JPH08142245A - Laminated non-woven fabric, electric carpet using the same and manufacture of the same fabric - Google Patents

Abstract

PURPOSE: To provide a laminated non-woven fabric in which anti-skid function is excellent even if resin using quantity is little and the strength is improved, an electric carpet and a method for manufacturing the fabric. CONSTITUTION: A laminated non-woven fabric comprises a non-woven fabric felt layer 1 made of a web or a short fiber, a span bonded non-woven fabric 2 of a long fiber, and a foamed resin layer 3, wherein the fabric 2 is formed of a finer fiber than that of the layer 1 with high density. An electric carpet uses a laminated non-woven fabric in which the layer 3 is used as the outermost layer as a rear surface material 5. A method for manufacturing the laminated non-woven fabric comprises the steps of laminating the fabric 2 on the layer 1, integrating by needle punching, then coating the surface of the fabric 2 with a resin composition containing a resin exhibiting viscoelasticity, and forming the layer 3 on the surface of the non-woven fabric.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a laminated nonwoven fabric useful as a backing material for an electric carpet, an electric carpet using the laminated nonwoven fabric, and a method for producing the laminated nonwoven fabric.

[0002]

2. Description of the Related Art The structure of a conventional electric carpet is shown in FIG. The front surface material 4 and the back surface material 5 are obtained by needle-punching a nonwoven fabric 11 made of a web formed of fiber layers in which short fibers are entwined in a spider web shape to form a felt.
Then, the heat-sealing film 8, the metal foil 9 made of aluminum or the like, and the heat-sealing film 8 are laminated in this order, and the heater unit 7 is further bonded to the lower surface thereof by pattern-wiring the heating wire 6 to the surface material 4 described above. , And the backside material 5 to sandwich the electric carpet.
When the front surface material 4, the heater unit 7, and the back surface material 5 that form the electric carpet are bonded by hot pressing, the overall strength decreases at the temperature of the hot pressing, and it is difficult to take out the product from the hot pressing. The heating wire 6 is likely to fail due to deformation due to heat.

On the other hand, it is known to provide a foamed resin layer on the felt as a constitution for imparting a non-slip function to the needle punched felt (Act No. 4-988).
No. 5). The foamed resin layer includes SBR (styrene-butadiene copolymer latex), NBR (acrylonitrile-butadiene copolymer latex), MB.
A rubber-based latex resin having viscoelasticity such as R (latex of methylmethacrylate-butadiene-based copolymer) is applied to the outer surface of the felt and dried. However, in order to effectively function as an anti-slip agent, the latex resin easily penetrates into the felt, so 300 to 500
There is a problem that it is necessary to apply a large amount of latex resin of about g / m ² and the foamed resin layer has low strength.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above facts, and an object of the present invention is to provide a laminate having an excellent anti-slip function and improved strength even if the amount of resin used is small. A non-woven fabric, an electric carpet, and a method for manufacturing a laminated non-woven fabric.

Another object of the present invention is to provide an electric carpet which is less likely to be deformed by heat.

[0006]

A laminated non-woven fabric according to claim 1 of the present invention comprises a non-woven felt layer 1 made of a web of short fibers, and a long-fiber made of the non-woven felt layer 1 integrated by needle punching. The spunbonded non-woven fabric 2 and the foamed resin layer 3 covering the outer surface of the spunbonded non-woven fabric 2, the spunbonded non-woven fabric 2 being made of finer fibers than the non-woven felt layer 1 and having a high density. Is characterized by.

The electric carpet according to claim 2 of the present invention comprises a heater unit 7 having a cord-shaped heating wire 6,
An electric carpet sandwiched between a front surface material 4 and a back surface material 5 made of a fiber sheet, wherein the back surface material 5 is the laminated nonwoven fabric according to claim 1, wherein the foamed resin layer 3 is the outermost layer. To do.

The method for producing a laminated non-woven fabric according to claim 3 of the present invention is a non-woven felt layer 1 made of a web of short fibers.
In addition, this non-woven felt layer 1 is made of finer fibers,
Laminated spunbonded nonwoven fabric 2 of high density long fibers,
After being integrated by needle punching, a resin composition containing a resin exhibiting viscoelasticity is applied to the surface of the spunbonded nonwoven fabric 2 to form a foamed resin layer 3 on the surface of the spunbonded nonwoven fabric 2. And

The present invention will be described in detail below. FIG. 1 is a cross-sectional view of an essential part showing an outline of a laminated nonwoven fabric according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view of an essential part of an electric carpet according to an embodiment of the present invention disassembled for each constituent material. It is a figure.

As shown in FIG. 1, the laminated nonwoven fabric of the present invention is
A nonwoven fabric felt layer 1 made of a web, a spunbonded nonwoven fabric 2, and a foamed resin layer 3.

Nonwoven felt layer 1 made of the above web
Is a fiber layer formed by depositing short fibers in a spider web form. Examples of the short fibers include nylon,
Examples thereof include synthetic fibers such as polyester, acrylic, rayon and vinylon, and individual and mixed cotton such as cotton and hemp.

The spunbonded non-woven fabric 2 is formed into a thin sheet by depositing long fibers melt-spun by a melt extruder and heating and pressing the long fibers with an embossing heat roll at a temperature higher than the melting temperature of the long fibers. It was created. As the long fiber. For example, polyester and the like can be mentioned. Further, as the spunbonded nonwoven fabric 2, a colored one such as a dyeing dyed at the time of spinning long fibers can be appropriately used.

The spunbonded nonwoven fabric 2 and the nonwoven fabric felt layer 1 are integrated by needle punching. Since the needle punching is performed, a part of the felt forming the nonwoven fabric felt layer 1 is in a fluffy state from the outer surface of the spunbonded nonwoven fabric 2. Further, the spunbonded nonwoven fabric 2 is made of finer fibers than the nonwoven fabric felt layer 1 and has a high density. Regarding the thickness of the fiber, specifically, the spunbonded nonwoven fabric 2 has a long fiber of 1 to 3 denier, and the nonwoven fabric felt layer 1 has a short fiber of 5 to 2 denier.
About 0 denier is appropriate.

The laminated nonwoven fabric covers the outer surface of the spunbonded nonwoven fabric 2 and has a foamed resin layer 3 formed thereon. The foamed resin layer 3 has a viscosity of SBR (latex of styrene-butadiene copolymer), NBR (latex of acrylonitrile-butadiene copolymer), MBR (latex of methylmethacrylate-butadiene copolymer), or the like. It is formed by foaming and solidifying a resin composition containing a resin exhibiting elasticity. The foamed resin layer 3 is deformed along a microscopic uneven shape of a floor or the like and adheres to it, and absorbs the lateral displacement force, so that the laminated nonwoven fabric is provided with a non-slip function.

Next, a method for manufacturing the laminated nonwoven fabric of the present invention will be described. Nonwoven felt layer 1 made of the above web
In addition, this non-woven felt layer 1 is made of finer fibers,
The high density spunbonded nonwoven fabrics 2 are laminated and integrated by needle punching. After that, a latex-like resin composition containing a resin having viscoelasticity such as SBR, NBR, and MBR is applied to the surface of the spunbonded nonwoven fabric 2 by a floss coating method or the like. The resin composition contains a cross-linking agent and a foaming agent together with the resin, and optionally contains thermal expansion microcapsules, a foaming aid, a filler, a heat stabilizer, an anti-aging agent, and a thickener. The copolymerization ratio of the above resin and the above material may be appropriately selected. Mix the above ingredients,
A latex-like resin composition in a foamed state by stirring is applied. In the present invention, since the spunbonded nonwoven fabric 2 is made of fine fibers and has a high density, it is difficult for the applied resin composition to penetrate inside.

After applying the above resin composition, 150 to
Hot-air drying at about 170 ° C. is performed to remove water and crosslink the resin composition to form the foamed resin layer 3 on the outer surface of the spunbonded nonwoven fabric 2. By the needle punching process, a part of the felt forming the nonwoven fabric felt layer 1 is in a fluffy state from the outer surface of the spunbonded nonwoven fabric 2, so that the foamed resin layer 3 is firmly bonded. Therefore, the foamed resin layer 3 effective for the anti-slip function can be produced with a resin amount of about ⅓ as compared with the case where the foamed resin layer 3 is applied to the outer surface of the conventional felt layer.

The resin composition is not limited to foaming by mechanical stirring, but if the composition contains thermal expansion microcapsules, the amount of resin can be further reduced and the thickness of the foamed resin layer 3 can be made uniform. preferable.

Next, an electric carpet using the laminated nonwoven fabric will be described with reference to FIG. The electric carpet of the present invention has a heater unit 7 having a cord-shaped heating wire 6 sandwiched between a surface material 4 and a back surface material 5, and the above-mentioned laminated nonwoven fabric is used as the back surface material 5. In the laminated nonwoven fabric which is the back material 5, the foamed resin layer 3 is the outermost layer. Since the foamed resin layer 3 is the outermost layer, the electric carpet has a non-slip function, and is stable in shape without wrinkling due to trampling or the like. Surface material 4
Is, for example, a fiber sheet, and may be a nonwoven fabric made of a web needle-punched into a felt. The heater unit 7 is manufactured by laminating a heat-sealing film 8, a metal foil 9 made of aluminum or the like, and a heat-sealing film 8 in this order, and further bonding a cord-shaped heating wire 6 by pattern wiring on the lower surface thereof. It was done.

In the laminated nonwoven fabric, when the layer of the spunbonded nonwoven fabric 2 is impregnated with the resin, the resin functions as a binder, so that the strength of the laminated nonwoven fabric is increased. Therefore, the electric carpet using the above-mentioned laminated nonwoven fabric as the backing material 5 can reduce the deformation due to heat and impart strength to the entire electric carpet. As a result, the product can be easily taken out of the hot press during the bonding by the hot press.

Since the non-woven felt layer 1 of the laminated non-woven fabric can retain its shape even in a loosely entangled state, it is possible to form the flexible backing material 5 and also the cord-shaped heating wire 6 is formed.
Since it is easily embedded, the heater unit 7 is not deformed. Further, since the laminated nonwoven fabric can easily secure a sufficient thickness, it is optimal as the backing material 5 of an electric carpet having good heat insulating properties.

[0021]

In the laminated nonwoven fabric according to claim 1 of the present invention, the spunbonded nonwoven fabric 2 has the above-mentioned nonwoven fabric felt layer 1 because of its constitution.
Since it is made of finer fibers and has a high density, it is possible to reduce the amount of the resin composition applied that penetrates inside,
Since they are integrated by needle punching, part of the felt forming the non-woven felt layer 1 is fluffed from the outer surface of the spunbonded non-woven fabric 2.
The adhesion of the foamed resin layer 3 becomes strong.

In the electric carpet according to claim 2 of the present invention, since the above-mentioned laminated nonwoven fabric is used for the backing material 5, it has the above-mentioned function, and further, the resin impregnated in the layer of the spunbonded nonwoven fabric 2 functions as a binder. Therefore, deformation due to heat can be reduced.

The method for producing a laminated non-woven fabric according to claim 3 of the present invention comprises finer fibers than the non-woven felt layer 1,
Since the high-density spunbonded non-woven fabric 2 is laminated and integrated by needle punching, the amount of the applied resin composition penetrating inside can be reduced and a part of the felt constituting the non-woven felt layer 1 is spun. Bonded nonwoven fabric 2
Since it is in a fluffy state from the outer surface, the adhesion of the foamed resin layer 3 to be formed is strengthened.

[0024]

【Example】

Example 1 A laminated nonwoven fabric was prepared as follows. Nonwoven felt layer 1
5-20 denier nylon, polyester,
Acrylic, rayon, vinylon synthetic fiber and cotton,
470g / formed by mixing cotton with hemp and anti-hair fibers
A web having a unit weight of m ² was used. As spunbond nonwoven fabric 2, 100% by weight of polyester dyed in black 3%
A denier filament having a thickness of 0.12 mm was used, which was heat-pressed with an embossing heat roll at a basis weight of 30 g / m ² . As a resin composition, MBR with a copolymerization ratio of 4: 6
100 parts by weight of resin (hereinafter referred to as "part"), 2 parts of crosslinking agent,
A water emulsion latex having a solid content of 50% by weight containing 5 parts of a foaming agent and 5 parts of thermal expansion microcapsules was used.

The nonwoven fabric felt layer 1 made of the above web and the spunbonded nonwoven fabric 2 were laminated and needle punched from the side of the nonwoven fabric felt layer 1 made of the web to entangle and integrate the web and the spunbonded nonwoven fabric. Next, 200 g / m ^{2 of} the resin composition obtained by stirring the above water emulsion type latex into a foamed state of 3 times with a wet state is applied from the 2 side of the above spunbonded nonwoven fabric and dried with hot air at 170 ° C., The foamed resin layer 3 is formed on the outer surface of the spunbonded nonwoven fabric 2 by removing water and crosslinking the resin composition.
To obtain a laminated nonwoven fabric having a total thickness of 6 mm. The obtained laminated nonwoven fabric has a resin amount after drying of 100 g / m ² , but has a thickness of about 1 mm at which the antiskid function is sufficiently exhibited.
The foamed resin layer 3 of No.

[0026]

[Table 1]

The electric carpet was produced as follows. The heater unit 7 has a thickness of 3 μm between two heat-sealing films 8 made of low-density polyethylene having a thickness of 100 μm.
It was produced by stacking a metal foil 9 made of an aluminum foil having a thickness of 0 μm, and further pattern-wiring a 1-wire type heat-generating wire 6 having a heat-bonding layer as an outer layer on the outer side thereof.

As the surface material 4, 85% by weight of polyester short fibers (of which 4 to 20 denier fibers are dispersed)
0% by weight is dyed cotton) and polypropylene short fiber 1
A 1.8 mm-thick non-woven fabric made of 5% by weight mixed cotton and having a weight of 200 g / m ² are needle-punched into a felt and then heat-treated at 180 ° C. to melt polypropylene fibers and reinforce by a binder effect. Was used.

The laminated nonwoven fabric is used as the backing material 5,
The heater unit 7 was sandwiched between the surface material 4 and the back surface material 5 having the foamed resin layer 3 as the outermost layer and bonded by hot pressing. After pressing, the product could be easily removed from the hot press.

Comparative Example 1 As the backing material, fibers of 5 to 20 denier were dispersed,
A web consisting of 85% by weight of polyester short fibers (of which 40% by weight is dyed cotton) and 15% by weight of polypropylene short fibers and having a weight of 500 g / m ² is needle-punched into felt and heated at 180 ° C. A non-woven fabric having a thickness of 4.5 mm, which was treated to melt polypropylene fibers and reinforced by a binder effect, was used. Surface material, and
The same heater unit as in Example 1 was used. Then, an electric carpet was produced in the same manner as in Example 1.
When bonding with a hot press, the strength of the product was weak and it was difficult to remove the product from the hot press.

The tensile strength and heat shrinkage of the backside materials of the electric carpets of Example 1 and Comparative Example 1 thus obtained were evaluated. The tensile strength was measured at room temperature and 100 ° C. in the state of being stretched by 3%. As for the heat shrinkage, the shrinkage was measured before the treatment and after the treatment at 120 ° C. for 1 hour. As shown in Table 2, the results were better in Examples than in Comparative Examples.

[0032]

[Table 2]

[0033]

The laminated non-woven fabric according to claim 1 of the present invention is
Due to its structure, the spunbonded nonwoven fabric is made of finer fibers and has a higher density than the above-mentioned nonwoven fabric felt layer, so it is possible to form a foamed resin layer with an excellent anti-skid function with a smaller amount of resin than before, and with good strength. is there.

In the electric carpet according to claim 2 of the present invention, since the above-mentioned laminated nonwoven fabric is used as the backing material, it has the above-mentioned effect, and the resin impregnated in the layer of the spunbonded nonwoven fabric functions as a binder. Little deformation due to heat. Further, the product can be easily taken out from the hot press at the time of bonding by the hot press.

According to the method for producing a laminated non-woven fabric according to claim 3 of the present invention, a laminated non-woven fabric having an excellent anti-slip function and good strength can be obtained even if the amount of resin used is small.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of an essential part showing an outline of a laminated nonwoven fabric according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of a main part of an electric carpet according to an embodiment of the present invention disassembled and shown for each constituent material.

FIG. 3 is a cross-sectional view of a main part of a conventional electric carpet disassembled for each constituent material.

[Explanation of symbols]

 1 Nonwoven Felt Layer 2 Spunbond Nonwoven Fabric 3 Foamed Resin Layer 4 Surface Material 5 Back Material 6 Heating Wire 7 Heater Unit

Claims (3)

[Claims] 1. A non-woven felt layer (1) made of a web of short fibers, a long-fiber spunbonded non-woven fabric (2) integrated with the non-woven felt layer (1) by needle punching, and a span thereof. A foamed resin layer (3) covering the outer surface of the bonded nonwoven fabric (2), and the spunbonded nonwoven fabric (2) is composed of finer fibers and has a higher density than the nonwoven fabric felt layer (1). And laminated non-woven fabric. 2. A heater unit (7) having a cord-shaped heating wire (6) is provided with a surface material (4) made of a fiber sheet.
An electric carpet sandwiched between a backing material (5) and a backing material (5), wherein the backing material (5) is the laminated nonwoven fabric according to claim 1, wherein the foamed resin layer (3) is the outermost layer. carpet. 3. A non-woven felt layer (1) made of a short fiber web is laminated with a spunbonded non-woven fabric (2) made of fine fibers and having a high density from the non-woven felt layer (1), After integration by needle punching, a resin composition containing a resin exhibiting viscoelasticity is applied to the surface of the spunbonded nonwoven fabric (2), and the foamed resin layer (3) is applied to the surface of the spunbonded nonwoven fabric (2). A method for producing a laminated non-woven fabric, which comprises: