JPH0765261B2 - Primary base fabric for toughened carpet - Google Patents

Description

TECHNICAL FIELD The present invention relates to a non-woven fabric used as a primary base fabric for toughened carpets, and provides a non-woven fabric with less tufts used as a primary base fabric for toughened carpets. It is a thing.

(Prior Art) It has been conventionally known to use a non-woven fabric composed of polyester filaments as a primary base fabric for tough carpets. As is conventionally known, these non-woven fabrics are made by continuously drawing polyester continuous filaments spun from a spinning nozzle by suction with an air-sucker, etc. Stabilized by a general method such as bonding, partially heat-bonding the web, or entanglement of the web with a needle punch, and further stabilizing by a combination of some of the above methods. It is a thing. These polyester continuous filament non-woven carpet primary base fabrics are generally formed into a carpet by subjecting the base fabric to a pulse by tufting, which is the next step, and if necessary dyeing and backing.

(Problems to be solved by the invention) However, when a non-woven fabric simply made of polyester continuous filament as described above is used as a primary carpet base fabric, a problem arises in that a tufted pile falls out from the primary base fabric, so-called pile loss occurs. was there. Pile pull-out occurs in various processes after tufting, and in extreme cases, so-called buck stitching occurs, in which the pile also comes off when the tuft needle driven into the primary backing together with the pile comes off, speeding up the machining process and toughening. Has become a major problem that deteriorates productivity with the increase in fine gauge. It is an object of the present invention to solve the drawbacks of the conventional carpet primary base fabric made of such a polyester continuous filament nonwoven fabric of the present invention, and to provide a carpet primary base fabric without pile loss.

(Means for Solving the Problems) That is, the present invention is a non-woven sheet composed of continuous filaments which are partially heat-pressed, and the continuous filaments have polyethylene entirely covering the surface of polyethylene terephthalate. It has a core-sheath structure and its weave is 2.
5 to 20 denier, the weave of the core component polyethylene terephthalate is 2 to 15 denier, and the weight ratio of the polyethylene terephthalate to the polyethylene is from 0.2 / 1.
The gist is the primary base fabric for toughened carpet, which is characterized in that it is in the range of 3.0 / 1.

The present invention will be described in detail below.

The polyethylene used in the present invention is generally industrially used polyethylene, and any of low density polyethylene having a density of 0.910 to 0.925, medium density polyethylene having a density of 0.926 to 0.940, and high density polyethylene having a density of 0.941 to 0.965. Is the target. Among them, the carbon number is 4
Commercially available linear low-density polyethylenes obtained by copolymerizing α-olefin with ethylene of ˜8 are particularly preferable from the viewpoints of their spinnability, texture when formed into a nonwoven fabric, and the like.

The polyethylene terephthalate used in the present invention may be any commercially available or industrially used ordinary polyethylene terephthalate, particularly those commercially available and used for fibers. Specifically, the intrinsic viscosity is 0.50 to 1 .
The range of 20 is preferable.

The two-component core-sheath structure of the fiber in the present invention may be any structure in which the surface of polyethylene terephthalate as the core is entirely covered with polyethylene as the sheath, and concentric circles sharing a common center in terms of cross-sectional shape. In addition to the shape, the eccentric core component and the core / sheath may have an irregular cross section other than a circular shape.

The weight ratio of the sheath component to the core component was limited to 0.2 / 1 to 3.0 / 1. When this ratio was less than 0.2 / 1, the amount of polyethylene fixing the pile was insufficient and sufficient effect could not be obtained. If the ratio exceeds 3.0 / 1, the strength of the sheet becomes weak because the amount of the core component responsible for the strength of the nonwoven fabric is insufficient.

The denier of the core component polyester itself directly controls the strength of the primary fabric for carpets of the present invention.
It must be at least 2 denier or more to withstand various processes such as tufting, dyeing and backing, and if it is 15 denier or more, the total denier as a composite yarn is inevitably large and the number of filaments that make up the non-woven fabric is large. It becomes a non-woven fabric with a reduced number of openings, and the effect of softening or partially melting the polyethylene of the sheath of the present invention and wrapping the pile cannot be expected. In order to exert the effects of the present invention, the total denier must be 2.5 to 20 denier and the core component must be 2 to 15 denier for the above reasons.

A continuous filament having such a two-component core-sheath structure can be manufactured using a conventionally known composite spinning device.
In order to make this continuous filament into a non-woven web, the fiber is stretched by using a generally known fiber-spreading device while stretching the fiber by using a conventionally known general method such as air pressure. Generally, a method of transporting while accumulating on the reticulated body is carried out.

(Function) According to the present invention, since the surface of the continuous filament constituting the nonwoven fabric is covered with polyethylene which is the sheath component, polyethylene is softened by the heat generated by friction between the needle or pile during tufting and the filament constituting the nonwoven fabric. It transforms into a shape that wraps around the filaments that make up the pile. After the tuft needle is removed, the polyethylene cools and solidifies. At this time, when the polyethylene softens, the polyethylene enclosing the pile filament fixes the pile filament to the primary backing as it is. Also, since the core component polyester cannot be easily softened by the frictional heat of the needles and piles during the tufting process that is usually performed, the primary backing fabric itself does not deform or deteriorate its physical properties during the tufting process. There is no problem, and no problem occurs in post-processing. In addition, if it is not possible to obtain sufficient frictional heat for softening polyethylene by simple tufting due to production reasons, the same effect can be obtained by heating the primary base cloth immediately before the tuft. Also, the same effect can be obtained by softening polyethylene by heating similarly immediately after tufting.

(Example) Next, a specific example will be described.

Note that the tuft conditions in the examples are a tuft tester and a tuft width of 30.
cm, 98 tuft needles, 8 gauges / inch, 8 stitches / inch, nylon tufts, loop tufts made of nylon with a loop length of 6 mm, and this sample was measured according to JIS-L-1021 pile thread pull-out strength measurement method. The maximum load when the pile comes off was measured.

The melting point of polyethylene is DSC-2 manufactured by Perkin Elmer.
It is the value measured with a C-type differential scanning calorimeter at a heating rate of 20 ° C / min.
l, value measured at a temperature of 20 ° C.

Examples and Comparative Examples A polyester having an intrinsic viscosity of 0.70 was used as a core component and a density of 0.
937g / cm ³ , composite index yarn made from linear low density polyethylene with melt index value of 25g / 10min and melting point of 128 ℃ by ASTM-D-1238 (E) method as a sheath component The filaments are spun at a fineness of 3,9,15 denier and a weight ratio of the sheath component to the core component shown in Table 1, and the filaments are spun by air pressure and then deposited on the operating porous strip for primary base cloth. It was a non-woven fabric. After tufting this non-woven fabric with a tuft tester, the pile yarn pull-out load was measured, and the obtained results are shown in Table 1.

(Effects of the Invention) As described above, the nonwoven fabric for the carpet primary base fabric of the present invention skillfully utilizes the two-component materials having different melting points, so that the pile is simply made of the primary material like the conventional nonwoven fabric for the carpet primary base fabric. Unlike the fact that the filaments that make up the non-woven fabric for the base fabric and the filaments that make up the pile are fixed only by the frictional force, the pile component is softened or partially melted, so that the pile filament is firmly attached to the primary base fabric. The primary base cloth itself has the excellent property of maintaining sufficient strength with polyester as the core component.

Claims (2)

[Claims] 1. A non-woven sheet comprising a continuous filament which is partially heat-pressed, wherein the continuous filament has a two-component core-sheath structure in which polyethylene entirely covers the surface of polyethylene terephthalate, and its weaving degree. Is 2.5 to 2
A tuft having a denier of 0 to 2 and a weaving degree of polyethylene terephthalate of 2 to 15 denier and a weight ratio of polyethylene terephthalate to polyethylene of 0.2 / 1 to 3.0 / 1. Primary base cloth for id carpet. 2. The primary backing fabric for tufted carpet according to claim 1, wherein the polyethylene is a linear low-density polyethylene which is a copolymer of α-olefin and ethylene.