JP2018000355A - Carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carpet excellent in water-catch property, water-retaining property and a drying property.SOLUTION: A carpet includes: a base cloth 2 having a woven cloth 3 and a cotton-like fiber layer 4 formed on the top surface of the woven cloth 3; and a pile yarn 5 implanted on the upper side of the base cloth 2. The cotton-like fiber layer 4 is structured by entangling innumerable cotton-like fibers 4a, the basis weight of the cotton-like fiber layer 4 is 50 g/m-200 g/m, and the fineness of the cotton-like fibers 4a forming the cotton-like fiber layer 4 is smaller than the fineness of fibers 5a forming the pile yarn 5.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a carpet excellent in water retention and drying properties.

Conventionally, so-called dust control tile carpets have been used as carpets laid at the entrances and exits of buildings such as office buildings, commercial facilities, and condominiums. The dust control tile carpet is required to have a dust removal property to remove dust adhering to the back of a person's shoes. Examples of the dust include earth and sand or dust adhering to the back of a shoe of a person entering the inside from the outside of the building or the wheel of a luggage carrier. The dust control tile carpet removes dust such as shoe soles in advance, making it difficult to bring dust into the building.
By the way, when a person or a luggage carrier enters or leaves, not only dust but also moisture such as rainwater adheres.
However, the conventional dust control tile carpet does not take much consideration on water absorption, and does not have sufficient performance to absorb and retain moisture adhering to the shoe sole and the like when it rains. For this reason, in a building where a large number of people come and go, water floats on the surface of the carpet, and the floating water further adheres to the shoe soles of people who enter the building later. Therefore, there is a problem that moisture is easily brought into the building.

Patent Document 1 proposes a carpet fabric having water absorption, moisture diffusibility and retention. In the case of the carpet fabric of Patent Document 1, moisture trapped by the pile yarn passes through the core fabric and moves to the entangled nonwoven web provided on the lower surface of the core fabric. For this reason, the surface may have a dry tactile sensation, but the upper side of the entangled nonwoven web is in a state of being covered with a core fabric, and the dryness is poor when viewed as the entire carpet. There is. Further, in the carpet of Patent Document 1, moisture held as described above is difficult to dry, and moisture attached to one portion of the carpet pile yarn remains intensively in one portion of the entangled nonwoven web below the carpet. Therefore, the limit of the amount of moisture that can be held by the entangled nonwoven web is fast, and moisture tends to accumulate on the upper surface of the core fabric and the pile yarn. For this reason, moisture is oozed out by the load of the person who enters later, and the moisture adheres to the shoe sole and is brought into the building.
In this way, conventional carpets are poor in water retention and drying properties, and when laid at the entrance of a building, removal of moisture brought in through the shoe sole from the outside during rainy weather becomes insufficient, and moisture adheres to the shoe sole. There was a problem of being brought indoors.

JP 2000-96421 A

  The objective of this invention is providing the carpet excellent in the water catching property which catches water, water retention, and drying property.

The carpet of the present invention has a woven fabric and a base fabric having a cotton-like fiber layer provided on the upper surface of the woven fabric, and pile yarns planted on the upper side of the base fabric, and the cotton-like fibers The layer is composed of innumerable cotton-like fibers entangled, the basis weight of the cotton-like fiber layer is 50 g / m ^{2 to} 200 g / m ² , and the layer of the cotton-like fibers constituting the cotton-like fiber layer The fineness is smaller than the fineness of the fibers constituting the pile yarn.

Preferably, the ratio between the fineness of the cotton-like fibers constituting the cotton-like fiber layer and the fineness of the fibers constituting the pile yarn is 1: 1.1 to 1:50.
Preferably, a backing layer is provided on the lower surface of the base fabric.

  The carpet of the present invention is excellent in water catching property, water retention and drying property. Such a carpet can be suitably used for a doorway of a building.

The top view of the carpet of this invention. Sectional drawing cut | disconnected by the II-II line | wire of FIG. FIG. 3 is an enlarged detailed cross-sectional view of a part of FIG. The enlarged plan view which shows an example of a woven fabric. The expanded detailed sectional view which cut | disconnected by the VV line | wire of FIG. 4, and expanded further. However, the warp is not shown in cross section (the same applies to FIG. 6). (A) And (b) is an expanded detailed sectional view which shows the various forms of the base fabric by which the cotton-like fiber layer was provided in the cloth. The reference top view which shows the 1st example of installation of the carpet of this invention. The reference top view which shows the 2nd example of installation of the carpet of this invention. The reference top view which shows the 3rd installation example of the carpet of this invention. The table | surface and graph which show the time-dependent change of the residual moisture content of Example 1 and Comparative Example 1. FIG.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In this specification, the “upper surface” or “upper” of a layer refers to the surface or direction far from the floor surface on which the carpet is applied, and the “lower surface” or “lower” refers to the opposite side (to apply the carpet). The surface or direction on the side close to the surface.
In the present specification, a numerical range represented by “to” means a numerical range including numerical values before and after “to” as a lower limit value and an upper limit value.
In addition, it should be noted that dimensions such as thickness and size in each drawing are different from actual ones.

FIG. 1 is a plan view of a carpet 1 according to one embodiment of the present invention, FIG. 2 is a sectional view of the carpet 1, and FIG. 3 is an enlarged sectional view showing details of each layer.
As shown in FIG. 1, the carpet 1 is formed in a sheet shape such as a substantially square shape in a plan view. However, the planar view shape of the sheet-like carpet 1 is not limited to a substantially square shape, and is formed in, for example, a substantially rectangular shape, a substantially circular shape, a substantially elliptical shape, a substantially polygonal shape such as a substantially triangular shape or a substantially hexagonal shape. May be. Such a sheet-like carpet 1 can be used as a tile carpet, a rug, a mat or the like. In this specification, “substantially” means a shape allowed in the technical field to which the present invention belongs. The “substantially” in a substantially polygonal shape such as a substantially square shape, a substantially rectangular shape, or a substantially triangular shape in a plan view includes, for example, a shape in which a corner is chamfered, a shape in which a part of a side is slightly inflated or depressed, and a side Includes a slightly curved shape. In addition, the “substantially” of the substantially circular shape and the substantially elliptical shape in a plan view includes, for example, a shape in which a part of the circumference is slightly inflated or depressed, and a shape in which a part of the circumference is slightly straight or oblique. .
Although the dimension of the carpet 1 of planar shape substantially square shape is not specifically limited, For example, 500 mm x 500 mm etc. are mentioned. The carpet 1 having such dimensions can be suitably used as a tile carpet.
In addition, the carpet of this invention can also be used as a roll carpet. In the case of a roll carpet, the carpet 1 of the present invention is usually formed in a long band shape in plan view and wound into a roll shape for storage and transportation. The long band shape in plan view is a rectangular shape in which the length in one direction is sufficiently longer than the length in the other direction (direction orthogonal to the one direction), for example, the length in one direction is the length in the other direction. 3 times or more, preferably 5 times or more.

As shown in FIGS. 2 and 3, the carpet 1 of the present invention includes a woven fabric 3 and a base fabric 2 having a cotton-like fiber layer 4 provided on the upper surface of the woven fabric 3, and an upper side of the base fabric 2. The pile yarn 5 is planted. Such a carpet 1 has the softness | flexibility of the grade which can be curved in the thickness direction.
Preferably, a backing layer 6 is provided on the lower surface of the base fabric 2.

In the carpet 1 of the present invention, when the shoe sole comes into contact with the pile yarn 5 located on the uppermost surface of the carpet 1, moisture attached to the shoe sole is captured by the pile yarn 5. The moisture adhering to the pile yarn 5 moves from the pile yarn 5 to the cotton-like fiber layer 4 and is once held by the cotton-like fiber layer 4. In the carpet 1 of the present invention, since the fineness of the cotton-like fiber constituting the cotton-like fiber layer 4 is smaller than the fineness of the fiber constituting the pile yarn 5, the pile-like fiber layer is separated from the pile yarn 5 by capillary action. Moisture transfer to 4 is promoted. And since the cotton-like fiber layer 4 is provided in the upper surface of the woven fabric 3 in which the pile yarn 5 was planted, most of the water | moisture content hold | maintained at the cotton-like fiber layer 4 does not pass the woven fabric 3, but weaves. It is dammed by the upper surface of the cloth 3, and moisture moves and diffuses in the surface direction according to the upper surface of the woven cloth 3 and the cotton-like fiber layer 4. For this reason, moisture can be retained by the cotton-like fiber layer 4 and the carpet 1 having excellent water retention can be obtained.
The moisture retained in the cotton-like fiber layer 4 moves in the entire surface direction of the cotton-like fiber layer 4 and diffuses over a wide range without remaining concentrated in one place. In particular, since moisture moves linearly along the warp and weft of the woven fabric 3 due to the capillary phenomenon of the cotton-like fiber layer 4, moisture can move and diffuse over the entire surface direction of the cotton-like fiber layer 4. Promoted.
The carpet 1 of the present invention uses a woven fabric 3 having a cotton-like fiber layer 4 on the upper side as a base fabric 2 on which pile yarns 5 are planted, so that moisture permeates the lower layer of the woven fabric 3. , Preventing it from remaining. Further, since the moisture retained in the cotton-like fiber layer 4 is unlikely to remain intensively in one place, the amount of moisture retained increases as the whole of the cotton-like fiber layer 4, and the cotton-like fiber layer 4 and the pile yarn 5 are increased. It is difficult to reach the moisture retention limit before the water overflows. Moisture spread over a wide range along the cotton-like fiber layer 4 evaporates from above the cotton-like fiber layer 4 and the pile yarn 5. Therefore, the carpet 1 of the present invention is excellent in drying properties. Thus, since drying is quick, the power (water catching property) which the pile yarn 5 captures the water | moisture content adhering to the shoe sole can be maintained at a high level.
Since the carpet 1 of the present invention is excellent in water retention and drying properties as described above, when it is laid at the entrance of a building, it should be removed even if a large amount of moisture is brought in from the outside through the shoe sole in the rain. It is possible to reduce the amount of moisture that is brought indoors while attached to the shoe sole.

(Woven fabric)
The woven fabric 3 has a function of moving the moisture that has moved from the pile yarn 5 to the cotton-like fiber layer 4 in the surface direction (omnidirectional direction) of the cotton-like fiber layer 4, that is, promoting the diffusion of moisture. .
Examples of the woven fabric 3 used in the present invention include those formed by weaving warps 31 and wefts 32 into a planar shape such as a sheet as shown in FIGS. Examples of the weaving method of the woven fabric 3 include plain weave, twill weave, satin weave, entangled weave, and combinations of these weaves. FIG. 4 illustrates a plain woven fabric. Plain weaving is preferred because it is difficult for moisture to flow downward through the gap between the warp 31 and the weft 32 from above.
Examples of the yarn constituting the woven fabric 3 include yarns made of natural fibers or chemical fibers as exemplified in the section of cotton-like fibers described later.
Since the woven fabric 3 is difficult to absorb moisture, the woven fabric 3 is preferably composed of a hydrophobic thread. Examples of the hydrophobic yarn include a yarn made of a hydrophobic thermoplastic resin such as polyolefin, a yarn made of inorganic fibers such as glass, and the like. The warp and weft materials may be the same or different.
Among them, the shape processing is easy, and the yarn of the woven fabric 3 is preferably a hydrophobic chemical fiber because it is suitable for plain weaving.

Examples of the shape of the warp 31 and the weft 32 constituting the woven fabric 3 include various shapes. For example, the cross-sectional view has a substantially circular shape, a substantially elliptical shape, a substantially rectangular shape, a substantially T-shaped shape, Examples include a U shape, a substantially Y shape, a substantially star shape, and a substantially flat shape.
In the present invention, from the viewpoint of facilitating the movement of moisture in the surface direction with a structure in which moisture is difficult to pass, it is preferable that at least one of the warp 31 and the weft 32 is a substantially flat yarn in cross section. It is more preferable that both the warp 31 and the weft 32 are substantially flat in cross section. In the example of illustration, the case where the cross-sectional view substantially flat warp 31 and the weft 32 are used is shown. The substantially flat yarn is not particularly limited, but is preferably a tape yarn or a split yarn because it has a good tufting property and can easily form a woven fabric 3 that hardly allows water to pass through. The tape yarn can be obtained, for example, by melt-extruding a thermoplastic resin with an extruder, forming a film by a T-die method or an inflation method, slitting, heat-drawing, and then heat-treating. For example, a split yarn is formed by an extruder in the same way as a tape yarn, and after stretching, a roll having a file, needle, blade or the like is rotated at high speed to split the film into fine nets. Can be obtained. A split yarn is preferable because the tuft property of the pile yarn 5 is particularly excellent.

The fineness of the yarn constituting the woven fabric 3 is preferably, for example, about 200 dtex to 1500 dtex. When the yarn constituting the woven fabric 3 is a substantially flat yarn such as a tape yarn, the width 3W is preferably 0.5 mm to 8 mm, more preferably 1 mm to 5 mm, and its thickness 3T. Is not particularly limited, but is, for example, about 0.01 mm to 0.05 mm (see FIG. 5).
If the width of the tape yarn is too small, it is necessary to increase the density of the yarn in order to form a woven fabric that does not allow moisture to pass through. If it is too large, it becomes difficult to tuft and the flexibility of the pile yarn 5 that has been implanted. And the texture may be reduced.
In this specification, the thickness of a fiber and a thread is represented by fineness. A fiber having a weight of 1 g per 1000 m and a fiber having a weight of 1 g per 10,000 m is referred to as 1 dtex. The thicker the fibers and yarn, the larger the tex. Further, 1 tex = 10 dtex.
In the present specification, the fineness means a value measured according to the method B described in “8.3.1 Positive Fineness” in JIS L 1013: 2010 “Chemical Filament Yarn Test Method”.

Basis weight of the fabric 3 is not particularly limited, for ^example, a ^{50g / m 2 ~200g / m 2} , ^preferably in the ^{60g / m 2 ~150g / m 2} , more preferably, 70 g / ^{m 2} ˜120 g / m ² . By being in the numerical range, the moisture that has moved from the cotton-like fiber layer 4 to the woven fabric 3 becomes difficult to pass to the lower side of the woven fabric 3, and the moisture is diffused over the entire surface direction of the cotton-like fiber layer 4. Can do.
In order to prevent moisture from passing below the woven fabric 3, it is preferable that the woven fabric 3 has a gap as small as possible between the warp and the weft.
From the above viewpoint, the woven fabric 3 is preferably densely woven. Depending on the fineness of the warp and the weft, the warp is 8 / inch to 30 / inch and the weft is 8 / inch to 30 / It is preferably woven in inches.

(Cotton fiber)
In the present invention, the cotton-like fibers constituting the cotton-like fiber layer 4 are fibers each having a short fiber length. The cotton-like fiber may be a long fiber or a long fiber called a filament cut into a desired length. The fiber length of the cotton-like fiber is, for example, about 20 mm to 150 mm, and preferably 30 mm to 100 mm. When the fiber length of the cotton-like fibers is within the above range, the cotton-like fibers are appropriately entangled, and the sheet-like cotton-like fiber layer 4 can be configured. Such a cotton-like fiber layer 4 has many voids inside. Since moisture is easily held in the voids inside the cotton-like fiber layer 4, the cotton-like fiber layer 4 has excellent water retention, and the carpet 1 of the present invention diffuses the trapped moisture over a wide range. Can hold.

  Examples of the material of the cotton-like fiber include natural fiber, chemical fiber, and inorganic fiber. Examples of the natural fiber include plant fibers such as cotton, hemp, and linen; animal fibers such as wool, silk, cashmere, alpaca, Angola, and mohair. Examples of the chemical fibers include synthetic fibers such as polyamide such as nylon, polyester, polyethylene, polypropylene, acrylic, polyvinyl chloride, and polyurethane; semi-synthetic fibers such as acetate, triacetate, and promix; rayon, cupra, and polynosic. Examples include recycled fibers. Examples of the inorganic fiber include carbon, glass, and metal. A cotton-like fiber may be used individually by 1 type, or may use 2 or more types together. Preferable cotton-like fibers used in the present invention include, for example, polyester fibers such as polyethylene terephthalate and polybutylene terephthalate; polyolefin fibers such as polyethylene and polypropylene. The cotton-like fiber may be either hydrophilic or hydrophobic, but is preferably hydrophilic from the viewpoint of retaining moisture, and is preferably hydrophobic from the viewpoint of ease of drying. Examples of hydrophilic cotton-like fibers include plant fibers such as cotton and hydrophilic semi-synthetic fibers such as acetate. Examples of the hydrophobic cotton-like fibers include hydrophobic synthetic fibers such as polyethylene terephthalate, polypropylene, and nylon.

  The fineness of the cotton-like fiber is not particularly limited as long as it is smaller than the fineness of the fiber constituting the pile yarn 5, and is, for example, about 1 dtex to 50 dtex, preferably 2 dtex to 20 dtex, more preferably 2 dtex. -10 dtex. Here, the fineness of the cotton-like fiber is the fineness of one fiber.

The cross-sectional shape of the cotton-like fiber is not particularly limited, and examples thereof include a substantially circular shape, a substantially oval shape, a substantially rectangular shape, a substantially T shape, a substantially U shape, a substantially Y shape, and a substantially star shape. In particular, a substantially Y-shaped cotton-like fiber is preferable because it easily retains and diffuses water, and therefore has a high effect of absorbing and diffusing moisture from the pile yarn 5 by capillary action. In addition, the substantially Y-shaped cotton-like fiber has an advantage that it is relatively easy to manufacture. Further, the inside of the cotton-like fiber may be solid or hollow.
The cotton-like fiber may be crimped or non-crimped.

(Cotton fiber layer)
As shown in FIG. 3, the cotton-like fiber layer 4 is configured by the innumerable cotton-like fibers 4 a entangled with each other. The cotton-like fiber layer 4 is formed in a planar shape such as a sheet shape without woven countless cotton-like fibers 4a. The cotton-like fiber layer 4 can be said to be a three-dimensional fiber assembly formed by intertwining a myriad of independently dispersed cotton-like fibers 4a by, for example, thermal, mechanical, or chemical action. The cotton-like fiber layer 4 is formed by, for example, a thermal bond method in which the cotton-like fibers are bonded by melting with heat, a chemical bond method in which the cotton-like fibers are bonded by impregnating or spraying an adhesive into the adhesive, and a needle with a barb. It can be formed by intertwining countless cotton-like fibers 4a by a needle punching method in which the cotton-like fibers are mechanically bonded by piercing, a spunlace method in which cotton-like fibers are entangled using a high-pressure water stream, or the like. In particular, the needle punching method is a simple manufacturing method that can simultaneously form the cotton-like fiber layer 4 and the woven fabric 3 and reduce the manufacturing process by one step. This is preferable because it can be firmly bonded to the cloth 3.

The cotton-like fiber layer 4 is provided on the upper surface of the woven fabric 3. The base fabric 2 is configured by integrating a cotton-like fiber layer 4 and a woven fabric 3. The method for integrating the cotton-like fiber layer 4 and the woven fabric 3 is not particularly limited, and examples thereof include the following methods. (1) The cotton-like fiber layer 4 and the woven fabric are formed simultaneously with the formation of the cotton-like fiber layer 4 by the needle punching method in which an infinite number of cotton-like fibers 4a are placed on the upper surface of the woven fabric 3 and repeatedly pierced with needles from above the cotton-like fibers. The base fabric 2 in which the fabric 3 is integrated can be obtained. (2) After the innumerable cotton-like fibers 4a are entangled by the chemical bond method or the like to form the cotton-like fiber layer 4, the cotton-like fiber layer 4 is placed on the upper surface of the woven fabric 3, and the needle punching method is used to The base fabric 2 in which the fibrous layer 4 and the woven fabric 3 are integrated can be obtained. (3) After the innumerable cotton-like fibers 4a are entangled by the chemical bond method or the like to form the cotton-like fiber layer 4, the entire upper surface of the woven fabric 3 (or / and the lower surface of the cotton-like fiber layer 4) or The base fabric 2 in which the cotton-like fiber layer 4 and the woven fabric 3 are integrated can be obtained by applying the adhesive in spots in some places and bonding the cotton-like fiber layer 4 and the woven fabric 3 together.
The density of needle punching when the cotton-like fiber layer 4 is provided on the upper surface of the woven fabric 3 is not particularly limited as long as the woven fabric 3 and the cotton-like fiber layer 4 can be integrated. Books ^/ cm 2 ^~350 this is a / cm ² about.

6 (a) and 3 show the base fabric 2 obtained by the method (1) or (2), and FIG. 6 (b) shows the base obtained by the method (3). The cloth 2 is shown.
6 (a) and 6 (b) both have a cotton-like fiber layer 4 provided on the upper surface of the woven fabric 3, but the base fabric 2 shown in FIG. The fiber layer 4 extends not only to the upper surface of the woven fabric 3 but also part of the cotton-like fibers 4 a to the inside of the woven fabric 3 and the lower surface of the woven fabric 3.
Specifically, when the cotton-like fiber layer 4 in FIG. 6A is conceptually distinguished, a main fiber layer 41 located on the upper surface side of the woven fabric 3, a penetrating fiber portion 42 located inside the woven fabric 3, And a protruding fiber portion 43 protruding to the lower surface side of the woven fabric 3. In the cotton-like fiber layer 4 of FIG. 6A, the fiber amount of the main fiber layer 41 is considerably larger than the fiber amount in the penetrating fiber part 42 and the protruding fiber part 43, and most of the cotton-like fiber 4 a is the main fiber layer 41. Is configured. Further, the fiber amounts of the penetrating fiber portion 42 and the protruding fiber portion 43 are substantially the same, or the fiber amount of the penetrating fiber portion 42 is slightly larger than that of the protruding fiber portion 43. Further, in the cotton-like fiber layer 4 of FIG. 6A, the cotton-like fibers 4 a constituting the penetrating fiber portion 42 and the protruding fiber portion 43 pass through the gap between the warp 31 and the weft 32 of the woven fabric 3. Others pass through the warp 31 and the weft 32. Such a difference is due to the density of the needle. When the needle pierces the gap or the warp 31 and the weft 32, the cotton-like fiber 4a penetrates there.
In addition, the cotton-like fiber layer 4 shown in FIG.6 (b) has the cotton-like fiber layer 4 arrange | positioned substantially only on the upper surface side of the woven fabric 3. FIG.

In the present invention, the basis weight of the cotton-like fiber layer 4 ^is a ^{50g / m 2 ~200g / m 2} , preferably ^{80g / m 2 ~150g / m 2} , more preferably, 90 g ^{/ m} 2 ~ 120 g / m ² . If the basis weight of the cotton-like fiber layer 4 is too large, the thickness of the cotton-like fiber layer 4 becomes large, and as a result, the overall thickness of the carpet 1 becomes too large. On the other hand, if the basis weight of the cotton-like fiber layer 4 is too small, the water retention of the cotton-like fiber layer 4 may be reduced.

  The moisture that has moved from the pile yarn 5 is held in the cotton-like fiber layer 4, but the moisture may be held in the cotton-like fibers 4a themselves, and in the gaps between the countless cotton-like fibers 4a. Sometimes it is retained. Therefore, the cotton-like fiber layer 4 preferably has a certain amount of voids.

  By providing the cotton-like fiber layer 4 on the upper surface side of the woven fabric 3 as in the present invention, most of the moisture retained in the cotton-like fiber layer 4 does not pass through the woven fabric 3, It is dammed and the moisture moves and diffuses in the surface direction according to the upper surface of the woven fabric 3 and the cotton-like fiber layer 4. For this reason, moisture spreads over a wide range and evaporates without remaining intensively in one place of the cotton-like fiber layer 4. Therefore, the carpet of the present invention is excellent in drying properties.

(Pile yarn)
As shown in FIGS. 2 and 3, the pile yarn 5 is planted (tufted) from the upper side of the base fabric 2 and is erected on the base fabric 2. Specifically, the pile yarn 5 implanted in the base fabric 2 has an upper portion thereof standing on the upper side of the cotton-like fiber layer 4, its base portion penetrating the cotton-like fiber layer 4 and the woven fabric 3, and a lower portion thereof. Is disposed below the woven fabric 3.
The pile yarn 5 may be a loop pile or a cut pile. Further, a combination of a loop pile and a cut pile may be used.
In the carpet 1 of the present invention, the countless cotton-like fibers 4a constituting the cotton-like fiber layer 4 support the base portion of the pile yarn 5 from the side surface, so that the pile yarn 5 does not easily fall sideways. Therefore, it is possible to configure the carpet 1 in which the pile yarn 5 is difficult to loosen even when used for a long time.
The height of the pile yarn 5 is not particularly limited, but is usually 2 mm to 20 mm. In the case of a loop pile, for example, 3 mm to 15 mm is preferable. If it is less than the lower limit, there is a possibility that a good footing feeling at the pile portion may not be obtained, and if it exceeds the upper limit, the pile yarn 5 may be easily sag. Moreover, the height of each pile thread | yarn 5 may be the same all, or may differ.

In the present invention, the fineness of the fibers 5 a constituting the pile yarn 5 is larger than the fineness of the cotton-like fibers 4 a constituting the cotton-like fiber layer 4. That is, the fineness of the cotton-like fiber 4 a constituting the cotton-like fiber layer 4 is smaller than the fineness of the fiber 5 a constituting the pile yarn 5. In other words, the thickness of the cotton-like fiber 4 a constituting the cotton-like fiber layer 4 is smaller than the thickness of the fiber 5 a constituting the pile yarn 5. In the present invention, the pile yarn 5 may be a monofilament or a multifilament. When the pile yarn 5 is a monofilament, the fineness (thickness) of the fiber constituting the pile yarn 5 is the fineness (thickness) of the monofilament. When the pile yarn 5 is a multifilament, that is, when the pile yarn 5 is a single yarn obtained by twisting or arranging a plurality of single fibers, the fineness of the fibers 5a constituting the pile yarn 5 ( (Thickness) is the fineness (thickness) per one fiber (single fiber) constituting the multifilament.
Preferably, the pile yarn 5 is comprised by the multifilament which consists of several fiber 5a, as shown in FIG. The number of filaments (number of single fibers) of the multifilament is not particularly limited, but is preferably 2 to 500, and more preferably 3 to 300.
One type of pile yarn may be used, or two or more types of pile yarns having different thicknesses may be used. As two or more types of pile yarns having different thicknesses, (a) two or more types of pile yarns having different single fiber thicknesses and the same number of single fibers, and (b) single fiber thicknesses are: Two or more types of pile yarns having the same number of single fibers, but (c) two or more types of pile yarns having different single fiber thicknesses and different numbers of single fibers; Including two or more types of pile yarn having two or more types of single fibers having different thicknesses, and the number of each single fiber being the same, (d) including two or more types of single fibers having different thicknesses of single fibers In addition, two or more types of pile yarns in which the number of at least one single fiber is different may be used.

In the carpet 1 of the present invention, the fineness of the cotton-like fiber 4a constituting the cotton-like fiber layer 4 is smaller than the fineness of the fiber 5a constituting the pile yarn 5, so that the pile yarn 5 is changed to the cotton-like fiber layer 4. The movement of moisture is promoted by the capillary phenomenon, and moisture hardly remains in the pile yarn 5.
From the viewpoint of promoting moisture movement due to the capillary phenomenon, the ratio between the fineness of the cotton-like fibers 4a constituting the cotton-like fiber layer 4 and the fineness of the fibers 5a constituting the pile yarn 5 is from 1: 1.1 to It is preferably 1:50, more preferably 1: 2 to 1:40, and more preferably 1: 5 to 1:30.
The fineness of the pile yarn 5 itself is not particularly limited, and is, for example, 500 dtex to 6000 dtex, and preferably 600 dtex to 4500 dtex.
Moreover, the fineness of the fiber 5a which comprises the pile thread | yarn 5 is not specifically limited on condition that it is larger than the fineness of the cotton-like fiber 4a, For example, it is 3dtex-50dtex, More preferably, it is 5dtex-30dtex. In particular, by using the pile yarn 5 in which the fine fibers 5a having the above-mentioned range have the above-mentioned number of filaments, the carpet 1 having an appropriate cushioning property and the pile yarn 5 is difficult to sag can be formed. The carpet 1 which is excellent also in the movement promoting effect can be configured.
In this specification, the fineness of the fiber 5a constituting the pile yarn 5 is (A) when a pile yarn consisting of only one type of single fiber is used for a carpet, the fineness of the single fiber is (B) When one type of pile yarn composed of two or more types of single fibers is used in the carpet, it means the average value of the fineness of the fibers of the pile yarn, (C) When two or more types of pile yarns composed of two or more types of single fibers are used in the carpet, it means the average value of the fineness of the fibers of those pile yarns.

The average value of the fineness of the fibers of the pile yarn (B) is determined by the following <Formula 1>.
<Formula 1>
First fineness × (weight of single fiber of first fineness / total weight of single fiber) + second fineness × (weight of single fiber of second fineness / total weight of single fiber) +... + Mth fineness × (Weight of single fiber of mth fineness / total weight of single fiber).
The first fineness, the second fineness,..., The mth fineness represent the fineness of single fibers having different thicknesses.
For example, when the pile yarn is composed of a single fiber having a fineness Z1 (dtex) and a single fiber having a fineness Z2, the fineness of the single fiber of the pile yarn is Z1 × (weight of single fiber having fineness Z1 / (fineness Z1 (Weight of single fiber + weight of single fiber of fineness Z2)) + Z2 × (weight of single fiber of fineness Z2 / (weight of single fiber of fineness Z1 + weight of single fiber of fineness Z2)).

The average value of the fineness of the fibers of the pile yarn (C) is obtained by the following <Expression 2>.
<Formula 2>
Fineness of single fiber of first pile yarn × (weight of first pile yarn / weight of whole pile yarn) + fineness of single fiber of second pile yarn × (weight of second pile yarn / weight of whole pile yarn) + ... + fineness of single fiber of n-th pile yarn x (weight of n-th pile yarn / weight of entire pile yarn).
The first pile yarn, the second pile yarn,..., The nth pile yarn represent n types of pile yarns having different thicknesses.
For example, the first pile yarn with a single fiber fineness of X1 (dtex) is Y1 (g), the second pile yarn with a single fiber fineness of X2 (dtex) is Y2 (g), and the single fiber fineness is X3 (dtex). ) Of the carpet in which the third pile yarn is planted with Y3 (g), the fineness of the fibers constituting the pile yarn of this carpet is X1 × (Y1 / (Y1 + Y2 + Y3)) + X2 × (Y2 / (Y1 + Y2 + Y3) )) + X3 × (Y3 / (Y1 + Y2 + Y3)).
In addition, when there are two or more types of single fibers constituting the first pile yarn, the second pile yarn,..., The nth pile yarn, the fineness of each pile yarn is obtained by Equation 1. .

The fiber constituting the pile yarn of the present invention can be specified by, for example, calculating the result measured by the following method using the above formula 1 or formula 2.
Step 1: Pull pile yarn from any part of the carpet and pull it out of the base fabric. Usually, since the extracted pile yarn has a resin component such as an adhesive (sealing agent) or a backing layer attached thereto, a solvent capable of dissolving the resin component without dissolving the pile yarn (for example, tetrahydrofuran solvent) Etc.) to remove the resin component.
Step 2: The pile yarn obtained in Step 1 is loosened, and the fineness of the single fiber is determined according to the method B described in “8.3.1 Positive Fineness” of JIS L 1013: 2010 “Chemical Filament Yarn Test Method”. Measure.
Step 3: When there are a plurality of single fibers having different finenesses, Step 1 and Step 2 are repeated for each single fiber, and the fineness of all the different single fibers is measured.

  When using a pile yarn composed of two or more types of single fibers, as described above, the average value may be larger than the fineness of the cotton-like fiber, but preferably all the yarns constituting the pile yarn 1 are used. It is preferable that the fineness of the single fiber is larger than the fineness of the cotton-like fiber.

The material of the fiber 5a constituting the pile yarn 5 is not particularly limited, and natural fibers and chemical fibers exemplified above can be used. Preferably, chemical fibers are used. Specifically, as the pile yarn 5, for example, a processed yarn of synthetic fiber such as polyamide such as nylon, polyester, polypropylene, polyethylene, polyvinyl chloride or the like can be used.
The basis weight of the pile yarn 5 is not particularly limited, can be appropriately set, for ^example, a ^{400g / m 2 ~3000g / m 2} , preferably from ^{500g / m 2 ~2000g / m 2} . By setting the weight per unit area of the pile yarn 5 within the above range, the carpet 1 that has excellent cushioning properties and the pile yarn 5 is difficult to sag can be configured.

The planting density of the pile yarn 5 is not particularly limited, but is preferably 1/4 gauge to 1/16 gauge. Here, 1 / X gauge means that X pile yarns 5 are driven per inch in the gauge direction. That is, the greater the value of X, the higher the density of the pile yarn 5 planted. In the carpet 1 of the present invention, the pile yarn 5 is planted at a high density so that the pile yarn 5 does not easily fall down, and the moisture retention when the foot is stepped on the sole and pressure is applied is improved. Can do.
The stitches of the pile yarn 5 are preferably 5-20.

The carpet 1 of the present invention is implanted in the base fabric 2 because the base fabric 2 having the woven fabric 3 and the cotton-like fiber layer 4 provided on the upper surface of the woven fabric 3 has excellent water retention and drying properties. It is not always necessary to provide the pile yarn 5 with water retention and drying properties. Therefore, the degree to which the pile yarn 5 can be freely selected as the material and shape of the pile yarn 5 is increased, and the carpet 1 having excellent design can be configured.
For example, when the carpet 1 of the present invention is punched into a predetermined size such as 500 mm × 500 mm or 250 mm × 1000 mm to be a tile carpet, the construction range and the arrangement of the carpet can be freely set according to the floor to be constructed. Can do. According to tile carpet, the amount of moisture brought in can be predicted from factors such as the user of the building and the size of the entrance, and the moisture treatment can be performed effectively by adjusting the number and arrangement of construction. Become. In the case where the carpet 1 of the present invention is a tile carpet, it is preferable to provide a backing layer on the back surface because the construction becomes easy and the number and arrangement of the constructions can be easily adjusted.

(Backing layer)
The carpet 1 of the present invention preferably has a backing layer 6 on the lower side of the base fabric 2. This is to improve the workability and dimensional stability of the carpet. In addition, it is preferable to provide the backing layer 6 because the trapped moisture does not easily move to the floor to be constructed.
As described above, since the cotton-like fiber layer 4 is mainly provided on the upper surface side of the woven fabric 3, the cotton-like fiber 4 a is not substantially interposed between the lower surface of the base fabric 2 and the backing layer 6. Therefore, the backing layer 6 is firmly bonded to the lower surface of the base fabric 2. For this reason, according to this invention, the carpet 1 which cannot produce delamination in the base fabric 2 and the backing layer 6 can be comprised. It is also an object of the present invention to provide a carpet in which such a backing layer 6 is difficult to peel off.
The lower surface of the backing layer 6 is affixed to the surface on which the carpet is to be applied via an adhesive or the like, or is fixed to the construction surface via a fixture or the like, or is in direct contact with the construction surface. Placed. As shown in FIG. 2, the backing layer 6 includes, for example, a backing layer 61, a reinforcing material 62, and a lower surface layer 63. However, the backing layer 6 may be composed of one or two of these three layers, or may have other functional layers.

The backing layer 61 includes a base fabric 2 on which the pile yarn 5 is implanted and a reinforcing material 62 (if the reinforcing material 62 is not provided or the reinforcing material 62 is embedded in the lower surface layer 63, the base fabric 2 and the lower surface layer 63) is provided on the lower surface side of the base fabric 2 on which the pile yarn 5 is planted.
The backing layer 61 is usually made of a synthetic resin. The synthetic resin is not particularly limited. For example, PVC such as vinyl chloride resin, EVA such as vinyl chloride-vinyl acetate copolymer, APP such as atactic polypropylene (APP) resin, and PUR such as polyurethane. The system etc. are mentioned. From the viewpoint of processability, durability, and cost, it is preferable to use a PVC system such as polyvinyl chloride resin.
The backing layer 61 may contain additives such as various pigments such as carbon black, fillers such as calcium carbonate and barium sulfate, stabilizers, and anti-aging agents as necessary.
The thickness of the backing layer 61 is not particularly limited, but is usually 0.5 mm to 5.0 mm. If the thickness of the backing layer 61 is too large, it is difficult to produce a carpet. On the other hand, if the thickness of the backing layer 61 is too small, the base fabric 2 and the reinforcing material 62 may not be joined with sufficient strength.
Note that the backing layer 61 can be omitted if the base fabric 2 and the reinforcing material 62 or the base fabric 2 and the lower surface layer 63 can be joined by another means such as thermal joining.

The reinforcing material 62 is provided to impart physical property stability such as dimensional stability to the carpet 1. The reinforcing material 62 may be provided at the boundary between the backing layer 61 and the lower surface layer 63, and may be embedded in the lower surface layer 63 although not particularly illustrated.
Examples of the reinforcing material 62 include woven or non-woven fabrics of inorganic fibers or synthetic fibers such as glass, polyester, and polyamide. In particular, since the dimensional stability effect is excellent, a glass fiber nonwoven fabric or woven fabric can be suitably used as the reinforcing material 62.

The lower surface layer 63 is a layer constituting the lowermost surface of the backing layer 6.
The lower surface layer 63 is usually made of synthetic resin or rubber. The synthetic resin is not particularly limited. For example, as exemplified above, polyvinyl chloride (PVC), vinyl chloride-vinyl acetate copolymer (EVA), atactic polypropylene (APP), polyurethane Resins such as (PUR) series may be mentioned. In view of processability, durability, and cost, it is preferable to use a PVC system such as polyvinyl chloride resin.
The thickness of the lower surface layer 63 is usually 1 mm to 3 mm, preferably 1.3 mm to 2 mm. If the thickness of the lower surface layer 63 is too thick, its production becomes difficult. On the other hand, if the lower surface layer 63 is too thin, the non-land absorption effect and the impact absorption performance are deteriorated.

  The carpet 1 of the present invention can be manufactured, for example, by the following method. But the carpet 1 of this invention is not limited to what was manufactured by the following method.

By providing a cotton-like fiber layer 4 on the upper surface of the woven fabric 3, the base fabric 2 is obtained. For the method of obtaining the base fabric 2 by integrating the cotton-like fiber layer 4 and the woven fabric 3, see the above-mentioned item of the cotton-like fiber layer.
A pile yarn 5 is planted on the base fabric 2 to produce a living machine. The pile yarn 5 can be planted by a known tufting machine or the like.
A backing layer 6 is formed on the lower surface of the obtained raw machine (the base fabric 2 on which the pile yarn 5 is planted).
The backing layer 6 can be formed by a conventionally known method. For example, a lower layer forming material such as a polyvinyl chloride resin paste is applied on a conveyor, and a reinforcing material and a backing layer forming material such as a polyvinyl chloride resin paste are laminated thereon as necessary. A long carpet can be obtained by stacking and integrating the whole by curing each forming material by heating or the like.
By cutting the obtained long carpet into a desired shape and size, the carpet 1 of the present invention can be obtained.

Since the carpet 1 of this invention is excellent in water retention and drying property, it can be used conveniently as a carpet laid in the entrance / exit of a building. As one preferred mode of use, a conventionally known dust control tile carpet is laid on the inner side of a building doorway, followed by the carpet 1 of the present invention, or on the outer side of a building doorway. For example, a conventionally known dust control tile carpet is laid, and the carpet 1 of the present invention is laid on the inner side of the entrance / exit of the building, that is, at a location between the entrance / exit of the building and the interior. With this type of usage, the dust control tile carpet removes dust that enters the inside of the shoe from the outside to the inside of the building, and the moisture that enters the inside from the outside through the shoe sole of the building when it rains. By removing the carpet 1 of the invention, moisture is not brought indoors, and a comfortable indoor space can be constructed.
For example, as shown in FIG. 7, a conventionally known dust control tile carpet is laid in an indoor portion connected to a doorway of a building, and the carpet of the present invention is connected to the surrounding portion of the dust control carpet to the indoor portion of the doorway of the building. Laying 1 7 to 9, dots are added to the conventional dust control carpet, and hatched lines are added to the carpet of the present invention. Solid color indicates floor materials other than these carpets (general-purpose carpets and the like).
In addition, as shown in FIG. 8, a conventionally known dust control tile carpet is laid in the indoor portion of the entrance of the building, and subsequently, the carpet 1 of the present invention is laid in the indoor portion, and both are alternately arranged. By doing so, a passage is formed by both carpets. Such a passage looks like there is a way visually depending on the color and design of the carpet, and is expected to lead the user who enters from the doorway to walk reliably on the dust control carpet and the carpet of the present invention. it can.
Further, as shown in FIG. 9, a conventionally known dust control tile carpet is laid on the indoor portion of the entrance of the building, and the carpet 1 of the present invention is laid irregularly on the indoor portion.

  EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.

[Example 1]
Polypropylene tape yarn (fineness: 440 dtex, width: 1.2 mm) as warp, polypropylene tape yarn (fineness: 1060 dtex, width: 2.0 mm) as weft, 22 warps / inch and 13 wefts A woven fabric (weight per unit area: 93 g / m ² ) made into a plain weave at / inch was prepared.
Also, countless hydrophilic polyethylene terephthalate fibers (fineness: 4.4 dtex, fiber length: 51 mm, cross-sectional shape: solid Y-shape) were prepared as cotton-like fibers.
The woven fabric is placed on the upper surface of the woven fabric, and needle-punched from the upper side of the cotton-like fiber so that the woven fabric and the cotton-like fiber are integrated, as shown in FIG. A base fabric 2 in which a cotton-like fiber layer 4 having a main fiber layer 41 was provided on the upper surface side of 3 was produced.
The overall basis weight of the cotton-like fiber layer 4 of the base fabric 2 was 100 g / m ² .

As pile yarns, nylon yarn A of 1375 dtex / 68 filament × 1380 dtex / 160 filament and twist number of 100S / 100T and nylon yarn B of 1375 dtex / 68 filament × 1375 dtex / 68 filament and twist number of 100S / 100T were prepared.
The fineness of the nylon yarn A (fineness of single fiber) was about 12 dtex, and the fineness of the nylon yarn B (fineness of single fiber) was 8.6 dtex.
In addition, the fineness of the single fiber of the cotton-like fiber and the pile yarn was measured according to B method described in “8.3.1 Positive fineness” of JIS L 1013: 2010 “Chemical filament yarn test method”.
Nylon yarn A and nylon yarn B were randomly planted on a base fabric with a tufting machine in approximately the same amount, thereby producing a raw machine having a pile yarn weight per unit area of 1000 g / m ² . The planting density was 1/12 gauge and 12.4 stitches. The pile height was a textured loop of 6.0 mm, 4.5 mm, and 3.0 mm.

The fineness of the fibers constituting the nylon yarn A is 20.2 × (93500 / (93500 + 220800)) + 8.6 × (220800 / (93500 + 220800)) = about 12 dtex.
The fineness of the fibers constituting the nylon yarn B is 20.2 × (93500 / (93500 + 93500)) + 20.2 × (93500 / (93500 + 93500)) = about 20.2 dtex.
Since the nylon yarn A and the nylon yarn B were planted in substantially equal amounts, the fineness of the fibers constituting the pile yarn in Example 1 (average fineness of single fibers of the nylon yarn A and the nylon yarn B) was 12 X (50/100) + 20.2 * (50/100) = about 16.1 dtex.

On the other hand, separately from the production of the living machine, a paste-like polyvinyl chloride having a thickness of about 1.5 mm in which a polyester resin net (trade name “Kurenet” manufactured by Kurashiki Boseki Co., Ltd.) is embedded as a reinforcing material on a conveyor. A lower layer made of resin was formed, and a backing layer made of a polyvinyl chloride resin paste having a thickness of about 2.0 mm was laminated on the lower layer.
After placing the raw machine on the backing layer, the whole was heated to cure the polyvinyl chloride resin to obtain a carpet. The carpet was cut into 500 mm × 500 mm in a gauge direction and a stitch direction that is orthogonal to the gauge by a cutting machine to produce a square tile carpet.

[Example 2]
A carpet was produced in the same manner as in Example 1 except that the density of the pile yarn was changed and the basis weight of the pile yarn was 900 g / m ² .

[Comparative Example 1]
A carpet was produced in the same manner as in Example 1 except that a polyester nonwoven fabric (Marix 80906 / GSE manufactured by Unitika Ltd.) was used as the base fabric instead of the woven fabric and the cotton-like fiber layer.

[Test Example 1: Evaluation of water retention and water absorption]
The carpets produced in Examples 1 and 2 and Comparative Example 1 were cut in a gauge direction and a stitch direction by a cutting machine to obtain a 10 cm × 10 cm test piece.
In addition, three types of commonly used dust control carpets (Lonstep carpets manufactured by Yamazaki Sangyo Co., Ltd., Nomad carpet mats manufactured by 3M, and DC1100 manufactured by Toli Co., Ltd.) have the same size. A specimen was obtained.
First, the weight W0 [g / 100 cm ² ] of each test piece was measured by an analytical balance (manufactured by METTTLER TOLEDO, model number AL20). The same balance was used for subsequent weight measurements.
The test piece was submerged in a water bath at room temperature for 1 minute, and the test piece was allowed to absorb water. Then, the test piece was taken out of the water bath and placed in a horizontal state. The weight W1 [g / 100 cm ² ] of the test piece after being placed in a horizontal state for 0.5 minutes was measured.
Immediately after measuring the weight W1, a weight (9.6 kg) was placed on the entire upper surface of the test piece for 0.5 minutes, and then the weight W2 [g / 100 cm ² ] of the test piece was measured.

Carpet water absorption, water retention and runoff are defined as follows:
Water absorption [g / m ² ] = (W1−W0) × 100
Water retention [g / m ² ] = (W2−W0) × 100
Outflow [g / m ² ] = Water absorption [g / m ² ] −Water retention [g / m ² ] = W 1 −W 2
From the above formula, the amount of water absorption indicates the amount that the carpet can absorb moisture. The water retention amount indicates the amount of moisture retained by the carpet after pressure is applied to the carpet. The water retention amount is also an index indicating how much moisture can be retained when a person steps on the carpet. The outflow amount indicates the amount of water that flows out when pressure is applied to the carpet. The smaller the amount of spillage, the more difficult it will be to float on the top surface (surface) of the carpet, and it will be difficult for water to adhere to the shoe soles of people who will walk later.
The results of Test Example 1 are shown in Table 1.

From the results in Table 1, the carpets of Examples 1 and 2 were superior in water retention compared to the carpets, long step mats and nomad carpets of Comparative Example 1.
In comparison between the carpets of Examples 1 and 2 and DC 1100, DC 1100 was superior in terms of water absorption and water retention, but the carpets of Examples 1 and 2 were superior in terms of outflow.

[Test Example 2: Evaluation of drying properties]
For Example 1 and Comparative Example 1, a 10 cm × 10 cm test piece was prepared, and the weight W0 [g / 100 cm ² ] was measured in the same manner as in [Test Example 1]. And 1.0 ml of normal temperature water was dripped at the test piece, and the weight Ws [g / 100 cm < ² >] of the test piece was measured immediately. The test piece is allowed to stand in a state of a temperature of 25 ° C. and a humidity of 65% RH, and the weight Wt [g] is measured every predetermined time. The residual moisture content [%] of the test piece at the time of measurement is calculated by the following equation. Asked.
Residual moisture content [%] = {(Wt−W0) / (Ws−W0)} × 100.
The results of Test Example 2 are shown in FIG.

From the results of FIG. 10, it can be seen that the carpet of Example 1 has a lower residual moisture content, that is, a faster drying rate, compared with the carpet of Comparative Example 1.
This is because the use of a woven fabric as in the example promotes the movement and diffusion of moisture linearly along the warp and weft of the woven fabric by capillary action, and the entire surface direction of the cotton-like fiber layer. This is thought to be due to the rapid movement and diffusion over the area. From this result, the carpet of the present invention has excellent drying properties.

DESCRIPTION OF SYMBOLS 1 Carpet 2 Base cloth 3 Woven cloth 4 Cotton-like fiber layer 4a Cotton-like fiber 5 Pile yarn 6 Backing layer

Claims (3)

A base fabric having a woven fabric and a cotton-like fiber layer provided on the upper surface of the woven fabric, and a pile yarn planted on the upper side of the base fabric,
The cotton-like fiber layer is composed of innumerable cotton-like fibers entangled,
Basis weight of the cotton-like fiber layer ^is a ^{50g / m 2 ~200g / m 2} ,
The carpet characterized in that the fineness of the cotton-like fibers constituting the cotton-like fiber layer is smaller than the fineness of the fibers constituting the pile yarn.   The ratio between the fineness of the cotton-like fiber constituting the cotton-like fiber layer and the fineness of the fiber constituting the pile yarn is 1: 1.1 to 1:50. Carpet.   The carpet according to claim 1 or 2, wherein a backing layer is provided on a lower surface of the base fabric.

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