JP2008054898A - Antiallergenic carpet and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an antiallergenic carpet which can efficiently reduce the amount of an allergen produced from the interior of the carpet, can be safely used even by an allergic disease patient, and is low-cost. <P>SOLUTION: The carpet is made up of pile thread 2, a foundation 3 and a backing layer 5. Even if the foundation 3 for which polypropylene tape yarn is used, an antiallergenic carpet 1 having high performance of allergen reduction and durability is obtained by fastening an allergen reduction agent to the pile yarn 2 side of the foundation by a binder resin of 0.2 to 5.0 g/m<SP>2</SP>and a penetrant. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a carpet coated with an allergen-reducing agent, and relates to a carpet that inactivates allergens such as pollen and mites adhering to the carpet and reduces symptoms of allergic diseases.

  Houses constructed in recent years have significantly improved heat insulation and airtightness, and high-performance energy-saving houses have been born that require several times the time for indoor air to be replaced by natural convection. However, because of its high airtightness, odors and house dust are likely to be trapped in the room, and these become allergens that cause allergies. It is said that many have developed.

  There are various types of allergens, including mites (parasites, carcasses, shells, feces), molds, pets (hair, dandruff), pollen, and the like, which are considered as the main causative agents of allergic diseases. In particular, dust mite allergens, even if the dust mites are exterminated with high heat or chemicals, the dead bodies remain in the tatami mats and carpets, and the dead bodies become more allergenic substances, and people move on the tatami mats and carpets As a result, allergens were released from the inside into the indoor space. Therefore, unless allergens such as mite carcasses, shells, and feces were removed from the tatami mats and carpets, the allergic disease could not be completely solved.

  In order to cope with this, deodorization, deodorization, and dust collection using an air conditioner, an air purifier, and the like are performed, and a method for collecting allergens in the air using a filter or the like has been proposed. However, these methods are effective for causative substances of allergic diseases floating in indoor air, but they are not effective even for causative substances inside carpets and the like. In carpets, it is said that it is effective to remove mites by sucking the surface layer of pile yarn of the carpet with a vacuum cleaner or the like while sucking it. However, although this method can remove the surface layer of the carpet, it cannot completely remove ticks and dead mites that have entered the carpet.

  In Patent Documents 1 to 3, a technique for fixing an allergen-reducing component to a fiber and reducing the allergen has been proposed. All of these techniques apply the allergen-reducing component to a fiber or the like by a method such as dipping, spraying, or printing. However, it is not a technique for efficiently supporting an allergen-reducing component on a special fiber assembly called carpet.

In addition, in the patent document 4, the applicant discloses a carpet in which a web layer is fixed to a surface of a base fabric on a pile yarn side, and an allergen reducing component is applied thereon and dried. Patent Document 5 discloses a technique in which split yarn is used for warp and / or weft of a base fabric, and a large amount of an allergen-reducing substance can be fixed without impairing the texture of the carpet. However, although these carpets are excellent in reducing allergens, the cost becomes high, and therefore, carpets having an allergen reducing performance are required at a lower cost.
JP2003-10089 JP2003-96670A JP 2003-313778 A WO 2005/087059 Japanese Patent Application No. 2005-341561

  The present invention has been made in view of such a technical background, and by directly supporting an allergen-reducing component on a commonly used base fabric, the amount of allergen generated from the carpet interior is efficiently reduced, The purpose is to provide an inexpensive carpet that can be used with peace of mind by allergic patients.

  As a result of intensive investigations to solve such problems, the present inventors have found that the surface of the polypropylene woven fabric that is most commonly used has a large amount of allergen-reducing substances and impairs the texture of the carpet. The present inventors have found a technique capable of fixing without any problem, and found that an allergen-reducing carpet that can be efficiently reduced, inexpensive, and durable can be obtained. In order to achieve the above object, the present invention provides the following means.

[1] A carpet comprising a pile yarn, a base fabric and a backing layer, wherein the allergen reducing agent is fixed to the pile yarn side surface of the base fabric.

[2] The anti-allergen carpet according to [1], wherein the base fabric is a woven base fabric woven with a polypropylene tape yarn.

[3] The anti-allergen carpet according to item 1 or 2, wherein the allergen reducing agent is fixed to 0.2 to 5.0 g / m ² on the pile yarn side surface of the base fabric.

[4] In a carpet composed of a pile yarn, a base fabric, and a backing layer, a solution containing a binder resin, a penetrant, and an allergen reducing agent is applied to the pile yarn side surface of the base fabric, and dried by heating. A method for producing an anti-allergen carpet to which an allergen reducing agent is fixed.

In the invention of [1], since the allergen reducing agent is fixed to the surface of the base fabric on the pile yarn side, it is effective for allergens that are supposed to accumulate near the root of the pile yarn while using the carpet. Can act.

In the invention of [2], since the allergen reducing agent is directly fixed to the pile yarn side surface of the woven base fabric woven by the polypropylene tape yarn often used as a carpet base fabric, the manufacturing cost is reduced. Can be suppressed. Moreover, since the allergen reducing agent is firmly fixed by the binder resin, the effect can be continuously maintained even if washing is performed.

In the invention [3], since the allergen reducing agent is applied to the base fabric in an amount of 0.2 to 5.0 g / m ² , a sufficient allergen reducing effect can be obtained.

In the invention of [4], since a solution containing a binder resin, a penetrating agent, and an allergen reducing agent is applied to the base fabric, it is woven with a polypropylene tape yarn that is difficult to fix the allergen reducing agent with the binder resin alone. Even a base fabric such as a woven base fabric can be a method for producing an anti-allergen carpet having a strong adhesive force. Moreover, it can be set as the manufacturing method of the anti-allergen carpet which the adhesiveness to a base fabric improved more by carrying out heat drying, and the continuous durability of the allergen reduction performance improved further.

  Next, an embodiment of the anti-allergen carpet according to the present invention will be described with reference to the drawings. The anti-allergen carpet 1 of this embodiment includes a pile yarn 2, a base fabric 3, and a backing layer 5, and an allergen reducing agent 7 is fixed to the pile yarn side of the base fabric 3 with a binder resin. (See Figure 1)

  In the anti-allergen carpet in the present invention, an allergen reducing agent is applied to the base fabric 3 in advance, and then a pile yarn is implanted from the side of the base fabric to which the allergen reducing agent is not applied using a tufting machine. The pile yarn 2 and the base fabric 3 are fixed.

  As the base fabric 3 in the present invention, a woven base fabric made of polypropylene which is generally most frequently used as a carpet base fabric is preferably used. The reason is that it is the cheapest base fabric, but in order to give a functional agent to the polypropylene base fabric, various binder resins are tried, but those with excellent flexibility and durability are However, it has been difficult to apply directly to the base fabric. For this reason, it is conceivable to apply a drug to the web layer integrated on the base fabric, or to use a split yarn for the yarn of the base fabric and physically fix the drug to the split yarn folds with a binder resin. Has been.

  In the present invention, since a solution containing a binder resin, a penetrating agent, and an allergen reducing agent is applied to the base fabric, the penetrating agent acts to impart wettability to the polypropylene tape yarn, thereby adhering to the binder resin. Is improved, and the allergen reducing agent can be firmly fixed to the base fabric. As the penetrant, an anionic surfactant is preferable, and examples thereof include sodium alkylnaphthalene sulfonate and sodium di (2-ethylhexyl) sulfosuccinate. The amount of the penetrant mixed is preferably 0.5 to 30 parts by weight with respect to 100 parts by weight of the binder resin. If the amount is less than 0.5 parts by weight, the penetrant becomes non-uniform, and unevenness occurs in the adhesion between the base fabric and the binder resin. If it exceeds 30 parts by weight, the cost will increase undesirably.

  The binder resin is not particularly limited as long as the allergen-reducing component can be fixed to the surface of the base fabric. For example, urethane resin, self-crosslinking acrylic resin, methacrylic resin, silicone resin, glyoxal resin, polyester resin, vinyl acetate Resin, vinylidene chloride resin, butadiene resin, melamine resin, epoxy resin, acrylic-silicone copolymer resin, styrene-butadiene copolymer resin (SBR), ethylene-vinyl acetate copolymer resin (EVA), isobutylene maleic anhydride Examples thereof include a copolymer resin and an ethylene-styrene-acrylate-methacrylate copolymer resin. In the present invention, styrene-butadiene copolymer resin (SBR), which is relatively inexpensive, is preferable, and urethane-modified SBR is more preferable.

  The method for applying the allergen reducing agent to the base fabric 3 is to uniformly disperse the penetrant and allergen reducing agent in the binder resin solution, and apply it to one side of the base fabric by a conventional method such as spraying or coating. Then, it is dried and fixed to one surface of the base fabric. The binder resin is preferably dried by heat treatment. Although the heat processing temperature at this time is based also on the raw material of a base fabric, it is preferable to set it as 100-180 degreeC. By the heat treatment at this temperature, the adhesion to the base fabric is further increased, and the continuous durability of the allergen reducing performance is further improved.

  The allergen reducing agent, penetrant and binder resin can be used as an aqueous dispersion dispersed in water. The binder resin is more preferably formed into an emulsion state with water. As the dispersion medium, alcohol or the like can be used in addition to water, but water is preferred. In order to disperse in water, it is preferable to disperse the penetrant and binder resin after dispersing the allergen reducing agent in water from the viewpoint of more uniformly dispersing the allergen reducing agent and the binder resin. Moreover, you may mix | blend various additives, such as a dispersing agent and a thickener, with this aqueous dispersion.

  The allergen-reducing component in the present invention is not particularly limited as long as it is a component that is inactivated by degenerating allergen and suppresses antigen-antibody reaction, for example, plant extracts such as tannic acid and catechin, And hydroxybenzoic acid such as 2,5-dihydroxybenzoic acid. In the present invention, a polymer having phenolic OH [3] is more preferable from the viewpoint of processability, washing resistance and colorability, and examples thereof include vinylphenol, tyrosine, 1,2-di (4-hydroxyphenyl) ethene and the like. It is done.

In the present invention, the allergen reducing agent fixed to the base fabric is preferably applied in an amount of 0.2 to 5.0 g / m ² . If the allergen reducing agent is less than 0.2 g / m ² , the allergen reducing effect is not exerted, and therefore, if it exceeds 5.0 g / m ² , the allergen reducing effect cannot be obtained economically. More preferably, 0.3-3.0 g / m < ² > is good.

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. In addition, carpets exceeding 2000 g / m ² are less likely to drop allergens on the surface of the base fabric during use, and are less likely to accumulate at the base of the pile yarn, so that the allergen reducing effect is not sufficiently exhibited. Therefore, it is not preferable.

  Next, the backing 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, Examples thereof include resins such as polyvinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber composition include SBR (styrene-butadiene), NBR (acrylonitrile-butadiene rubber) MBR (methyl methacrylate-butadiene rubber), and natural rubber. In general, calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash or the like is added as a filler and used as a backing layer.

Further, as shown in FIG. 1, a non-woven fabric layer 6 may be provided as a second base fabric to provide cushioning properties and protection performance of the backing layer below the backing layer 5. The nonwoven fabric layer 6 is not particularly limited, and examples thereof include a needle punch nonwoven fabric and a spunbond nonwoven fabric. The basis weight of the nonwoven fabric layer 6 is preferably 50 to 1000 g / m ² , its thickness is set to 0.5 to 15 mm, and the fineness of the constituent fibers is preferably set to a range of 0.1 to 30 dtex. If the fabric weight of the nonwoven fabric layer 6 is less than 50 g / m ² , the function and quality of the carpet are inferior, which is not preferable. If it exceeds 1000 g / m ² , the cost will increase unnecessarily. 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. Further, a non-slip layer may be formed on the lowermost surface of the nonwoven fabric layer 6 with a resin composition or a rubber composition, and the deodorizing composition is fixed to the nonwoven fabric layer 6 with a binder resin, and further has a deodorizing function. A certain nonwoven fabric layer 6 may be used.

  Next, the carpet material, structure, type of allergen reducing agent, processing method, allergen performance measurement test and determination method used as examples of the present invention are as follows.

<Materials used>
Base fabric: Woven base fabric composed of polypropylene tape yarn (22.2 dtex) as warp and polypropylene tape yarn (60.0 dtex) as weft (warp density 18 / inch, weft density 16 / inch, basis weight 98 g / m ² )
Pile yarn: Pile yarn made of polyester fiber is planted on the base fabric using a tufting machine
(Pile basis weight 700g / m ² )
Backing layer: SBR latex (calcium carbonate as filler)
Allergen reducing agent ... Tyrosine (Wako Pure Chemical Industries, Ltd.)
Binder resin ... Urethane-modified SBR resin and SBR resin Penetration agent ... Sodium di (2-ethylhexyl) sulfosuccinate

<Allergen performance measurement test>
The allergenicity is measured using an allergen measurement kit (trade name “Daniscan” manufactured by Asahi Breweries, Ltd.). Rub the carpet with a dust collector, drain the developer, and determine the contamination status by the shade and position of the red line that appears. The criteria for tick scan are as follows, with 2 or less being acceptable.
1 ... No mite allergen contamination.
2 ... Slightly contaminated with mite allergens, but not so much.
3 ... Contamination of mite allergen is progressing.
4 ... Very contaminated with mite allergens.

<Washing durability test>
The method according to JIS 0217 103 method was performed 10 times.

<Example 1>
After 0.2 part by weight of the allergen reducing agent is dispersed in 100 parts by weight of water, an aqueous solution in which 0.3 part by weight of a penetrant and 2.2 parts by weight of a binder resin are dispersed is sprayed on one side of the base fabric. It was applied and dried at 110 ° C. for 3 minutes to obtain a base fabric having an allergen reducing agent fixed to 0.5 g / m ² on one surface of the base fabric. Next, this base fabric is placed on a tufting machine, and pile yarn is implanted from the side to which the allergen reducing agent is not fixed, and a cut pile having a pile length of 7 mm is formed on the side to which the allergen reducing agent is fixed. Got a semi-finished product. Next, a backing layer was applied to the opposite side of the pile side of this semi-finished product and dried to obtain an anti-allergen carpet.

  Next, dust (3 mg) collected from a general carpet used for 3 years was placed on the anti-allergen carpet (5 cm × 5 cm) and rubbed so that dust could not be seen on the surface. H. In order to confirm the allergenicity of the pile root, the allergenicity was measured with a tick scan (trade name, manufactured by Asahi Brewery Co., Ltd.) and the judgment result of 1 was obtained. . Next, allergenicity was measured in the same manner on the carpet that had been washed 10 times, and a determination result of 1 was obtained.

<Example 2>
An anti-allergen carpet was obtained in the same manner as in Example 1 except that a base fabric having an allergen reducing agent fixed to 4 g / m ² was obtained. The determination by tick scan gave a result of 1. Next, allergenicity was measured in the same manner on the carpet that had been washed 10 times, and a determination result of 1 was obtained.

<Example 3>
An anti-allergen carpet was obtained in the same manner as in Example 1 except that a base fabric having an allergen reducing agent fixed to 0.3 g / m ² was obtained. Judgment by tick scan gave a result of 2. Next, the allergenicity was measured in the same manner on the carpet that had been washed 10 times, and a determination result of 2 was obtained.

<Comparative Example 1>
A carpet was obtained in the same manner as in Example 1 except that a base fabric to which the allergen reducing agent was not fixed was used, and a result of 4 was obtained when judged by tick scanning.

<Comparative example 2>
An anti-allergen carpet was obtained in the same manner as in Example 1 except that a base fabric having an allergen reducing agent fixed to 4 g / m ² was obtained without mixing a penetrant. The determination by tick scan gave a result of 1. Next, the allergenicity was measured in the same manner on the carpet that had been washed twice, and a determination result of 4 was obtained.

<Comparative Example 3>
Anti-allergen was the same as in Example 1 except that the allergen reducing agent was sprayed onto the pile yarn at 0.5 g / m ² and dried and fixed, and the allergen reducing agent was not fixed to the base fabric. Got the carpet. The determination by tick scan gave a result of 3. Next, allergenicity was measured in the same manner on the carpet that had been washed 10 times, and a determination result of 4 was obtained.

As described above, in the case where the allergen reducing agent is fixed to 0.2 to 5.0 g / m ² on the pile yarn side of the base fabric, the tick is more than the unprocessed one and the one fixed to the pile yarn. Good results were obtained by scanning. In Comparative Example 2 where no penetrant was used, the durability to washing was poor.

It is a schematic sectional drawing which shows the anti-allergen carpet which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Anti-allergen carpet 2 ... Pile yarn 3 ... Base fabric 4 ... Skin layer 5 ... Backing layer 6 ... Nonwoven fabric layer 7 ... Allergen reducing agent

Claims (4)

    A carpet comprising a pile yarn, a base fabric and a backing layer, wherein the allergen reducing agent is fixed to the pile yarn side surface of the base fabric.   The anti-allergen carpet according to claim 1, wherein the base fabric is a woven base fabric woven with polypropylene tape yarn. The anti-allergen carpet according to claim 1 or 2, wherein an allergen reducing agent is fixed to 0.2 to 5.0 g / m ² on the pile yarn side surface of the base fabric.   In a carpet comprising a pile yarn, a base fabric, and a backing layer, a solution containing a binder resin, a penetrant, and an allergen reducing agent is applied to the pile yarn side surface of the base fabric, and dried by heating to reduce allergen. A method for producing an anti-allergen carpet with a fixed agent.

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