JP2002345624A - Polyester carpet having excellent adhesion durability and soundproofness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a regenerated polyester carpet which is broad in width and has excellent adhesion durability and soundproofness by bonding a tuft gray fabric of the carpet to a laminated sheet formed by needle punching of a regenerated polyester nonwoven fabric and a foamed sheet and further to obtain an ecological carpet by using environmentally friendly regenerated polyester fibers. SOLUTION: The tuft gray fabric of the carpet is bonded by using the laminated sheet formed by protruding the polyester fibers to the rear surface of the foamed sheet by needle punching the polyester nonwoven fabric to the foamed sheet, by which the polyester carpet which can be made as broad as >=2.5 m and has the excellent adhesion durability and the soundproofness is obtained. Further, the weight and gage of the nonwoven fabric and the foamed sheet are optimized, by which the carpet well balanced in adhesiveness, soundproofness, lightweightness, handing quality, cost, etc., is obtained. The carpet with an ecological mark is obtained by using the regenerated polyester fibers obtained by subjecting recovered PET(polyethylene terephthalate) bottles to pulverizing and melting.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet made of polyester fibers, which is made to adhere to a tuft greige machine by needle-punching a polyester non-woven fabric into a foam sheet to cause fibers to fly out on the back surface of the foam sheet. An object of the present invention is to obtain a carpet excellent in soundproofing that can be widened to 0.5 m or more.

[0002]

2. Description of the Related Art At present, it is known that a polyester fiber is formed into a non-woven fabric by needle punching, and that the non-woven fabric is bonded to another base fabric by a binder or thermocompression bonding to produce a sheet or a carpet. Due to the peeling of the adhesive surface and the increase in cost, and furthermore, due to the restriction of the width of the heat roller, a wide one of 2.5 m or more could not be obtained by thermocompression bonding. on the other hand,
Carpets using only a foamed polyurethane sheet without a polyester nonwoven fabric as a base material are also well known, but have the drawbacks of insufficient soundproofing, poor adhesion due to deterioration of polyurethane, and poor appearance. Further, a method of applying a polyurethane to a polyester non-woven fabric and foaming the polyurethane and then bonding the same to a carpet tuft greige, a method of bonding a non-woven fabric, a foam sheet and a tuft greige with a binder, or a method of bonding a felt and a tuft greige However, there have been problems that the cost is high, the bonding durability is poor, and the soundproofing is insufficient.

[0003]

According to the present invention, a polyester nonwoven fabric is needle-punched into a foamed sheet and then adhered to a carpet tuft greige made of polyester fiber, thereby providing a wide width, excellent durability and excellent soundproofing. The purpose is to obtain a polyester carpet. Further, the present invention aims to obtain an eco-friendly eco-carpet using polyester fibers regenerated from a collected PET bottle.

[0004]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies in order to achieve the above object and as a result, the polyester nonwoven fabric was needle-punched into a foamed sheet to cause the polyester fibers to fly out to the back surface of the foamed sheet. By improving the adhesiveness of the carpet made of polyester fiber to the tuft greige, a soundproof carpet having an adhesive durability that can be widened particularly by 2.5 m or more has been obtained. Furthermore, since the polyester fiber is a recycled fiber obtained by crushing and melting a collected PET bottle, an eco-friendly carpet with an eco-mark has been obtained.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The polyester fiber referred to in the present invention is a fiber obtained by reacting and polymerizing high-purity terephthalic acid and ethylene glycol and melt-spinning and drawing pellets having an intrinsic viscosity (IV) of 0.6 or more. means. Recycled polyester fibers are PET bottles used for beverages and foods, collected, crushed, washed and dried polyester flakes, or melt-extruded polyester pellets, and spun and drawn in the usual manner. 100% recycled polyester. It should be noted that there is no problem even if the polyester fiber contains a functional material such as a pigment, an antioxidant, an ultraviolet absorber, an anti-mite agent, an antibacterial agent, and a far-red heat retaining agent as required.

In the present invention, the polyester fiber is crimped
When cutting into staples (cotton-like) and forming into a non-woven fabric or after forming the non-woven fabric, it is necessary to perform needle punching together with the foamed sheet so that a part of the polyester fiber jumps out to the back surface of the foamed sheet.

The basis weight of the polyester nonwoven fabric is 30 to 30.
Preferably 0 g / ^{m 2,} in particular 50 to 200 g / ^{m 2.} If it is less than 30 g / m ² , the effect of enhancing the soundproofing property will be reduced, and the foam sheet will be visible, and the sense of quality tends to be lost. On the other hand, if it exceeds 300 g / m ² , the cost becomes high and heavy, and the handleability of the carpet deteriorates.

[0008] The foam sheet has soundproofing, cushioning,
Any material can be used as long as it is lightweight, such as polyurethane, natural rubber, synthetic rubber, polyester,
Polyolefin, polyamide and the like are mentioned, but polyurethane having the above-mentioned function and a high foaming rate is particularly preferable.
The thickness of the foam sheet is preferably 3 to 30 mm, and more preferably 5 to 30 mm.
20 mm is preferred. If it is less than 3 mm, the desired soundproofing effect cannot be obtained. If it exceeds 30 mm, in addition to cost and poor handling, the probability of the polyester fiber jumping out to the back side of the foam sheet by needle punching is reduced, and the adhesion to the tuft greige is reduced. Is not preferred.

A first feature of the present invention resides in that the fibers are ejected to the back surface of the foam sheet to improve the adhesion of the carpet to the tuft greige. The reason why the adhesiveness is improved may be that irregularities due to the polyester fibers are formed on the back surface of the foamed sheet to increase the bonding area, and that the same type of polyester fibers are exposed on the back surface of the tuft greige, so that adhesion is easy.

The second feature is that a wide width of 2.5 m or more is made possible by using a needle punching method for bonding the nonwoven fabric and the foam sheet. Conventionally, thermocompression bonding between a nonwoven fabric and a foamed sheet was limited to 2 m or less due to the regulation of the width of the heat roller, so when placing a carpet in a wide place such as a flooring, it was necessary to connect the carpets, resulting in trouble and poor appearance. Was. Further, the method of bonding the nonwoven fabric and the foam sheet using a binder has problems such as hardening and easy peeling.

The third characteristic is that by optimizing the basis weight of the nonwoven fabric and the thickness of the foam sheet, the adhesive durability, soundproofing,
The purpose is to obtain a carpet that is balanced in weight, cost, and the like.

A fourth desirable feature is that it employs as many environmentally friendly recycled products as possible. In the present invention, it is preferable that the tuft yarn of the nonwoven fabric or carpet is made of recycled polyester. Currently, polyolefin tape yarns are mainly used as the tuft base fabric, but in the future, by using recycled polyester with the foamed sheet, all carpets will be composed of recycled polyester, and the used carpet can be recycled.

In the present invention, the back surface of the laminated sheet obtained by needle-punching the polyester nonwoven fabric and the foam sheet and the back surface of the tuft greige of a carpet are bonded to a binder of natural rubber or synthetic rubber or an ethylene / vinyl acetate, urethane, epoxy or the like. To obtain a carpet that is inexpensive and has excellent adhesion durability and soundproofing properties.

Hereinafter, the present invention will be described in detail with reference to examples, but the present invention is not limited to these examples unless it exceeds the gist of the invention. The physical properties of the molded article described in this example were measured by the following methods.

1) Adhesiveness After cutting the carpet into a width of 2.54 cm and a length of 20 cm, a gap of 5 cm is opened between the foam sheet and the tuft greige machine.
The strength (g) when both ends are peeled at a pulling speed of 5 cm / min while holding both ends with a chuck of a tensile tester of Instron is measured, and an average value of 10 points from the higher strength is calculated. This was repeated n = 10 times, and the average strength (g) was adopted.

2) Soundproofing properties According to JISA-1440, width 1800 mm, length 2
A 700 mm carpet is placed on a concrete floor, and the impact point is 4 points, the downstairs receiving point is 5 points, and the frequency is 500 Hz and 1 point.
000 Hz floor impact sound (dB) was measured.

Example 1 Using a recycled polyester pellet obtained from a recovered PET bottle, a spinning-drawing-crimping-cutting method was used to produce a 6 dx76 mm raw cotton. Next, a non-woven fabric having a width of 3000 mm and a basis weight of 80 g / m ² was prepared using a carding machine, and subsequently subjected to needle punching with a needle density of 76 needles / in ² together with a urethane foam sheet having a thickness of 5 mm to obtain a width of 28 mm.
A 00 mm laminated sheet was obtained. On the back surface (urethane sheet surface) of the laminated sheet, a large number of the polyester fibers were projected by needle punching. On the other hand, spinning-drawing-crimping-interlacing (interlacing) is performed by using a regenerated polyester pellet in a conventional manner to give 1600 d / 40.
After obtaining a bulky filament of 8f, the basis weight of the polypropylene cloth was 600 g / m ^2.
The pile yarn thus obtained was shirred to prepare a tufted greige having a nap length of 8 mm. The back surface of the obtained laminated sheet and the back surface of the tuft greige were adhered with a styrene-butadiene-based synthetic rubber paste so that the coating amount became 500 g / m ² , to obtain a carpet having a basis weight of 1390 g / m ² . The peel strength between the laminated sheet of the carpet and the tufted greige machine was as large as 1420 g, and the adhesive strength was sufficient to withstand external force. The impact noise is at a frequency of 500H.
The soundproofness was as low as 51 dB at z and 39 dB at 1000 Hz, and it was a wide and light soundproof carpet for flooring.

Example 2 In accordance with Example 1, a virgin polyester raw cotton of 6 d × 76 mm, which is not recycled, is 3000 mm wide and has a basis weight of 1
A 30 g / m ² nonwoven fabric was prepared, and a laminated sheet having a width of 2800 mm was obtained by needle punching with a needle density of 100 needles / in ² together with a foamed polyurethane sheet having a thickness of 10 mm. On the other hand, a total of two 1600d / 408f non-regenerated virgin polyester filaments of 150
After twisting at t / m, a tuft greige machine having a pile length of 6 mm was prepared by tufting a polypropylene base cloth so that the basis weight of the pile was 900 g / m ² . The back surface of the obtained laminated sheet and the back surface of the tuft greige are coated at a coating amount of 600 g / m 2.
Is bonded with a natural rubber adhesive such that ² basis weight 1710g
/ M ² of pile carpet. The peel strength of the carpet was as large as 1690 g, and showed an adhesive property that could be used for a long time. The impact noise is 47dB at 500Hz,
It showed 36 dB at 1000 Hz, and had a soundproofing performance not obtainable with a conventional product having the same basis weight, and became a carpet most suitable for offices and public facilities.

Comparative Example 1 In Example 1, a nonwoven fabric was prepared by mixing low-melting binder cotton with regenerated polyester raw cotton, and then pressed together with a urethane foam sheet with a hot roller to obtain a laminated sheet having a width of 2000 mm. . Since the width of the heat roller capable of performing uniform heating is regulated, a width of 2100 mm or more was impossible. The polyester fiber did not protrude from the back surface of the obtained laminated sheet, and the same tuft greige as in Example 1 was adhered to produce a carpet having a basis weight of 1580 g / m ² .
The peel strength dropped to 1130 g. The impact noise is 5
As high as 57 dB at 00 Hz and 45 dB at 1000 Hz,
The soundproofing performance was poor.

Comparative Example 2 In Example 2, the basis weight was 30
A felt of 0 g / m ² was prepared and bonded to the tuft greige without using a foam sheet to obtain a pile carpet having a basis weight of 1800 g / m ² . The peel strength of the carpet is 1600
g, but the impact noise was 500 because there was no foam sheet.
It was 59 dB at 60 Hz and 48 dB at 1000 Hz.

 ────────────────────────────────────────────────── ─── Continued on the front page (72) Inventor Hirofumi Sano 3143 Fuku term, Obicho, Kishiwada-shi, Osaka F-term (reference) 3B120 AA08 AA19 AB15 BA21 BA24 BA38 CA12 CA13 EB11 EB16 4L032 AA07 AB04 AB05 AB07 AC02 BA02 BD05 CA03 DA00 EA08 4L047 AA21 AB05 BA03 CA06 CA08 CA19 CB03 CB10 CC09 CC16 EA14

Claims (4)

[Claims] 1. A polyester carpet excellent in adhesion durability and soundproofing, characterized in that a laminated sheet in which a polyester nonwoven fabric is needle-punched on a foam sheet and a tuft greige are adhered. 2. The adhesive durability and soundproofness according to claim 1, wherein the polyester nonwoven fabric has a basis weight of 30 to 300 g / m ² and the foamed sheet is a polyurethane having a thickness of 3 to 30 mm. Excellent polyester carpet. 3. The polyester carpet according to claim 1, wherein the width of the carpet is 2.5 m or more. 4. A recycled polyester carpet according to claim 1, wherein said nonwoven fabric and said carpet have tuft yarns made of recycled polyester fibers.