JP4959165B2 - Method for producing tufted carpet primary base fabric - Google Patents

Description

  The present invention relates to a tufted carpet primary base fabric made of a nonwoven fabric in which long fiber groups are accumulated, and more particularly to a tufted carpet primary base fabric having deodorizing properties.

  In recent years, in order to realize a more comfortable clothing life and living environment, a life without unpleasant odor has been strongly desired. In addition, products and technologies that have been deodorized as welfare products for an aging society have been put into practical use. In response to these demands, it has been proposed to attach various deodorizing substances by various methods even in the deodorizing method using textile products.

  For example, Patent Document 1 proposes a carpet in which a deodorant composed of an amine compound having a specific particle size is fixed to a pile yarn constituting a pile layer with a resin. However, with this method, when a cleaner (vacuum cleaner) is applied during carpet maintenance, the rotating brush of the cleaner strikes the carpet surface fiber layer, and the deodorant and resin adhering to the surface fiber layer are peeled off. As a result, the deodorizing performance cannot be maintained.

  On the other hand, Patent Document 2 and Patent Document 3 can be cited as those considering the durability of the deodorizing effect. Patent Document 2 discloses a method in which a deodorant composed of plant phenols is attached to the fiber surface constituting the fiber structure, and further, durability such as heat resistance and washing resistance of the deodorizing effect is disclosed. In order to enhance the above, an inorganic porous material represented by zeolite, titanium / zinc composite oxide, silicon / zinc composite oxide or the like, or a layered inorganic compound represented by smectite, swellable mica, layered phosphate, It is described that it is supported beforehand. In Patent Document 3, as processing of the carpet back surface, a specific odor adsorbing material and a hydrazine derivative as a deodorizing material are mixed in a backing material, and a deodorizing material composed of a photocatalyst and a hydrazine derivative is mixed in a carpet surface fiber layer. It is disclosed that the binder resin is fixed to the surface fiber layer.

Patent Document 4 proposes a carpet in which a specific deodorant is applied to a carpet primary base fabric. According to this method, the primary base fabric provided with a deodorant is superior in deodorization durability against washing because the surface is covered with pile yarn and the back is covered with a backing material. .
JP 2002-077855 JP2002-242074 JP 2005-198584 A JP 2000-014520 A

  The above-described deodorant having excellent deodorization durability is an inorganic solid, and there are the following problems when trying to impart this to the primary base fabric. The primary base fabric serves as a support for tufting the pile yarn (the pile yarn is planted and installed), and the primary base fabric is subjected to a large impact by the penetration of the tuft needle. It can not withstand the impact and easily falls off. In the production over a long period of time, there is a problem that the deodorant (inorganic solid material) that has fallen off contaminates the machine. Moreover, when applying these inorganic solids, an aqueous dispersion in which the inorganic solid is dispersed in water is used regardless of the presence or absence of the binder resin for fixing. Many problems occur in handling in the manufacturing process, such as sedimentation of inorganic solids and clogging of spray nozzles.

  An object of the present invention is to provide a carpet that is excellent in handling in the manufacturing process and excellent in deodorizing durability.

  As a result of various studies to solve the problems of the conventional deodorant made of inorganic solids, the present inventor has mixed an aqueous solution containing an iron (divalent) chelate compound and a binder emulsion solution. When the solution was used, the handling property was good and the problem in the production process was solved. Also, the material added together with the binder was found to be difficult to fall off even by impact, and the present invention was achieved.

That is, the present invention is a method for obtaining a tufted carpet primary base fabric to which a binder has been applied. A mixed solution obtained by mixing an aqueous solution containing an iron (divalent) chelate compound and a binder emulsion solution is prepared. After applying the mixed solution to the nonwoven fabric in which the fiber group is accumulated, drying and curing are performed to give the nonwoven fabric a binder containing an iron (divalent) chelate compound, and the binder given to the nonwoven fabric is: A gist is a method for producing a tufted carpet primary base fabric characterized in that a binder film is formed and an iron (divalent) chelate compound is dispersed and present in the binder film .

  Hereinafter, the present invention will be described in detail.

The tufted carpet primary base fabric in the present invention is made of a nonwoven fabric in which long fiber groups are accumulated.

  Examples of the form of the nonwoven fabric include a nonwoven fabric in which long fibers are entangled and integrated with each other by needle punching, and a nonwoven fabric in which a part of the fibers are melted or softened by heat and the long fibers are integrated by thermal bonding.

  In the case of a nonwoven fabric in which long fibers are entangled and integrated with each other by needle punching, polyester-based long fibers, polyamide-based long fibers, and the like are used as the long fibers. In addition, composite long fibers such as core-sheath composite long fibers and side-by-side composite long fibers in which two kinds of polymers are combined are also used. In the case of a nonwoven fabric in which long fibers are bonded and integrated with each other by heat, composite long fibers such as two-component core-sheath composite long fibers and side-by-side composite long fibers are preferably used. A mixture of fibers made of a high melting point polymer and fibers made of a low melting point polymer is also preferably used. The combination of two types of polymers in the case of composite long fibers, or the combination of polymers constituting two types of fibers in the case of a mixture of two types of fibers having different melting points include polyester / polyamide, polyester / copolymer. Examples include polymerized polyester. In the present invention, it is preferable to use long fibers made of a polyester polymer from the viewpoint of excellent mechanical strength and versatility.

  The single yarn fineness of the long fiber is arbitrary, but generally 3 to 30 dtex is preferable, and 3 to 20 dtex is more preferable. When the fineness is less than 3 dtex, when tufting the pile yarn, the long fibers are easily cut, and the tensile strength of the primary base fabric after tufting tends to decrease. On the other hand, when the fineness exceeds 30 dtex, the primary base fabric itself becomes rough and rigid. For example, when it is desired to impart moldability to the tufted carpet, the use is likely to be limited.

In the tufted carpet primary base fabric according to the present invention, a binder is applied to the nonwoven fabric in which the long fiber group is accumulated, and the binder contains an iron (divalent) chelate compound.

  Iron (divalent) compounds have long been known as deodorant components, and provide an odor eliminating effect by oxidation-reduction reaction or the like against alkaline odor, acidic odor, neutral odor and the like. However, this divalent iron is easily oxidized in the air or water to become trivalent iron, and the deodorizing ability is lowered. In the present invention, by adding an ethylenediaminetetraacetic acid component, the iron (divalent) compound and the ethylenediaminetetraacetic acid component are bound and stabilized as an iron (divalent) chelate compound, so that it has a deodorizing ability. Can be maintained. In order to obtain an iron (divalent) chelate compound, an iron (divalent) compound and an ethylenediaminetetraacetic acid component are once mixed and dissolved to obtain an aqueous solution. Further, the iron (divalent) chelate compound is uniformly dispersed in the aqueous solution.

  In the present invention, by applying to the nonwoven fabric a mixed solution obtained by mixing an aqueous solution containing such an iron (divalent) chelate compound and a binder emulsion solution, the applied binder forms a binder film, An iron (divalent) chelate compound may be present in a dispersed state. Because it is applied to the nonwoven fabric as a binder film, the binder does not easily fall off due to the impact caused by the penetration of the tuft needle when tufting the pile yarn. Durability is maintained.

  Examples of the iron (divalent) compound used in the present invention include iron (eg, ferrous sulfate, ferrous chloride, ferrous nitrate, ferrous bromide, ferrous iodide, ferrous ammonium sulfate ( And divalent) inorganic salts. Any other materials can be used as long as they dissolve in water to form divalent iron ions.

  As the ethylenediaminetetraacetic acid component, salts such as sodium salt, potassium salt, and ammonium salt of ethylenediaminetetraacetic acid may be used.

In data off Ted carpet primary backing, iron (divalent) component is a deodorant component, tufted carpet primary backing area of the fabric (m ²⁾ per 0.5g or more and granted by 5g or less . If it is less than 0.5 g, it is difficult to obtain the desired deodorizing effect. On the other hand, if it exceeds 5 g, the quality becomes excessive, which is not preferable from the viewpoint of cost.

  The binder imparted to the non-woven fabric plays a role of holding an iron (divalent) chelate compound as a deodorizing component and a role of maintaining the mechanical strength of the primary base fabric. What is necessary is just to select the application amount of a binder suitably according to the form of a nonwoven fabric, the use of a primary base fabric, required performance, etc. in the range which does not impair the objective of this invention. For example, when using a nonwoven fabric in which long fibers are entangled and integrated with each other by needle punching, 5 to 20 parts by mass of binder is preferably added to 100 parts by mass of the nonwoven fabric. When the amount is less than 5 parts by mass, the effect of retaining an iron (divalent) chelate compound as a deodorant component is sufficient, but it is difficult to give a desired tensile strength to the tufted carpet base fabric. On the other hand, when the amount exceeds 20 parts by mass, the binding force of the binder becomes too strong, and the primary base fabric itself may be broken by an impact caused by the penetration of the tuft needle. As a nonwoven fabric, when using the nonwoven fabric formed by heat bonding and integration between long fibers by heat, it is preferable to give 3-5 mass parts of binders with respect to 100 mass parts of nonwoven fabrics. By setting it as 3 mass parts or more, an iron (bivalent) chelate compound can fully be hold | maintained and can be provided to the whole nonwoven fabric. On the other hand, when the amount exceeds 5 parts by mass, adhesion between fibers becomes too strong due to adhesion by heat and adhesion by a binder, and the primary base fabric itself may be broken due to impact caused by penetration of a tuft needle.

  As a binder, a copolymer obtained by copolymerizing two or more monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and the like in a desired molar ratio is used. It is preferable to do this. In addition, it is preferable to use a binder that does not contain N-methylolacrylamide and styrene monomer, which have been useful since they are excellent in heat resistance. This is because these components cause the generation of so-called volatile organic compounds (VOC).

In the present invention , the tufted carpet primary base fabric can be preferably produced by the following method.

  First, the long fiber group is accumulated. The long fiber group can be accumulated by a conventionally known method. For example, by collecting the long fiber group by a melt spinning method such as a spunbond method, the long fiber group is deposited on a moving collection conveyor. Accumulate.

  Next, it is preferable that the accumulated long fiber group is entangled and integrated by needle punching, or heat treatment is performed to melt or soften a part of the long fiber and integrate. Moreover, you may use together the process by needle punch, and heat processing.

When entangled and integrated with a needle punch, the punch density of the needle punch is appropriately set depending on the type of needle needle used and the needle depth, but is generally preferably 30 to 120 times / cm ² . When the punch density is less than 30 times / cm ² , the degree of entanglement between the long fibers is low. On the other hand, when the punch density exceeds 120 times / cm ² , the entanglement between the long fibers becomes too strong. There is a possibility that the long fibers are cut when the needle punching is performed.

  When heat treatment is applied to melt and soften part of the long fibers to integrate them, hot fibers or a hot roll is used to melt or soften part of the long fibers to heat the fibers together. Adhere. What is necessary is just to set suitably according to a processing apparatus, a processing speed, a linear pressure etc., when applying a heat roll, and set temperature is set to the temperature which a part of polymer which comprises a long fiber fuse | melts or softens.

  The mixed solution which mixed the aqueous solution containing an iron (bivalent) chelate compound and the binder emulsion solution is provided to the nonwoven fabric obtained by integrating the long fibers as described above. The mixing ratio of the aqueous solution containing the iron (divalent) chelate compound and the binder emulsion solution is appropriately set in consideration of the amount of iron (divalent) chelate compound to be imparted to the nonwoven fabric and the amount of binder (solid content). The application method of the mixed solution is, for example, applied by a spray method, an impregnation method, a coating method, etc., and if necessary, excess liquid is removed by mangle, followed by drying and curing, and an iron (divalent) chelate compound is contained. A binder is applied to the nonwoven fabric to obtain a tufted carpet primary base fabric.

  The obtained primary base fabric can be planted with a desired pile yarn and provided with a precoat or a backing material to form a tufted carpet. As a matter of course, a deodorant or the like may be attached to the pile on the surface of the tufted carpet or the backing material on the back surface by a conventionally known method or technique. It is particularly preferred when immediate effect on odor is required.

The tufted carpet primary base fabric in the present invention is provided with a binder, and the binder contains an iron (divalent) chelate compound. In the present invention, by providing a mixed solution of an aqueous solution containing an iron (divalent) chelate compound and a binder emulsion solution in the form of a binder prescription solution, the primary group for carpet excellent in mechanical strength provided with a binder. Simultaneously with obtaining the cloth, the iron (divalent) chelate compound can be applied to the primary base cloth in a state of being dispersed in the binder.

  Therefore, no extra binder is required for fixing the deodorant, and the carpet primary base fabric is not too hard. In addition, the applied binder forms a film, and the iron (divalent) chelate compound is dispersed in the binder film, so that it falls off due to a large impact caused by the penetration of the tuft needle when the pile yarn is implanted. Hard to do. Accordingly, the deodorant durability is excellent.

  In addition, since the iron (divalent) chelate compound can be applied in the form of an aqueous solution, the iron (divalent) component can maintain stability as a deodorant component, and can be seen as an inorganic solid in the mixed solution. It is difficult to cause sedimentation and clogging such as spray nozzles, and is easy to handle in the manufacturing process.

Further, according to the primary base fabric of the present invention, even when washing or vacuuming is performed for carpet maintenance, the binder containing an iron (divalent) chelate compound is difficult to fall off, and the surface of the primary base fabric is a carpet. Because the back is covered with a backing material, etc., the physical impact is not directly transmitted, so the binder is difficult to drop off, and deodorant durability, even without adding a deodorant to the carpet surface, A carpet excellent in washing durability can be obtained.

  Next, the present invention will be described in more detail with reference to examples. Moreover, about the primary base fabric and the carpet in an Example, deodorant evaluation was performed as follows.

(1) Deodorant evaluation <Sample>
Samples: [1] primary base fabric after processing, [2] primary base fabric after processing, passed through tuft machine without using tuft yarn (primary base fabric after empty tuft), [3] processing Deodorizing properties were evaluated for four types of carpets, [4] carpets after 5 washes. For the sample of [2], using a tuft machine (product name 500 mm, 1/10 gauge tuft machine), the primary base fabric was stitched at 10 stitches / inch and at a rotational speed of 600 times / minute. An empty tuft was performed with a tuft needle having a major axis of 2.5 mm. In addition, the sample of [4] was washed according to JIS L-0217 (1995) symbol-specific test method—washing method (water washing).
<Evaluation>
Gas detection tube method Samples sampled 10cm x 10cm in a 3L polyfluorinated polyethylene bag, and 600ml of gas with a predetermined initial concentration (100ppm for acetaldehyde, 900ppm for ammonia, 300ppm for hydrogen sulfide) The gas concentration after standing for 3 hours at room temperature is measured with a gas detector tube (manufactured by Komyo Chemical Co., Ltd.). Next, for comparison with a blank, 600 ml of the same gas with the same concentration is sealed in a 3 liter polyfluoroethylene bag in another container, and the gas concentration after standing at room temperature for 3 hours is measured with a gas detector tube. This is the density B. Deodorization rate is calculated by the following formula.
Deodorization rate (%) = (concentration B−concentration A) / concentration B × 100

Example 1
Using a spinneret having a hole diameter of 0.35 mmφ and a hole number of 160, polyethylene terephthalate having an intrinsic viscosity of 0.70 dl / g and a melting point of 255 ° C. was melt-spun from the die at a melting temperature of 285 ° C. The filament to be discharged was taken up while being drawn with air soccer so that the spinning speed was 5000 m / min, and a polyester long fiber group having a single yarn fineness of about 4.4 dtex was obtained. The long fiber group was opened with a fiber opening device provided at the outlet of the air soccer ball, and then deposited on a moving wire mesh collecting conveyor to obtain a fiber web. Next, the fiber web was passed through a needle punching machine in which a needle needle of RPD36 # manufactured by Organ was implanted, and needle punching was performed at a needle density of 60 times / cm ² . Thereafter, the punch web was passed through a hot press welding apparatus comprising a pair of smooth rolls heated to 190 ° C., and the punch web was compressed to obtain a nonwoven fabric having a basis weight of 85 g / m ² .

On the other hand, a deodorant aqueous solution (product name “Efnica K60” manufactured by Nanban Efnica Co., Ltd.) containing ferrous sulfate, ethylenediaminetetraacetic acid sodium salt, magnesium sulfate, and sodium sulfate, and methyl acrylate and ethyl acrylate. A mixed solution was prepared by mixing a binder emulsion solution (binder solid content ratio: 45%) obtained by emulsifying and dispersing in water an acrylic ester copolymer copolymerized as a component. The mixing ratio was deodorant aqueous solution / binder emulsion solution = 100/110. Then, the non-woven fabric is impregnated into the mixed solution, dried, and heat treated (cured) at 160 ° C. to fix a binder containing a deodorant, so that it is used for a primary base fabric with a basis weight of 100 g / m ² . A nonwoven fabric was obtained.

Example 2
Polyethylene terephthalate having a melting point of 255 ° C. was disposed as a core component, and a copolymer polyester having a melting point of 230 ° C. was disposed as a sheath component, and a core-sheath fiber was melt-spun from a melt base. The yarn group to be discharged is taken up while being stretched with an air soccer so that the spinning speed is 5000 m / min, and the yarn group is opened with a fiber opening device provided at the outlet of the air soccer, and then moved. A fiber web (100 g / m ² per unit area) obtained by depositing long fibers having a single yarn fineness of about 3.3 dtex was deposited on a wire mesh collecting conveyor. Next, the fiber web is passed through a hot embossing device composed of an embossing roll and a smooth roll, the surface temperature of both rolls is set to 190 ° C., the linear pressure between the rolls is set to 490 N / cm, and a heat embossing treatment is performed. A nonwoven fabric obtained by thermally bonding each other was obtained.

In the same manner as in Example 1, the mixed solution used in Example 1 is impregnated with a non-woven fabric by adjusting the amount of impregnation, and dried and heat treated (cured) to fix a binder containing a deodorant. A nonwoven fabric for tufted carpet primary base fabric having a basis weight of 106 g / m ² was obtained.

<Manufacture of carpets>
A crimped bulky nylon thread (product name: 1890 dtex-108 (HQBA) manufactured by Unitika Fiber Co., Ltd.) was prepared on the primary base fabric obtained in Examples 1 and 2, and a tuft machine (product name 500 mm, manufactured by Trunker Industries Co., Ltd.) 10 gauge tuft machine), tufting conditions 1/10 gauge, 10 pieces / 1 inch, loop pile height of 6 mm to obtain a living machine, then ethylene vinyl acetate on the back of the obtained living machine Resin was coated to make a tufted carpet.

As is clear from Table 1, the primary base fabric and carpet of the present invention have a very excellent deodorizing effect on acetaldehyde, ammonia, and hydrogen sulfide gas species, and have excellent washing durability. Met. Moreover, the primary base fabric after processing and the primary base fabric after tufting show almost the same deodorizing effect, and the primary base fabric of the present invention removes the binder (deodorant) by the impact of the tuft. It is difficult to produce, and it is understood that the deodorizing durability is excellent.

Claims (4)

A method for obtaining a tufted carpet primary base fabric provided with a binder, comprising a mixed solution in which an aqueous solution containing an iron (divalent) chelate compound and a binder emulsion solution is prepared, and a nonwoven fabric in which long fibers are accumulated After applying the mixed solution to, by drying and curing, the binder containing an iron (divalent) chelate compound is given to the nonwoven fabric, and the binder given to the nonwoven fabric forms a binder film, A method for producing a tufted carpet primary base fabric, wherein an iron (divalent) chelate compound is dispersed and present in a binder film . A tufted carpet primary base fabric obtained by the method for producing a tufted carpet primary base fabric according to claim 1. The tufted carpet primary base fabric according to claim 2 , wherein the iron (divalent) chelate compound is a combination of an iron (divalent) compound and an ethylenediaminetetraacetic acid component. A tufted carpet in which pile yarn is planted on the primary base fabric of the tufted carpet according to claim 2 or 3 .