WO2014171042A1 - Tufted carpet primary base fabric - Google Patents

Tufted carpet primary base fabric Download PDF

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Publication number
WO2014171042A1
WO2014171042A1 PCT/JP2013/084781 JP2013084781W WO2014171042A1 WO 2014171042 A1 WO2014171042 A1 WO 2014171042A1 JP 2013084781 W JP2013084781 W JP 2013084781W WO 2014171042 A1 WO2014171042 A1 WO 2014171042A1
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WO
WIPO (PCT)
Prior art keywords
primary base
base fabric
shape
long fibers
polyester
Prior art date
Application number
PCT/JP2013/084781
Other languages
French (fr)
Japanese (ja)
Inventor
木原　幸弘
Original Assignee
ユニチカ株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ユニチカ株式会社 filed Critical ユニチカ株式会社
Priority to EP13882225.9A priority Critical patent/EP2987899B1/en
Priority to US14/784,854 priority patent/US20160060798A1/en
Publication of WO2014171042A1 publication Critical patent/WO2014171042A1/en

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets
    • D10B2503/041—Carpet backings
    • D10B2503/042—Primary backings for tufted carpets

Definitions

  • the present invention relates to a primary base fabric for obtaining a tuft carpet by planting pile yarn.
  • the tufted carpet is obtained by applying a pile yarn to the primary base fabric by tufting (tufting process), followed by pre-coating and backing (backing process). Moreover, after passing through a tufting process, it may pass through a dyeing process.
  • the tuft carpet primary base fabric is required to have a tufting property and a tufting property in which the base fabric is not easily broken by the penetration of the tuft needle in the tufting process and the stress that is not easily deformed by a load applied during the tufting process or the dyeing process. .
  • Patent Document 1 a primary base fabric provided with a specific thermocompression bonding portion by hot embossing so as not to cause problems such as tearing in a specific direction during the carpet manufacturing process.
  • thermocompression bonding portion As a tuft carpet primary base fabric, a long-fiber non-woven fabric having a thermocompression bonding portion by heat embossing is well known. And the long fiber which comprises a primary base fabric is restrained and joined by the thermocompression bonding part. In order to make the constrained long fibers difficult to be damaged by the penetration of the tuft needle, it is not firmly bonded to the inner layer of the nonwoven fabric in the partially provided thermocompression bonding portion (for example, implementation described in Patent Document 1, Example 1 In the embodiment, heat embossing is performed at a set temperature that is 25 ° C.
  • the tuft needle penetrates into the thermocompression bonding part, the restrained state of the long fibers in the thermocompression bonding part If the long fibers are easily released without being cut so that the long fibers can move freely, the strength of the long fibers can be maintained.
  • the thermocompression bonding part is released in the tufting process, the strength of the long fiber can be maintained, but the strength as the base fabric is remarkably reduced.
  • the bonded state is released and the long fibers are simply accumulated, and the form of the primary base fabric itself cannot be maintained. Then, for example, once a pile arrangement failure is found after tufting the pile yarn, even if a part of the pile yarn is extracted and then tried to tuft again, the primary base fabric itself cannot maintain the form, so tufting cannot be performed again.
  • the present invention is to provide a tufted carpet primary base fabric in which the long fibers in the primary base fabric are bonded to each other even after the tufting step, and the primary base fabric itself maintains a good shape.
  • the present inventor has succeeded in obtaining a polyester long-fiber nonwoven fabric with higher rigidity by making the cross-sectional shape of the long fiber into a shape that has not been known conventionally. And when this polyester long fiber nonwoven fabric was applied to a tuft carpet primary base fabric, there was little damage to the long fibers by the tufting needle in the tufting process, and there was little breakage of the bonded part due to fusion of the long fibers, even after the tufting process The present inventors have found that the rigidity of the primary base fabric is maintained and the shape can be maintained well, and the present invention has been achieved.
  • the present invention is a tufted carpet primary base fabric composed of a nonwoven fabric composed of long fibers having a single yarn fineness of 10 dtex or more, and the transverse cross-sectional shape of the long fibers is substantially vertical at the lower end of the Y shape.
  • substantially Y4 shape Connected to Shape (hereinafter referred to as “substantially Y4 shape”),
  • the long fiber is a composite type polyester long fiber in which each substantially V-shaped portion of a substantially Y4 shape is formed of a low-melting polyester component, and other substantially + -shaped portions are formed of a high-melting polyester component,
  • the long fibers are connected to a primary base fabric of a tuft carpet characterized by being bonded by fusion of the low melting point polyester component.
  • the non-woven fabric constituting the primary tuft carpet of the present invention has long fibers as constituent fibers and is characterized by the cross-sectional shape of the constituent fibers.
  • This cross-sectional shape has four substantially Y-characters as shown in FIG. And it is connected to the upper and lower sides and the right and left at the lower end 1 of a substantially Y shape, and has a substantially Y4 shape as shown in FIG.
  • the substantially Y4 shape has four concave portions 2, eight convex portions 3, and four small concave portions 4.
  • the substantially + -shaped part 5 at the center and the four substantially V-shaped parts 6 connected to the respective ends of the approximately + -shaped part 5 are highly rigid. In other words, it is not a simple shape such as a hexagon or a Y-shape, but a higher rigidity is achieved by a combination of the substantially + -shaped portion 5 and the substantially V-shaped portion 6 having high rigidity.
  • the long fiber is composed of a low-melting polyester component and a high-melting polyester component.
  • the substantially V-shaped portion 6 having a cross-sectional shape is formed of the low-melting polyester component, and the substantially + -shaped portion 5 is formed of the high-melting polyester component.
  • This is a composite type polyester continuous fiber.
  • the tufted carpet primary base fabric according to the present invention is obtained by accumulating composite polyester long fibers, softening or melting the low melting point polyester component, and then solidifying it, so that the polyester long fibers are fused by the low melting point polyester component. It is made of a non-woven fabric. Since the long fibers are bonded to each other by the fusion of the low melting point polyester component, the rigidity of the primary base fabric of the tuft carpet is more excellent.
  • the fusion of the low-melting-point polyester component is obtained by performing a heat treatment, and this heat treatment is performed by hot embossing or hot air treatment.
  • hot embossing the intersections of long fibers are fused in a partially provided thermocompression bonding part.
  • hot air treatment the intersections of long fibers are fused together.
  • hot embossing and hot air treatment may be used in combination.
  • heat embossing in which thermocompression bonding is performed by partially applying heat and pressure is preferable.
  • the pressure-bonding area ratio of the embossing roll to be used (area ratio of the convex part of the embossing roll) is preferably 10 to 20%. If the pressure-bonding area ratio is too small, a part of the pressure-bonded portion is destroyed by the penetration of the tuft needle in the tufting process, so that the ratio of the pressure-bonded portion remaining after the tuft becomes too small and it becomes difficult to maintain rigidity. On the other hand, when the pressure-bonding area ratio is too large, damage due to penetration of the tuft needle is large, and it becomes difficult to maintain the strength of the primary base fabric after the tuft.
  • the composite ratio of the low-melting-point polyester component and the high-melting-point polyester component constituting the long fiber is considered in consideration of the strength of the long fiber and the bonding strength at the intersection of the long fibers, the bonding portion is not excessively resinized, etc. 1/4 to 1/1 is preferable.
  • the composite ratio of the low-melting polyester component is reduced, the substantially V-shape formed by the low-melting polyester component becomes flatter, and the tip portions of each of approximately four crosses formed by the high-melting polyester component.
  • it is needless to say that such deformed substantially V-shaped and substantially cross-shaped shapes are within the scope of the present invention.
  • the long fiber nonwoven fabric can be obtained by a conventionally known method except that the nozzle hole used for melt spinning is changed. That is, in the method for producing a long fiber nonwoven fabric by accumulating long fibers obtained by melt spinning two kinds of polyester resins, the shape of the nozzle hole used for melt spinning is vertically and horizontally at the lower end of the Y-shape. Connected and adjacent Y-shaped // and ⁇ are parallel The one having a shape (hereinafter referred to as “Y4 shape”) is used.
  • This nozzle hole has four Y-shapes shown in FIG. And it connects with the upper and lower sides and right and left by the lower end 7 of Y character, and becomes Y4 form shown in FIG.
  • Y4 form adjacent Y-shaped / 8s and 8s are parallel to each other, and ⁇ 9,9s are parallel to each other.
  • polyester continuous fiber having a substantially Y4 cross section can be obtained.
  • polyester long fibers having four concave portions 2 can be obtained by making adjacent Y-shaped / 8,8 and ⁇ 9,9 parallel to each other.
  • tip can be obtained.
  • the low-melting-point polyester resin is supplied to the Y4-shaped V-shaped portion 10 and the high-melting-point polyester resin is supplied to the Y4-shaped + shaped portion 11.
  • melt spinning in such a supply mode a composite type polyester continuous fiber in which the substantially V-shaped portion 6 is formed of a low-melting polyester component and the substantially + -shaped portion 5 is formed of a high-melting polyester component is obtained.
  • composite type polyester continuous fibers After obtaining composite type polyester continuous fibers, they are accumulated to form a fiber web. Then, the fiber web is subjected to heat treatment to soften or melt the low melting point polyester component in the composite polyester long fiber, and to cool and solidify, so that the composite polyester long fiber is melted with the low melting point polyester component. To obtain a polyester long fiber nonwoven fabric. If necessary, a small amount of a binder may be added to the obtained long fiber nonwoven fabric.
  • the fineness of the polyester long fiber is 10 dtex or more, more preferably 15 dtex or more in consideration of rigidity and shape stability after tufting. By setting it to 10 dtex or more, the rigidity is excellent, and damage to the long fibers due to penetration of the tuft needle in the tufting process can be reduced.
  • the upper limit of the fineness is not particularly limited, but about 30 dtex is preferable in consideration of the cooling property at the time of melt spinning.
  • the basis weight of the tuft carpet primary base fabric is preferably about 60 to 130 g / m 2 in consideration of pile yarn retention.
  • the primary base fabric according to the present invention is excellent in rigidity and form stability, even if the basis weight is smaller than that generally used as a tuft carpet primary base cloth, the rigidity and form retainability are good. We can expect weight reduction by lowering the basis weight.
  • a pile yarn may be tufted on the primary base fabric to form a pile on the surface of the primary base fabric.
  • the pile yarn nylon yarn, polypropylene yarn, polyester yarn or the like is used.
  • a backing material after pre-coating resin as necessary. Examples of the backing material include a polyvinyl chloride paste and a resin such as polyethylene.
  • the polyester continuous fiber which is a constituent fiber of the nonwoven fabric constituting the tufted carpet primary base fabric according to the present invention, has a cross section consisting of a substantially + character part and a substantially V-shaped part provided at each tip. Both the substantially + -shaped part and the substantially V-shaped part have higher rigidity than a circular shape and the like, and the rigidity is further increased by combining high rigidity parts. Therefore, a tuft carpet primary base fabric made of a nonwoven fabric comprising such polyester long fibers as a constituent fiber has an effect of being highly rigid.
  • the long fiber has rigidity, so it is easy to escape by avoiding the collision of the tuft needle, and the collision Even if it does, damage to a long fiber stays in part and damage is very little, and damage to a primary base fabric can be kept to the minimum. Therefore, the shape change due to impact in the tufting process is small, the original form is maintained, delamination does not occur easily, and it is difficult to deform against the severe stress added in the next dyeing process or backing process, It can withstand sufficiently and has the effect of excellent process stability during tuft carpet processing.
  • the non-woven fabric constituting the tufted carpet primary base fabric according to the present invention has a substantially V-shaped cross section formed of a low-melting polyester component and a substantially + -shaped portion formed of a high-melting polyester component.
  • This is a composite polyester long fiber. Since the long fibers are bonded to each other by fusion of the low melting point polyester component, the nonwoven fabric has more excellent rigidity.
  • the constituent fibers are bonded to each other by the low-melting-point polyester component that forms four independent substantially V-shaped portions at the four distal end portions of the substantially cross portion that is the central portion of the cross section.
  • the long fibers are bonded to each other by fusion of the low melting point polyester component, but the long fibers are bonded by four substantially V-shaped portions protruding from the long fiber core portion.
  • the contact between the long fibers is less and the V between the long fibers is approximately V. Characters form a plurality of joint points, and the joint portion is not excessively resinized. Therefore, it is difficult to be destroyed even by the penetration of the tuft needle, and it is possible to maintain a good bonding strength, and the form maintaining property of the primary base fabric after the tufting process is excellent.
  • this unusually shaped cross section has a high degree of irregularity and a large number of recesses, so that a plurality of voids are formed between the long fibers, the bulkiness of the long fiber nonwoven fabric is increased, and the tufted pile yarn is retained. The property is also good.
  • melt point of polymer (° C): The temperature at which the maximum value of the melting endothermic peak measured at a heating rate of 20 ° C./min using a DSC-7 differential scanning calorimeter manufactured by Perkin Elmer was taken as the melting point.
  • Intrinsic viscosity of polyester 0.5 g of a sample was dissolved in 100 ml of a mixed solvent having an equal weight ratio of phenol and ethane tetrachloride, and measurement was performed by a conventional method at a temperature of 20 ° C.
  • Fineness (dtex) of long fibers constituting the nonwoven fabric The mass of 5 samples of a 1.8 m long sample stored overnight at a temperature of 20 ° C. and a humidity of 60% was measured using an upper pan balance (Mettler AE50), and the fineness was determined from the average value.
  • Tensile strength (N / 5 cm width): A strip described in JIS L 1096 using a constant speed extension type testing machine Tensilon RTM-500 manufactured by Toyo Baldwin Co., Ltd. Measured according to the law. And the average value of ten sample pieces was calculated
  • Stress at 10% elongation (N / 5 cm width): The stress at the time of 10% elongation was obtained from the SS curve drawn by the above tensile test, and the average value thereof was taken as the stress at the time of 10% elongation. The average value of 10 sheets was determined for each of the MD direction and the CD direction.
  • Example 1 Low melting point polyester (relative viscosity [ ⁇ rel] 1.44, which is a copolymer of 92 mol% terephthalic acid (TPA) and 8 mol% isophthalic acid (IPA) as a dicarboxylic acid component and 100 mol% ethylene glycol (EG) as a diol component, A melting point of 230 ° C. was prepared, and 4% by mass of titanium oxide added as a crystal nucleating agent to this low melting point polyester was used as a low melting point polyester component.
  • TPA terephthalic acid
  • IPA isophthalic acid
  • EG ethylene glycol
  • polyethylene terephthalate obtained by cocondensation polymerization of a monomer composed of 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component is converted into a high melting point polyester component (relative viscosity [ ⁇ rel] 1.38, melting point 260 ° C.).
  • a low melting point polyester component is supplied to the V-shaped portion, and a high melting point polyester component is supplied to the + -shaped portion, and the spinning temperature is 285 ° C., the single-hole discharge rate is 8.33 g / Melt spun in minutes.
  • the mass ratio of the supply amount of the low melting point polyester component and the supply amount of the high melting point polyester component was 1/2.
  • the long fiber group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the long fiber was 17 dtex.
  • the composite polyester long fiber group having the cross section shown in FIG. 2 discharged from the air soccer exit was opened using a fiber opening device and then accumulated on a moving net conveyor to obtain a long fiber web.
  • This long fiber web was introduced into a hot embossing device consisting of an embossing roll (the area of each embossing convex part is 0.7 mm 2 and the area ratio of the embossing convex part to the total area of the roll is 15%) and a flat roll, Thermal embossing was performed under conditions of a surface temperature of 210 ° C.
  • a tuft carpet primary base fabric was obtained by applying 0.7% by mass of the dimethylpolysiloxane emulsion to the nonwoven fabric in terms of solid content with respect to the mass of the fiber.
  • Example 2 In Example 1, in place of the basis weight 120 g / m 2, except that the 100 g / m 2, to obtain a tufted carpet primary backing in the same manner as in Example 1.
  • Comparative Example 1 Using the low-melting polyester and the high-melting polyester used in Example 1, using a nozzle hole in which six slit holes radially extend from the center shown in FIG. High melting point polyester was supplied to part b, and melt spinning was performed at a spinning temperature of 285 ° C. and a single hole discharge rate of 2.46 g / min. In addition, the mass ratio of the supply amount of the low melting point polyester resin and the supply amount of the high melting point polyester resin was set to 1/2.
  • the long fiber group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the long fiber was 4.9 dtex.
  • the composite polyester long fiber group having a six-leaf cross-sectional shape discharged from the air soccer outlet was opened with a fiber opening device and then accumulated on a moving net conveyor to obtain a fiber web.
  • This fiber web was introduced into the heat embossing apparatus used in Example 1, and subjected to heat embossing under conditions of a roll surface temperature of 204 ° C. and a roll linear pressure of 300 N / cm, and a polyester long fiber nonwoven fabric having a basis weight of 120 g / m 2.
  • a dimethylpolysiloxane emulsion was applied to the nonwoven fabric in a solid content of 0.7% by weight based on the fiber mass to obtain a tuft carpet primary base fabric.
  • Tufting was performed using pile yarns made of 1930 dtex nylon crimped yarns, with 10 gauges / 2.54 cm, 10 stitches / 2.54 cm, and a cut pile height of 3.5 mm. .
  • Table 1 shows the physical properties of the tufted carpet primary base fabrics of Examples 1 and 2 and Comparative Example 1.
  • the tuft carpet primary base fabrics of Examples 1 and 2 had excellent mechanical strength. Further, when the pile yarn was pulled out after tufting, it was evaluated that the pile yarn had higher resistance than the comparative example and had excellent pile yarn retention. The strength of the primary base fabric after pulling out the pile yarn was less reduced than that of the comparative example, and the thermocompression bonding portion remained partially, the rigidity was maintained, and the shape retention was good. Therefore, even when a pile arrangement failure is found after tufting the pile yarn, it is also possible to take out the pile yarn at that location and to tuft it again.
  • SYMBOLS 1 One substantially Y-shaped lower end of the substantially Y shape which is the cross-sectional shape of a long fiber 2
  • the recessed part formed in the substantially Y4 shape 3 The convex part formed in the substantially Y4 shape 4
  • the small recessed part formed in the substantially Y4 shape 5 Approximate cross section in the approximate Y4 shape 6
  • One Y-shaped lower end of the Y4 shape that is the shape of the nozzle hole at the time of melt spinning 8 9 Y-shaped ⁇ 10 Y4 V-shaped part 11 Y4 cross

Abstract

The problem to be solved by the present invention is to provide a tufted carpet primary base fabric in which, even after the tufting process, the junctions between long fibers in the primary base fabric are maintained and form stability is kept. This tufted carpet primary base fabric is configured from a nonwoven fabric in which the long fibers having a fineness of 10 decitex or greater are the constituent fibers. The cross-sectional shape of the long fibers is characterized by linking substantially "Y"-shaped bottom ends up and down and to the left and right (below, this shape is referred to as a "substantially Y4 shape"). The long fibers are of a composite-type polyester, wherein the substantially "V"-shaped parts (6) of the substantially Y4 shape are formed from a low melting point polyester, and the remaining, substantially "+"-shaped part (5) is formed from a high melting point polyester. The long fibers are bonded together by fusion of the low melting point polyester.

Description

タフトカーペット一次基布Tuft carpet primary fabric
　本発明は、パイル糸を植設してタフトカーペットを得るための一次基布に関するものである。 The present invention relates to a primary base fabric for obtaining a tuft carpet by planting pile yarn.
　タフトカーペットは、一次基布にタフティングによりパイル糸を打ち込む工程（タフト工程）を経た後、プレコート、バッキングが施されて（バッキング工程）得られる。また、タフト工程を経た後、染色工程を経る場合もある。タフトカーペット一次基布は、タフト工程や染色工程において、工程中に付与される荷重によって容易に変形しない応力と、タフト工程でのタフト針の貫通によって基布が破壊されにくいタフト性が要求される。 The tufted carpet is obtained by applying a pile yarn to the primary base fabric by tufting (tufting process), followed by pre-coating and backing (backing process). Moreover, after passing through a tufting process, it may pass through a dyeing process. The tuft carpet primary base fabric is required to have a tufting property and a tufting property in which the base fabric is not easily broken by the penetration of the tuft needle in the tufting process and the stress that is not easily deformed by a load applied during the tufting process or the dyeing process. .
　本出願人は、カーペット製造工程中に特定の方向に裂ける等の不具合が生じないために、熱エンボス加工によって特定の熱圧着部を設けた一次基布を提案している（特許文献１）。 The applicant has proposed a primary base fabric provided with a specific thermocompression bonding portion by hot embossing so as not to cause problems such as tearing in a specific direction during the carpet manufacturing process (Patent Document 1).
　タフトカーペット一次基布として、このように熱エンボス加工による熱圧着部を有する長繊維不織布はよく知られている。そして、一次基布を構成する長繊維は、熱圧着部により長繊維が拘束され接合している。拘束された長繊維がタフト針の貫入によって損傷を受けにくくするために、部分的に設けられた熱圧着部において不織布内層まで強固に接合させず（例えば、特許文献１　実施例１に記載の実施態様では低融点ポリエステル成分の融点よりも２５℃低い設定温度にて熱エンボス加工を施している。）、熱圧着部にタフト針が貫入したときは、熱圧着部での長繊維の拘束状態を、長繊維を切断することなく容易に解除して、長繊維が自由に動けるようにすると、長繊維強度を保持することができる。しかしながら、この方法では、タフト工程で、熱圧着部が解除されるために、長繊維強度は保持できるものの、基布としての強度が著しく低下し、また、熱圧着部の解除により長繊維同士の接合状態が解かれて長繊維が単に堆積した状態となって一次基布自体の形態を維持できなくなる。そうすると、例えば、一旦、パイル糸をタフト後にパイル配列不良を発見した際、パイル糸を一部抜き取り、再度、タフトしようとしても、一次基布自体で形態保持できないため、再度タフティングができない。 As a tuft carpet primary base fabric, a long-fiber non-woven fabric having a thermocompression bonding portion by heat embossing is well known. And the long fiber which comprises a primary base fabric is restrained and joined by the thermocompression bonding part. In order to make the constrained long fibers difficult to be damaged by the penetration of the tuft needle, it is not firmly bonded to the inner layer of the nonwoven fabric in the partially provided thermocompression bonding portion (for example, implementation described in Patent Document 1, Example 1 In the embodiment, heat embossing is performed at a set temperature that is 25 ° C. lower than the melting point of the low-melting polyester component.) When the tuft needle penetrates into the thermocompression bonding part, the restrained state of the long fibers in the thermocompression bonding part If the long fibers are easily released without being cut so that the long fibers can move freely, the strength of the long fibers can be maintained. However, in this method, since the thermocompression bonding part is released in the tufting process, the strength of the long fiber can be maintained, but the strength as the base fabric is remarkably reduced. The bonded state is released and the long fibers are simply accumulated, and the form of the primary base fabric itself cannot be maintained. Then, for example, once a pile arrangement failure is found after tufting the pile yarn, even if a part of the pile yarn is extracted and then tried to tuft again, the primary base fabric itself cannot maintain the form, so tufting cannot be performed again.
特開２００５－２８７７４５号公報JP 2005-287745 A
　本発明は、タフト工程後においても、一次基布中における長繊維同士の接合が維持され、一次基布自体においても良好に形態保持してなるタフトカーペット一次基布を提供することにある。 The present invention is to provide a tufted carpet primary base fabric in which the long fibers in the primary base fabric are bonded to each other even after the tufting step, and the primary base fabric itself maintains a good shape.
　本発明者は、今般、長繊維の横断面形状を従来知られていなかった形状とすることにより、より剛性に優れたポリエステル長繊維不織布を得ることに成功した。そしてこのポリエステル長繊維不織布をタフトカーペット一次基布に適用したところ、タフト工程においてタフト針による長繊維の損傷が少なく、かつ長繊維同士の融着による結合箇所の破壊も少なく、タフト工程後においても一次基布の剛直性が保持され、形態を良好に維持できることを見出し、本発明に到達した。 The present inventor has succeeded in obtaining a polyester long-fiber nonwoven fabric with higher rigidity by making the cross-sectional shape of the long fiber into a shape that has not been known conventionally. And when this polyester long fiber nonwoven fabric was applied to a tuft carpet primary base fabric, there was little damage to the long fibers by the tufting needle in the tufting process, and there was little breakage of the bonded part due to fusion of the long fibers, even after the tufting process The present inventors have found that the rigidity of the primary base fabric is maintained and the shape can be maintained well, and the present invention has been achieved.
　すなわち、本発明は、単糸繊度１０デシテックス以上の長繊維を構成繊維とする不織布により構成されるタフトカーペット一次基布であり、該長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した
Figure JPOXMLDOC01-appb-I000002
形状（以下、「略Ｙ４形状」という。）であり、
　該長繊維は、略Ｙ４形状の各々の略Ｖ字部が低融点ポリエステル成分で形成され、その他の略＋字部が高融点ポリエステル成分で形成されてなる複合型ポリエステル長繊維であり、
　該長繊維相互間は、該低融点ポリエステル成分の融着によって結合されていることを特徴とするタフトカーペット一次基布に関するものである。 That is, the present invention is a tufted carpet primary base fabric composed of a nonwoven fabric composed of long fibers having a single yarn fineness of 10 dtex or more, and the transverse cross-sectional shape of the long fibers is substantially vertical at the lower end of the Y shape. Connected to
Figure JPOXMLDOC01-appb-I000002
Shape (hereinafter referred to as “substantially Y4 shape”),
The long fiber is a composite type polyester long fiber in which each substantially V-shaped portion of a substantially Y4 shape is formed of a low-melting polyester component, and other substantially + -shaped portions are formed of a high-melting polyester component,
The long fibers are connected to a primary base fabric of a tuft carpet characterized by being bonded by fusion of the low melting point polyester component.
　本発明のタフトカーペット一次基布を構成する不織布は長繊維を構成繊維とし、その構成繊維の横断面形状に特徴を有するものである。この横断面形状は、図１に示すような略Ｙ字を四個持つものである。そして、略Ｙ字の下端１で上下左右に連結して、図２に示すような略Ｙ４形状となっている。この略Ｙ４形状は、四個の凹部２と八個の凸部３と四個の小凹部４とを有している。特に、中央の略＋字部５と、略＋字部５の各先端に連結された四個の略Ｖ字部６により、高剛性となっている。すなわち、六角形やＹ字等の単なる異形ではなく、剛性の高い略＋字部５と略Ｖ字部６の組み合わせによって、より高剛性となるのである。 The non-woven fabric constituting the primary tuft carpet of the present invention has long fibers as constituent fibers and is characterized by the cross-sectional shape of the constituent fibers. This cross-sectional shape has four substantially Y-characters as shown in FIG. And it is connected to the upper and lower sides and the right and left at the lower end 1 of a substantially Y shape, and has a substantially Y4 shape as shown in FIG. The substantially Y4 shape has four concave portions 2, eight convex portions 3, and four small concave portions 4. In particular, the substantially + -shaped part 5 at the center and the four substantially V-shaped parts 6 connected to the respective ends of the approximately + -shaped part 5 are highly rigid. In other words, it is not a simple shape such as a hexagon or a Y-shape, but a higher rigidity is achieved by a combination of the substantially + -shaped portion 5 and the substantially V-shaped portion 6 having high rigidity.
　長繊維は、低融点ポリエステル成分と高融点ポリエステル成分とによって構成されており、横断面形状の略Ｖ字部６が低融点ポリエステル成分で形成され、略＋字部５が高融点ポリエステル成分で形成された複合型ポリエステル長繊維である。本発明に係るタフトカーペット一次基布は、複合型ポリエステル長繊維を集積し、低融点ポリエステル成分を軟化又は溶融させた後、固化させることにより、ポリエステル長繊維相互間が低融点ポリエステル成分によって融着された不織布よりなるものである。低融点ポリエステル成分の融着によって、長繊維相互間が結合されているため、タフトカーペット一次基布の剛性がより優れる。 The long fiber is composed of a low-melting polyester component and a high-melting polyester component. The substantially V-shaped portion 6 having a cross-sectional shape is formed of the low-melting polyester component, and the substantially + -shaped portion 5 is formed of the high-melting polyester component. This is a composite type polyester continuous fiber. The tufted carpet primary base fabric according to the present invention is obtained by accumulating composite polyester long fibers, softening or melting the low melting point polyester component, and then solidifying it, so that the polyester long fibers are fused by the low melting point polyester component. It is made of a non-woven fabric. Since the long fibers are bonded to each other by the fusion of the low melting point polyester component, the rigidity of the primary base fabric of the tuft carpet is more excellent.
　低融点ポリエステル成分の融着は、加熱処理を施すことにより得られるが、この加熱処理は、熱エンボス加工により又は熱風処理により行われる。熱エンボス加工の場合には、部分的に設けられた熱圧着部において、長繊維同士の交点が融着される。また、熱風処理の場合には、全体において、長繊維同士の交点が融着される。なお、熱エンボス加工と熱風処理を併用してもよい。本発明においては、タフトカーペット一次基布の形態安定性の点から、部分的に熱と圧力とを付加することにより熱圧着する熱エンボス加工が好ましい。用いるエンボスロールの圧着面積率（エンボスロールの凸部の面積率）は、１０～２０％がよい。圧着面積率が小さすぎると、タフト工程におけるタフト針の貫通によって圧着部の一部が破壊されるため、タフト後に残存する圧着部の比率が少なくなりすぎて、剛性を保持しにくくなる。一方、圧着面積率が大きすぎると、タフト針の貫通による損傷が大きく、タフト後の一次基布の強力を保持しにくくなる。 The fusion of the low-melting-point polyester component is obtained by performing a heat treatment, and this heat treatment is performed by hot embossing or hot air treatment. In the case of hot embossing, the intersections of long fibers are fused in a partially provided thermocompression bonding part. In the case of hot air treatment, the intersections of long fibers are fused together. Note that hot embossing and hot air treatment may be used in combination. In the present invention, from the viewpoint of the shape stability of the tufted carpet primary base fabric, heat embossing in which thermocompression bonding is performed by partially applying heat and pressure is preferable. The pressure-bonding area ratio of the embossing roll to be used (area ratio of the convex part of the embossing roll) is preferably 10 to 20%. If the pressure-bonding area ratio is too small, a part of the pressure-bonded portion is destroyed by the penetration of the tuft needle in the tufting process, so that the ratio of the pressure-bonded portion remaining after the tuft becomes too small and it becomes difficult to maintain rigidity. On the other hand, when the pressure-bonding area ratio is too large, damage due to penetration of the tuft needle is large, and it becomes difficult to maintain the strength of the primary base fabric after the tuft.
　長繊維を構成する低融点ポリエステル成分と高融点ポリエステル成分との複合比は、長繊維の強度や長繊維同士の交点での接合強度、接合部が過度に樹脂化しないこと等を考慮して、１／４～１／１が好ましい。なお、低融点ポリエステル成分の複合比が小さくなると、低融点ポリエステル成分により形成される略Ｖ字がより扁平形になり、また、高融点ポリエステル成分により形成される略十字の各４箇所の先端部分が末広がりの形状になるが、このような変形した略Ｖ字および略十字であっても、本発明の範囲にあることは言うまでもない。 The composite ratio of the low-melting-point polyester component and the high-melting-point polyester component constituting the long fiber is considered in consideration of the strength of the long fiber and the bonding strength at the intersection of the long fibers, the bonding portion is not excessively resinized, etc. 1/4 to 1/1 is preferable. When the composite ratio of the low-melting polyester component is reduced, the substantially V-shape formed by the low-melting polyester component becomes flatter, and the tip portions of each of approximately four crosses formed by the high-melting polyester component However, it is needless to say that such deformed substantially V-shaped and substantially cross-shaped shapes are within the scope of the present invention.
　長繊維不織布は、溶融紡糸する際に用いるノズル孔を変更する以外は、従来公知の方法で得られる。すなわち、２種のポリエステル樹脂を溶融紡糸して得られた長繊維を集積して長繊維不織布を製造する方法において、溶融紡糸する際に用いるノズル孔の形状が、Ｙ字の下端で上下左右に連結し、かつ、隣り合うＹ字の／同士及び＼同士が平行である
Figure JPOXMLDOC01-appb-I000003
形状（以下、「Ｙ４形」という。）のものを用いるというものである。 The long fiber nonwoven fabric can be obtained by a conventionally known method except that the nozzle hole used for melt spinning is changed. That is, in the method for producing a long fiber nonwoven fabric by accumulating long fibers obtained by melt spinning two kinds of polyester resins, the shape of the nozzle hole used for melt spinning is vertically and horizontally at the lower end of the Y-shape. Connected and adjacent Y-shaped // and \ are parallel
Figure JPOXMLDOC01-appb-I000003
The one having a shape (hereinafter referred to as “Y4 shape”) is used.
　このノズル孔は、図３に示すＹ字を四個持つものである。そして、Ｙ字の下端７で上下左右に連結して、図４に示すＹ４形となっている。このＹ４形は、隣り合うＹ字の／８，８同士が平行であり、また＼９，９同士が平行となっている。かかるＹ４形のノズル孔にポリエステル樹脂を供給して溶融紡糸することにより、横断面が略Ｙ４形状のポリエステル長繊維を得ることができるのである。特に、隣り合うＹ字の／８，８同士及び＼９，９同士が平行となっていることにより、四個の凹部２を持つポリエステル長繊維を得ることができる。また、略＋字部５と、その各々の先端に設けられた略Ｖ字部６とを持つポリエステル長繊維を得ることができる。かかるＹ４形状のノズル孔にポリエステル樹脂を供給するにあたっては、低融点ポリエステル樹脂をＹ４形のＶ字部１０に供給し、高融点ポリエステル樹脂をＹ４形の＋字部１１に供給する。かかる供給態様で溶融紡糸することにより、略Ｖ字部６が低融点ポリエステル成分で形成され、略＋字部５が高融点ポリエステル成分で形成された複合型ポリエステル長繊維が得られる。 This nozzle hole has four Y-shapes shown in FIG. And it connects with the upper and lower sides and right and left by the lower end 7 of Y character, and becomes Y4 form shown in FIG. In this Y4 form, adjacent Y-shaped / 8s and 8s are parallel to each other, and \ 9,9s are parallel to each other. By supplying a polyester resin to the Y4 nozzle hole and melt spinning, a polyester continuous fiber having a substantially Y4 cross section can be obtained. In particular, polyester long fibers having four concave portions 2 can be obtained by making adjacent Y-shaped / 8,8 and \ 9,9 parallel to each other. Moreover, the polyester continuous fiber which has the substantially + character part 5 and the substantially V-shaped part 6 provided in each front-end | tip can be obtained. In supplying the polyester resin to the Y4-shaped nozzle hole, the low-melting-point polyester resin is supplied to the Y4-shaped V-shaped portion 10 and the high-melting-point polyester resin is supplied to the Y4-shaped + shaped portion 11. By melt spinning in such a supply mode, a composite type polyester continuous fiber in which the substantially V-shaped portion 6 is formed of a low-melting polyester component and the substantially + -shaped portion 5 is formed of a high-melting polyester component is obtained.
　複合型ポリエステル長繊維を得た後、これを集積して繊維ウェブを形成する。そして、繊維ウェブに熱処理を施すことにより、複合型ポリエステル長繊維中の低融点ポリエステル成分を軟化又は溶融させ、冷却して固化させることにより、複合型ポリエステル長繊維相互間を低融点ポリエステル成分で融着して、ポリエステル長繊維不織布を得る。得られた長繊維不織布には必要に応じて、少量のバインダーを付与してもよい。 After obtaining composite type polyester continuous fibers, they are accumulated to form a fiber web. Then, the fiber web is subjected to heat treatment to soften or melt the low melting point polyester component in the composite polyester long fiber, and to cool and solidify, so that the composite polyester long fiber is melted with the low melting point polyester component. To obtain a polyester long fiber nonwoven fabric. If necessary, a small amount of a binder may be added to the obtained long fiber nonwoven fabric.
　ポリエステル長繊維の繊度は、剛性やタフト後の形態安定性を考慮して、１０デシテックス以上であり、より好ましくは１５デシテックス以上である。１０デシテックス以上とすることにより、剛性に優れ、また、タフト工程でのタフト針の貫通による長繊維への損傷を少なくできる。繊度の上限は特に限定しないが、溶融紡糸の際の冷却性を考慮すると、３０デシテックス程度がよい。 The fineness of the polyester long fiber is 10 dtex or more, more preferably 15 dtex or more in consideration of rigidity and shape stability after tufting. By setting it to 10 dtex or more, the rigidity is excellent, and damage to the long fibers due to penetration of the tuft needle in the tufting process can be reduced. The upper limit of the fineness is not particularly limited, but about 30 dtex is preferable in consideration of the cooling property at the time of melt spinning.
　タフトカーペット一次基布の目付は、パイル糸の保持性を考慮して、６０～１３０ｇ／ｍ2程度がよい。なお、本発明に係る一次基布は剛性と形態安定性に優れるため、一般にタフトカーペット一次基布として使用されるものよりも目付を小さくしても剛性や形態保持性が良好であることから、目付を下げて軽量化を図ることが期待できる。 The basis weight of the tuft carpet primary base fabric is preferably about 60 to 130 g / m 2 in consideration of pile yarn retention. In addition, since the primary base fabric according to the present invention is excellent in rigidity and form stability, even if the basis weight is smaller than that generally used as a tuft carpet primary base cloth, the rigidity and form retainability are good. We can expect weight reduction by lowering the basis weight.
　本発明に係る一次基布を用いてタフトカーペットを得るには、一次基布に、パイル糸をタフティングして一次基布表面にパイルを形成させればよい。パイル糸としては、ナイロン糸、ポリプロピレン糸、ポリエステル糸等が用いられる。パイル糸が植え込まれたタフテッドカーペットの裏面に、パイル糸を固定する目的と、タフテッドカーペットの形態保持のために、必要に応じて樹脂をプレコートした後に、バッキング材を設けるとよい。バッキング材としては、例えば、ポリ塩化ビニルのペースト、ポリエチレン等の樹脂が挙げられる。 In order to obtain a tufted carpet using the primary base fabric according to the present invention, a pile yarn may be tufted on the primary base fabric to form a pile on the surface of the primary base fabric. As the pile yarn, nylon yarn, polypropylene yarn, polyester yarn or the like is used. In order to fix the pile yarn on the back surface of the tufted carpet in which the pile yarn is implanted and to maintain the shape of the tufted carpet, it is preferable to provide a backing material after pre-coating resin as necessary. Examples of the backing material include a polyvinyl chloride paste and a resin such as polyethylene.
　本発明に係るタフトカーペット一次基布を構成する不織布の構成繊維であるポリエステル長繊維は、その横断面が、略＋字部とこの各先端に設けられた略Ｖ字部とからなる。略＋字部も略Ｖ字部も、いずれも円形等の比べて高剛性であり、しかも高剛性のものが組み合わされていることにより、さらに高剛性になる。したがって、かかるポリエステル長繊維を構成繊維とする不織布よりなるタフトカーペット一次基布は、高剛性であるという効果を奏する。このような特異な異形断面であることから、タフト工程でのタフト針が一次基布に貫通した場合に、長繊維が剛性を有することから、タフト針の衝突を避けて逃げやすく、また、衝突したとしても、長繊維への損傷が一部に留まりダメージが非常に少なく、一次基布へのダメージを最小限に留まらせることができる。したがって、タフト工程での衝撃による形態変化が小さく、元の形態が維持され、層間剥離が起こりにくく、次工程である染色工程やバッキング工程にて付加される過酷な応力に対して変形しにくく、十分に耐えうることができ、タフトカーペット加工時における工程安定性に優れるという効果を奏する。 The polyester continuous fiber, which is a constituent fiber of the nonwoven fabric constituting the tufted carpet primary base fabric according to the present invention, has a cross section consisting of a substantially + character part and a substantially V-shaped part provided at each tip. Both the substantially + -shaped part and the substantially V-shaped part have higher rigidity than a circular shape and the like, and the rigidity is further increased by combining high rigidity parts. Therefore, a tuft carpet primary base fabric made of a nonwoven fabric comprising such polyester long fibers as a constituent fiber has an effect of being highly rigid. Because of such a specially shaped cross section, when the tuft needle in the tufting process penetrates the primary base fabric, the long fiber has rigidity, so it is easy to escape by avoiding the collision of the tuft needle, and the collision Even if it does, damage to a long fiber stays in part and damage is very little, and damage to a primary base fabric can be kept to the minimum. Therefore, the shape change due to impact in the tufting process is small, the original form is maintained, delamination does not occur easily, and it is difficult to deform against the severe stress added in the next dyeing process or backing process, It can withstand sufficiently and has the effect of excellent process stability during tuft carpet processing.
　また、本発明に係るタフトカーペット一次基布を構成する不織布の構成繊維は、横断面形状の略Ｖ字部が低融点ポリエステル成分で形成され、略＋字部が高融点ポリエステル成分で形成された複合型ポリエステル長繊維である。低融点ポリエステル成分の融着によって、長繊維相互間が結合されているため、不織布の剛性がより優れる。そして、その横断面の中心部である略十字部のそれぞれの四個の先端部に四個の独立した略Ｖ字部を形成する低融点ポリエステル成分によって、構成繊維同士が接合する。長繊維同士が低融点ポリエステル成分の融着により接合しているが、長繊維同士は、長繊維芯部から突出した４個の略Ｖ字部分によって接合しているため、例えば、芯部に高融点重合体、芯部の周りを取り囲むように低融点重合体が配された芯鞘型複合長繊維同士の接合と比べて、長繊維同士の面での接触が少なく、長繊維間における略Ｖ字同士が複数の接合点を形成するものとなり、接合部分が過度に樹脂化しない。したがって、タフト針の貫入によっても破壊されにくく良好な接合強力を維持でき、タフト工程後の一次基布の形態維持性が優れる。また、この特異な異形断面は異形度が高く多数の凹部を有することから、長繊維相互間にも複数の空隙が形成され、長繊維不織布の嵩高性が高くなり、タフティングしたパイル糸の保持性も良好である。 In addition, the non-woven fabric constituting the tufted carpet primary base fabric according to the present invention has a substantially V-shaped cross section formed of a low-melting polyester component and a substantially + -shaped portion formed of a high-melting polyester component. This is a composite polyester long fiber. Since the long fibers are bonded to each other by fusion of the low melting point polyester component, the nonwoven fabric has more excellent rigidity. The constituent fibers are bonded to each other by the low-melting-point polyester component that forms four independent substantially V-shaped portions at the four distal end portions of the substantially cross portion that is the central portion of the cross section. The long fibers are bonded to each other by fusion of the low melting point polyester component, but the long fibers are bonded by four substantially V-shaped portions protruding from the long fiber core portion. Compared to the joining of core-sheath type composite long fibers in which a low melting point polymer is disposed so as to surround the melting point polymer and the core, the contact between the long fibers is less and the V between the long fibers is approximately V. Characters form a plurality of joint points, and the joint portion is not excessively resinized. Therefore, it is difficult to be destroyed even by the penetration of the tuft needle, and it is possible to maintain a good bonding strength, and the form maintaining property of the primary base fabric after the tufting process is excellent. In addition, this unusually shaped cross section has a high degree of irregularity and a large number of recesses, so that a plurality of voids are formed between the long fibers, the bulkiness of the long fiber nonwoven fabric is increased, and the tufted pile yarn is retained. The property is also good.
　次に、本発明の実施例に基づいて説明する。なお、実施例中の物性等は下記により測定した。
（１）重合体の融点（℃）：
　パーキンエルマー社製ＤＳＣ－７型の示差走査型熱量計を用いて、昇温速度２０℃／分で測定した融解吸熱ピークの最大値を与える温度を融点とした。
（２）ポリエステルの固有粘度：
　フェノールと四塩化エタンとの等重量比の混合溶媒１００ｍｌに試料０. ５ｇを溶解し、温度２０℃の条件で常法により測定した。
（３）不織布を構成する長繊維の繊度（ｄｔｅｘ）：
　温度２０℃、湿度６０％の環境下で１昼夜保管した長さ１．８ｍの試料５点の質量について上皿天秤（ＭｅｔｔｌｅｒＡＥ５０）を用いて測定し、その平均値より繊度を求めた。
（４）目付（ｇ／ｍ2）：
　標準条件の試料から５０ｃｍ×５０ｃｍの試料片を１０枚切り取り、平衡水分にした後に、各試料片の重量を秤量し、この平均値を単位平方メートル当りの重量に換算し、目付（ｇ／ｍ2）とした。
（５）引張強力（Ｎ／５ｃｍ幅）：
　株式会社東洋ボールドウイン製の定速伸長型試験機テンシロンＲＴＭ－５００を用い、幅５ｃｍ、長さ３０ｃｍの短冊状試料片を、つかみ間隔２０ｃｍ、引張速度２０ｃｍ／分でＪＩＳ  Ｌ  １０９６に記載のストリップ法に準じて測定した。そして、試料片１０枚の平均値を求め、これを引張強力とした。ＭＤ方向とＣＤ方向についてそれぞれ、１０枚の平均値を求めた。
（６）１０％伸張時の応力（Ｎ／５ｃｍ幅）：
　上記の引張試験で描かれたＳ－Ｓ曲線から、１０％伸長時の応力を求め、これの平均値を１０％伸長時の応力とした。ＭＤ方向とＣＤ方向についてそれぞれ、１０枚の平均値を求めた。 Next, a description will be given based on an embodiment of the present invention. In addition, the physical property etc. in an Example were measured by the following.
(1) Melting point of polymer (° C):
The temperature at which the maximum value of the melting endothermic peak measured at a heating rate of 20 ° C./min using a DSC-7 differential scanning calorimeter manufactured by Perkin Elmer was taken as the melting point.
(2) Intrinsic viscosity of polyester:
0.5 g of a sample was dissolved in 100 ml of a mixed solvent having an equal weight ratio of phenol and ethane tetrachloride, and measurement was performed by a conventional method at a temperature of 20 ° C.
(3) Fineness (dtex) of long fibers constituting the nonwoven fabric:
The mass of 5 samples of a 1.8 m long sample stored overnight at a temperature of 20 ° C. and a humidity of 60% was measured using an upper pan balance (Mettler AE50), and the fineness was determined from the average value.
(4) Weight per unit area (g / m 2 ):
Cut 10 sheets of sample pieces of 50 cm × 50 cm from a sample of standard conditions, after the equilibrium moisture, was weighed weight of each sample piece, and converting the average value of the weight per unit square meter, basis weight (g / m 2 ).
(5) Tensile strength (N / 5 cm width):
A strip described in JIS L 1096 using a constant speed extension type testing machine Tensilon RTM-500 manufactured by Toyo Baldwin Co., Ltd. Measured according to the law. And the average value of ten sample pieces was calculated | required, and this was made into tensile strength. The average value of 10 sheets was determined for each of the MD direction and the CD direction.
(6) Stress at 10% elongation (N / 5 cm width):
The stress at the time of 10% elongation was obtained from the SS curve drawn by the above tensile test, and the average value thereof was taken as the stress at the time of 10% elongation. The average value of 10 sheets was determined for each of the MD direction and the CD direction.
実施例１
　ジカルボン酸成分としてテレフタル酸（ＴＰＡ）９２ｍｏｌ％とイソフタール酸（ＩＰＡ）８ｍｏｌ％、ジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％との共重合体である低融点ポリエステル（相対粘度〔ηｒｅｌ〕１．４４、融点２３０℃）を準備し、この低融点ポリエステルに、結晶核剤として４質量％の酸化チタンを添加したものを低融点ポリエステル成分として用いた。 Example 1
Low melting point polyester (relative viscosity [ηrel] 1.44, which is a copolymer of 92 mol% terephthalic acid (TPA) and 8 mol% isophthalic acid (IPA) as a dicarboxylic acid component and 100 mol% ethylene glycol (EG) as a diol component, A melting point of 230 ° C. was prepared, and 4% by mass of titanium oxide added as a crystal nucleating agent to this low melting point polyester was used as a low melting point polyester component.
　一方、ジカルボン酸成分としてテレフタル酸（ＴＰＡ）１００ｍｏｌ％とジオール成分としてエチレングリコール（ＥＧ）１００ｍｏｌ％とからなる単量体が共縮重合してなるポリエチレンテレフタレートを高融点ポリエステル成分（相対粘度〔ηｒｅｌ〕１．３８、融点２６０℃）として用いた。 On the other hand, polyethylene terephthalate obtained by cocondensation polymerization of a monomer composed of 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component is converted into a high melting point polyester component (relative viscosity [ηrel] 1.38, melting point 260 ° C.).
　そして、図４に示したノズル孔を用い、Ｖ字部に低融点ポリエステル成分を供給し、＋字部に高融点ポリエステル成分を供給して、紡糸温度２８５℃、単孔吐出量８．３３ｇ／分で溶融紡糸した。なお、低融点ポリエステル成分の供給量と高融点ポリエステル成分の供給量の質量比は、１／２であった。 Then, using the nozzle hole shown in FIG. 4, a low melting point polyester component is supplied to the V-shaped portion, and a high melting point polyester component is supplied to the + -shaped portion, and the spinning temperature is 285 ° C., the single-hole discharge rate is 8.33 g / Melt spun in minutes. In addition, the mass ratio of the supply amount of the low melting point polyester component and the supply amount of the high melting point polyester component was 1/2.
　ノズル孔から排出された長繊維群を、２ｍ下のエアーサッカー入口に導入し、長繊維の繊度が１７デシテックスとなるように牽引した。エアーサッカー出口から排出された図２に示す横断面を有する複合型ポリエステル長繊維群を開繊装置にて開繊した後、移動するネット製コンベア上に集積し、長繊維ウェブを得た。この長繊維ウェブを、エンボスロール（各エンボス凸部先端の面積は０．７ｍｍ2で、ロール全面積に対するエンボス凸部の占める面積率は１５％）とフラットロールからなる熱エンボス装置に導入し、表面温度２１０℃、線圧３００Ｎ／ｃｍの条件で熱エンボス加工を施して、目付１２０ｇ／ｍ2のポリエステル長繊維不織布を得た。この不織布にジメチルポリシロキサンのエマルションを固形分で繊維質量に対し、０．７質量％付与してタフトカーペット一次基布を得た。 The long fiber group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the long fiber was 17 dtex. The composite polyester long fiber group having the cross section shown in FIG. 2 discharged from the air soccer exit was opened using a fiber opening device and then accumulated on a moving net conveyor to obtain a long fiber web. This long fiber web was introduced into a hot embossing device consisting of an embossing roll (the area of each embossing convex part is 0.7 mm 2 and the area ratio of the embossing convex part to the total area of the roll is 15%) and a flat roll, Thermal embossing was performed under conditions of a surface temperature of 210 ° C. and a linear pressure of 300 N / cm to obtain a polyester long fiber nonwoven fabric having a basis weight of 120 g / m 2 . A tuft carpet primary base fabric was obtained by applying 0.7% by mass of the dimethylpolysiloxane emulsion to the nonwoven fabric in terms of solid content with respect to the mass of the fiber.
実施例２
　実施例１において、目付１２０ｇ／ｍ2に替えて、１００ｇ／ｍ2としたこと以外は、実施例１と同様にしてタフトカーペット一次基布を得た。 Example 2
In Example 1, in place of the basis weight 120 g / m 2, except that the 100 g / m 2, to obtain a tufted carpet primary backing in the same manner as in Example 1.
比較例１
　実施例１で用いた低融点ポリエステルと高融点ポリエステルとを用い、図５に示した中心から六本のスリット孔が放射状に延びているノズル孔を用い、スリット孔のａ部に低融点ポリエステル、ｂ部に高融点ポリエステルを供給して、紡糸温度２８５℃、単孔吐出量２．４６ｇ／分で溶融紡糸した。なお、低融点ポリエステル樹脂の供給量と高融点ポリエステル樹脂の供給量の質量比は、１／２とした。 Comparative Example 1
Using the low-melting polyester and the high-melting polyester used in Example 1, using a nozzle hole in which six slit holes radially extend from the center shown in FIG. High melting point polyester was supplied to part b, and melt spinning was performed at a spinning temperature of 285 ° C. and a single hole discharge rate of 2.46 g / min. In addition, the mass ratio of the supply amount of the low melting point polyester resin and the supply amount of the high melting point polyester resin was set to 1/2.
　ノズル孔から排出された長繊維群を、２ｍ下のエアーサッカー入口に導入し、長繊維の繊度が４．９デシテックスとなるように牽引した。エアーサッカー出口から排出された横断面が六葉断面形状である複合型ポリエステル長繊維群を開繊装置にて開繊した後、移動するネット製コンベア上に集積し、繊維ウェブを得た。この繊維ウェブを、実施例１で用いた熱エンボス装置に導入し、ロール表面温度２０４℃、ロール線圧３００Ｎ／ｃｍの条件で熱エンボス加工を施して、目付１２０ｇ／ｍ2のポリエステル長繊維不織布を得た。この不織布にジメチルポリシロキサンのエマルションを固形分で繊維質量に対し、０．７重量％付与してタフトカーペット一次基布を得た。 The long fiber group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the long fiber was 4.9 dtex. The composite polyester long fiber group having a six-leaf cross-sectional shape discharged from the air soccer outlet was opened with a fiber opening device and then accumulated on a moving net conveyor to obtain a fiber web. This fiber web was introduced into the heat embossing apparatus used in Example 1, and subjected to heat embossing under conditions of a roll surface temperature of 204 ° C. and a roll linear pressure of 300 N / cm, and a polyester long fiber nonwoven fabric having a basis weight of 120 g / m 2. Got. A dimethylpolysiloxane emulsion was applied to the nonwoven fabric in a solid content of 0.7% by weight based on the fiber mass to obtain a tuft carpet primary base fabric.
　得られた実施例１、２、比較例１のタフトカーペット一次基布にパイル糸をタフティングした後、タフトしたパイル糸を抜き取り、タフト抜き取り後のタフトカーペット一次基布の引張強力および１０％伸長時の応力を上記した方法により測定し、タフト後の強度保持性を評価した。 After pile yarn was tufted to the obtained tuft carpet primary base fabric of Examples 1 and 2 and Comparative Example 1, the tufted pile yarn was pulled out, and the tensile strength and 10% elongation of the tuft carpet primary base fabric after tuft removal. The stress at the time was measured by the method described above, and the strength retention after tufting was evaluated.
　タフトの条件は、１９３０デシテックスのナイロン捲縮加工糸よりなるパイル糸を用いて、ゲージ１０本／２．５４ｃｍ、ステッチ１０本／２．５４ｃｍ、カットパイルの高さ３．５ｍｍの条件で行った。 Tufting was performed using pile yarns made of 1930 dtex nylon crimped yarns, with 10 gauges / 2.54 cm, 10 stitches / 2.54 cm, and a cut pile height of 3.5 mm. .
　実施例１、２および比較例１のタフトカーペット一次基布の物性を表１に示す。実施例１、２のタフトカーペット一次基布は、優れた機械的強力を有していた。また、タフト後にパイル糸を抜き取る際には、比較例に比べて抵抗があり、パイル糸の保持性に優れたものであると評価できた。パイル糸を抜き取った後の一次基布の強力は、比較例よりも強力低下が少なく、部分的に熱圧着部も十分に残存しており剛性が維持され形態保持性も良好であった。よって、一旦、パイル糸をタフト後にパイル配列不良を発見した場合であっても、その箇所のパイル糸を抜き取り、再度タフティングすることにも対応可能であるものであった。 Table 1 shows the physical properties of the tufted carpet primary base fabrics of Examples 1 and 2 and Comparative Example 1. The tuft carpet primary base fabrics of Examples 1 and 2 had excellent mechanical strength. Further, when the pile yarn was pulled out after tufting, it was evaluated that the pile yarn had higher resistance than the comparative example and had excellent pile yarn retention. The strength of the primary base fabric after pulling out the pile yarn was less reduced than that of the comparative example, and the thermocompression bonding portion remained partially, the rigidity was maintained, and the shape retention was good. Therefore, even when a pile arrangement failure is found after tufting the pile yarn, it is also possible to take out the pile yarn at that location and to tuft it again.
Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000004
本発明に用いる長繊維の横断面形状である略Ｙ４形状の一つの略Ｙ字を示した図である。It is the figure which showed one substantially Y character of the substantially Y4 shape which is the cross-sectional shape of the long fiber used for this invention. 本発明に用いる長繊維の横断面形状である略Ｙ４形状を示した図である。It is the figure which showed the substantially Y4 shape which is the cross-sectional shape of the long fiber used for this invention. 本発明に用いるＹ４形のノズル孔の一つのＹ字を示した図である。It is the figure which showed one Y character of the Y4 type nozzle hole used for this invention. 本発明に用いるＹ４形のノズル孔を示した図である。It is the figure which showed the Y4 type nozzle hole used for this invention. 比較例で用いたノズル孔を示した図であり、このノズル孔により六葉断面の長繊維が得られる。It is the figure which showed the nozzle hole used by the comparative example, The long fiber of a six-leaf cross section is obtained by this nozzle hole.
  １　　長繊維の横断面形状である略Ｙ形状の一つの略Ｙ字の下端
　２　　略Ｙ４形状で形成された凹部
　３　　略Ｙ４形状で形成された凸部
　４　　略Ｙ４形状で形成された小凹部
　５　　略Ｙ４形状中の略十字部
　６　　略Ｙ４形状中の略Ｖ字部
  ７　　溶融紡糸する際のノズル孔の形状であるＹ４形状の一つのＹ字の下端
　８　　Ｙ字の／
　９　　Ｙ字の＼
　１０　Ｙ４形のＶ字部
　１１　Ｙ４形の十字部 DESCRIPTION OF SYMBOLS 1 One substantially Y-shaped lower end of the substantially Y shape which is the cross-sectional shape of a long fiber 2 The recessed part formed in the substantially Y4 shape 3 The convex part formed in the substantially Y4 shape 4 The small recessed part formed in the substantially Y4 shape 5 Approximate cross section in the approximate Y4 shape 6 Approximate V-shaped section in the approximate Y4 shape 7 One Y-shaped lower end of the Y4 shape that is the shape of the nozzle hole at the time of melt spinning 8
9 Y-shaped \
10 Y4 V-shaped part 11 Y4 cross

Claims (3)

  1. 　繊度１０デシテックス以上の長繊維を構成繊維とする不織布により構成されるタフトカーペット一次基布であり、該長繊維の横断面形状が、略Ｙ字の下端で上下左右に連結した
    Figure JPOXMLDOC01-appb-I000001
    形状（以下、「略Ｙ４形状」という。）であり、
    　該長繊維は、略Ｙ４形状の各々の略Ｖ字部が低融点ポリエステル成分で形成され、その他の略＋字部が高融点ポリエステル成分で形成されてなる複合型ポリエステル長繊維であり、
    　該長繊維相互間は、該低融点ポリエステル成分の融着によって結合されていることを特徴とするタフトカーペット一次基布。     It is a tufted carpet primary base fabric composed of non-woven fabrics having long fibers with a fineness of 10 dtex or more, and the cross-sectional shape of the long fibers is connected to the top, bottom, left and right at the lower end of a substantially Y-shape.
    Figure JPOXMLDOC01-appb-I000001
    Shape (hereinafter referred to as “substantially Y4 shape”),
    The long fiber is a composite type polyester long fiber in which each substantially V-shaped portion of a substantially Y4 shape is formed of a low-melting polyester component, and other substantially + -shaped portions are formed of a high-melting polyester component,
    A tuft carpet primary base fabric characterized in that the long fibers are bonded to each other by fusion bonding of the low melting point polyester component.
  2. 　熱エンボス加工により部分的に熱圧着部が形成され、長繊維相互間が結合されていることを特徴とする請求項１記載のタフトカーペット一次基布。 The tufted carpet primary base fabric according to claim 1, wherein a thermocompression bonding part is partially formed by hot embossing, and long fibers are bonded to each other.
  3. 　請求項１または請求項２記載のタフトカーペット一次基布に、パイル糸がタフティングされてパイルが形成されていることを特徴とするタフトカーペット。 A tuft carpet, wherein a pile yarn is tufted on the primary base fabric of the tuft carpet according to claim 1 or 2 to form a pile.
PCT/JP2013/084781 2013-04-16 2013-12-26 Tufted carpet primary base fabric WO2014171042A1 (en)

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US14/784,854 US20160060798A1 (en) 2013-04-16 2013-12-26 A primary cloth for a tufted carpet

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JPH10273863A (en) * 1997-03-28 1998-10-13 Toray Ind Inc Base cloth for tufted carpet and tufted carpet
JP2001181956A (en) * 1999-12-24 2001-07-03 Unitika Ltd Base fabric for tufted carpet and method for producing the same
JP2005287745A (en) 2004-03-31 2005-10-20 Unitika Ltd Tufted carpet primary ground fabric and tufted carpet
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See also references of EP2987899A4

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EP2987899B1 (en) 2017-11-01
US20160060798A1 (en) 2016-03-03

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