JPS6228433A - Carpet base cloth - 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 (a) Field of Industrial Application The present invention relates to a carpet base fabric, more specifically, a carpet fabric woven from propylene-based resin drawn tape yarn,
Concerning carpet base fabrics that are impregnated with adhesive properties to backing materials.

(b) Prior Art Conventionally, instead of jute woven fabrics as carpet base fabrics, propylene resin stretched tape yarns or woven fabrics of their split yarns have been widely used as carpet base fabrics. Furthermore, it has begun to be put to practical use as a secondary base fabric.

However, when a propylene resin stretched tape yarn or a woven fabric made of its split yarn is used as a secondary base fabric, there is a problem of poor adhesion to the backing material, which is mainly made of styrene-butadiene rubber latex. In addition, a method has been proposed in which woven fabrics made of these yarns are treated with a nap to improve their adhesion to the backing material.
This does not solve the problem of poor adhesion. In addition, when used as a secondary base fabric, the pile threads planted in the base fabric contribute to adhesion with the backing material, so the problem of poor adhesion is as fundamental as the secondary base fabric. However, for example, in industrial car vents whose peripheral edges are not reinforced with reinforcing threads, etc.
A problem has arisen in that the base fabric and the backing material tend to separate easily, especially at the periphery.

On the other hand, the present inventors applied an aqueous ethylene resin emulsion to a woven fabric made of propylene resin drawn tape yarn in order to solve the problem of poor adhesion with backing materials when the fabric is used as a carpet base fabric. I have already proposed a method to do so. (Refer to JP-A-59-168190 and JP-A-59-214633.) (c) Problems to be solved by the invention The present inventors have discovered that a carpet base fabric of a woven fabric of propylene-based resin drawn tape yarn As a result of further studies regarding the above-mentioned adhesion problem, we have arrived at the present invention as a woven fabric for making the previously proposed ethylene resin aqueous emulsion coating method particularly effective.

B) Means for solving the problem The carpet base fabric of the present invention has a thickness of 0.5 to 5 μm on both surfaces.
The tape is woven using propylene-based resin drawn tape yarn having an ethylene-based resin layer in at least one of the warp and weft.

The propylene resin in the present invention includes a homopolymer of propylene, a copolymer of propylene with ethylene, butene-1, etc., a mixture thereof, and a small amount of the ethylene resin described below in the present invention. A mixture of

Among these, a propylene homopolymer is most preferred.

In addition, the ethylene-based resin in the present invention refers to a polymer, an ethylene/vinyl acetate copolymer, an ethylene/acrylic acid copolymer, or a metal salt thereof (K+, core, znS At
), ethylene/methacrylic acid copolymer or its metal salt, ethylene/acrylic acid alkyl ester (alkyl group has 1 to 8 carbon atoms) copolymer, ethylene/methacrylic acid alkyl ester copolymer, etc. A random copolymer prepared by reacting % by weight, preferably 80 to 98% by weight, with 50 to 2% by weight of monomers such as α, β-unsaturated carboxyl, vinyl ester, etc. (B), Monomers such as maleic anhydride, acrylic acid, itaconic acid, styrene, and acrylamide are added to polyolefins such as low-density polyethylene, high-density polyethylene, and ethylene/vinyl acetate copolymers (vinyl acetate content 5 to 35%). 0.0
It refers to an ethylene-based graft copolymer obtained by graft copolymerization at a ratio of 5 to 10% by weight.

The stretched tape yarn in the present invention is made of the propylene resin and has the ethylene resin layer on both surfaces with a thickness of 0.5 to 5 μm, preferably 0.5 to 3 μm. If the thickness of this ethylene resin layer is less than 0.5μ, it will not be possible to obtain a base fabric with sufficient adhesion to the backing material, and if it exceeds 5μ, no improvement in adhesiveness can be expected as the thickness increases. On the contrary, it only causes a deterioration in performance as a base fabric, such as deterioration in heat shrinkability.

The stretched tape yarn contains the propylene resin and the ethylene resin, respectively, and optionally a heat stabilizer.
Light stabilizers, pigments, lubricants, anti-blocking agents, flame retardants,
By adding antibacterial agents, inorganic fillers and their dispersants, etc.
Melt and knead using a known method such as a Banbury, roll, pravender, -screw extruder, or twin-screw extruder, and form a laminated film using a known method such as sequential extrusion lamination, coextrusion lamination, dry lamination, etc., and then, After slitting the film to a predetermined width, open it,
It is obtained by uniaxially stretching 3 to 9 times by a known method using rolls, hot plates, etc., and subjecting it to a relaxation heat treatment of 5 to 20%.

The carpet base fabric of the present invention is manufactured using a sluzer type loom using the above-mentioned stretched tape yarn for at least one of the warp and weft, preferably both, and the number of threads per 2.54 ctn width of each group is about 6 to 30. It can be obtained by weaving it into plain weave, twill weave, twill weave, etc. using a water jet loom, circular loom, etc. In addition, in the carpet base fabric of the present invention, in addition to the case where the above-mentioned stretched tape yarn is used for all yarns of at least one of the warp and weft yarns as described above, depending on the required level of various uses, for example, three of each yarn may be used. to 1
This also includes the case where the drawn tape yarn is mixed with a conventional drawn tape yarn at a ratio of one in five.

It also includes the case where the drawn tape yarn is a split yarn further subjected to splint processing.

The carpet base fabric of the present invention configured as explained above, the primary base fabric on which the pile thread is planted, and the secondary base fabric applied to the back side of the backing material applied to the back side of the base fabric,
Although it can be used with any of the following, it is particularly useful as a secondary base fabric, which has a serious problem of poor adhesion with backing materials.

In addition, the carpet base fabric of the present invention can particularly effectively improve the adhesion with the backing material in the method of applying an aqueous ethylene resin emulsion to the base fabric, which has already been proposed by the present inventors.

This ethylene resin aqueous emulsion preparation method uses the same ethylene resin aqueous emulsion as in the present invention as a base fabric with a solid content of 1 to 15 S'/W? It is to be applied within the range of .

(E) Function and effect The carpet base fabric of the present invention has a thickness of 0.5 to 0.0 μm on both surfaces.
Since it is woven with a globi having an ethylene resin layer and a ethylene resin drawn tape yarn in at least one of the warp or weft, it has excellent adhesion to the backing material as a secondary base fabric and a secondary base fabric. It is excellent.

(To) Examples 1 to 4, Comparative Example 1.2 A propylene homopolymer (Mitsubishi Noblen FY4J, manufactured by Mitsubishi Yuka Co., Ltd.) was heated using an extruder with a diameter of 65 mm to produce an ethylene/vinyl acetate copolymer (Mitsubishi Noblen FY4J). Manufactured by Yukasha, "Yukan on EVA4"
tHJ) A three-layer laminate film is obtained by melt-kneading each layer in an extruder with a k diameter of 40 mm, coextruding the three-layer laminate with the former as the middle layer and the latter as both surface layers at an extrusion temperature of 230°C, and cooling and solidifying it. None, then after slitting the film, it was uniaxially stretched to 6 times using a hot plate, and then stretched in an oven at 130°C.
By carrying out relaxation heat treatment at ℃, fibers [450 denier and 1000 denier propylene resin drawn tape yarns having ethylene resin layers with thicknesses of 0.3μ, 0.6μ, 2μ, and 5μ, respectively, on both surfaces were produced. Regarding the stretched tape yarn made of ethylene resin and having a resin layer thickness of 0.6 μm, a tape yarn of 1800 denier was also produced and subjected to split processing to obtain a split yarn. In addition, 450 denier and 1000 denier stretched tape yarns without an ethylene resin layer on the surface were also produced using only the same propylene homopolymer and in the same manner as described above.

Using the obtained stretched tape yarn and its split yarn, one carpet base fabric shown in Table 1 was woven using a Sluzer type loom.

(Left below) These woven fabrics were coated with an aqueous emulsion of ethylene/vinyl acetate copolymer (Evaflex 220J, manufactured by Mitsui Petrochemical Industries, Ltd., manufactured by the method described in the aforementioned patent publication) as shown in Table 2. It was coated using a dip coater to achieve the coating amount shown. On the other hand, using only the propylene homopolymer described above, a 300-denier stretched tape yarn produced in the same manner as described above was used as the warp yarn, and a 450-denier stretched tape yarn was used as the weft yarn, and the number of threads in each was 24.
The primary base fabric is a woven fabric plain woven with a thread per inch.
A 6m-cut nylon semi-worsted yarn pile was planted with 16 stitches/inch, and 10009/y7 with styrene-butadiene rubber latex as a solid content was planted on the back side.
After applying the aqueous emulsion to the back side, the woven fabric coated with the aqueous emulsion was layered as a secondary base fabric, compressed with a pair of rolls, and then placed in a heating furnace at 120°C for 3
A tufted carpet was manufactured by allowing the mixture to stand for 0 minutes to completely remove water from the latex and emulsion.

Regarding the obtained tufted carpet, the peel strength between the secondary base fabric and the backing material was measured based on JISL4405. The results are shown in Table 2.

Table 2

Claims (1)

[Claims] A carpet base fabric woven using a propylene resin stretched tape yarn having an ethylene resin layer with a thickness of 0.5 to 5 μm on both surfaces for at least one of the warp and weft.