JPS62231066A - Long fiber nonwoven sheet for tuft base material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a base material for tufts used for carpets, carpets, mats, and the like.

[Conventional technology]

Conventionally known tuft g materials include Bo IJ 7"a Bilene Tape Ya-7 cloth, polyglos spunbond, jute cloth, etc.The base material for tufts is a pile yarn that does not lose its strength even if it is tufted with a needle. It is important that the tufting base materials are small in strength.The conventionally known tufting base materials are excellent in that there is little loss of strength and are widely used today. In order to prevent the pile yarn from being pulled out, as a countermeasure against problems such as the pile yarn being easy to pull out and the high-density structure of the pile yarn being difficult to maintain,
The back side is coated with synthetic latex or the like to fix the pile yarn. At this time, it is necessary to use a large amount of resin. On the other hand, it is impossible to create a high-density pile yarn structure with conventional tufted fabrics due to its physical properties.Furthermore, as tufted products become more diverse, there is a demand for, for example, molding of uneven shapes. There is. However, carpets and mats made from current tufted base fabrics have nine problems, such as the use of a large amount of resin and the inability to mold them.

The present inventors have discovered that the above-mentioned problems can be solved by using a long fiber nonwoven sheet having latent shrinkage properties, and have arrived at the present invention.

[Problem that the invention seeks to solve]

The present invention solves the above-mentioned problems of conventionally known tuft base materials, makes it difficult for pile yarns to come off, allows pile yarns to be arranged at high density, and provides molding such as an uneven shape to a tufted product. SUMMARY OF THE INVENTION It is an object of the present invention to provide a tufted substrate which can be made using a semi-drawn yarn made of a fiber-formable thermoplastic polymer. This is achieved by a long fiber nonwoven sheet for a tuft base material, which has a latent shrinkage of at least 5% in water production shrinkage in at least one of the vertical and horizontal directions.

The nonwoven sheet according to the present invention is characterized in that it is made using semi-drawn yarn. For this reason, through heat treatment, crystallization progresses, the surfaces are fused at the intertwined portions of the single yarns, and the fiber density within the single yarns increases, resulting in increased hardness.
Provides the hardness required for carpets and mats. Second, it has latent contractility. By heat-treating the nonwoven sheet of the present invention, the sheet as a whole undergoes surface shrinkage, so that even if the pile yarn is tufted under normal conditions, a high-density structure of the pile yarn can be obtained. This eliminates the need to change conditions such as gauge and stitching during tufting, so there is no deterioration in physical properties, and on the contrary, the surface shrinkage improves strength, dimensional stability, and hardness. Furthermore, the needle holes during tufting become smaller due to surface shrinkage, and the pile yarns are tightened, making it difficult for the pile yarns to come out.

Furthermore, in the nonwoven sheet of the present invention, the long fiber nonwoven sheet of semi-drawn yarn is subjected to surface shrinkage by heat treatment, so crystallization progresses as a characteristic of single fibers, but the orientation becomes lower (1=lower), so it is difficult to cool. Although it is hard at times, it has the characteristic of being soft when heated, so it can be easily molded into irregularities by heat molding, and as a result, it becomes a base material for tufts that has moldability.

As described above, when the nonwoven sheet of the present invention is used as a tufting base material, (1) the tufted needle holes shrink, making it difficult for the pile threads to come out. ■Heat treatment causes surface shrinkage, resulting in a high-density structure. ■To heat shrink the semi-drawn yarn,
The semi-drawn yarn retains its tendency to stretch when heated, making it excellent for thermoforming. It has the following characteristics. Because of these characteristics, if tufted products are made using the tufted base material according to the present invention, it becomes possible to diversify product development.

Hereinafter, the tuft base material of the present invention will be explained in detail along the manufacturing procedure Vζ.

The nonwoven sheet of the present invention is produced by forming a web of a large number of long fibers, and then using a pair of hot rolls having an embossed roll pattern on at least one side of the sheet to mutually bond the constituent fibers of the embossed portion. This is a nonwoven sheet that is embossed so that its movement is restricted, and it is important to set the embossing conditions so that latent shrinkage remains.

Polymers used in the production of thermoplastic semi-drawn yarns for nonwoven sheets in the present invention include polyesters, polyester copolymers, polyester conjugates, polyamide copolymers, Polyolefin copolymers, etc. can be applied, but the second-order transition is substantial above room temperature, non-quality semi-stretching can be stably produced, and crystals can be crystallized by heat treatment. The polymer must be a polymer with a As polyester, polyethylene terephthalate provides excellent results for the purpose of the present invention in terms of heat resistance, heat moldability, strength, and the like.

Next, the polymer is bonded using a known spunbond method.
The nonwoven web is spun to form a long fiber nonwoven web, and the nonwoven web is embossed with a pair of rolls having an embossed pattern on at least one surface. The surface temperature used at this time greatly affects latent shrinkage9 strength, uniformity of fiber dispersion, etc.

Specifically, it is preferable to carry out embossing at a temperature above the secondary transition point and below the secondary transition point + 100°C, or preferably because the embossing process is carried out in two steps, since the fibers are made of shrinkable fibers. A uniform nonwoven sheet is obtained. That is, first, partial thermocompression bonding is performed with the surface temperature set to above the secondary transition point and below the secondary transition water +30°C, and then the higher temperature in the partial thermocompression bonding is set to above the secondary transition point +50°C and the melting point - 60
It is recommended to perform the partial thermocompression bonding in two steps, one at a temperature below ℃ and the other at a temperature below the secondary transition point.

FIG. 1 is a schematic cross-sectional view of the nonwoven plate of the present invention. ]
9 indicates a relatively high fiber density area that was heat embossed at a higher temperature, and 2 indicates a area that was heat embossed at a lower wet temperature and has a coarse fiber density. 1 indicates a part that is partially thermo-compressed and the mechanical density is quite dense, and lateral force is restrained, and part 30 is an important part that affects strength, hardness, dimensional stability, etc. On the other hand, the second part has latent shrinkage, which means that this part is made of fibers that have not been heat treated, which is lacking in the nonwoven sheet with latent shrinkage, which is the object of the present invention. This is an important part that cannot be done.

FIG. 2 is a schematic cross-sectional view of the nonwoven sheet described above which has been subjected to resin processing and then heat treated. 4
5 indicates a portion with relatively high fiber density, 6 indicates a portion with a relatively low fiber density, 6 indicates a partial joint, and 7 indicates resin mixed in the nonwoven sheet due to resin processing. In this way, if the thermocompression-bonded nonwoven sheet is processed with resin in advance and then subjected to the following heat treatment, the hardness of the nonwoven sheet can be reduced to −Nj.
It is important that the resin at this time be cured by a crosslinking reaction, etc. by heat treatment for heat shrinkage, and when processed into a nonwoven sheet,
Needless to say, processing must be carried out at a temperature that does not cause loss of latent shrinkage. Specifically, styrene resins, acrylic resins, SBR resins, melamine resins, etc. can be selected depending on the purpose. Preferably, solvent type resins are used because they have excellent processability at low temperatures. However, various types of resins may be used without being limited thereto. In addition to the above-mentioned resin processing, processing such as coating and lamination of other materials such as films may be performed as necessary. Pile yarn is tufted using the obtained nonwoven sheet of the present invention. This tufting can be performed using a conventionally known tufting machine.
The stitches, needles, etc. were carried out under conventional conditions, and there were no problems with CC.

Next, the nonwoven sheet tufted with pile yarns is heat treated to cause surface shrinkage. At this time, it is necessary to increase the heat shrinkage rate to 5 or more. Preferably, heat shrinkage of 1 (1 or more) yields preferable results such as thread pull-out of the pile yarn, improvement in pile density, 1 strength, etc. If the heat shrinkage is 5% or less, the pile yarn, which is the object of the present invention, When removing the threads, it is not possible to obtain satisfactory results in terms of quality, high density of pile threads, etc.

The heat treatment in the present invention is performed using a pin tenter, a clip tenter, a hot roll, etc. in a temperature range of 90° C. to 200° C. to cause a thermal shrinkage of orders of magnitude of several seconds to several tens of seconds.

The heat treatment conditions are changed depending on the purpose. That is, to obtain a high-density structure, the heat shrinkage rate is set high, and conversely, when the density is not to be increased much, the heat shrinkage rate is set low.

In this heat treatment, the back side is treated with resin to prevent the pile yarn from pulling out, and even if the resin treatment is applied at the same time as surface shrinkage,
There are no problems for a long time, and since there is no new process added to the process of manufacturing conventionally known carpets and carpets, there is a cost advantage.

FIG. 3 shows a schematic cross-sectional view in which the pile yarns in FIG. 4 are tufted into the nonwoven sheet of the present invention by tufting, and then subjected to the heat treatment to undergo surface shrinkage and become a high-density structure. 8 indicates the nonwoven sheet of the present invention, and 9 indicates the pile yarn. FIG. 4 shows a schematic cross-sectional view of the nonwoven sheet of the present invention tufted with pile threads before heat treatment.

Next, the nonwoven sheet of the present invention, which is made by tufting pile yarns and subjected to heat treatment, has excellent thermoformability.

In order to have excellent thermoformability, the elongation at break when heated to 150°C is large, and the stress at 20% elongation when heated to 50°C is small, which makes it difficult to deform during molding and prevents the mold from forming. The nonwoven sheet of the present invention satisfies these conditions.

〔Example〕

The present invention will be specifically described below with reference to Examples. still,
The definitions and measurement methods of the characteristics described in the examples are shown below. A flood shrinkage rate sheet of 10 non-woven sheet was cut into 25 (supports) x 25 squares, and marked at the vertical and horizontal valley positions of 20c1n. After being submerged for 1 minute, the dimensional change of the sample is measured and the shrinkage rate is determined. A 20m x 20mm sample is taken, and the 1i flea is converted to the basis weight.

A 0 tensile strength and elongation sample of 3 cm x 20 cm was taken both vertically and horizontally using a constant speed extension type tensile tester (Autograph DSS-2 manufactured by Shimadzu Corporation).
Gripping length 10 cWL:
Measurement was performed at a tensile rate of 20c1n for 7 minutes.

0 bail yarn pull-out strength Same method as above tensile strength and elongation, gripping length 5, tensile speed 20
Measured in cPn/min and shown as the maximum value of tensile strength and elongation at 0.150°C and 20% erosive stress using the same method as above for tensile strength and elongation, gripping length 10cm and tensile speed 20c.
Measure at 1n7 minutes. The value of medium-length stress is the value divided by the cross-sectional area of the sample.
Take the test specimen in the middle of the test piece and slide it gently in the direction of the slope on a smooth horizontal table with a 45IfO wound surface on one end, and measure the length at which the center point of one end of the specimen reaches the slope. Tsuyoshi Sade? represents degree.

Examples 1-4. Comparative Examples 5 to 7 Using a short type spinneret with a hole diameter U of 25 mm and 1000 holes, the specific force (1,72
Polyethylene terephthalate is spun at a melting temperature of 290'C, and an air flow is applied to it using an air sucker for 1, which is located at a position of 1,000 degrees below the spinneret. By changing t, the spinning speed was 25oO.
A web with a weight of 10 ('1.9/W?) is formed on a conveyor that moves at +yt/min.

The obtained web was opened between an upper roll having a rectangular embossed pattern with a long side of 3 mm, a short side of 1 wa, a depth of 0.6 a+m, and an area ratio of 18 mm, and a lower roll with a smooth surface, and the lower roll temperature. 110℃, linear pressure 2 ('+kg/m, speed 10
m/speed 1a A nonwoven sheet for Example 1 was prepared.

In Examples 2 to 4, the nonwoven web obtained under the same spinning conditions as in Example 1 was used, and embossing was performed twice under different conditions.

The length of the obtained non-woven web is 10.

Side 3 coral. Short side 1-9 depth n. 6 mm, area ratio 18
The temperature of the upper and lower rolls is 85°C between the upper roll having a rectangular embossed pattern and the lower roll having a smooth surface.

After thermocompression bonding under a linear pressure of 20 g/cln and a speed of 1 on/min, a depth of 0. 2 Ill! II
The nonwoven sheet was again thermocompressed between an upper roll having a textured embossed pattern with an area ratio of 23 cm and a lower roll having a smooth surface. For thermocompression bonding, the upper roll temperature is 140
℃, lower roll temperature of 60°C, linear pressure of 40 kg/cm, and speed of 10 m/min. The obtained nonwoven sheet was used as the nonwoven sheet for Example 2 and Example 3.

The nonwoven sheet for Example 4 was obtained by further resin-processing the nonwoven sheet obtained for Example 2 or Example 3, and used a combination of acrylic resin and melamine resin as mouth koji resin. . (The acrylic resin is Nippon Carbide FX-3.
59. The melamine resin was prepared using Beckamine manufactured by Dainippon Ink in a ratio of 10 parts to 100 parts of the acrylic resin.0) The nonwoven sheet was immersed in the above mixed solution, It was dried at 85°C and processed with resin so that the N ratio was 25.

Touch ink processing was performed using the above tuft base material. 1 as pile yarn, %5 using nylon pile yarn
//32 Gauge, 8 stitches.

Subsequently, one heat treatment was performed using a pin tenter. The heat shrinkage rate was controlled vertically and horizontally to be 14.5% and 20φ, and a heat treatment was performed at a temperature of 120°C for 30 seconds to cause shrinkage on one side. That is, the nonwoven sheet for Example 4 was Heat treatment is carried out in a manner that allows for 20% heat shrinkage.
Example 1. The nonwoven sheets of Examples 3 and 4 were made, and the nonwoven sheet of Example 2 was heat treated to allow heat shrinkage of 5% of the nonwoven sheet NC for Example 2.

On the other hand, Comparative Examples 5, 6, and 7 are nonwoven sheets that were heat-treated with a heat shrinkage rate of 04;
In Comparative Example 6, a tape yarn cloth made of polypropylene film was heat-treated, and in Comparative Example 7, a tape yarn cloth made of polypropylene film was heat-treated.
The above heat treatment was applied to ester spunbond at a rate of 1 m/min.

Table 1 shows the performance comparison results of the sheet-like products of Examples 1 to 4 and Comparative Examples 5 to 7. From the results in Table 1,
In the tufted base materials of the present invention of Examples 1 to 4, the pull-out strength of the pile yarns was high, and the density of the piles was also high,
Hardness increased by heat treatment. Further, results were obtained in which the elongation at break when heated was extremely large and the elongation stress at modulus 20 when heated was extremely small. This means that it is easily deformed during hot molding, and it is easy to form uneven molds and undergo large deformations. From the above results, it is possible to obtain a high-density structure of the pile yarn, which is the object of the present invention, in which the pile yarn does not easily come off, without deteriorating its physical properties.
Furthermore, a tufted base material with excellent thermoformability could be obtained.

On the other hand, in Comparative Example 5, when heat treatment is performed without shrinkage, the drawability of the pile yarn and the density of the pile yarn also change as a natural result, which is not the objective of the industrial water invention. This means that the latent shrinkage rate of the nonwoven sheet is required to be 5% or more.In addition, in Comparative Examples 6 and 7, the pile threads are easy to pull out, the density remains unchanged, and the heat resistance, moldability, etc. No results were obtained that satisfied the purpose of the present invention.0 or less margin [Effects of the Invention] The base material for tufts of the present invention provides a structure with a higher density than that of conventionally known pile yarns. Since it does not easily come off and has thermoformability, it can be used in a wider range of products in the conventional carpet and mat fields, as well as in molded carpets, bottom-shaped mats, and the like.

[Brief explanation of drawings]

FIG. 1 is a schematic cross-sectional view of the tuft base material of the present invention. 1 indicates a portion with high fiber density, 2 indicates a portion with low fiber density, and 3 indicates a partially crimped portion. FIG. 2 is a schematic cross-sectional view of the resin-processed tuft base material of the present invention. 4 is a part with high fiber density. 5 indicates a portion with low fiber density, and 6 indicates a partially crimped portion. 7 shows a resin interposed in the nonwoven sheet due to resin processing. FIG. 3 shows a schematic cross-sectional view of a state in which the pile yarn is tufted onto the tufting base material of the present invention and then heat-shrinked by heat treatment. FIG. 4 shows a schematic cross-sectional view of the tufting base material of the present invention in which pile yarn is tufted.

Claims (1)

[Claims] 1. A long-fiber nonwoven sheet made using semi-drawn yarn made of a thermoplastic polymer capable of forming fibers, which has a boiling water shrinkage rate of 5 in at least one of the vertical and horizontal directions.
A fibrous nonwoven sheet for tufted substrates that has a latent shrinkage of % or more.