JP3237196B2 - Needle punch carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet for indoor or outdoor laying or vehicles, and more particularly, to a base cloth,
The present invention relates to a needle punch carpet which is excellent in light weight and economical efficiency by making use of a laminating material and latex unnecessary, and which facilitates recycling after use.

[0002]

2. Description of the Related Art Conventionally, carpets to be laid on floors of exhibition halls, event halls and the like (hereinafter referred to as exhibition carpets).
Is generally composed of a pile portion made of a needle punched nonwoven fabric forming a surface layer, a base fabric lining the pile portion, and a latex impregnated on the back surface, and imparts flame retardancy to the carpet. Therefore, latexes often contain flame retardants. Needle punch car for car floor
Pets are generally used in which latex is impregnated on the back surface of a pile portion forming a surface layer, and a sheet such as polyolefin is further laminated on the pile portion. In these display carpets and floor carpets for vehicles, the current standard value is 60 kg in the former.
/ 5 cm or more, and the latter is required to have a strength of 80 kg / 5 cm or more.

[0003]

Recently, there has been an increasing demand for economy and light weight for both the needless carpets for exhibition and vehicles. Recently, recycling of waste has become an issue as a countermeasure for environmental pollution, and recycling of used carpet has been studied in the field of carpet. In particular, the use of exhibition carpets is short, only during exhibitions and events.
The need for recycling is particularly high because all of them are disposed after use. However, current needle punch cars
Most pets are made of different materials for the pile and other structural materials, and because each material is firmly joined, it is very difficult to separate the desired materials for recycling. . As mentioned above, demand for economy, light weight,
Alternatively, as a method of satisfying the demand for recycling, it is conceivable to omit the base fabric, the laminating material, and the latex which are the structural materials of the carpet. However, omitting the structural material such as the base cloth, the laminating material, or the latex involves a decrease in carpet physical properties such as a decrease in carpet strength and flame retardancy. SUMMARY OF THE INVENTION An object of the present invention is to provide a needle punch carpet that is excellent in economy and light weight, is easy to recycle, and does not cause deterioration in carpet properties.

[0004]

Means for Solving the Problems The present inventors have made intensive studies to achieve the above object, and as a result, have found that polypropylene staple fibers and polypropylene-based heat-fusible composite staple fibers (hereinafter simply referred to as staple fibers). A mixed fiber with a composite staple fiber).
Then, it was found that the intended purpose could be achieved by fusion-fixing the contact points between the fibers with the low melting point component of the composite fiber by heat treatment, and the present invention was completed. That is, the present invention comprises a first component made of polypropylene and an olefin-based binary copolymer and / or terpolymer based on propylene having a melting point lower than the melting point of the first component by 20 ° C. or more. Heat-fusible composite staple fibers 25 to 9 obtained by compound-spinning the second component into a parallel type or a sheath-core type so that the second component occupies the majority of the fiber surface.
0% by weight and polypropylene staple fiber 75-1
After the mixed fiber comprising 0% by weight of the composite staple fiber is subjected to needle punching , the melting point of the second component is higher than the melting point of the second component.
Achieved by heat treatment at a temperature below the melting point of the components
Needle punch carpet having a tensile strength of 60 kg / 5 cm or more. Hereinafter, the present invention will be described in detail.

The olefin-based binary copolymer containing propylene as the main component in the present invention means 85 to 99% of propylene.
And a random copolymer of ethylene 1 to 15% or a random copolymer of propylene 50 to 99% and butene-1 1 to 50%. The olefin-based terpolymer mainly composed of propylene is 84 to 97% of propylene,
A crystalline copolymer of 1 to 10% ethylene and 1 to 15% butene-1. The olefin-based terpolymer or terpolymer based on propylene is obtained by polymerizing propylene, ethylene, and butene-1 with a known Ziegler-Natta type catalyst so that the content of each of the above components is attained. Polymer, which is essentially a random copolymer. In addition to the method of polymerizing the mixed gas from the beginning, in order to improve the productivity, a polymer of 20% or less of the total amount of the polymer is previously obtained by propylene homopolymerization, and then the mixed gas of each component is fed. Alternatively, the polymerization may be performed by a polymerization method. The ethylene content greatly affects the melting point, while the butene-1 content greatly affects the melting point and heat-fusibility. If the content of any of the comonomers (ethylene and butene-1) in the copolymer is less than 1%, the heat sealability becomes insufficient. On the other hand, as the content of the comonomer increases, the melting point of the copolymer decreases and the heat fusibility increases, but at the same time, the ratio of by-products soluble in the polymerization solvent (hydrocarbon) during polymerization increases. Since the productivity is reduced, those having a content higher than the upper limit in the previous period are not suitable for industrial production. These binary copolymers and ternary copolymers can be used alone as the second component of the composite staple fiber, however, the binary copolymers and the ternary copolymers can also be used as a mixture. .

The conjugated staple fiber used in the present invention comprises a first component comprising polypropylene, the propylene-based olefin-based binary copolymer having a melting point lower than the melting point of the first component by 20 ° C. or more, and And / or a heat-fusible composite staple fiber obtained by compound-spinning a second component comprising a terpolymer into a parallel type or a sheath-core type so that the second component occupies a majority of the fiber surface. is there. If the melting point of the second component of the composite staple fiber is not lower than the melting point of the first component by 20 ° C. or more, the first component is softened or melted during heating for melting the second component, and loses the fiber shape. This is undesirable because it impairs the appearance of the carpet of the product. The method of compound spinning the first component and the second component such that the second component occupies the majority of the fiber surface may be by a known parallel type compound spinning or sheath-core type compound spinning. In the sheath-core composite spinning, the second component is a sheath. The preferred single yarn fineness of the composite staple fiber is 2 to 150 denier, more preferably 4 to 100 denier. Since the single-fiber fineness of the staple fiber of polypropylene used for the needle punch carpet is usually 2 to 150 denier, if the single-fiber fineness of the composite staple fiber is less than 2 denier, the mixing is In the subsequent carding step, the mixed state of the composite staple fibers becomes non-uniform or a nep occurs, which is not preferable. On the other hand, if the single fiber fineness of the composite staple fiber exceeds 150 deniers, the number of inter-fiber adhesion points due to fusion of the composite staple fiber decreases. Therefore, the network structure in the carpet pile becomes coarse and the tensile strength and tear strength of the carpet become insufficient, which is not preferable.

In order to impart a desired color tone to a carpet, a pigment is added to one or both of the first component and the second component during the spinning of the conjugate staple fiber, so-called undiluted color spinning, It can be a stock solution colored composite staple fiber. Also, many carpets require a certain level of flame retardancy, but this requirement can be met by adding the required amount of flame retardant to the second component of the composite staple fiber. By adding the flame retardant only to the second component of the composite staple fiber, a sufficient effect can be obtained with a smaller amount of the flame retardant than when the flame retardant is added to the entire fiber. Similarly, a flame retardant may be added to the second component as needed for the stock solution colored composite staple fiber. One staple fiber of the polypropylene used in the present invention is a staple fiber having a single yarn fineness of 2 to 150 denier obtained by melt-spinning crystalline polypropylene, which is substantially a homopolymer of propylene. . The relationship between the single yarn fineness ratio of the composite staple fiber / polypropylene staple fiber in the mixed fiber is not particularly limited, but preferably 1/2 to 1/10 is suitable for the properties of the carpet.

In the present invention, a composite staple fiber composed of the first component and the second component and a polypropylene staple fiber are mixed and used. As a method of mixing fibers,
A known method such as an air-ray method or a card method can be used. The amount of the composite staple fiber in the mixed fiber is 25 to 90.
%, Preferably 30 to 80% by weight, more preferably 40 to 70% by weight. When the amount of the composite staple fiber in the mixed fiber is less than 25% by weight, the number of inter-fiber adhesion points due to fusion of the composite staple fiber decreases. Therefore, the stitch structure in the carpet pile becomes coarse, so that the tensile strength of the carpet becomes insufficient, and at the time of use of the carpet, the fibers drop off from the pile portion or the carpet is pulled. Is unfavorable because it impairs the appearance.
On the other hand, as the amount of the composite staple fiber in the mixed fiber increases, the web after the needle punching tends to expand in the width direction, and the shrinkage after the heat treatment increases, resulting in lack of dimensional stability. . If the mixing amount of the conjugate staple fiber exceeds 90% by weight, the influence is remarkably increased. On the other hand, when the mixing amount of the composite staple fiber exceeds 90% by weight, it becomes difficult to satisfy the current standard value (60 kg / 5 cm or more) of the tensile strength (BI) of the carpet for display. In addition, a reduction in abrasion strength, which can be said to be an appearance characteristic of the carpet for display, and a noticeable drop in the surface state after abrasion are observed, resulting in a decrease in quality. In the present invention, after the above-mentioned mixed fiber (web) is subjected to a needle punching process by a known needle punching method, a heat treatment is performed at a temperature not lower than the melting point of the second component of the composite staple fiber and not higher than the melting point of the first component. And the tensile strength (BI) is 60 kg / 5
cm carpet. To give the carpet the desired tensile strength, the carpet weight is 300 g / cm.
^The heat treatment temperature and time are determined by a trial method in consideration of the melting point of the second component of the composite staple fiber.
The needle punch carpet of the present invention has a tensile strength of 6%.
Although it has a weight of 0 kg / 5 cm or more, it also has the above-mentioned wear strength of 300 mg or less, and maintains a quality of the surface state after the wear of class 3 or higher. The olefin-based binary copolymer and / or terpolymer based on propylene used in the present invention has an extremely high affinity between the first component and the second component, and can be used even in the case of a parallel structure having a composite structure. It is very difficult to peel off between both components. Therefore, a commonly used composite fiber having a composite component of polyethylene and polypropylene is used.
There is no so-called choke mark, which is a problem with pets. In addition, the heat fusion property is also good, and the composite fiber itself is fused while maintaining the fiber shape at the time of heat treatment after mixing with the staple fiber of polypropylene, so that the mixed fiber in the carpet is three-dimensional. The stitch structure is formed.

[0009]

The present invention will be described more specifically with reference to examples and comparative examples. The carpet was evaluated according to the following method. Ca - Pet Thickness: Measurement conditions pressurizer area due 6.4.1 20 cm ² pressing time 10 sec pressing pressure 40 gf / cm ² tensile strength of JIS L1021: tensile strength values (Bonding Index) is vertical strength And the geometrical mean of the horizontal strength and calculated using the following formula. Tensile strength (BI) = √ (vertical strength × horizontal strength) Measurement conditions According to JIS L1021 Section 6.9.1, test piece width 5 cm, gripping interval 20 cm, tensile speed 10 cm / min, vertical direction and horizontal direction The breaking strength is measured. Abrasion strength: Measurement conditions according to JIS L1021 paragraph 6.12 Abrasion wheel H-38 Load 1 kg Friction frequency 1000 times Note) Abrasion strength is the weight (m) of the fiber dropped off by abrasion.
g). Surface condition after abrasion test The surface condition after the abrasion test was evaluated by a five-step evaluation based on visual judgment, and a class of 3 or higher was judged as passing. Judgment criteria: Class 5: The wear surface is flat, and no fluffing of the fiber is observed. Grade 4: Fluff with a fiber length of 1 mm or less is observed. Grade 3: The generation of fluff or tufts having a fiber length of 2 to 4 mm is observed. Grade 2: The generation of fluff or tufts with a fiber length of 5 to 9 mm is observed. Grade 1: The generation of fluff or tufts with a fiber length of 10 mm or more is observed. Flame retardant performance: 45 ° air-mix burner method specified in Article 4-3 of the Fire Services Act Enforcement Regulations Evaluation of recyclability Suitability evaluation of regenerative pellets is as follows. Was used as a criterion. In the process of processing the regenerated pellets, the carpet is shredded and crushed so that the average size is 3 to 5 mm. The crushed small pieces are melt-extruded in a strand shape by an extruder with a vent. The molten strand is cooled in a water bath. The cooled and solidified strand is cut into granules by a pelletizer to form regenerated pellets. The criteria for recyclability suitability are as follows: ：: The process can be completed from step to step. ：: In the step, the molten strand discharged from the extruder is sometimes cut. X: In the process, the molten strand discharged from the extruder is easily cut. Note) JIS L1021 Testing Methods for Textil
e Floorcoverings A mixture of decabromodiphenyl ether and antimony trioxide in a weight ratio of 2: 1 was used as a flame retardant.

EXAMPLE 1 A terpolymer (melting point: 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene and 4.5% by weight of butene to which 10% by weight of a bromine flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single fiber fineness 5 denier) 25% by weight and polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) mixed weight 75% by weight using a carding machine. After forming a web of 440 g / m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of No. 30 to obtain a raw carpet. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the present carpet, which was modeled on a carpet for display, showed a value of 60 kg / 5 cm or more without using a base cloth, and showed excellent flame retardancy without using latex. The surface of the carpet after the measurement of the abrasion strength was practically grade 3 or so. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Example 2 A terpolymer (melting point: 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene and 4.5% by weight of butene to which 10% by weight of a brominated flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single fiber fineness 5 denier) 50% by weight and polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) 50% by weight using a carding machine to make a mixed fiber with a basis weight of about 50% by weight. After forming a web of 440 g / m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of No. 30 to obtain a raw carpet. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the present carpet, which was modeled on a carpet for display, showed a value of 60 kg / 5 cm or more without using a base cloth, and showed excellent flame retardancy without using latex. The surface condition of the carpet after the measurement of abrasion strength was about 5th grade, which was excellent. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Example 3 A terpolymer (melting point: 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene and 4.5% by weight of butene to which 10% by weight of a bromine flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single fiber fineness 5 denier) 75% by weight and polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) 25% by weight by using a carding machine with a mixed fiber weight of approx. After forming a web of 440 g / m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of No. 30 to obtain a raw carpet. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the present carpet, which was modeled on a carpet for display, showed a value of 60 kg / 5 cm or more without using a base cloth, and showed excellent flame retardancy without using latex. The surface condition of the carpet after the measurement of abrasion strength was about grade 4 and excellent. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Example 4 A terpolymer (melting point: 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene and 4.5% by weight of butene to which 10% by weight of a brominated flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single fiber fineness 5 denier) 90% by weight and polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) 10% by weight were mixed using a carding machine. After forming a web of 440 g / m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of No. 30 to obtain a raw carpet. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the present carpet, which was modeled on a carpet for display, showed a value of 60 kg / 5 cm or more without using a base cloth, and showed excellent flame retardancy without using latex. The surface of the carpet after the measurement of the abrasion strength was practically grade 3 or so. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Example 5 96.1 Propylene with Bromine Flame Retardant Added at 10% by Weight
50/50 sheath-core composite having a core component of a binary copolymer (melting point 139 ° C.) composed of 3.9% by weight of ethylene and 3.9% by weight of ethylene and a core component of crystalline polypropylene (melting point 160 ° C.). A blended fiber of 50% by weight of staple fiber (fiber length 64 mm, single yarn fineness 5 denier) and 50% by weight of polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) is used as a carrier. About 440g /
After forming a web of m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of 30th count to obtain a raw carpet. This carpet material is heated with a suction band dryer to a hot air temperature of 135 ° C.
For 12 minutes and air-cooled naturally. The strength of the present carpet, which was modeled on a carpet for display, showed a value of 60 kg / 5 cm or more without using a base cloth, and showed excellent flame retardancy without using latex. The surface condition of the carpet after the measurement of abrasion strength was about 5th grade, which was excellent. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Comparative Example 1 A terpolymer (melting point: 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene and 4.5% by weight of butene to which 10% by weight of a brominated flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single denier fineness: 5 denier) was formed into a web having a basis weight of about 440 g / m ² using a carding machine, and then kneaded at a needle density of 400 needles / cm ² using a 30th felt felt needle. The carpet material was processed by dollar punching. This web made of 100% sheath-core type composite fiber staple has a strong tendency that the web stretches in the width direction during needle punching, and the basis weight of the carpet web after processing is as follows. The basis weight from about 440 g / m ² to about 390 g / m ² ,
Lack of dimensional stability. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the carpet, which was prototyped using the carpet for exhibition as a model, did not reach 60 kg / 5 cm, and was insufficient. After the measurement of the abrasion strength, the surface condition of the carpet was about the first or second grade, and the fiber was strongly pulled. In the process of processing the regenerated pellets, pelletization was possible without any trouble, and recyclability was good.

Comparative Example 2 A terpolymer (melting point 130 ° C.) composed of 92% by weight of propylene, 3.5% by weight of ethylene, and 4.5% by weight of butene to which 10% by weight of a bromine flame retardant was added was used as a sheath component. Sheath / core composite staple fiber having a composite ratio of 50/50 (filament length of 64) containing crystalline polypropylene (melting point: 160 ° C.) as a core component.
mm, single fiber fineness 5 denier) 20% by weight and polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) 80% by weight are mixed using a carding machine. After forming a web of 440 g / m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of No. 30 to obtain a raw carpet. This carpet raw material was heated by a suction band dryer at a hot air temperature of 135 ° C. for 12 minutes and cooled naturally. The strength of the carpet, which was prototyped using the carpet for exhibition as a model, did not reach 60 kg / 5 cm, and was insufficient. The surface condition of the carpet after the measurement of the abrasion strength was about the second grade, and the fibers were severely pulled. In the process of processing recycled pellets,
Pelletization was possible without any trouble, and the suitability for regeneration was good.

Comparative Example 3 A sheath having a composite ratio of 50/50, comprising high-density polyethylene (melting point: 130 ° C.) containing 10% by weight of a brominated flame retardant as a sheath component and crystalline polypropylene (melting point: 160 ° C.) as a core component. Mixed fiber of 50% by weight of core type composite staple fiber (fiber length 64 mm, single yarn fineness 5 denier) and 50% by weight of polypropylene staple fiber (fiber length 64 mm, single yarn fineness 18 denier) Is about 440 g / using a card machine.
After forming a web of m ² , needle punching was performed at a needle density of 400 needles / cm ² using a felt needle of 30th count to obtain a raw carpet. This carpet material is heated with a suction band dryer to a hot air temperature of 135 ° C.
For 12 minutes and air-cooled naturally. This carpet, which was modeled on an exhibition carpet, was manufactured under the same conditions as in Example 2 except that high-density polyethylene was used as the sheath component. However, the tensile strength of the carpet was less than 60 kg / 5 cm. Insufficient strength. It is considered that the bonding between the fibers was performed only between the composite fibers, and the density of the stitch structure was low. The surface condition of the carpet after the measurement of the abrasion strength was about the second grade, and the fibers were severely pulled. In the processing step of the regenerated pellets, the compatibility between the high-density polyethylene and the polypropylene was inferior, so that a phenomenon in which the molten strand discharged from the extruder was occasionally cut was observed, and the recyclability was slightly poor.

Comparative Example 4 A polypropylene staple fiber (fiber length: 64 mm, single-filament fineness: 18 denier) was weighed using a carding machine at 220 g / weight.
After forming a web of m ^2, the web was overlaid with a base fabric of polyester spunbond having a basis weight of 100 g / m ² and subjected to needle punching under the same conditions as in Example 1 to obtain a raw carpet. 100 g of latex is applied to the base cloth side of this carpet material.
g / m ^{2 was} impregnated to prepare a carpet. Comparative Example 4
Are typical of conventional needle punches using a base cloth and latex. The weight of the pile portion is 220 g / m ² , but the weight of the entire carpet is 420 g / m ^{2, which} is almost the same as the carpet weight of the example, when the base cloth and latex are added.
Becomes The surface condition of the carpet after the measurement of abrasion strength was about grade 4 and excellent. However, in the process of processing recycled pellets,
The molten strand discharged from the extruder was easily cut, and pelletization was impossible. Recyclability was poor.
Table 1 shows various data of the needle punch carpets of the examples and the comparative examples.

[0019]

[Table 1]

[0020]

The basic concept of the present invention is that a mixed staple fiber obtained by mixing a composite staple fiber with a polypropylene staple fiber is subjected to a needle punching process, heat-treated, and carpeted. By forming a three-dimensional network structure by fusing fibers in the pile, the strength of the carpet pile is improved, and sufficient carpet pile can be obtained without using a base cloth, a laminating material, or a latex. It is to develop pet strength. As described above, a method of improving the strength of a nonwoven fabric by forming a network structure by fusing the composite staple fibers in the nonwoven fabric has been widely performed, but simply forming a network structure of the composite staple fibers. However, sufficient carpet strength could not be obtained just to meet the specifications. A feature of the present invention is that the network structure is formed three-dimensionally not only between composite staple fibers but also between composite staple fibers and non-composite staple fibers. That is, the low melting point component of the composite staple fiber that contributes to the formation of the network structure by heat melting and the staple fiber to be mixed are unified with a polypropylene resin, so that not only the composite staple fiber but also the composite Staple fiber and non-composite stay
Strong adhesion points are formed between the pull fibers, and a higher-density three-dimensional network structure is obtained. As a result, a high pile strength, which cannot be obtained by the network structure formed only by the composite staple fibers, can be obtained. Even when the base cloth, the laminating material, or the latex is not used, a sufficient curl to satisfy the specifications can be obtained. Pet strength can now be obtained. Further, the carpet has excellent wear strength, which can be regarded as appearance quality, and excellent surface condition after wear. In the carpet of the present invention, the thermoplastic resin components constituting the carpet are all unified with a polypropylene resin. Polypropylene is one of the most suitable resins for reprocessing because it does not hydrolyze at the time of heating and melting and has little thermal deterioration under normal processing temperature conditions. Therefore, the carpet according to the present invention has excellent reproducibility. Carpets are required to have a certain level of flame retardancy. Conventionally, flame retardants were added to latex, but in the present invention, the required amount of flame retardant was added to the second component of the composite staple fiber. In this case, the flame retardancy is imparted to the carpet, so that the flame retardancy of the latex can be substituted. If the base cloth, laminating material or latex is not used for the needle punch carpet,
The following advantages are also obtained. (1) The manufacturing process is simplified. (2) In the case of a carpet for exhibition, the use of a base cloth is not required, so that a needle for patterning can be used. Needle punching is now possible.

Claims (4)

(57) [Claims] 1. A first component comprising a polypropylene, a first component comprising:
A second component composed of an olefin-based binary copolymer and / or a terpolymer having a melting point of at least 20 ° C. lower than the melting point of the component such that the second component occupies a majority of the fiber surface. A mixed fiber consisting of 25 to 90% by weight of a heat-fusible composite staple fiber and 75 to 10% by weight of a polypropylene staple fiber obtained by composite spinning into a parallel type or a sheath-core type. -After dollar punching,
A needle punch carpet having a tensile strength of 60 kg / 5 cm or more achieved by heat-treating the composite staple fiber at a temperature not lower than the melting point of the second component and not higher than the melting point of the first component. 2. The needle puncher according to claim 1, wherein the composite staple fiber is a stock solution-colored composite staple fiber obtained by adding a pigment to one or both of the first component and the second component. -Pets. 3. The needle punch carpet according to claim 1, wherein the composite staple fiber is a flame-retardant composite staple fiber obtained by adding a flame retardant to the second component. 4. The needle punch carpet according to claim 2, wherein the stock solution-colored composite staple fiber is a stock solution-colored flame-retardant composite staple fiber having a flame retardant added to the second component.