JPH0892877A - Textile product excellent in recyclability - Google Patents

Abstract

PURPOSE: To obtain the subject readily recyclable textile product, having a high fixing power of fibers, excellent in abrasion resistance, dimensional stability, etc., by integrating a polyester fiber assembly with a specific resin binder. CONSTITUTION: This polyester-based textile product is obtained by impregnating and/or coating a fiber assembly (a nonwoven fabric) consisting essentially of polyester fibers with a binder containing (A) a polyester resin as a principal component and (B) one kind of resin selected from acrylic resins, styrenic resins and vinyl acetate-based resins, etc. Since the resultant product is excellent in practical performances such as heat formability and shape retaining properties and good in touch feeling, it is suitably used for moquettes, etc.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyester fiber product excellent in practical performance and recyclability.

[0002]

2. Description of the Related Art Conventionally, the comfort,
Textile products play an important role in imparting and improving beauty and protection, and in recent years, various products have been used in large quantities. Such textile products include weaving, knitting, and other processing methods that have been used since ancient times, as well as tufting, needle punching, and hot melt molding (spun bonding).
It is processed into a fiber aggregate having a required shape by various methods such as the above, and is put to practical use. Of these textile products, the woven fabric is
Although it has a certain degree of strength in itself and can generally hold a shape suitable for the purpose of use, other processed products do not give practical performance by integrating a binder (binder) or a backing material with the fiber aggregate. Need to improve. Conventionally, as such a binder or backing material,
Generally, SBR (styrene / butadiene rubber) latex, EVA (ethylene / vinyl alcohol copolymer),
Compounds in which fillers, flame retardants, thickeners, colorants, etc. are added to resin emulsions such as polyacrylic acid ester and polyvinyl acetate as needed are used.These binders and backing materials are impregnated. It is applied to the fiber assembly by coating, etc. As the fibers used in the fiber assembly, various natural fibers and processed products thereof, as well as synthetic fibers such as polyamide, polyacrylonitrile, PP (polypropylene), PET (polyethylene terephthalate) are used. Today, PET, which is easy to impart flame retardancy, is becoming the mainstream. By the way, from the viewpoint of environmental protection in recent years, the treatment of used products and by-products generated during product production has become an important issue, and these treatments are disposed of by landfill, incineration, etc. Proper disposal is becoming increasingly difficult due to problems such as securing land and generating harmful gas. on the other hand,
As a treatment method that does not have an adverse effect on the environment and also from the viewpoint of effective use of resources, recycling of used products and scraps has been attempted. In the case of textile products mainly composed of thermoplastic resins such as PET, use It is considered that the most preferable method is to heat and melt the finished product or mill ends, pelletize (repelletize) again, spin and use as a raw fabric. However, in the case of fiber products that use binders or backing materials, if the materials of the binder and backing material are different from those of the fibers, it is possible to properly separate each material so that it can be processed smoothly and to ensure the quality of recycled products. It is necessary to solve the problem of. That is, if pelletization is performed with incomplete material separation, various problems may occur due to differences in materials. For example, if the melting temperatures of the materials are different, spinning may become impossible, and re-pelletization may be difficult. When trying to melt a material, it causes thermal decomposition of the material having a low melting temperature, and the generation of harmful gas is also a problem, and it is the actual situation that it is not always easy to recycle a fiber product using a binder or a backing material. As a method for solving such a problem, it has been proposed to use a fiber aggregate and a binder or a backing material of the same quality. For example, JP-A-6-40278 discloses a PET fiber aggregate and a PET fiber aggregate. A method of back coating an emulsion of resin is disclosed. However, in the method of the publication, the adhesive force of the PET resin, which is the backing material, with the PET fiber is low,
It is not always satisfactory in terms of practical performance of textile products.

[0003]

DISCLOSURE OF THE INVENTION According to the present invention, by using a specific binder, the fixing force of the fiber is high, and it is excellent in practical performance such as abrasion resistance, dimensional stability, thermoformability, and mold holding property. The purpose of the present invention is to provide a polyester fiber product that is easy to recycle.

[0004]

The present invention provides a fiber assembly mainly composed of polyester fibers, which is mainly composed of (a) polyester resin and (b) acrylic resin, styrene resin and vinyl acetate resin. A gist is a fiber product obtained by integrally integrating a binder containing at least one resin selected from the group.

The present invention will be described in detail below, which will clarify the purpose, constitution and effect of the present invention. The fiber assembly constituting the fiber product of the present invention is a polyester obtained by polycondensation of dicarboxylic acid and glycol or polycondensation of oxycarboxylic acid (hereinafter,
It is called "Polyester A". ) Is mainly composed of fibers. Typical polyester A includes a resin obtained by polycondensation of terephthalic acid or its ester or acid chloride with a polyhydric alcohol,
Industrially, transesterification polycondensates of dimethyl terephthalate and / or dimethyl isophthalate and ethylene glycol and / or cyclohexanedimethanol are mentioned. Further, in the present invention, other fibers may be mixed and used with the polyester A fibers as long as the desired effect is not impaired. Examples of such other fibers include fibers made of thermoplastic synthetic resins such as polypropylene, polyethylene, polyamide, and polycarbonate. In this case, the mixing ratio of other fibers is usually 2 with respect to the total of polyester A fibers and other fibers.
It is 5% by weight or less, preferably 10% by weight or less. The fiber assembly according to the present invention includes fibers mainly composed of polyester A, for example, knitting, moquette weaving, needle punching, tufting, hot melt molding (spun bonding).
It is used after being processed into a predetermined shape. For example, after molding a fiber composed mainly of polyester A into a web,
A non-woven fabric can be obtained by needle-punching with a keyed needle and intertwining, or by tufting a pile of fibers mainly composed of polyester A onto a primary base fabric of fibers mainly composed of polyester A,
A tufted carpet material can be obtained. If desired, a woven fabric may be used as the fiber assembly. The fiber mainly composed of polyester A in the fiber assembly is usually 3 to 100 denier, preferably 5 to 50 denier. The basis weight of the fiber assembly is usually 10
It is 0 to 1000 g / m ² .

Next, the binder used in the textile product of the present invention comprises (a) a polyester resin as a main component, and (b) at least one selected from the group consisting of an acrylic resin, a styrene resin and a vinyl acetate resin. It contains one kind of resin. The polyester resin (a) is a condensation resin obtained by an esterification reaction of a polycarboxylic acid and a polyhydric alcohol, and examples thereof include an unsaturated polyester resin, an alkyd resin, and a maleic acid resin.
Examples of the polyvalent carboxylic acid (a) used in the polyester resin include aromatic dicarboxylic acids such as orthophthalic acid, isophthalic acid, terephthalic acid, monochlorophthalic acid and polychlorophthalic acid; dimethylenetetrahydrophthalic acid and hexahydroterephthalate. Aliphatic dicarboxylic acids such as acids, maleic acid, fumaric acid, itaconic acid, citraconic acid, succinic acid, adipic acid, suberic acid, sebacic acid; acid anhydrides of these dicarboxylic acids, and the like,
In particular, orthophthalic acid, isophthalic acid, terephthalic acid, maleic acid, fumaric acid, acid anhydrides thereof and the like are preferable.
The polycarboxylic acids may be used alone or in admixture of two or more. Examples of the polyhydric alcohol used in (a) the polyester resin include ethylene glycol, propylene glycol, diethylene glycol, triethylene glycol, polyethylene glycol, 1,3-butylene glycol, 1,4-butylene glycol, and trimethylolpropane. And the like, and particularly ethylene glycol, diethylene glycol, polyethylene glycol and the like are preferable. The polyhydric alcohols may be used alone or in admixture of two or more. Furthermore, in the present invention, if necessary,
(A) A part of the functional groups in the polyvalent carboxylic acid and / or the polyhydric alcohol used in the polyester resin may be modified with a compound reactive with these groups. Examples of such modified polyesters include urethane modified polyester resins obtained by reacting a polyether urethane, which is a reaction product of an isocyanate compound and a polyhydric alcohol, with a polybasic acid; a polycarboxylated polyether and a polyhydric alcohol. Polyester resin obtained by reaction with polyester polyol; Polyester resin obtained by reaction of polyester polyol with aromatic polyvalent carboxylic acid and / or aliphatic polyvalent carboxylic acid; Rosin and aromatic polyvalent carboxylic anhydride and / or fat Examples thereof include a rosin-modified polyester resin obtained by reacting a reaction product of a group polyvalent carboxylic anhydride with a polyhydric alcohol. The modified polyester may be water-soluble or self-emulsifying depending on the type and amount of other functional groups, and is easy to disperse in water even when it is not water-soluble or self-emulsifying. Becomes The (a) polyester resin in the present invention is usually used as an emulsion or an aqueous solution. In the component (b) used together with the polyester resin (a), as the acrylic resin, for example, 5 to 35 parts by weight of an alkyl acrylate having an alkyl group having 2 to 4 carbon atoms, acrylic acid and / or A resin comprising 0.05 to 5 parts by weight of methacrylic acid and 90 to 60 parts by weight of styrene; examples of the styrene resin include styrene 100 to 60 (preferably 100).
To 65) parts by weight, aliphatic conjugated diene-based monomer 0 to 35
(Preferably 0 to 30) parts by weight and a resin consisting of 0 to 5 (preferably 0 to 3) parts by weight of ethylenically unsaturated carboxylic acid; and vinyl acetate resins, for example, vinyl acetate 100 to 70 (preferably 100). Up to 90) parts by weight and 0 to 30 (preferably 0 to 10) parts by weight of ethylene. These resins are usually produced by emulsion polymerization of the above-mentioned monomer mixture and used as an emulsion together with the polyester resin (a). The mixing ratio of (a) polyester resin and (b) at least one resin selected from the group consisting of acrylic resin, styrene resin and vinyl acetate resin is a weight ratio,
Usually 50 to 95/50 to 5, preferably 60 to 90 /
40 to 10 Furthermore, the binder in the present invention may be a filler, a reinforcing material, a flame retardant, an antioxidant, a light absorber, a light stabilizer, a penetrant, a water repellent, an antistatic agent, a dye or pigment, etc., depending on the purpose of use. It can also be used in combination with additional components.

The integration of the fiber aggregate mainly composed of polyester A fibers and the binder in the present invention is carried out by, for example, a method used for lining a carpet, a method used for processing a woven fabric or a non-woven fabric, and the like. And specifically, a method of impregnating and / or applying a binder to the fiber assembly can be mentioned. The amount of the binder used in the fiber product of the present invention varies depending on the purpose of use of the fiber product to be obtained, but is usually 10 to 100 per 100 parts by weight of a fiber aggregate mainly composed of polyester A fibers.
Parts by weight. In this case, for a relatively hard textile product such as an automobile floor carpet, the binder is
It is preferable to use within the range of 10 to 80 parts by weight per 100 parts by weight of the fiber assembly, and in the case of a relatively soft fiber product such as automobile seat material or tufted carpet material, the binder is used as the fiber assembly 100. It is preferable to use within the range of 20 to 100 parts by weight per part by weight. Further, when a particularly soft texture is desired for the textile product or when it is necessary to reduce the amount of the binder used for weight reduction, the binder may be foamed and used. The textile product of the present invention is used in a living part of a transportation device such as an automobile, a railroad, an aircraft, or a ship, or in a space where a person lives, such as a living room of a house, an office, a hotel, a hospital, or the like, Floor carpet,
It can be very suitably used as an interior material such as a door trim, a sheet material, and a ceiling material, a general household carpet, an electric carpet, a commercial carpet, a tile carpet, a rug, a mat, and the like.

[0008]

EXAMPLES The present invention will be described in more detail with reference to examples of the textile products of the present invention. However, the present invention is not limited to these examples. In FIG. 1, a fiber assembly composed of a non-woven fabric is impregnated with an emulsion of a binder composed of a polyester resin (a2) (a) shown in Table 1 and components (b) (b1 to b4) shown in Table 2 and dried. The cross section of the non-woven fabric interior material is shown. In the figure, 1 indicates a nonwoven fabric and 2 indicates an emulsion impregnated layer. Here, the nonwoven fabric 1 is PE
This is obtained by forming T-fiber (15 denier) or PET / PP mixed-spun fiber (15 denier) into a web, and then needle-punching with a keyed needle to entangle them (basis weight: 500 g / m ² ). Practical performance and recycling performance of the non-woven fabric interior material were evaluated by the following evaluation procedure (1). The evaluation results are shown in Table 3. Here, the evaluation criteria other than hardness are ◯: good, Δ: normal, and x: bad. Evaluation procedure (1) Wear resistance: In accordance with JIS L1023 (wear strength). Dimensional stability: In accordance with JIS L1904 (Dimensional stability under the influence of heat and water). Thermoformability: After preheating the test body at 220 ° C. for 2 minutes, immediately observe the properties of the molded product when the molded product is molded by the cold mold. Hardness: Sense of touch and interval of 7 cm wide test piece 1
It depends on the strength when it is set between fulcrums of 0 cm and the center is pressed. Mold holding property: 90 ° C of a test body thermoformed into an L shape
Measure the degree of shape collapse when heated for 6 hours. Repelletization: Specimens are evaluated by a constant load extrusion type capillary rheometer. Compatibility: Judge the test piece with a constant load extrusion type capillary rheometer. As a result, the textile product of the present invention is excellent in practical performance and recycling performance, and as an automobile interior material,
When b1 and b2 were used as the component (b) of the binder, the hardness and the mold holding property were particularly good.

[0009]

[Table 1]

[0010]

[Table 2]

[0011]

[Table 3] In Table 3, (* 1) (a) Polyester resin emulsion and component (b)
Mixing ratio with emulsion (solid content conversion, 100 in total). (* 2) Dry weight (g) per 1 m ^{2 of} non-woven fabric.

Next, in FIG. 2, (a) polyester resin (a1) shown in Table 1 and components (b) (b5, b6) shown in Table 2 are provided on the back surface of the fiber assembly made of tufted carpet. The binder which consists of is applied as an emulsion, it is made to dry, and the cross section of the carpet which adhered the secondary base cloth to the application side of the emulsion is shown. In the figure, 3 is a primary base cloth, 4 is a pile, 5 is an emulsion coating layer, and 6 is a secondary base cloth. In this case, the tufted carpet material is a plain weave primary base fabric 3 (basis weight 100 g / m ² ) made of PET fiber, and PE.
Pile 4 made of T fiber (3 denier) is used for pile basis weight 7
It was obtained by tufting to 00 g / m ² , and the secondary base cloth 6 was a plain weave made of PET fiber (basis weight 90
g / m ² ). The recycling performance of the tufted carpet was evaluated in the same manner as in the evaluation procedure (1), and the practical performance was evaluated in the following evaluation procedure (2). The evaluation results are shown in Table 4. Evaluation procedure (2) Adhesion force: 100 mm /
The force required to peel from the primary backing at a speed of 10 minutes (unit: 10
N / 5 cm). Unthreading force: The force required to unthread one pile at a speed of 100 mm / min (unit: 10 N / thread). Texture: It depends on the texture. As a result, by using the polyester resin (a) having a low glass transition point (Tg) and the component (b), it is possible to obtain a fiber product which has a particularly good texture and is suitable as a tufted carpet, and has an extremely good recycling performance. there were.

[0013]

[Table 4] In Table 4, (* 1) and (* 2) are the same as in Table 3.

Next, in FIG. 3, (a) polyester resin (a) shown in Table 1 is provided on the back surface of the fiber assembly made of moquette.
A cross-sectional view of a moquette obtained by applying a binder comprising 1) and the components (b) (b5, b6) shown in Table 2 as an emulsion and drying the emulsion is shown. In the figure, 7 is a base cloth, 8 is a pile, and 9 is an emulsion coating layer. Here, in the moquette fabric, both the base fabric made of warp and weft and the pile yarn are made of PET.
It is composed of fibers (basis weight: 300 g / m ² ). The recycling performance of the moquette was evaluated in the same manner as in the evaluation procedure (1), and the practical performance was evaluated in the following evaluation procedure (3). The evaluation results are shown in Table 5. Evaluation procedure (3) Yarn removal force: The number of pile yarns removed when the adhesive tape (width 2.5 cm x length 5.0 cm) attached to the surface of the moquette fabric was peeled off. Texture: It depends on the texture. As a result, by using the polyester resin (a) having a low glass transition point (Tg) and the component (b), a particularly good texture was obtained, a fiber product suitable as a moquette was obtained, and the recycling performance was also very good. .

[0015]

[Table 5] In Table 5, (* 1) and (* 2) are the same as in Table 3.

[0016]

EFFECTS OF THE INVENTION The textile product of the present invention has a high fixing strength of polyester fiber and is excellent not only in practical performance such as abrasion resistance, dimensional stability, thermoformability and mold retention but also in recycling performance. Is also excellent.

[Brief description of drawings]

FIG. 1 is a cross-sectional view illustrating a nonwoven fabric interior material according to the present invention.

FIG. 2 is a sectional view illustrating a tufted carpet according to the present invention.

FIG. 3 is a cross-sectional view illustrating a moquette according to the present invention.

[Explanation of symbols]

 1 Nonwoven Fabric 2 Emulsion Impregnation Layer 3 Primary Base Fabric 4 Pile 5 Emulsion Coating Layer 6 Secondary Base Fabric 7 Base Fabric 8 Pile 9 Emulsion Coating Layer

Claims (1)

[Claims] 1. A fiber assembly mainly composed of polyester fibers, and further comprising (a) a polyester resin as a main component, and (b) at least one selected from the group consisting of an acrylic resin, a styrene resin and a vinyl acetate resin. Textile products that integrate a resin-containing binder.