JP3641652B2 - carpet - Google Patents

Description

【００３３】
上記（イ）弾性複合繊維は、鞘成分（６０重量％）がポリエステル系エラストマーであり、芯成分（４０重量％）がポリエチレンテレフタレートより構成されている。
前記の如くして得られたシート状物の滑り試験を、下記方法によって測定した結果は下記のとおりであた。
上層部（前記短繊維ウェブのみよりなるウェブ層） ９０ｇ
下層部（前記イ、ロおよびハよりなるウェブ層） ２２０ｇ
このシート状物の上層部側にＳＢＲラテックスを塗布し、通常のタフティングによるラグを接着して縁縢を行い、滑り防止効果を有するラグが得られた。
滑り試験法
アクリル板上に、巾５０ｍｍで長さ５０ｍｍのサンプル（シート状物またはカーペット）片を置き、その上に荷重３００ｇの板（巾５０ｍｍ、長さ５０ｍｍ）を重ねてサンプルの端部より糸で引っ張り、サンプルが動き出す時の荷重を測定する。
【００３４】
実施例２
目付３００ｇ／ｍ²の熱可塑性ポリエステル短繊維ウェブを上層に、下層に下記綿構成のウェブを積層し、ニードリング一体化した後、弛緩状態で乾熱１５０℃、６分間熱処理を行い、厚さ３.５ｍｍのシート状物を得た。
下層部ウェブ構成
【００３５】
【表２】

【００３６】
前記（ａ）の弾性複合繊維は、実施例１の（イ）と同じ繊維であり、（ｂ）の繊維はバインダー繊維であり、鞘成分（５０重量％）が軟化点が５５℃である共重合ポリエステルであり、芯成分（５０重量％）がポリエチレンテレフタレートで構成されている複合繊維である。
得られたシート状物の滑り試験の結果は、下記のとおりであった。
上層部 １００ｇ
下層部 ３００ｇ
このシート状物の上層部上に、ホットカーペットの配線を行い、さらにその上に目付２５０ｇ／ｍ²の熱可塑性ポリエステル短繊維不織布を積層して一体化し、滑り止め効果を有するホットカーペットを得た。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a carpet. More specifically, the present invention relates to a carpet having slip resistance in which a sheet-like material having slip resistance is integrated on the back surface.
[0002]
[Prior art]
Carpets are widely used with Western lifestyles and modern office environments. Carpets can be categorized into fixed carpets and movable carpets depending on their usage. In particular, the latter laid carpets are widely used, for example, hot carpets, rugs, bath mats, toiletry mats, entrance mats, etc., have many types, and have various purposes.
Since the fixed carpet is bonded to the floor surface or fixed at the end with a clipper, the carpet does not slide from the floor surface during use.
[0003]
However, the laying carpet is usually used in a state where it is placed on the floor surface, and sometimes it is moved, stored, or washed depending on the usage pattern. Such movable carpets are usually used in a state where they are simply placed on a floor such as tatami mats, wooden flooring, resin board flooring or tiles.
[0004]
[Problems to be solved by the invention]
As described above, the carpet laid on various floor surfaces may be dangerous in some cases because the back surface and the floor surface may slip during use. In particular, infants, children and the elderly tend to lose balance, and slipping can cause injury and fractures.
Therefore, in order to make it difficult to slip with respect to the floor surface, it has been proposed to perform various processes on the back surface of the carpet. For example, it has been proposed to attach a soft rubber or urethane resin lump or sheet having high frictional resistance or an adhesive sheet to the back surface of the carpet.
[0005]
However, these means have to apply a soft resin or adhesive to the entire back surface or the periphery of the carpet, so that not only the texture and flexibility of the carpet are impaired, but also the appearance is deteriorated. In addition, when a soft resin is pasted, the whole becomes heavy, and another problem arises that washing and storage cannot be easily performed.
Furthermore, it is impossible to keep the adhesive function for a long period of time when the adhesive substance is applied to the back surface.
Recently, there has been a demand for a practical carpet that has a texture and softness, that can be washed and that does not affect storage and that has an anti-slip effect.
[0006]
Accordingly, a first object of the present invention is to provide a non-slip laid carpet that does not impair the texture and softness of the carpet.
A second object of the present invention is to provide a non-slip laying carpet that can be easily washed and stored.
The third object of the present invention is to provide a laying carpet that has an anti-slip effect for a long period of time and has an excellent appearance.
Another object of the present invention is to provide a non-slip laid carpet that is easy to process and can be produced economically advantageously.
[0007]
[Means for Solving the Problems]
According to the present invention, the object of the invention is to use a non-elastic polyester-based crimped short fiber aggregate as a matrix, and the short fiber aggregate has a melting point that is 40 ° C. lower than the melting point of the polyester constituting the short fiber. A sheet comprising a thermoplastic polyester elastomer and a non-elastic polyester, in which the elastic composite fiber exposed at least on the fiber surface is dispersed and mixed, and the short fiber aggregate is integrated by fusion of the thermoplastic polyester elastomer This is achieved by a carpet having slip resistance in which a sheet-like material having a basis weight of 100 to 700 g / m ² and a thickness of 0.5 to 8 mm is integrated on the back surface of the carpet.
[0008]
In the carpet of the present invention, the sheet-like material is integrated on the back surface, and the sheet-like material is formed by mixing an elastic composite fiber having a thermoplastic polyester elastomer on the fiber surface. It is considered that the effect of preventing slippage with the floor surface is expressed by the effect of.
Hereinafter, although the carpet of this invention is demonstrated in more detail, the structure of the sheet-like object integrated with the back surface of a carpet and its manufacturing method are demonstrated first.
[0009]
In this sheet-like material, a non-elastic polyester fiber crimped short fiber aggregate is used as a matrix, and an elastic composite fiber in which a low melting thermoplastic polyester elastomer is exposed on the fiber surface is dispersed and mixed in the short fiber aggregate. The sheet-like product is formed of short fiber aggregates, and the following flexible thermal fixing points (A) and (B) are scattered due to fusion of the thermoplastic polyester elastomer.
[0010]
(A) a flexible heat fixing point formed by heat-sealing each other in a state where the elastic composite fibers are crossed, and (B) heat in a state where the elastic composite fibers and the non-elastic polyester short fibers are crossed. Flexible heat fixing point formed by fusion bonding
Inelastic polyester short fibers forming a matrix in a sheet-like material integrated on the back surface of the carpet of the present invention are ordinary polyethylene terephthalate, polybutylene terephthalate, polyhexamethylene terephthalate, polytetramethylene terephthalate, poly- Examples thereof include short fibers composed of 1,4-dimethylcyclohexane terephthalate, polypivalolactone, or a copolymer ester thereof, a blend of these fibers, or a composite fiber composed of two or more of the above polymers. The cross-sectional shape of the short fiber may be circular, flat, irregular, or hollow. In particular, short fibers made of polyethylene terephthalate or a copolymer thereof are preferable.
[0012]
Since the polyester short fibers are fused by elastic composite fibers to form a matrix that forms a framework of a sheet-like material, the polyester short fibers are required to be bulky and exhibit repulsion. The single bulkiness (JIS L-1097) is preferably 45 cm ³ / g or more under a load of 0.5 g / cm ² and more preferably 15 cm ³ / g or more under a load of 10 g / cm ^2. These are desirably 50 cm ³ or more and 20 cm ³ / g or more, respectively.
[0013]
The short fiber may have a fineness of 4 denier or more, preferably in the range of 4 to 100 denier, and more preferably in the range of 8 to 40 denier. If the fineness is less than 4 denier, the bulkiness will not be exhibited, and the cushioning and repulsion will be poor. On the other hand, when it becomes larger than 100 denier, it becomes difficult to form the fiber sheet.
[0014]
On the other hand, the number of crimps of the polyester-based short fibers is preferably 4 to 25 per inch, and the degree of crimp is preferably 10 to 40%. If the number of crimps or the degree of crimp is too small, it is not preferable because the bulk of the sheet-like material is difficult to be produced or it becomes difficult to form a sheet. The obtained sheet-like material is also poor in repulsion or only having low durability. On the other hand, if the number of crimps or the degree of crimp is too large, the bulkiness of the sheet-like material does not increase, and the fiber is strongly entangled during sheeting, which is undesirable.
The polyester short fiber has a fiber length of 5 mm or more, preferably 10 to 100 mm, particularly preferably 15 mm to 90 mm.
[0015]
On the other hand, the elastic composite fiber for fusing the short fiber aggregate as the matrix in the sheet-like material of the present invention has a low melting point thermoplasticity having a melting point of 40 ° C. or more lower than the melting point of the non-elastic polyester short fiber as the matrix. It is an elastic composite fiber that an elastomer has at least a part, particularly on the fiber surface, and a short fiber that can be fused with at least a part of the surface by heating and fused with polyester-based short fibers or elastic composite fibers. When the melting point difference is 40 ° C. or less, the processing temperature becomes close to the melting point of the polyester short fibers, and the physical properties and crimp characteristics of the polyester short fibers are deteriorated, so that the sheet performance is lowered, or at the time of molding. The shrinkage of the will increase. In this sense, the melting point of the low-melting point thermoplastic elastomer is preferably 40 ° C. or more, particularly 60 ° C. or more lower than the melting point of the polymer constituting the short fiber. The melting point of such a thermoplastic elastomer can be, for example, a temperature in the range of 130-220 ° C.
[0016]
In the sheet-like material of the present invention, the elastic conjugate fiber used to form a flexible heat fixing point that plays an important role is formed of a thermoplastic polyester elastomer and a non-elastic polyester. At that time, it is preferable that the former occupy 50% or more, preferably 70% or more, particularly preferably 80% or more of the fiber surface. In terms of weight ratio, it is appropriate that the former and the latter are in the range of 40/60 to 80/20 as a composite ratio. The form of the elastic conjugate fiber may be either side-by-side or sheath-core type, but the latter is preferred. In this sheath / core type, of course, inelastic polyester is the core, but this core may be concentric or eccentric. In particular, the eccentric type is more preferable because coiled elastic crimps are developed.
[0017]
The polyester elastomer present on the surface of the elastic conjugate fiber is a polyetherester block copolymer obtained by copolymerizing thermoplastic polyester as a hard segment and poly (alkylene oxide) glycol as a soft segment, more specifically, Such as terephthalic acid, isophthalic acid, phthalic acid, naphthalene-2,6-dicarboxylic acid, naphthalene 2,7-dicarboxylic acid, diphenyl-4,4-dicarboxylic acid, diphenoxyethanedicarboxylic acid, sodium 3-sulfoisophthalate, etc. Aromatic dicarboxylic acid, alicyclic dicarboxylic acid such as 1,4-cyclohexanedicarboxylic acid, succinic acid, oxalic acid, adipic acid, sebacic acid, dodecanedioic acid, aliphatic dicarboxylic acid such as dimer acid, or ester-forming derivatives thereof Dicarboxylic acid selected from At least one of the following, an aliphatic diol such as 1,4-butanediol, ethylene glycol, trimethylene glycol, tetramethylene glycol, pentamethylene glycol, hexamethylene glycol, neopentylene glycol, decamethylene glycol, or 1,1- At least one diol component selected from cyclohexadimethanol, alicyclic diols such as 1,4-cyclohexanedimethanol and tricyclodecane dimethanol, or ester-forming derivatives thereof, and an average molecular weight of about 400 to 5000 Polyethylene glycol, poly (1,2- and 1,3-propylene oxide) glycol, poly (tetramethylene oxide) glycol, copolymers of ethylene oxide and propylene oxide, ethylene oxide A terpolymer composed of at least one of poly (alkylene oxide) glycol and copolymers of tetrahydrofuran.
[0018]
However, a block copolymer polyether polyester having polybutylene terephthalate as a hard segment and polyoxytetramethylene glycol as a soft segment is preferable from the viewpoints of adhesion to polyester short fibers, temperature characteristics, strength, physical properties, and the like. In this case, the polyester portion constituting the hard segment is polybutylene terephthalate in which the main acid component is terephthalic acid and the main diol component is a butylene glycol component. Of course, a part of this acid component (usually 30 mol% or less) may be substituted with another dicarboxylic acid component or an oxycarboxylic acid component. Similarly, a part of the glycol component may be a dioxyl other than a butyrene collyl component. It may be replaced with a component. The polyether component constituting the soft segment may be a polyether substituted with a dioxy component other than tetramethylene glycol. In the polymer, various stabilizers, ultraviolet absorbers, thickening and branching agents, matting agents, coloring agents, other various improving agents, and the like may be blended as necessary.
[0019]
On the other hand, in the elastic composite fiber in the sheet-like material of the present invention, the non-elastic polyester used as the counterpart component of the elastomer is adopted from the polyester constituting the crimped short fiber forming the matrix. Polybutylene terephthalate is more preferably used.
[0020]
The elastic conjugate fiber is a blended component when producing a sheet-like material, and is an adhesive component when forming into a sheet-like material, so that the denier is preferably 2 to 100 denier, particularly 4 ~ 40 denier is preferred. If the denier is small, the number of bond points will increase and the texture will be difficult. On the other hand, if it is too thick, the number of bonding points is too small and the repelling property is too low, or it becomes easy to scatter during use. It is preferable that the cut length is 38 to 255 mm and the number of crimps is 4 to 50 pieces / inch. When it deviates from this range, it becomes difficult to mix cotton and it becomes difficult to form a sheet. Moreover, the performance and durability of the sheet-like material are also lowered.
[0021]
The blending ratio of the low-melting point elastic composite fiber is 10 to 60% by weight, preferably 15 to 50% by weight. When the ratio of the low melting point composite fiber is less than 10% by weight, the adhesion point of the sheet-like material becomes too small, the compression repellency is too low, the durability is too low, and the slip prevention property is lowered. On the other hand, if the ratio is higher than 60% by weight, the number of bonding points of the sheet-like material becomes too hard and it becomes difficult to obtain a web-shaped sheet shape designed in advance.
[0022]
In particular, as a sheet-like material of the present invention, a polyester-based crimped short fiber aggregate described in Japanese Patent Republished No. 3-819082 is used as a matrix, and in the short fiber aggregate, the melting point of the polyester constituting the short fiber is used. It consists of a thermoplastic polyester elastomer having a melting point lower by 40 ° C. or more and polyester, and the former is dispersed and mixed with at least the elastic composite fiber exposed on the fiber surface.
(A) a flexible heat fixing point formed by heat-sealing each other in a state where the elastic composite fibers are crossed, and (B) heat in a state where the elastic composite fibers and the non-elastic polyester short fibers are crossed. It is preferable that the flexible heat fixing points formed by fusion are scattered.
The specific contents and manufacturing method are described in the above publication.
[0023]
The basis weight of the sheet is 100 to 700 g / m ² , preferably 120 to 400 g / m ² , and the thickness of the sheet is 0.5 to 8 mm, preferably 1 to 5 mm. If the basis weight is too small in this range, the fiber density is too low and the anti-slip effect cannot be sufficiently achieved. On the other hand, if the basis weight is too large, the fiber density and the density of the bonding points are too large and too hard.
[0024]
The sheet-like product of the present invention is generally produced by forming a multilayer web of the short fiber aggregates containing elastic composite fibers. At that time, the sheet-like material may be formed by laminating a large number of webs made of uniform short fiber aggregates. When the sheet-like material is integrated with the carpet, the floor surface Is formed of a web having a relatively large amount of fibers (elastic composite fibers) having a thermoplastic polyester elastomer on the surface thereof, for example, 40 to 80% by weight, preferably 50 to 75% by weight. It is preferable to use what is. By doing so, it becomes a sheet-like thing with the more excellent antislip effect with a floor surface.
[0025]
Further, it is desirable that the fuzz resistance on the surface of the carpet of the present invention on the side in contact with the floor surface of the integrated sheet is 2nd grade or higher, preferably 3rd grade or higher. This fuzz resistance is a value measured by a fuzz test of JIS L-1023, and the condition is a value due to wear at a load of 8 kg × 10 minutes.
[0026]
The value of the slip test (measured by the method described later) of the carpet of the present invention is 200 g or more, preferably 200 g to 500 g, particularly preferably 250 g to 500 g.
[0027]
The carpet of the present invention has a structure in which the sheet-like material is integrated on the back surface thereof. The carpet integrated with the sheet (hereinafter sometimes referred to as “carpet body”) is not particularly limited as long as it is called a normal carpet, but the object of the present invention is to prevent slipping. Therefore, any movable carpet may be used. Therefore, specific examples of the carpet body include hot carpets, rugs, bath mats, toiletry mats, entrance mats, and the like.
[0028]
Further, the surface structure of the carpet body may be pile, cut pile, or a form in which both pile and cut pile coexist. The fiber forming the pile may be a spun yarn or a filament fiber. Furthermore, the structure of the carpet body can vary depending on the intended use or application, and may be, for example, a needle punch carpet, tuft carpet, woven carpet, or knitted carpet.
[0029]
The integration of the sheet and the carpet body can be performed by various means. A few examples are: a method in which sheet-like materials are laminated on the back surface of the carpet body and integrated by needling; a method in which the back surface of the carpet body and the sheet-like material are integrated using an adhesive such as synthetic rubber; Examples include a method of integrating the carpet body and the sheet-like material by sewing using a sewing machine, and a method of laminating and integrating a thermoplastic resin sol between the carpet body and the sheet-like material. Other methods may be used.
[0030]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the laying carpet which is excellent in an external appearance, and has the soft and soft slip prevention effect can be provided. Further, the carpet of the present invention can be easily stored and can be washed as a whole. In addition, it can be produced economically advantageously.
[0031]
【Example】
Hereinafter, the present invention will be described in detail with reference to examples.
Example 1
After laminating a thermoplastic polyester short fiber web having a basis weight of 300 g / m ^{2 on} the upper layer and a web having the following cotton composition on the lower layer and integrating the needling, heat treatment is performed at a dry temperature of 170 ° C. for 10 minutes in a relaxed state. A 4 mm sheet was obtained.
Lower layer web configuration [0032]
[Table 1]

[0033]
In the elastic composite fiber (a), the sheath component (60% by weight) is a polyester elastomer, and the core component (40% by weight) is made of polyethylene terephthalate.
The result of measuring the slip test of the sheet-like material obtained as described above by the following method was as follows.
90 g of upper layer part (web layer which consists only of the said short fiber web)
Lower layer (web layer consisting of the above-mentioned b), 220g
SBR latex was applied to the upper layer side of this sheet-like material, and a lug having an anti-slip effect was obtained by adhering a lug formed by ordinary tufting to form an edge.
Sliding test method A sample (sheet or carpet) having a width of 50 mm and a length of 50 mm is placed on an acrylic plate, and a plate (width 50 mm, length 50 mm) with a load of 300 g is placed on the sample. Pull the wire from the end of the wire and measure the load when the sample starts moving.
[0034]
Example 2
After laminating a thermoplastic polyester short fiber web with a basis weight of 300 g / m ^{2 on} the upper layer and a web having the following cotton composition on the lower layer and integrating the needling, heat treatment is performed in a relaxed state at 150 ° C. for 6 minutes in a relaxed state. A 3.5 mm sheet was obtained.
Lower layer web configuration [0035]
[Table 2]

[0036]
The elastic composite fiber (a) is the same fiber as (a) in Example 1, the fiber (b) is a binder fiber, and the sheath component (50% by weight) has a softening point of 55 ° C. It is a composite fiber which is a polymerized polyester and whose core component (50% by weight) is composed of polyethylene terephthalate.
The result of the slip test of the obtained sheet-like material was as follows.
Upper layer 100g
Lower layer 300g
On the upper layer part of this sheet-like material, wiring of a hot carpet was performed, and further, a thermoplastic polyester short fiber nonwoven fabric having a basis weight of 250 g / m ² was laminated and integrated to obtain a hot carpet having an anti-slip effect. .

Claims (4)

A non-elastic polyester crimped short fiber aggregate is used as a matrix, and the short fiber aggregate consists of a thermoplastic polyester elastomer having a melting point lower by 40 ° C. or more than the melting point of the polyester constituting the short fiber and an inelastic polyester, The former is a sheet-like product in which at least the elastic composite fiber exposed on the fiber surface is dispersed and mixed, and the short fiber aggregate is integrated by fusion of the thermoplastic polyester elastomer, and the basis weight is 100 to 700 g / m ^2, and carpet with anti slip properties of and thickness with integrated sheet is 0.5~8mm on the back of the carpet. The carpet according to claim 1, wherein the value of the slip test is 200 g or more. The carpet according to claim 1 or 2, wherein at least 80% of the fiber surface of the elastic composite fiber is occupied by a thermoplastic polyester elastomer. The carpet according to any one of claims 1 to 3, wherein a ratio of the elastic composite fiber in the sheet-like material is 15 to 60% by weight.