JPH10273860A - Needle-punched carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a needle-punched carpet resistant to the falling off of pile yarns and having a laminated structure, light weight and excellent quality, processability and shape-retainability with a simplified process at a low cost without necessitating an adhesive such as latex. SOLUTION: The web constituting this needle-punched carpet has a two- or multi-layer structure. Each web layer 11, 12 has a part composed of a low- melting resin and a part composed of a high-melting resin on the cross-section of the fiber. A conjugate fiber having the part composed of the low-melting resin exposed on at least a part of the fiber surface is present at least as a part of the staple fibers constituting the web layer and the content of the conjugate fiber in each web layer is higher at the outermost web layer 11 than at the inner web layer 12.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a needle punch carpet, and more particularly to a needle punch carpet made by forming a pile on a surface thereof, preferably a pile patterned in a cord tone or a dieloor tone. The present invention relates to a moldable needle punch carpet in which piles are prevented from coming off without using an adhesive or a thermoplastic resin sheet.

[0002]

2. Description of the Related Art A conventional needle punch carpet as shown in FIG. 1, FIG. 2 or FIG. 3 is known.

FIG. 1 shows a structure in which a pile 1 having a pattern such as a cord tone or a dielore tone is provided on the surface of a nonwoven fabric base fabric (web) 2 so that the pile portion is fixed and a carpet can be formed. Needle punched carpet impregnated with an adhesive such as latex 3
No. 0, JP-A-61-132667 and the like.

FIG. 2 shows that a latex 3 having a structure as shown in FIG. 1 further contains an inorganic substance such as a polypropylene sheet, a polyamide sheet, or calcium carbonate in order to be moldable for vehicles. It is obtained by laminating a thermoplastic resin sheet 4 such as an ethylene-vinyl acetate copolymer (EVA) sheet, and is disclosed in JP-A-59-140175 and JP-A-57-205251.
And JP-A-59-204982.

Further, as a structure having no adhesive such as latex as described above, a low-melting polyester resin 5 as shown in FIG. -Core type composite fiber 7 having
As shown in FIG. 3, as a part of the fibers constituting the web, ordinary fibers (high-melting-point polyester resin fibers) 8
This web is needle-punched, and the low melting point polyester resin of the composite fiber is melted to bond the entanglement points 9 of the fiber as shown in FIG. It is disclosed in, for example, JP-A-5-115347.

[0006]

However, a needle punch carpet having a structure as shown in FIGS.
In order to prevent hair loss, it is necessary to impregnate with an adhesive such as latex, which complicates the manufacturing process and increases the cost. In addition, since the materials of the web and the latex are different, it is not preferable in terms of recycling.

Further, in the needle punch carpet having a structure as shown in FIG. 3, since the web has a single-layer structure, when the content of the above-mentioned conjugate fiber showing heat-fusibility is small, it is sufficient. The problem of not being able to obtain a suitable molded shape occurs, and conversely, when the content of the conjugate fiber is large,
There is a problem that the number of bonding points of the fibers increases, which is not preferable in terms of texture.

Accordingly, the present invention has been made in view of such problems in the conventional needle punched carpet, and does not require an adhesive such as latex and the like, and can prevent piles from coming off and have a lightweight laminated structure. It is an object of the present invention to provide a needle punched carpet having excellent quality, moldability, and shape retention while providing a product at a low cost with a simplified process.

[0009]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a needle punch carpet in which a web has a two-layer or multi-layer structure. A conjugated fiber having a structure consisting of and a site consisting of the low-melting point resin is exposed at least in part of the fiber surface portion,
The staple fiber constituting at least a part of the staple fiber constituting the web layer, and the content of the conjugate fiber in each web layer is smaller in the lowermost web layer than in the outermost web layer. Is achieved by a needle punched carpet, characterized in that

In the needle-punched carpet of the present invention, the blending amount of the conjugate fiber in the outermost web layer is 10 to 30% of the total weight of the staple fibers in the web layer, and the lower web is It is preferable that the compounding amount of the conjugate fiber in the layer is 50 to 100% of the total weight of the staple fibers of the web layer.

[0011] The present invention is also directed to the present invention, wherein the conjugate fiber blended in each web layer comprises a low melting polyester resin and a high melting polyester resin, and the remaining staple fibers constituting the web layer comprise high melting polyester. 1 shows a needle-punched carpet as a base resin fiber.

[0012] The present invention also provides the composite fiber, wherein
The needle-punched carpet has a denier fineness, and the high-melting polyester resin fiber has a fineness of 2 to 20 denier.

[0013] As a typical constitutional example of the needle punch carpet of the present invention, the web constituting the needle punch carpet has a two-layer structure, of which the surface side web layer is a 2 to 20 denier high melting point polyester-based material. A resin fiber, having a portion made of a low-melting-point polyester resin and a portion made of a high-melting-point polyester resin in a fiber cross section, and having a portion made of the low-melting-point polyester resin exposed to at least a part of the fiber surface portion. A 1-20 denier composite polyester fiber having a structure,
The lower web layer is composed of a high-melting polyester resin fiber of 2 to 20 denier, and a portion composed of a low-melting polyester resin in a fiber cross section, and 90 to 70:10 to 30 by weight. A composite polyester fiber of 1 to 20 denier having a structure composed of a high melting point polyester-based resin and having a structure in which the low melting point polyester-based resin is exposed to at least a part of the fiber surface, 50 to 0:50 to 10 by weight
There is one characterized by being contained at a ratio of 0.

In the present invention, the basis weight of the whole web is 240 to 600 g / m ² , and the total content of the conjugate fibers contained in the whole web is 15 to 70 g / m ² of the above total basis weight. %.

The needle-punched carpet of the present invention heats the web to a temperature not lower than the melting temperature of the low-melting resin of the composite fiber and lower than the melting temperature of the high-melting resin fiber and the high-melting resin of the composite fiber. After being put into a pressure molding machine, it can be molded by cooling the composite type fiber and the high melting point fiber by cooling.

According to the present invention, there is also provided the above-mentioned two-layer or multi-layer web, wherein at least two cross layers (horizontal laminating apparatuses) are arranged in parallel to flow through each web layer.
It is formed by laminating while continuously collecting on a conveyor, or by separately forming and laminating each web layer of a predetermined length, and then integrating them by needle punch or thermal bonding or both. 1 shows a needle punch carpet.

The present invention further provides a needle-punched carpet in which a pile is projected from the back surface of the web constituting the carpet using a fork needle, and a pattern such as a cord tone, a velor tone, and a diroa tone is obtained. It is.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in more detail based on embodiments.

In the needle punch carpet according to the present invention, the web has a two-layer or multi-layer structure, and a low-temperature-fusible conjugate fiber is disposed on each of the web layers. The blending ratio is a predetermined ratio.

In the needle-punched carpet of the present invention, the staple fiber constituting the web is mixed with a composite fiber as described in detail below, so that the composite can be heated by heating without using an adhesive such as latex. Melting the low melting point resin of the mold fiber and joining the entanglement points of the fibers, the web is formed into a two-layer or multilayer structure, and by changing the compounding ratio of the composite fiber in each layer, the composite mold in the web is formed. Needle punch carpet when heat-fusing and forming into a product by distributing fibers, that is, by distributing a small amount of composite fibers on the surface side and a large amount of composite fibers on the lower layer side Of the surface of the resin and satisfactory moldability. In addition, as the number of layers of the web, as described above, it is possible to use a multilayer having more than two layers. However, if the number of layers is too large, not only the cost is increased but also the characteristics are further improved. Can be expected, so preferably 2
~ 3 layers, most preferably two layers. FIG. 5 is a cross-sectional view schematically showing a web configuration in such a preferred embodiment of the needle punch carpet according to the present invention. The web 10 has an upper layer (surface layer) 11 and a lower layer 1.
2 are formed from two layers. Further, FIG. 6A shows an example of fiber composition in the web upper layer 11 in the embodiment, and FIG. 6B shows the web lower layer 12 in the embodiment.
Are shown in the unfused state, respectively, in which the compounding ratio of the composite fiber 14 in the upper layer is smaller than the compounding ratio of the composite fiber 14 in the lower layer, as shown in these figures. It has been done. In addition,
In these figures, reference numeral 15 indicates the high-melting-point fibers constituting the remainder of the fibers of the web. The conjugate fiber and the high melting point fiber will be described in detail below.

In the present invention, the conjugate fiber disposed in the web layer is defined as having a portion made of a low-melting resin and a portion made of a high-melting resin in a cross section of the fiber, and having a portion made of the low-melting resin. It has a structure exposed at least a part of the fiber surface portion, typically,
As shown in FIG. 7A, there is a fiber having a core-sheath structure having a core made of a high-melting resin 21 and a sheath made of a low-melting resin 22 surrounding the core. If it does, the part consisting of the high melting point resin 21 and the low melting point resin 2
The cross-sectional shape and arrangement of the portion composed of the resin 2 are not limited to those having the above-mentioned core-sheath structure. In addition, for example, the high melting point resin 2 shown in FIG.
1 and the low melting point resin 22 form a half-split structure, or further have a more complicated cross-sectional structure as shown in FIGS. 7 (c) and 7 (d). Further, not only single filament fibers but also multifilament fibers combining low-melting fibers and high-melting fibers may be used as long as sufficient fiber strength can be maintained even after the heat fusion treatment. However, among these various cross-sectional structures, a core-sheath type structure is most preferable because bonding by heat fusion is reliable and sufficient fiber strength can be exhibited after heat fusion.

In the present invention, the high melting point resin constituting a part of the composite fiber is not particularly limited. For example, semi-synthetic fibers such as rayon and acetate,
Various types of synthetic fibers such as polyester resins, polyamide resins, acrylic resins, polyolefin resins, polyurethane resins, and polyvinyl resins, and composite fibers thereof, and the like, are used. It can be melted or softened at a sufficiently lower temperature than the melting point resin, has sufficient adhesion to the high melting point resin and the common-point resin fiber described below, and can be co-spun with the high melting point resin. The resin is not particularly limited, and various resins similar to those exemplified as the high melting point resin can be used. In addition,
The high-melting-point resin and the low-melting-point resin do not necessarily have to be the same kind, and may be a combination of different kinds of resins, as long as they have sufficient adhesion and can be co-spun.

However, in the present invention, it is preferable that the high-melting point resin and the low-melting point resin are both made of polyester resin. As the high melting point polyester-based resin, for example, polyethylene terephthalate synthesized from terephthalic acid and ethylene glycol or butylene glycol, thermoplastic polyester generally used as a fiber such as polybutylene terephthalate and the like can be used. , 220 ° C or higher, more preferably about 225 to 265 ° C. On the other hand, as the low-melting polyester fiber, those having a sufficiently lower melting point than the high-melting polyester resin, for example, 105 to 105
It is desirable to have a melting point of about 230 ° C, more preferably about 105 to 200 ° C. If the temperature is lower than 105 ° C., there is a problem that tacking occurs due to fusion between single yarns at the time of spinning, and there is a problem that fibrillation becomes difficult due to fusion between multifilaments. If there is, there is a possibility that not only the low melting point component but also the high melting point component may be softened or melted during heating, and it may become a lump and lose its shape as a fiber, which may be a problem in appearance and increase the heating temperature. This is because molding becomes difficult. Such a low melting polyester fiber, for example,
As a saturated polycarboxylic acid component, adipic acid, azelaic acid, sebacic acid, succinic acid, phthalic anhydride, trimellitic acid, pyromellitic acid, tetrahydrophthalic anhydride,
Hexahydrophthalic acid and the like, and as glycol components, diethylene glycol, triethylene glycol,
It can be synthesized by blending at least a part of a monomer such as pentanediol 1,5, hexanediol 1,6, polyethylene glycol, and polypropylene glycol that shifts the heat distortion temperature to a lower temperature side.
These low-melting-point monomers are combined with a main saturated polycarboxylic acid component such as terephthalic acid and isophthalic acid, and a main glycol component such as ethylene glycol and butylene glycol.

The fineness of such a composite fiber is suitably about 1 to 20 denier.

On the other hand, in each web layer of the web of the needle-punched carpet of the present invention, a high-melting staple fiber may be blended in addition to the above-mentioned composite fiber. It is not particularly limited as long as it is sufficiently stable at the melting temperature of the low-melting-point resin component of the conjugated fiber, and has a good adherence with the low-melting-point resin component. Similar to those exemplified as the high melting point resin component, semi-synthetic fibers and synthetic fibers, furthermore, natural fibers, inorganic fibers, etc. can also be used, and the high melting point resin component or the low melting point resin component of the composite fiber described above. Need not necessarily be of the same system, may be of different systems, and it is also possible to use a plurality of different systems.
However, the high melting point staple fiber is preferably a polyester fiber, and is a general thermoplastic polyester fiber such as polyethylene terephthalate and polybutylene terephthalate. In addition, the fineness of the high melting point staple fiber is 2 to 20.
Denier grades are appropriate.

[0026] Carpets generally require a predetermined level of flame retardancy in many cases, but flame retardants such as bromide can be sufficiently difficult to be blended only with the low melting point resin component of the composite fiber. Flammability can be ensured, and by adopting such an aspect, cost reduction can be achieved. In addition, carpets
Usually, the desired coloring is applied, but when the web has a two-layer or multi-layer structure as in the present invention, a pigment or the like is compounded only in the composite type fiber or the high melting point fiber constituting the outermost layer. The fibers forming the lower layer may be dyed, and the appearance of the finally obtained carpet can be substantially inferior even if the fibers are not colored. Cost can be reduced.

The needle-punched carpet of the present invention has a two-layer or multi-layer structure as described above, a low-temperature fusible composite fiber is disposed on each web layer, and each of the composite fibers is The mixing ratio in the web layer is smaller on the surface layer side and higher on the lower layer side, but the compounding amount of the conjugate fiber in each layer depends on the number of layers constituting the web, the conjugate fiber and the high melting point fiber. Type,
Although it depends on the fineness, etc., in the outermost surface layer,
The compounding amount of the conjugate fiber is 10 to 30% of the total weight of the staple fibers of the web layer, and in the lower layer, the compounding amount of the conjugate fiber is the total weight of the staple fibers of the web layer. Is preferably 50 to 100%.

That is, if the compounding amount of the conjugate fiber is less than 10% by weight in the outermost surface layer, there is a high possibility that the pile will not be sufficiently prevented from coming off. If it exceeds, the number of bonding points between the fibers increases, so that there is a great possibility that the texture will be reduced. Also,
In the lower layer, the compounding amount of the composite fiber is 50.
If the amount is less than the weight%, there is a high possibility that a sufficient molded shape cannot be obtained.

In addition, in the present invention, the basis weight of the entire web is 240 to 600 g / m ² , and the total content of the conjugated fibers contained in the whole web is 15 to 15% of the total basis weight described above. Preferably, it is 70%. If the total content of the bicomponent fibers is less than 15% of the total basis weight, there is a high possibility that a sufficient molded shape cannot be obtained.
%, The number of bonding points of the fibers increases, which may impair the texture and increase the cost, which is not preferable.

In the present invention, the method for forming each web layer of the web having a laminated structure as described above and the method for laminating these layers are not particularly limited, and can be carried out based on conventionally known various methods. It is. For example, after weighing the conjugate fiber and the high-melting fiber so as to have a desired fiber composition, defibrating and blending, and forming each web layer by a card method (carding), an air lay method, or the like. it can. Then, after the web forming step by carding or the like as described above, for example, at least two cross layers (horizontal laminating devices) are arranged in parallel, and each web layer is flown, and is continuously fed by one conveyor. It is possible to adopt a method such as laminating while collecting, or laminating each web layer of a predetermined length separately and then laminating. Integrate by both.

More preferably, the pile is protruded from the back surface of the laminated web formed in this manner using a fork needle or the like, so that a cord tone, a velor tone,
It is desirable to perform a pattern such as a diroa tone. FIG.
FIG. 6 schematically shows a cross-sectional shape when such patterning is performed on a web having a two-layer structure as shown in FIG. 5, and a plurality of piles 13 project from the surface of the web 10. I have.

The needle-punched carpet according to the present invention having the above-mentioned structure is preferably a melting point of the low melting point resin of the conjugated fiber or higher and lower than a melting point of the high melting point resin fiber and the high melting point resin of the conjugate fiber. The web is heated to a temperature of, and then put into a press forming machine, and then cooled to fuse the conjugate fiber and the high-melting fiber to a desired shape, for example, as shown in FIGS. 9 and 10. It can be formed into a carpet shape for a car floor. In addition, it is of course possible to adopt a method of simultaneously heating in a pressure molding machine.

In the needle punch carpet of the present invention, since the fibers in the web are joined to each other by the low melting point resin of the composite fiber melted by the heat treatment as described above, the back (lower) side of the web Therefore, sufficient formability and strength can be obtained without using a backing material made of a thermoplastic sheet such as a polyethylene sheet, a polyamide sheet, or an ethylene-vinyl acetate copolymer (EVA) containing an inorganic substance such as calcium carbonate. It is a material that does not have such a backing material, from the viewpoint of reducing the weight of the carpet, reducing the cost, recycling and facilitating the patterning process, etc. Of course, it is also possible to arrange a backing material according to a request in the use.

[0034]

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to the following examples. The abrasion resistance test in the following Examples and Comparative Examples was performed using a Taber abrasion tester (manufactured by Toyo Seiki Seisaku-sho, Co., Ltd., wear wheel: H-38) to determine the pile retention at 1 kg and 500 rotations. did.

Example 1 A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the non-woven fabric, the upper layer was 80% by weight of a 6-denier 51 mm-long round cross-section ordinary polyester staple fiber (manufactured by Kanebo Co., Ltd., melted at 225 ° C.) of 80% by weight and similarly grayed. 4-denier low-temperature heat-fusible polyester staple fiber having a 51 mm long sheath-core structure (CZ91, 1 manufactured by Unitika Ltd.)
(10 ° C. melting type) was 20% by weight. The fiber composition of the lower layer is a non-originated (white) 10-denier 51 mm long round polyester staple fiber having a round cross section (Kanebo Co., Ltd.)
Low-temperature heat-fusible polyester staple fiber having a sheath-core structure having a length of 51 mm and having a length of 4 denier (unit temperature: 225 ° C., melt type) (Unitika Ltd.)
4080, 110 ° C. melting type) was 50% by weight. After blending the upper and lower fibers, respectively, they are subjected to carding and cross-layer processes to obtain an upper unit weight of 125 g /
m ² , lower layer basis weight 125 g / m ² , overall basis weight 250 g / m ²
It was m ^2. Next, through a needle punching process, the thickness is 8m
m of non-woven fabric. After forming a pile part by penetrating the fork needle from the lower layer side of the obtained raw material,
A raw material of a needle-punched brushed nonwoven fabric which was subjected to shirring treatment and patterned in a lower layer was obtained. 180
The mixture was heated to ° C. and put into a press equipped with a molding die to obtain a molded body. The shape retention after molding is good, the Taber abrasion test result is also good, and the texture of the deloy is maintained,
The desired color tone was obtained.

Example 2 A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the nonwoven fabric, the upper layer was 90% by weight of a 6-denier 51 mm-long round cross-section ordinary polyester staple fiber (manufactured by Kanebo Co., Ltd., melting type at 225 ° C.), which was soaked in gray. 4-denier low-temperature heat-fusible polyester staple fiber having a 51 mm long sheath-core structure (CZ91, 1 manufactured by Unitika Ltd.)
(10 ° C. melting type) was 10% by weight. As the lower layer fiber composition, a non-originated (white) low-density heat-fusible polyester staple fiber having a sheath core structure of 4 denier and 51 mm length (4080 manufactured by Unitika Ltd., melted at 110 ° C.)
Was set to 100% by weight. After blending the upper and lower fibers, the upper layer weight was 180 g / m ² , the lower layer weight was 60 g / m ² , and the total weight was 240 g / m ² through carding and cross layer processes. Next, a 10-mm-thick raw nonwoven fabric was obtained through a needle punching process. Thereafter, through the same steps as in Example 1, a raw material of a needle-punched brushed nonwoven fabric was obtained. The obtained raw material was heated to 180 ° C. and put into a press equipped with a forming die to obtain a formed body. Good shape retention after molding, good Taber abrasion test results,
The texture of Diloa tone was maintained, and the desired color tone was obtained.

Example 3 A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the non-woven fabric, the upper layer was 80% by weight of a 6-denier, 51 mm long, normal cross-section polyester staple fiber (manufactured by Kanebo Co., Ltd., melted at 255 ° C.) 80% by weight and similarly grayed. 4-denier low-temperature heat-fusible polyester staple fiber having a 51 mm long sheath-core structure (CZ91, 1 manufactured by Unitika Ltd.)
(10 ° C. melting type) was 20% by weight. The fiber composition of the lower layer is a non-originated (white) 10-denier 51 mm long round polyester staple fiber having a round cross section (Kanebo Co., Ltd.)
Low-temperature heat-fusible polyester staple fiber having a sheath-core structure having a length of 51 mm and having a length of 4 denier (unit temperature: 255 ° C., manufactured by Unitika Ltd.)
4080, 110 ° C. melting type) was 50% by weight. After blending the upper and lower fibers, the upper layer is weighed 200 g /
m ² , lower layer weight 200 g / m ² , total weight 400 g / m ²
It was m ^2. Next, through a needle punching process, the thickness 12
mm was obtained. Thereafter, through the same steps as in Example 1, a raw material of a needle-punched brushed nonwoven fabric was obtained. The obtained raw material was heated to 180 ° C. and put into a press equipped with a forming die to obtain a formed body. The shape retention after molding was good, the Taber abrasion test result was also good, the texture of the Deloy tone was maintained, and the desired color tone was obtained.

Example 4 A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the nonwoven fabric, the upper layer was 90% by weight of a 6-denier, 51 mm long round cross-section ordinary polyester staple fiber (manufactured by Kanebo Co., Ltd., 255 ° C. melting type), which was soaked in brown, and was similarly soaked in brown. 4
Low-temperature heat-fusible polyester staple fiber having a denier 51 mm long sheath-core structure (CZ61, 1 manufactured by Kanebo Co., Ltd.)
(10 ° C. melting type) was 10% by weight. As the lower layer fiber composition, a non-originated (white) low-density heat-fusible polyester staple fiber having a sheath core structure of 4 denier and 51 mm length (4080 manufactured by Unitika Ltd., melted at 110 ° C.)
Was set to 100% by weight. After blending the upper and lower fibers, the upper layer weight was 300 g / m ² , the lower layer weight was 100 g / m ² , and the total weight was 400 g / m ² through the steps of carding and cross layer. Next, through a needle punching step, a 12-mm-thick raw nonwoven fabric was obtained. Thereafter, through the same steps as in Example 1, a raw material of a needle-punched brushed nonwoven fabric was obtained. The obtained raw material was heated to 180 ° C. and put into a press equipped with a forming die to obtain a formed body. The shape retention after molding was good, the Taber abrasion test result was also good, the texture of the Deloy tone was maintained, and the desired color tone was obtained.

Comparative Example 1 A nonwoven fabric having a single-layer structure was prepared. 10 denier 51mm long regular polyester staple fiber (Kanebo Co., Ltd., 255 ° C melting type) which was originally colored in gray
To 50% by weight, and similarly 4 denier 5
A low-temperature heat-fusible polyester staple fiber having a sheath-core structure of 1 mm length (CZ91 manufactured by Unitika Ltd., 110 ° C.)
After blending 50% by weight of (melt type), a nonwoven fabric having a single-layer structure with a thickness of 4 mm and a basis weight of 300 g / m ² was prepared through carding, cross layer, and needle punching steps. Next, through the needle punching step, the same procedure as in Example 1 was performed to obtain a raw material of the needle-punched brushed nonwoven fabric. The obtained raw material was heated to 180 ° C. and put into a press equipped with a forming die to obtain a formed body. The shape retention after molding was good, and the Taber abrasion test result was also good, but the surface texture was insufficient because the surface contained many heat-fused fibers.

Comparative Example 2 A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the nonwoven fabric, the upper layer was made of 100% by weight of a 6-denier, 51 mm-length, normal polyester staple fiber (manufactured by Kanebo Co., Ltd., melted at 255 ° C.) having a gray cross section. As the fiber composition of the lower layer, a non-originated (white) 10-denier 51 mm-length regular polyester staple fiber having a round section (manufactured by Kanebo KK, 25
A low-temperature heat-fusible polyester staple fiber having a sheath-core structure of 50% by weight (5 ° C. fusion type) and also non-originated (white) 4 denier 51 mm length (408 Unitika)
0, 110 ° C melting type) was 50% by weight. After blending the upper and lower fibers, the upper layer weight was 200 g / m ² , the lower layer weight was 200 g / m ² , and the total weight was 400 g / m ² through carding and cross layer processes. Next, through a needle punching step, a 12-mm-thick raw nonwoven fabric was obtained. Thereafter, through the same steps as in Example 1, a raw material of a needle-punched brushed nonwoven fabric was obtained. 18
The mixture was heated to 0 ° C. and put into a press equipped with a molding die to obtain a molded body. Although the shape retention after molding was good, the Taber abrasion test result was insufficient because the upper layer did not contain heat-fused fibers.

Reference Example A nonwoven fabric having a two-layer structure of an upper layer and a lower layer having different fiber formulations was prepared. As for the composition of the nonwoven fabric, the upper layer was 90% by weight of a 6-denier, 51 mm long round cross-section ordinary polyester staple fiber (manufactured by Kanebo Co., Ltd., 255 ° C. melting type), which was soaked in brown, and was similarly soaked in brown. 4
Low-temperature heat-fusible polyester staple fiber having a denier 51 mm long sheath-core structure (CZ61, 1 manufactured by Kanebo Co., Ltd.)
(10 ° C. melting type) was 10% by weight. As the lower layer fiber composition, a non-originated (white) low-density heat-fusible polyester staple fiber having a sheath core structure of 4 denier and 51 mm length (4080 manufactured by Unitika Ltd., melted at 110 ° C.)
Was set to 100% by weight. After blending the upper and lower fibers, the upper layer weight was 350 g / m ² , the lower layer weight was 50 g / m ² , and the total weight was 400 g / m ² through carding and cross layer processes. Next, through a needle punching step, a 12-mm-thick raw nonwoven fabric was obtained. Thereafter, through the same steps as in Example 1, a raw material of a needle-punched brushed nonwoven fabric was obtained. The obtained raw material was heated to 180 ° C. and put into a press equipped with a forming die to obtain a formed body. The shape retention was insufficient because the basis weight of the lower layer was small.

Table 1 summarizes the evaluation results in the above Examples and Comparative Examples.

[0043]

[Table 1]

[0044]

As described above in detail, the needle-punched carpet of the present invention has a web having a two-layer or multi-layer structure. A conjugate fiber having a structure comprising a portion consisting of and the portion comprising the low melting point resin is exposed at least a part of the fiber surface portion, as at least a part of the staple fibers constituting the web layer. And the content of the bicomponent fiber in each web layer is higher in the lower web layer than in the outermost web layer. Abolished the impregnation of adhesives such as latex and lamination of backing material from the back,
Furthermore, abrasion resistance, surface texture and formability (shape retention)
Can be compatible.

Further, in the needle punch carpet of the present invention, the blending amount of the conjugate fiber in the outermost web layer is 1% of the total weight of the staple fibers in the web layer.
0-30%, and the compounding amount of the conjugate fiber in the lower web layer is 50-100% of the total weight of the staple fibers of the web layer, and the conjugate fiber is made of a low melting polyester resin. A high-melting polyester resin, the rest of the staple fibers constituting the web layer are high-melting polyester resin fibers, the conjugate fiber has a fineness of 1 to 20 denier, and the high-melting polyester resin When the fibers have a fineness of 2 to 20 denier, more favorable texture and moldability can be obtained. Further, the web constituting the needle punch carpet has a two-layer structure, and the web layer on the surface side has a high melting point polyester resin fiber of 2 to 20 deniers, a portion composed of a low melting point polyester resin in the fiber cross section, and a high melting point. A 1-20 denier conjugated polyester fiber having a structure comprising a polyester resin and having a structure in which the low melting polyester resin is exposed on at least a part of the fiber surface, 90 ~
A low-melting polyester resin fiber in which the lower web layer has a denier of 2 to 20 denier, a portion composed of a low-melting polyester resin in a fiber cross section, and a high-melting polyester resin And a composite polyester fiber of 1 to 20 denier having a structure in which a portion composed of the low melting point polyester resin is exposed to at least a part of the fiber surface portion, in a weight ratio of 50 to When it is contained at a ratio of 0:50 to 100, it becomes particularly suitable, for example, as a carpet for an automobile floor, and the basis weight of the entire web is 240 to 600 g / m ² , and If the total content of the composite polyester fibers contained in the entire web is 15 to 70% of the above-mentioned total basis weight, the shape is maintained. Sex, becomes more excellent. Further, the needle punch carpet of the present invention can easily perform patterning such as chord tone, velor tone, and dilore tone by projecting a pile from the back side of the web constituting the carpet using a fork needle. When such patterning is performed, the commercial value thereof is further increased.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view schematically showing a structural example of a conventional needle punch carpet.

FIG. 2 is a cross-sectional view schematically showing another example of the structure of a conventional needle punch carpet.

FIG. 3 is an enlarged plan view schematically showing a fiber configuration in still another structural example of a conventional needle punch carpet,

FIG. 4 is an enlarged cross-sectional view schematically showing the structure of a composite fiber used in the conventional example shown in FIG.

FIG. 5 is a cross-sectional view schematically showing a web configuration in one embodiment of the needle punch carpet of the present invention.

6 (a) is an enlarged plan view schematically showing an example of the fiber composition of the upper layer of the web in the embodiment shown in FIG. 5, (b)
Is an enlarged plan view schematically showing an example of blending fibers in the web lower layer in the embodiment shown in FIG. 5,

FIGS. 7A to 7D are enlarged cross-sectional views each showing a structural example of a conjugate fiber used in the present invention;

FIG. 8 is a cross-sectional view schematically showing a cross-sectional shape of the web configuration according to the embodiment of the present invention shown in FIG. 5 when patterning is performed.

FIG. 9 is a perspective view schematically showing a forming example of the needle punch carpet of the present invention;

FIG. 10 is a sectional view taken along line SA-SA in FIG. 9;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... pile, 2 ... nonwoven fabric base cloth, 3 ... latex, 4 ... thermoplastic resin sheet, 5 ... low melting polyester resin, 6 ... high melting polyester resin, 7 ... sheath-core type composite fiber, 8 ... normal fiber ( 9 ... entangled point, 10 ... web, 11 ... web upper layer (surface layer), 12 ... web lower layer, 13 ... pile, 14 ... composite fiber, 15 ... high melting point fiber 21 ... high melting point Resin, 22 ... Low melting point resin

Claims (9)

[Claims] 1. A web constituting a needle punch carpet has a two-layer or multi-layer structure, and each web layer comprises
A conjugate fiber having a structure in which a section composed of a low melting point resin and a section composed of a high melting point resin in a fiber cross section and having a structure in which the section composed of the low melting point resin is exposed to at least a part of a fiber surface portion, It has as at least a part of the staple fibers constituting the layer, and the content of the conjugate fiber in each web layer is larger in the lower web layer than in the outermost web layer. A needle punch carpet characterized by the following. 2. The blending amount of the conjugate fiber in the outermost web layer is 10 to 30% of the total weight of the staple fibers in the web layer, and the blending of the conjugate fiber in the lower web layer. The needle punched carpet according to claim 1, wherein the amount is 50 to 100% of the total weight of the staple fibers of the web layer. 3. The conjugate fiber is composed of a low melting polyester resin and a high melting polyester resin, and the remaining staple fibers constituting the web layer are high melting polyester resin fibers. The needle punched carpet according to item 1. 4. The conjugate fiber has a fineness of 1 to 20 denier, and the high-melting polyester resin fiber has a fineness of 2 to 20 denier.
4. It has a fineness of ~ 20 denier.
The needle punch carpet according to any one of the above. 5. A part of a web constituting a needle punch carpet having a two-layer structure, wherein a web layer on the surface side is composed of a high-melting polyester resin fiber of 2 to 20 deniers and a low-melting polyester resin in a fiber cross section. And a composite polyester fiber of 1 to 20 denier having a structure made of a high-melting polyester resin and having a structure in which the low-melting polyester resin is exposed to at least a part of the fiber surface. 90% by weight
A low-melting polyester resin fiber in which the lower web layer has a denier of 2 to 20 denier, a portion composed of a low-melting polyester resin in a fiber cross section, and a high-melting polyester resin And a composite polyester fiber of 1 to 20 denier having a structure in which a portion composed of the low melting point polyester resin is exposed to at least a part of the fiber surface portion, in a weight ratio of 50 to A needle punch carpet, characterized in that it is contained at a ratio of 0:50 to 100. 6. A web having a basis weight of 240 to 600.
g / m ^2, further total content of the composite polyester fiber in the entire web, needle-punched carpet according to claim 5, wherein 15 to 70% of the weight of the whole as described above. 7. A pressure molding machine that heats the web to a temperature equal to or higher than the melting temperature of the low-melting resin of the composite fiber and lower than the melting temperatures of the high-melting resin fiber and the high-melting resin of the composite fiber. The needle-punched carpet according to any one of claims 1 to 6, wherein the needle fiber is formed by fusing the conjugate fiber and the high-melting fiber after being charged into the needle punch. 8. The present invention also relates to a method for producing a web having a double-layered or multi-layered structure, wherein at least two cross-layers are arranged in parallel, each web is flowed, and continuously collected by one conveyor. The method according to any one of claims 1 to 7, wherein the layers are formed by laminating or by separately forming each web layer having a predetermined length and then laminating and integrating them by needle punch or thermal bonding or both. Needle punched carpet according to Crab. 9. A pile is projected from the back side of the web constituting the carpet using a fork needle,
The needle punch carpet according to any one of claims 1 to 8, wherein a pattern is formed.