JP4114681B2 - Non-woven fabric for nonwoven fabric and tufted carpet and tufted carpet - Google Patents

Description

  The present invention relates to a long-fiber non-woven fabric that is extremely excellent in curling and warping suppression, a method for producing the same, a base fabric for tufted carpet, and a tufted carpet using the same.

  After melt spinning a continuous filament made of thermoplastic resin and pulling it at high speed by air soccer etc., the filament group is opened and collected on a moving net, and the continuous filaments are fixed by any means. The base fabric for tufted carpet obtained by the so-called spunbond nonwoven fabric, which is made of nonwoven fabric, has better pile yarn order and no fiber fraying compared to polypropylene film slit yarn fabric, jute base fabric, etc. And so on.

  Tufted carpet is a tufted machine that tufts pile yarn such as bulked continuous filament (BCF) onto these base fabrics using a tufting machine to create a loop steamer type continuous dyeing machine, etc. After the pile yarn is dyed by, the back side of the pile fabric is backed with various resins such as vinyl chloride resin paste, styrene-butadiene rubber (SBR) resin, ethylene-vinyl acetate copolymer resin, etc. is there. Among tufted carpets, tile carpets are manufactured by cutting into a tile shape such as a 50 cm square after a resin backing or the like.

  As a conventional tufted carpet base fabric using a long-fiber nonwoven fabric by the spunbond method, a polyethylene terephthalate proposed in Patent Document 1 (Japanese Patent Laid-Open No. 3-104973) is used as a core component and a low melting point component is a fiber surface. Tufted carpet base obtained by fixing non-woven fabric for tufted carpet and polyester-based long fiber web with resin adhesive, using core-sheath composite fiber covering the entire surface A nonwoven fabric composed of continuous filaments of a high melting point component fiber and a low melting point component fiber proposed in Patent Document 2 (Japanese Patent Laid-Open No. 5-93356) is partially thermocompression bonded by an embossing roll, and a binder There is a base fabric for tufted carpet that is bonded and fixed with (resin adhesive).

  However, the tufted carpet base fabric obtained by the prior art is required to have a large width shrinkage due to the influence of heat during resin backing after being processed into tufted and dyed pile fabric (green machine). The width dimension cannot be secured, resulting in a deterioration in product yield, and even in the obtained tufted carpet, distortion remains due to the shrinkage force of the base fabric, curling occurs, and in particular, tile carpets are warped at the four corners. There was a problem above.

This problem is prominently observed when a resin yarn is backed without performing dyeing after tufting using a pre-dyed yarn or an original yarn for a pile yarn. It was.
Japanese Patent Laid-Open No. 3-104497 JP-A-5-93356

  In the present invention, in view of such problems, a long-fiber nonwoven fabric that does not cause thermal shrinkage when heated, in particular, dimensional stability during backing processing, tufted carpet base fabric excellent in curling and warping suppression, curling and warping are less, quality It is intended to provide excellent tufted carpets, especially tile carpets.

The present invention employs the following means in order to solve such problems. That is, the long-fiber non-woven fabric of the present invention is a non-woven fabric composed of continuous filaments of thermoplastic resin obtained by stretching with air soccer, and is measured in accordance with JIS L 1906 in the width direction (horizontal direction). ) In the range of -10 to -0.2 %.

The base fabric for tufted carpet of the present invention is such a long-fiber nonwoven fabric, and the dry heat shrinkage in the width direction (horizontal direction) of the nonwoven fabric measured according to JIS L 1906 is -5 to -0.2. % Range.

  Furthermore, the tufted carpet of the present invention is characterized in that pile yarn is tufted on the tufted carpet base fabric and a backing resin layer is provided on the back surface of the pile surface.

  ADVANTAGE OF THE INVENTION According to this invention, the base fabric for tufted carpets which is excellent in the dimensional stability in the backing process etc. with small heat shrinkage of the width direction, especially curling and a curvature suppression which does not generate | occur | produce heat shrink at the time of a heating. The tufted carpet obtained by using such a tufted carpet base fabric, in particular, a tile carpet, has less curling and warping and is excellent in quality.

  The present invention is a result of diligent investigation as to whether heat shrinkage of a long-fiber nonwoven fabric used for a primary base fabric of tufted carpet, in particular, a tufted carpet base fabric (pile) after being tufted can be suppressed. Non-woven fabrics, and the dry heat shrinkage in the width direction (horizontal direction) measured according to JIS L 1906 of tufted carpet base fabrics using such nonwoven fabrics are excellent in the above requirements. In producing such a long-fiber non-woven fabric, a web sheet in which continuous filaments of a thermoplastic resin obtained by stretching with air soccer is accumulated in a heat-fusion process, or Immediately after the heat fusion treatment, the sheet is stretched in the longitudinal direction under specific conditions, whereby a long-fiber nonwoven fabric that satisfies the above requirements conveniently, It was found that a base fabric for tufted carpet can be obtained.

  That is, it is important for the long fiber nonwoven fabric of the present invention that the dry heat shrinkage range in the width direction (horizontal direction) of the nonwoven fabric measured according to JIS L 1906 is -10 to 0%. The treatment temperature at the time of measuring the dry heat shrinkage varies depending on the type of fiber. For example, polyester is 180 ° C. ± 2 ° C., nylon is 160 ° C. ± 2 ° C., and polypropylene is 100 ° C. ± 2 ° C. Conditions are adopted.

  A long-fiber nonwoven fabric with such properties is obtained by melt-spinning a thermoplastic resin, spraying and accumulating continuous filaments obtained by drawing with air soccer from air soccer to obtain a web sheet, and then heat-fusing treatment. The sheet can be produced by stretching the sheet in the longitudinal direction at a draft ratio of 0.5 to 10% during or immediately after the heat fusion treatment.

  The draft ratio indicates the ratio of the rotational speed of stretching rolls and stretching drums such as at least two rolls and drums, and indicates the ratio of stretching by the speed ratio of the rolls and drums. In the case of 2 rolls (drums) or more, the rotation speed ratio of the first and last rolls is shown. In addition, it is not necessary to use a drawing roll or the like, and when the heat-fusing process is a pressure bonding with a hot embossing roll or the like, the speed ratio between the embossing roll and the next transport roll, hot air from two suction drums, etc. In the case of the air-through process, the speed ratio of the two drums can also be indicated by the speed ratio of the roll or drum used during the heat-sealing process.

  When the dry heat shrinkage in the width direction (horizontal direction) of the long-fiber nonwoven fabric is less than -10%, the above-described production method requires that the longitudinal stretching process be performed at a draft ratio of 10% or more. It is easy to induce troubles such as sheet tearing in the process, which is not preferable from the viewpoint of productivity. On the other hand, when the dry heat shrinkage rate exceeds 0%, when backing the base fabric after tufting the pile yarn when used for the base fabric for tufted carpet, 80 to 130 ° C. in the preheating step, In addition to the structural shrinkage in the width direction linked to the thermal shrinkage of the pile yarn, the base fabric itself is greatly heat-shrinked in the width direction at a temperature of 120 to 180 ° C. during drying, curing and curing of the backing resin. Therefore, it is not preferable because a necessary dimension in the width direction cannot be ensured and a problem of remarkably deteriorating carpet productivity such as deterioration in product yield is induced. Also, for example, it is possible to secure the product yield by increasing the number of pile yarns tufted in the width direction and securing the width direction dimensions, but there is a disadvantage that leads to an increase in the cost of the increased pile yarn. In addition, it is possible to secure the necessary width direction dimension by reducing the temperature of the preheating process, drying and curing of the backing resin, and curing, and suppressing the width shrinkage of the base fabric. However, the tufted carpet obtained in this case has a shrinkage force remaining on the base fabric, so that the curling phenomenon and the carpet that is cut into a square such as a tile carpet are warped at the four corners. It is difficult to solve even problems related to

  When such a long fiber nonwoven fabric is applied to a tufted carpet base fabric, the range of the dry heat shrinkage in the width direction (horizontal direction) of the nonwoven fabric measured according to JIS L 1906 is -5 to 0%. This is very important. When the range of the dry heat shrinkage ratio in the width direction (horizontal direction) is less than −5%, the draft ratio needs to be set relatively high in the stretching process in the longitudinal direction in the nonwoven fabric manufacturing process. The dry heat shrinkage in the longitudinal direction of the long-fiber nonwoven fabric (tufted carpet base fabric) increases, and the shrinkage in the longitudinal direction tends to increase in the tufted carpet manufacturing process, particularly in the backing process. Compared with problems that cannot be ensured, it is mild, but this is not preferable because it results in a deterioration in product yield.

  In the method for producing a long-fiber nonwoven fabric of the invention, the stretching treatment in the longitudinal direction of the sheet is preferably performed under heating conditions. When the sheet is stretched after being cooled, not only the thermal adhesion between the filaments is easily broken, but also the filaments are likely to be cut in some cases, and the strength of the nonwoven fabric tends to be difficult to obtain. In addition, when the low melting point component or adhesive as an adhesive component is present in the nonwoven fabric, the heating condition during the stretching treatment is a temperature below the melting point or softening point, more preferably 30 to 100 ° C. above the melting point. A low temperature condition is preferred. Moreover, when the temperature at the time of the heat-fusion process remains as residual heat in the sheet, it is not always necessary to heat at the time of the stretching process.

  Moreover, it is preferable to quench the sheet after the stretching treatment in the longitudinal direction. The method of rapidly cooling the sheet can include a method of passing several cooling rolls, a method of blowing cool air on the sheet, and the like. After the sheet is stretched, it is preferable that the sheet is kept in a stretched state by rapid cooling.

  The long-fiber nonwoven fabric of the present invention and the base fabric for tufted carpet using such a long-fiber nonwoven fabric are composed of a high melting point component and a low melting point component from the viewpoint of physical properties such as strength, and also from the viewpoint of the productivity of the nonwoven fabric. It is preferably composed of continuous filaments of thermoplastic synthetic resin, and it is particularly preferable that the continuous filaments are bonded together by hot-melt solidification of the low melting point component.

  In the process of bonding the continuous filaments by heat melting and solidifying the low melting point component (heat fusion process), a process of pressing the web sheet with a pair of heated embossing rolls or a heated embossing roll and a heated flat roll, and hot air For example, a treatment (hot air air-through treatment) for allowing the water to permeate through the web sheet can be preferably used.

  In this heat-sealing treatment, the melting point of the low melting point component is preferably at least 20 ° C. lower than the melting point of the high melting point component, particularly preferably 40 ° C. or higher, from the viewpoint of cost due to energy consumption during production. In addition, it is preferable that the heat heat fusion treatment is performed at a temperature equal to or higher than the melting point of the low melting point component.

  Thus, having a difference in melting point is very preferable in terms of the characteristics of the obtained base fabric for tufted carpet. Due to this difference in melting point, continuous filaments are bonded together only by hot-melt solidification of low melting point components, so that the bonding points between filaments are appropriately scattered and the nonwoven fabric has a moderately loose structure. Sometimes, the filament is not easily cut by the tuft needle, and the strength of the base fabric after the tuft does not decrease. For this reason, it is preferable that the long fiber nonwoven fabric is a mixed fiber web of filaments composed of high melting point components and filaments composed of low melting point components.

From the viewpoint of the strength, heat resistance, weather resistance, etc. of the long fiber nonwoven fabric, it is preferable to use polyester, particularly polyethylene terephthalate, as the high melting point component.
The low melting point component may be any thermoplastic resin as long as it has a melting point lower than that of the high melting point component, but is composed of a similar resin at the time of recycling and adhesion with the high melting point component. From the viewpoint of preferable, it is preferably a copolyester such as isophthalic acid copolymer or adipic acid copolymer.

  In addition, the cross-sectional shape of the filament can be any shape such as a circle, ellipse, triangle, quadrangle, hollow structure, etc., but when used for a tuft carpet base fabric, it reduces cutting and friction with tuft needles. Therefore, a circular shape is preferably used. The filament may contain additives such as inorganic particles such as carbon black and titanium oxide, ultraviolet absorbers, antibacterial agents, antifungal agents, flame retardants, conductive agents, antistatic agents, and deodorants. Needless to say.

  The long fiber nonwoven fabric of the present invention may be in the form of a nonwoven fabric in which filaments are three-dimensionally entangled with a needle punch or a water jet punch, or may be a nonwoven fabric obtained by heat-sealing such a nonwoven fabric. .

  Further, in the nonwoven fabric of the present invention, when the thermoplastic resin constituting the filament does not have a low melting point component or contains a low melting point component, in order to further improve the bonding point and adhesion strength between the filaments, It is preferable that an agent adheres.

  Resin adhesives include poly (meth) acrylate resin, vinyl chloride resin, vinyl acetate resin, ethylene-vinyl acetate copolymer resin, vinylidene chloride resin, melamine resin, urea resin, olefin resin, polyester Resin, styrene-butadiene rubber, acrylonitrile-butadiene rubber, etc. can be used, and emulsion or latex resin adhesive is impregnated, spray method, coating method, roll coater method, gravure coater method, foam impregnation method, etc. It can be made to adhere using the means of. At this time, it is particularly preferable that the gap between the continuous filaments is maintained to some extent from the viewpoint of tufting.

  Further, when used as a base fabric for tufted carpet, it is preferable that a smoothing agent such as silicone oil, polyethylene wax, higher fatty acid ester or the like adheres to the nonwoven fabric in order to reduce friction between the tuft needle and the filament. .

  By using the long fiber nonwoven fabric of the present invention as a base fabric for tufted carpet, it is possible to suppress shrinkage in the width direction due to heat particularly in the backing process during the manufacture of tufted carpet, and the longitudinal direction in the dyeing process. Since the film is stretched at the nonwoven fabric production stage, the dimensional stability with small width shrinkage is very excellent. In addition, the tufted carpet having the tufted pile yarn and the backing resin layer, particularly the tile carpet cut into a tile shape, has no curling and little warping at the four corners. The quality is very excellent.

  The long fiber nonwoven fabric of the present invention is not limited to a base fabric for tufted carpets, but includes industrial materials such as filter base materials, roofing reinforcing base materials, wire holding tapes, civil engineering materials, and architectural materials. It can be used as materials, packaging and decorations, and life-related materials around the kitchen.

  In particular, when used as a filter substrate, after pleating the long-fiber nonwoven fabric of the present invention in the longitudinal direction, the upper and lower ends of the nonwoven fabric (width direction) are shaped with a resin or the like, for example, in a cylindrical shape on a circular star shape When heating is performed to cure the resin when fixing (potting), the nonwoven fabric does not shrink, and problems such as the resin being destroyed by the shrinkage force of the nonwoven fabric can be solved.

Hereinafter, the present invention will be described in more detail based on examples, but it goes without saying that the present invention is not limited to the following embodiments. In addition, the evaluation method of each characteristic in an Example is as follows.
(1) Tensile strength of long-fiber non-woven fabric (base fabric for tufted carpet; hereinafter abbreviated as base fabric) and post-tuft base fabric (pile fabric) Tensile strength of long-fiber non-woven fabric (base fabric) and post-tuft fabric (pile fabric) The strength was measured according to JIS L 1906.
(2) Horizontal direction dry heat shrinkage of long fiber nonwoven fabric (base fabric) The dry heat shrinkage rate in the horizontal direction of long fiber nonwoven fabric (base fabric) was measured according to JIS L1906.
(3) Horizontal heat shrinkage rate of base fabric (pile) after tufting Using nylon BCF (product number: 2600d-160f-M207 manufactured by Toray Industries, Inc.) for the base fabric, 1/10 gauge, stitch 11 After the tufting base fabric (pile) obtained using a tufting machine under the conditions of KO / 2.54 cm and pile height of 3.5 mm, it is cut into a 50 cm square and is heated with a hot air dryer at 130 ° C. for 15 minutes. After the treatment, the change in the width dimension was determined as the dry heat shrinkage.
(4) Warp of tile carpet The warp of the tile carpet was measured according to JIS L1904.
Examples 1-3
After melting polyethylene terephthalate having a melting point of 262 ° C. as a high melting point component and isophthalic acid copolymer polyester having a melting point of 230 ° C. as a low melting point component, a mixed-type base hole of a high melting point component filament and a low melting point component filament A large number of nozzles of several 30 holes are arranged, and while the molten polymer is extruded and cooled so that the weight ratio of the high melting point component and the low melting point component is 85:15, the ejector (filament fineness becomes 11.1 dtex) After pulling the filament group at high speed with air soccer), it was sprayed and accumulated on the moving net conveyor. Subsequently, after press bonding under the condition of a linear pressure of 60 kg / cm using an embossing roll (concave / convex roll) having a surface temperature of 235 ° C. and a convex portion pressing area of 12% of the roll surface area and a flat roll, 150 ° C. Under an atmosphere, the draft ratio (rotational ratio of the vertical stretching roll) was (1) 1%, (2) 3%, (3) 5%, and then stretched, and then cooled with cold air at 15 ° C. Further, the resulting sheet was sprayed with 1% of an dimethylpolysiloxane emulsion smoothing agent as an active ingredient to the nonwoven fabric to produce three types of tufted carpet base fabrics having a basis weight of about 100 g / m ² . The dry heat shrinkage rates in the horizontal direction of the obtained base fabric were (1) -0.2%, (2) -0.8%, and (3) -1.5%, respectively.

  Next, using a tufting machine, pile yarn (nylon BCF, 2600d-160f-M207, manufactured by Toray Industries, Inc.) from the back layer side of the base fabric was 1/10 gauge, stitch 11 pieces / 2.54 cm, pile height 3 After tufting with a loop of 0.5 mm and dyeing with a loop steamer type continuous dyeing machine, the edge of the base fabric was held with a pin tenter and spread at 130 ° C. for drying.

Further, the following vinyl chloride backing resin composition (X) was coated on the endless belt at a thickness of 1.3 mm, impregnated with a glass fiber nonwoven fabric having a basis weight of 40 g / m ² , and further the following vinyl chloride backing resin composition. (Y) is coated with a thickness of 1.3 mm, and a pile fabric preheated at about 100 ° C. is laminated on the top, and the vinyl chloride backing resin composition is heated at 175 ° C. from the endless belt side, and then cooled. The tile carpet was made by cutting into 50 cm square.
<Vinyl chloride backing resin composition (X)>
Vinyl chloride paste 100 parts by weight Dioctyl phthalate 90 parts by weight Calcium carbonate 350 parts by weight Carbon toner 2 parts by weight <Vinyl chloride backing resin composition (Y)>
100 parts by weight of vinyl chloride paste
95 parts by weight of dioctyl phthalate
300 parts by weight of calcium carbonate
Carbon toner 2 parts by weight
Example 4
In Example 2 (draft ratio is 3%), the heat fusion treatment is performed using air suction through 240 ° C. hot air using a suction drum roll instead of an embossing roll (uneven roll) and a flat roll. In the same manner as in No. 2, tufted carpet base fabric and tile carpet were prepared.

The resulting base fabric had a horizontal heat shrinkage of -0.5%.
Example 5
In the nonwoven fabric, an emulsion of ethylene-vinyl acetate copolymer resin as a resin adhesive and a dimethylpolysiloxane emulsion smoother as a smoothing agent are applied to the sheet before applying the smoothing agent described in Example 2 (draft ratio is 3%). The active ingredients were impregnated at 6% and 1%, respectively, and dried at a temperature of 150 ° C. In addition, after drying with a net dryer, drying is performed at a draft ratio of 1% using a number of suction drums, followed by curing to produce a base fabric for tufted carpet having a basis weight of about 100 g / m ^2. did. The resulting base fabric had a dry heat shrinkage in the horizontal direction of -1.0%. A tile carpet was prepared in the same manner as in Example 2. Comparative Example 1
In Example 1, a base fabric for tufted carpet and a tile carpet were prepared in the same manner as in Example 1 except that the stretching process in the vertical direction was not performed (relaxed state).

  The dry heat shrinkage rate in the horizontal direction of the obtained base fabric was 2.2%.

  Strength of Examples 1-5 and Comparative Example 1 (long fiber nonwoven fabric), dry heat shrinkage, strength of base fabric after tufting (pile), dry heat shrinkage, and warp quality of the obtained tile carpet Table 1 shows.

  The base fabric for tufted carpet using the long-fiber nonwoven fabrics of Examples 1 to 5 according to the present invention is superior to Comparative Example 1 in the dry heat shrinkage of the tufted base fabric (pile), and the width direction. The tile carpet obtained had excellent dimensional stability, and the warp of the obtained tile carpet was small, and the warp quality was excellent.

Claims (9)

A nonwoven fabric composed of continuous filaments of a thermoplastic resin obtained by stretching by air soccer, and the range of the dry heat shrinkage rate in the width direction (horizontal direction) of the nonwoven fabric measured according to JIS L 1906, A long-fiber nonwoven fabric characterized by being −10 to −0.2 %.   The long-fiber non-woven fabric according to claim 1, wherein the non-woven fabric is composed of a continuous filament of a thermoplastic resin composed of a high melting point component and a low melting point component.   The long-fiber nonwoven fabric according to claim 2, wherein the continuous filaments are bonded to each other by hot-melt solidification of the low-melting-point component.   The long fiber nonwoven fabric according to any one of claims 2 to 3, wherein the low melting point component is at least 20 ° C lower than the melting point of the high melting point component.   The long fiber nonwoven fabric according to any one of claims 2 to 4, wherein the high melting point component is polyethylene terephthalate and the low melting point component is a copolyester.   The long-fiber nonwoven fabric according to any one of claims 1 to 5, wherein the nonwoven fabric contains a resin adhesive. A long-fiber nonwoven fabric according to claim 1, dry heat shrinkage rate in the width direction of the nonwoven fabric measured according to JIS L 1906 (transverse direction) -5 -0.2% A base fabric for tufted carpet characterized by being in the range.   A tufted carpet according to claim 7, wherein pile yarn is tufted on the tufted carpet base fabric and a backing resin layer is provided on the back surface of the pile surface.   The tufted carpet according to claim 8, wherein the tufted carpet is a tile carpet cut into a tile shape.