JP2006149591A - Tufted-piled cloth - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To add a sealing capacity to a tufted-piled cloth without damaging the gas permeability and the moisture permeability. <P>SOLUTION: The tufted-piled cloth is formed by plastering a back cloth 15 coated with an emulsion resin composite 14 on a back surface of a tufted cloth 13 on which piles are formed by inserting a pile thread 12 comprised of a fiber with the fineness of 20 dtex or less in a foundation cloth 11, wherein the pile thread 12 is a non-twisted single thread, the back cloth 15 is a nonwoven fabric with the weight of 60-500 g/m<SP>2</SP>, and 10-70 g/m<SP>2</SP>(the mass of solid contents) of a water repellent composite 17 having a binder resin and a water repellent agent as essential ingredients is added to the outer surface 16 of the back cloth 15. Anti-slip resin such as natural rubber-latex, synthetic rubber-latex, acrylic resin, ethylene-vinyl acetate resin, vinyl chloride resin or the like is preferably used for the binder resin of the water repellent composite 17 to add the anti-slip capacity together with the sealing capacity to the tufted-piled cloth. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a tufted pile fabric used as an indoor floor carpet, an electric carpet surface material, an entrance / exit mat, an automobile floor mat, a wall carpet, a tile carpet and the like.

  The tufted pile fabric is formed by applying the emulsion resin composition 14 to the back surface of the tufted fabric 13 in which a pile yarn 12 made of fibers having a fineness of less than 20 dtex is inserted into the base fabric 11 and bonding the backing fabric 15. Depending on the purpose of use, water-impervious (non-water-permeable / water-proof), water-permeable, moisture-permeable, breathable, soundproof, sound-absorbing, water-repellent, antifouling, antistatic, antibacterial, antibacterial , Insect repellent properties, flame proof properties, deodorant properties, aromaticity, moldability, cushioning properties and the like are added.

For example, in order to give sound absorption and breathability to tufted piles used as automobile floor mats, non-woven fabric is used for the back fabric, and the tufted fabric and the back fabric are bonded to each other with heat-fusible resin powder. It is known to finish at a degree of 1 to 50 cm / cc / sec (for example, see Patent Document 1). In order to impart anti-slip properties to a tufted pile used as an entrance / exit mat, it is known to spray-coat rubber latex as an anti-slip resin on the outer surface of a backing bonded to a tufted fabric (for example, , See Patent Document 2). As the anti-slip agent, hydrogenated styrene / diene / copolymer is suitable (for example, see Patent Document 3). In order to provide water resistance to tufted piles used for indoor floor carpets (floor mats), it is known that a plastic film is layered on the back surface of tufted fabric (see, for example, Patent Document 4). ). In order to impart water repellency to tufted pile fabric used for indoor floor carpets, a volatile oil agent is applied to the pile yarn, the oil agent is volatilized and removed after the pile is formed, and then a water repellent agent is applied to the pile surface. It is known to give (for example, refer patent document 5).
Japanese Patent Laid-Open No. 2002-219989 Japanese Patent No. 2935406 (Japanese Patent Laid-Open No. 7-308255) Japanese Patent No. 3366368 (JP-A-6-269347) Japanese Utility Model Publication No. 7-17174 Japanese Patent No. 2572503 (JP-A-5-302256)

  It is difficult to impart many functionalities to a tufted pile at the same time, and when one functionality is imparted, other functionality is often impaired. For example, as described in the above-mentioned Patent Document 4, in order to provide water-proofing to tufted piles used for electric carpet surface materials and automobile floor mats, the back surface thereof, or between tufted fabric and back fabric In addition, when a plastic film is overlaid, air permeability, moisture permeability, sound absorption and the like are impaired. In addition, as described in the above-mentioned Patent Document 5, in order to impart water repellency to tufted piles used for electric carpet surface materials and automobile floor mats, a water repellent is applied to the pile surface. The color tone and texture of the pile surface are impaired.

  When a solid water repellent powder such as wax is blended with an emulsion resin composition in which a tufted fabric and a backing fabric are bonded together in order to impart water barrier properties while maintaining air permeability, moisture permeability and sound absorbing properties, the tufted fabric and the backing Bonding with cloth becomes difficult. Therefore, when the amount of application (application) of the emulsion resin composition is increased, not only the air permeability, moisture permeability and sound absorption of the tufted pile are impaired, but the flexibility is also impaired, and the tufted pile Finished in a plate shape, it becomes unsuitable for electric carpet surface materials and automobile floor mats.

  Therefore, the present invention provides an anti-slip and water-proof property to a tufted pile ground without impairing the air permeability, moisture permeability, sound absorption, flexibility, cushioning, or the color and texture of the pile surface. The object is to obtain a tufted pile suitable for surface materials, automobile floor mats, indoor floor carpets and the like.

The tufted pile fabric according to the present invention is formed by applying an emulsion resin composition 14 to the back surface of a tufted fabric 13 in which a pile yarn 12 made of fibers having a fineness of less than 20 dtex is inserted into a base fabric 11 to form a back fabric 15. In the tufted pile fabric formed by bonding, the pile yarn 12 is a single yarn of non-twisted yarn, the backing fabric 15 is a nonwoven fabric having a basis weight of 60 to 500 g / m ² , and the outer surface 16 of the backing fabric 15 (tufted pile fabric) The first feature is that 10 to 70 g / m ² (solid content mass) of a water repellent composition 17 containing a binder resin and a water repellent as essential components is applied to the back surface of the resin.

A second feature of the tufted pile fabric according to the present invention is that, in addition to the first feature, the emulsion resin composition 14 applied to the tufted fabric 13 is 500 parts by weight or less (100 parts by weight of the resin solid content) ( 0 to 500 parts by weight) containing a filler, the solid content coating amount is 80 to 1000 g / m ² , and the water repellent composition 17 has a solid content mass ratio of 1 to 30 masses. It is in the point which is%.

  The third feature of the tufted pile according to the present invention is that, in addition to any of the first and second features, the binder resin of the water-repellent composition 17 is an anti-slip resin.

  According to the present invention, a water-tight tufted pile ground where a container storing water falls on the pile surface, the water overflows from the container to the pile surface vigorously, and the water is not absorbed into the back surface even if the water is absorbed by the pile layer. can get. The reason why water does not ooze to the back surface (16) is considered to be as follows.

  That is, the water absorbed and held by the pile layer 19 is in a state where it can ooze out to the back surface of the tufted fabric 13 through the fibers at the pile root. However, the pile yarn 12 is not a twisted and twisted bundle, but is a non-twisted single yarn that is easily bulky and is uniformly mixed in the needle through-hole 18 formed by inserting the pile yarn into the base fabric 11. Since the needle through-hole 18 is placed under the plugging condition by the pile fiber that is going to expand in bulk, the water absorbed and held in the pile layer is difficult to bleed out through the needle through-hole 18 to the back surface of the tufted fabric. Become. The water that has oozed to the back surface of the tufted fabric over time is absorbed and held by the back stitch 20 because the back stitch 20 is a bulky, unspun single yarn, and the tufted fabric. Since the coating film 14 of the emulsion resin composition integrated with the back stitch 20 and the back cloth 15 contains a surfactant as an emulsifier, the coating film 14 is also absorbed and retained. The Thus, the water absorbed and retained on the back surface of the tufted fabric is favorably pushed back by the water repellent action of the water shielding layer 24 in which the back fabric 15 and the water repellent composition 17 are integrated. Exudation is prevented.

  It is conceivable that when the woven fabric is used for the backing cloth 15 or when the twisted yarn consisting of a plurality of single yarns 21 and 22 is used for the pile yarn 12, the water-repellent effect by the water-repellent composition 17 is considered. This is because water does not ooze out and water oozes out to the outer surface 16 of the backing cloth. The reason for this is that water easily oozes out from the fabric in the woven fabric, and the back stitch 20 does not easily bulge in the double twisted yarn, so that the water retention capacity is small, and the twist groove 23 between the single yarns is formed in the needle through hole 18. This is thought to be due to the action of a conduit that leads water to the back of the tufted fabric.

  In order to effectively implement the present invention, the pile yarn 12 is composed of fibers having a fineness of less than 20 dtex, the pile layer, the pile root (needle through hole 18), the back stitch 20, and the back stitch 20 and the backing cloth 15. The water retention capacity of the coating film 14 of the integrated emulsion resin composition is increased. For this purpose, it is desirable to use a fiber having a fineness of less than 10 dtex, preferably less than 5 dtex, for the pile yarn 12, and a fiber having a fineness of less than 5 dtex is also used for the backing fabric (nonwoven fabric) 15.

  In the present invention, the ratio of the filler in the emulsion resin composition 14 is 500 parts by weight or less with respect to 100 parts by weight of the resin solid content. This is also to prevent the flexibility from being impaired, and to maintain the sound absorption characteristics of the tufted pile ground by the softness and flexibility of the coating film 14. As the filler, it is preferable to use a filler having water retention properties such as diatomaceous earth, zeolite, calcium carbonate and the like. In order to increase the moisture permeability and breathability of the coating film 14 and to increase the sound absorption of the tufted pile fabric, the emulsion resin composition 14 may be applied by foaming with a mixer.

  The binder resin used together with the water repellent agent is an anti-slip resin having rubber viscoelasticity, such as natural rubber / latex, synthetic rubber / latex, ethylene / vinyl acetate resin, soft acrylic resin, and soft vinyl chloride resin, which are known as anti-slip agents. When used, it is possible to impart anti-slip properties to tufted piles at the same time as water shielding.

According to the present invention, a water-impervious tufted pile fabric can be obtained without applying a water repellent to the pile surface, so that the appearance (color tone) and texture of the pile surface are not impaired. In this way, it is not necessary to apply a water repellent to the pile surface in order to provide water resistance to the tufted pile ground, so a moisturizing agent, antifouling agent, antistatic agent, antifungal agent, antibacterial agent on the pile surface It is possible to freely enhance the functionality of tufted pile fabric by applying insecticides, flameproofing agents, deodorants and the like. Further, according to the present invention, it is not necessary to adhere and laminate a non-breathable plastic film in order to impart water barrier to tufted pile, and the water repellent composition applied to impart water barrier to tufted pile. Since the coating amount of the product is also as small as 10 to 70 g / m ² (solid content mass), water impermeability can be imparted to the tufted pile ground without impairing air permeability, sound absorption and moisture permeability.

According to the present invention, a water-blocking tufted pile can be obtained without applying a water repellent to the pile surface, which means that a water repellent should not be applied to the pile surface. In order to enhance the water shielding effect according to the present invention, a water repellent agent can be applied to the pile surface (19) or the surface of the base fabric 11 (pile surface side). To the basis weight of the backing fabric 15 and from 60 to 500 g / m ^2, it is not 60 g / m ² less dense water shield layer 24 as it has formed, the water absorbs moisture retaining emulsion resin composition coating film 14 This is because it tends to exude to the outer surface 16 of the backing fabric. On the other hand, when the basis weight exceeds 500 g / m ² , a thick water-retaining layer 25 composed of only non-woven fibers is formed between the water-impervious layer 24 formed of the emulsion resin composition coating film 14 and the water-repellent composition 17, so This is because it becomes difficult to exude to the outer surface 16 of the cloth and there is no reason to apply the special water repellent composition 17.

  The water-blocking effect according to the present invention is that the water overflowing from the surface of the pile surface of 150m of water dropped from a cup on the pile surface of the tufted pile ground laid on the concrete floor and linoleum construction finished floor surface. However, the water does not ooze out to the outer surface of the backing cloth after 3 minutes, and when the water is wiped from the pile surface 5 minutes after the overflow, the water does not ooze out to the outer surface of the backing cloth. This is because tufted pile is not used as a waterproof sheet, and water that has accidentally overflowed the pile surface is wiped off. The water-blocking property of the tufted pile is not required, and the present invention aims to provide water-blocking properties without impairing the air permeability and moisture permeability. This is because a pile land is obtained.

  The timing for applying the water repellent composition 17 to the backing cloth 15 may be before or after bonding with the tufted fabric 13. When applying before bonding with the tufted fabric 13, it is applied only to one side of the backing fabric 15, and the other side is set as a non-water shielding layer (25) that can be easily bonded to the tufted fabric 13.

[Example 1]
A multifilament single yarn having a total fineness of 3960 dtex made of polyester fiber having a fineness of 8 dtex is used as the pile yarn 12, a polypropylene tape yarn having a fineness of 590 dtex is used as a warp, and a warp density of 20 yarns / 2.54 cm using a polypropylene tape yarn having a fineness of 790 dtex as a weft. Pile length 7 mm with a weft density of 15 pieces / 2.54 cm and a fabric weight of 110 g / m ² as a base fabric 11, needle gauge 1/10 × 2.54 cm, stitch gauge 5/32 × 2.54 cm, pile basis weight 773 g / On the back surface of the m ² tufted fabric 13, 30 parts by weight of styrene-butadiene latex (resin content: 50%), 4 parts by weight of extender (carboxyl methylcellulose soda salt solid content: 4%), and filler (calcium carbonate) 50 parts by weight, 4 parts by weight of stabilizer and 12 parts by weight of water The emulsion resin composition 14 455g / m ² (dry coating amount) is applied consisting of, attaching a weight per unit area 70 g / m ² nonwoven fabric made of polyester fibers having a fineness 6dtex as fabric backing 15, the outer surface 16 of the rear cloth 15 Then, a water repellent composition 17 shown in [Table 1] was spray-coated to finish a tufted pile.

[Example 2]
A multifilament single yarn used in Example 1 is a pile yarn 12, a non-woven fabric having a basis weight of 110 g / m ² made of polyester fiber having a fineness of 10 dtex is used as a base fabric 11, and a tufted fabric 13 having the same tufting specification as that in Example 1 is used. On the back surface, the emulsion resin composition 14 used in Example 1 was applied in the same manner as in Example 1, and the backing cloth 15 used in Example 1 was bonded to the outer surface 16 of the backing cloth 15 as shown in [Table 1]. The water repellent composition 17 shown was sprayed to finish the tufted pile.

[Comparative Example 1]
A pile yarn 12 is a spun yarn in which two spun yarns having a total fineness of 1980 dtex (5th) made of acrylic fiber having a fineness of 8 dtex are used as the pile yarn 12, and the polyester fiber nonwoven fabric used in the above Example 2 is used as the base fabric 11, and the tufting specification is used. The emulsion resin composition 14 used in Example 1 was applied to the back surface of the tufted fabric 13 as in Example 1 in the same manner as in Example 1, and the backing fabric 15 used in Example 1 was bonded to the back fabric. A water-repellent composition 17 shown in [Table 1] was sprayed on the outer surface 16 of 15 to finish a tufted pile fabric.

[Comparative Example 2]
The multifilament single yarn used in Example 1 is a pile yarn 12, the fabric used in Example 1 is a base fabric 11, and the back side of the tufted fabric 13 having the same tufting specifications as Example 1 is used. The emulsion resin composition 14 used in Example 1 was applied in the same manner as in Example 1, the backing cloth 15 used in Example 1 was bonded, and the acrylic resin emulsion shown in Table 1 was sprayed on the outer surface 16 of the backing cloth 15. Apply to finish tufted pile.

[Comparative Example 3]
The multifilament single yarn used in the above Example 1 is used as the pile yarn 12, the polyester fiber nonwoven fabric used in the above Example 2 is used as the base fabric 11, and the tufting specification is performed on the back surface of the tufted fabric 13 which is the same as that in Example 1. The emulsion resin composition 14 used in Example 1 was applied in the same manner as in Example 1, the backing cloth 15 used in Example 1 was bonded, and the acrylic resin emulsion shown in Table 1 was attached to the outer surface 16 of the backing cloth 15. Sprayed to finish the tufted pile.

[Comparative Example 4]
The multifilament single yarn used in Example 1 is a pile yarn 12, the fabric used in Example 1 is a base fabric 11, and the back side of a tufted fabric 13 having the same tufting specifications as Example 1 is used. The emulsion resin composition 14 used in Example 1 was applied in the same manner as in Example 1, the backing cloth 15 used in Example 1 was bonded, and the silicone-based water repellent shown in Table 1 was attached to the outer surface 16 of the backing cloth 15. Sprayed to finish the tufted pile.

[Comparative Example 5]
The multifilament single yarn used in the above Example 1 is used as the pile yarn 12, the polyester fiber nonwoven fabric used in the above Example 2 is used as the base fabric 11, and the tufting specification is performed on the back surface of the tufted fabric 13 which is the same as that in Example 1. The emulsion resin composition 14 used in Example 1 was applied in the same manner as in Example 1, and the backing cloth 15 used in Example 1 was bonded together. As shown in [Table 1], the backing cloth 15 was applied in the same manner as in Example 1. And a silicon-based water repellent shown in [Table 1] was sprayed onto the outer surface 16 of the backing cloth 15 to finish a tufted pile.

[Waterproof test]
The tufted piles according to the above examples and comparative examples are laid down on the concrete ground and linoleum construction finish floor surface, and 150 cc of water is dropped immediately from the cup from 1 m above, and the overflowing water on each pile surface After 3 minutes, it was checked whether or not the outer surface of the backing cloth had oozed, and after 5 minutes, when the water overflowing the pile surface was wiped off, it was checked whether or not water had oozed on the outer surface of the backing cloth. The result was obtained.

It is a perspective view of the tufted pile place which concerns on the comparative example of this invention.

Explanation of symbols

11: Base fabric 12: Pile yarn 13: Tufted fabric 14: Emulsion resin composition (coating film)
15: Back fabric (nonwoven fabric)
16: Outer surface (back surface)
17: Water repellent composition 18: Needle through-hole 19: Pile layer 20: Back stitch 21: Single yarn 22: Single yarn 23: Twist groove 24: Water shielding layer 25: Water retaining layer

Claims (3)

In a tufted pile fabric in which an emulsion resin composition 14 is applied to the back surface of a tufted fabric 13 in which a pile yarn 12 having a fineness of less than 20 dtex is inserted into the base fabric 11 to form a pile, and the backing fabric 15 is bonded together.
The pile yarn 12 is a single yarn of non-twisted yarn,
The backing fabric 15 is a nonwoven fabric having a basis weight of 60 to 500 g / m ² .
Tufted pile in which water repellent composition 17 having binder resin and water repellent as essential components is applied to outer surface 16 (back surface of tufted pile ground) of backing cloth 15 in an amount of 10 to 70 g / m ² (solid content mass). Earth. The emulsion resin composition 14 applied to the tufted fabric 13 contains a filler that is 500 parts by weight or less with respect to 100 parts by weight of the resin solid content,
The solid content coating amount is 80 to 1000 g / m ² ,
The tufted pile fabric according to claim 1, wherein the water repellent composition has a solid mass ratio of 1 to 30 mass% in the water repellent composition 17.   The tufted pile fabric according to any one of claims 1 and 2, wherein the binder resin of the water repellent composition 17 is an anti-slip resin.

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