JP6519869B2 - Tuft carpet backing and tuft carpet - Google Patents

Description

  The present invention relates to a tuft carpet base fabric having a function of inactivating allergens such as pollen and ticks attached to carpets and a function of reducing viral infectivity such as influenza virus, and a tuft carpet using the same.

  In recent years, houses constructed in recent years have significantly improved thermal insulation and air tightness, and high-performance energy-saving houses have also been developed in which time when indoor air is replaced by natural convection takes several times longer than conventional houses. However, in a house of such a design, the air tightness is high, so indoor odor and dust called house dust are easily accumulated, and these become allergens that cause allergies, atopic dermatitis, bronchial It is said to cause symptoms of allergic diseases such as asthma and allergic rhinitis.

  In addition, it is said that viruses infected in the room are easy to stay in the room by people infected with the virus soaking and vomiting. As a result, it can be said that the virus infection rate in the house interior in recent years is increasing.

  There are various types of allergens, including pollen, mites (insects, carcasses, shellfish, feces), molds, pets (hair, dandruff), etc., which are considered to be the main causative agents of allergic diseases. ing. For example, even if the dust mite, which is an allergen, is eliminated with high fever or a drug, the corpse remains in the carpet, and when the person walks and moves on the carpet, the corpse of these dust mite is indoors from inside the carpet. It was regarded as a problem to be released into space. Therefore, it has been difficult to prevent the onset of allergic diseases caused by these, unless allergens such as pollen, mites, tick dead bodies, tick shells and tick droppings are removed from the carpet.

  There are two types of viruses: enveloped viruses represented by influenza A and non-enveloped viruses represented by norovirus. Generally, viruses scattered in the room can be infected for about one week. It is said to exist.

  From such a background, deodorization and dust collection using air conditioners, air purifiers and the like are often performed, and for example, a method of collecting an allergen in the air by a filter and the like has been proposed. Although such a collection method using an air conditioner, an air cleaner or the like is effective for allergen suspended in the air in the room, almost no effect can be obtained for the allergen attached to the carpet. In order to remove the allergen adhering to the carpet, it is said that it is an effective method to perform aspiration to repeat the allergen repeatedly by tapping repeatedly on the surface of the pile of the carpet with a vacuum cleaner or the like. However, although this method can also remove the allergen attached to the surface of the carpet, it has not been possible to sufficiently remove the allergen such as pollen, mite, mite carcass etc. which got into the inside of the carpet. Thus, if the allergens such as pollen, ticks and ticks which have penetrated to the inside of the carpet can not be sufficiently removed, the person using the carpet should be sufficiently inhibited from contacting them. It was difficult to say that there was a living environment that could sufficiently prevent the onset of allergic diseases.

  The virus can also be wiped away from the living environment, but it can create a safe and secure living environment for the virus that has entered the carpet unless the ability to infect the virus is reduced in any way. I was in a situation where I could not do it.

  On the other hand, the thing of patent documents 1-3 is mentioned as what was made to fix an allergen reduction component to fiber etc. and to give an allergen reduction function. That is, Patent Document 1 describes a wiping sheet for carpets in which a substrate (woven fabric, non-woven fabric, etc.) is impregnated with an allergen-reducing component, and Patent Document 2 discloses that the allergen-reducing component is chemically converted to fibers. Patent Document 3 describes an allergen-reduced non-woven fabric in which an ink containing an allergen-reducing component is printed on at least one side of a non-woven fabric. ing.

  As described above, conventionally, an allergen reducing functional body in which an allergen reducing component is impregnated and fixed to a fiber or a base fabric (woven fabric, non-woven fabric, etc.) is known. However, in the fiber assembly having a special structure of tuft carpet having piles on the surface, there has not been proposed any one for effectively reducing the allergen or reducing the virus infection. For example, Patent Document 4 proposes a tuft carpet in which an anti-mite agent and an anti-microbial agent are applied to a pile yarn together with a resin binder, but when an agent is applied to the pile yarn, the flexibility of the pile is lost and the agent There was a problem with the sustainability of the drug function. In addition, although it is conceivable to incorporate functional fibers such as antibacterials into pile yarns, such fibers have a problem in the dimensional stability at the time of tufting because such fibers have weak fiber physical properties, and allergens etc. deeply penetrated inside the carpet. The effect was not enough.

JP 2003-10089 A Japanese Patent Application Publication No. 2003-96670 Unexamined-Japanese-Patent No. 2003-313778 JP 7-327807 A

  The present invention has been made in view of the current state of the prior art, and the purpose thereof is to efficiently inactivate allergens such as pollen, ticks and ticks which have penetrated particularly in the carpet, and also to the inside of the carpet. It is providing a tuft carpet base fabric which reduces the infective virus efficiently in the infective virus, and a tuft carpet using the same.

  In order to achieve the above object, the inventors of the present invention conducted intensive research on the placement of fibers having anti-allergen and antiviral functions together with the construction of the base fabric, and continue to use Tuft carpet as pollen, mites, A large amount of allergens and viruses such as mites are accumulated at the root of the pile of tuft carpet, and a cross-linked acrylate having anti-allergen and antiviral functions in the layer on the pile side with the base fabric structure as two layers. It has been found that the inclusion of a specific amount of fibers can sustainably reduce the effects of allergens and viruses deeply penetrated into the tuft carpet while maintaining the dimensional stability after tufting, leading to the completion of the present invention. The

That is, the present invention has the following configurations (1) to (4).
(1) anti-allergen and a nonwoven layer containing 5 to 40 wt% of the crosslinked acrylate-based fiber with antiviral function, filter shift carpet having a two-layer structure consisting of a spunbonded nonwoven fabric layer laminated to the layer It is a base fabric , The non-woven fabric layer containing the cross-linked acrylate fiber of the two-layer structure is a layer on the pile implantation side, and the cross-linked acrylate fiber has a carboxyl group and / or a salt thereof. A silver and / or copper is adhered to the surface of a tuft carpet base fabric.
(2) The tuft carpet base fabric according to (1), wherein the cross-linked acrylate fiber-containing non-woven fabric layer and the spun-bonded non-woven fabric layer are bonded by needle punching.
(3) The influenza A virus infectious value reduction value is 1.0 or more, and the cedar pollen / mite allergen substance adsorption amount is 1.0 mg / m ² or more, (1) or (2) Tuft carpet backing as described.
(4) A tuft carpet using the tuft carpet base fabric according to any one of (1) to (3), characterized in that a pile is planted on the upper surface of the crosslinked acrylate fiber-containing non-woven fabric layer. Tuft carpet.

  Since the tuft carpet base fabric of the present invention has a two-layer structure of non-woven fabric layer containing cross-linked acrylate fiber having anti-allergen and antiviral function and spun-bonded non-woven fabric layer, it is good when used as tuft carpet. Anti-allergen and antiviral effects can be sustained while maintaining high toughness and dimensional stability.

  The tuft carpet base fabric of the present invention has a two-layer structure comprising a non-woven fabric layer containing a specific amount of cross-linked acrylate fiber having anti-allergen and antiviral function and a spun-bonded non-woven fabric layer laminated to that layer. A pile is intended to be implanted on top of the non-woven fabric layer containing the cross-linked acrylate fiber when it is characterized and processed into a tufted carpet product.

  The cross-linked acrylate fiber-containing non-woven fabric layer used in the tuft carpet base fabric of the present invention is a non-woven fabric layer for tufting tuft yarns such as spun yarns and multifilament yarns and planting piles. It is a layer containing an acrylate fiber having a virus function. Such acrylate fibers are contained in the non-woven fabric layer in a proportion of 5 to 40% by weight, preferably 8 to 35% by weight. If the content of the cross-linked acrylate fiber is less than the above range, the anti-allergen and antiviral function are not sufficiently exhibited, and if it exceeds the above range, the drop of the acrylate fiber easily occurs, which is not preferable.

  Examples of fibers that can be used in the cross-linked acrylate fiber-containing non-woven fabric layer other than the cross-linked acrylate fiber include synthetic fibers such as polyester, polypropylene and nylon, and natural fibers such as wool, cotton and hemp. It is preferable to use a synthetic fiber in terms of dimensional stability and ease of processing.

  The cross-linked acrylate fiber having anti-allergen and antiviral function used in the present invention is not particularly limited as long as it has anti-allergen and anti-viral function, but for example, cross-linked acrylate fiber having a carboxyl group and / or a salt thereof It is preferable that silver and / or copper be fixed to the surface preferably 2.5 to 20% by weight, more preferably 4 to 10% by weight of the total weight of the fibers. If the adhesion amount is less than the above range, the anti-allergen and antiviral function may not be sufficient, and if the above range is exceeded, the functional effect may be saturated and cost may be increased.

  The cross-linked acrylate fiber having anti-allergen and antiviral functions used in the present invention is, for example, after subjecting an acrylonitrile-based fiber containing 70% by weight or more of an acrylonitrile-derived unit to crosslinking and hydrolysis with hydrazine. They can be produced by contact treatment with a compound containing silver and / or copper, and further alkali treatment. In this case, in order to sufficiently fix silver and / or copper, the amount of carboxyl groups in the crosslinked acrylate fiber after hydrolysis treatment is preferably 0.2 mmol / g or more.

  The cross-linked acrylate fibers described above exert excellent effects on inactivation of allergens such as pollen and mites and reduction of infectivity of viruses such as influenza virus. Silver and / or copper fixed to the cross-linked acrylate fiber are in the form of ultrafine particles and firmly fixed, and are difficult to be detached even by washing, friction or the like, and the function can be exhibited semipermanently.

  The spunbond nonwoven fabric layer used in the tuft carpet base fabric of the present invention is a nonwoven fabric layer for the dimensional stability of the crosslinked acrylate fiber-containing nonwoven fabric layer and the backing, and is laminated to the crosslinked acrylate fiber-containing nonwoven fabric layer. The material of the spunbond nonwoven layer is not particularly limited, and conventionally known materials made of long fibers such as polyester, polypropylene and nylon may be used. Also, the production method may be in accordance with a conventionally known method, and is not particularly limited. For example, a thermoplastic polymer is melt-spun to form a continuous filament, and then the filament is deposited on a moving collection surface to form a web. After that, the filaments can be bonded and maintained in shape.

The cross-linked acrylate fiber-containing non-woven fabric layer and the spun-bonded non-woven fabric layer described above are manufactured separately, and are integrally laminated to form a two-layer structure. Although the fabric weight of each non-woven fabric layer is not particularly limited, it is generally 10 to 100 g / m ² . The method of laminating and integrating each non-woven fabric layer is not particularly limited, and can be performed by a conventionally known method. For example, integration of melting of binder components such as an adhesive and a heat-melting resin can be performed, and lamination by a needle punch method can be performed. In the present invention, in order to simplify the process, it is preferable to entangle and bond the fibers of both nonwoven fabric layers by needle punching. In this case, the needle density of the needle punch is preferably 30 to 150 times / cm ² . Moreover, it is also preferable to use the above-mentioned method together.

  The tuft carpet base fabric produced as mentioned above can manufacture a tuft carpet by tufting a tuft yarn from the upper surface of a crosslinked acrylate type fiber containing nonwoven fabric layer. The tuft yarn may be a conventionally known one. The tuft yarn may only reach the cross-linked acrylate fiber containing non-woven layer, or may extend into the spun-bonded non-woven layer, and may even penetrate the spun-bonded non-woven layer. The outer surface of the spunbond non-woven layer can be coated with a backing material such as latex for anti-slip and pile release if necessary. A conventionally known method for producing a tuft carpet other than those mentioned here can also be appropriately employed as long as the object of the present invention is not violated.

Since the tuft carpet of the present invention is produced as described above, it can have the following virus infectivity reducing function and allergen inactivating function.
Influenza A titer reduction value 1.0 or more Sugi Pollen / mite allergen protein adsorption amount 1.0 mg / m ² or more

  The effects of the tufted carpet using the tufted carpet backing of the invention are illustrated in the following examples, without being limited thereto. The evaluation in the examples was based on the following method.

(1) Influenza A infectious disease titer reduction value (Mv)
According to the ISO 18184 method (plaque method), the evaluation was carried out at a test viral solution sample of 0.4 g, standing condition: 25 ° C., 2 hours. The test target virus is influenza virus, the virus strain is influenza A virus (H3N2) A / Hong Kong / 8/68: TC adapted ATCC VR-1679, the host cell is MDCK cells (dog liver-derived cells) ATCC CCL-34 and did. The antiviral activity value: Mv was calculated by the following formula.
Mv = Log (Vb)-Log (Vc)
Log (Vb): Test virus solution normal log average value of 3 samples immediately after inoculation of test virus solution of standard cloth Log (Vc): Test virus solution on tufting spunbond (Tuffed carpet backing) of example or comparative example Infectious titer common log average value of 3 samples after 2 hours of inoculation and leaving for 2 hours

(2) Adsorbed amount of cedar pollen / mite allergen protein Adsorbed amount of 20 mg of sample in 200 μL of phosphate buffer containing 20 ng of purified cedar pollen antigen Cry J1 (manufactured by Seikagaku Corporation), and without addition of sample as a control Were treated at 30.degree. C. for 24 hours, and the amount of cedar pollen allergen was measured by enzyme immunoassay (ELISA) on these supernatants.

Specifically, first, 50 μL of the primary antibody monoclonal antibody 013 (manufactured by Seikagaku Corporation) is dispensed into each well of a microplate and allowed to stand at room temperature for 3 hours, and then the plate is PBS-T (PBS (Phosphate buffered saline, 0.01 mol / l, pH 7.2 to 7.4) of 0.05% polyoxyethylene (20) sorbitan monolaurate (manufactured by Wako Pure Chemical Industries, Ltd., equivalent to Tween 20) The solution was washed three times. Subsequently, 300 μL of PBS-T containing 1% BSA (Nacalai Tesque, Inc., bovine serum albumin (F-V), pH 5.2) is dispensed to each well and allowed to stand at 4 ° C. for 12 hours Then, it was washed 3 times with PBS-T. Next, 50 μL of the above-mentioned supernatant was dispensed to each well, allowed to stand at room temperature for 2 hours, and then washed three times with PBS-T. Subsequently, 50 μL of peroxidase-labeled monoclonal antibody 053 (manufactured by Seikagaku Corporation) as a secondary antibody was dispensed to each well, allowed to stand at room temperature for 2 hours, and then washed four times with PBS-T. Next, 100 μL of TMB reagent (Funakoshi Co., Ltd. product) was dispensed to each well and allowed to react for 5 minutes. Thereafter, 100 μL of 1 M hydrochloric acid was dispensed to each well, the reaction was stopped, and the absorbance (measurement wavelength: 490 nm) was measured with a microplate reader (manufactured by Bio-Rad Laboratories Inc). The cedar pollen allergen concentration in the supernatant was determined from the obtained measured values using a calibration curve, and the amount of adsorbed allergen protein was calculated according to the following equation.
Allergen protein adsorption amount [mg / m ² ] = (B−A) / C
(A = allergen concentration when sample is added, B = allergen concentration of control, C = measurement sample area)

  In the case of a mite allergen, 20 mg of a sample was added to 200 μL of a phosphate buffer solution containing 10 ng of purified mite antigen Der fII (manufactured by Seikagaku Corporation), and the amount of adsorbed allergen protein was calculated in the same manner as cedar pollen allergen.

(3) Tufting Tufting uses a pile yarn made of 1930 dtex nylon crimped yarn, and measures 10 gauges / 2.54 cm, 10 stitches / 2.54 cm, cut pile height 3.5 mm It went on condition. The processability of tufting was evaluated visually with respect to the fiber dropout property or the form retention during tufting.

(4) Dimensional stability Tufted pile yarn was removed from the sample after tufting evaluation, and the dimensional change of the base fabric was evaluated. The evaluation results are indicated by ○ when the dimensional change is less than 10%, and by x when the dimensional change is 10% or more.

Example 1
The spunbond production facility has a card web production facility attached to the spunbond production line, and the card web is laminated on the spunbond during the production process, and the spunbond production facility capable of being integrally molded by needle punching is used.
-Manufacture of a crosslinked acrylate fiber containing nonwoven fabric layer Crosslinked acrylate fiber (fineness: 3.8 dtex, fiber length: 48 mm) was obtained by the method described in JP2013-14774. Ten parts by weight of the acrylate fiber and 90 parts by weight of polyester fiber (fineness: 3.3 dtex, fiber length 48 mm) were passed through a carded web line of a spunbond production facility to obtain an 80 g / m ² disintegrated web.
-Production of spunbond nonwoven fabric layer 50% by weight of polyester filament having a fineness of 4.4 dtex in the above-mentioned spunbond production facility and 50% of copolyester filament comprising a isophthalic acid having a melting point of 110 ° C. The% by weight was mixed and collected on a conveyor to produce a spunbond long-fiber non-woven fabric having a basis weight of 120 g / m ² .
-Integration of both In the production process, the above-described disintegrating web was laminated on the above-described spunbond and needle punching was performed to perform integral molding. The basis weight of the final-made tufting spunbond (Tuffed carpet backing) was 200 g / m ² .
-Production of tuft carpet After tufting nylon multifilaments on the obtained spunbond for tufting (tuft carpet backing), heat treatment is performed for 5 minutes in a hot air circulating furnace at 130 ° C. to obtain a tuft carpet raw fabric. Obtained.
The above-mentioned evaluations (1) to (4) were carried out for the tufting spunbond (tuft carpet backing) and tuft carpet manufactured as described above. The details of the tuft carpet of Example 1 and the evaluation results are shown in Table 1.

(Example 2)
Tuft carpet was manufactured and evaluated in the same manner as in Example 1 except that the content of the crosslinked acrylate fiber was changed as described in Table 1. Details of the tuft carpet of Example 2 and the evaluation results are shown in Table 1.

(Example 3)
Tuft carpet was manufactured and evaluated in the same manner as in Example 1 except that the content of the crosslinked acrylate fiber was changed as described in Table 1. Details of the tuft carpet of Example 3 and the evaluation results are shown in Table 1.

(Comparative example 1)
Tuft carpet was manufactured and evaluated in the same manner as in Example 1 except that the content of the crosslinked acrylate fiber was changed as described in Table 1. Details of the tuft carpet of Comparative Example 1 and the evaluation results are shown in Table 1.

(Comparative example 2)
Tuft carpet was manufactured and evaluated in the same manner as in Example 1 except that the content of the crosslinked acrylate fiber was changed as described in Table 1. The details of the tuft carpet of Comparative Example 2 and the evaluation results are shown in Table 1.

(Comparative example 3)
A tufted carpet was produced and evaluated in the same manner as in Example 2 except that needle punching was carried out with the card web alone without forming a spunbond nonwoven layer. The details of the tuft carpet of Comparative Example 3 and the evaluation results are shown in Table 1.

(Comparative example 4)
A tuft carpet was produced and evaluated in the same manner as in Comparative Example 1 except that a crosslinked acrylate fiber was used in a proportion of 20% by weight for the tuft yarn. Details of the tuft carpet of Comparative Example 4 and the evaluation results are shown in Table 1.

  As can be seen from Table 1, a base fabric having a two-layer structure in which a non-woven fabric layer containing an appropriate amount of cross-linked acrylate fiber having an anti-allergen and antiviral function and a spunbond non-woven fabric layer (Examples 1 to 3) Were excellent in the durability of anti-allergen and antiviral functions and did not cause problems in tufting and dimensional stability. On the other hand, a base fabric which contains no crosslinked acrylate fiber or deviates from an appropriate amount or a base fabric using crosslinked acrylate fiber for tuft yarn has insufficient anti-allergen and antiviral function, or is tough There are problems with coating and dimensional stability.

  Since the tuft carpet backing of the present invention is extremely excellent in the durability of anti-allergen and antiviral functions, it can greatly contribute to the suppression of allergic diseases and viral infections caused by allergens and viruses attached to the carpet.

Claims (4)

And the nonwoven fabric layer containing 5 to 40 wt% of the crosslinked acrylate-based fiber with a antiallergenic and antiviral functions, with filter shift carpet base fabric having a two-layer structure consisting of a spunbonded nonwoven fabric layer laminated to the layer The non-woven fabric layer containing the cross-linked acrylate fiber of the two-layer structure is the layer on the pile implantation side, and the cross-linked acrylate fiber is on the surface of the cross-linked acrylate fiber having a carboxyl group and / or a salt thereof. A tuft carpet backing characterized in that silver and / or copper is fixed.   The tuft carpet base fabric according to claim 1, wherein the cross-linked acrylate fiber-containing non-woven fabric layer and the spun-bonded non-woven fabric layer are bonded by needle punching. The tuft carpet group according to claim 1 or 2, wherein the influenza A infectivity titer reduction value is 1.0 or more, and the adsorption amount of cedar pollen / mite allergen protein is 1.0 mg / m ² or more. cloth.   It is a tuft carpet using the tuft carpet base fabric in any one of Claims 1-3, Comprising: The pile is planted by the upper surface of the crosslinked acrylate fiber containing nonwoven fabric layer, The tuft carpet characterized by the above-mentioned.