JP2006204603A - Deodorant carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a deodorant carpet capable of efficiently absorbing and removing malodor components such as formaldehyde, ammonia and acetic acid in indoor air by a natural air flow. <P>SOLUTION: Compared with an impermeable carpet, an air permeable carpet having an air permeability of 1-50 cm<SP>3</SP>/cm<SP>2</SP>sec slightly circulates the air by natural convection and can efficiently reduce the malodor. This carpet efficiently adsorbs and removes the malodor components by carrying deodorant at least in one or more of pile yarns, a ground fabric, a filling layer, and a backing layer of the air permeable carpet. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a carpet having a deodorizing function capable of efficiently adsorbing and removing malodors such as formaldehyde, ammonia, and acetic acid in indoor air.

  Houses constructed in recent years have significantly improved heat insulation and airtightness, and high-performance energy-saving houses have been born that take several times longer than conventional houses to change room air due to the flow of natural air. . However, because of its high airtightness, it is said that odors and house dust are likely to be trapped in the room, which are said to cause allergies and cause discomfort. It has become a big concern.

  Examples of such components that cause daily odors include ammonia, hydrogen sulfide, methyl mercaptan, acetic acid, formaldehyde, and the like. Among them, tobacco odor is a typical bad odor.

  In order to deal with such problems, deodorization, deodorization and dust collection using air conditioners and air purifiers have been carried out, and a method for collecting odors and dust in the air using filters and the like has been proposed. ing. Patent Documents 1 to 3 have proposed fabrics such as carpets having a deodorizing function.

Patent Document 1 proposes a technique in which a hydrazine derivative and a deodorant inorganic substance are kneaded into a carpet backing. In Patent Document 2, a carpet having an adsorbent that adsorbs at least aldehydes to the carpet body is proposed. Patent Document 3 proposes a technique for applying a hydrazine derivative and a deodorizing inorganic substance to a primary base fabric of a carpet. These technologies are those in which a deodorant such as hydrazine is applied to and carried on a fiber by a method such as dipping, spraying or printing, and exhibits a deodorizing effect to some extent. A technique for efficiently removing malodors by carrying a deodorant on a special fiber assembly called pet has not been disclosed yet.
Japanese Patent Application Laid-Open No. 11-113720 Japanese Patent Laid-Open No. 11-46965 JP 2000-14520 A

  The present invention has been made in view of such a technical background, and an object of the present invention is to provide a carpet capable of efficiently adsorbing and removing malodorous components in room air by a natural air flow.

  As a result of intensive studies to solve such problems, the present inventors have found that it is possible to efficiently reduce bad odors by allowing air to flow by natural convection inside a carpet having a deodorizing function. The present invention has been reached. In order to achieve the above object, the present invention provides the following means.

[1] Carpet comprising a pile yarn, a base fabric, a sealing layer, a backing layer, and an adhesive layer, and at least one of the pile yarn, the base fabric, the sealing layer, and the backing layer carries a deodorant. The carpet is characterized in that the air permeability is 1 to 50 (cm ³ / cm ² · sec).

  [2] The carpet according to item 1 above, wherein the backing layer is made of a non-woven fabric, and the adhesive layer is melted with a powdered heat-fusible resin to form a breathable adhesive layer.

  [3] The carpet according to the above item 1 or 2, wherein the deodorant comprises a hydrazine derivative having an average particle size of 10 μm or less and an inorganic substance, and is supported by a binder resin.

[4] The carpet according to any one of items 1 to 3, wherein the deodorant is applied in an amount of ² to 15 g / m2.

According to the invention of [1], a deodorant is carried on at least one of a pile yarn, a base fabric, a sealing layer, and a backing layer, and the air permeability is 1 to 50 (cm ³ / cm ² · sec). Therefore, the indoor air can pass through the interior of the carpet by natural convection and can be effectively deodorized by the deodorant.

  According to the invention of [2], the backing layer is made of a nonwoven fabric, and the adhesive layer is melted with a powder-like heat-fusible resin to form a breathable adhesive layer. It is ensured and can be effectively deodorized by the deodorant.

  According to the invention of [3], the deodorant comprises a hydrazine derivative having an average particle size of 10 μm or less and an inorganic substance and is supported by a binder resin, so that the pile yarn, base fabric, backing layer When the deodorant is carried on one or more of them, there is no rough feeling, it can withstand washing well, and a deodorant carpet having a deodorizing effect can be obtained.

According to the invention of [4], a deodorizing carpet having a sufficient deodorizing effect in which ² to 15 g / m ^{2 of the} deodorant is applied can be obtained.

  Next, an embodiment of a deodorizing carpet according to the present invention will be described with reference to the drawings. The deodorizing 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, a backing layer 7 (with air permeability), and adhesion. It consists of a layer 6 (with air permeability), and a deodorant made of a hydrazine derivative and an inorganic substance is carried on the pile yarn 2 by a resin binder. Since the deodorizing carpet 1 has air permeability, a gentle flow of air is generated from the pile side to the backing layer side, from the backing layer side to the pile side, or between the pile yarns, and the malodorous component is eliminated. Opportunity to come in contact with odorants increases and deodorized efficiently. (See Figure 1)

In the present invention, the air permeability refers to the air permeability in the thickness direction of the entire deodorant carpet, and is a numerical value measured in a state where the pile yarn 2, the base fabric 3, the backing layer 7 and the adhesive layer 6 are laminated and integrated. However, it substantially reflects the air permeability of the adhesive layer 6 and is generally considered to be substantially equivalent to the air permeability of the adhesive layer 6. 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.

As the backing layer 7, a breathable nonwoven fabric is preferable, and a needle punched nonwoven fabric, a spunbonded nonwoven fabric and the like can be exemplified. The basis weight of the backing layer 7 is preferably set to 50 to 1000 g / m ² , its thickness is set to 0.5 to 15 mm, and the fineness of the constituent fibers is set to a range of 0.1 to 30 dtex. The basis weight of the backing layer 7 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.

The breathable adhesive layer 6 is preferably an adhesive layer formed by heating and melting a powder-like heat-fusible resin. The powder-like heat-fusible resin is not particularly limited, but a polyolefin resin is preferably used. Examples of the polyolefin resin include polyethylene and polypropylene. The basis weight of the breathable adhesive layer 6 is preferably set to 30 to 500 g / m ² . Less than 30 g / m ² is not preferable because sufficient adhesive force cannot be obtained. If it exceeds 500 g / m ² , air permeability cannot be obtained sufficiently, which is not preferable.

The particle size of the powder-like heat-fusible resin is preferably 90 to 5000 μm and the melt flow rate value is preferably 2 to 520. Thereby, the carpet which set the air permeability to the range of 1-50 (cm < ³ > / cm < ² > / second) can be manufactured reliably.

Further, according to the present invention, as shown in FIG. 1, a sealing layer 5 is provided on the lower surface of the skin layer 4 to prevent the pile from coming off. The sealing layer 5 is not particularly limited as long as it is a resin composition or a rubber composition that can fix the pile yarn 2 and the base fabric 3. For example, the resin component of the resin composition may be acrylic, urethane, polychlorinated. Examples thereof include resins such as vinyl, 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. As a coating method of the sealing layer 5, the resin composition or the rubber composition may be applied and dried by a roll coating method, a spray coating method or the like. Alternatively, a deodorizing agent may be kneaded into the treatment liquid for the sealing layer and applied to the lower surface of the skin layer 4 to form a sealing layer having air permeability and a deodorizing function. Of course, in this case as well, the air permeability in the thickness direction of the entire carpet must be designed to be in the range of 1 to 50 (cm ³ / cm ² · sec).

  As a method for producing a breathable carpet, the surface of the skin layer 4 provided with a sealing layer is turned up, and a heat-fusible resin is sprayed thereon, and then heated and melted to form an adhesive layer 6. Further, the backing layer 7 is superposed on this and pressed by a pressure roller, thereby being bonded and integrated through the adhesive layer 6 having air permeability.

  As the pressure roller, a cooling pressure roller is preferably used. When pressure is applied with such a cooling and pressure roller, forced cooling can be performed simultaneously with lamination, so that the solidification of the melted heat-fusible resin can be accelerated and the processing speed (productivity) can be improved. Shrinkage of the backing layer 7 due to processing, pile collapse of the skin layer 4 and the like can be prevented. Further, an anti-slip resin may be applied to the ground surface side of the backing layer 7 so as not to hinder air permeability.

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 having an average particle size of 10 μm or less and an inorganic substance is preferable. Since the average particle size is 10 μm or less, a carpet having a good texture can be obtained without being rough when it is carried on a pile yarn. Among these, the average particle size is preferably 5 μm or less, and particularly preferably 3 μm or less.

  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. By using such a hydrazine derivative, excellent malodor removal performance can be ensured. 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.

  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 has a smaller influence on the color of the pile yarn than activated carbon when it is supported on a fiber and is good.

The application amount of the deodorant is preferably ^{2 to} 15 g / m ² (dry weight). Less than 2 g / m ² is not preferable because sufficient removal performance cannot be obtained. Moreover, even if it exceeds 15 g / m < ² >, there is no big improvement in deodorization performance, and it will increase cost easily, and is not preferable.

  In the method of applying the deodorant, first, a treatment agent comprising an aqueous dispersion is prepared by dispersing the deodorant and a binder resin in water. At this time, it is preferable to disperse these deodorants and binder resin as much as possible, and it is more preferable that the binder resin forms an emulsion state with water. In addition, it is preferable to disperse the deodorant in water before mixing and then disperse the binder resin in order to more uniformly disperse the deodorant and the binder resin.

  As the binder resin, any resin can be used. For example, self-crosslinking acrylic resin, methacrylic resin, urethane resin, silicone resin, glyoxal resin, vinyl acetate resin, vinylidene chloride resin, butadiene resin, melamine resin, epoxy resin, acrylic-silicone copolymer resin, ethylene- Examples thereof include vinyl acetate copolymer resin, isobutylene maleic anhydride copolymer resin, ethylene-styrene-acrylate-methacrylate copolymer resin, and the like. Two or more of these resins may be mixed to form a binder resin.

  In addition, various additives may be added to the treatment agent to improve the properties of the treatment agent such as a dispersant or a thickener, and antibacterial agents, Additives such as a flame retardant can be appropriately blended within a range that does not hinder the present invention.

  The treatment agent thus obtained is fixed to one or more of the carpet pile yarn, base fabric, sealing layer, and backing layer. The means for fixing is not particularly limited, and examples thereof include a spray method, a dipping method, a coating method, and a padding method. The fixing time may be a single state of the pile yarn, the base fabric, or the backing layer, or the treatment agent may be fixed in the form of a skin layer in which the pile yarn is laid on the base fabric, or a breathable adhesive. The skin layer and the backing layer may be bonded and integrated with each other through the layers. Moreover, it is good also as a sealing layer which has a deodorizing function by mixing a deodorizing agent in the process liquid of a sealing layer, and apply | coating with a spray or roller coating.

  As described above, the treatment agent is applied and then dried, but 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 the heat treatment at this temperature, it is possible to further improve the sticking property of the deodorant and further improve the durability of the malodor removal performance.

  Next, the material and structure of the carpet used as an example of the present invention, the structure of the deodorant and the binder resin, the evaluation method of the deodorization test, and the measurement method of the air permeability are as follows.

<Materials used>
Base fabric: Spunbond nonwoven fabric base fabric made of polyester fibers (110 g / m ² per unit area)
Pile yarn …… Pile yarn made of polyester fiber is planted on the base fabric using a tufting machine
(Pile length 7mm, pile weight 700g / m ² )
Sealing layer: SBR latex (SBR content 50% by weight) was spray-processed (coating amount 30 g / m ² )
Backing layer: Needle punch nonwoven fabric made of polyester fiber (3.4 dtex, thickness 7 mm, basis weight 310 g / m ² )
Adhesive layer: Polyethylene resin powder (particle size 400 μm, melt flow rate value 200, melting point 107 ° C.)
Deodorant …… Composition of one-on-one mixture of sebacic acid dihydrazide and zeolite (average particle size is 8μm)
Binder resin ... Urethane resin emulsion (Binder U-30 manufactured by Daiwa Chemical Industry Co., Ltd.)

<Deodorization test>
In addition, the measurement of various deodorizing performance in the said Example was performed as follows.
(Ammonia deodorization performance)
After putting a test carpet piece (10 cm x 20 cm) into a bag with an internal volume of 500 ml, inject ammonia gas so that the concentration becomes 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 the ammonia deodorization performance measurement except that hydrogen sulfide gas was used instead of ammonia gas so that the concentration in the bag was 20 ppm.

(Methyl mercaptan deodorization performance)
A methyl mercaptan gas was used instead of ammonia gas so that the concentration was 40 ppm in the bag, and the remaining concentration of the methyl mercaptan gas was measured after 4 hours. The removal rate (%) of methyl mercaptan gas was calculated.

(Acetic acid deodorization performance)
The acetic acid gas removal rate (%) was calculated in the same manner as in the ammonia deodorizing performance measurement except that acetic acid gas was used instead of ammonia gas and the concentration was 100 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 air permeability>
It was measured by A method of 8.27.1 of JIS L1096-1999.

<Melt flow rate>
It was measured according to JIS K6924-2 1997.

<Example 1>
First, SBR latex (containing 50% by weight of SBR) was sprayed on the stitch side of the skin layer and dried by heating to obtain a sealing layer 5. Next, with the sealing layer 5 facing upward, a polyethylene resin powder is sprayed with 300 g / m ^{2 by a} scatter, heated by a heater at 180 ° C. for 1 minute, melted to form an adhesive layer, and deodorized thereon. A backing layer carrying 10 g / m ^{2 of the} agent was laminated and pressed with a pressure roller to obtain a carpet. A method in which a deodorant is previously supported on the backing layer includes a needle punch nonwoven fabric made of polyester fiber, 100 parts by weight of a urethane resin emulsion, 200 parts by weight of a composition in which sebacic acid dihydrazide and zeolite are mixed in a one-to-one relationship, and a surfactant. A backing layer carrying 10 g / m ^{2 of} deodorant was obtained by immersing in 1 part by weight of a processing solution, squeezing with mangle and drying. The air permeability of the entire carpet was 20 cm ³ / cm ² · sec.

<Example 2>
A processing liquid consisting of 100 parts by weight of a urethane resin emulsion, 200 parts by weight of a composition in which sebacic acid dihydrazide and zeolite are mixed in a one-to-one manner, and 1 part by weight of a surfactant is spray-processed and heat-dried on a pile yarn of the skin layer A carpet was obtained in the same manner as in Example 1 except that a skin layer carrying 3.1 g / m ^{2 of} deodorant was used. The air permeability of the entire carpet was 19 cm ³ / cm ² · sec.

<Example 3>
A carpet was obtained in the same manner as in Example 1 except that a base cloth carrying 2.1 g / m ^{2 of} deodorant was used after spraying the treatment liquid onto the base cloth of the skin layer and drying by heating. It was. The air permeability of the entire carpet was 18 cm ³ / cm ² · sec.

<Example 4>
A carpet was obtained in the same manner as in Example 1 except that a polyethylene resin powder was sprayed at 430 g / m ² by a scatterer as an adhesive layer in Example 1. The air permeability of the entire carpet was 8 cm ³ / cm ² · sec.

<Example 5>
A deodorant was added to the SBR latex emulsion in Example 1 (SBR content 40 wt%, deodorant content 10 wt%) and spray-processed (coating amount 60 g / m ² ). A carpet was obtained. The air permeability of the entire carpet was 20 cm ³ / cm ² · sec.

<Comparative Example 1>
A carpet was obtained in the same manner as in Example 1 except that a polyethylene resin powder was used as the adhesive layer. The air permeability of the entire carpet was 0.8 cm ³ / cm ² · sec.

<Comparative example 2>
A carpet was obtained in the same manner as in Example 1 except that a backing layer carrying 1.8 g / m ² of deodorant was laminated. The air permeability of the entire carpet was 20.8 cm ³ / cm ² · sec.

<Comparative Example 3>
In Example 2, a carpet was obtained in the same manner as in Example 2 except that sebacic acid dihydrazide having an average particle size of 18 μm was used as a deodorant. The air permeability of the entire carpet was 19 cm ³ / cm ² · sec.

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 ... Adhesive layer 7 ... Backing layer fabric 8 .... ·Deodorants

Claims (4)

In carpets consisting of pile yarn, base fabric, sealing layer, backing layer and adhesive layer, at least one of the pile yarn, base fabric, sealing layer and backing layer carries a deodorant and allows ventilation. A carpet characterized by a degree of 1 to 50 (cm ³ / cm ² · sec).   2. The carpet according to claim 1, wherein the backing layer is made of a non-woven fabric, and the adhesive layer is formed by melting a powder-like heat-fusible resin to form a breathable adhesive layer.   The carpet according to claim 1 or 2, wherein the deodorant comprises a hydrazine derivative having an average particle size of 10 µm or less and an inorganic substance, and is supported by a binder resin. The carpet according to any one of claims 1 to 3, wherein the deodorant is applied in an amount of ² to 15 g / m2.

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