JPH09273063A - Nonwoven fabric, primary base cloth for tufted carpet, tufted carpet, base material for filter and filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a nonwoven fabric excellent in rigidity, a primary base cloth for a tufted carpet excellent in processability for dyeing, resin backing, etc., and product characteristic, a tufted carpet, a filter base material excellent in processability for pleat formation and a filter having high rigidity and pleat retainability. SOLUTION: A long fiber nonwoven fabric made of filaments mainly composed of polyethylene terephthalate whose crystallization degree is >=35%. A primary base cloth for a tufted carpet consisting of the nonwoven fabric having an average fineness of the filaments of 2-15 denier and an apparent density of 0.15-0.4g/cm<3> . A tufted carpet made of the primary base cloth by tufting and having a backing layer consisting of pile yarns and resin. A filter base material consisting of the nonwoven fabric having an average fineness of the filaments of 0.5-10 denier and an apparent density of 0.25-0.65g/cm<3> . A filter made of the filter base material by pleating.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-woven fabric having excellent rigidity, and particularly to a primary base fabric for tufted carpet and tufted carpet, which has a soft texture and is excellent in processability and rigidity, and pleated. The present invention relates to a filter base material having excellent properties and a filter having excellent pleating shape retention and having a good shape retention during use.

[0002]

2. Description of the Related Art Nonwoven fabrics are obtained by needle-punching short fibers and mechanically intertwining them, non-woven fabrics obtained by adhering and fixing short fibers with a resin binder, and extruding from a spinneret and sucking at high speed. The so-called spunbonded non-woven fabric, which is obtained by suction drawing with an ejector and collecting the filament on a moving net, and then adhering it with an embossing roll, is common, and in recent years, the demand for industrial materials and civil engineering materials has increased. There is.

In particular, as primary base fabrics for tufted carpets, the use of spunbonded nonwoven fabrics is increasing because of the advantages that tufted pile yarns have good orderliness and fibers do not fray. Kosho 61-81
As proposed in Japanese Patent Publication No. 89, a thermoplastic synthetic resin is melted by heating, extruded from a spinneret having a large number of pores, sucked and stretched by an ejector sucking at high speed, and a filament is collected on a moving net. Primary fabric for tufted carpet obtained by mechanically entangled fibers by needle punching and further adhering them together with an adhesive, and polyethylene proposed in JP-A-3-104973. A primary base cloth for tufted carpet obtained by thermocompression bonding with an embossing roll, using a core-sheath composite fiber in which terephthalate is used as a core component and a low melting point component covers the entire surface of the fiber, and Japanese Patent Publication No. 3-17948. A non-woven fabric having an orthogonal structure, in which polyester filaments are folded back and laminated in a length direction and a width direction, which is proposed in the publication. In the manufacturing process, a tufted carpet obtained by combing the copolyester having a melting point lower than that of the polyester filament to the air jet device, mixing the polyester filament with the polyester filament, and then thermally welding the mixture through a heating cylinder. The primary base cloth for use is used.

A tufted carpet is produced by tufting pile yarns such as polyamide bulky continuous filament yarns (BCF) on these primary base fabrics by using a tufting machine to form a so-called pile fabric, and loop steamer. After dyeing the pile yarn with a continuous dyeing machine of the type, vinyl chloride resin paste, styrene-butadiene rubber (SB
R) resin, ethylene-vinyl acetate copolymer resin, or other various resins, or by backing the nonwoven fabric by needle punching without using the resin. Among tufted carpets, tile carpets are manufactured by cutting into a tile shape such as a square of 50 cm square after resin backing and the like.

Also in the filter substrate, because of its high performance and excellent durability and processability, the demand for spunbonded non-woven fabric as a substitute for a filter paper filter is increasing more and more. A pleated filter substrate is used.

[0006]

However, the conventional non-woven fabric has a problem in that, particularly when it is used as a primary base fabric for tufted carpet or as a filter base material, poor workability is caused by insufficient rigidity. .

[0007] For example, when it is used as a primary base cloth for tufted carpet, the rigidity of the pile fabric obtained by tufting pile yarns cannot be obtained due to insufficient rigidity of the nonwoven fabric, and when passing through the loop steamer in the dyeing process. Wrinkles, in some cases, the central part of the pile fabric may be folded and overlapped, resulting in dyeing unevenness of the pile yarn, and wrinkles and waviness of the pile fabric during resin backing, resulting in an uneven backing product. There is a processing problem such as yield deterioration, and tufted carpet obtained by resin backing, especially tile carpet, is not stiff because of its low rigidity and has a markedly reduced commercial value and has satisfactory properties. The reality was that we could not provide anything.

Even when used as a filter base material, if the rigidity of the nonwoven fabric is insufficient, there is a problem in that pleating becomes defective and satisfactory workability cannot be obtained, and the rigidity of the filter after pleating is also low. If the amount is insufficient, the irregularities (mountains and valleys) of the pleats will be deformed during use, and the filtration area will be reduced. As a result, there is a problem in that a product having a satisfactory dust collection performance cannot be provided.

The present invention has been made in view of such conventional non-woven fabrics, particularly primary base fabrics for tufted carpets and filter substrates.
Non-woven fabric with excellent rigidity, especially primary fabric for tufted carpet and tufted carpet, which have excellent processability such as dyeing and resin backing and excellent product characteristics.
Further, the present invention aims to provide a filter base material having excellent pleating property and a filter having high rigidity and excellent pleating shape retention.

[0010]

The present invention employs the following means in order to solve the above-mentioned problems.

That is, the non-woven fabric of the present invention is a long-fiber non-woven fabric composed of filaments containing polyethylene terephthalate as a main component, and has a crystallinity of 35% or more. is there.

The primary base fabric for tufted carpet of the present invention is such a non-woven fabric having an average filament fineness of 2 to 15 denier and an apparent density of the non-woven fabric of 0.15 to 0.4 g / and a characterized in that it is cm ^3, and tufted carpet of the present invention, by consuming tufted carpet primary backing, characterized in that it has a backing layer by tufting pile yarn and resin is there.

Further, the filter substrate of the present invention is such a non-woven fabric, wherein the filament has an average fineness of 0.5-0.5.
It is 10 denier and the apparent density of the nonwoven fabric is 0.25 to 0.25.
It is characterized in that it is 0.65 g / cm ³ , and the filter of the present invention is characterized in that the filter substrate is pleated.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is a nonwoven fabric excellent in rigidity,
In particular, we examined carefully whether it would be possible to provide a primary base fabric for tufted carpets that is excellent in processability during dyeing or backing and a filter base material that is excellent in pleating processability. Polyethylene terephthalate having a specific degree of crystallinity was found. It has been clarified that the above-mentioned requirements can be satisfactorily achieved by using a filler having a main component (hereinafter abbreviated as PET) while keeping the excellent characteristics of the nonwoven fabric.

Further, when used as a primary base fabric for tufted carpet and a filter base material, such a nonwoven fabric has a specific average fineness and a specific apparent density, and thus has a specific average fineness and a specific apparent density. It has been made possible to provide a primary base cloth for tufted carpet and a filter base material which satisfy the above-mentioned requirements while maintaining many performances required for the base material.

According to the present invention, it is possible to provide a primary base cloth for tufted carpet and a filter base material having high rigidity and excellent workability. Further, such a primary base cloth for tufted carpet and a filter base material are provided. By using, it is possible to provide a tufted carpet having a good feel and a high commercial value, and a filter having excellent pleated shape retention and excellent dust trapping performance with little loss of shape.

A feature of the present invention is a long fiber non-woven fabric composed of filaments containing PET as a main component.
The crystallinity of ET is 35% or more, preferably 37% or more,
More preferably, it is at least 38%. PET
Has characteristics such as high strength, thermal dimensional stability, wet dimensional stability, and weather resistance, and it is necessary that at least 50% or more of PET is contained in the nonwoven fabric.

When the crystallinity is expressed by a birefringence index, it is 6
The PET is preferably 0 × 10 ⁻³ or more, preferably 80 × 10 ⁻³ or more, and more preferably 100 × 10 ⁻³ or more. By adopting such PET,
For the first time, it is possible to provide a non-woven fabric satisfying all the characteristics such as high strength, thermal dimensional stability, wet dimensional stability, and weather resistance. In the present invention, the main body means P in the nonwoven fabric.
This means that at least 50% or more of ET is contained.

When it is used as a primary base fabric for tufted carpet or a filter substrate, it is indispensable that it is a long-fiber non-woven fabric because it has high strength, excellent durability, and no fibers fall off.

The degree of crystallinity as used in the present invention is determined from the nonwoven fabric to PE.
The T filament (component) was separated and evaluated by a differential scanning calorimeter method (DSC method). The measuring method will be described below. (1) If the non-woven fabric is composed of PET filament single component or a mixture of PET filament and other component filament, about 5 mg of PET filament is separated from the non-woven fabric and set in a standard aluminum container, and the temperature is raised. The initial heating run curve (DSC curve) was measured under an atmosphere of a rate of 10 ° C./min (standard sensitivity method) and a nitrogen flow of 30 ml / min. From this initial temperature rising curve (DSC curve), the melting peak temperature (endothermic peak) and the heat of fusion (C) of PET were obtained, and the crystallinity was calculated from the following equation.

Crystallinity (%) = (C / D) × 100 where C: heat of fusion of PET filament (cal / g) D: heat of fusion of a perfect crystal of PET (reference value: 33.5 cal / g)
(2) If the nonwoven fabric is a composite filament of PET and other components such as core-sheath type or bimetal type, and PET cannot be separated, about 5 mg of the nonwoven fabric is used as a sample.
The melting peak temperature and the heat of fusion (A) of the original sample were obtained by the same operation as in (1) above, and the PET content was used to determine PET.
The heat of fusion (C ') was converted and the crystallinity was calculated from the following formula.

Converted heat of fusion of PET (C ') (cal / g)
= (A / B) x 100 where A: heat of fusion per unit weight of the original sample (cal / g)
[Measurement Value] B: Content of PET (%) Crystallinity (%) = (C ′ / D) × 100 where C ′: Converted heat of fusion of PET (cal / g) D: Complete crystal of PET Heat of fusion (reference value: 33.5cal /
g) The literature values are based on "Thermal Analys" by Bernhard Wunderlich.
I referred to "is" (Academic press), p418 (1990).

The crystallinity is measured by the DS used in the present invention.
In addition to the C method, there are measurement methods such as a specific gravity (density) method and an X-ray diffraction method. The value of the crystallinity varies depending on each measurement method, but the crystallinity can be measured by a measurement method other than the DSC method. In the case of calculation, it goes without saying that the bias with the DSC method is obtained using the same sample, converted into the crystallinity measured by the DSC method, and the value may be 35% or more.

When the crystallinity of PET is less than 35%,
Sufficient tufted carpet because the filament itself cannot have sufficient rigidity because the crystalline portion of the filament is too small, and the rigidity of the non-woven fabric used for the primary base cloth for tufted carpet or filter base material cannot be obtained. It is impossible to obtain workability and pleating workability.

As a means for obtaining a long fiber non-woven fabric composed of PET filaments having a crystallinity of 35% or more, for example, PET is extruded from a spinneret, drawn and drawn by an ejector sucking at high speed, and a filament is moved on a net. It can be obtained by subjecting the nonwoven fabric (web) to heat treatment with hot air or the like using a hot suction drum, a hot plate, a heater or the like. At this time, the temperature of the hot air is preferably (PET melting point −90 ° C.) or higher, and more preferably {(PET melting point −20.
C.) to (melting point of PET-60.degree. C.)}. The heating time depends on the heating temperature, but is preferably at least 10 seconds or more, more preferably 20 seconds or more, and particularly preferably 30 seconds or more.

When the temperature of the hot air is (melting point of PET-90 ° C.) or lower, or when the heating time is less than 10 seconds, it tends to be difficult to obtain a satisfactory PET crystallinity.

Further, in the case of thermally bonding the filaments containing PET as a main component using the low melting point component, for example, in the case of thermocompression bonding using an embossing roll, it is better to perform the heat treatment with hot air before the thermocompression bonding. , The shape of the non-woven fabric after thermocompression bonding has a certain thickness such as cardboard paper, and the difference in fiber density between the front and back layers and the inner layer easily causes a cardboard-like shape,
It is preferable in that a nonwoven fabric having higher rigidity can be obtained.

More preferably, the melting point of the low melting point component is (P
The melting point of ET is not more than −60 ° C. and the temperature is not lower than the melting point of the low-melting point component, for example, by heat treatment using a thermal suction drum or the like.
This is preferable from the viewpoint of manufacturing cost because the PET can be highly crystallized at the same time that the filaments containing as a main component are thermally bonded.

In order to have the strength and durability required for the primary base cloth for tufted carpet and the filter base material, further, the spinning stability at the time of manufacturing the nonwoven fabric, the uniformity of the sheet weight due to the electrification of the jet collision plate, the recycling, etc. Therefore, it is preferable that the non-woven fabric is composed of PET and filaments made of copolyester such as adipic acid copolyester and isophthalic acid copolyester, and the filaments are bonded and fixed by heat fusion. Further, the melting point of the copolyester is preferably 20 to 90 ° C., more preferably 30 to 70 ° C. lower than the melting point of PET. If the melting point difference between the copolyester and PET is less than 30 ° C., the adhesive strength between the PET filaments due to melting of the copolyester tends to be insufficient. Conversely, if the melting point difference exceeds 90 ° C., PET
In addition, spinnability such as single yarn breakage due to instability at the time of filament spinning during the production of a nonwoven fabric due to the difference in the melting point of the copolyester is likely to occur.

The filaments made of PET and copolymerized polyester have a filament in which PET is a core portion and a copolymer is a copolymerized polyester from the viewpoints of spinning stability during production of a nonwoven fabric, ease of heat fusion, and strength of the nonwoven fabric. It is preferable that the polyester is a core-sheath type composite filament having a sheath portion, or a non-woven fabric composed of a bimetal type composite filament of polyethylene terephthalate and a copolyester, or a non-woven fabric composed of a mixed fiber of a PET filament and a copolyester filament.

As a method for adhering and fixing the filaments by thermal fusion, thermocompression bonding with a hot embossing roll, a thermal suction drum, or the like can be used. When a hot embossing roll is used, it is preferable that the pressure bonding area is 5 to 30%, more preferably 10 to 20%. If the pressure-bonding area is less than 5%, it is difficult to obtain a heat-bonding strength that can withstand processing because the bonding area is small.
If the pressure-bonding area exceeds 30%, the entire sheet tends to be adhered to form a film, so that not only is it difficult to obtain satisfactory rigidity, but when it is used as a primary base cloth for tufted carpet, it is difficult to obtain Problems such as increased base cloth penetration resistance, filament breakage, and increased noise during tufting are likely to occur.In addition, when used as a filter base material, the ventilation performance of the nonwoven fabric decreases and pressure loss increases. Inconvenience tends to occur.

From the viewpoints of workability and performance of the primary base fabric for tufted carpets and filter substrates, it is preferable to provide a difference in thermal adhesive strength between the front and back layers of the nonwoven fabric.

Providing a difference in thermal adhesive strength between the front and back layers of the non-woven fabric means that when used as a primary base cloth for tufted carpet, tufting is applied from the surface having a low thermal adhesive strength.
The tuft needle's base cloth penetration resistance value can be reduced to suppress noise during filament cutting and tufting, and since the side with high thermal adhesive strength is on the pile side, fiber fluff from the base cloth is on the pile surface. The backing resin is easy to physically penetrate into the inside of the base fabric because the backing surface is excellent in carpet quality that does not rise and the heat bonding strength is low, and the filament of the base fabric plays a role as an anchor. It is possible to obtain a tufted carpet having excellent durability such as pull-out strength and high commercial value. Further, when it is used as a filter substrate, the inner layer filtration performance inside the non-woven fabric is improved by making the surface having low thermal adhesion a dust collection surface, and as a result, the dust collection performance is excellent. In order to satisfy the above-mentioned function, it is more preferable that the surface of the nonwoven fabric has a thermal adhesive strength of J
Class 3 or higher, more preferably 3.5 or higher, particularly preferably 4 or higher when expressed by the abrasion strength of the surface layer measured according to the Taber method of the abrasion strength test of IS L-1906, and particularly preferably 4 or higher, and The difference in thermal adhesive strength between the front and back layers of the nonwoven fabric is JIS
When expressed by the abrasion strength measured according to the Taber method of the abrasion strength test of L-1906, the abrasion strength of the surface layer is at least 0.5 grade or more than the abrasion strength of the back layer, more preferably 1
It is preferably larger than the grade.

When the abrasion strength of the surface layer of the non-woven fabric is less than the third grade, the thermal adhesive strength is low, and when it is used as a primary base fabric for tufted carpet, it becomes difficult to obtain the strength that can withstand the processing tension, and during the processing. Width shrinkage occurs, resulting in a poor product yield and resulting in poor yield, and difficulty in obtaining the required rigidity.Fibers from the non-woven fabric on the pile surface are raised, and so-called fluff occurs. It is difficult to say because it causes problems, and when used as a filter substrate, fibers tend to be fluffy during use of the filter, and strength that can withstand a pressure increase during use tends to be difficult to obtain. Not preferred. Further, when the difference in the thermal adhesive strength between the surface layer and the back layer of the nonwoven fabric is less than 0.5 when expressed by the abrasion strength measured according to the Taber method of the abrasion strength test of JIS L-1906, for example, In the case of the primary fabric for tufted carpet, it suppresses filament cutting and noise by reducing the fabric penetration resistance of the tuft needle of the back layer, and the carpet quality that does not cause fiber fluff to float on the pile surface from the surface fabric. It is recognized that it is difficult to balance the contradictory functions of obtaining the non-woven fabric between the front layer and the back layer in a well-balanced manner.

Further, when it is used as a filter substrate, especially when it is used for the purpose of removing dust from the filter substrate and reusing it, the dust collecting surface of the filter also needs to have thermal adhesive strength. In order to suppress the fiber fluff generated from the non-woven fabric during use, the thermal adhesive strength of the front and back layers of the non-woven fabric was expressed by the wear strength measured according to the Taber method of the wear strength test of JIS L-1906. At this time, both the surface layer and the back layer are grade 3 or higher, and more preferably 4 or higher.
Grade 5 or higher, and particularly preferably grade 5 or higher.

In order to provide the front and back layers of the long fiber non-woven fabric with a difference in thermal adhesive strength, and in particular to have a surface layer having abrasion resistance of grade 3 or higher, the following non-woven fabric structural form is preferable. The structural forms of the non-woven fabric described below may be used alone or in combination of two or more.

First, it is preferable that the content ratio of the copolymerized polyester in the surface layer of the non-woven fabric is higher than the content ratio of the copolymerized polyester in the back layer, and in this case, it is more preferable to copolymerize with PET in the surface layer of the non-woven fabric. The polyester ratio is preferably 90:10 to 60:40, the back layer PET to copolymer polyester ratio is preferably 95: 5 to 70:30, and particularly preferably the non-woven surface layer PET to copolymer polyester ratio. The ratio is 85:15 to 70:30, and the ratio of PET and the copolyester of the back layer is 90:10.
It is preferably 80:20. If the content ratio of the copolymerized polyester in the front and back layers of the nonwoven fabric is the same, it tends to be difficult to provide a difference in thermal adhesive strength between the front and back layers.

When the content ratio of the copolyester in the surface layer of the non-woven fabric exceeds 40%, the polymer is melted during heat fusion and the entire sheet tends to be formed into a film. As a primary base fabric for tufted carpet, There is a tendency that the penetration resistance of the base cloth at the time of tufting tends to be large, and it is not preferable in terms of cost, and conversely, when the content ratio of the copolyester is less than 10%, it tends to be difficult to obtain a wear strength of grade 3 or higher. Therefore, heat adhesion between fibers is apt to be insufficient, it is difficult to obtain the required sheet strength, and fluff is likely to occur on the pile surface, which is an unfavorable tendency.

Second, it is preferable that the melting point of the copolyester contained in the surface layer of the nonwoven fabric is lower than that of the copolyester contained in the back layer.

When there is no difference between the melting point of the copolyester contained in the surface layer of the non-woven fabric and the melting point of the copolyester contained in the back layer, it tends to be difficult to obtain a difference in thermal adhesive strength between the front and back layers. In particular, when the difference in the thermal adhesive strength between the front and back layers of the nonwoven fabric is expressed by the wear strength measured according to the Taber method of the wear strength test of JIS L-1906, it is at least 0.5.
In order to obtain a grade or higher, the melting point of the copolyester contained in the surface layer of the nonwoven fabric is more preferably 5 to 50 ° C. lower than the melting point of the copolyester contained in the back layer, particularly preferably 10 to 30 ° C. It is preferably a polymer.

Thirdly, the fineness of the single fibers constituting the surface layer of the non-woven fabric is smaller than the fineness of the single fibers constituting the back layer, so that the number of interfiber bonding points in the front layer increases and the heat in the front and back layers increases. It is preferable because a difference in adhesive strength can be provided.

Fourth, the surface layer of the non-woven fabric is a non-woven fabric layer composed of a core-sheath type composite fiber having a core of PET and a sheath of copolyester, and the back layer is a mixed fiber of PET filament and copolyester filament. It is preferable that the constructed nonwoven fabric layers are laminated. In other words, the surface layer is a non-woven fabric layer in which all the fibers are composed of core-sheath type composite fibers having a function as a heat-bonding fiber, so that the heat-bonding strength is higher than that of the non-woven fabric layer composed of the mixed fiber of the back layer This is because it is easy to obtain, and the difference in thermal adhesive strength between the front and back layers of the nonwoven fabric can be easily obtained.

Fifth, in the heat fusion method for providing a difference in thermal bonding strength between the front and back layers of the nonwoven fabric, a temperature difference is provided between the upper and lower rolls by using a pair of embossing rolls to increase the temperature on the surface layer side of the nonwoven fabric. A method of blowing hot air from the surface layer side using a suction drum or a suction drum can be preferably used.

The non-woven fabric may be needle punched non-woven fabric. The needle-punched nonwoven fabric can be used as a civil engineering material or a roofing reinforcing material because of its properties such as strength and elongation characteristics and water permeability. Further, it may be subjected to heat fusion treatment using a hot embossing roll after needle punching.

Further, the non-woven fabric may be such that each filament is adhered and fixed by a resin binder in order to improve rigidity. The method of applying the resin binder to the non-woven fabric is not particularly limited, and a method of immersing the non-woven fabric in the emulsion-type resin binder and then drying it, applying the emulsion-type resin binder to the non-woven fabric by spraying or rolls, a doctor A method of applying after using a knife and then drying can be used.

The types of resin binders include urea resins, melamine resins, acrylic ester resins, vinyl acetate resins ethylene-vinyl acetate copolymer resins, vinyl chloride resins, polyester resins, styrene-butadiene rubber, methacrylic acid. Methyl-butadiene rubber, acrylonitrile-butadiene rubber, etc. can be used. At this time, the amount of the resin binder applied to the non-woven fabric is preferably 5 to 30% from the viewpoint of strength, feel, ventilation performance and the like.

Further, when used as a primary base fabric for tufted carpet, the above-mentioned non-woven fabric having an average filament fineness of 2 to 15 denier and an apparent density of the non-woven fabric of 0.15 to 0. It should be 0.4 g / cm ³ .

The average fineness of the filament is preferably 5
It is preferably 10 to 10 denier, more preferably 5 to 8 denier, and the apparent density of the non-woven fabric is preferably 0.2 to 0.35 g / cm ³ , more preferably 0.
It is preferably 25 to 0.3 g / cm ³ .

When the average fineness of the filament is less than 2 denier, there is a problem that the filament is cut by the tuft needle at the time of tufting, and the strength of the pile fabric after tufting is remarkably reduced. On the contrary, the average fineness of the filament is 15 denier. If it exceeds the above range, not only the filament spinnability during the production of the nonwoven fabric is significantly deteriorated, but also the number of filaments per unit weight is reduced, so that the strength of the base fabric necessary for processing cannot be obtained as the primary base fabric for tufted carpet.

The apparent density of the non-woven fabric is 0.15 g / cm ³
If it is less than the above, not only the rigidity required for the base cloth, the pile cloth and the tufted carpet tends to be difficult to obtain, but also the thickness tends to be too thick, and the pile height required when tufting the pile yarn is required. This is not preferable in terms of cost because the amount of pile yarn used increases in order to obtain the desired strength, and conversely, when the apparent density of the nonwoven fabric exceeds 0.40 g / m ² , the penetration resistance of the base fabric by the tuft needle during tufting is increased. It is not preferable because the tufted carpet tends to have a large pullout strength due to insufficient tendency of the backing resin to penetrate into the inside of the base fabric during backing because of an increase in noise.

It is generally used to add a smoothing agent to the primary base fabric for tufted carpet in order to reduce the resistance to penetration of the base fabric by the tuft needle during tufting and to suppress filament breakage. As a result of the study by the present inventors, it was clarified that the leveling agent applied to the primary base fabric for tufted carpet greatly contributes to the rigidity of the pile fabric and the tufted carpet. That is, when a smoothing agent having a small frictional resistance and a good slipping property is applied to the non-woven fabric to reduce the penetration of the backing fabric by the tuft needles and to suppress filament breakage, slippage occurs even between the filaments forming the non-woven fabric (base fabric). As a result of easy occurrence, it was confirmed that the texture of the pile fabric became less stiff, and the tufted carpet obtained by backing had a reduced rigidity, particularly a bending rigidity, and tended to be softened.

From these results, it was found that the smoothing agent has a coefficient of static friction (F / F) between PET filaments measured by the radar method.
Fμs) is preferably 0.28 or more, more preferably 0.3 or more, and particularly preferably 0.35 or more, and the coefficient of static friction (F / Fμs) between PET filaments is less than 0.28. It was found that the leveling agent of No. 3 is difficult to obtain a satisfactory pile fabric and tufted carpet rigidity. Further, the amount of the smoothing agent attached to the filament component of the non-woven fabric is preferably 0.01 to 3 wt%, more preferably 0.1 to 1 wt%. When the adhesion amount is less than 0.01 wt%, the adhesion amount of the smoothing agent is reduced, and as a result, the original purpose of suppressing the filament cutting through the tuft needle is reduced, and the original purpose cannot be achieved. On the contrary, if the amount of the smoothing agent attached exceeds 3 wt%, the coefficient of static friction (F / Fμs)
Is 0.28 or more, the pile fabric and the tufted carpet tend to have low rigidity and are not preferable in terms of cost.

The original purpose of the smoothing agent is to reduce the resistance to penetration of the base cloth by the tuft needle to suppress filament breakage. From this viewpoint, the coefficient of dynamic friction between the polyethylene terephthalate filament of the smoothing agent and the metal is reduced. The dynamic friction coefficient (F / Mμd) between the polyethylene terephthalate filament and the metal (F / Mμd) is preferably 170 or less, more preferably 150 or less, and particularly preferably 120 or less. .

Most preferably, in consideration of both the rigidity of the pile cloth and the tufted carpet and the reduction of the penetration resistance of the base cloth by the tuft needle, the coefficient of static friction between PET filaments ( F
/ Fμs) is 0.30 or more and the coefficient of kinetic friction (F / Mμd) between the polyethylene terephthalate filament and the metal measured by the running method is 150 or less. Preferred are primary tufted carpet backings. Examples of the smoothing agent having F / Fμs of 0.30 or more and F / Mμd of 150 or less include oleyl oleate (F / Fμs: 0.34, F / Mμd: 127) depending on the degree of polymerization. Hindered ester (F / Fμs: 0.33, F / Mμ
d: 131) and other fatty acid ester-based smoothing agents, dimethylpolysiloxane (F / Fμs: 0.35, F / Mμd:
101) and amino-modified silicone (F / Fμs: 0.3
1, F / Mμd: 106) and other silicone-based leveling agents. Further, even if a smoothing agent other than the above-mentioned examples is used, there is no problem, and some smoothing agents are mixed to obtain an F / F.
It is also possible to balance μs and F / Mμd.

The unit weight of the primary base fabric for tufted carpet is not particularly limited, but from the performance required as the primary base fabric for tufted carpet such as price and strength,
It is preferably 80 to 120 g / m ² .

By using the primary base fabric for tufted carpet as described above, tufting pile yarns and backing with a resin, the tufted carpet having excellent rigidity and high commercial value, particularly the tufted carpet is tiled. By cutting, it is possible to provide a tile carpet having excellent rigidity and workability.

When used as a filter substrate, the nonwoven fabric has an average fineness of 0.5 to 10 denier and an apparent density of 0.25 to 0.65 g / cm 3. it is necessary to be a ^3.

The average fineness of the filament is preferably 1
It is preferably from 8 to 10 denier, more preferably from 2 to 5 denier, and the apparent density of the non-woven fabric is preferably 0.30 to 0.55 g / cm ³ , more preferably 0.
It is preferably 38 to 0.45 g / cm ³ . When the average fineness of the filament is less than 0.5 denier, it cannot withstand high-speed spinning at a filament spinning speed of 5000 m / min at the time of manufacturing a non-woven fabric, and as a result, spinnability such as single yarn breakage is significantly deteriorated, resulting in extremely low productivity. However, if the average fineness of the filaments exceeds 10 denier, the number of filaments per unit weight becomes small, and the dust collection performance as a filter becomes unsatisfactory.

The apparent density of the non-woven fabric is 0.25 g / cm ^3.
If it is less than the above, it becomes difficult to obtain the rigidity required as a filter base material, resulting in poor product yield due to defective pleating, or deterioration in shape retention after pleating, resulting in deformation of the pleats of the filter during use and dust. This will result in impairing the collection performance and reduce the commercial value.
On the other hand, if the apparent density of the nonwoven fabric exceeds 0.65 g / m ² , the density is too high, and the breathability of the nonwoven fabric is significantly deteriorated, and the pressure loss during use increases, resulting in satisfactory filter performance. This is not preferable because it causes inconvenience such as not being obtained.

Considering the pleats shape retention property and the dust collecting performance as a filter, the basis weight of the nonwoven fabric as a filter substrate is 120 g / m ² or more, more preferably 200 g / m ² or more, and particularly preferably 250 g. / M ²
It is preferable that it is above. When the basis weight is less than 120 g / m ² , the rigidity is insufficient and pleating processing is liable to occur, which tends to make it difficult to obtain a satisfactory dust collecting performance.

By pleating using such a filter base material, it is possible to provide a high-performance filter having excellent pleats shape retention, durability and dust collection.

[0062]

The present invention will be described in more detail with reference to the following examples.
It goes without saying that the present invention is not limited only to the following embodiments. In addition, the evaluation method of each characteristic in an Example is as follows.

(A) Crystallinity of PET The crystallinity of PET was evaluated by a differential scanning calorimeter method (DSC method) after separating PET filaments (components) from the nonwoven fabric. The details of the measuring method will be described below.

(1) When the nonwoven fabric is composed of a PET filament single component or a mixture of PET filament and other component filaments: Perkin-Elmer D
Using a SC-2C type device, about 5 mg of PET filament was separated from the non-woven fabric and set in a standard container made of aluminum, under a temperature rising rate of 10 ° C./min (standard sensitivity method) and a nitrogen flow of 30 ml / min. Initial heating run curve (DS
C curve) was measured. This initial temperature rise curve (DSC curve)
The melting peak temperature (endothermic peak) and the heat of fusion (C) of PET were obtained from the above, and the crystallinity was calculated from the following equation.

Crystallinity (%) = (C / D) × 100 where C: heat of fusion of PET filament (cal / g) D: heat of fusion of a perfect crystal of PET (reference value: 33.5 cal / g)
) Reference value; "Thermal Analysis" by Bernhard Wunderlich
(Academic press), p418 (1990) (2) When the nonwoven fabric is a composite filament of PET and other components such as core-sheath type or bimetal type and PET cannot be separated, Perkin-Elmer DSC-2C type device Using about 5 mg of non-woven fabric as a sample, the melting peak temperature and the heat of fusion (A) of the original sample were obtained by the same procedure as above.
The heat of fusion (C ′) of PET was converted from the content of the above, and the crystallinity was calculated from the following equation.

Converted heat of fusion of PET (C ') (cal / g)
= (A / B) x 100 where A: heat of fusion per unit weight of the original sample (cal / g)
[Measurement Value] B: Content of PET (%) Crystallinity (%) = (C ′ / D) × 100 where C ′: Converted heat of fusion of PET (cal / g) D: Complete crystal of PET Heat of fusion (reference value: 33.5cal /
g) Literature value; Bernhard Wunderlich, “Thermal Analysis”
(Academicpress), p418 (1990) (B) The thickness of the apparent density nonwoven nonwoven thickness of JIS L-1906 ^-1994 hardly sample deformed by load (load: 10 kPa) was measured according to the following The apparent density was calculated by the formula. Apparent density (g / cm ³⁾ = thickness of the basis weight / nonwoven nonwoven (C) Wear strength front and back layers of the nonwoven fabric, measured in accordance with Taber form method abrasion strength test of JIS L-1906 ^-1994 , 0.5 grade unit.

[0067] (D) was measured according to the tensile strength JIS L-1906 ^-1994 of the non-woven fabric. In addition,
The longitudinal direction of the nonwoven fabric is described as vertical and the width direction is described as horizontal.

[0068] (E) non-woven fabric was measured in accordance with (the filter substrate) of bending resistance JIS L-1906 Gale form method of bending resistance test of ^-1994. In addition, the longitudinal direction of the nonwoven fabric was described as vertical and the width direction was described as horizontal.

(F) Static friction coefficient (F / F μs) between PET filaments of smoothing agent 1.4 denier, using 38 mm PET filament
With the amount of the active ingredient of the smoothing agent being 0.2%, the temperature is 20 ° C.,
The static friction coefficient (F / Fμs) was measured by a radar method in an atmosphere with a humidity of 60%.

(G) Dynamic Friction Coefficient (F / Mμd) Between PET Filament of Smoothing Agent and Metal Using PET spun yarn, the amount of the active ingredient of the smoothing agent attached was set to 0.
The tension was 110 g, the speed was 100 m / min, and the dynamic friction coefficient (F / Mμd) with a satin roll having a surface diameter of 26 mm and a surface temperature of 100 ° C. was measured. (Running method) (H) Base fabric penetration resistance value by tuft needle of primary base fabric for tufted carpet was set to 1/10 gauge 44
Two tuft needles (22 staggered two-row stagger, needle type; KPE-41 manufactured by Organ Co., Ltd.) were set in a constant-speed extension type tensile tester, and the primary base cloth for tufted carpet (speed: 20 cm / min. The maximum load when vertically piercing a non-woven fabric) was measured.

The maximum load at this time was evaluated as ◯ when less than 18 kgf, Δ when 18 kgf to less than 23 kgf, and x when 23 kgf or more. (I) Workability during continuous dyeing A pile fabric obtained by tufting nylon-BCF (2600 denier-160 filaments) on a primary base fabric (nonwoven fabric) for tufted carpet is dyed with a continuous dyeing machine using a continuous dyeing machine. Then, the presence or absence of wrinkles when passing through the loop steamer was visually determined.

A state in which the pile fabric does not float or wrinkle is ◯, a state in which the pile fabric is slightly floated in the central part is Δ, and a state in which a folded wrinkle is generated in the central part of the pile fabric is It was evaluated as x.

(J) Workability of backing The dyed pile fabric obtained by the processing of (I) was laminated and visually inspected for lamination.

A state where the pile cloth is not floated and is uniformly backed is ○, a state where the pile cloth is slightly floated but is not lifted after the backing is △, and the pile cloth is floated even after the backing. The state in which voids remained with the backing layer was evaluated as x.

(K) Toughness of Tile Carpet A tile carpet obtained by backing with a vinyl chloride resin paste was used, with the pile side up.
Measurement was carried out according to the 45 ° cantilever method bending resistance test of JIS L-1906 ^-1994. However, the length of the sample was measured at 500 mm.

(L) Pleatability of Filter Substrate The processability when the filter substrate was pleated with a rotary pleating machine was visually determined.

The pleats having unevenness (mountains and valleys) which can be processed to have a sharp bending angle (sharp) were evaluated as ◯, and the pleats having unevenness (mountains and valleys) having a sharp bending angle and rounded were evaluated as x.

(M) Pleated shape retention of the filter A 1 kg iron plate was placed on a 5 pleat filter (5 peaks) set at an opening angle of about 25 °, and the open angle was measured before and after the iron plate was placed. The rate of change in angle was calculated by the following formula.

Change rate of opening angle (%) = {(B−A) / A} × 100 A: Opening angle before placing the iron plate, B: Opening angle after placing the iron plate Note that the pleats of the filter are kept. The moldability is judged by ◯ when the change rate of the open angle is less than 20%, Δ when the change rate of the open angle is less than 20 to 50%, and 5 when the change rate of the open angle is 5.
Those with 0% or more were evaluated as x.

Example 1 Polyethylene terephthalate having a melting point of 260 ° C. was used as a high melting point polymer, and isophthalic acid copolyester having a melting point of 225 ° C. was used as a low melting point polymer, and melted at 285 ° C. 0.5 mm, 30 holes
After arranging a large number of mixed fiber type spinnerets that are holes and extruding and cooling the molten polymer so that the mixed fiber ratio of polyethylene terephthalate filaments and isophthalic acid copolyester filaments is 80:20, single yarn denier becomes 8 denier. So that it can be pulled by an ejector at high speed, charged by a collision plate mainly composed of lead, opened the filament bundle, and then jetted onto a moving net conveyor,
It was collected in a width of 4.3 m and heat-treated for 30 seconds on a 200 ° C. thermal suction drum. Continuously, the crimping area is 1
A pair of 8% embossing rolls were used to control the roll temperature at the surface layer of the long fiber web at 235 ° C. and the back layer at 220 ° C.
After thermocompression bonding so that the apparent density is about 0.25 g / cm ³ at a linear pressure of 50 kg / cm, F / Fμs is 0.35, F / Fμs is
Spraying an emulsion of dimethylpolysiloxane with Mμd of 101, the solid content is 1 wt% with respect to the constituent fibers.
After adhering and drying at 140 ° C. for 2 minutes, slitting was performed so as to have a width of 4.2 m to prepare a primary base cloth for tufted carpet.

Then, using a tufting machine,
Pile yarn (nylon BCF, 26
00 denier, 160 filaments) 1/10 gauge, 12 stitches / inch, pile height 3.5 mm, loops and tufts so that the pile yarn implantation width is about 4.1 m (the surface side of the primary base cloth is After dyeing with a loop steamer type continuous dyeing machine, the pile side, the back layer is the backstitch side), then hold the edge of the primary base cloth with a pin tenter so that the pile thread implantation width becomes about 4.15 m. It was spread and dried at 130 ° C. Further, the following vinyl chloride backing resin composition (X) was applied on an endless belt in a thickness of 1.3 mm, and a glass fiber non-woven fabric having a basis weight of 40 g / m ² was impregnated thereon, and the following vinyl chloride backing resin composition was further applied. (Y) was applied to a thickness of 1.3 mm, and a pile fabric (primary base fabric after tufting) preheated at about 100 ° C. was laminated on top of it, and 175 of vinyl chloride backing resin composition was applied from the endless belt side. After heat treatment at ℃, it was cooled and cut into 50 cm square to make a tile carpet.

<Vinyl chloride backing resin composition (X)> Vinyl chloride paste 100 parts by weight Dioctyl phthalate 90 parts by weight Calcium carbonate 350 parts by weight Carbon toner 2 parts by weight <Vinyl chloride backing resin composition (Y)> Vinyl chloride paste 100 Parts by weight Dioctyl phthalate 95 parts by weight Calcium carbonate 300 parts by weight Carbon toner 2 parts by weight Examples 2-3 Polyethylene terephthalate having a melting point of 260 ° C is used as a high melting point polymer, and isophthalic acid copolyester having a melting point of 225 ° C is used as a low melting point. After being made into a polymer and melted at 285 ° C., the spinneret has a spinneret hole diameter of 0.5 mm and a number of holes of 30.
Isophthalic acid copolyester, which is a hole, is on the sheath side,
After arranging a large number of core-sheath type caps with polyethylene terephthalate on the core side and extruding and cooling the molten polymer so that the ratio of polyethylene terephthalate and isophthalic acid copolyester is 80:20, single yarn denier is 8 denier So that it can be pulled at high speed by an ejector, charged by a collision plate mainly composed of lead, opened the filament bundle, and then jetted onto a moving net conveyor,
It was collected in a width of 4.3 m and heat-treated for 30 seconds on a 200 ° C. thermal suction drum. The crimping area is 18
%, The roll temperature is set to 220 ° C. on the surface side of the long fiber web and 200 ° C. on the back side, and heat is applied so that the apparent density becomes about 0.25 g / cm ³ at a linear pressure of 50 kg / cm. After crimping, (1) F / Fμs is 0.35,
Dimethylpolysiloxane emulsion having F / Mμd of 101, (2) F / Fμs of 0.26, F / Mμd
A wax emulsion containing polyethylene as the main component of 145 is sprayed onto the constituent fibers in a solid content of 1 wt% and dried at 140 ° C. for 2 minutes.
The slitting was performed so that a primary base cloth for tufted carpet was prepared.

Subsequently, a tile carpet was prepared under the same conditions as in Example 1.

Example 4 Polyethylene terephthalate having a melting point of 260 ° C. was used as a high melting point polymer, and adipic acid copolyester having a melting point of 187 ° C. was used as a low melting point polymer, and melted at 285 ° C. After arranging a large number of mixed fiber type die having 0.5 mm and 30 holes, the molten polymer was extruded and cooled so that the mixed fiber ratio of polyethylene terephthalate filament and adipic acid copolyester filament was 80:20, 3. High-speed pulling with an ejector so that the single yarn denier becomes 8 denier, charging with a collision plate mainly composed of lead, opening the filament bundle, and then spraying on a moving net conveyor.
It was collected in a width of 3 m and subjected to heat treatment with a heat suction drum at 210 ° C. and, at the same time, heat fusion. Continue to F /
Spraying an emulsion of dimethylpolysiloxane having Fμs of 0.35 and F / Mμd of 101 to the constituent fibers in a solid content of 1 wt% and drying it at 140 ° C. for 2 minutes to give a width of 4.2 m. It slitted and created the primary base fabric for a tufted carpet.

Subsequently, a tile carpet was prepared under the same conditions as in Example 1.

Example 5 Two polyethylene terephthalates having a melting point of 260 ° C. were used.
After melting at 85 ° C, the spinneret has a spinneret hole diameter of 0.5 m.
m, the number of holes 30 holes is arranged, and the molten polymer is extruded and cooled, then pulled at high speed by an ejector so that the single yarn denier becomes 8 denier, charged by a collision plate mainly composed of lead, and filament. After opening the bundle,
It was jetted on a moving net conveyor and collected in a width of 4.3 m, and heat-treated for 30 seconds on a thermal suction drum at 220 ° C. Successively, the roll temperature was set to 235 ° C. on the surface layer of the long fiber web and 230 ° C. on the back layer side by a pair of embossing rolls having a crimping area of 18%, and a linear pressure of 50 kg.
After thermocompression bonding so that the apparent density becomes about 0.25 g / cm ^{3 at} / cm, it is impregnated in the emulsion of acrylic ester resin and then squeezed with a mangle, and the solid content is about 15 wt. %, And dried at 150 ° C. for 2 minutes, then further heated at 180 ° C. with a thermal suction drum.
Cure for minutes, and F / Fμs is 0.3
5. A dimethylpolysiloxane emulsion having an F / Mμd of 101 was sprayed onto the constituent fibers in an amount of 1 wt% as a solid content and dried at 140 ° C. for 2 minutes, and then a width of 4.
It slit so that it might become 2 m, and created the primary base cloth for tufted carpets.

Subsequently, a tile carpet was prepared under the same conditions as in Example 1.

Comparative Example 1 The same as Example 1 except that the filament net was jetted onto the conveyor and collected, and then directly thermocompression-bonded by an embossing roll without heat treatment. The primary base fabric for tufted carpet and tile carpet were prepared under the conditions.

Comparative Examples 2 to 3 In Examples 2 to 3, the filaments were sprayed on a net conveyor, collected, and then directly heat-pressed by an embossing roll without heat treatment. 2-3
A primary base cloth for tufted carpet and a tile carpet were prepared under the same conditions as described above.

Comparative Example 4 In Example 1, the roll temperature of the embossing roll was 200 ° C. on the surface layer of the long fiber web and 180 ° C. on the back layer side.
Then, a primary base cloth for tufted carpet and a tile carpet were prepared under the same conditions as in Example 1 except that thermocompression bonding was performed so that the apparent density was about 0.14 g / cm ³ at a linear pressure of 10 kg / cm. did.

Comparative Example 5 A tufted carpet was produced under the same conditions as in Example 1 except that the single yarn denier was changed to 1 denier. Subsequently, tufting was performed in the same manner as in Example 1, but the strength of the obtained pile fabric was significantly reduced,
In the subsequent continuous dyeing process, width shrinkage was remarkably caused by the tension when passing through the loop steamer, and the width was insufficient, so that the tile carpet could not be obtained. Example 1
Table 1 shows the characteristics and processability of the primary base fabric for tufted carpets of Comparative Example 5 and Comparative Examples 1 to 4, and the characteristics of tile carpets.

[0092]

[Table 1] As shown in Table 1, the polyethylene terephthalate of Examples 1 to 5 has a crystallinity of 35% or more (average fineness: 2 to 15).
The primary base cloth for tufted carpet having a denier and an apparent density of 0.15 to 0.4 g / cm ³ ) has a workability that does not cause wrinkles during dyeing and backing, as compared with Comparative Examples 1 to 5. The tufted carpet (tile carpet) obtained by using such a base fabric had excellent rigidity and high commercial value.

Examples 6 to 7 Polyethylene terephthalate having a melting point of 260 ° C. was used as a high melting point polymer, and isophthalic acid copolyester having a melting point of 225 ° C. was used as a low melting point polymer. After melting at 285 ° C., a spinning device was used. Mouth hole diameter 0.5 mm, number of holes 30
After arranging a large number of mixed fiber type spinnerets that are holes and extruding and cooling the molten polymer so that the mixed fiber ratio of polyethylene terephthalate filament and isophthalic acid copolyester filament becomes 80:20, single yarn denier becomes 3 denier. After pulling at high speed with an ejector, charging with a collision plate mainly composed of lead and opening the filament bundle, the basis weight is (1) 130 g / m ² , (2) 2
It was jetted onto a net conveyor moving so as to have a rate of 60 g / m ² , collected in a width of 4.3 m, and heat-treated for 30 seconds on a thermal suction drum at 200 ° C. Subsequently, a pair of embossing rolls having a pressure-bonding area of 18% were used to control the roll temperature at the long fiber web surface layer side roll 235 ° C. and the back layer side roll 230.
℃, linear pressure 70kg / cm, apparent density 0.3 ~ 0.4g /
thermocompression bonding so that the cm ^3, created a filter substrate was slit to a width 0.5 m.

Subsequently, pleating was performed using a rotary pleating machine to prepare a filter.

Examples 8 to 9 Polyethylene terephthalate having a melting point of 260 ° C. was used as a high melting point polymer, and isophthalic acid copolyester having a melting point of 225 ° C. was used as a low melting point polymer. After melting at 285 ° C., a spinning device was used. Mouth hole diameter 0.5 mm, number of holes 30
Isophthalic acid copolyester, which is a hole, is on the sheath side,
After arranging a number of core-sheath type caps with polyethylene terephthalate on the core side and extruding and cooling the molten polymer so that the ratio of polyethylene terephthalate and isophthalic acid copolyester is 80:20, single yarn denier is 3 denier After pulling at high speed with an ejector, charging with a collision plate mainly composed of lead and opening the filament bundle, the basis weight is (1) 130 g / m ² , (2) 2
It was jetted onto a net conveyor moving so as to have a rate of 60 g / m ² , collected in a width of 4.3 m, and heat-treated for 30 seconds on a thermal suction drum at 200 ° C. Subsequently, a pair of embossing rolls having a crimping area of 18% were used to control the roll temperature to 220 ° C. for the surface layer of the long fiber web and the roll 21 for the back layer.
The apparent density is 0.3 to 0.4 at a linear pressure of 70 kg / cm at 0 ° C.
It thermocompression-bonded so that it might be set to g / cm ^3, and slit it to width 0.5m, and created the filter base material.

Subsequently, filters were prepared under the same conditions as in Examples 6-7.

Example 10 In Example 8, before thermocompression bonding with an embossing roll,
A filter base material and a filter were prepared under the same conditions as in Example 8 except that the needle punching treatment was performed. However, at this time, the apparent density of the non-woven fabric was 0.27 g / cm ³ .

Comparative Example 6 A filter under the same conditions as in Example 7 except that the filament was jetted onto a net conveyor, collected, and then thermocompression bonded by an embossing roll without heat treatment. The substrate and filter were made.

Comparative Example 7 A filter substrate was prepared under the same conditions as in Example 8 except that the filament was jetted onto the net conveyor, collected, and then thermocompression bonded by an embossing roll without heat treatment. Wood and filters were created.

Comparative Example 8 In Example 10, the linear pressure of the embossing roll was 30 kg / c.
As the m 2, a filter base material and a filter were prepared under the same conditions as in Example 10 except that the apparent density was 0.20 g / cm ³ .

Table 2 shows the characteristics of the filter base materials of Examples 6 to 10 and Comparative Examples 6 to 8, the pleating processability, and the pleating shape retention of the filters.

[0102]

[Table 2] As shown in Table 2, the crystallinity of the polyethylene terephthalate of Examples 6 to 10 of the present invention is 35% or more (average fineness: 0.5 to 10 denier, apparent density: 0.25 to 0.
The filter base material having a weight of 65 g / cm ³ ) has better pleating processability than Comparative Examples 6 to 8, and the filter obtained using such a base material has excellent pleating shape retention and durability. It had excellent properties.

[0103]

Since the nonwoven fabric of the present invention is composed of filaments containing polyethylene terephthalate having a crystallinity of 35% or more as a main component, it is excellent in rigidity, and the nonwoven fabric is used as a primary base fabric for tufted carpet and When used as a filter substrate, it exhibits excellent processability, and further, a tufted carpet and a filter obtained by using such a tufted carpet primary base fabric and a filter substrate have excellent rigidity, It is possible to provide products with high commercial value.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Internal reference number FI Technical display location D01F 6/84 301 D01F 6/84 301D 8/14 8/14 Z D02G 3/02 D02G 3/02 D04H 3/10 D04H 3/10 A D05C 17/02 D05C 17/02

Claims (22)

[Claims] 1. A long-fiber nonwoven fabric composed of filaments containing polyethylene terephthalate as a main component, wherein the polyethylene terephthalate has a crystallinity of 35%.
The above is the non-woven fabric. 2. A long-fiber nonwoven fabric composed of filaments containing polyethylene terephthalate as a main component, wherein the polyethylene terephthalate has a birefringence of 60 ×.
A non-woven fabric characterized by being 10 ⁻³ or more. 3. The nonwoven fabric according to claim 2, wherein the polyethylene terephthalate has a birefringence of 80 × 10 ⁻³ or more. 4. The non-woven fabric according to claim 1, wherein the long-fiber non-woven fabric is composed of filaments composed of polyethylene terephthalate and copolyester, and the filaments are adhesively fixed by heat fusion. 5. The non-woven fabric according to claim 3, wherein the front and back layers of the long-fiber non-woven fabric are provided with a difference in thermal adhesive strength. 6. The thermal adhesive strength of the surface layer of the long fiber non-woven fabric is
When expressed by the abrasion strength of the surface layer measured according to the taper method of the abrasion strength test of JIS L-1906, it is of grade 3 or higher, and the thermal adhesive strength difference between the front and back layers of the long fiber nonwoven fabric is J
The wear strength of the surface layer, when expressed by the wear strength measured according to the Taber method of the wear strength test of ISL-1906, is at least 0.5 class or more higher than the wear strength of the back layer. Non-woven fabric. 7. The thermal adhesion strength of the front and back layers of the long-fiber nonwoven fabric is 3 or higher in terms of both the front and back layers when expressed by the wear strength measured according to the Taber method of the wear strength test of JIS L-1906. The nonwoven fabric according to any one of claims 3 to 6. 8. The core-sheath type composite filament comprising polyethylene terephthalate as a core part and a copolyester as a sheath part, or a bimetal type composite filament of polyethylene terephthalate and a copolyester as claimed in any one of claims 1 to 7. The non-woven fabric described. 9. The non-woven fabric according to any one of claims 1 to 8, wherein the long-fiber non-woven fabric comprises a mixed fiber of a copolymerized polyester filament and a polyethylene terephthalate filament. 10. The non-woven fabric according to claim 1, wherein the long-fiber non-woven fabric is a needle punched non-woven fabric. 11. The long-fiber nonwoven fabric has a pressure-bonding area of 5 to 3.
The non-woven fabric according to any one of claims 1 to 10, which is thermocompression bonded in the range of 0%. 12. The nonwoven fabric according to claim 1, wherein the melting point of the copolyester is 20 to 90 ° C. lower than the melting point of polyethylene terephthalate. 13. The long fiber non-woven fabric is adhered and fixed between filaments by a resin binder.
The nonwoven fabric according to any one of 2. 14. The non-woven fabric according to any one of claims 1 to 13, wherein the filament has an average fineness of 2 to 15 denier and an apparent density of the non-woven fabric of 0.15 to 0.4 g / cm.
Primary tufted carpet base fabric characterized by being ³ . 15. A coefficient of static friction (F / F) between polyethylene terephthalate filaments measured by a radar method.
The primary base fabric for tufted carpet according to claim 14, wherein a smoothing agent having a µs) of 0.28 or more is attached to the filament component of the nonwoven fabric. 16. A dynamic friction coefficient (F / F) between a polyethylene terephthalate filament and a metal measured by a running method.
The primary base fabric for tufted carpet according to claim 14, wherein a smoothing agent having a Mμd) of 170 or less is attached to the filament component of the nonwoven fabric. 17. The adhesion amount of the smoothing agent is 0.01 to 3 wt% with respect to the filament component of the nonwoven fabric.
The primary base fabric for tufted carpet according to 5 or 16. 18. A tufted carpet, wherein the primary tufted carpet base fabric according to any one of claims 14 to 17 has a tufted pile yarn and a resin backing layer. 19. The tufted carpet according to claim 18, wherein the tufted carpet is a tile carpet cut into tiles. 20. The nonwoven fabric according to claim 1, wherein the filament has an average fineness of 0.5 to 10.
Denier and the apparent density of the nonwoven fabric is 0.25 to 0.
A filter substrate having a weight of 65 g / cm ³ . 21. The filter substrate according to claim 20, wherein the basis weight of the nonwoven fabric is 120 g / m ² or more. 22. A filter obtained by pleating the filter substrate according to any one of claims 20 to 21.