WO2017179519A1 - タフテッドカーペット用一次基布およびその製造方法 - Google Patents
タフテッドカーペット用一次基布およびその製造方法 Download PDFInfo
- Publication number
- WO2017179519A1 WO2017179519A1 PCT/JP2017/014613 JP2017014613W WO2017179519A1 WO 2017179519 A1 WO2017179519 A1 WO 2017179519A1 JP 2017014613 W JP2017014613 W JP 2017014613W WO 2017179519 A1 WO2017179519 A1 WO 2017179519A1
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- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven web
- base fabric
- primary base
- embossing
- tufted carpet
- Prior art date
Links
- 239000004744 fabric Substances 0.000 title claims abstract description 54
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 239000000835 fiber Substances 0.000 claims abstract description 45
- 238000004049 embossing Methods 0.000 claims abstract description 44
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 29
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 29
- 239000000470 constituent Substances 0.000 claims abstract description 28
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 8
- 238000002844 melting Methods 0.000 claims description 19
- 230000008018 melting Effects 0.000 claims description 17
- 229920005989 resin Polymers 0.000 claims description 9
- 239000011347 resin Substances 0.000 claims description 9
- 238000010030 laminating Methods 0.000 claims description 3
- 238000000034 method Methods 0.000 abstract description 4
- 239000004745 nonwoven fabric Substances 0.000 description 13
- 239000003086 colorant Substances 0.000 description 11
- 239000002131 composite material Substances 0.000 description 8
- 239000010410 layer Substances 0.000 description 7
- 229920000642 polymer Polymers 0.000 description 7
- -1 polyethylene terephthalate Polymers 0.000 description 6
- 238000009732 tufting Methods 0.000 description 5
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 239000002356 single layer Substances 0.000 description 4
- 239000004952 Polyamide Substances 0.000 description 3
- 230000001747 exhibiting effect Effects 0.000 description 3
- 229920002647 polyamide Polymers 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920003002 synthetic resin Polymers 0.000 description 3
- 239000000057 synthetic resin Substances 0.000 description 3
- 229920001169 thermoplastic Polymers 0.000 description 3
- 239000004416 thermosoftening plastic Substances 0.000 description 3
- LLLVZDVNHNWSDS-UHFFFAOYSA-N 4-methylidene-3,5-dioxabicyclo[5.2.2]undeca-1(9),7,10-triene-2,6-dione Chemical compound C1(C2=CC=C(C(=O)OC(=C)O1)C=C2)=O LLLVZDVNHNWSDS-UHFFFAOYSA-N 0.000 description 2
- 229920001634 Copolyester Polymers 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920006149 polyester-amide block copolymer Polymers 0.000 description 2
- 229920000742 Cotton Polymers 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- BXKDSDJJOVIHMX-UHFFFAOYSA-N edrophonium chloride Chemical compound [Cl-].CC[N+](C)(C)C1=CC=CC(O)=C1 BXKDSDJJOVIHMX-UHFFFAOYSA-N 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 230000002441 reversible effect Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
- B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
-
- 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
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B38/00—Ancillary operations in connection with laminating processes
- B32B38/06—Embossing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/08—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
-
- 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
- D05C17/026—Tufted products characterised by the tufted pile surface
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
- D06N7/006—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the textile substrate as base web
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/106—Carbon fibres, e.g. graphite fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2471/00—Floor coverings
- B32B2471/04—Mats
Definitions
- the present invention relates to a primary base fabric for tufted carpet and a method for producing the same.
- a primary base fabric for tufted carpet.
- This primary base fabric is used as a support when tufting pile yarn, that is, when planting pile yarn.
- a raw machine is obtained by tufting a desired pile yarn on the primary base fabric.
- a carpet is obtained by performing a backing process to this living machine. The obtained carpet is subjected to desired molding as required.
- Patent Document 1 describes a non-woven fabric as a primary base fabric colored in different colors. As a result, it is possible to reduce the amount of inventory required to arrange the required number of colors.
- Patent Document 2 also describes a tufted carpet base fabric (lining material) in which the front and back colors are different.
- the present invention when laminating two types of non-woven fabric composed of fibers of different colors, It aims at making it possible to laminate
- the present invention has the following gist.
- a primary base fabric for tufted carpet having a laminated first nonwoven web and second nonwoven web
- the first nonwoven web is composed of first constituent fibers formed of the first thermoplastic resin and containing carbon
- the second nonwoven web is composed of second constituent fibers formed of the second thermoplastic resin and having a carbon content lower than that of the first constituent fibers or not containing carbon
- the primary base fabric is obtained by embossing a first nonwoven web and a second nonwoven web.
- the first and second constituent fibers each have a low melting point resin having a lower melting point than that of the core resin disposed around the core resin.
- the constituent fibers are bonded to each other by melting and solidifying the low-melting point resin in the embossed portion of the embossing.
- the primary base fabric for tufted carpet characterized by the above-mentioned.
- the surface of the first nonwoven web has a processing mark by a flat roll for embossing
- the surface of the second nonwoven web has a processing mark by an embossing roll for embossing.
- the primary base fabric for tufted carpet according to any one of (1) to (3).
- the primary base fabric for tufted carpet of the present invention is obtained by integrating a first nonwoven web and a second nonwoven web having different carbon contents by embossing, and for embedding by embossing.
- the processing temperature and the processing pressure which are typical processing conditions, good integration can be achieved regardless of the difference in the carbon content. Therefore, according to the present invention, when two types of nonwoven webs composed of fibers having different colors due to different carbon contents are laminated, the nonwoven webs are laminated and integrated well tough.
- a primary base fabric for a ted carpet can be obtained.
- a primary base fabric 10 for tufted carpet has a configuration in which a first nonwoven web 11 and a second nonwoven web 12 are laminated and integrated. is there.
- the first nonwoven web 11 is configured such that the constituent fibers are formed of a thermoplastic synthetic resin and the constituent fibers contain carbon.
- the constituent fibers are formed of a thermoplastic synthetic resin, but the carbon content in the constituent fibers is lower than the carbon content in the first nonwoven web 11.
- the structure does not contain carbon.
- a first nonwoven web 11 is formed by discharging first constituent fibers 13 from a first nozzle 14. Then, the second non-woven web 12 is laminated on the first non-woven web 11 by discharging the second constituent fibers 15 from the second nozzle 16.
- the embossing device 18 has an embossing roll 19 and a flat roll 20. These rolls 19 and 20 are arranged such that the first nonwoven web 11 contacts the flat roll 20 and the second nonwoven web 12 contacts the embossing roll 19.
- the first and second constituent fibers 13 and 15 may be single-phase fibers or composite fibers formed by combining two types of thermoplastic synthetic resins.
- a core-sheath composite fiber in which a high melting point polymer is disposed in the core and a low melting point polymer is disposed around the core is preferable.
- a composite fiber having a cross-sectional structure shown in FIG. 2, that is, a core-sheath multi-leaf cross-sectional structure having a core portion 22 and a leaf portion 23 surrounding the core portion 22 and having a multi-leaf shape is preferable.
- the core portion 22 is formed of a high melting point polymer
- the leaf portion 23 is formed of a polymer having a lower melting point than the polymer of the core portion 22.
- Examples of the combination of the high melting point polymer and the low melting point polymer include high melting point polyester / low melting point polyester, polyester / polyamide, polyester / polyolefin, high melting point polyamide / low melting point polyamide, and the like.
- polyester polyethylene terephthalate or polybutylene terephthalate is preferably used.
- polyethylene terephthalate / polybutylene terephthalate, polyethylene terephthalate / copolyester (a resin obtained by copolymerizing a third component with ethylene terephthalate as a main repeating unit). ) Can be preferably used.
- the temperature in the embossing device 18 By appropriately setting the conditions and pressure conditions, the leaf portions 23 of the constituent fibers 13 and 15 are melted or softened, and the core portion 22 can be maintained in a fiber form without being melted or softened. As a result, the leaf portions 23 of the adjacent constituent fibers 13 and 15 are joined together, and the constituent fibers of the first nonwoven web 11 and the constituent fibers of the second nonwoven web 12 are integrated with each other.
- the primary nonwoven fabric 11 is manufactured by integrating the first nonwoven web 11 and the second nonwoven web 12 with each other.
- the constituent fibers are melt-solidified, that is, thermally bonded at the embossed portions, that is, a large number of discrete spot portions in the base fabric 10, and are not thermally bonded except at the spot portions. It is kept free.
- the laminate 17 is passed through the embossing device 18 so that the first nonwoven web 11 is in contact with the flat roll 20 and the second nonwoven web 12 is in contact with the embossing roll 19.
- the surface of the first nonwoven web 11 has a processing mark by the flat roll 20 for embossing
- the surface of the second nonwoven web 12 is embossed for embossing. It has a processing mark by the roll 19.
- the second nonwoven web 12 has a lower carbon content than the first nonwoven web 11 or does not contain carbon, so the first nonwoven web 11 is black or dark gray.
- the second nonwoven web 12 exhibits a lighter gray or white color.
- the primary base fabric 10 which exhibits black, gray, or white from which density differs on the front and back can be obtained.
- the first nonwoven web 11 having a higher carbon content is more flexible than the second nonwoven web 12.
- the processing conditions that is, the temperature condition and the pressure condition must be adjusted well.
- the first nonwoven web 11 and the second nonwoven web 12 are not sufficiently joined to each other, particularly during tufting in which a pile yarn is driven into the primary base fabric 10, peeling between the two tends to occur.
- Tend to be. This is because the non-woven web formed of a thermoplastic resin changes its heat conductivity due to the high and low carbon content, which is better than that of the thermoplastic resin, and the non-woven web has a particularly low carbon content. This is because heat is not easily transmitted on the web, and as a result, the thermal adhesiveness between different types of nonwoven webs decreases.
- the first nonwoven web 11 exhibiting a dark gray color and the second nonwoven web exhibiting a lighter gray color are used.
- the temperature and pressure conditions are higher than those when the embossing is performed on the first non-woven web 11 having a dark gray color.
- the temperature and pressure conditions that would normally be embossed on the single layer of second nonwoven web 12 exhibiting a light gray color, or Emboss under high temperature and high pressure conditions.
- the primary base fabric for tufted carpets which is composed of a reversible laminated nonwoven fabric with different colors on one side and the other side, and in which occurrence of delamination between layers is effectively prevented 10 is obtained.
- the primary base fabric for carpet constituted by the laminated nonwoven fabric of the present invention has a peel strength between two layers of the first nonwoven web and the second nonwoven web of 2.0 N / 50 mm width or more. preferable. If the peel strength is less than 2.0 N / 50 mm width, the two layers will be insufficiently crimped and the base fabric will peel into two layers in the tufting process, or cotton will occur. There is a possibility that the cloth fiber comes out on the surface or the gripping force of the tuft yarn is lowered. More preferably, the peel strength is 2.5 N / 50 mm width or more.
- Example 1 The polyethylene terephthalate having a hexalobal cross-sectional structure shown in FIG. 2 and having a melting point of 256 ° C. is arranged in the core, and 8 mol of isophthalic acid is copolymerized in the leaf as a main repeating unit of ethylene terephthalate.
- the fineness of this composite fiber was 5 dtex.
- the first constituent fiber having a carbon content of 0.35% by mass in both the core part and the leaf part in the form of this composite fiber, and the carbon content in both the core part and the leaf part in the form of this composite fiber.
- a second constituent fiber of 0.05% by mass, a dark gray first nonwoven web and a light gray second nonwoven web each having a basis weight of 60 g / m 2 are obtained. It was.
- the first and second nonwoven webs were laminated, and the obtained laminate was passed through an embossing apparatus (an apparatus comprising an embossing roll and a flat roll).
- embossing apparatus an apparatus comprising an embossing roll and a flat roll.
- the second nonwoven web colored with a low carbon content and therefore colored light gray is used as the embossing roll side, and the first carbon colored with a high carbon content and therefore colored dark gray.
- the nonwoven web was the flat roll side.
- the embossing conditions were as follows. In other words, if the second nonwoven web is a single layer, the carbon content is high, so the heat conductivity is good compared to the case where the first nonwoven web is a single layer. For example, the conditions of a temperature of 200 ° C. and a linear pressure of 22 kg / cm are optimal. However, for the above-mentioned laminate, conditions of a higher temperature, a temperature of 213 ° C., and a linear pressure of 22 kg / cm were applied. The temperature referred to here is the surface temperature of both rolls of the embossing apparatus.
- the primary base fabric for tufted carpet of Example 1 in which the first nonwoven web and the second nonwoven web were firmly integrated was obtained.
- the peel strength of the obtained primary base fabric was 2.6 N / 50 mm width.
- the sample obtained by cutting the obtained primary base fabric into a width of 50 mm and a length of 300 mm was placed between the first nonwoven web and the second nonwoven web, with two layers on the short side. 100 mm away from the edge. Then, using a tensile tester (manufactured by Toyo Baldwin Co., Ltd .: Tensilon RTM-500), it was pulled at a speed of 100 mm / min. From the elongation-strength plot obtained in this way, read the three locations from the highest strength maximum (peak extreme value) and the three lowest from the lowest (peak extreme). The value obtained by calculating the average value of was taken as the peel strength between the two layers.
- the primary base fabric for tufted carpet obtained as a further high temperature and high pressure condition of a temperature of 216 ° C. and a linear pressure of 43 kg / cm had a peel strength of 3.9 N / 50 mm width.
- Example 2 The embossing conditions were changed to the temperature of 213 ° C. and the linear pressure of 22 kg / cm in Example 1, and the temperature was 200 ° C. and the linear pressure was 22 kg / cm, which is the optimum condition when the second nonwoven web is a single layer. changed to cm. And otherwise, it was the same as Example 1, and obtained the primary base fabric for tufted carpets of Example 2. When the peel strength of the obtained primary base fabric was measured under the same conditions as in Example 1, it was 1.7 N / 50 mm width.
- Example 1 Only the second nonwoven web used in Example 1 (with a carbon content of 0.05% by mass in both the core and the leaf and a basis weight of the nonwoven web of 60 g / m 2 ) was laminated, and the resulting laminate was obtained.
- the body was passed through an embossing device.
- the embossing conditions were a temperature of 200 ° C. and a linear pressure of 22 kg / cm, which are the optimum conditions described above.
- the peel strength of the obtained base fabric was satisfactory with a width of 2.4 N / 50 mm, but both the front and back were the same color, and therefore different from the primary base fabric of the present invention having different colors on the front and back. Met.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Transportation (AREA)
- Mechanical Engineering (AREA)
- Carpets (AREA)
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
第1の不織ウェブは、第1の熱可塑性樹脂にて形成されかつカーボンを含有した第1の構成繊維にて構成され、
第2の不織ウェブは、第2の熱可塑性樹脂にて形成されかつカーボン含有率が第1の構成繊維よりも低いかまたはカーボンを含有しない第2の構成繊維にて構成され、
前記一次基布は、第1の不織ウェブと第2の不織ウェブとがエンボス加工によって一体化されたものである、
ことを特徴とするタフテッドカーペット用一次基布。
一次基布は、エンボス加工のエンボス部における低融点樹脂の溶融固化によって構成繊維同士が互いに接合されている、
ことを特徴とする(1)のタフテッドカーペット用一次基布。
第1の不織布ウェブと第2の不織ウェブとを積層し、
前記積層された第1の不織布ウェブと第2の不織ウェブとを、第1の不織ウェブをフラットロール側に配置するとともに、第2の不織ウェブをエンボスロール側に配置したうえで、フラットロールとエンボスロールとの間に通してエンボス加工を行う、
ことを特徴とするタフテッドカーペット用一次基布の製造方法。
図2に示される六葉形の断面構造を有し、芯部に融点が256℃のポリエチレンテレフタレートが配されるとともに、葉部に、エチレンテレフタレートを主たる繰り返し単位としてイソフタル酸を8モル共重合した共重合ポリエステルであって融点が230℃であるものが配された、複合繊維を用いた。この複合繊維において、芯部と鞘部との比率は、質量比で(芯部)/(鞘部)=6/4であつた。この複合繊維の繊度は5dtexであった。
エンボス加工の条件を、実施例1の温度213℃、線圧22kg/cmに代えて、上述の第2の不織ウェブが単層である場合の最適条件である温度200℃、線圧22kg/cmに変更した。そして、それ以外は実施例1と同じとして、実施例2のタフテッドカーペット用一次基布を得た。得られた一次基布について実施例1と同じ条件で剥離強力を測定したところ、1.7N/50mm幅であった。
実施例1で用いた第2の不織ウェブ(芯部および葉部ともにカーボン含有率が0.05質量%、不織ウェブの目付60g/m2)のみを2枚積層し、得られた積層体をエンボス加工装置に通した。エンボス加工の条件は、上記した最適条件である温度200℃、線圧22kg/cmとした。得られた基布の剥離強力は2.4N/50mm幅と満足なものであったが、表裏がいずれも同じ色彩であったために、表裏で色彩の異なる本発明の一次基布とは異なるものであった。
Claims (5)
- タフテッドカーペット用一次基布であって、積層された第1の不織ウェブと第2の不織ウェブとを有し、
第1の不織ウェブは、第1の熱可塑性樹脂にて形成されかつカーボンを含有した第1の構成繊維にて構成され、
第2の不織ウェブは、第2の熱可塑性樹脂にて形成されかつカーボン含有率が第1の構成繊維よりも低いかまたはカーボンを含有しない第2の構成繊維にて構成され、
前記一次基布は、第1の不織ウェブと第2の不織ウェブとがエンボス加工によって一体化されたものである、
ことを特徴とするタフテッドカーペット用一次基布。 - 第1および第2の構成繊維は、いずれも、芯部の樹脂の周囲に芯部の樹脂よりも低融点の低融点樹脂が配置されており、
一次基布は、エンボス加工のエンボス部における低融点樹脂の溶融固化によって構成繊維同士が互いに接合されている、
ことを特徴とする請求項1記載のタフテッドカーペット用一次基布。 - 第1の不織ウェブと、第2の不織ウェブとの間の剥離強力が2.0N/50mm幅以上であることを特徴とする請求項1記載のタフテッドカーペット用一次基布。
- 第1の不織ウェブの表面はエンボス加工のためのフラットロールによる加工跡を有し、第2の不織ウェブの表面はエンボス加工のためのエンボスロールによる加工跡を有することを特徴とする請求項1記載のタフテッドカーペット用一次基布。
- 請求項1から4までのいずれか1項に記載のタフテッドカーペット用一次基布を製造するに際し、
第1の不織布ウェブと第2の不織ウェブとを積層し、
前記積層された第1の不織布ウェブと第2の不織ウェブとを、第1の不織ウェブをフラットロール側に配置するとともに、第2の不織ウェブをエンボスロール側に配置したうえで、フラットロールとエンボスロールとの間に通してエンボス加工を行う、
ことを特徴とするタフテッドカーペット用一次基布の製造方法。
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EP17782332.5A EP3443875B1 (en) | 2016-04-11 | 2017-04-10 | Primary base fabric for tufted carpet, and method of manufacturing same |
CN201780014307.9A CN108697254B (zh) | 2016-04-11 | 2017-04-10 | 簇绒地毯用一次底布和其制造方法 |
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EP3443875A4 (en) | 2019-02-20 |
CN108697254A (zh) | 2018-10-23 |
US20190112740A1 (en) | 2019-04-18 |
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