JPS6336242B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to an antifouling carpet treated with a fluorine-containing polymer and a method for producing the same. In order to satisfy the demand for keeping carpets clean for a long time, a method of spraying water-repellent and oil-repellent substances onto the surface of the finished carpet pile has been used. Although the spray treatment method has the advantage of being simple, it is not necessarily satisfactory in terms of the effect of preventing stains. In other words, in spraying, the antifouling treatment is applied only to the surface of the pile, that is, only the tip, and the rest of the pile is not antifouled, so the liquid that causes contamination spills onto the carpet. seeps into the pile and contaminates the carpet. The present inventor has completed the present invention after repeated studies in order to develop an antifouling carpet free of such problems. The purpose of the present invention is to provide a method for producing an antifouling carpet, and an object of the present invention is to provide a method for producing an antifouling carpet. This is achieved by using an antifouling carpet formed from a pile yarn containing a water- and oil-repellent fluorine-containing polymer, which consists of a fluoroalkyl group-containing monomer as the main constituent unit and a small amount of fluorine-containing polymer. A carpet is formed from pile yarn containing a water-repellent and oil-repellent fluorine-containing polymer consisting of cross-linkable monomer units and a cross-linking agent, and an adhesive is applied to the back side of the carpet without backing with a secondary base fabric. or by backing with a secondary base fabric and then heating to dry the adhesive and crosslink the polymer. In the antifouling carpet obtained by the method of the present invention, the entire pile is antifouling treated, and the polymer itself as an antifouling agent is crosslinked, so the antifouling effect is greater than that of conventional spray treated carpet. It can be said that it is an excellent stain-proof carpet that lasts long and has a markedly improved stain-proofing effect. The water- and oil-repellent fluorine-containing polymer used in the present invention is a polymer composed of a fluoroalkyl group-containing monomer as a main component and a small amount of a crosslinkable monomer. As a fluoroalkyl group-containing monomer, JP-A-Sho
Preferred monomers include acrylates and methacrylates having a fluoroalkyl group at the end of the side chain, which are disclosed in Japanese Patent Application Laid-open No. 49-61072 and Japanese Patent Application Laid-open No. 53-50077. There is no particular restriction as long as it is an oily polymerizable fluoroalkyl group-containing monomer. for example Particularly preferred monomers include acrylates and methacrylates containing a _C3-20 perfluoroalkyl group. The amount of the fluoroalkyl group-containing monomer unit in the polymer is usually 50 to 80% by weight, preferably 55 to 75% by weight. The crosslinkable monomer may be one that can form a copolymer with a fluoroalkyl group-containing monomer that can be crosslinked by the use of a crosslinking agent or simply by the action of heat, including conjugated diene monomers such as butadiene and isoprene. unsaturated carboxylic acids such as acrylic acid and methacrylic acid; epoxy group-containing monomers such as glycidyl acrylate, glycidyl methacrylate, and allyl glycidyl ether; N-methylol acrylamide, N-methylol methacrylamide, methylolated diacetone acrylamide, methylol acrylamide and methacrylamide such as diacetone methacrylamide; ethylene dimethacrylate, 2-chloroethyl vinyl ether, chlorvinyl acetate, and the like. Particularly preferred crosslinkable monomers are methylol group-containing acrylamide and methacrylamide, which are crosslinked by mere heating. The amount of crosslinkable monomer units in the polymer is usually 0.5 to 10% by weight, preferably 1 to 3% by weight. As a structural unit of the polymer of the present invention, a third monomer unit that can improve the feel of the pile yarn, washing resistance, dry cleaning resistance, solubility of the polymer, etc. can be included. For example, aromatic vinyl monomers such as vinyl chloride, vinyl fluoride, and styrene; butyl acrylate,
Alkyl esters of acrylic acid and methacrylic acid such as butyl methacrylate; ethylene,
Examples include, but are not limited to, vinyl acetate, acrylonitrile, and the like. The number of such third monomer units in the polymer is usually 10 to 10.
It is 49.5% by weight. The method for producing the fluorine-containing polymer used in the present invention is not particularly limited, and for example,
It can be produced using the known polymerization method disclosed in No. 1, etc. The crosslinking agent used in the present invention is not particularly limited, and any crosslinking agent conventionally used for crosslinking crosslinkable monomers containing the various crosslinkable monomers described above as constituent units can be used. Crosslinkable monomers and their typical crosslinking agents are shown below. In the case of diene monomers, organic peroxides, in the case of epoxy group-containing monomers, amines, in the case of unsaturated carboxylic acids, epoxy compounds, aziridinyl compounds, etc., methylol group-containing acrylamide and methacrylamide Examples include acidic catalysts such as oxalic acid and citric acid. The amount of the crosslinking agent used is not particularly limited, but is usually 0.1 to 10 parts by weight per 100 parts by weight of the polymer. The method for producing a carpet of the present invention includes the steps of forming a carpet using pile yarn containing the above-mentioned fluorine-containing polymer and a crosslinking agent (both may be collectively referred to as an antifouling agent hereinafter), and heating. crosslinking the polymer in the pile yarn. The antifouling agent-containing pile yarn used in the first stage is prepared by impregnating the raw cotton with an antifouling agent by soaking the raw cotton in a solution or emulsion of the antifouling agent at the raw cotton stage of various fibers before spinning the pile yarn. , pile yarn that is dried at a temperature that does not cause crosslinking and then spun using a conventional method, or pile yarn that is treated in the same way as raw cotton to contain an antifouling agent. Either may be used. In the present invention, a conventional method can be used for producing the antifouling agent-containing pile yarn, and the method is not limited to the above method. The method using immersion will be explained below as an example. The antifouling agent can be used in the form of latex when a fluorine-containing polymer is produced by emulsion polymerization. The crosslinking agent may be mixed into the latex as a solution in a suitable soluble solvent. When the polymer is produced by solution polymerization, the solution of the polymer may be used as is, and the crosslinking agent may be dissolved therein. When the antifouling agent is used in the form of a latex or as a solution, the concentration of the antifouling agent is usually 0.1 to 10% by weight, preferably 0.5 to 5% by weight, more preferably 0.5 to 3% by weight as a solid content. . The contact time of the raw cotton or pile yarn with the antifouling agent is not particularly limited as long as the antifouling agent is sufficiently impregnated into the raw cotton or pile yarn. Immersion for one hour or less is usually sufficient. Of course, it is also possible to add insect repellents, antibacterial and antifungal agents, flame retardants, and antistatic agents to the antifouling agent latex or solution for use in combination. Raw cotton or pile yarn containing a wet antifouling agent needs to be dried. If crosslinking progresses during drying, it will cause various inconveniences during the spinning of raw cotton or the stage of forming carpets using pile yarn, so it is desirable to suppress crosslinking during drying. Therefore, the drying temperature is 100°C or lower, preferably 70°C or lower. The drying method itself is not particularly limited, and examples include drying in a hot air circulation oven. After drying,
Raw cotton is spun into pile yarn using conventional methods. To manufacture a carpet using pile yarn containing an antifouling agent, the pile yarn is first pierced through a base fabric using a tufting machine to form a greige fabric as usual.
If the pile yarns are cut at the carpet surface during tufting, it will be a cut pile carpet, and if it is not cut, it will be a loop pile carpet. In the present invention, the pile yarn may be made of any variety, including wool, rayon, acrylic fiber, nylon, polyester, polypropylene, and the like. The base fabric is also not particularly limited, and examples thereof include jute, polypropylene, and the like. An adhesive is generally applied to the back side of the greige fabric of a tufted carpet in order to fix the pile threads to the base fabric, but the adhesive is not particularly limited in the present invention. Usually, an adhesive containing a latex of styrene-butadiene copolymer as a binder is used. The amount of adhesive to be used is not particularly limited as long as it follows a conventional method. Carpets backed with adhesive using a doctor roll etc. may be placed in a dryer such as a drying oven to evaporate the moisture in the adhesive without backing with a secondary base fabric, or with a secondary base fabric on the back. be guided. The subsequent crosslinking of the invention is carried out in a dryer with drying of the adhesive. The temperature at which crosslinking sufficiently proceeds can be appropriately determined depending on the combination of crosslinking monomer and crosslinking agent in the antifouling agent. Normally it is around 150℃. Normally, drying is done by blowing hot air onto the back side of the carpet or heating it with an infrared heater, and the drying temperature is usually around 150°C, but the heat in the pile on the front side of the carpet is absorbed by the back side of the carpet. The temperature drops to around 100℃ due to the loss of heat.
Therefore, if crosslinking of the antifouling agent in the pile yarn is insufficient at about 100°C, it is necessary to heat-treat the carpet surface after leaving the drying oven again using a suitable heating means such as an infrared heater. The temperature of the heat treatment may be appropriately determined depending on the type of crosslinkable monomer and crosslinking agent in the antifouling agent so that crosslinking is sufficient. The stain-resistant carpet pile obtained by the method of the present invention has a strong stain-proofing fluorine-containing polymer throughout the pile, so it has a remarkable water and oil repellent effect as well as a stain-proofing effect. Since the durability of the carpet is also improved, by carrying out the method of the present invention, it is possible to provide an extremely excellent stain-resistant carpet. The present invention will be specifically explained below using Examples. Example 1 Fluoroalkyl group-containing monomer [CH ₂ =
A fluorine-containing polymer containing 70% by weight of CHCOOCH ₂ CH ₂ C ₉ F ₁₉ , 28% by weight of n-butyl acrylate, and 2% by weight of N-methylolacrylamide was produced by conventional emulsion polymerization. The obtained latex was diluted with water to a solid content concentration of 0.5% by weight.
And so. For this latex, per 100g of latex
0.001g of citric acid was added. Pile yarn of 1/10 gauge acrylic fiber was immersed in latex containing a crosslinking agent for 5 minutes, water was thoroughly shaken off, and then dried at 50°C for 8 hours. This antifouling pile thread is inserted into a polypropylene base fabric to create a cut pile carpet (pile length 7
mm) was prepared. A styrene-butadiene rubber adhesive composition was uniformly applied to the back surface at a rate of 1.5 kg/ ^m2 , dried in a drying oven at 150°C for 10 minutes, and crosslinked to obtain a cut pile carpet (carpet of the present invention). . A cut pile carpet using acrylic fiber pile yarn without antifouling treatment was made in a similar manner. A solution of the copolymer separated from the latex and dried in methyl chloroform (solid content 0.5
% by weight) was applied by spraying and dried at 150°C for 10 minutes (comparative carpet). Water repellency and oil repellency were measured using the above two types of cut pile carpets. The results are shown in Table 1. Test method (1) Water repellency Isopropyl alcohol 20vol%/water 80vol%
Using a pipette with a droplet size of 3 mm in diameter, gently drop the mixed solution onto 9 locations on the pile surface, and observe the shape of the droplets. If the droplets at six locations maintain their shape after 3 minutes or more, it is determined to pass, and if the shape of the droplets disappears in less than 3 minutes, it is determined to be failed. (2) Oil repellency According to AATCC118, use a pipette with a droplet size of 5 mm to gently drop each of the standard solutions in the table below onto 9 locations on the pile surface, and observe the shape of the droplets after 30 seconds. Observe that the droplet does not penetrate into the pile6.
Observe whether the droplet shape is maintained at several points, and find the highest grade that will prevent the droplet from penetrating.

【table】

【table】

[Table] This is the test result on a surface where the pile surface was cut off by 1 to 2 mm.
In addition, water and oil repellency tests were conducted after rubbing the surfaces of the two types of carpet with a dry cloth 300 times.The carpet of the present invention reproduced the results shown in Table 1, but the comparative example carpet showed instantaneous water repellency. The oil repellency was grade 1 and the effectiveness was reduced. Example 2 Polymerization was carried out in methyl chloroform using azobisisobutyronitrile as a catalyst, and two types of copolymers were obtained.

[Table] was obtained. The polymer solution was diluted with methyl chloroform to a solids concentration of 0.5% by weight. The same pile yarn as in Example 1 was immersed in a polymer solution for 5 minutes, the liquid was thoroughly drained, and then left to dry at room temperature for one day. The same carpet as in Example 1 was made using this pile yarn. Drying and crosslinking at 150℃,
It was set as 20 minutes. The results of water repellency and oil repellency are shown in Table 2.

【table】

Claims (1)

[Scope of Claims] 1. In a carpet having antifouling-treated piles, the piles are crosslinked, and the water repellency consists of a fluoroalkyl group-containing monomer as a main structural unit and a small amount of crosslinkable monomer units; An antifouling carpet characterized in that it is formed from pile yarn containing an oil-repellent fluorine-containing polymer. 2 A carpet is formed from a pile yarn containing a water-repellent and oil-repellent fluorine-containing polymer consisting of a fluoroalkyl group-containing monomer as a main structural unit and a small amount of cross-linkable monomer units, and a cross-linking agent, and The method is characterized in that the adhesive is dried and the polymer is cross-linked by applying an adhesive to the back surface and heating it without backing a secondary base fabric or after pasting a secondary base fabric on the back. A method for manufacturing stain-resistant carpet.