JPS59150157A - Tufted carpet base cloth - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a tufted carpet base fabric made of a nonwoven fabric with an orthogonal structure using polyester filaments.

As a tufted carpet base fabric, a large number of synthetic fiber filaments are arranged in the length direction and width direction, and the arrangement ratio in the length direction, width direction, and diagonal direction is specified. Increases the resistance to deformation in the directional and diagonal directions, which improves the strength after tufting.
And to prevent neck-down that occurs during dyeing and other processing steps after tufting! - is known (see Japanese Patent Publication No. 55'-42175). however,
This known nonwoven fabric is characterized by the arrangement ratio and structure of synthetic fiber filaments located in the length direction, width direction, and diagonal direction]? ] It only stipulates the required performance of tufted carpella)-X fabric, and does not specify the manufacturing conditions necessary to satisfy this required performance, so it does not necessarily provide a sufficient effect. I couldn't. In other words, although the texture of the base fabric is destroyed by tufting, resulting in a completely different state from before tufting and a decrease in physical properties, conventional studies have focused only on the state and physical properties of the base fabric before tufting. Because of this, we were unable to solve one problem, and we did not know the physical property values that should be used as a basis for setting the structural structure and manufacturing conditions necessary to obtain a product with excellent performance, so we had no choice but to rely on intuition. This resulted in a product with poor performance, such as neck-down and bowing, and a lack of strength.

The inventor has developed a tufted carpet that does not cause neck-down due to processing tension during processing after tufting, has high tensile strength and tear strength, and does not have the bowing or twisting of the tufting pattern. Researched with the aim of providing. Simply improving the physical properties of the base fabric before tufting does not necessarily improve the physical properties and product performance after tufting, and the above-mentioned neck-down, bowing, and twisting are caused by The stress at 5% elongation has an influence on the tensile strength and tear strength of the product. The ratio of the stress at 5% elongation of the original fabric], the tensile strength retention rate of the intermediate product (ratio of the tensile strength of the intermediate product to the tensile strength of the base fabric original fabric), and the tensile strength retention rate and 5 By discovering that the ratio of the stress retention rate at % elongation has an effect, managing these physical property values, and selecting the structure structure and manufacturing conditions that satisfy these physical property values, excellent product performance can be achieved. This invention was achieved by successfully obtaining a tufted carpet base fabric.

That is, in the present invention, a large number of polyester filaments are arranged in the length direction and the width direction in a substantially stretched state, and these polyester filaments in the length direction and the width direction are folded in the length direction and the width direction, respectively. tufted carbela with orthogonal structure that is laminated and laminated)
! In the cloth, the polyester filaments in the length direction and the width direction each have a thickness of 10 to 20 deniers, the folded length of the polyester filament in the length direction is 30 cm or more, and the length of the folded point is 30 cm or more. The direction deviation l is set to 115 or less of the above folding length B, the folding length D of the polyester filament in the width direction is 2.0 cm or more, and the widthwise deviation 6 of the folding point is set to the above folding length. The polyester filaments in the length and width directions are bonded to each other and the stress at 5% elongation after tufting is 10 kQ/5α or more in the length direction and 6 in the width direction.
kg/5 an or more, stress retention rate at 5% elongation after tufting (ratio of stress at 5% elongation after tufting to stress at 5% elongation before tufting) is 55% in the length direction
or more, 40% or more in the width direction, tensile strength after tufting is 22 kQ/5 Cm or more in the length direction, 14 k in the width direction
Q15C1n or more, tensile strength retention rate after tufting (ratio of tensile strength after touch/r puffing to tensile strength before tufting) is 50% or more in the length direction, 40% in the width direction
% or more, and the ratio of the tensile strength retention rate after tufting to the stress retention rate at 5% elongation after tufting is 075 or more in both the length direction and the width direction. Enjoy with cloth.

In the present invention, the orthogonally textured nonwoven fabric can be manufactured, for example, as follows. In Fig. 1, ■ and 2 are a large number of polyester filaments that are self-aligned in a comb shape, and are discharged in a comb shape from an elongated rectangular nozzle (not shown) provided above. The material is stretched to a predetermined stretching ratio by being stretched as a belt around several feed rollers and draw rollers, and then directed toward a deflection oscillating plate with a variable inclination angle provided below by an air jet device having a narrow slit. The flying direction is periodically changed as the deflection oscillation plate swings, and the particles are collected on the collection conveyor 3 below. At this time, one polyester filament 2 is deposited while being swung in the length direction (direction of arrow M) and piled up on the collection conveyor 3, and the other polyester filament 2 is deposited in the width direction (direction of arrow C). It is deposited while being oscillated, and is laminated on top of the longitudinal polyester filament l-1 already superimposed on the collecting conveyor 3.

The above-mentioned polyester filaments 1 and 2 have Vf=2, where Vf is the running speed, L is the swinging amplitude (turning length) on the collecting conveyor 3, and is the swinging period -iN.
By preserving the NL relationship.

It is collected on the collection conveyor 3 in a substantially stretched state. For example, Vf = 750 yn/sin, L=
60Cmf required torque, N=Vf/2L=625
By setting L'/ytin, the polyester filaments can be overlapped in a substantially linearly stretched state. When the oscillation period N of the deflection oscillation plate is larger than the above value, the deposition amplitude of the polyester filament 1.2 is reduced and automatically corrected to an amplitude that satisfies the above equation.

The amplitude of the above equation is illustrated using D for the polyester filament 2 in the width direction.

The polyester filament 1.2 collides with a deflection rocking plate that is fixed to a horizontal shaft directly below the air jet device and rotates back and forth, and a vertical line passes through the center of this deflection rocking plate.
The polyester filament l is deposited between the direction deflected by the swing angle θ with respect to the vertical line, and if the distance between the deflection swing plate and the collecting conveyor 3 is H,
The folding length L of 2 is expressed as L = Htan (/.The above swing angle θ is preferably 35 degrees or less, and if it exceeds 35 degrees, the mechanical load will be excessive. #
IH is preferably 1227 or less; if it exceeds 177), the polyether filament 1 collides with the deflection rocking plate and is deflected.
-1.2 stalls, making it difficult to obtain the desired folding length.

In order to set the width, texture, tensile strength, and other physical properties of the nonwoven fabric to the desired size, a rectangular nozzle, stretching roller, air jet device, deflection oscillating plate, etc. are used as shown in Figure 2. Supply unit in erosion direction and width direction l-4M
and 4c are arranged in parallel. Units 1-4M in the longitudinal direction are arranged so that the web deposited on the collection conveyor 3 has no gaps and the distribution of the weight is even.
, 4M are preferably arranged in a staggered manner so as not to interfere with each other. Then, in order to maintain an even distribution of grains in the length direction (=1), the number of laminated sheets is 10 or more, that is, the length of the folding point 1a7 is hlk, the folding length T is 15
The following settings are required. Therefore, if the speed of the collection conveyor 3 is Vc, it is necessary to satisfy TJ≧5VC/N. For example, VC=34m/sin,
When N = 625 cycles/string, L≧27.2 c
If m, L//≦115 is satisfied and the basis weight distribution becomes uniform. Also, L = 5 Q cm, Vc =
34771/sin, N -625 cycles/si
If n, the deviation β of the turning point 1a in the vertical direction is 1=
Vc/NVC is 5.4c shoulder, and the number of stacked sheets at this time is 18.5 sheets.

On the other hand, for the width direction supply unit 4c, overlap conditions are set in consideration of the uniformity of the web as well as the uniformity of physical properties such as the tensile strength in the width direction.

In other words, since the turning length D on the collection conveyor 3 is usually [7 - 1], the maximum length is the supply unit in the width direction.
4C are arranged at a pitch of % or less of the folding length D. In other words, the deviation 6 in the width direction of the folding point 2a of the polyester filament 2 in the width direction is set to be equal to or less than D/4. Since the polyester filaments 2 in the width direction are deposited on the collection conveyor 3 moving at -4 speed & Vc, the number of layers is set to 10 or more in order to equalize the distribution of deposition in the length direction. It is recommended that consideration be given to That is, when the band width of the polyester filament 2 in the width direction is W, it is preferable to satisfy W≧5Vc/N. For example, Vc = 34 nVmin, N4625
When the cycle/min is set, W is set to 27.2 cm or more. When W=40on and N=625 cycles/win, set Vci to less than 50n7/win.

In this invention, the above polyester filament 1
．． 2 is made of polyester such as polyethylene terephthalate, polybutylene terephthalate, polyethylene terephthalate isophthalate, and poly(ethylene butylene) terephthalate. The gluttony is 10 to 20 deniers, and if the thickness is less than 10 deniers, it is too thin and the bonded area increases, and it is cut by the needle during tufting, and when elongated by 5%. Stress and tensile strength are insufficient, necking and bowing are likely to occur, and the t-plane resistance of the needle during tufting becomes large.On the other hand, if the needle exceeds 20 denier, it becomes too thick and rigid. At the same time, the tensile strength becomes insufficient due to the decrease in bonding points.

In order to bond the orthogonally textured web consisting of the polyester filaments 1-1 and 2 in the longitudinal and width directions, fibers having a softening point or melting point lower than that of the polyester filaments 1-2 during the formation of the web; For example, it is desirable to mix filaments made of undrawn polyethylene terephthalate, copolymerized polyester, or the like. In other words, when feeding the polyester filament L and 2 to the air sheeting device, the adhesive filament such as the above-mentioned low south point fiber or low softening point fiber is made into a webbing shape and overlapped with the polyester filament 1.2 to form a mixed fiber. After being deposited together with the polyester filament 1-1.2 on the collection conveyor 3 made of net, other nets are overlapped and sandwiched, and passed through a heat cylinder to be thermally welded. The ratio (S/F') between the average adhesive point strength S after the adhesive treatment and the tensile strength F of the polyester filament 1.2 is 0.02.
~0.12 is preferred. If this S/F is less than 0.02, the adhesive strength will be too weak, resulting in insufficient tensile strength and tear resilience of the product.On the other hand, if it exceeds 0.12, the adhesive strength will be too strong, resulting in poor tufting. In this case, the penetration resistance of the needle is large, and the filament is cut by the needle and the bonding point is destroyed, resulting in insufficient characteristic values such as stress at 5% elongation and its retention rate after tufting. Note that the above average bond point strength is the average of the measured values of tensile strength (fracture accompaniment) per bond point in the nonwoven fabric.

In addition, the preferable grain depth of the tufted carpet base fabric of the present invention is 50 to 200%, and 60 to 160 is especially generous.

The tufted carpet base fabric obtained in this way is
The fabric is manufactured by tufting processed synthetic fiber yarn, wool yarn, etc. as pile yarn using conventional methods, dyeing and other processing, and then applying backing.The base fabric after tufting is There is something that has the physical properties shown in the table. The retention rate is the ratio (%) after tufting to that before tufting.

Table 1 In other words, the characteristic values such as stress at 5% elongation after tufting in Table 1 above are based on the size of polyester filaments 1 and 2, Young's modulus, tensile strength, and linear stretching in a nonwoven fabric. However, the above will depend on the length of the attached part and the state of adhesion.

The stress at 5% elongation after tufting is 10 kq in the length direction.
If it is less than / 5 Cm and less than 6 kQ / 5 Cm in the part direction, bowing or twisting will occur, and wrinkles or stop marks will occur due to the difference in elongation between the tufted part and the non-tufted part. In addition, if the stress retention rate at 5% elongation after tufting is less than 55% in the length direction and less than 40% in the width direction, the breakage of the bond and the breakage of polyester filaments 1 and 2 will be large during processing. The dimensional stability decreases, and the tensile strength after tufting decreases in the longitudinal direction.
Less than 21 cq/5 on, width direction 14 kg 75 c
If it is less than m, the tensile accompaniment of the product will be insufficient. Tensile accompaniment retention rate after twisting and tufting is 55% in the longitudinal direction
If it is less than 40% in the width direction, the strength of the product will be insufficient because the Borien ter filament 1-1.2 will break easily and the bonded portion will break. Furthermore, if the ratio of the tensile strength retention rate after tufting to the stress retention rate at 5% elongation after tufting is less than 0.75 in both the length direction and the width direction, the polyester filament 1.2 If the base fabric is severely damaged due to cutting, the strength of the product will be insufficient.

Next, a more specific explanation will be given using examples. However, the tensile strength was measured using a constant speed extension type tester.

Width 5cm, length 20 (: il + test piece interval l
(Jcm, chuck width 5cm, tension speed 2o±2cm
/Tested with pin.

The stress at 5% elongation was determined from the SS curve of the above tensile υ test. The tensile strength and stress at 5% elongation of the intermediate product after tufting were measured by removing the pile from the intermediate product. Moreover, the average adhesive point strength is determined by utilizing the fact that a peak appears in the S-8 curve every time one adhesive point is broken during a tensile test. In other words, the Special Public Service of 1970-
According to the method described in Publication No. 30747, the sample was pulled at a tensile rate of 0.05 Dn/i using a Tensilon tensile tester.
The adhesive strength was determined from the number of adhesive points with an adhesive strength of 017 or more and the adhesive strength.

Example 1 Polyethylene terephthalate (limiting viscosity) M 0.63 was passed through 300 orifices (diameter 0.3 mm, length O-6
The extrusion amount from a rectangular nozzle with ml) is 1.25 V.
/ho]-e” InIn, extruded into a webbing shape at 290°C for 1 m, using a 5-wood feed roll (side-i500ff
M, surface speed 150n7/Min, latter three trees at 90℃
), followed by 5 wooden doo -o-)
v (Surface speed: 750,777/win) The filament is stretched 5 times by applying an IF belt to obtain 300 filaments of 15 denier. On the other hand, polyethylene terephthalate isophthalate (inphthalate content 10 mol%) with an intrinsic viscosity f0.63 was heated at 250'C from a rectangular nozzle containing 60 orifices (diameter Q, 3 mm, length 0.6 mm). ', extrude with (extrude! 1.259
/ hO]-e yin), face length 50 in blind condition
cm shoulder, guided to a take-up roller with a surface speed of 750 yyt/win to obtain a low edge [point filament 60 wood for gluing]. The above-mentioned 300mm polyester filament and 60mm low melting point filament were led in a blind state to a submerged roller with a surface length of 500mm and a surface speed of 750nVmin, and were layered with approximately the same width spread to evenly mix the fibers. do.

The above-mentioned mixed fiber filament 1- is deposited and superimposed in a straight line in the length direction, width direction, and diagonal direction on the series of spinning equipment N from the above-mentioned 2-conductor 1 m nozzle to the mixed fiber guide roller, or !
, or by combining an air jet device and a four-time oscillation device for randomly stacking and stacking the mixed filaments in the length direction, width direction, 45-degree inclined direction, 20-degree inclined direction and random stacking. A supply unit was constructed for this purpose, and these supply units were combined to produce six types of webs (Example 1 and Comparative Examples 1 to 5), and the obtained web was sandwiched between two upper and lower net conveyors. 22
The web was bonded to a heated roll at 0°C (at a pressure of 1.2 kq/cr4 and treated for 20 seconds to bond it. The width of the even part was set to 36 cm, and both ends where the distribution was uneven were cut off 1-, and the center part was used as a sample.
The conveyor speed when obtaining a web of 00 lead is 9.4
m/grin, 78yn/ for 120% web
It was min. The obtained nonwoven fabric was tufted with 1500 denier nylon bulk yarn (gauge %, number of stitches 7/254 l), and then polyethylene was laminated on the back side (fabric weight 45 ON). The manufacturing conditions of the above nonwoven fabric are shown in Table 2, and the ml of tufting
The physical properties after this are shown in Table 3, and the physical properties of the final product after backing are shown in Table 4. However, the stress retention rate in the table is the stress retention rate at 5% elongation, and the strength retention rate is the tensile accompaniment retention rate. Moreover, MD and CD indicate the length direction and the width direction, respectively.

Table 2 Table 8 Table 4 Table 1 61 2 0 × x-1 −-1 In Tables 3 and 4, ◎ indicates an excellent visual appearance with no defects, and ○ indicates a defect. Δ is almost good with no visible defects, Δ is slightly poor with some defects, ×
indicates a defective product with very noticeable defects. Also, in Table 4, the required amount is the amount necessary to satisfy the physical property values in Table 1. show.

As is clear from Tables 2 to 4 above, Example 1 has a perpendicular structure and satisfies the characteristic values shown in Table 1, resulting in stable stop mark resistance and bowing resistance in one dimension. It has excellent properties and appearance, and requires only a small amount of basis weight. On the other hand, comparative example 1
~5 are all of orthogonal and anisotropic tissues,
In addition, since the physical property values do not satisfy Table 1, the stop mark resistance, bowing resistance, dimensional stability, and appearance are all inferior to those of Example 1. It increases by 1.25 to 4.0 times.

It was also found that the above properties have a large influence on the physical properties of the product (stress at 5% elongation, tensile strength), and in particular, the tensile strength of the product as well as its retention rate after tufting. It can be seen that the influence of

Examples 2 to 5 Tufted carpets of Examples 2 to 5 and Comparative Example 6 were manufactured under the same conditions as in Example 1, except for the thickness of Borien ether filaments 1 and 2 and the adhesion temperature of the web. The manufacturing conditions at this time are shown in Table 5, and the physical properties are shown in Table 6.

Table 5 (blank below) Table 6 As is clear from Tables 5 and 6 above, in Examples 2 to 5, the physical properties of the intermediate products satisfy Table 1, so that the product Comparative Example 6 has excellent tensile strength and stress at 5% elongation, whereas Comparative Example 6 has excellent tensile strength retention and 5% elongation.
Since the ratio to the stress retention rate during elongation is smaller than 0.75 in Table 1, the tensile strength of the product is significantly reduced. ! ifc
, the S/F of the nonwoven fabric constituent fibers influences the stress retention rate at 5% elongation, tensile strength retention rate, stress retention rate at 15% elongation, etc. after tufting, and this S/]7 When the ratio is 0.13 or more (ratio; see Example 6), the amount of woven material; /I+ during touch ink increases, and the physical properties deteriorate significantly due to Kuftink. On the other hand, if the S/F becomes smaller, the adhesion will be weaker, and the handleability such as fluffing of the base fabric and the physical properties of the base fabric will deteriorate, so it is desirable that the S/F is greater than 0.02. (See Example 4).

Examples 6 to 8 Cedar one turn length of polyester filament l-1, 2 [・
, except for one change: 1) Tufted carpets of IJ Examples 6 to 8 and Comparative Examples 7 and 8 were manufactured in exactly the same manner as in Example 1 described in 11. The folded length above.

Table 7 shows the physical properties of the base fabric and the intermediate product, and Table 8 shows the physical properties of the product. In addition, Ml) direction and CD
Directional filament I-constituent distribution ratio (weight ratio) MD/
CD is 4/6, the thickness of the constituent filament is 15 denier, the bonding temperature is 220' C1 average bonding point strength is 3.6g
, filament strength is 60F.
(Blank below) Table 7 Table 8 As is clear from Tables 7 and 8 above, in Examples 6 to 8, the folding length was greater than the lower limit, and the physical property values of the intermediate products were Since it satisfies Table 1, the product has excellent physical properties, stop mark resistance, bowing resistance, dimensional stability, appearance, etc. On the other hand, in Comparative Example 7, the CJ) direction of the stress retention rate at 5% elongation of the intermediate product was below the lower limit, so the dimensional stability during continuous dyeing was poor and the product dimensional stability was low. In comparative example 8, the folded length is smaller than the lower limit, so the stress at 5% elongation and tensile strength of the intermediate product are lower than the lower limit in Table 1, and the stop mark resistance and bowing resistance are lower. , -71 method stability and appearance were poor, and product performance was also poor.

As explained above, the present invention provides a tufted carpet based on a non-woven fabric with an orthogonal structure made of polyester filaments, and the thickness of the polyester filament, the folded length, and the base fabric after touch ink. Since the physical properties such as stress at 5% elongation are determined, a tufted carpet base fabric with excellent stop mark resistance, bowing resistance, stability under the 71 degree method, and appearance 1 can be obtained.

[Brief explanation of drawings]

Figure 1 is a perspective view for explaining the manufacturing method of the nonwoven fabric for base fabric used in this invention, 'p, g. Figure 2 is another manufacturing method example k.
FIG. 3 is a plan view for explaining the W side. l: Longitudinal Borienutel filaments arranged in a sash pattern 1-12: Polyester filaments in the width direction arranged in a sash pattern, 1a, -2a, 24-turn points, L no, D : Folding length, (J, (E: deviation) Procedural amendment March 17, 1980 Kazuo Wakasugi, Commissioner of the Patent Office (Examiner of the Patent Office) 1, Indication of case 1982 Patent Application No. 21832 No. 2, Name of the invention Tufted carpet base fabric 3, Relationship with the case of the person making the amendment Patent applicant's residence 2-2-8 Dojimahama, Kita-ku, Osaka Name (
3i6) Toyobo Co., Ltd. 6, Subject of amendment Detailed description of the invention in the specification January 7th, Contents of amendment (1) Specification section, page 8, line 17, "Deflection rocking plate" and "Deflection Corrected to "The central axis of rocking of the rocking plate." (2) Statement on page 28, line 2 of the specification, "r O, 21cq/c first J k ro, 2/cq/C 陹G". (3) Page 28 of the specification, lines 3-2 from the bottom: “Because,
·········low. " was corrected to "and the stability in other dimensions is also low."

Claims (1)

[Scope of Claims] [l] A large number of polyester filaments are arranged in a substantially stretched state in the length direction and the width direction, and the polyester filaments in the length direction and the width direction are arranged in the length direction and the width direction, respectively. In the tufted carpet base fabric with an orthogonal structure folded in the direction and laminated in an overlapping manner, the polyester filaments in the length direction and the width direction each have a thickness of 10 to 20 deniers, and the polyester filaments in the length direction Folded length L is 30cm
In addition, the deviation in the length direction of the folding point is set to 115 or less of the above folding length L, and the folding length D of the polyester filament in the width direction is 30 cm.
In addition, the folding points in the width direction are each set to be less than % of the folding length D, and the polyester filaments in the length and width directions are bonded to each other and the tufting is completed. Stress at 5% elongation is 10kQ/5cm or more in the length direction, 6kq/5an in the width direction
Above, the stress retention rate at 5% elongation after tufting (the ratio of the stress at 5% elongation after tufting to the stress at 5% elongation before tufting) is 55% or more in the length direction and 40% in the width direction.
Above, the tensile strength after tufting is 22kQ in the length direction.
/5 ctn or more, width direction 14 kti/5 cm
The tensile strength retention rate after tufting (the ratio of the tensile strength after tufting to the tensile strength before tufting) is 50% or more in the length direction and 40% or more in the width direction, and the tensile strength after tufting is Strength retention rate and 5 after tufting
A tufted carpet base fabric characterized in that the ratio to the stress retention rate at % elongation is 0.75 or more in both the length direction and the width direction.