包括一种不同的聚合物或多种不同的聚合物的另一非织造纤维层可合并入地毯基底布中以例如调节基底布的正面的可染色性和/或防止乳胶渗出。
薄膜可合并入地毯基底布中以例如提供抵抗乳胶渗出的屏障。乳胶渗出应当理解成意指涂敷至地毯原坯、即簇绒的地毯基底布的背面上的预涂层移动穿过基底布而变得在簇绒地毯的正面可见。
每个附加纤维层的纤维都可包括至少两种不同的聚合物。该至少两种不同的聚合物可存在于双组分纤维中或可存在于非织造纤维层的单独的纤维中。替代地，每个附加纤维层的纤维可由单种聚合物组成。
优选地，根据本发明的基底布中的非织造纤维层具有统一的组成成分以实现一致的层离强度，其中附加层合并入基底布中。
在本发明的一实施例中，簇绒地毯包括根据本发明的地毯基底布。
具体实施方式
所有示例均是采用将长丝层彼此叠置地沉积在收集器表面上的已知技术来纺粘的。在沉积之后，沉积的长丝层被热粘合以形成单个粘在一起的非织造纤维层。
示例1
示例1的基底布由在收集器表面上沉积四个长丝层而生产，每个长丝层具有27.5g/m2的重量。示例1的基底布的单位面积重量为110g/m2。长丝均为皮芯型长丝，芯-皮比为84％/16％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。长丝的线密度为15dtex。
对比示例1的基底布由四个长丝层组成，每个长丝层具有27.5g/m2的单位面积重量。对比示例1的基底布的单位面积重量为110g/m2。长丝均为皮芯型长丝，芯-皮比为76％/24％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。
基底布在750rpm下在具有每10cm 50针的1/10隔距的簇绒机上被植绒以形成重量为930g/m2的地毯原坯。
基底布的针迹保持能力借助于如下过程来确定：在对于背部污渍毛的形成是关键/临界(critical)的情况下给基底布植绒和在含有9600个绒头的1m×2.2cm的区域中计算在簇绒期间所形成的完整背部污渍毛的数量、即计算完全从地毯原坯中除去的绒头的数量。簇绒用格罗茨0660针以1/5英寸(5.08mm)的隔距、Texture Tex PA6.6簇绒纱线类型3252O 2x1350dtex、600rpm的机器速度、6.5％的在基底布的供给速度与地毯原坯的输出速度之间的速度差、每10cm 40针的针速、以及对应于11.8mm绒长的纱线进给来进行。绒长是通过从地毯原坯拉出100个绒头并测量所除去的簇绒纱线的总长度而确定的。绒长可用簇绒纱线的总长度除以所除去的绒头的数量来计算得出。
在表1中概括出示例1的结果。
表1
簇绒后的性质 示例1 对比示例1
MD强度[N/5cm] 332 336
CMD强度[N/5cm] 236 234
MD伸长率[％] 56 40
CMD伸长率[％] 56 49
针迹保持能力[-] 19 39
示例1的地毯原坯的强度与对比示例1的强度相当，而断裂伸长率增大了，这对于汽车地毯应用而言是特别有利的。示例1的针迹保持能力与对比示例1相比得到改善。
示例2
示例2的基底布由在收集器表面上沉积四个长丝层而产生，每个长丝层具有27.5g/m2的重量。示例2的基底布的单位面积重量为110g/m2。长丝均为皮芯型长丝，芯-皮比为84％/16％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。长丝的线密度为15dtex。
对比示例2的基底布由四个长丝层组成，每个长丝层具有27.5g/m2的单位面积重量。对比示例2的基底布的单位面积重量为110g/m2。层1和2中的长丝为皮芯型长丝，芯-皮比为77％/23％(体积百分比)。层3中的长丝为皮芯型长丝，芯-皮比为90％/10％(体积百分比)。层4中的长丝为皮芯型长丝，芯-皮比为77％/23％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。
基底布在具有每10cm 36针的1/13隔距的大型簇绒机上以移动的方式被植绒，以形成重量为476g/m2的地毯原坯，簇绒的原坯随后被预涂覆以将绒头锁定在其位置中。在表2中概括出示例2的结果。
示例2的回针针迹被认为是更平滑的、更紧密的，所述回针针迹通过在下部附加预涂层来进行支承。预涂覆在由在预涂覆机上的拉幅针板执行。
示例2的修补比对比示例2的更好。可修补性通过拉出每卷中一个修补部分来测试并且测试可重复修补性。示例2在第三次的可修补性与第一次的可修补性一样好并且在第三次修补后与第一次修补后具有相同的针迹锁定。
表2
簇绒后的性质 示例2 对比示例2
簇绒的地毯部段的宽度
在针后方[cm] 188.913 187.960
在卷起处[cm] 187.008 186.690
宽度变化[cm] -1.905 -1.270
预涂覆后卷起[cm] 189.865 189.865
宽度的总变化[cm] 0.953 1.905
基底布的宽度
在针后方[cm] 197.644 197.485
在卷起处[cm] 197.326 196.850
宽度变化[cm] -0.318 -0.635
预涂覆后卷起[cm] 199.708 200.343
宽度的全部变化[cm] 2.064 2.858
所附加的预涂层[g/m2] 754 795
预涂覆后的簇绒结合[N] 48.2 46.6
制成的地毯片中的簇绒结合[N] 58.5 65.6
Aachen测试宽度[％] -0.014 -0.010
Aachen测试宽度[％] -0.006 0.015
地毯原坯的可修补性 + o
示例3
示例3的基底布由在收集器表面上沉积四个长丝层而产生。对于示例3a，每个长丝层具有30g/m2的重量。示例3a的基底布的单位面积重量为120g/m2。对于示例3b，每个长丝层具有33.75g/m2的重量。示例3b的基底布的单位面积重量为135g/m2。长丝均为皮芯型长丝，芯-皮比为84％/16％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。长丝的线密度为15dtex。
对比示例3的基底布由四个长丝层组成，每个长丝层具有33.75g/m2的单位面积重量。示例2的基底布的单位面积重量为135g/m2。层1和2中的长丝为皮芯型长丝，芯-皮比为77％/23％(体积百分比)。层3中的长丝为皮芯型长丝，芯-皮比为90％/10％(体积百分比)。层4中的长丝为皮芯型长丝，芯-皮比为77％/23％(体积百分比)。所有长丝的皮层由作为较低熔点组分的聚酰胺-6聚合物组成。所有长丝的芯层由作为较高熔点组分的聚对苯二甲酸乙二醇酯聚合物组成。
基底布在900rpm下在具有每10cm 44针的1/12(1/8+1/4)隔距的CMC斯可罗(Scroll)簇绒机上被簇绒，以形成重量为645g/m2的地毯原坯。在表3中概括出示例3的结果。
表3
簇绒后的性质 示例3a 示例3b 对比示例2
簇绒的地毯部段的宽度
在针后方[cm] 187.17 187.96 190.50
在卷起处[cm] 186.69 187.96 190.50
宽度变化[cm] -0.48 0.00 0.00
可修补性 o + o
示例3a和3b的回针针迹被认为是比对比示例3更平滑的。
示例3a的可修补性被认为是比对比示例3的可修补性更好，而示例3b的可修补性被认为是与对比示例3的可修补性相当。

Claims (12)

1.一种包括非织造纤维层的地毯基底布，所述非织造纤维层具有包括较高熔点组分和较低熔点组分的纤维，其特征在于，所述纤维包括12～20％体积百分比的较低熔点组分。
2.根据权利要求1所述的地毯基底布，其特征在于，所述纤维包括14～18％体积百分比的较低熔点组分。
3.根据权利要求1或2所述的地毯基底布，其特征在于，所述非织造纤维层在整个非织造纤维层上具有统一的组成成分。
4.根据权利要求1或2所述的地毯基底布，其特征在于，所述纤维为双组分纤维。
5.根据权利要求4所述的地毯基底布，其特征在于，所述双组分纤维为皮芯型双组分纤维。
6.根据权利要求5所述的地毯基底布，其特征在于，所述双组分纤维由聚酯芯层和聚丙烯皮层组成。
7.根据权利要求5所述的地毯基底布，其特征在于，所述双组分纤维由聚酯芯层和聚酰胺皮层组成。
8.根据权利要求1或2所述的地毯基底布，其特征在于，所述地毯基底布借助双组分纤维的较低熔点组分而热粘合。
9.根据权利要求1或2所述的地毯基底布，其特征在于，所述地毯底布包括选自非织造纤维层、织造纤维层或稀松平纹棉麻织物的附加纤维层。
10.根据权利要求2所述的地毯基底布，其特征在于，所述纤维包括15～17％体积百分比的较低熔点组分。
11.根据权利要求10所述的地毯基底布，其特征在于，所述纤维包括16％体积百分比的较低熔点组分。
12.一种包括根据前述权利要求中任一项所述的地毯基底布的簇绒地毯。
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