JP4324895B2 - Nonwoven fabric and carpet for lining - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a non-woven fabric for lining that is used by being bonded to the back surface of a base sheet that is finished by applying a lining adhesive.
[0002]
[Prior art]
Many tufted pile fabrics produced by planting piles on a primary base fabric are used as carpets by applying a backing adhesive on the back surface and bonding the pile to the primary base fabric. In many cases, when applying the backing adhesive, a secondary base fabric such as a woven fabric, a knitted fabric or a non-woven fabric is bonded to provide a feeling of weight to the carpet and to ensure dimensional stability and shape stability. In order to enhance the properties, the foamed resin composition is thickly applied and laminated. For the foamed resin composition, a latex emulsion compound or a vinyl chloride paste sol is mainly used. The vinyl chloride paste sol has a problem because it contains a large amount of a plasticizer that is harmful to the human body and generates harmful gas containing halogen during combustion. In that respect, many latex emulsion compounds are harmless to the human body, but the foamed backing layer formed is weaker than the foamed backing layer of vinyl chloride paste sol and has a problem in durability.
[0003]
[Problems to be solved by the invention]
Therefore, an attempt has been made to attach a thick nonwoven fabric composed of fibers that are much stronger than the foamed cell coating of the foam backing layer to the tufted pile fabric as a cushioning material. However, in a thick non-woven fabric with high cushioning properties, the amount of heat energy for heating and drying of the backing adhesive applied for the bonding is large, the drying time is long, and the thicker it is, There is a problem in that delamination easily occurs. However, in order to increase the peel strength within the layer, it is only necessary to increase the coating amount of the backing adhesive and to deeply impregnate it to join the fibers of the nonwoven fabric. The cost of the carpet increases by the increased amount, the consumption of heat energy for the heat drying increases, and the drying time becomes longer. Further, when the coating amount is increased, the carpet becomes coarse and hard to feel, and it is difficult to obtain a soft carpet.
[0004]
OBJECT OF THE INVENTION
Accordingly, an object of the present invention is to speed up the heating and drying process of the backing adhesive applied to attach a thick nonwoven fabric to a tufted pile fabric or other base sheet. Another object of the present invention is to increase the in-layer peel strength of a thick non-woven fabric bonded to a tufted pile fabric or other base sheet without increasing the coating amount of the special backing adhesive. It is in. Another object of the present invention is to obtain a soft carpet in which a thick nonwoven fabric is backed and laminated, instead of the carpet in which the foamed backing layer of the foamed resin composition is laminated.
[0005]
[Means for Solving the Problems]
According to the present invention, when the nonwoven fabric 12 is bonded to the base sheet 14 with the emulsion resin backing adhesive 13, the nonwoven fabric 12 is opened so that the ratio of the opening area in the entire surface is 1 to 5%. Through holes 11 having an area of 4 to 50 mm ² are formed with an interval of 10 to 70 mm.
Since the nonwoven fabric 12 with the through-holes 11 is bonded to the base material sheet 14, the through-holes that overlap the through-holes 11 of the nonwoven fabric 12 are never made with the base material sheet 14.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Examples of the base sheet 14 used as a rug indoors and outdoors include a tufted pile fabric raw fabric, a Wilton carpet original fabric, a double raschel warp knitted fabric original fabric, a pile flat knitted fabric original fabric, and a needle punching felt original fabric. Applied. However, the base material sheet to which the nonwoven fabric is bonded in the present invention has its quality, such as tensile strength, tear strength, thickness, weight, cushioning, dimensional stability, shape stability, etc. The material, shape, and other qualities and uses of the base sheet are not limited. Therefore, although the Example of this invention is related to a tufted carpet, the use of the nonwoven fabric for lining is not limited to the secondary base fabric of a tufted carpet.
[0007]
The nonwoven fabric may be constituted by long filament filaments that are continuous, or may be constituted by short fibers. The nonwoven fabric used to supplement the physical properties of the base sheet, such as tensile strength, tear strength, dimensional stability, shape stability, etc., like the secondary base fabric of tufted carpet, includes polyester resin and polyolefin resin. It is preferable to use a needle punching nonwoven fabric with an interlining which is based on a woven fabric using tough yarns such as tape yarns for warp and weft yarns, and is laminated with a fiber web and subjected to needle punching. In order to increase the in-layer peel strength of the nonwoven fabric, a heat-fusible fiber is mixed in the fiber web, or a core-sheath composite fiber having a heat-fusible resin as a sheath component is used in the fiber web, and the heat fusion is performed. The fibers may be bonded with an adhesive resin, or the fibers may be bonded by impregnating with an adhesive. In particular, when the base sheet is used as a tile carpet, a needle-punched non-woven fabric with interlining is used in which a fiber web is laminated based on a woven fabric using glass fibers together with a woven fabric using polyester resin or polyolefin resin tape yarn. Alternatively, a woven fabric using a porous net or mesh-like thin glass fiber may be sandwiched between the base material sheet to be bonded and the nonwoven fabric.
[0008]
The through hole may be punched out or may be formed by inserting a heating needle. In the through-hole formed by the heating needle, the thermoplastic synthetic fibers constituting the nonwoven fabric are fused and connected across the front and back of the through-hole, so that the in-layer peel strength and compressive elasticity recovery force of the nonwoven fabric are increased. However, even if the through hole is punched out, the backing adhesive applied at the time of bonding penetrates into the through hole, and the fibers constituting the nonwoven fabric are bonded across the front and back of the through hole. This improves the peel strength and compressive elasticity recovery force, and also prevents the nonwoven fabric from unraveling from the opening periphery of the through hole. The shape of the opening periphery of the through hole is appropriately set such as a triangle, a square, or a star shape, but is preferably a circle.
[0009]
The reason why the ratio of the opening area of the through-holes occupying the entire surface of the nonwoven fabric is 1 to 5% is that, if the ratio is less than 1%, as shown in the data of the examples, the adhesive for emulsion resin backing is achieved by drilling through-holes On the other hand, the drying efficiency of the adhesive for emulsion resin backing does not improve in proportion to the opening area of the through-hole, even if the ratio exceeds 5%. This is because when the content exceeds 5%, the strength of the nonwoven fabric is also lowered. Is to a 4 mm ² the minimum opening area of each of the through holes, drying efficiency of the emulsion resin backing adhesives also opening area is bored small holes of less than 4 mm ² is not particularly improved, the maximum aperture When the area exceeds 50 mm ² , the emulsion resin backing adhesive oozes out from the through-holes and is contaminated, and the substrate sheet is exposed from the through-holes and the appearance is impaired. The reason why the interval L between the through holes is set to 10 to 70 mm is to set the ratio of the opening area of the through holes having an opening area of 4 to 50 mm ^{2 to} the entire surface of the nonwoven fabric to 1 to 5%.
[0010]
The emulsion resin backing adhesive contains moisture, and the type of resin as the main material is not limited as long as it requires heating and drying after application. In laminating the base sheet and the backing nonwoven fabric, the emulsion resin backing adhesive is preferably applied to the back surface of the base sheet, and the backing nonwoven fabric is overlaid on the coated surface.
[0011]
【Example】
Circular through-holes 11 having a hole diameter D of 4 mm were formed in a needle punching nonwoven fabric having an apparent thickness of 3.5 mm and a basis weight of 390 g / m ² with an interval L of 35.4 mm, with an opening area ratio accounting for 1% of the entire nonwoven fabric. The perforated nonwoven fabric 12a, the perforated nonwoven fabric 12b perforated with an interval L of 25.1 mm where the opening area ratio occupying the entire surface of the nonwoven fabric is 2%, and the opening area ratio occupying 3% of the entire area of the nonwoven fabric is 20.5 mm. A perforated nonwoven fabric 12c perforated with a spacing L, a perforated nonwoven fabric 12d perforated with a spacing L of 17.7 mm with an opening area ratio of 4% in the whole nonwoven fabric, and a blank nonwoven fabric 12e without perforating holes A total of five types of non-woven fabrics are prepared, and a styrene / butadiene latex compound (solid content 40 wt%) 13 is applied at an application amount of 1500 g / ² is set to (wet weight) was applied to the back surface of a tufted pile fabric 14, those of the nonwoven fabric 12a · 12b · 12c · 12d · 12e respectively bonded by pressure bonding the coated surface of the latex compound, respectively 120 ° C. The latex compound was introduced into a dryer and dried by heating to finish a tufted carpet.
[0012]
In this heating and drying process, when the drying time until the moisture contained in the applied latex compound 13 evaporates was measured by 98% by weight, the perforated nonwoven fabric 12a having a through hole opening area ratio of 1% was used. In the case of using a porous nonwoven fabric 12b having a drying time of 21 minutes and 20 seconds and a through hole opening area ratio of 2%, a porous nonwoven fabric 12c having a drying time of 20 minutes and 10 seconds and a through hole opening area ratio of 3% is obtained. In the case of using a porous nonwoven fabric 12d having a drying time of 19 minutes 34 seconds and an opening area ratio of the through holes of 4%, a drying time of 14 minutes 12 seconds was used, and a blank nonwoven fabric 12e having no through holes was used. The used product had a drying time of 25 minutes.
[0013]
The relationship between the opening area ratio of the through holes of the nonwoven fabric 12 of each of these tufted carpets and the drying time until the latex compound is dried to 98% by weight is shown in FIG. It was confirmed that the heating and drying process of the latex compound was greatly speeded up when the ratio of the opening area to 1 to 5%. In FIG. 1, 12a is a drying time of a porous nonwoven fabric having an opening area ratio of 1%, 12b is a drying time of a porous nonwoven fabric having an opening area ratio of 2%, and 12c is a porous hole having an opening area ratio of 3%. Non-woven fabric drying time, 12d represents measurement data of a porous non-woven fabric having an opening area ratio of 4%, and 12e represents measurement data of a dry time of a blank non-woven fabric without through holes.
[0014]
【The invention's effect】
As shown in the above examples, according to the present invention (claims 1 and 2), when the backing nonwoven fabric is bonded to the base sheet with the emulsion resin backing adhesive, it is applied between the base sheet and the nonwoven fabric. The drying efficiency of the emulsion resin backing adhesive can be increased, and the heating and drying process can be speeded up.
[0015]
The nonwoven fabric for lining according to the present invention (claims 1 and 2) has 10 to 10 through-holes with an opening area of 4 to 50 mm ² so that the ratio of the opening area to the entire surface is 1 to 5%. It is perforated with an interval of 70 mm, and the backing adhesive for adhering to the base sheet is infiltrated into the through hole, and the fibers constituting the nonwoven fabric for backing are bonded across the front and back of the through hole. It is not necessary to increase the coating amount of the backing adhesive so as to deeply penetrate into the inside of the backing nonwoven fabric in order to improve the in-layer peel strength and compressive elasticity recovery force of the nonwoven fabric. Since the maximum opening area of the through hole is 50 mm ² and the hole diameter (D) is about 7 to 8 mm, the backing adhesive does not ooze out from the through hole and is contaminated. The inconvenience that the base sheet is exposed through the holes and impairs the appearance of the nonwoven fabric for backing is also avoided.
[0016]
In order to add functionality such as cushioning properties, heat insulation properties, sound absorption / soundproofing properties, etc. to the base material sheet, the apparent thickness of the backing nonwoven fabric is preferably 2 mm or more and generally 5 to 25 mm. According to the present invention (Claims 1 and 2), even a thick backing nonwoven fabric having an apparent thickness of 2 mm or more can be efficiently bonded to the base sheet, and the apparent thickness is 5 to 20 mm. Can be used to obtain a carpet excellent in functionality such as cushioning, heat insulation, sound absorption / soundproofing, and so on, using a thick backing nonwoven fabric with an apparent thickness of 5 to 20 mm. When the carpet is cut into tiles, a tile carpet that is easy to construct by matching the cross section is obtained. Therefore, the present invention (Claims 1 and 2) has a base sheet as a tufted pile fabric that requires a large amount of adhesive for backing to fix the pile to the primary base fabric. Insulating carpets, tile carpets, dust control mats, etc. that require high physical properties such as heat insulation, sound absorption / soundproofing, tensile strength, tear strength, thickness, weight, dimensional stability, and shape stability Convenient.
[Brief description of the drawings]
BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a relationship diagram between the drying time of an emulsion resin backing adhesive for tufted carpet bonded with a backing nonwoven fabric according to the present invention and the opening area ratio of through holes.
FIG. 2 is a partially cut perspective view of a tufted carpet according to the present invention.
[Explanation of symbols]
11 Through hole 12 Non-woven fabric for backing 13 Latex compound (adhesive for emulsion resin backing)
14 Tufted pile fabric (base sheet)

Claims (2)

The ratio of the opening area of the through-hole which occupies the entire area of the nonwoven fabric, the opening area of the through-hole is 4 to 50 mm ² and the interval between the holes is 10 to 70 mm. A nonwoven fabric for carpet backing, which is used by adhering to the back surface of the carpet with an emulsion resin backing adhesive of 1 to 5%. The ratio of the opening area of the through-hole which occupies the entire area of the nonwoven fabric, the opening area of the through-hole is 4 to 50 mm ² and the interval between the holes is 10 to 70 mm. A carpet in which the non-woven fabric for lining having a content of 1 to 5% is bonded to the back surface with an emulsion resin lining adhesive, and the through-holes of the non-woven fabric do not penetrate the carpet.

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