JPH08260322A - Primary substrate for tufted carpet - Google Patents

Abstract

PURPOSE: To obtain the subject substrate by fixing intersections between filaments with an amorphous poly α-olefin, slightly evolving a harmful gas in combustion, having excellent durability of draw strength of pile yarn, etc. CONSTITUTION: This primary substrate for a tufted carpet is obtained by fixing intersections of a synthetic fiber filament group constituting a primary substrate with an amorphous poly α-olefin. Pile yarns are firmly bonded to a backing layer composed of the amorphous poly α-olefin-based resin to improve pile yarn draw resistance.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a primary base fabric for tufted carpet which produces little harmful gas during combustion and is excellent in durability such as pull-out strength of pile yarn.

[0002]

2. Description of the Related Art At present, as a primary base cloth for tufted carpet, polypropylene tape yarn woven cloth, spun bonded nonwoven cloth, jute base cloth and the like are used.

Among primary fabrics for tufted carpets, non-woven fabrics produced by the spunbond method are increasing in number because of the advantage that the pile yarns are well-ordered and the yarns do not fray. As disclosed in Japanese Patent No. 8189, a thermoplastic synthetic resin is melted by heating, extruded from a spinneret having a large number of pores, sucked and stretched by an ejector that sucks at high speed, and the filament is collected on a moving net. And then the fibers are mechanically entangled with each other by needle punching and further adhered to each other with an adhesive, or a method of producing the same, as disclosed in JP-A-3-104.
Using a core-sheath composite fiber proposed in Japanese Patent No. 973, in which polyethylene terephthalate is used as a core component and a low melting point component covers the entire surface of the fiber, the nonwoven fabric for tufted carpet is thermocompression bonded with an embossing roll. A method for producing the nonwoven fabric for a tufted carpet, which is proposed by Japanese Patent Laid-Open No. 5-93356 and is composed of a high melting point component and a low melting point component, thermocompression-bonded by an embossing roll, and adhesively fixed with a binder. Further, a method for producing a non-woven fabric by adhering a polyethylene terephthalate single-component non-woven fabric with an acrylic ester resin or a vinyl chloride resin binder is used.

A tufted carpet is obtained by tufting pile yarns on these primary base fabrics using a tufting machine to form a so-called pile fabric, and after dyeing the pile yarns through a dyeing process such as continuous dyeing and wince dyeing. , Vinyl chloride resin, ethylene-vinyl acetate copolymer resin, urethane resin, etc. But,
Carpets lined with vinyl chloride-based resins or urethane-based resins have had the problem of producing harmful gases such as hydrogen chloride and hydrogen cyanide due to combustion during a fire or incineration during carpet disposal. As proposed in Kaihei 6-128863, a carpet using an amorphous poly α-olefin resin as a backing layer is manufactured in order to suppress generation of harmful gas during combustion as much as possible.

[0005]

However, even if an acrylic ester resin or an amorphous poly-α-olefin resin is used for the backing layer as described above, the backing layer and the primary backing fabric are not well compatible with each other, There was a problem that satisfactory characteristics such as the pile yarn pull-out strength of the carpet could not be obtained.

The present invention solves the problems of the primary base cloth for tufted carpet, generates less harmful gas during combustion, and is excellent in durability such as pull-out strength of pile yarn. Is intended to be provided.
According to the present invention, it is possible to provide a tufted carpet using an amorphous poly α-olefin resin as a backing agent, which has particularly excellent pile yarn drawing strength and durability.

[0007]

The present invention employs the following means in order to solve the above problems.

That is, the primary base cloth for tufted carpet of the present invention is characterized in that the intersections of the filament groups constituting the nonwoven fabric containing synthetic fiber filaments as the main component are fixed by the amorphous poly α-olefin. It is what

[0009]

The present invention has been made in order to solve the problems such as the generation of toxic gas during combustion of a conventional primary base fabric for tufted carpet and the resistance to pile yarn loss. That is, it has been clarified that such a problem can be solved all at once by adding an amorphous poly α-olefin resin in advance.

Examples of the amorphous poly-α-olefin resin used in the present invention include non-crystalline resins such as ethylene, propylene, butene, hexene, ethylene-propylene, ethylene-butene, ethylene-hexene, propylene-butene and propylene-hexene. At least one of the crystalline polymers can be used.

The synthetic fiber filament referred to in the present invention may be made of any synthetic resin such as polyester and polypropylene, but it produces little harmful gas during combustion and has dimensional stability during dyeing of tufted carpet. A good one is preferable. From this viewpoint, polyester, particularly polyethylene terephthalate, is preferably used.

Further, the non-woven fabric used in the present invention has a strength necessary for the primary base cloth for tufted carpet, such as a tensile strength and a tear strength, for example, it is partially thermocompressed or mechanically bonded. A non-woven fabric in which fibers are entangled with each other is preferable.

For example, in the case of thermocompression bonding with an embossing roll, a nonwoven fabric in which low melting point fibers are mixed with polyester fibers in order to obtain strength, or a core-sheath composite fiber in which the surface of polyester fibers is covered with a low melting point component. The non-woven fabric manufactured by using can be used. In addition, for example, when the fibers are mechanically entangled with each other by needle punching or water jet punching, the needle density is 50 to 150 in order to obtain strength.
It is preferable that punching is performed about times / cm ² .

Amorphous poly α-olefin resin is applied to the non-woven fabric containing the synthetic fiber filament as a main component, and the intersection point of the single filament or the filament group constituting the non-woven fabric is defined by the non-crystalline poly α-olefin system. When fixed with a resin, the pile yarn is tufted thereafter, and when the back surface thereof is lined with an amorphous poly α-olefin resin, the non-woven fabric and the backing material have a good familiarity and are more firmly fixed. As a result of sandwiching the pile yarn inside the base cloth, excellent pull-out strength and durability of the pile yarn are exhibited. That is, the pile fabric is generally preheated at 80 to 130 ° C. before being lined, but at this time, the amorphous poly α-olefin resin provided in the nonwoven fabric is softened to form a backing material. As a result of the compatibility, it has been clarified that stronger adhesion is achieved.

The method for applying the amorphous poly α-olefin resin to the non-woven fabric is not limited, and for example, the amorphous poly α-olefin resin which has been heated and melted in advance is applied by coating with a doctor knife or a roll coater. Method, spray coating method using an applicator or band gun, laminating film-like amorphous poly α-olefin resin, or sprinkling powdered poly α-olefin resin on a non-woven fabric and then melting and fixing by heat A method etc. can be adopted. However, in the case of coating or film laminating, if the thickness of the amorphous poly-α-olefin resin film is large, the tuft needle causes fiber breakage of the non-woven fabric during tufting, and the strength of the pile fabric is significantly reduced. Since the force of gripping the pile yarn of the subsequent base cloth is lowered, the pile may easily come off during processing, and noise generated during tufting may increase. The film thickness of the olefin resin is preferably about 5 to 25 μm. More preferably, it is preferable to adopt a method of spray coating or a method of spraying a powdery amorphous poly α-olefin onto a non-woven fabric, and then a method of melting and fixing by heat. The non-woven fabric can be fixed at the intersections of individual filaments or filament groups, and voids can be achieved in the non-woven fabric.

The amount of the amorphous poly-α-olefin resin applied is 5 wt% with respect to the total fiber components constituting the nonwoven fabric.
If less than 30% by weight, sufficient adhesion to the polyolefin resin of the backing material cannot be obtained, and the pull-out strength of the pile yarn and abrasion resistance cannot be satisfied.
The strength of the base cloth is increased because the adhesion of the individual filaments or the intersections of the filaments that make up the non-woven fabric is strong, but the texture is also hard and the tuft needle causes fiber breakage during tufting, resulting in pile fabric. Strength is significantly reduced, and the force to grip the pile threads of the base fabric after tufting is also reduced, resulting in pile loss during processing.
This part could not be recovered. *** Examples The present invention will be described in more detail based on the following examples.

The tensile strength of the pile fabric is obtained by using a tufting machine on the primary base cloth to make a pile yarn 2600 denier 1
After tufting in a loop with 60 filaments, 1/10 gauge, 10 stitches / inch, and pile height of 3.0 mm, based on L1096 (general woven fabric test method), a constant speed extension type tensile tester, width 5 cm Then, a sample having a length of 20 cm was grasped, and the interval was 10 cm, and the tensile speed was 20 ± 1 cm / min. The pulling strength of the pile yarn after lining is JIS L102.
Based on 3 (Test method for performance of fiber floor coverings),
It was measured with a loop pile.

Examples 1 to 285 Polyethylene terephthalate having a melting point of 262 ° C. is 285
After melting at 0 ° C., it was extruded from a die having a large number of holes, and was ejected and collected on a moving net conveyor with a high-speed suction by an ejector so that the single yarn fineness was 10 denier, to form a web. At this time, the basis weight is 90 g / m ² and 23
A base cloth partially thermocompressed with an embossing roll heated to 5 ° C. was obtained. Subsequently, an amorphous poly α-olefin (manufactured by Ube Lexen Co., Ltd., trade name: Uvetak UT2715) melted at 180 ° C. was sprayed onto the base cloth, and the ratio of application was 5w based on the total fiber components of the non-woven fabric.
After adjusting to be t%, 15 wt%, and 25 wt%, a silicone oil agent containing polydimethylsiloxane as a main component was applied by spraying to obtain a primary base cloth for tufted carpet.

Then, a pile thread 2600 denier 160 filament 1
/ 10 gauge, 10 stitches / inch, pile height 3.0mm, loop tufts, dyed with rope dyeing machine,
Got pile pile.

A tufted carpet was obtained by lining the pile fabric with an amorphous poly α-olefin resin (APAO) having the following composition so as to have a coating thickness of 2.0 mm.

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

(Distribution) APAO (UT2215 manufactured by Ube Lexen) 23 parts Homopropylene 2 parts Tackifier (ECR217 manufactured by Tonex Co.) 5 parts Calcium carbonate 70 parts Examples 4 to 6 Polyethylene terephthalate having a melting point of 262 ° C. A web was prepared by extruding from a spinneret having a large number of holes, sucking at high speed by an ejector so that the single yarn fineness was 10 denier, and spraying and collecting on a moving net conveyor. At this time, the basis weight is 90 g / m ² , the needle density of the needling is 80 times / cm ² by the needle punch machine, and the needle depth is 7 mm.
Needle punching was performed under the conditions described above to obtain a base fabric. Continued, 18
Amorphous poly α-olefin (manufactured by Ube Lexen Co., Ltd., trade name; Uvetak UT2715) melted at 0 ° C. was sprayed onto a base fabric with a ratio of 5 wt% to the total fiber components of the nonwoven fabric, After adjusting to 15 wt% and 25 wt%, a silicone oil agent containing polydimethylsiloxane as a main component was sprayed to obtain a primary tufted carpet base fabric. This primary base cloth was tufted, dyed and lined with an amorphous poly α-olefin in the same manner as in Example 1 to obtain a tufted carpet.

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

Comparative Example 1 A tufted carpet was prepared in the same manner as in Example 1, except that the nonwoven fabric containing polyethylene terephthalate as the main component of Example 1 was used and no amorphous poly α-olefin was added to the nonwoven fabric. Got

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

Comparative Example 2 The same as Example 1 except that the non-woven fabric containing polyethylene terephthalate as the main component of Example 1 was used and the amorphous poly-α-olefin was added to the non-woven fabric in an amount of 35 wt% with respect to the total fiber components of the non-woven fabric. The same processing was performed to obtain a tufted carpet.

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

Comparative Example 3 The same processing as in Example 4 was carried out except that the nonwoven fabric containing polyethylene terephthalate as the main component of Example 4 was used and no amorphous poly α-olefin was added to the nonwoven fabric.
I got a tufted carpet.

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

Comparative Example 4 The same as Example 4 except that the non-woven fabric containing polyethylene terephthalate as the main component of Example 1 was used and the amorphous poly-α-olefin was added to the non-woven fabric in an amount of 35 wt% with respect to all the fiber components of the non-woven fabric. The same processing was performed to obtain a tufted carpet.

The tensile strength of the pile fabric thus obtained and the pull-out strength of the pile yarn of the tufted carpet are shown in Table 1.

[0032]

[Table 1] As is clear from Table 1, in each of the primary base fabrics for tufted carpets of the present invention, the pile fabric after tufting has high strength, and the pile yarn drawing after lining with the amorphous poly α-olefin resin is carried out. It had high strength and excellent durability. On the other hand, when the amorphous poly α-olefin resin was not applied to the nonwoven fabric, the pile fabric strength after tufting was good, but the pile yarn pull-out strength after the amorphous poly α-olefin resin backing There was a problem with low durability.

When 30 wt% or more of the amorphous poly α-olefin resin is applied to the nonwoven fabric, the pile yarn pulling strength after lining the amorphous poly α-olefin resin is good, but the nonwoven fabric is Since the adhesion between the constituent filaments becomes strong and the texture becomes hard, fiber breakage occurs during tufting and there is a problem in the strength of the pile fabric.

[0034]

As described above, since the primary base fabric for tufted carpet of the present invention is a non-woven fabric in which polyester fibers are bonded and fixed with a crystalline poly α-olefin resin, generation of toxic gas during combustion is small. , A tufted carpet that is firmly adhered to a backing made of an amorphous poly α-olefin resin and is excellent in durability such as pile yarn pull-out strength.

Claims (5)

[Claims] 1. An amorphous poly-α is formed at the intersection of the filaments constituting the non-woven fabric containing synthetic fiber filaments as a main component.
Primary tufted carpet base fabric characterized by being fixed by olefins. 2. The primary base fabric for tufted carpet according to claim 1, wherein the filament is polyester. 3. The primary base fabric for tufted carpet according to claim 1, wherein the nonwoven fabric is partially thermocompression bonded. 4. The primary base fabric for tufted carpet according to claim 1, wherein the non-woven fabric is mechanically entangled. 5. The primary for tufted carpet according to claim 1, wherein the amorphous poly α-olefin is added in an amount of 5 to 30 wt% with respect to the total fiber components constituting the nonwoven fabric. Base cloth.