JP6712290B2 - Primary fabric for tufted carpet and method for producing the same - Google Patents
Primary fabric for tufted carpet and method for producing the same Download PDFInfo
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Description
本発明は、主としてダニアレルゲンを低減化しうる抗アレルゲン不織布よりなるタフトカーペット用一次基布及びその製造方法に関するものである。 TECHNICAL FIELD The present invention mainly relates to a primary base fabric for tufted carpet, which comprises an anti-allergen nonwoven fabric capable of reducing mite allergen, and a method for producing the same.
従来より、カーテン、カーペット、ソファーや椅子の表皮材、テーブルクロス及び布団等の室内で用いる繊維製品に、ダニアレルゲンや花粉アレルゲン等のアレルゲンが付着して、居住者がアレルゲンを吸入しアレルギー疾患を発症することは知られている。このため、繊維製品に抗アレルゲン物質を付着させることにより、アレルギー疾患の発症を少なくすることが要求されている。特許文献１には、抗アレルゲン物質として、粘土鉱物からなるアレルゲン吸着剤を用いることが開示されている。 Conventionally, allergens such as mite allergens and pollen allergens have adhered to textile products used indoors such as curtains, carpets, skin materials for sofas and chairs, table cloths and futons, etc. It is known to develop. Therefore, it is required to reduce the onset of allergic diseases by attaching an anti-allergen substance to textile products. Patent Document 1 discloses that an allergen adsorbent made of clay mineral is used as an anti-allergen substance.
本発明の課題は、繊維製品の一種である抗アレルゲン機能を持つ不織布よりなるタフトカーペット用一次基布を提供することにある。 An object of the present invention is to provide a primary base fabric for a tufted carpet, which is a type of textile product and is made of a non-woven fabric having an anti-allergen function .
本発明は、不織布本体に、酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子と、親水化剤と、油剤とを付着させた抗アレルゲン不織布よりなるタフトカーペット用一次基布及びその製造方法に関するものである。 TECHNICAL FIELD The present invention relates to a primary base cloth for tufted carpet , which comprises an inorganic fine particle containing aluminum oxide, silicon dioxide and zinc oxide , a hydrophilizing agent, and an oil agent adhered to a nonwoven fabric main body, and a method for producing the same. Is.
無機微粒子を付着させる不織布本体としては、従来公知のスパンボンド不織布、ニードルパンチ不織布、バインダーボンド不織布又はスパンレース不織布等が採用される。不織布本体がスパンボンド不織布の場合は、溶融紡糸した長繊維を構成繊維として集積した繊維ウェブに、熱エンボス加工を施し、構成繊維相互間を融着させて得ることができる。また、ニードルパンチ不織布の場合は、繊維ウェブにニードルパンチを施して、構成繊維相互間を絡合させて得ることができる。バインダーボンド不織布の場合は、繊維ウェブに結合剤を付与することにより、構成繊維相互間を結合して得ることができる。スパンレース不織布の場合は、繊維ウェブに高圧水流を施して、構成繊維相互間を絡合することにより得ることができる。また、ニードルパンチ、熱エンボス加工、結合剤の付与及び高圧水流処理を任意に組み合わせて不織布本体を得ることもできる。不織布本体の目付は任意であるが、タフトカーペット用一次基布として用いる場合は、一般的に５０〜２００ｇ／ｍ2程度である。 As the nonwoven fabric body to which the inorganic fine particles are attached, conventionally known spunbonded nonwoven fabric, needle punched nonwoven fabric, binder bond nonwoven fabric, spunlace nonwoven fabric, or the like is adopted. When the non-woven fabric body is a spunbonded non-woven fabric, it can be obtained by subjecting a fibrous web in which melt-spun long fibers are accumulated as constituent fibers to hot embossing and fusing the constituent fibers together. In the case of a needle-punched nonwoven fabric, it can be obtained by subjecting the fibrous web to needle-punching to entangle the constituent fibers with each other. In the case of the binder-bonded nonwoven fabric, the constituent fibers can be bonded to each other by applying a binder to the fibrous web. In the case of a spunlaced nonwoven fabric, it can be obtained by applying a high-pressure water stream to the fibrous web to entangle the constituent fibers with each other. The nonwoven fabric body can also be obtained by arbitrarily combining needle punching, hot embossing, application of a binder, and high-pressure water stream treatment. The basis weight of the nonwoven fabric body is arbitrary, but when it is used as a primary base fabric for tufted carpet, it is generally about 50 to 200 g/m 2 .
不織布本体に付着させる無機微粒子は、酸化アルミニウム（Ａｌ2Ｏ3）、二酸化珪素（ＳｉＯ2）及び酸化亜鉛（ＺｎＯ）を含むものである。具体的には、無機微粒子が酸化アルミニウム、二酸化珪素及び酸化亜鉛の混合体となっている。また、無機微粒子が酸化アルミニウム、二酸化珪素及び酸化亜鉛の焼結体となっていてもよい。酸化アルミニウム、二酸化珪素及び酸化亜鉛の組成は任意であるが、一般的には、モル比で、酸化アルミニウム：二酸化珪素：酸化亜鉛＝１：１０〜２０：１０〜２０であるのが好ましい。無機微粒子の粒径は、均一な分散液を得る程度に微細であればよく、たとえば、多くの微粒子が１５μｍ以下となっているのが好ましく、５μｍ以下となっているのがより好ましい。分散液中における無機微粒子の含有量は、１〜２０重量％程度である。 The inorganic fine particles attached to the nonwoven fabric body contain aluminum oxide (Al 2 O 3 ), silicon dioxide (SiO 2 ), and zinc oxide (ZnO). Specifically, the inorganic fine particles are a mixture of aluminum oxide, silicon dioxide and zinc oxide. Further, the inorganic fine particles may be a sintered body of aluminum oxide, silicon dioxide and zinc oxide. The composition of aluminum oxide, silicon dioxide and zinc oxide is arbitrary, but it is generally preferable that the molar ratio is aluminum oxide:silicon dioxide:zinc oxide=1:10 to 20:10 to 20. The particle size of the inorganic fine particles may be so small as to obtain a uniform dispersion liquid. For example, many fine particles preferably have a particle size of 15 μm or less, and more preferably 5 μm or less. The content of the inorganic fine particles in the dispersion is about 1 to 20% by weight.
無機微粒子を不織布本体に付着させるには、従来公知の方法を採用すればよいが、一般的に結合剤を用いて付着させるのが好ましい。この結合剤としては、不織布本体の構成繊維相互間を結合するための結合剤と同一のものを採用するのが好ましい。同一の結合剤を採用すると、構成繊維相互間の結合と無機微粒子の付着とが同時に行えるからである。もちろん、不織布本体の構成繊維相互間を結合剤で結合した後、同種又は異種の結合剤で無機微粒子を不織布本体に付着させてもよい。かかる結合剤としては、従来公知のものが採用されるが、アクリル酸エステル系結合剤又はＮＢＲやＳＢＲ等のゴム系結合剤等が用いられる。結合剤は、無機微粒子が分散している分散液中に含有させておき、無機微粒子と共に不織布本体に付与するのが一般的である。分散液中に結合剤を含有させる場合、結合剤の含有量は無機微粒子の含有量と同程度であるのが好ましい。結合剤の含有量が無機微粒子の含有量に比べて少なすぎると、無機微粒子を不織布本体に付着させにくくなる。また、結合剤の含有量が無機微粒子の含有量に比べて多すぎると、結合剤が無機微粒子を完全に被覆して、アレルゲンが無機微粒子と反応しにくくなる。 In order to attach the inorganic fine particles to the nonwoven fabric body, a conventionally known method may be adopted, but it is generally preferable to attach them by using a binder. As this binder, it is preferable to use the same binder as that for bonding the constituent fibers of the nonwoven fabric body. This is because when the same binder is used, the constituent fibers can be bonded to each other and the inorganic fine particles can be adhered at the same time. Of course, after binding the constituent fibers of the nonwoven fabric body with a binder, the inorganic fine particles may be attached to the nonwoven fabric body with the same or different binder. As such a binder, a conventionally known one is adopted, but an acrylic ester binder or a rubber binder such as NBR or SBR is used. The binder is generally contained in the dispersion liquid in which the inorganic fine particles are dispersed, and is generally applied to the nonwoven fabric body together with the inorganic fine particles. When the dispersion contains a binder, the content of the binder is preferably about the same as the content of the inorganic fine particles. When the content of the binder is too small as compared with the content of the inorganic fine particles, it becomes difficult to attach the inorganic fine particles to the nonwoven fabric body. Further, if the content of the binder is too large as compared with the content of the inorganic fine particles, the binder completely covers the inorganic fine particles and the allergen becomes difficult to react with the inorganic fine particles.
分散液中には、さらに親水化剤及び油剤を含有させておき、無機微粒子と共に不織布本体に付着させるのが好ましい。親水化剤は、無機微粒子が抗アレルゲン効果を奏するのに有効である。すなわち、親水化剤により水分が吸着され、水分の介在によってアレルゲンが無機微粒子と反応しやくなるのである。親水化剤としては、各種の界面活性剤を用いることができ、具体的には、ポリオキシアルキレンアルキルエーテル系ノニオン界面活性剤やスルホコハク酸系アニオン界面活性剤等が用いられる。分散液中の親水化剤の含有量は若干量であればよく、たとえば、１重量％以下でよい。 It is preferable that the dispersion liquid further contains a hydrophilizing agent and an oil agent, and is made to adhere to the nonwoven fabric body together with the inorganic fine particles. The hydrophilizing agent is effective for the inorganic fine particles to exert an anti-allergen effect. That is, water is adsorbed by the hydrophilizing agent, and the presence of water facilitates the reaction of the allergen with the inorganic fine particles. As the hydrophilizing agent, various surfactants can be used, and specifically, polyoxyalkylene alkyl ether-based nonionic surfactants, sulfosuccinic acid-based anionic surfactants, and the like are used. The content of the hydrophilizing agent in the dispersion may be a slight amount, for example, 1% by weight or less.
また、本発明において、分散液中の油剤としては、従来公知の繊維油剤を用いることができ、たとえば、シリコーンオイル系や脂肪酸エステル系の合成潤滑油を用いることができる。油剤を無機微粒子と共に繊維本体に付着させることにより、得られた抗アレルゲン不織布にタフティング機の針を貫通させやすくなるのである。すなわち、本発明に係る抗アレルゲン不織布を、タフトカーペット用一次基布の用途に用いる場合、タフティング機の針が抗アレルゲン不織布に通されパイル糸が埋め込まれるのであり、この際、油剤が抗アレルゲン不織布中に存在すると、無機微粒子があっても針を通しやすくなるのである。分散液中における油剤の含有量も、無機微粒子の含有量と同程度であるのが好ましい。油剤の含有量が無機微粒子の含有量に比べて少なすぎると、タフティング機の針が通しにくくなる。また、油剤の含有量が無機微粒子の含有量に比べて多すぎると、油剤の撥水性により、アレルゲンが無機微粒子と反応しにくくなる。 Further, in the present invention, a conventionally known fiber oil agent can be used as the oil agent in the dispersion liquid, and for example, a silicone oil-based or fatty acid ester-based synthetic lubricating oil can be used. By attaching the oil agent together with the inorganic fine particles to the fiber main body, the needle of the tufting machine can be easily penetrated through the obtained anti-allergen nonwoven fabric. That is, when the anti-allergen non-woven fabric according to the present invention is used as a primary base fabric for tufted carpet, the needle of the tufting machine is passed through the anti-allergen non-woven fabric to embed the pile yarn, and at this time, the oil agent is the anti-allergen. When it is present in the non-woven fabric, it becomes easier for the needle to pass through even if there are inorganic fine particles. The content of the oil agent in the dispersion is also preferably about the same as the content of the inorganic fine particles. When the content of the oil agent is too small as compared with the content of the inorganic fine particles, it becomes difficult for the needle of the tufting machine to pass through. If the content of the oil agent is too large compared to the content of the inorganic fine particles, the water repellency of the oil agent makes it difficult for the allergen to react with the inorganic fine particles.
結合剤、親水化剤及び油剤は、上記したように、無機微粒子の分散液中に含有させて不織布本体に付着させてもよいが、分散液中に含有させておく必要はなく、別途、不織布本体に付着させてもよい。すなわち、不織布本体に無機微粒子を付着させる前に、結合剤、親水化剤及び油剤を不織布本体に付着させておいてもよいし、無機微粒子を付着させた後に、結合剤、親水化剤及び油剤を付着させてもよい。さらに、本発明で用いる抗アレルゲン不織布に、所望により、消臭剤、抗菌剤、防ダニ剤又は抗ウイルス剤等を、別途付着させてもよい。 The binder, the hydrophilizing agent and the oil agent may be contained in the dispersion liquid of the inorganic fine particles and adhered to the nonwoven fabric body as described above, but it is not necessary to be contained in the dispersion liquid, and the nonwoven fabric is separately prepared. It may be attached to the body. That is, a binder, a hydrophilizing agent and an oil agent may be attached to the nonwoven fabric body before attaching the inorganic fine particles to the nonwoven fabric body, or a binder, a hydrophilizing agent and an oil agent may be attached after attaching the inorganic fine particles. May be attached. Furthermore, if desired, a deodorant, an antibacterial agent, an anti-mite agent, an antiviral agent, or the like may be separately attached to the anti-allergen nonwoven fabric used in the present invention.
本発明に係る抗アレルゲン不織布よりなるタフトカーペット用一次基布は、ダニアレルゲンに対する反応性が高く、ダニアレルゲンが堆積しやすい、カーペットの材料に適している。 Tufted carpet primary backing made of anti-allergen non-woven fabric in accordance with the present invention has high reactivity to mite allergens, mite allergens are likely to deposit, are suitable for carpet material.
本発明に係る抗アレルゲン不織布よりなるタフトカーペット用一次基布には、酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子が付着している。そして、この無機微粒子はダニアレルゲン等のアレルゲンに対して高い反応性を有しているため、アレルゲンと反応して、それを不活性化させる。したがって、本発明に係る抗アレルゲン不織布よりなるタフトカーペット用一次基布が、たとえば、室内や自動車等のカーペットの材料として用いられていると、室内の居住者や自動車の使用者等がアレルギー疾患を発症しにくいという効果を奏する。また、本発明で用いる無機微粒子は、消臭効果、抗菌効果、抗カビ効果及び抗ウイルス効果等も、ある程度併有しているので、これらの効果も奏しうる。 Inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide are adhered to the primary base fabric for tufted carpet made of the anti-allergen nonwoven fabric according to the present invention. Since the inorganic fine particles have high reactivity with allergens such as mite allergen, they react with the allergens to inactivate them. Therefore, when the primary fabric for tufted carpets comprising the anti-allergen non-woven fabric according to the present invention is used as a material for carpets such as indoors and automobiles, indoor residents and automobile users are allergic to allergic diseases. The effect that it is hard to develop is exhibited. Further, since the inorganic fine particles used in the present invention have a deodorant effect, an antibacterial effect, an antifungal effect, an antiviral effect, etc. to some extent, these effects can also be exhibited.
実施例１
［不織布本体の準備］
カーボンブラックを含むポリエチレンテレフタレートを、スパンボンド法で溶融紡糸し、繊度約４．０デシテックスの長繊維群を集積して繊維ウェブを得た。この繊維ウェブに、パンチ密度６０回／ｃｍ2でニードルパンチを施し、長繊維相互間を絡合させて、目付１０５ｇ／ｍ2のパンチウェブを得た。このパンチウェブに、アクリル酸メチル及びアクリル酸エチルを主成分として共重合したアクリル酸エステル系結合剤を水中に乳化分散してなる結合剤エマルジョンを含浸し、１７０℃で乾燥及び熱処理して、長繊維相互間が絡合及び結合されてなる目付１１０ｇ／ｍ2の不織布本体を得た。
Example 1
[Preparation of non-woven fabric body]
Polyethylene terephthalate containing carbon black was melt-spun by a spunbond method, and a long fiber group having a fineness of about 4.0 decitex was accumulated to obtain a fiber web. This fiber web was needle punched at a punch density of 60 times/cm 2 to entangle the long fibers with each other to obtain a punch web having a basis weight of 105 g/m 2 . This punch web is impregnated with a binder emulsion obtained by emulsifying and dispersing an acrylic acid ester-based binder copolymerized with methyl acrylate and ethyl acrylate as main components, dried at 170° C., and heat treated to A non-woven fabric body having a basis weight of 110 g/m 2 in which the fibers were entangled and bonded together was obtained.
［分散液の準備］
酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子を水中に分散させたスラリー（商品名「Ｍ−ＤＳ３３Ｂ」）と、上記した結合剤エマルジョンと、シリコーン系油剤とを準備し、重量比で、無機微粒子：結合剤：シリコーン系油剤＝１：１：１となる割合で混合し混合液を調製した後、ジオクチルスルホコハク酸ナトリウムを主成分とする親水化剤を、この混合液に対して０．２重量％添加して分散液を得た。
[Preparation of dispersion]
A slurry (commercial name "M-DS33B") in which inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide are dispersed in water, the binder emulsion described above, and a silicone-based oil agent are prepared, and the weight ratio of the inorganic material is Fine particles: binder: silicone oil = 1:1:1 to prepare a mixed solution, and then a hydrophilizing agent containing sodium dioctylsulfosuccinate as a main component was added to the mixed solution in an amount of 0.2. A weight% addition was made to obtain a dispersion.
［抗アレルゲン不織布の製造］
不織布本体に分散液を含浸した後、１７０℃で乾燥及び熱処理することにより、無機微粒子が結合剤によって付着されてなる目付１１９ｇ／ｍ2の抗アレルゲン不織布を得た。この抗アレルゲン不織布中には、無機微粒子３ｇ／ｍ2を含有するものであった。
[Manufacture of anti-allergen nonwoven fabric]
The non-woven fabric body was impregnated with the dispersion liquid, and then dried and heat-treated at 170° C. to obtain an anti-allergen non-woven fabric having a basis weight of 119 g/m 2 with inorganic fine particles attached by a binder. This non-allergen nonwoven fabric contained 3 g/m 2 of inorganic fine particles.
実施例２
［不織布本体の準備］
実施例１と同一の方法で、目付１０５ｇ／ｍ2のパンチウェブを得た。このパンチウェブを不織布本体として準備した。
Example 2
[Preparation of non-woven fabric body]
A punch web having a basis weight of 105 g/m 2 was obtained in the same manner as in Example 1. This punch web was prepared as a nonwoven fabric body.
［分散液の準備］
酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子を水中に分散させたスラリー（商品名「Ｍ−ＤＳ３３Ｂ」）と、実施例１で用いた結合剤エマルジョンとを準備し、重量比で、無機微粒子：結合剤＝３：８となる割合で混合し、分散液を得た。
[Preparation of dispersion]
A slurry (trade name "M-DS33B") in which inorganic fine particles containing aluminum oxide, silicon dioxide and zinc oxide are dispersed in water and the binder emulsion used in Example 1 are prepared, and the inorganic fine particles are used in a weight ratio. : Binder = 3:8 were mixed to obtain a dispersion liquid.
［抗アレルゲン不織布の製造］
不織布本体に分散液を含浸した後、１７０℃で乾燥及び熱処理することにより、無機微粒子を結合剤によって付着した後、シリコーン系油剤を塗布して、目付１１９ｇ／ｍ2の抗アレルゲン不織布を得た。この抗アレルゲン不織布中には、無機微粒子３ｇ／ｍ2、結合剤８ｇ／ｍ2及びシリコーン系油剤３ｇ／ｍ2を含有するものであった。
[Manufacture of anti-allergen nonwoven fabric]
After impregnating the non-woven fabric body with the dispersion liquid, and drying and heat-treating at 170° C., the inorganic fine particles are attached by the binder, and then the silicone-based oil agent is applied to obtain an anti-allergen non-woven fabric with a basis weight of 119 g/m 2 . .. This anti-allergen non-woven fabric contained 3 g/m 2 of inorganic fine particles, 8 g/m 2 of binder and 3 g/m 2 of silicone oil.
［抗アレルゲン性の評価］
実施例１で用いた不織布本体及び実施例１で得られた抗アレルゲン不織布の各々から、７０ｍｍ×７０ｍｍの試験片を採取した。リン酸緩衝液にてダニアレルゲン（Ｄｅｒ２）濃度約７５ｎｇ／ｍｌに調製したアレルゲン溶液２ｍｌを、各試験片に浸み込ませた後、各ポリエチレン袋に密封した。このポリエチレン袋を４℃下で２４時間放置した後、アレルゲン溶液を搾り出して回収した。回収液をＥＬＩＳＡ用の溶媒組成に変換するため、変換液と等量混合した後、遠心処理を施して浮遊残渣を取り除き試験液とした。この試験液をＥＬＩＳＡ法によりアレルゲン濃度を測定した。その結果、不織布本体については１４１ｎｇであり、抗アレルゲン不織布については７ｎｇであった。このことから、実施例１で得られた抗アレルゲン不織布は、良好な抗ダニアレルゲン性を有することが分かる。また、実施例１に係る抗アレルゲン不織布をタフトカーペット用一次基布として用い、１９３０デシテックスのナイロン糸をタフト糸とし、１／１０ゲージで１０ステッチの条件でタフティングしたタフトカーペットを、前記と同様にしてアレルゲン濃度を測定したところ、２８ｎｇであった。したがって、実施例１に係る抗アレルゲン不織布をタフトカーペット用一次基布とした場合でも、カーペットに抗アレルゲン性を与えることができる。
[Evaluation of antiallergenicity]
A 70 mm×70 mm test piece was taken from each of the nonwoven fabric body used in Example 1 and the anti-allergen nonwoven fabric obtained in Example 1. 2 ml of the allergen solution prepared with a phosphate buffer solution to a mite allergen (Der2) concentration of about 75 ng/ml was immersed in each test piece and then sealed in each polyethylene bag. After leaving this polyethylene bag at 4° C. for 24 hours, the allergen solution was squeezed and collected. In order to convert the recovered liquid into a solvent composition for ELISA, an equal amount of the converted liquid was mixed and then centrifuged to remove a floating residue to obtain a test liquid. The allergen concentration of this test solution was measured by the ELISA method. As a result, the non-woven fabric body was 141 ng and the anti-allergen non-woven fabric was 7 ng. From this, it can be seen that the anti-allergen nonwoven fabric obtained in Example 1 has good anti-mite allergen properties. Also, using the anti-allergen non-woven fabric according to Example 1 as a primary base fabric for tufted carpet, nylon tufts of 1930 decitex as tufted yarn, tufted tufted under the condition of 1/10 gauge and 10 stitches, the same as above. The allergen concentration was measured and found to be 28 ng. Therefore, even when the anti-allergen non-woven fabric according to Example 1 is used as the primary base fabric for tufted carpet, it is possible to impart anti-allergen properties to the carpet.
Claims (5)
前記繊維ウェブ中の構成繊維相互間を結合剤で結合させて不織布本体を得るか又は該構成繊維相互間を絡合させて不織布本体を得る工程及び
前記不織布本体に、酸化アルミニウム、二酸化珪素及び酸化亜鉛を含む無機微粒子と、親水化剤と、油剤とを含む分散液を付与して、該無機微粒子を該不織布本体に付着させる工程を具備することを特徴とする抗アレルゲン不織布よりなるタフトカーペット用一次基布の製造方法。 A step of obtaining a fibrous web in which constituent fibers are accumulated,
A step of binding the constituent fibers in the fibrous web with a binder to obtain a non-woven fabric body or entanglement of the constituent fibers with each other to obtain a non-woven fabric body; and the non-woven fabric body with aluminum oxide, silicon dioxide and oxidation. A tufted carpet made of an anti-allergen nonwoven fabric, comprising a step of applying a dispersion liquid containing zinc-containing inorganic fine particles , a hydrophilizing agent, and an oil agent to adhere the inorganic fine particles to the nonwoven fabric body . Method for manufacturing primary base cloth .
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