JPH0739154B2 - Tough Tethered Pet - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a tufted carpet having excellent pile pull-out strength and secondary backing adhesive strength.

(Prior Art) Due to recent changes in lifestyle and improvement of living standard, carpets have been rapidly growing mainly for homes and automobiles.

The tufted carpet is a straight pattern obtained by applying a latex compound to a base material a (hereinafter referred to as "kibata") in which a pile is embedded in a primary base cloth and fixing the pile to the primary base cloth. It is called a king, and a backed latex layer can be seen on the back surface of the carpet. Since it is not necessary to bond the secondary lining b, the amount of applied latex is small, and it is generally marketed as an inexpensive carpet.

On the other hand, many secondary linings are further laminated on the latex layer to provide dimensional stability and bulkiness, and a high-grade carpet has been used for this purpose.

Conventionally, as the primary base cloth, a woven cloth of nonwoven fabric, polypropylene (hereinafter referred to as PP), woven cloth or non-woven cloth using a synthetic resin such as polyethylene terephthalate has been used, but among them, a pile is used for the PP primary base cloth. Those that are planted and fixed with a latex are poor in the compatibility between PP and latex, so the pull-out strength of the pile is weak and sufficient pile gripping force cannot be obtained. Therefore, there is a drawback that the pile falls out due to the fluctuating force.

Further, although the gut woven fabric has been conventionally used as the material for the secondary lining b, since the gute is an imported product, there is concern about a stable supply, and price fluctuations are severe due to market prices, and it is weak against chemical substances. Since there are problems in hygiene such as generation of mold due to moisture absorption, PP woven fabrics, especially woven fabrics of split yarn, have been used as secondary linings in recent years.

Conventionally, as a method for adhering the secondary lining to a raw fabric, a wet lamination method using a water-dispersed latex containing natural rubber, styrene-butadiene rubber, carboxylated styrene-butadiene rubber or the like as a main component has been used.

For this reason, a drying process is required after bonding, and since a large amount of latex is applied particularly when bonding the secondary lining, it takes time to dry, for example, a drying temperature of 60 to 70% by weight of binder solid component latex is used. When dried at 130 to 140 ° C, it takes about 10 minutes to dry, and as a result, the line speed of the carpet production process becomes slow, productivity becomes low, and energy cost also becomes high. Furthermore, since this PP secondary lining has a poor affinity with the latex compound, it has the drawback that the adhesive strength with the latex compound is extremely weak. A method of physically improving the adhesive force with the latex by positively raising the surface of the secondary lining of the split yarn woven in order to make up for this defect in contact with the latex with a raising machine such as a needle roller. However, it has not yet been able to maintain sufficient adhesive strength. In addition, since a raising process is required, equipment cost and space are taken up, and the cost becomes high.
In addition, the fluff (fluffs) and powder that separate during brushing scatter around, which is also environmentally unfavorable.

(Problems to be Solved by the Invention) The present inventors have diligently studied to solve the above-mentioned drawbacks. As a result, when the greige and the secondary lining b are adhered, the resin layer containing polypropylene having a thickness of 0.05 to 0.5 mm extruded as a main component as an adhesion layer c is used as the adhesion layer c and the crepe and the secondary lining. Based on this finding, it was found that by bonding the lining b with pressure to bond the greige to the secondary lining b, the toughened carpet is strong and the productivity is not reduced. The present invention has been completed.

As is clear from the above description, the object of the present invention is a tufted carpet in which the bond between the greige and the secondary lining b is strong, and the tufted carpet can be manufactured at low cost without lowering productivity. To provide a docket.

(Means for Solving Problems) The present invention has the following configurations.

In a tufted carpet in which a polypropylene secondary lining b is back-bonded to a substrate a in which piles are implanted in a polypropylene primary base cloth via an adhesive layer, the substrate a and the secondary lining b are A tufted carpet characterized in that it is pressure-bonded and adhered via an adhesive layer (c) which is a resin layer mainly composed of melt-extruded polypropylene having a thickness of 0.05 mm to 0.5 mm.

The pile material used in the tufted carpet of the present invention includes wool spun yarn, spun yarn of polyacrylonitrile, spun yarn of polyethylene terephthalate, spun yarn of nylon, etc. as spun yarn, and polyacrylonitrile filament yarn, polyethylene terephthalate as filament yarn. Filament yarn, nylon filament yarn, PP filament yarn, etc. are used.

Examples of the material for the primary base cloth include polyethylene terephthalate, woven cloth or non-woven cloth made of synthetic resin such as PP and woven cloth of natural fiber such as jute, but in the present invention, woven cloth made of PP as a main raw material. Alternatively, a primary non-woven fabric is used. In this case, PP may be a propylene homopolymer, a crystalline propylene-ethylene copolymer containing 80% by weight or more of a propylene component, or a propylene-ethylene-butene terpolymer, but the dimensional stability of the primary backing fabric From the standpoints of flexibility and stiffness, a primary base fabric using a propylene homopolymer is preferable. By using the PP primary base cloth, the adhesive strength between the melt-extruded PP adhesive layer c and the primary base cloth is improved, and the pile pull-out strength is also greatly improved.

As the secondary lining b in the present invention, PP is used as a main raw material, and flat yarn, split yarn, spun yarn, monofilament, or the like is woven, or a woven fabric in which the intersections are heat-sealed by crossing the warp and the cross is used. It is particularly preferable to use a woven fabric of split yarn whose main raw material is PP in terms of bulkiness and adhesiveness with the adhesive layer c.

The PP split yarn is prepared by weaving a PP stretched tape with a pin roller or a filer roller to give irregular or regular trunk fibers and branch fibers to give a texture similar to that of a jute. In this case, a split yarn fiber cloth is used. The secondary lining b may have a surface raised in contact with the adhesive layer raised by a raising machine or may not be raised. The PP used for the secondary lining b is not particularly limited as is the case with the PP used for the primary backing fabric, but a propylene homopolymer is preferable from the viewpoints of dimensional stability and ease of disentanglement of the split. Further, a blend of polyethylene, polystyrene or the like may be used to facilitate disentanglement. The blending amount of the polyethylene or polystyrene is 1 to 10% by weight.

In addition, PP added with inorganic fillers such as calcium carbonate, titanium oxide, and talc may be used for preventing deterioration during weaving and improving feeling.

In the present invention, the resin used for the adhesive layer c for adhering the greige and the secondary lining b is mainly composed of PP. PP
It is possible to achieve a great improvement in the adhesive force between the secondary lining b of the tufted carpet and the greige and a great improvement in the pull-out strength of the pile, which is the object of the present invention.

As the PP used for the adhesive layer c, a propylene homopolymer, a crystalline propylene-ethylene copolymer containing 80% by weight or more of a propylene component, a propylene-ethylene-butene terpolymer, an atactic polypropylene or a mixture thereof. Examples thereof include a mixture of two or more kinds. In order to give flexibility to the adhesive layer, low density polyethylene, linear low density polyethylene, high density polyethylene,
A mixture of an ethylene-vinyl acetate copolymer saponified product (EVA), ethylene-propylene rubber and the like can also be used. The mixing amount is preferably 1 to 20% by weight.

In addition, inorganic fillers may be mixed in order to give a weight feeling and sound insulation. Examples of typical inorganic fillers include calcium carbonate, talc, silica, clay, barium sulfate, zinc white carbon black, and the like. The mixing amount of these inorganic fillers is preferably 80% by weight or less, and when it exceeds 80% by weight, the adhesive layer c becomes too hard and brittle and cannot be put to practical use.

When the greige machine and the secondary lining b are bonded via the PP adhesive layer c by melt extrusion, a high-speed processing is possible because a drying process is not required compared to the conventional adhesive method of applying latex and then drying, and processing cost is reduced. In addition, the energy cost required for drying can be reduced. In addition, the unpleasant odor unique to LATEX is eliminated and the working environment is improved.

As a method for bonding the greige and the secondary lining in the present invention, the above-mentioned PP is an extruder with a T-die (L / D24-40, compression ratio 2.5
~ 4.0) and melt-kneading at a temperature of 250-300 ° C, and a thickness of 0.05 between the pile planting surface of the raw machine and the secondary lining b.
It is carried out by extruding a molten web of about 0.5 mm through a T-die and immediately thereafter passing it through a pair of pressure-bonding rolls to press-bond the green fabric and the secondary lining b. At this time, as the above-mentioned pair of pressure-bonding rolls, a normal pressure-bonding roll in which one of the rolls is a metal roll and the other is a rubber roll is used, and the pressure-bonding rolls are passed through so that the secondary lining comes into contact with the metal roll.

As the metal roll, a roll having a mirror-finished surface or a matte-finished (matte-finished) roll is used, but a matte-finished roll is used for the purpose of improving the texture of the obtained tufted carpet. It is preferable to use. The surface temperature of the metal roll is 10 to 50 ° C, preferably 20 to 30 ° C.

As described above, the thickness of the adhesive layer c is preferably in the range of 0.05 mm to 0.5 mm, more preferably 0.1 to 0.4 mm. Thickness
If it is less than 0.05 mm, strong adhesion between the secondary lining b and the greige and strong pulling force of the pile cannot be obtained, and if it exceeds 0.5 mm, the molten resin forming the adhesive layer c is the texture of the secondary lining b. It is not preferable because it exudes to the outside through it and also penetrates into the pile surface of the greige machine, causing pile fatigue and deteriorating the texture of the carpet.

The adhesive layer c of the present invention is preferably foamed. Since the adhesive layer c is foamed, the obtained tufted carpet has a voluminous feel, and the cushioning property is improved, and the breathability can be imparted. Further, the weight is reduced and the handling is preferable. In order to foam the adhesive layer c, for example, a method of injecting CFC gas or N ₂ gas into the extruder at the time of melt-kneading extrusion, or a raw material PP that is solid at room temperature and is heated to a temperature equal to or higher than the decomposition temperature is N ₂ gas or ammonia gas. An organic decomposition type foaming agent which decomposes while generating gas such as azodicarbonamide, metal salt of azodiamide, hydrazizocarbonamide, N, N'-dinitrosopentamethylenetetramine p-toluenesulphonylhydrazide The method of addition can be mentioned.

Hereinafter, the present invention will be described in detail with reference to Examples. In addition, each measurement in an Example followed the following method.

(1) Secondary lining peel strength, pile pull-out strength ... JISL-1021
Complies with.

(2) Carpet appearance: X indicates that the PP resin of the adhesive layer exudes to the secondary lining or pile side of the raw machinery, and ○ indicates that it does not.

Examples 1 to 4 and Comparative Examples 1 to 2 A raw fabric a in which a nylon pile was planted at 1/10 gauge and 9 stitches on a PP primary base cloth, a warp yarn was a flat yarn using a propylene homopolymer, and a weft yarn was propylene alone. A secondary lining b produced by a split yarn using a polymer,
Using a propylene homopolymer with an MFR (temperature 230 ° C, discharge amount of molten resin for 10 minutes when a load of 2.16 kg is applied) of 22, 280 ° C from a T-die attached to the tip of an extruder with a diameter of 50 mm
Melt extruded at the temperature
And a linear pressure of 10 kg / cm and a surface temperature of 30 ° C through the adhesive layer c.
This was crimped with a pair of crimping rolls and was taken at a speed of 5 m / mm to obtain a tufted carpet in which the greige a and the secondary lining b were adhered via the adhesive layer c.

The thickness of the adhesive layer c was 0.06 mm in Example 1 and 0 in Example 2.
1 mm, 0.2 mm in Example 3, and 0.4 mm in Example 4.
In addition, as Comparative Examples 1 and 2, Comparative Example 1 is performed in the same manner as the example.
Then, the thickness of the adhesive layer c was set to 0.8 mm and the thickness of Comparative Example 2 was set to 0.4 mm to obtain tough carpets.

Comparative Example 3 Using the same raw machine a as in Example 1, a general SBR latex compound having a solid content of 70% by weight was applied as an adhesive to the planting surface of the pile of the raw machine evenly with an apparent weight of 1200 g / m ^2. Then, the same secondary lining b as in Example 1 was applied thereon. This 13
It was dried at 0 ° C. for 10 minutes to obtain a tufted carpet.

Comparative Example 4 A tufted carpet was obtained in the same manner as in Example 2 except that a polyester non-woven fabric was used as the primary base fabric.

Comparative Example 5 A tufted carpet was obtained in the same manner as in Example 2 except that a jute was used as the secondary lining b.

Example 5 The same greige a and secondary lining b as in Example 1 were applied to a propylene homopolymer of MFR10, an organic decomposition type blowing agent azodicarbonamide.
Add 0.3% by weight and melt extrude at 200 ° C, expand ratio 2
Double (foaming ratio = adhesive layer PP density before foaming / adhesive layer after foaming)
Through a 0.3 mm thick adhesive layer c foamed to PP density), it was crimped with a pair of crimping rolls with a linear pressure of 10 kg / cm and a surface temperature of 30 ° C., and this was taken at a speed of 5 m / mm to produce raw machine a. Secondary lining b
To obtain a tufted carpet which is adhered via the adhesive layer c.

This tufted carpet was light, easy to carry and had a voluminous feel.

First, the test results of these examples and comparative examples are summarized.
Shown in the table.

As is clear from the results in Table 1, the tufted carpet of the present invention has high pile pull-out strength and secondary backing adhesive strength.

On the other hand, when the thickness of the adhesive layer c is outside the range of the present invention or when the adhesive layer c is made of latex, the pile pull-out strength is
The secondary lining has low adhesive strength and the appearance of the carpet is poor, and the primary base cloth made of a material other than PP, such as polyester, has a low pile pull-out strength, and the secondary lining b is made of jute. Only the secondary lining having a low adhesive strength could be obtained.

(Effect of the invention) In the tufted carpet of the present invention, the pile vegetation and the secondary lining are firmly adhered to each other, and since the pile pull-out strength is high, the pile does not fall out and the dimension is stable. It is a tufted carpet with excellent properties.

Further, the tufted carpet of the present invention using the foamed adhesive layer for the adhesive layer c is a tufted carpet which has a volume feeling in addition to the above-mentioned effects, is excellent in cushioning property, breathability, and is lightweight. is there.

Further, since organic solvent-based latex is not used as an adhesive for bonding the greige and the secondary lining, there is no decrease in productivity of the carpet and environmental hygiene problems during manufacturing, and it can be manufactured at low cost. It is a tufted carpet.

Since the tufted carpet of the present invention is a carpet having the above-mentioned excellent functions, it can be used in general households, offices,
It can be suitably used as a carpet for hospitals, hotels, restaurants, theaters, automobiles, and artificial turf.

Claims (4)

[Claims] 1. A tufted carpet in which a polypropylene secondary backing b is backed through a bonding layer to a base material a in which piles are embedded in a polypropylene primary base cloth,
The thickness of the substrate a and the secondary lining b melt-extruded is from 0.05 mm to
A tufted carpet characterized in that it is pressure-bonded and adhered via an adhesive layer c which is a resin layer containing 0.5 mm of polypropylene as a main component. 2. The tufted carpet according to claim 1, wherein the secondary lining b uses polypropylene split yarn in one or both of the lengthwise direction and the widthwise direction. 3. The adhesive layer c, which is a resin layer containing melt-extruded polypropylene as a main component, has a thickness in the range of 0.1 mm to 0.4 mm. The tufted carpet according to item. 4. The tufted product according to any one of claims 1 to 3, wherein the adhesive layer c, which is a resin layer containing melt-extruded polypropylene as a main component, is foamed with a foaming agent. carpet.