JPH08142245A - Laminated non-woven fabric, electric carpet using the same and manufacture of the same fabric - Google Patents
Laminated non-woven fabric, electric carpet using the same and manufacture of the same fabricInfo
- Publication number
- JPH08142245A JPH08142245A JP28466994A JP28466994A JPH08142245A JP H08142245 A JPH08142245 A JP H08142245A JP 28466994 A JP28466994 A JP 28466994A JP 28466994 A JP28466994 A JP 28466994A JP H08142245 A JPH08142245 A JP H08142245A
- Authority
- JP
- Japan
- Prior art keywords
- nonwoven fabric
- layer
- fabric
- laminated
- woven fabric
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Carpets (AREA)
- Surface Heating Bodies (AREA)
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
【0001】[0001]
【産業上の利用分野】本発明は電気カーペットの裏面材
として有用な積層不織布、その積層不織布を用いた電気
カーペット、及びその積層不織布の製造方法に関するも
のである。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】[0002]
【従来の技術】従来の電気カーペットの構成を図3に示
す。短繊維がくもの巣状に絡まった繊維層で形成された
ウエブからなる不織布11をニードルパンチ加工してフ
ェルトにしたものを表面材4、及び、裏面材5とする。
そして、熱融着フィルム8、アルミニウム等の金属箔
9、熱融着フィルム8をこの順に積層すると共に、さら
にその下面に発熱線6をパターン配線して接着したヒー
タユニット7を、上記表面材4、及び、裏面材5の間に
挟持することにより電気カーペットが構成されている。
上記電気カーペットを構成する表面材4、ヒータユニッ
ト7、及び、裏面材5をホットプレスにより接着する際
に、ホットプレスの温度で全体の強度が低下し、ホット
プレスから製品が取り出し難くいと共に、熱による変形
により発熱線6の故障を生じやすい。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.
【0003】一方、ニードルパンチ加工したフェルトに
すべり止め機能を付与する構成として、フェルトに発泡
樹脂層を設けることが知られている(実公平4−988
5号公報)。この発泡樹脂層は、SBR(スチレン−ブ
タジエン系共重合体のラテックス)、NBR(アクリロ
ニトリル−ブタジエン系共重合体のラテックス)、MB
R(メチルメタアクリレート−ブタジエン系共重合体の
ラテックス)等の粘弾性を有するゴム系ラテックス樹脂
をフェルトの外面に塗布し、乾燥させて形成する。しか
し、すべり止めとして有効に機能するためには、ラテッ
クス樹脂がフェルトに浸透し易いので、300〜500
g/m2 程度の多量のラテックス樹脂を塗布する必要が
あり、また、発泡樹脂層は強度が弱いという問題があ
る。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】[0004]
【発明が解決しようとする課題】本発明は上記事実に鑑
みてなされたもので、その目的とするところは、樹脂の
使用量が少なくてもすべり止め機能が優れ、且つ、強度
の向上した積層不織布、電気カーペット、及び、積層不
織布の製造方法を提供することにある。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.
【0005】さらに、他の目的とするところは、熱によ
る変形の少ない電気カーペットを提供することにある。Another object of the present invention is to provide an electric carpet which is less likely to be deformed by heat.
【0006】[0006]
【課題を解決するための手段】本発明の請求項1に係る
積層不織布は、短繊維のウエブよりなる不織布フェルト
層1と、この不織布フェルト層1とニードルパンチ加工
で一体化した、長繊維のスパンボンド不織布2と、及
び、このスパンボンド不織布2の外面を覆う発泡樹脂層
3とからなり、且つ、上記スパンボンド不織布2が上記
不織布フェルト層1より、細い繊維からなり、高密度で
あることを特徴とする。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.
【0007】本発明の請求項2に係る電気カーペット
は、コード状の発熱線6を備えるヒータユニット7を、
繊維のシートからなる表面材4と裏面材5の間に挟持す
る電気カーペットであって、上記裏面材5が発泡樹脂層
3を最外層とした請求項1記載の積層不織布であること
を特徴とする。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.
【0008】本発明の請求項3に係る積層不織布の製造
方法は、短繊維のウエブよりなる不織布フェルト層1
に、この不織布フェルト層1より、細い繊維からなり、
高密度である長繊維のスパンボンド不織布2を積層し、
ニードルパンチ加工で一体化した後に、上記スパンボン
ド不織布2の表面に粘弾性を示す樹脂を含有する樹脂組
成物を塗布し、上記スパンボンド不織布2の表面に発泡
樹脂層3を形成することを特徴とする。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
【0009】以下、本発明を詳細に説明する。図1は本
発明の一実施例に係る積層不織布の概略を示す要部断面
図であり、図2は本発明の一実施例に係る電気カーペッ
トを構成材毎に分解して示した要部断面図である。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.
【0010】図1に示す如く、本発明の積層不織布は、
ウエブよりなる不織布フェルト層1と、スパンボンド不
織布2と、及び、発泡樹脂層3とからなる。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.
【0011】上記ウエブよりなる不織布フェルト層1
は、短繊維をくもの巣状に堆積した繊維層で形成される
ものである。上記短繊維としては、例えば、ナイロン、
ポリエステル、アクリル、レーヨン、ビニロン等の合成
繊維、綿、麻等の単独や混綿が挙げられる。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.
【0012】上記スパンボンド不織布2は、溶融押出機
で溶融紡糸等をした長繊維を堆積させ、これをエンボス
ヒートロールによって長繊維の溶融温度以上の温度で加
熱圧接することにより、薄いシート状に作製されたもの
である。上記長繊維としては。例えば、ポリエステル等
が挙げられる。また、スパンボンド不織布2は、長繊維
を紡糸する際に染色した原着染めのもの等、着色したも
のを適宜使用することができる。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.
【0013】上記スパンボンド不織布2と不織布フェル
ト層1はニードルパンチ加工で一体化されている。上記
ニードルパンチ加工がなされているので、不織布フェル
ト層1を構成するフェルトの一部はスパンボンド不織布
2の外面から毛羽立った状態となっている。さらに、上
記スパンボンド不織布2は、上記不織布フェルト層1よ
り細い繊維からなり、高密度である。繊維の太さとして
は、具体的には、上記スパンボンド不織布2の長繊維は
1〜3デニール、不織布フェルト層1の短繊維は5〜2
0デニール程度が適当である。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.
【0014】上記積層不織布は上記スパンボンド不織布
2の外面を覆い発泡樹脂層3が形成されている。上記発
泡樹脂層3は、SBR(スチレン−ブタジエン系共重合
体のラテックス)、NBR(アクリロニトリル−ブタジ
エン系共重合体のラテックス)、MBR(メチルメタア
クリレート−ブタジエン系共重合体のラテックス)等の
粘弾性を示す樹脂を含有する樹脂組成物が発泡し、固化
して形成されたものである。上記発泡樹脂層3は床等の
ミクロな凹凸形状に沿って変形し、密着すると共に、横
ずれの力に対し、この力を吸収するので、積層不織布に
すべり止めの機能が付与される。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.
【0015】次に、本発明の積層不織布の製造方法につ
いて説明する。上記ウエブよりなる不織布フェルト層1
に、この不織布フェルト層1より、細い繊維からなり、
高密度であるスパンボンド不織布2を積層し、ニードル
パンチ加工で一体化する。その後、上記スパンボンド不
織布2の表面に、SBR、NBR、MBR等の粘弾性を
示す樹脂を含有するラテックス状の樹脂組成物を、フロ
スコート法等により塗布する。上記樹脂組成物は、上記
樹脂と共に、架橋剤、起泡剤を含み、必要に応じ、熱膨
張マイクロカプセル、発泡助剤、充填剤、熱安定剤、防
老剤、増粘剤を含有する。上記樹脂の共重合比率、及
び、上記材料は適宜選定すればよい。上記材料を混ぜ、
攪拌して発泡状態になったラテックス状の樹脂組成物を
塗布する。本発明においては、スパンボンド不織布2が
細い繊維からなり、高密度であるので、塗布した樹脂組
成物が内部に浸透しにくくしている。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.
【0016】上記樹脂組成物を塗布した後に、150〜
170℃程度の熱風乾燥を行い、水分の除去、及び、樹
脂組成物の架橋反応を行わせ、スパンボンド不織布2の
外面に発泡樹脂層3を形成する。上記ニードルパンチ加
工により、不織布フェルト層1を構成するフェルトの一
部はスパンボンド不織布2の外面から毛羽立った状態と
なっているので、発泡樹脂層3の接着が強固となる。従
って、すべり止め機能に有効な発泡樹脂層3を、従来の
フェルト層の外面に塗布した場合に比べ、1/3程度の
樹脂量で作製することができる。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.
【0017】なお、上記樹脂組成物は、機械的攪拌によ
る発泡のみでなく、組成物に熱膨張マイクロカプセルを
含有すると、より樹脂量を少なくできると共に、発泡樹
脂層3の厚みを均一にするので好ましい。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.
【0018】次に、上記積層不織布を用いた電気カーペ
ットを図2に基づいて説明する。本発明の電気カーペッ
トは、表面材4と裏面材5の間にコード状の発熱線6を
備えるヒータユニット7を挟持したものであり、この裏
面材5として上述の積層不織布が用いられている。上記
裏面材5である積層不織布は、発泡樹脂層3を最外層と
する。発泡樹脂層3を最外層としているので、電気カー
ペットはすべり止め機能を有し、踏みつけ等でシワにな
ったりすることがなく、形状が安定する。上記表面材4
は、例えば、繊維のシートからなるものであり、ウエブ
からなる不織布をニードルパンチ加工してフェルトにし
たもの等が挙げられる。上記ヒータユニット7は、熱融
着フィルム8、アルミニウム等の金属箔9、熱融着フィ
ルム8をこの順に積層すると共に、さらにその下面にコ
ード状の発熱線6をパターン配線して接着し、作製され
たものである。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.
【0019】上記積層不織布においては、スパンボンド
不織布2の層に樹脂が含浸すると、樹脂がバインダーと
して機能するために積層不織布の強度が増加する。従っ
て、上記積層不織布を裏面材5として用いた電気カーペ
ットは、熱による変形を少なくできると共に、電気カー
ペットの全体に強度が付与される。その結果、ホットプ
レスによる接着の際にホットプレスから製品が取り出し
易い。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.
【0020】上記積層不織布の不織布フェルト層1は緩
く絡んだ状態でも形状を保持できるため、柔軟な裏面材
5を形成することができると共に、コード状の発熱線6
が容易に埋設されるためヒータユニット7が変形するこ
とがない。さらに、上記積層不織布は厚みを十分に確保
し易いので、断熱性の良い電気カーペットの裏面材5と
して最適である。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】[0021]
【作用】本発明の請求項1に係る積層不織布は、その構
成からスパンボンド不織布2が上記不織布フェルト層1
より、細い繊維からなり、高密度であるので、塗布した
樹脂組成物が内部に浸透する量を少なくできると共に、
ニードルパンチ加工により一体化しているので、不織布
フェルト層1を構成するフェルトの一部はスパンボンド
不織布2の外面から毛羽立った状態となっているため、
発泡樹脂層3の接着が強固となる。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.
【0022】本発明の請求項2に係る電気カーペット
は、裏面材5に上記積層不織布を用いるので、上述の作
用を有すると共に、さらに、スパンボンド不織布2の層
に含浸した樹脂がバインダーとして機能するので、熱に
よる変形を少なくできる。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.
【0023】本発明の請求項3に係る積層不織布の製造
方法は、不織布フェルト層1より、細い繊維からなり、
高密度であるスパンボンド不織布2を積層し、ニードル
パンチ加工で一体化するので、塗布した樹脂組成物が内
部に浸透する量を少なくできると共に、不織布フェルト
層1を構成するフェルトの一部はスパンボンド不織布2
の外面から毛羽立った状態となっているため、形成する
発泡樹脂層3の接着を強固にする。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】[0024]
実施例1 積層不織布を次のように作製した。不織布フェルト層1
として、5〜20デニールのナイロン、ポリエステル、
アクリル、レーヨン、ビニロンの合成繊維、及び、綿、
麻からなる反毛や雑毛繊維の混綿で形成した470g/
m2 目付のウエブを用いた。スパンボンド不織布2とし
て、黒色に原着染めしたポリエステル100重量%の3
デニールの長繊維を30g/m2 目付でエンボスヒート
ロールにて熱圧接加工した厚み0.12mmのものを用
いた。樹脂組成物として、共重合比率が4:6のMBR
樹脂を100重量部(以下部と記す)、架橋剤を2部、
起泡剤を5部、熱膨張マイクロカプセルを5部の比率で
含有する固形分50重量%の水エマルジョン型ラテック
スを用いた。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.
【0025】上記ウエブからなる不織布フェルト層1と
スパンボンド不織布2を積層し、ウエブからなる不織布
フェルト層1側よりニードルパンチ加工を施してウエブ
とスパンボンド不織布を絡ませ、一体化した。次に、上
記水エマルジョン型ラテックスを攪拌して3倍の発泡状
態にした樹脂組成物を、上記スパンボンド不織布2面側
より、ウエットで200g/m2 塗布し、170℃の熱
風乾燥を行い、水分の除去、及び、樹脂組成物の架橋反
応を行い、スパンボンド不織布2の外面に発泡樹脂層3
を形成し、全体の厚みが6mmの積層不織布を得た。得
た積層不織布は、乾燥後の樹脂量が100g/m2 であ
るが、すべり止め機能が十分発揮された厚みが約1mm
の発泡樹脂層3を有していた。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】[0026]
【表1】 [Table 1]
【0027】電気カーペットは次のように作製した。ヒ
ータユニット7は、厚み100μmの低密度ポリエチレ
ンよりなる2枚の熱融着フィルム8、8の間に、厚み3
0μmのアルミニウム箔よりなる金属箔9を重ね、さら
にその外側に外層に熱接着層を有する1線式形状の感熱
の発熱線6をパターン配線することによって作製した。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.
【0028】表面材4としては、5〜20デニールの繊
維が分散した、ポリエステル短繊維85重量%(うち4
0重量%は染色した染め綿)とポリプロピレン短繊維1
5重量%の混綿よりなる200g/m2 目付のウエブを
ニードルパンチ加工してフェルトにした後、180℃で
加熱処理してポリプロピレン繊維を溶融させてバインダ
ー効果で補強した、厚み1.8mmの不織布を用いた。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.
【0029】そして、上記積層不織布を裏面材5とし、
上記表面材4と発泡樹脂層3を最外層とした裏面材5の
間にヒータユニット7を挟持し、ホットプレスにより接
着した。プレス後、ホットプレスから容易に製品が取り
出せた。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.
【0030】比較例1 裏面材としては、5〜20デニールの繊維が分散した、
ポリエステル短繊維85重量%(うち40重量%は染色
した染め綿)とポリプロピレン短繊維15重量%の混綿
よりなる500g/m2 目付のウエブをニードルパンチ
加工してフェルトにした後、180℃で加熱処理してポ
リプロピレン繊維を溶融させてバインダー効果で補強し
た、厚み4.5mmの不織布を用いた。表面材、及び、
ヒータユニットは実施例1と同様のものを用いた。その
後、実施例1と同様にして電気カーペットを作製した。
ホットプレスによる接着の際に、製品の強度が弱くホッ
トプレスから製品が取り出し難かった。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.
【0031】得られた実施例1、及び、比較例1の電気
カーペットの裏面材の抗張力と熱収縮率を評価した。上
記抗張力は常温と100℃における、3%伸びた状態の
値を測定した。上記熱収縮率は処理前と120℃1時間
処理後における収縮率を測定した。結果は表2に示すと
おり、実施例が比較例に比べ良好であった。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】[0032]
【表2】 [Table 2]
【0033】[0033]
【発明の効果】本発明の請求項1に係る積層不織布は、
その構成からスパンボンド不織布が上記不織布フェルト
層より、細い繊維からなり、高密度であるので、従来に
比べ少量の樹脂量ですべり止め機能が優れた発泡樹脂層
を形成できると共に、強度が良好である。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.
【0034】本発明の請求項2に係る電気カーペット
は、裏面材に上記積層不織布を用いるので、上述の効果
を有すると共に、さらに、スパンボンド不織布の層に含
浸した樹脂がバインダーとして機能するので、熱による
変形が少ない。また、ホットプレスによる接着の際にホ
ットプレスから製品が取り出し易い。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.
【0035】本発明の請求項3に係る積層不織布の製造
方法によると、樹脂の使用量が少なくてもすべり止め機
能が優れ、且つ、強度の良好な積層不織布が得られる。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.
【図1】本発明の一実施例に係る積層不織布の概略を示
す要部断面図である。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.
【図2】本発明の一実施例に係る電気カーペットを構成
材毎に分解して示した要部断面図である。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.
【図3】従来の電気カーペットを構成材毎に分解して示
した要部断面図である。FIG. 3 is a cross-sectional view of a main part of a conventional electric carpet disassembled for each constituent material.
1 不織布フェルト層 2 スパンボンド不織布 3 発泡樹脂層 4 表面材 5 裏面材 6 発熱線 7 ヒータユニット 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)
層(1)と、この不織布フェルト層(1)とニードルパ
ンチ加工で一体化した、長繊維のスパンボンド不織布
(2)と、及び、このスパンボンド不織布(2)の外面
を覆う発泡樹脂層(3)とからなり、且つ、上記スパン
ボンド不織布(2)が上記不織布フェルト層(1)よ
り、細い繊維からなり、高密度であることを特徴とする
積層不織布。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.
ユニット(7)を、繊維のシートからなる表面材(4)
と裏面材(5)の間に挟持する電気カーペットであっ
て、上記裏面材(5)が発泡樹脂層(3)を最外層とし
た請求項1記載の積層不織布であることを特徴とする電
気カーペット。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.
層(1)に、この不織布フェルト層(1)より、細い繊
維からなり、高密度である長繊維のスパンボンド不織布
(2)を積層し、ニードルパンチ加工で一体化した後
に、上記スパンボンド不織布(2)の表面に粘弾性を示
す樹脂を含有する樹脂組成物を塗布し、上記スパンボン
ド不織布(2)の表面に発泡樹脂層(3)を形成するこ
とを特徴とする積層不織布の製造方法。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:
Priority Applications (1)
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JP28466994A JP3446349B2 (en) | 1994-11-18 | 1994-11-18 | Laminated nonwoven fabric, electric carpet using the laminated nonwoven fabric, and method for producing the laminated nonwoven fabric |
Applications Claiming Priority (1)
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---|---|---|---|
JP28466994A JP3446349B2 (en) | 1994-11-18 | 1994-11-18 | Laminated nonwoven fabric, electric carpet using the laminated nonwoven fabric, and method for producing the laminated nonwoven fabric |
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Family
ID=17681454
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JP28466994A Expired - Fee Related JP3446349B2 (en) | 1994-11-18 | 1994-11-18 | Laminated nonwoven fabric, electric carpet using the laminated nonwoven fabric, and method for producing the laminated nonwoven fabric |
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JP2001057935A (en) * | 1999-08-20 | 2001-03-06 | Sanyo Electric Co Ltd | Surface layer material of carpet |
JP2002339217A (en) * | 2001-05-09 | 2002-11-27 | Kanebo Ltd | Heat insulating material |
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JP2005290626A (en) * | 2004-04-01 | 2005-10-20 | Sanyo Electric Co Ltd | Method for producing electric blanket and electric blanket produced by the method |
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