JP2005087649A - Carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To efficiently and economically provide a carpet excellent in sound absorption and sound prevention property by improving moisture permeability of a nonwoven fabric of a high basis weight which is used for improving the sound absorption and sound prevention performance of the carpet and where the basis weight is ≥250 g/m<SP>2</SP>without damaging the sound absorption performance so as to improve drying speed of a water base adhesive in an adhering process with the carpet surface material. <P>SOLUTION: On the rear surface of the carpet surface material, a fiber back material 14 of a basis weight of ≥250 g/m<SP>2</SP>is bonded with the water base adhesive 13. The fiber back material has a laminated structure of a base fiber web layer 20 and an outer surface fiber web layer 21. Then, ≥70 wt.% of the basis weight of the fiber back material is made to be a base fiber web layer, and ≤30 wt.% of the basis weight is made to be an outer surface fiber web layer. Besides, ≥50 wt.% of the base fiber web layer is made to be main material fiber 19 of <15 dtex, and ≤50 wt.% thereof is made to be thick fiber of ≥30 dtex. A flat thread 18 is used for at least a part of the thick fiber. The outer surface fiber web layer consists of thin fibers of <15 dtex. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a rug formed by bonding a fiber backing composed of fibers to the back surface in order to enhance the sound absorption and sound insulation properties, such as cushioning properties, sound absorption and sound insulation properties, and heat insulation and heat insulation properties.

In order to improve the cushioning property, sound absorbing and soundproofing property, heat insulation and heat insulating property of the rug, it is known that a thick nonwoven fabric is bonded to the back surface of the rug as a fiber backing (see, for example, Patent Documents 1, 2, and 3). In order to make the needle punch nonwoven fabric used for the fiber backing bulky, the needle punch nonwoven fabric is made of recycled polyester fiber having a thick circular cross section with a fineness of 15 to 150d as the main material fiber, and the fall off of the thick fiber In order to prevent this, heat-fusible fibers are mixed (for example, see Patent Document 2). In the case of a thick non-woven fabric having a basis weight of 200 to 700 g / m ^2, a thick fiber of 20 to 60 dtex, preferably a core-sheath type heat-sealable thick, is used in order to increase the drying rate of the adhesive in the bonding process to the back of the rug. The nonwoven fabric is made of hand fibers (see, for example, Patent Document 3).
Japanese Unexamined Patent Publication No. 2000-01452 (Summary, 0006, FIGS. 1 and 2) JP 2000-83895 (Abstract, 0021) JP 2003-00421 (Abstract, 0007, 0026, FIG. 1)

The basis weight of a nonwoven fabric usually used as a backing (secondary base fabric) for tufted carpet is 150 g / m ² or less, generally 40 to 80 g / m ² . On the other hand, the basis weight of the nonwoven fabric used for imparting functionality such as sound absorption and soundproofing to the rug is 200 g / m ² or more, which is more than three times the basis weight of the normally used nonwoven fabric. For this reason, as pointed out in the above-mentioned Patent Document 3, a non-woven fabric having a basis weight of 200 g / m ² or more is applied to the back of the rug using a water-based adhesive as a normal backing having a basis weight of 40 to 80 g / m ^2. In the case of matching, the drying time of the applied water-based adhesive becomes longer, and the production rate is lowered. And in order to avoid the speed fall, a nonwoven fabric must be comprised with a thick fiber. However, not only is the amount of fiber used large, but when thick fibers are used, as mentioned in Patent Documents 2 and 3, it is essential to mix heat-fusible fibers. As the fiber becomes more expensive and the fineness of the constituent fibers becomes thicker, it becomes difficult to absorb the sound pressure energy, and the sound absorption characteristics of the nonwoven fabric used for the fiber backing also deteriorate.

Therefore, the present invention improves moisture permeability without impairing the sound absorption characteristics of a high-weight nonwoven fabric having a basis weight of 250 g / m ² or more, particularly used to enhance the sound absorption and soundproofing property of the rug, and can be applied to the rug surface material. The object is to increase the drying rate of the water-based adhesive in the combining step, and to provide a rug excellent in sound absorption and soundproofing efficiently and economically.

That is, the rug according to the present invention is configured by bonding a fiber backing having a basis weight of 250 g / m ² or more to the back surface of the surface material with an aqueous adhesive, and the fiber backing constitutes a bonding surface with the surface material. The base fiber web layer and the outer fiber web layer appearing on the back of the rug have a two-layer laminated structure, and the base fiber web layer and the outer fiber web layer are integrated by a needle punching process. The fibers of the layer and the fibers of the outer fiber web layer are intertwined, the base fiber web layer occupies 70% by weight or more of the fiber backing, and the outer fiber web layer accounts for 30% by weight or less of the fiber backing. The base fiber web layer is composed mainly of a main fiber of less than 15 dtex occupying 50% by weight or more and a thick fiber of 30 dtex or more occupying 50% by weight or less. , At least a portion of the thick hand fibers are constituted by flat yarns forming the flat cross section, the outer surface fibrous web layer has a first feature in that it is constituted by Hosote fibers of less than 15 dtex.

The second feature of the rug according to the present invention is that, in addition to the first feature, 70% by weight or more of the base fiber web layer is occupied by main fiber less than 10 dtex, and 95% by weight or more of the outer surface fiber web layer. Fine fibers of less than 10 dtex occupy, and some of the thick fibers in the base fiber web layer are composed of flat yarns with a flatness ratio of 4 or more, and the flat yarns with a flatness ratio of 4 or more are at least the fiber backing It exists in the point which is interposed in a part of unit area 49cm < ² > (vertical and horizontal 7cm each).

  The third feature of the rug according to the present invention is that, in addition to any of the first and second features, a coating powder obtained by pulverizing a solidified coating of an aqueous adhesive is mixed in the base fiber web layer. There is in point.

A thick flat yarn is difficult to fit into fine fibers because of its shape, and a gap is easily formed between the flat yarn and the thin fibers in the fiber web layer, and the resulting gap creates a fiber backing. Increases moisture permeability. For this reason, the fiber backing of the present invention does not hinder the drying of the aqueous adhesive applied in the bonding step with the surface material even when the basis weight is 250 g / m ² or higher and the basis weight is high. Does not cause a decrease in production speed in the combined process. Even if the fineness is the same, the flat yarn is more easily bent than the general fiber having a circular cross section due to the difference in cross-sectional shape (secondary coefficient of cross section), and the flat yarn is fine in the needle punching process. The main material fiber is easily inserted and entangled. For this reason, even if the flat yarn is a thick fiber of 30 dtex or more, it is difficult to fall off from the fiber backing, and the outer fiber web layer becomes a fine fiber that covers the base fiber web layer containing the flat yarn. Therefore, it is not necessary to mix the heat-fusible fiber with the fiber backing in order to prevent the flat yarn from falling off, so that the fiber backing can be constructed at low cost. .

And even if the fineness is the same, the flat yarn is rich in flexibility compared to general fibers with a circular cross section, and even if it is a thick fiber of 30 dtex or more, it is easy to absorb sound pressure energy. The amount of the flat yarn used is 50% by weight or less of the basis weight of the base fiber web layer, and the flat yarn is bent by the needle punching process to form an internal gap in the fiber backing. The use of flat yarns of 30 dtex or more does not impair the sound absorption characteristics of the fiber backing. In particular, the flat yarn acts like a conduit for diffusing moisture in the fiber web layer, and the amount of the flat yarn used for the operation is that the unit area of the fiber backing is 49 cm ² . A moderately small amount intervening in the part, generally less than 10% by weight of the base fiber web layer basis weight, or even less than 5% by weight may be used, and the sound absorbing property of the fiber backing is not affected by the use of the flat yarn.

  Since the outer surface of the base fiber web layer is covered with the outer surface fiber web layer made of fine fibers of less than 15 dtex as in the case of the general nonwoven fabric, it is mixed in the base fiber web layer so that slight flat yarns are scattered. Even so, the beauty of the back of the rug (fiber backing) is not impaired.

  For the surface material, a tufted pile fabric, a pile woven fabric, a pile knitted fabric, a needle punching felt, a heel, a thick flat woven fabric or the like is used. FIG. 1 illustrates a rug 15 in which a tufted pile fabric in which a pile 12 is planted on a primary base fabric 11 is used as a surface material, and a fiber backing 14 is bonded to the back surface thereof with a water-based adhesive 13. is there. In FIG. 1, 16 is a back stitch of the pile 12, and 17 is a needle insertion mark generated in the fiber backing 14 by the needle punching process. The base fiber web layer 20 may be subjected to a needle punching process before it is integrated with the outer surface fiber web layer 21. The thickness of the fiber backing 14 is 2 mm or more, preferably the apparent thickness is 5 mm or more. Resin emulsions and latexes are used for the water-based adhesive, and fillers, flame retardants, thickeners, waxes and the like are appropriately blended.

In order to enhance the sound absorption characteristics of the fiber backing 14, the basis weight is 350 g / m ² or more, more preferably 500 g / m ² or more, and the base fiber web layer occupies 80% by weight or more of the basis weight. The outer surface fiber web layer occupies 10% by weight or less of the basis weight, the main fiber of less than 10 dtex occupies 80% by weight or more of the base fiber web layer, and the flatness is 4 or more and the fineness is 10% by weight or less of the base fiber web layer. Is made up of flat yarns of 100 dtex or more, and fine fibers of less than 10 dtex occupy 80% by weight or more of the basis weight of the outer fiber web layer. The flat yarn 18 is interposed inside the fiber backing 14 like a conduit that promotes the moisture transfer of the aqueous adhesive 13 on the front and back of the fiber backing 14. Therefore, the length of the flat yarn 18 may be about 2 to 3 times the thickness of the base fiber web layer (fiber backing 14).

  By the way, many of the general-purpose tufted carpets are flat monofilament yarns of polypropylene tape yarns or split yarns having a flatness ratio (ratio of the maximum dimension to the minimum dimension of the cross section) of 10 times or more and a single yarn fineness of 500 to 2000 dtex. A woven fabric is used as a primary base fabric, and piles made of fine fibers having a fineness of less than 10 dtex are planted thereon, and a water-based adhesive is applied and backed on the back surface thereof. Therefore, the cutting waste of the tufted carpet waste includes broken pieces of flat yarn (primary base fabric) 18, main material fibers (pile) 19 having a fineness of less than 10 dtex, and coating powder of a solid coating film of an aqueous adhesive It will consist of For this reason, the base fiber web layer 20 can be configured by using such cut tufted carpet scrap as a raw material and performing needle punching treatment on the deposited laminate (fiber web) having a required thickness. Therefore, the present invention can be practiced also as a waste treatment of a conventional tufted carpet. In the base fiber web layer 20 made from the cut waste of the tufted carpet, the coating powder of the water-based adhesive is mixed therein. Because of this commonality, it is easy to become familiar with the aqueous adhesive 13 used for bonding the surface material and the fiber backing 14, so to speak, it acts like water for attracting the aqueous adhesive 13. It is easily absorbed by the material 14. Therefore, it is desirable to carry out the present invention together with waste disposal of tufted carpet, and the present invention is very practical in that it can also be practiced as waste disposal of tufted carpet.

  The flat yarn 18 has an effect such as a conduit that promotes the water transfer of the water-based adhesive 13 on the front and back of the fiber backing 14, and its length is 2 times the thickness of the base fiber web layer (fiber backing 14). About 3 times may be sufficient, and about 2 to 3 cm is sufficient. The flat yarn 18 only needs to have a flatness ratio of 4 or more, and the flat yarn 18 includes a woven fabric formed of a flat yarn having a single yarn fineness of 500 to 2000 dtex used for a primary base fabric or packaging material of tufted carpet. The waste cutting waste can be used and mixed with the waste cutting waste of the tufted carpet as required. If the flat yarn 18 contained in the cutting waste maintains a flat cross-section with a flatness ratio of 4 or more, preferably 10 or more, it has been opened to a fineness of 500 dtex or less by cutting. There may be.

1 is a cross-sectional side view of a rug according to the present invention, and shows an enlarged view partially encircled.

Explanation of symbols

11: Primary base fabric 12: Pile 13: Water-based adhesive 14: Fiber backing 15: Rug 16: Back stitch 17: Needle insertion trace 18: Flat yarn 19: Main material fiber 20: Base fiber web layer 21: Outer surface Fiber web layer

Claims (3)

In a rug formed by bonding a fiber backing having a basis weight of 250 g / m ² or more to a back surface of a surface material with a water-based adhesive, the fiber backing comprises a base fiber web layer constituting a bonding surface with the surface material, It forms a two-layer laminated structure with the outer surface fiber web layer appearing on the back surface, and the base fiber web layer and the outer surface fiber web layer are integrated by needle punching processing, and the fibers of the base fiber web layer and the outer surface fiber web layer The fibers are intertwined, the base fiber web layer occupies 70% by weight or more of the basis weight of the fiber backing, the outer fiber web layer occupies 30% by weight or less of the basis weight of the fiber backing, and the base fiber web layer is The main material fiber is less than 15 dtex occupying 50% by weight or more and the thick fiber of 30 dtex or more occupying 50% by weight or less, and at least a part thereof. Futoshite fibers are constituted by flat yarns forming the flat cross section, rug, characterized in that the outer surface fiber web layer is constituted by Hosote fibers of less than 15 dtex. Main fiber of less than 10 dtex occupies 70% by weight or more of the base fiber web layer, and fine fiber of less than 10 dtex occupies 95% by weight or more of the outer surface fiber web layer. The above-mentioned claim, wherein the fibers are composed of flat yarns having a flatness ratio of 4 or more, and the flat yarns having a flatness ratio of 4 or more are interposed in at least a part of a unit area of 49 cm ² (vertical and horizontal 7 cm each). Item 2. The rug according to item 1.   3. The rug according to claim 1, wherein a coating powder obtained by pulverizing a coating film obtained by solidifying a water-based adhesive is mixed in the base fiber web layer.

Images