JPH01204617A - Mat - Google Patents

Abstract

PURPOSE:To obtain a mat of an excellent bulk restoration property, a repelling elasticity, and a soft feeling, by fixing a specific diameter of fiber rods including a specific amount or more of a thermal fusing type complex fiber which have a specific elasticity restoration rate or more even after a thermal fusing process, and formed in such a thermal fusing process, to a basic cloth. CONSTITUTION:Of thermal fusing type complex fibers, such a fiber to have 90% or more elasticity restoration rate even after heating once up to the fusion temperature of low melting point resin is selected and used. The thermal fusing type complex fiber and a high melting point fiber are made into a mixture fiber silver with a card loom or the like. The amount of the thermal fusing type complex fiber in the mixture fiber silver is made 20wt.% or more. A mixture fiber silver consisting of two or three kinds of fibers is heat-treated at the temperature higher than the melting point of the thermal fusing component of the thermal fusing type complex fiber, and lower than the melting point of a high melting point component of said complex fiber, and formed into fiber rods. The fiber rods of the diameter 5-15mm are used, and are tufted to a basic cloth, for example, to process into a piled carpet, and used as a mat.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to rugs such as carpets, bead mats, and round seats, and more particularly to rugs using large diameter fiber rondo as the surface material.

[Prior art]

Traditionally, tufted carpets or needle-punched pile carpets have been widely used in fields where rugs with low rebound and soft touch are preferred. In addition, in fields where high rebound and a hard touch are preferred, rugs woven from plasti 1B-straw, large-count hard twisted spun yarn, or rugs stitched and fixed to the base fabric are used. It is being

[Problem that the invention seeks to solve]

Rugs using plastic straws have a strong gloss and are inferior in quality, and when used in pile form, the pile has too little flexibility and the texture is poor, and when used with stitches on the base fabric, the surface is smooth. However, it has drawbacks such as giving a sticky feeling. Those using hard twisted spun yarns have the drawbacks of hair pulling, and although the pile is flexible, its repellency is low, and when stitched to a base fabric, the depth of the cushion is small.

[Means to solve the problem]

The inventor of the present invention has conducted intensive research to obtain a rug with low gloss and flatness, high rebound and bulk recovery properties, and moderate flexibility.
20% of heat-fusible composite fibers having an elastic recovery coefficient of 0 or more
Contains more than the weight factor and is molded by heat fusion method with a diameter of 5~
The present invention was completed after learning that the desired purpose could be achieved by fixing the fiber rod of 15 times to the base fabric.

The heat-fusible composite fiber used in the present invention is made by spun two types of thermoplastic resins with melting points different by 20°C or more in a parallel type or sheath-core type so that the lower melting point resin is present on the fiber surface. Examples of such thermoplastic resin combinations include crystalline polypropylene (PP)/high density polyethylene (HDPE), polyethylene terephthalate (P
ET)/HDPE, PET/polyethylene terephthalate isophthalate (PETI), nylon 66/
, nylon 6, etc. are exemplified. In the present invention, among the heat-fusible conjugate fibers, a low melting point resin (heat-fusible component)
A material that still has an elastic recovery rate of 90% or more even after being heated to the fusion temperature is selected and used. The method for obtaining heat-fusible composite fibers having such elasticity varies depending on the thermoplastic resin constituting the heat-fusible composite fiber and the combination thereof, and appropriately sets the spinning temperature, stretching temperature, and stretching ratio. There is a need.

There are no particular limitations on the fineness and fiber length of heat-fusible composite fibers, but from the viewpoint of ease of mixing with other fibers and good feel of the rug, fibers of approximately 1 to 15 d/f x 25 to 150 m are preferred. preferable.

The high melting point fiber used in the present invention refers to a fiber having a melting point higher than the melting point of the high melting point thermoplastic resin constituting the heat-fusible composite fiber, and includes natural fibers such as cotton, linen, and wool, or rayon, Medium-sized chemical fibers such as nylon, PET, and PP are appropriately selected according to the properties of the intended rug.

Heat-fusible composite fibers and high-melting point fibers are manufactured using well-known card machines, etc.
method to make mixed fiber sliver. If the amount of heat-fusible conjugate fibers in the mixed fiber sliver is less than 20% by weight, the fiber rod obtained by heat treatment will have low rebound resilience and will easily become fluffy, and the rug will also preferably have low bulk recovery properties. do not have.

In the present invention, for the purpose of preventing fluffing of the fiber rod, heat-fusible non-composite fibers having a melting point of seven points below the melting point of the heat-fusible component of the heat-fusible conjugate fiber are added to the mixed fiber sliver.
They can be mixed at a ratio below 0 weight plate. Examples of such heat-fusible non-composite fibers include homogeneous fibers made of thermoplastic resins such as polyethylene, ethylene-vinyl acetate copolymers, or mixtures thereof, polypropylene, and low-melting point polyesters. If the amount of heat-fusible non-composite fibers mixed exceeds 40% by weight, the fiber rod will become hard and the rug made using it will also have less flexibility, which is undesirable.

The mixed fiber sliver made of the above two or three types of fibers is formed into a fiber rod of the heat-fusible component of the heat-fusible composite fiber. As such a forming method,
The method disclosed in No. 938 is exemplified, and according to this method, the desired shape can be obtained by appropriately selecting the diameter of the mouthpiece of the molding machine, the total fineness of the mixed fiber sliver fed thereto, the heating temperature, and the heat treatment time. A fiber rod with a desired thickness and desired porosity (fiber density) can be obtained.

For example, the larger the total fineness of the supplied sliver and the longer the molding conditions at high temperature, the smaller the porosity and the greater the rebound resilience. A fiber rod having a surface porosity of 60 to 95 qb and a tensile strength of 6 to 50 kg can be easily obtained.

In the present invention, the fiber rod used has a diameter of 5 to 15 mm. If the fiber rod has a diameter of less than 5 mm, a pile made of the fiber rod will have low rebound resilience, and if a stiffener is attached to the base fabric, the cushion depth will be insufficient. Also, the diameter is 1
If it exceeds 5ioa, it becomes difficult to process it into a pile shape, and when it is stitched to a base fabric, the irregularities on the surface of the rug become too large and the texture is impaired, which is not preferable.

The fiber rods obtained in this way can be processed into pile carpet by tufting them onto a base fabric using a tufting machine, or processed into cord carpet by arranging them in parallel or spirally on the base fabric and using a stiffener. This is used as a rug of the present invention.

〔Example〕

The present invention will be explained in more detail with reference to Examples. The physical property evaluation methods used on each side are summarized below.

Elastic recovery rate: After heating the sample fiber in a non-tension state for 5 minutes in a hot air dryer adjusted to a predetermined temperature, it was left to cool at room temperature for 24 hours, and tested using a self-recording constant speed tensile tester.
L 1015 (Chemical fiber staple test method) 7,
According to method 10 B, elongate the sample by 5% at a gripping interval of 50 mm (L) and a tensile speed of 2 sm/min, leave it for 3 minutes, then remove the weight at the same speed, and calculate the residual elongation (L, ) from the load-elongation curve described. Average value of 10 readings calculated using the following formula.

Bulk recovery rate = A test piece is obtained by bonding fiber rods of length 30 crrL on a square polypropylene spunbond nonwoven fabric (fabric weight 1501/m”) with one side of 30 cm at intervals of 411! using a parallel binder. This test A square plate of 35 cm on a side and a weight of 1,070.9 cm is placed on top of the piece or carpet sample, and the thickness (Ho) of the test piece is measured after being left for 4 hours. A weight was placed on it so that the total weight was 80ki9, and after leaving it for 20 hours, the weight was removed and it was left for 4 hours.

After repeating this loading/unloading operation 10 times, the thickness (Hn) of the test piece is measured, and the bulk recovery rate is determined by the following formula: Flexibility: A sensory test is conducted by five panelists.

A test piece prepared in the same way as the one used to measure the bulk recovery rate or a carpet sample of 30 crrL x 30 cIrL was held down by hand, and those that gave the hard feel of a plastic drawer were judged as defective (1), and those with bent piles and dents. Those that give a soft feel are rated as good (3) and ranked in three stages.

A sensory test of rebound resilience was conducted by 25 panelists. Step on a test piece or carpet sample of 30 crrL x 30 cIrL made in the same way as the one used to measure the bulk recovery rate with bare feet, and feel the sensation of pushing and releasing it with your bare feet. (4) Small items are considered defective (1) and ranked in four stages.

Examples 1 to 5, Comparative Examples 1 to 5 Using the heat-fusible conjugate fibers shown in Table 1, the high melting point fibers and heat-fusible non-conjugate fibers shown in Table 2, the products shown in Table 3 were prepared. Carded in various combinations and mixing ratios, total fineness is approximately 2.
Using a 6,000 denier mixed fiber sliver and a molding machine described in Japanese Patent Publication No. 59-40938, 152
Fiber rods each having a diameter of 6 mm were produced by heat treatment with superheated steam at ℃.

Table 3 also shows the results of bulk recovery rate, flexibility, and impact resilience measured using these fiber rods.

*All composite ratios are so/s.

PP,: PP, with 0.05% titanium oxide added PP4: PP, with 0.125% added 〃P
P, :PP, // 0.375% 〃P
E,: PE1 with 0.05% titanium oxide added P
E, :PE, // 0.125% to 〃PE
, :PE, to // 0.375% 〃I'E
, :PE, to which 5btOs O,3 and 0.6% of decabromophenyl oxide were added Table 3 W, From the results shown in Table 3, even after heat treatment, the
Fiber rods using heat-fusible composite fibers with an elastic recovery rate of more than It can be seen that fiber rods using heat-fusible conjugate fibers with a low ratio are inferior in all of these properties.

Examples 6 to 8, Comparative Example 6.7 Example 1 was prepared using a big pile tufting machine on a base fabric made of polypropylene spunbond nonwoven fabric with a basis weight of 14097 m.
The fiber rods with a diameter of 6111 manufactured in Comparative Example 1.2 and Comparative Example 1.2 were each tufted, and the back side was coated with a fabric weight of 245 g.
A secondary base fabric consisting of 1rrl of Sudo woven fabric was laminated using ABS latex adhesive to give a weight of 3250 g.
/m pile carpet was obtained. The properties of these fiber rods and carpets are shown in Table 4.

Table 4 Examples 9 to 12 Each of the fiber rods having a diameter of 6 yen produced in Example 1.2 was individually coiled onto a base fabric made of polypropylene spunbond nonwoven fabric having a basis weight of 150 JF/m''. The fiber rods were arranged densely and fixed using a stapler at 8-h intervals in the longitudinal direction using 30-count cotton thread.Furthermore, a secondary jute base fabric with a fabric weight of 2459/n? was attached to the bottom surface of the base fabric.
Layered with S latex adhesive, diameter 30mm, basis weight approx. 20mm
001! /- cord carpet was obtained (Example 9.1
0).

Further, a cord carpet was produced in the same manner as above except that a highly shrinkable monofilament was used in place of the 30 count cotton yarn (Example 11.12).

The physical property evaluation results of these rugs are shown in Table 5.

In addition, the high shrinkage monofilament here refers to the conditions for drying the binder when manufacturing rugs (generally 110 to 1
20°C, 1 to 3 hours) means a monofilament that exhibits a heat shrinkage of 20% or more, and the monofilament used in Example 11.12 is a monofilament made of a ternary random copolymer of ethylene, propylene, and butene-1. A monofilament of 1,020 denier obtained by spinning showed a heat shrinkage of 28 when subjected to heat treatment at 110° C. for 10 minutes.

Table 5 In Examples 11 and 12, the fiber rods were squeezed and became thinner at the stitching points, creating a delicate uneven pattern on the surface of the rug, resulting in a rug with better texture than in Examples 9 and 10.

〔effect〕

The rug of the present invention is made using fiber rods made of heat-fusible composite fibers that have a high elastic recovery rate even after heat-sealing treatment, so it has excellent bulk recovery properties and rebound resilience, as well as a soft feel. It is suitable for use as car mats, indoor carpets, door rugs, wall coverings with a sense of mass, or chair upholstery.

Claims (2)

[Claims] (1) Composite fiber consisting of a high melting point component and a low melting point component, which still has a
Fibers with a diameter of 5 to 15 mm obtained by heat-treating a mixed fiber sliver consisting of 20% by weight or more of heat-fusible composite fibers having an elastic recovery rate of 0% or more and 80% by weight or less of high-melting point fibers at the above-mentioned fusion temperature. A rug made by adhering rod to a base fabric. (2) The mixed fiber sliver contains not more than 40% by weight of heat-fusible non-composite fibers having a melting point lower than the melting point of the high-melting point component of the heat-fusible composite fiber, in addition to heat-fusible composite fibers and high-melting point fibers. A rug according to claim 1 containing: