JPH0317947B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a tufted carpet base fabric made of a nonwoven fabric with an orthogonal structure using polyester filaments. As a tufted carpet base fabric, a large number of synthetic fiber filaments are arranged in the length direction and width direction, and the arrangement ratio in the length direction, width direction, and diagonal direction is specified. It is also known that the resistance to deformation in the diagonal direction is increased, thereby improving the strength after tufting, and preventing the neck down that occurs during dyeing and other processing steps after tufting (Japanese Patent Publication No. 55-42175 (see publication). However, this known nonwoven fabric only defines the arrangement ratio of synthetic fiber filaments located in the length direction, width direction, and diagonal direction and its organizational structure, and the required performance as a tufted carpet base fabric and this Since it does not specify the manufacturing conditions necessary to satisfy the required performance, sufficient effects have not always been obtained. In other words, the structure of the base fabric is destroyed by tufting, leaving it in a completely different state than before tufting, and even though its physical properties deteriorate,
Previously, only the state and physical properties of the base fabric before tufting were considered, making it impossible to clarify the problems and using it as a basis for setting the structural structure and manufacturing conditions necessary to obtain products with excellent performance. Since the required physical property values were not known, they had no choice but to rely on their intuition, which resulted in products with poor performance such as neck down and bowing, and lack of strength. The present inventor provides a tufted carpet that does not cause neckdown due to processing tension during processing after tufting, has high tensile strength and tear strength, and does not have bowing or twisting of the tufting pattern. The purpose of this research was to Simply improving the physical properties of the base fabric before tufting does not necessarily improve the physical properties and product performance after tufting. is influenced by
In addition, the tensile strength and tear strength of the product are determined by the stress retention rate at 5% elongation of the intermediate product (stress at 5% elongation of the intermediate product and 5% of the base fabric original fabric before tufting).
% stress at elongation), the tensile strength retention rate of the above intermediate product (ratio between the tensile strength of the intermediate product and the tensile strength of the base fabric original fabric), and the above tensile strength retention rate and the stress at 5% elongation. By discovering that the ratio between the retention rate and the retention rate has an effect on each other, managing these physical property values, and selecting the structure structure and manufacturing conditions that satisfy these physical property values, we are able to create tufted carpets that provide excellent product performance. We succeeded in obtaining the base fabric and arrived at this invention. That is, in the present invention, a large number of polyester filaments are arranged in the length direction and the width direction in a substantially stretched state, and these polyester filaments in the length direction and the width direction are folded in the length direction and the width direction, respectively. In the tufted carpet base fabric with an orthogonal structure that is laminated and laminated, each of the polyester filaments in the length direction and the width direction has a thickness of 10 to 20 deniers, and a large number of polyester filaments in the length direction are used. A plurality of strips consisting of polyester filaments are arranged densely in the width direction of the base fabric so that the intervals between the polyester filaments are uniform, forming a longitudinally aligned web layer, and the strips of polyester filaments in the longitudinal direction The folding length L is 30cm or more, and the lengthwise deviation l of the folding point is the above folding length L.
A large number of strips each made of a large number of polyester filaments are arranged in the width direction and folded in parallel to each other in a zigzag pattern, and one of the folded parts adjacent to each other in the width direction is The folded part of the other band is sandwiched inside to form a widthwise aligned web layer, and the folded length D of the widthwise polyester filament band is 30 cm or more;
Further, the deviation d of the turning point in the width direction is set to 1/4 or less of the above-mentioned turning length D, and the deviation of the turning point in the longitudinal direction is set to 1/5 or less of the width W of the band, When the above polyester filaments in the length and width directions are glued together and 5% elongated after tufting, the stress is 10 kg/5 cm or more in the length direction, 6 kg/5 cm or more in the width direction, and 5% after tufting.
% elongation stress retention rate (ratio of stress at 5% elongation after tufting to stress at 5% elongation before tufting) is 55% or more in the length direction, 40% or more in the width direction, and the tensile strength after tufting is long 22Kg/5cm or more in the length direction, 14Kg/5cm or more in the width direction, tensile strength retention rate after tufting (ratio of tensile strength after tufting to tensile strength before tufting) is 50% or more in the length direction, 40% in the width direction As described above, the tufted carpet base fabric is characterized in that the ratio of the tensile strength retention rate after tufting to the stress retention rate at 5% elongation after tufting is 0.75 or more in both the length direction and the width direction. . In the present invention, the orthogonally textured nonwoven fabric can be manufactured, for example, as follows. In FIG. 1, reference numerals 1 and 2 each indicate a large number of polyester filaments arranged in a comb shape. It is stretched to a predetermined stretching ratio by hanging it in the form of a belt around the feed roller and draw roller of the book, and is sprayed by an air jet device having a thin slit toward a deflecting rocking plate with a variable inclination angle provided below. As the deflection oscillation plate swings, the flying direction of the particles is periodically changed, and the particles are collected on the collection conveyor 3 below. At this time, one polyester filament 1 is deposited while being swung in the length direction (direction of arrow M) and superimposed on the collection conveyor 3, and the other polyester filament 2 is deposited while being swung in the length direction (direction of arrow C). The polyester filament 1 is deposited while being oscillated, and is laminated on top of the longitudinal polyester filament 1 already superimposed on the collecting conveyor 3. The above polyester filaments 1 and 2 maintain the relationship Vf = 2NL, where the running speed is Vf, the amplitude of swinging (turning length) on the collection conveyor 3 is L, and the period of swinging is N. By doing so, it is collected on the collection conveyor 3 in a substantially stretched state. For example, Vf=750m/min, L
= 60 cm, by setting N=Vf/2L=625 cycles/min, the polyester filaments 1 and 2 can be overlapped in a substantially linearly stretched state. When the oscillation period N of the deflection oscillation plate is larger than the above value, the deposition amplitude of the polyester filaments 1 and 2 is reduced and automatically corrected to an amplitude that satisfies the above equation. Note that the amplitude L in the above equation is illustrated using D for the polyester filament 2 in the width direction. The above-mentioned polyester filaments 1 and 2 collide with a deflection rocking plate that is fixed to the horizontal shaft directly below the air jet device and rotates back and forth. The folded length of the polyester filaments 1 and 2 is the same as the length of the folded polyester filaments 1 and 2. L is represented by L=Htanθ. The above swing angle θ is preferably 35 degrees or less,
If it exceeds 35 degrees, the mechanical load will be excessive. Also,
The above-mentioned distance H is preferably 1 m or less; if it exceeds 1 m, the polyester filaments 1 and 2 collide with the deflection rocking plate and deflect, thereby stalling, making it impossible to obtain the desired folded length L. In order to set the width, area weight, tensile strength, and other physical properties of the nonwoven fabric to the desired size, as shown in Fig. A plurality of supply units 4M and 4C in the width direction and in the width direction are respectively arranged in parallel. Unit 4M in length direction
Of course, the webs deposited on the collection conveyor 3 are arranged so that there are no gaps and the weight distribution is even, but also the webs deposited on the collection conveyor 3 are arranged so that the webs are evenly distributed.
It is preferable to arrange the M and 4M in a staggered manner so as not to interfere with each other. In order to maintain an even distribution of fabric weight in the length direction, the number of laminated layers is 10 or more.
That is, it is necessary to set the longitudinal deviation l of the turning point 1a to 1/5 or less of the turning length L. Therefore, if the speed of collection conveyor 3 is Vc,
It is necessary to satisfy L≧5Vc/N. For example, when Vc = 34 m/min and N = 625 cycles/min, if L≧27.2 cm, L/l≦1/5 is satisfied and the basis weight distribution becomes uniform. Also, L=50cm,
If Vc = 34 m/min and N = 625 cycles/min, the longitudinal deviation l of the turning point 1a is l =
Vc/N is 5.4 cm, and the number of stacked sheets at this time is 18.5. On the other hand, for the supply unit 4C in the width direction, overlapping conditions are set taking into consideration not only the uniformity of the web but also the uniformity of physical properties such as tensile strength in the width direction. That is, since the maximum folding length D on the collecting conveyor 3 is usually 1 m, the supply units 4C in the width direction are arranged at a pitch of 1/4 or less of the folding length D. Note that the supply units 4C in the width direction are arranged in a horizontal line because it is necessary to satisfy the above-mentioned overlap condition and deposit the polyester filament 2 in such a way that the strips of polyester filament 2 supplied from the supply unit 4C bite into each other. However, if the spacing is narrow due to the mechanism of installation and installation is difficult, it is possible to arrange them in multiple rows as long as the above conditions are not violated. In other words, the polyester filament 2 in the width direction
The deviation d of the turning point 2a in the width direction is set to be D/4 or less. That is, the polyester filaments 2 in the width direction are stacked and deposited so that 3/4 or more of the folded width D overlaps. Therefore, the polyester filament 2 in the width direction has a constant speed Vc
Since it is deposited on the collecting conveyor 3 that moves at
The number of layers is 10 to equalize the deposition distribution in the length direction.
It is desirable to consider setting it to more than one sheet. That is, when the band width of the polyester filament 2 in the width direction is W, W≧5Vc/N is satisfied, thereby setting the deviation of the turning point 2a in the length direction to 1/5 or less of the band width W. For example, Vc=34m/min, N=
At 625 cycles/min, set W to 27.2 cm or more. When W=40cm and N=625 cycles/min, Vc is set to 50m/min or less. In this invention, the polyester filaments 1 and 2 are polyethylene terephthalate,
Polybutylene terephthalate, polyethylene terephthalate/isophthalate, poly(ethylene/
It is made of polyester such as (butylene) terephthalate. The thickness is 10 to 20 deniers, and if the thickness is less than 10 deniers, it will be too thin and the number of adhesive points will increase, and it will be cut by the needle during tufting, causing stress at 5% elongation. Tensile strength is insufficient, making it easy to cause necking and bowing, and the penetration resistance of the needle during tufting increases.On the other hand, if it exceeds 20 denier, it becomes too thick and rigid, and the bonding point The tensile strength is insufficient due to the decrease in . In order to bond the orthogonally textured web consisting of the polyester filaments 1 and 2 in the longitudinal and width directions, fibers having a softening point or melting point lower than that of the polyester filaments 1 and 2, such as unstretched fibers, are used during the formation of the web. It is desirable to mix filaments made of polyethylene terephthalate, copolymerized polyester, or the like. That is, when supplying the polyester filaments 1 and 2 to an air jet device, the adhesive filaments such as the above-mentioned low melting point fibers or low softening point fibers are made into a sash shape and overlapped with the polyester filaments 1 and 2 to mix the fibers. After being deposited together with the filaments 1 and 2 on a collecting conveyor 3 made of net, other nets are stacked and sandwiched, and the filaments are passed through a heat cylinder to be thermally welded. The ratio (S/F) between the average adhesive point strength S after the adhesive treatment and the tensile strength F of the polyester filaments 1 and 2 is preferably 0.02 to 0.12. If this S/F is less than 0.02, the adhesive force will be too weak and the tensile strength and tear strength of the product will be insufficient.On the other hand, if it exceeds 0.12, the adhesive force will be too strong and the needle will penetrate during tufting. The resistance is large, and the filament is cut by the needle and the bonding points are destroyed, resulting in insufficient characteristic values such as stress at 5% elongation and its retention rate after tufting. In addition, the above-mentioned average bonding point strength is the average of the measured values of tensile strength (breaking strength) per bonding point in the nonwoven fabric. The tufted carpet base fabric of the present invention preferably has a basis weight of 50 to 200 g/ ^m2 , particularly 60 g/m2.
~160 g/ ^m2 is preferred. The tufted carpet base fabric obtained in this way is made into a product by tufting processed synthetic fiber yarn, wool yarn, etc. as pile yarn using a conventional method, then dyeing and other processing, and then backing. The base fabric after tufting has the physical properties shown in Table 1 below. Note that the retention rate is the ratio (%) after tufting to that before tufting.

[Table] That is, 5% after tufting in Table 1 above.
Characteristic values such as stress during elongation are all controlled by the thickness of polyester filaments 1 and 2, Young's modulus, tensile strength, length of the linearly elongated portion in the nonwoven fabric, and bonding state. However, the stress in the longitudinal direction at 5% elongation after tufting is 10
If it is less than Kg/5cm or less than 6Kg/5cm in the width direction, bowing or twisting will occur, and wrinkles or stop marks will occur due to the difference in elongation between the tufted part and the non-tufted part. In addition, if the stress retention rate at 5% elongation after tufting is less than 55% in the length direction and less than 40% in the width direction, the bonding part will be broken and the polyester filaments 1 and 2 will be cut to a large extent, so the dimensions at the time of processing Stability is reduced and
Tensile strength after tufting is 22kg/5 in the longitudinal direction
If the weight is less than 14 kg/5 cm in the width direction, the tensile strength of the product will be insufficient. In addition, the tensile strength retention rate after tufting is less than 55% in the length direction and in the width direction.
If it is less than 40%, the polyester filaments 1 and 2 will be cut and the bonded portion will be broken, resulting in insufficient strength of the product. Furthermore, if the ratio of the tensile strength retention after tufting to the stress retention at 5% elongation after tufting is less than 0.75 in both the length and width directions, polyester filaments 1 and 2
Due to the large amount of destruction of the base fabric due to cutting, the strength of the product becomes insufficient. Next, the present invention will be explained in more detail with reference to Examples. However, to measure the tensile strength, use a constant speed extension tester to grasp test pieces 5 cm wide and 20 cm long at intervals of 10 cm.
cm, chuck width 5cm, and tensile speed 20±2cm/min. The stress at 5% elongation is S of the above tensile test.
- Determined from the S curve. The tensile strength and 5% elongation stress of the intermediate product after tufting were measured by removing the pile from the intermediate product. In addition, the average adhesive point strength is determined by utilizing the fact that a peak occurs in the SS curve every time one adhesive point is broken during a tensile test. In other words, the special public service in the 1970s
- According to the method described in Publication No. 30747, the sample was pulled at a speed of 0.05 using a Tensilon tensile tester.
The adhesive strength was determined from the number of adhesive points with an adhesive strength of 0.1 g or more and the adhesive strength after elongation at a rate of cm/min. Example 1 Polyethylene terephthalate with an intrinsic viscosity of 0.63 was inserted into 300 orifices (diameter 0.3 mm, length 0.6 mm).
Output amount 1.25g/hole from a rectangular nozzle with
Extruded into a webbing shape at a temperature of 290°C, using 5 feed rolls (surface length 500mm, surface speed 150m/
min, the latter three are heated to 90℃), and the following five draw rolls (surface viscosity 750m/
Stretch the filament 5 times by hanging it with a belt to obtain 300 filaments of 15 denier. on the other hand,
Polyethylene terephthalate/isophthalate with intrinsic viscosity 0.63 (Isophthalate content 10 mol%)
, 60 orifices (diameter 0.3mm, length 0.6mm)
Extruded at 250℃ from a rectangular nozzle with (extrusion amount
1.25g/hole・min), surface length 500mm in blind condition,
Guided to a take-up roller with a surface speed of 750 m/min,
Obtain 60 pieces of low melting point filament for gluing. the above
300 polyester filaments and 60 low melting point filaments with a surface length of 500 mm and surface speed of 750
The fibers are guided through guide rollers at a speed of m/min in a blind state, and the fibers are overlapped with almost the same width and mixed evenly. The above-mentioned mixed fiber filaments are stacked linearly in the length direction, width direction, and diagonal direction on a series of spinning devices from the above two types of nozzles to the guide roller for mixed fibers, or are stacked randomly. A supply unit is constructed by combining an air jet device for stacking and a deflection oscillation device to deposit and stack the above-mentioned mixed fiber filaments in the length direction, width direction, 45 degree inclined direction, 20 degree inclined direction and randomly. ,
Six types of webs (Example 1 and Comparative Examples 1 to 5) were manufactured by combining these supply units, and the obtained webs were sandwiched between two upper and lower net conveyors, and heated at 220°C with a temperature of 0.2 mm. They were pressed together at a pressure of Kg/cm ² G and treated for 20 seconds to bond. The above web is deposited on the collection conveyor 3 to a width of 60 cm, and the width of the evenly distributed part is 36 cm.
Both ends with uneven distribution were cut off, and the central part was used as a sample. The conveyor speed was 9.4 m/min when obtaining a web with a basis weight of 100 g/cm ² , and 7.8 m/min when obtaining a web with a basis weight of 120 g/cm ² . The obtained non-woven fabric is tufted with 1500 denier nylon bulk yarn (gauge 1/8, number of stitches 7/
25.4 mm), and then polyethylene was laminated on the back side (fabric weight 450 g/m ² ). Table 2 shows the manufacturing conditions of the nonwoven fabric, Table 3 shows the physical properties before and after tufting, and Table 4 shows the physical properties of the final product after backing. However, the stress retention rate in the table is the stress retention rate at 5% elongation, and the strength retention rate is the tensile strength retention rate. Also, M.D.
and CD indicate the length direction and width direction, respectively.

【table】

【table】

【table】

[Table] In Tables 3 and 4, ◎ indicates that the appearance is excellent with no defects as determined by visual inspection, ○ indicates that there are no defects and is almost in good condition, and △ indicates that there are some defects and is somewhat poor. , × indicates a defective product with very noticeable defects. Further, in Table 4, the required basis weight indicates the basis weight necessary to satisfy the physical property values in Table 1. As is clear from Tables 2 to 4 above, in Example 1, the structure is an orthogonal structure, and the first
By satisfying the characteristic values shown in the table, stop mark resistance, bowing resistance, dimensional stability, and appearance are all excellent, and the required basis weight may be small. On the other hand, Comparative Examples 1 to 5 all have a structure different from the orthogonal structure, and their physical properties do not satisfy Table 1, resulting in poor stop mark resistance, bowing resistance, dimensional stability, and appearance. Both are inferior to Example 1, and the required basis weight is 1.25 to 4.0 times that of Example 1.
In addition, product physical properties (stress at 5% elongation, tensile strength)
It can be seen that the above-mentioned properties have a large influence on the product, and in particular, it can be seen that the tensile strength of the product is greatly influenced by the tensile strength after tufting as well as its retention rate. Examples 2 to 5 Tufted carpets of Examples 2 to 5 and Comparative Example 6 were manufactured under the same conditions as Example 1 except for the thickness of polyester filaments 1 and 2 and the adhesion temperature of the web. The manufacturing conditions at this time are shown in Table 5, and the physical properties are shown in Table 6.

【table】

[Table] As is clear from Tables 5 and 6 above, in Examples 2 to 5, the physical properties of the intermediate products satisfy Table 1, so that the stress and tensile stress at 5% elongation of the products Comparative example 6 has excellent strength.
Since the ratio of tensile strength retention to stress retention at 5% elongation is smaller than 0.75 in Table 1, the tensile strength of the product is significantly reduced. In addition, stress retention rate at 5% elongation after tufting, tensile strength retention rate,
The S/F of the nonwoven fabric constituent fibers has an influence on the tensile strength retention rate/stress retention rate at 5% elongation, etc.
When the ratio is 0.13 or more (see Comparative Example 6), fiber breakage during tufting increases, resulting in a significant decrease in physical properties due to tufting. On the other hand, when the S/F is small, the adhesion is weak and the handling properties such as fluffing of the base fabric and the physical properties of the base fabric are deteriorated.
is preferably larger than 0.02 (see Example 4). Examples 6 to 8 Tufted carpets of Examples 6 to 8 and Comparative Examples 7 and 8 were produced in the same manner as in Example 1 except that the folded lengths L and D of the polyester filaments 1 and 2 were changed. did. Table 7 shows the above folding length, the physical properties of the base fabric and the intermediate product,
The physical properties of the products are shown in Table 8. In addition, MD
The filament component distribution ratio (weight ratio) MD/CD in the direction and CD direction is 4/6, the thickness of the constituent filament is 15 denier, the bonding temperature is 220℃, the average bonding point strength is 3.6g, and the filament strength is 60g. be.

【table】

[Table] As is clear from Tables 7 and 8 above, in Examples 6 to 8, the folding length was greater than the lower limit, and the physical properties of the intermediate products satisfied Table 1. As a result, the product has excellent physical properties, stop mark resistance, bowing resistance, dimensional stability, and appearance. On the other hand, in Comparative Example 7, the CD direction of the stress retention rate at 5% elongation of the intermediate product is below the lower limit value, and other characteristic values are also near the limit values, so the bowing resistance and the dimensions during continuous dyeing are Poor stability;
The dimensional stability of the product is also low. In addition, in Comparative Example 8, the folding length is smaller than the lower limit, so 5 of the intermediate product
The stress at % elongation and tensile strength were lower than the lower limit values in Table 1, and the stop mark resistance, bowing resistance, dimensional stability, appearance, etc. were poor, and the product performance was also poor. Examples 9 and 10 Next, a plurality of widthwise supply units 4C were arranged in parallel as shown in FIG. 2 to produce a base fabric. That is, after the fibers were mixed in the same manner as in Examples 1 to 5 above, the polyester filament 1 in the length direction was supplied to an air jet device with a slit width of 570 mm, and the polyester filament 2 in the width direction was supplied to an air jet device with a slit width of 200 mm. They were each sprayed onto the lower deflection rocking plate and deposited on a collection conveyor 3 made by Nettsu (travel speed: 9.4 m/min). in this case,
Lengthwise supply unit 4M (effective deposit width 36cm)
A plurality of units are arranged in a staggered manner at a pitch of 36 cm in the width direction and are alternately slightly shifted in the traveling direction of the collection conveyor 3, while the supply unit 4C in the width direction is
Arrange multiple pieces at equal intervals in a horizontal row to determine the basis weight.
A web of 100 g/m ² of orthogonally arranged texture was obtained. The oscillating deposition amplitude of the supply unit was set to 60 cm in both the length and width directions, and the oscillation period was set to 625 cycles/min in both the length and width directions. The deviation in the length direction of the filament 2 in the width direction was set to 1.5 cm. Next, the above web was bonded in the same manner as above to form a carpet base fabric, tufted, and lined to form a product. Table 9 shows the manufacturing conditions for the base fabric, and Table 10 shows the physical properties of the intermediate product and finished product.

【table】

【table】

【table】

[Table] In addition, the variation (CV% ) are shown in Table 11.

[Table] As is clear from Tables 9 to 11 above, the widthwise deviation d of the widthwise filaments 2 is reduced, the overlap width of the adjacent widthwise filaments 2 is increased, and the number of overlaps and stacks is increased. Examples 9 and 10 with increased
Compared to Comparative Examples 9 to 11 where the deviation d is large, the physical property values (average values) of the base fabric, intermediate product, and final product are not only larger, but also the variation in the physical property values (CV%) in the width direction is particularly large. is small and homogeneous. On the other hand, in Comparative Examples 9 to 11, in which the number of superimposed/laminated layers is small and the deviation d is large, as the deviation d increases, the variation in physical property values (CV%) increases and becomes significantly non-uniform. In the base fabric for tufted carpets, the destruction of the bonding points progresses due to tufting, so the physical property deterioration at the overlap end (laminated part at the folding point) is more remarkable than in other parts. In Comparative Examples 9 to 11, which have large variations in physical properties in the fabric state, the variations tend to be further amplified by tufting, which increases the unevenness of deformation and strain during processing, resulting in unevenness and distortion of product physical properties. This results in uneven fixation of .
On the other hand, in Examples 9 and 10, the nonwoven fabric constituent fibers,
In particular, since the bands of filaments 2 in the width direction are deeply interdigitated and stacked one on top of the other, not only the average value of the physical properties is high, but also the dispersion is small, and an excellent carpet can be obtained. As explained above, the present invention specifies the thickness of the polyester filaments and the lamination conditions thereof in a tufted carpet based on a nonwoven fabric with an orthogonal structure made of polyester filaments. The number of laminated sheets of each of the filament band and the filament band in the width direction is increased, and the basis weight distribution and physical properties are homogenized.Furthermore, the filament band in the width direction is made so that one folded part of the adjacent part is sandwiched between the other folded part. Because they are laminated, the tensile strength in the width direction of the web layer aligned in the width direction is improved, making it easier to handle before the adhesive treatment.Moreover, the physical properties before and after tufting are specified, so it is possible to improve the tensile strength in the width direction of the web layer. By cutting a test piece from the base fabric, tufting it, and measuring the physical properties before and after, feedback on the previous process can be performed more quickly and accurately than with conventional peel-off adhesion tests, and quality control is therefore possible. The stop mark resistance, bowing resistance, dimensional stability, and appearance of the product after tufting are significantly improved.

[Brief explanation of the drawing]

FIG. 1 is a perspective view for explaining the manufacturing method of the nonwoven fabric for base fabric used in the present invention, and FIG. 2 is a plan view for explaining another example of the manufacturing method. 1: Polyester filaments in the length direction arranged in a sash pattern, 2: Polyester filaments in the width direction arranged in a sash pattern, 1a, 2a:
Turning point, L, D: turning length, l, d: deviation.

Claims (1)

[Claims] 1 A large number of polyester filaments are arranged in the length direction and width direction in a substantially stretched state, and these polyester filaments in the length direction and width direction are folded back in the length direction and width direction, respectively, and stacked one on top of the other. In the tufted carpet base fabric with an orthogonal structure, the polyester filaments in the length and width directions are respectively
A plurality of strips having a thickness of 10 to 20 deniers and consisting of a large number of polyester filaments in the length direction are densely arranged in the width direction of the base fabric so that the intervals between the polyester filaments are uniform. to form a longitudinally aligned web layer, and the folded length L of the longitudinal polyester filament strip is
is set to be 30 cm or more, and the lengthwise deviation l of the folding point is set to 1/5 or less of the above folding length L, and a large number of strips consisting of a large number of polyester filaments in the width direction are set in the width direction. They are arranged and folded in a zigzag shape parallel to each other, and the folded part of one band adjacent to the width direction is sandwiched inside the folded part of the other band to form a widthwise aligned web layer. The folding length D of the filament band is 30 cm or more, and the deviation d of the folding point in the width direction is 1/4 or less of the folding length D,
In addition, the deviation in the length direction of the folding point is set to 1/5 or less of the width W of the band, and when the polyester filaments in the length direction and width direction are bonded to each other and elongated by 5% after tufting. Stress is 10Kg/5cm or more in the length direction, 6Kg/5cm in the width direction
As mentioned above, the stress retention rate at 5% elongation after tufting (the ratio of the stress at 5% elongation after tufting to the stress at 5% elongation before tufting) is 55% in the longitudinal direction.
40% or more in the width direction, tensile strength after tufting is 22Kg/5cm or more in the length direction, 14Kg/5 in the width direction
cm or more, tensile strength retention rate after tufting (ratio of tensile strength after tufting to tensile strength before tufting) is 50% or more in length direction, width direction
40% or more, and the ratio of the tensile strength retention after tufting to the stress retention at 5% elongation after tufting is 0.75 or more in both length and width directions. .