JP4267400B2 - Tufted carpet base fabric - Google Patents

Description

  The present invention relates to a tufted carpet base fabric made of a nonwoven fabric in which long fiber groups are integrated, and particularly reduces the generation of formaldehyde by adopting a special binder resin for bonding between long fibers. In addition, the present invention relates to a tufted carpet base fabric that can obtain a carpet without causing problems in the dyeing process and the molding process.

  Conventionally, it is known to use a nonwoven fabric in which long fiber groups are accumulated as a tufted carpet base fabric. This tufted carpet base fabric serves as a support for tufting pile yarn (planting pile yarn). The manufacturing method of the tufted carpet using such a tufted carpet base fabric is divided roughly into the following two. That is, as a first method, after tufting undyed pile yarn (for example, pile yarn made of undyed nylon yarn) on a tufted carpet base fabric, it is piled using a pad steam continuous dyeing machine or the like. The yarn is dyed to a desired shade to obtain a tufted carpet, and as another method, tufting is performed using an original yarn or a pre-dyed yarn that is pre-colored as a pile yarn, A tufted carpet is obtained without dyeing. In both cases, when it is desired to mold the tufted carpet into a desired mold, heat is applied to the tufted carpet, and a mold (mould composed of a male mold and a female mold) is used and pressed to mold the tufted carpet. Get.

  In the former method involving dyeing, a relatively high moist heat is applied to the tufted carpet base fabric at the same time as the mass of pile yarn and dye liquor is loaded. Under such severe conditions, the tufted carpet base fabric may stretch or break without being able to withstand the stress. In order to solve such a problem, a tufted carpet base fabric having good dimensional stability is required even under relatively high heat and humidity, and Patent Document 1 is disclosed as a technology that meets this requirement. According to this technology, as the binder resin that bonds long fibers, the one that has a glass transition point of 20 ° C. or higher with crosslinkability can be used to move the bonding points with the binder resin even under relatively high heat and humidity. It is difficult. When such a binder resin is used, if it is desired to mold a tufted carpet, it must be heated at a relatively high temperature. This is because, in low-temperature heating, the bonding portion between the long fibers due to the binder resin does not move easily and is difficult to mold into a desired mold.

Japanese Patent Publication No. 61-8189

  In the latter method that does not involve dyeing, the tufted carpet is not subjected to the mass of the dyeing solution or relatively high wet heat, so that the tufted carpet base fabric is not required to have strict physical properties. Therefore, it is not necessary to adopt a glass transition point having a high heat resistance of 20 ° C. or higher as a binder resin for bonding between long fibers, and any glass transition point may be used. . Therefore, when molding a tufted carpet, it is not affected by the glass transition point of the binder resin, so there is little need for heating at a high temperature, and from the viewpoint of energy saving, the bonding portion between long fibers can easily move by low temperature heating. There is a need for binder resins. As a technique suitable for this method, the present patent applicant has proposed the technique described in Patent Document 2. According to this technique, long fibers are bonded to each other by a binder resin having a glass transition point and a softening point in a specific range. As a result, it is possible to provide a carpet base fabric that facilitates the movement of the joining portion and is excellent in low-temperature moldability.

Japanese Patent No. 3259945

  The methods for obtaining the two carpets have their own characteristics and are not easily unified. In other words, the former is dyed after the tufting process, so it is possible to produce small lots, so it is particularly well suited to the actual consumption situation in Japan, and it is possible to respond quickly to production. Have. On the other hand, the latter has the advantage that it is excellent in processing cost and energy cost because it does not require a dyeing process and can be molded at low temperature.

  Recently, however, the required performance of tufted carpet base fabrics has occupy a greater weight on placing importance on the safety aspect of the consumer than on the producer's side of the carpet production. For example, there is a great demand to reduce VOCs (volatile organic compounds) represented by sick houses, and formaldehyde, one of the VOCs, is the most widely used crosslinking agent in binder resins used for carpet base fabrics. It has been found to be generated from the N-methylol acrylamide used. N-methylol acrylamide is widely known as a self-crosslinking agent particularly excellent in heat resistance, and is indispensable for applications exposed to severe conditions such as the above-described dyeing process where relatively high wet heat is applied. When a binder resin that does not use N-methylol acrylamide is used for applications that are exposed to severe conditions such as a dyeing process, the tufted carpet base fabric easily stretches or breaks the base fabric. There is a demand for a binder excellent in heat resistance that replaces N-methylolacrylamide.

  In view of the above situation, the present invention can reduce the generation of formaldehyde that causes sick house syndrome, and the tufted carpet base fabric stretches or breaks even under severe conditions such as high wet heat as in the dyeing process. An object of the present invention is to provide a base fabric in which no occurrence occurs.

  As a result of various studies to maintain the performance of the conventional excellent cross-linking agent, the present inventor is excellent in heat resistance and moldability by using a specific resin constituting the binder, and is formaldehyde. The present inventors have found that a tufted carpet base fabric having no occurrence of the above can be obtained, and have reached the present invention.

That is, the present invention is a tufted carpet base fabric that becomes a support when tufting pile yarn, wherein the tufted carpet base fabric is composed of a collection of long fiber groups , and the long fibers are separated from each other. binder Ri Na are combined, the said binder, N- methylcarbamoyl without acrylamide constituents, the glass transition point at least containing a resin a of 30 ° C. to 80 ° C., a glass transition point of apparent binder -15 The gist of the tufted carpet base fabric is 40 ° C.

Further, in the tufted carpet base fabric according to the present invention, the binder includes N-methylolacrylamide as a constituent component, and a resin A having a glass transition point of 30 ° C. to 80 ° C. and a resin B other than the resin A. Thus, the gist of the tufted carpet base fabric is characterized in that the apparent glass transition point of the binder is −15 to 10 ° C.

  In the present invention, a crosslinking agent called N-methylolacrylamide (hereinafter sometimes abbreviated as N-MAM), which has been useful since it has excellent heat resistance, is not used as a binder to be applied to the base fabric. The use of the resin A having a glass transition point of 30 ° C. or higher, which hardly heat-flows at high temperatures, has the effect of imparting heat resistance to this and reducing the generation of formaldehyde. Further, in the binder obtained by mixing the resin A specialized for heat resistance and another resin B, the carpet base fabric which is excellent in both heat resistance and moldability by setting the apparent glass transition point in a specific range. Is what I was able to get.

As described above, the tufted carpet base fabric according to the present invention uses N-methylolacrylamide as a constituent component, and a resin containing a resin A having a glass transition point of 30 ° C. to 80 ° C. as a binder, This is a combination of accumulated long fibers. Therefore, generation | occurrence | production of the formaldehyde which is a causative substance of sick house syndrome can be reduced, and a safe carpet can be provided to a consumer.

  Further, since the resin A is excellent in heat resistance, the carpet can be satisfactorily produced without the base fabric being greatly stretched even under severe conditions such as a dyeing process. Moreover, the moldability which was excellent in the tufted carpet base fabric can be provided by making an apparent glass transition point into a specific range in a binder.

  Furthermore, by setting the apparent glass transition point of the binder to −15 to 10 ° C., moldability at low temperature becomes possible, and both heat resistance and low temperature moldability in the dyeing process can be satisfied at the same time. A tufted carpet base fabric can be provided, and thereby, it is possible to achieve a great effect that a small lot production is possible at a low energy cost.

  The tufted carpet base fabric according to the present invention is formed by accumulating long fiber groups, and the long fibers are bonded together with a binder. As long fibers, polyester-based long fibers and polyamide-based long fibers are used. In addition, composite long fibers such as two-component core-sheath type composite long fibers and side-by-side type composite long fibers are also used. As the core-sheath type composite long fiber, a core component of polyester and a sheath component of polyamide or copolyester, or vice versa can be used. Moreover, as a side-by-side type composite fiber, what consists of polyester / polyamide, what consists of polyester / copolyester, etc. are used. In particular, in the present invention, it is preferable to use a polyester long fiber having a relatively high melting point. The reason for this is to prevent deterioration of long fibers constituting the base fabric when the tufted carpet is heat-molded.

  The fineness of the long fiber is arbitrary, but generally about 3 to 30 dtex is preferable, and 3 to 20 dtex is more preferable. When the fineness is less than 3 dtex, when the pile yarn is tufted, the long fibers are likely to be cut, and the tensile strength of the base fabric tends to decrease when the tufted carpet is formed. On the other hand, if the fineness exceeds 30 dtex, the base fabric itself becomes rough and rigid, which may impair the flexibility and moldability of the tufted carpet.

The long fiber group is accumulated by a conventionally known method. For example, while collecting the long fiber group by melt spinning, the long fiber group is accumulated by being deposited on a moving collection conveyor. Then, a binder is applied to the fiber web in a state where the long fiber group is accumulated to bond the long fibers together. In the present invention, it is preferable to entangle the long fibers by needle punching before applying the binder. This is because the tensile strength of the obtained tufted carpet base fabric is improved. That is, if needle punching is performed, a tufted carpet base fabric having a desired tensile strength can be obtained by applying a relatively small amount of binder. The needle density of the needle punch applied to the fiber web is appropriately set depending on the type of needle needle used and the needle depth, but is generally preferably 30 to 120 times / cm ² . When the needle density is less than 30 times / cm ² , the degree of entanglement between long fibers is low, and unless a relatively large amount of binder is used, it becomes difficult to impart desired tensile strength to the tufted carpet base fabric. In addition, when the needle density exceeds 120 times / cm ² , the entanglement between the long fibers becomes too intense, and there is a possibility that the long fibers may be cut when the needle punching is performed. May be worse.

  What is characteristic in the present invention is that a binder that satisfies specific conditions is adopted as a binder for bonding long fibers.

  That is, the binder used in the present invention does not contain N-MAM as a constituent component and contains at least a resin A having a glass transition point of 30 ° C. or higher.

  Since the binder used in the present invention does not contain N-MAM, a tufted carpet base fabric capable of reducing formaldehyde can be obtained. Furthermore, the resin A having a glass transition point of 30 ° C. or higher of the binder is difficult to flow even when exposed to high temperatures. Therefore, even if tension is applied to the base fabric under severe conditions where high moist heat is applied in the dyeing process, the resin A contained in the binder does not flow easily, and therefore, the bonded portions between the long fibers are difficult to move. Therefore, it is possible to prevent the base fabric from being deformed, such as the base fabric extending or entering into the width. When the glass transition point of the resin A is less than 30 ° C., the base fabric is deformed when tension is applied to the base fabric under a high temperature condition. In addition, the said effect can be show | played favorably by containing at least 5 mass% or more of resin A in a binder.

The present invention, by using the high resin A glass transition point, because it was made from finding that can suppress the fluidity of the binder in the high temperature, the upper limit of the glass transition point of the resin A is, carpet moldability 80 ° C. in consideration of the above .

The apparent glass transition point of the binder in the present invention is −15 to 40 ° C. Here, the apparent glass transition point of the binder is a mass average glass transition point, and the value of the glass transition point of each resin constituting the binder, with respect to all resins constituting the binder, It is the sum of the product multiplied by the mass ratio occupied by each resin. In the present invention, those having a glass transition point is only the resin A of 30 ° C. to 80 ° C. may be used as a binder, but the resin A having a glass transition point of 30 ° C. to 80 ° C., lower than that of the resin A glass transition temperature The resin B is mixed with a resin B other than the resin A that is excellent in heat fluidity, and a binder having a specific apparent glass transition point is used to further improve thermoformability. Here, the resin B is also a resin not containing N-MAM as a constituent component.

  When the apparent glass transition point of the binder is less than −15 ° C., the bonding portion between the long fibers due to the binder tends to move excessively. Therefore, in the dyeing process, the tufted carpet base fabric is stretched and deformed, and when the tufted carpet is molded, the entire base fabric is not uniformly deformed, and only the molded portion is excessively stretched. The base fabric becomes thin, and it becomes difficult to obtain a tufted carpet having a uniform thickness. In particular, considering the dimensional stability in the dyeing process, the lower limit of the apparent glass transition point is preferably −5 ° C. or higher. On the other hand, when the apparent glass transition point of the binder exceeds 40 ° C., the bonding portion between the long fibers by the whole binder becomes difficult to move, and thermoforming becomes impossible, which is not preferable. In this case, if the forced molding is performed, the base fabric may be broken.

  Also, when thermoforming, from the viewpoint of energy saving, or depending on the material of the pile yarn (for example, when polypropylene, which is a material having a low melting point, is used as the pile yarn, if thermoforming is performed at a high temperature, the loop will melt. When it is carried out at a relatively low temperature of about 100 to 140 ° C., the binder has an apparent glass transition point of −15 to 10 ° C. Can be thermoformed. That is, resin A having a high glass transition point that hardly flows even at high temperatures and having heat resistance and resin B having a relatively low glass transition point and easily flowing and having thermoformability are mixed in an appropriate amount. By using a binder having an apparent glass transition point of −15 to 10 ° C., in the dyeing process, deformation of the base fabric is prevented by the resin A having heat resistance, and in the subsequent thermoforming process, the flow at a low temperature is prevented. The resin B having excellent properties makes it easy to move the joints between the long fibers and enables thermoforming at a low temperature. In the conventional technology, in order to withstand the dyeing process, a binder having a glass transition point of 20 ° C. or higher using N-MAM, which is a crosslinking agent having excellent heat resistance, must be used. When a binder having a glass transition point of 20 ° C. or higher is used, deformation of the base fabric can be prevented in the dyeing process, but in the subsequent thermoforming process, the binder does not flow unless it is inevitably set at a high temperature. In addition, it is impossible to perform thermoforming at a low temperature, which reduces the selection range of pile yarns, and is disadvantageous from the viewpoint of energy saving.

  In the case of this low temperature molding, it becomes possible by setting the apparent glass transition point of the binder in the range of −15 to 10 ° C. However, when the apparent glass transition point of the binder is less than −15 ° C., it is described above. On the other hand, when the apparent glass transition point of the binder exceeds 10 ° C., in the low temperature range of 140 ° C. or less, the bonding portion between long fibers due to the entire binder becomes difficult to move, and thermoforming at a low temperature. Becomes impossible.

  In the present invention, the apparent glass transition point of the binder is set within a specific range by mixing the resin A responsible for heat resistance and the resin B having high flow characteristics in an appropriate amount, which is achieved in the past prior art. After tufting the undyed pile yarn that was not obtained, the pile yarn was dyed to a desired color using a pad steam continuous dyeing machine, etc., and after obtaining a tufted carpet, it was at a low temperature range of 140 ° C. or lower. Giving heat to the tufted carpet, using a mold (a mold composed of a male mold and a female mold), and pressurizing to obtain a molded tufted carpet. Can produce various effects.

  The apparent glass transition point of the binder in the present invention is appropriately set in accordance with the set temperature at the time of thermoforming within the above-mentioned range (-15 to 40 ° C, in the case of low temperature molding, -15 to 10 ° C). Can do. Further, the apparent glass transition point of the binder can be set by appropriately selecting the glass transition point and the mixing ratio of the resin A and the other resin B constituting the binder. Further, the resin B may be a single type or a mixture of two or more types.

  The resin constituting the binder in the present invention (resin A and / or other resin B) does not contain N-MAM as a constituent component, and is methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate. , Butyl methacrylate, acrylonitrile, and styrene are preferably used in combination. Furthermore, among the above monomers, it is preferable to use a copolymer obtained by copolymerizing styrene as an essential constituent in combination of two or more. A copolymer containing styrene as a constituent component is preferable because it has good sliding properties and excellent rigidity, and therefore, when a tufted carpet base fabric is molded, a molded carpet having good mold retention can be obtained.

  Here, the glass transition point of the resin constituting the binder in the present invention is measured by, for example, the following method. That is, the binder resin liquid is applied onto a release plate such as a glass plate, and is left to dry at room temperature to form a film. And this film is heat-processed at 160 degreeC for 5 minute (s), and it is set as a binder resin sample. This binder resin sample is obtained by drying and heat treatment of a binder resin solution, and is considered to exhibit the same physical properties as the binder that bonds the long fibers of the tufted carpet base fabric. Then, a heat of fusion curve is drawn for this binder resin sample using a DSC-7 model manufactured by Perkin Elmer Co., Ltd. at a temperature rising rate of 10 ° C./min. In this heat of fusion curve, the intersection of the extended line of the baseline in the glass state and the tangent of the maximum slope was taken as the glass transition point.

  The binder is used for bonding between long fibers. Specifically, the binder web is impregnated or sprayed with a binder resin solution, dried, and heat-treated as desired. Adhere between long fibers. The binder resin liquid is generally used in the form of a latex in which a binder resin is dispersed in water in an emulsified state. Accordingly, if the binder resin liquid is applied to the fiber web and then dried, the binder is adhered between the long fibers.

The amount of the binder adhered between the long fibers is preferably 5 to 30% by mass with respect to the total mass of the tufted carpet base fabric. When the adhesion amount of the binder is less than 5% by mass, the bond between the long fibers tends to be weakened, and the tensile strength of the tufted carpet base fabric may be lowered, and the effect of the binder in the present invention is obtained. It becomes difficult. On the other hand, when the adhesion amount of the binder exceeds 30% by mass, the binder existing between the long fibers becomes too much, and when tufting the pile yarn, it becomes difficult for the tufting needle to penetrate the base fabric, In the first place, it becomes difficult to obtain a tufted carpet to be used. Furthermore, the moldability of the tufted carpet tends to be inferior. The total mass (weight per unit area) of the tufted carpet base fabric is a matter that can be appropriately designed, but is generally preferably 50 to 150 g / m ² . When the basis weight of the tufted carpet base fabric is less than 50 g / m ² , the amount of fibers in the base fabric is small, and the tensile strength tends to decrease. On the other hand, if the basis weight exceeds 150 g / m ² , the physical properties are excessive, which is not economical. In addition, the basis weight of the tuft carpet base fabric was obtained by cutting 10 pieces of 50 cm × 50 cm sample pieces from the base fabric and making them equilibrated moisture in a standard state, then weighing the weight of each sample piece and calculating the average value per unit square meter. It is converted to the mass of.

  The longitudinal direction (MD direction) of the tufted carpet base fabric matches the longitudinal direction of the tufted carpet, and the lateral direction (CD direction) of the tufted carpet base fabric matches the lateral direction of the tufted carpet. Therefore, when tufting the pile yarn, a relatively high load tends to be applied in the longitudinal direction of the base fabric, and a relatively low load tends to be applied in the lateral direction of the base fabric. Therefore, in order to prevent breakage due to such a load, it is preferable that the tensile strength in the longitudinal direction and the transverse direction of the tufted carpet base fabric is as follows. That is, the longitudinal tensile strength of the tufted carpet base fabric according to the present invention is preferably 150 N / 5 cm width or more, and the transverse tensile strength is preferably 120 N / 5 cm width or more. Further, when tufting a pile yarn, the tufted carpet base fabric needs to be stretched to some extent, and it is preferable to use one having the following strong elongation characteristics. That is, the stress at 10% elongation in the longitudinal direction of the base fabric is preferably 70 N / 5 cm width or more, and the stress at 10% elongation in the transverse direction is preferably 30 N / 5 cm width or more. The tensile elongation in the machine direction is preferably 30% or more, and the tensile elongation in the transverse direction is preferably 40% or more.

The tensile strength as used in the field of this invention is measured as follows. That is, a strip-shaped sample piece having a width of 5 cm was prepared, and a constant speed extension type testing machine Tensilon UTM-4-1-100 manufactured by Toyo Baldwin Co., Ltd. was used at a grip interval of 10 cm and a tensile speed of 20 cm / min. It is measured according to the strip method described in 1096. And the average value of ten sample pieces was calculated | required, and the value which converted this per 100g / m < ² > of fabric weight was made into tensile strength. Further, the tensile elongation referred to in the present invention is measured in the same manner as in the tensile strength measurement method, except that it is not converted to a basis weight of 100 g / m ² . In addition, the average value of 10 sheets in which the length direction of the strip-shaped sample piece is matched with the MD direction of the base fabric is defined as the tensile strength and tensile elongation in the machine direction (MD) of the base fabric, The average value of 10 sheets whose length direction matched the CD direction of the base fabric was defined as the tensile strength (N / 5 cm width) and tensile elongation (%) in the cross direction (CD) of the base fabric. Further, the stress at 10% elongation referred to in the present invention is measured as follows. That is, the stress at the time of 10% elongation was obtained from the SS curve drawn in the above tensile test, and the average value of this was converted to a weight per 100 g / m ² per unit area as the stress at the time of 10% elongation. In addition, about the meaning of the vertical direction (MD) and horizontal direction (CD) of a base fabric, it is the same as that of the cases, such as tensile strength.

  The tufted carpet base fabric according to the present invention preferably has a hot water width of 5% or less. When this value exceeds 5%, the pile fabric and the dye liquor are loaded in the dyeing process, and at the same time, a relatively high wet heat is applied. Absent.

The hot water filling rate here is determined by the following method. That is, a strip-shaped sample piece having a width of 10 cm and a length of 31 cm is prepared. At this time, the sample piece is collected with its width direction matched with the lateral direction (CD direction) of the base fabric. Each end of the sample piece in the longitudinal direction is folded by 3 cm, and a loop is formed by sewing the folded end. Next, a straight line having a length of 10 cm parallel to the width direction is drawn at the center in the length direction of the sample piece, and the length of this line segment is measured to a unit of 0.5 mm. To do. Pipes are inserted into the rings at both ends of the sample, and a load is applied to one pipe together with the pipe so as to have a mass of 2.4 kg. The obtained sample is hung with the pipe to which no load is applied facing upward, and is immersed in hot water at 80 ° C. in this state. After 5 minutes, gently pull up the sample, measure the length of the central line (the length of the line after immersion) in the same manner as described above, and calculate the change in the length before and after immersion in hot water using the following formula. .
Hot water width ratio (%) = [(line segment length before immersion−line segment length after immersion) / line segment length before immersion] × 100
In addition, it calculated about each of 5 sample pieces, and made the average value into the hot water width penetration rate (%).

  In order to produce a tufted carpet, a pile yarn may be tufted into a tufted carpet base fabric according to the present invention. For example, as a pile yarn, uncolored nylon pile yarn or the like that has been conventionally used is tufted to obtain a living machine, and then dyed. In addition, when the dyeing process which is post-processing is unnecessary, an original yarn or a pre-dyed yarn may be used as the pile yarn. As the original yarn, an original polypropylene yarn, an original polyester yarn, an original nylon yarn or the like is used. In addition, as the dyed yarn, yarn-dyed polypropylene yarn, yarn-dyed polyester yarn, yarn-dyed nylon yarn or the like is used.

  For the purpose of fixing pile yarn on the back of the tufted carpet in which the pile yarn is implanted and for holding the molded tufted carpet, a resin that is a backing agent such as polyethylene is poured from the T die and fixed. Get a ted carpet. Further, when obtaining a molded tufted carpet, the tufted carpet is molded. In particular, when manufacturing a tufted carpet for an automobile, it is preferably molded into a shape that matches the floor or ceiling of the automobile or the inner surface of the door. In the present invention, thermoforming may be performed at a temperature corresponding to the base fabric depending on the apparent glass transition point of the binder applied to the base fabric, and the molding can be performed at a temperature of about 100 to 180 ° C. In particular, when a binder having an apparent glass transition point of −15 ° C. to 10 ° C. is used, it can be molded even at a low temperature of 140 ° C. or lower. In order to mold the tufted carpet, heat treatment is performed at a predetermined temperature, and then pressure molding is performed using a mold including a male mold and a female mold.

  Hereinafter, the present invention will be described specifically by way of examples. The low temperature moldability and formaldehyde generation amount of the base fabric in the examples were evaluated by the following methods. In the examples, the glass transition point of the resin constituting the binder, the apparent glass transition point of the binder, the basis weight of the base fabric, the tensile strength of the base fabric, the tensile elongation of the base fabric, and the 10% elongation of the base fabric The stress and hot water filling rate are measured by the methods described above.

(1) Low temperature moldability: Evaluation was carried out by the following method using the instrument shown in FIG. First, ten samples 4 having a size of 50 cm × 25 cm are prepared from the base fabric. On the other hand, a die comprising a conical piston 1 (male) with a rounded tip and a female die 2 with a corresponding conical recess (diameter 120 mm, depth 80 mm) with a rounded tip. prepare. And each sample 4 is fixed to the frame 3, and it processes for 5 minutes with a 130 degreeC hot air dryer in this state. Thereafter, the frame 3 is fixed on the female mold 2, and in this state, the piston 1 is pressed toward the concave portion of the female mold 2 to perform molding. After pressurization, it is left to stand for 10 seconds, and the molded sample 5 together with the frame 3 is taken out from the mold. After confirming that the molded sample 5 has cooled, remove the molded sample 5 from the frame 3. This state is as shown in FIG. 2, and the appearance of this molded sample 5 is visually judged and evaluated in the following three stages. In other words, ○: the base fabric is evenly stretched and neatly shaped, Δ: the base fabric is not torn, but the base fabric is not evenly stretched and the tip is thin, and X: the base fabric is torn Rated by stage. And the average result about each 10 sheets of samples was evaluated as moldability of a base fabric.

(2) Amount of formaldehyde generated: “Method for determining formaldehyde volatilized from vehicle interior parts / materials”, that is, formaldehyde generated from a sample piece heated at a predetermined temperature in a sealed space is collected, and this is collected as DNPH (dinitrophenylhydrazine). ) After derivatization, it was measured by analytical quantification.
Formaldehyde was collected by the 10 L Tedlar bag method. That is, an 80 cm ² sample piece was put into a 10 L capacity Tedlar bag, filled with 4 L of nitrogen gas, held at a heating temperature of 65 ° C. for 2 hours, and then the entire amount of gas in the Tedlar bag was sucked.
For analytical quantification, the amount of formaldehyde generated was analyzed and quantified using the DNPH derivatized solid layer adsorption-solvent extraction-HPLC method for the gas sucked in the above manner. The DNPH cartridge was Sep-Pak Long manufactured by Waters, and the solvent extraction was 4 ml of acetonitrile (Wako Pure Chemical Industries). The HPLC analysis was performed with a high performance liquid chromatograph (Waters 2690-996 PDA). The conditions were a detector UV of 355 nm, a column ODS of 4 mm × 10 mm, a column temperature of 40 ° C., and a developing solution of acetonitrile 55% -H ₂ O 45%.
The value measured by the same method as described above without introducing the sample piece was used as a blank value, and the amount of formaldehyde generated from the sample piece was obtained by subtracting the blank value from the measured value. The amount of formaldehyde generated was 0.1 μg or less per sample piece (80 cm ² ) as good (non-hollow region).

Example 1
Using a spinneret having a pore diameter of 0.35 mmφ and a hole number of 160, polyethylene terephthalate having an intrinsic viscosity of 0.70 dl / g was melt-spun from the die at a melting temperature of 285 ° C. The filament to be discharged was taken up while being drawn with air soccer so that the spinning speed was 5000 m / min, and a polyester long fiber group having a single yarn fineness of about 4.4 dtex was obtained. The long fiber group was opened with a fiber opening device provided at the outlet of the air soccer ball, and then deposited on a moving wire mesh collecting conveyor to obtain a fiber web. Next, the fiber web was passed through a needle punching machine in which a needle needle of RPD36 # manufactured by Organ was implanted, and needle punching was performed at a needle density of 60 times / cm ² . Thereafter, the punch web was passed through a hot press welding apparatus comprising a pair of smooth rolls heated to 190 ° C., and the punch web was compressed to obtain a nonwoven fabric having a basis weight of 100 g / m ² .

On the other hand, acrylic acid copolymerized with styrene, methyl methacrylate and ethyl acrylate as main components, and copolymerized with acrylate ester copolymer (resin A) and butyl acrylate and ethyl acrylate as main components. A binder resin liquid prepared by emulsifying and dispersing an ester copolymer (resin B) in water was prepared. The glass transition point of resin A was 32 ° C., the glass transition point of resin B was −7 ° C., and the mixing ratio of resin A and resin B was resin A / resin B = 20/80 (mass%). Therefore, the apparent glass transition point in the whole binder was set to 0.8 ° C. Then, the non-woven fabric was impregnated with the binder resin solution, followed by drying and heat treatment to obtain a tufted carpet base fabric having a basis weight of 110 g / m ² . Therefore, the adhesion amount of the binder is 9% by mass.

  When the moldability of this tufted carpet base fabric was evaluated, the moldability was good as shown in Table 1. The other physical properties of the tufted carpet base fabric were as shown in Table 1, and were excellent in form stability even at high temperatures. Also, the detected amount of formaldehyde was a preferable value in the non-hol region.

このタフテッドカーペット基布に、１３００デニールのナイロン糸よりなるパイル糸を用いて、ゲージ１／１０，ステッチ１０本／１インチ，ループパイルの高さ６ｍｍの条件で、タフティングし、連続染色加工を行ったが、タフティング性、染色前後での巾方向縮み性などの加工性についても問題なく良好であった。

This tufted carpet base fabric is tufted using pile yarn made of 1300 denier nylon yarn under the conditions of 1/10 gauge, 10 stitches per inch, and 6 mm loop pile height. However, workability such as tufting property and shrinkage in the width direction before and after dyeing was also satisfactory without problems.

Example 2
In Example 1, a tufted carpet base fabric was obtained in the same manner as in Example 1 except that the following were used as binders. That is, an acrylate ester copolymer (resin A) copolymerized with styrene, methyl methacrylate and ethyl acrylate as main components, and an acrylate ester copolymerized with butyl acrylate and ethyl acrylate as main components A binder resin liquid prepared by emulsifying and dispersing the system copolymer (resin B) in water was prepared. The glass transition point of Resin A was 32 ° C., the glass transition point of Resin B was −10 ° C., and the mixing ratio of Resin A and Resin B was Resin A / Resin B = 40/60 (mass%). Therefore, the apparent glass transition point in the whole binder was 6.8 ° C.

  By using the obtained tufted carpet base fabric, a tufted carpet was obtained in the same manner as in Example 1. Table 1 shows the moldability and other physical properties of the obtained tufted carpet base fabric. When obtaining a tufted carpet, the workability such as tufting property and width direction shrinkage before and after dyeing was satisfactory.

Example 3
In Example 1, a tufted carpet base fabric was obtained in the same manner as in Example 1 except that the following were used as binders. That is, an acrylate ester copolymer (resin A) copolymerized with styrene, methyl methacrylate, and ethyl acrylate as main components, and butyl acrylate, ethyl acrylate as a main component. A binder resin liquid prepared by emulsifying and dispersing the copolymer (resin B) in water was prepared. The glass transition point of Resin A was 42 ° C., the glass transition point of Resin B was −7 ° C., and the mixing ratio of Resin A and Resin B was Resin A / Resin B = 30/70 (mass%). Therefore, the apparent glass transition point in the whole binder was 7.7 ° C.

  By using the obtained tufted carpet base fabric, a tufted carpet was obtained in the same manner as in Example 1. Table 1 shows the moldability and other physical properties of the obtained tufted carpet base fabric. When obtaining a tufted carpet, the workability such as tufting property and width direction shrinkage before and after dyeing was satisfactory.

Example 4
In Example 1, as the resin B constituting the binder, a resin mainly composed of an acrylate ester copolymer obtained by copolymerizing ethyl acrylate and butyl acrylate as main components, and having a glass transition point of 16 ° C. And a tufted carpet base fabric was obtained in the same manner as in Example 1 except that the apparent glass transition point of the whole binder was 25.6 ° C. This tufted carpet base fabric was hard as a whole, and the base fabric was torn during a thermoforming test at a low temperature. Therefore, when the thermoforming temperature was set to 180 ° C., the molding could be performed satisfactorily. The other physical properties of the tufted carpet base fabric were as shown in Table 1. Using this tufted carpet base fabric, a tufted carpet was obtained in the same manner as in Example 1. Table 1 shows. When obtaining a tufted carpet, the workability such as tufting property and width direction shrinkage before and after dyeing was satisfactory.

Example 5
In Example 1, the resin B constituting the binder is a resin mainly composed of an acrylate-based copolymer copolymerized mainly with butyl acrylate and methyl methacrylate, and has a glass transition point of 5 ° C. A tufted carpet base fabric was obtained in the same manner as in Example 1 except that the apparent glass transition point of the whole binder was 10.4 ° C. and the amount of the binder attached was 17% by mass. It was. This tufted carpet base fabric was hard as a whole, and the base fabric was torn during a thermoforming test at a low temperature. Therefore, when the thermoforming temperature was set to 160 ° C., the molding could be performed satisfactorily. The physical properties of the tufted carpet base fabric are shown in Table 1. Using this tufted carpet base fabric, a tufted carpet was obtained in the same manner as in Example 1. When obtaining a tufted carpet, the workability such as tufting property and width direction shrinkage before and after dyeing was satisfactory.

Comparative Example 1
In Example 1, as the resin B constituting the binder, a resin mainly composed of an acrylate ester copolymer obtained by copolymerizing butyl acrylate and methyl acrylate as main components, and having a glass transition point of −40 ° C. A tufted carpet base fabric in the same manner as in Example 1 except that the apparent glass transition point of the whole binder was set to −25.6 ° C. and the adhesion amount of the binder resin was set to 17% by mass. Got. This tufted carpet base fabric was too soft as a whole, and the whole of the tufted carpet did not stretch uniformly during the molding test, and the portion corresponding to the tip of the piston 1 was severely stretched, and the portion became thin. The physical properties of the tufted carpet base fabric are shown in Table 1. Using this tufted carpet base fabric, an attempt was made to obtain a tufted carpet in the same manner as in Example 1. However, in the dyeing process, the base fabric was filled and the dimensional stability was poor. there were.

It is a typical sectional view showing arrangement of a metallic mold and a sample in evaluating moldability of a tufted carpet base fabric. It is typical sectional drawing which showed the shape of the tufted carpet base fabric after giving a shaping | molding test.

Explanation of symbols

1: Piston (male)
2: Female mold 3: Frame 4: Sample 5: Molded sample

Claims (6)

A tufted carpet base fabric used as a support for tufting pile yarn, wherein the tufted carpet base fabric is composed of a collection of long fiber groups , and the long fibers are bonded together with a binder. The binder does not contain N-methylol acrylamide, contains at least a resin A having a glass transition point of 30 ° C. to 80 ° C. , and an apparent glass transition point of the binder is −15 to 40 ° C. Characteristic tufted carpet base fabric. The binder does not contain N-methylolacrylamide as a constituent component, and consists of a resin A having a glass transition point of 30 ° C. to 80 ° C. and a resin B other than the resin A, and an apparent glass transition point of the binder of −15 to 10 ° C. The tufted carpet base fabric according to claim 1, wherein:   Resin A and / or resin B other than resin A is a combination of any two or more of methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, acrylonitrile, and styrene. The tufted carpet base fabric according to claim 1 or 2, which is a copolymer obtained by copolymerization.   4. The tufted carpet base fabric according to claim 3, wherein the resin A and / or the resin B other than the resin A is a copolymer containing styrene as an essential constituent component.   The tufted carpet base fabric according to any one of claims 1 to 4, wherein long fibers are entangled with each other by a needle punch.   The tufted carpet base fabric according to any one of claims 1 to 5, wherein an adhesion amount of the binder is 5 to 30% by mass.

Images