JP5019426B2 - Standing blanket with reduced aldehyde emission - Google Patents

Description

    The present invention intends to prevent the contamination of indoor air by adsorbing and removing a small amount of aldehyde gas diffused from a napped fabric such as carpet.

  In recent years, raised fabrics such as carpets are increasingly used recycled materials, and these recycled materials have various usage histories, and are managed and recycled with complete prevention of contamination. It is considered impossible. Therefore, even if it is a material that does not have a particular problem in appearance, from the fiber fabric such as carpet manufactured with these recycled raw materials, although it is a very small amount, the emission of aldehyde gases may be confirmed, It has been regarded as a problem. Houses constructed in recent years have significantly improved airtightness, and even a trace amount of gas is said to affect the human body and cause sick house syndrome. Yes.

  In order to deal with such problems, deodorization, deodorization and dust collection using air conditioners and air purifiers will be carried out, and aldehyde gas, odor, dust etc. in the air will be collected by filters etc. A method has been proposed.

Patent Document 1 proposes a carpet in which an adipic acid dihydrazide compound is an adsorbent that adsorbs aldehydes. Patent Document 2 discloses a fiber structure in which a composite oxide containing titanium and silicon on the fiber surface and a hydrazide compound or a nitrogen-containing heterocyclic compound as an aldehyde deodorizing composition are adhered by a resin. ing. In addition, in the patent documents 3 and 4, the applicant has selected one or more compounds selected from hydrazine derivatives, one or more compounds selected from porous inorganic substances, and a metal oxide 1 A deodorizing fabric in which a deodorizing composition comprising at least one kind of compound is carried on a fiber layer by a binder resin is disclosed. These technologies apply deodorant compositions such as hydrazine to fibers, etc. by applying them by methods such as dipping, spraying, printing, etc., and mixing them in the backing layer. However, all of them have been proposed for the purpose of deodorizing aldehydes in the air, and as in the present application, to suppress the emission of trace amounts of aldehydes. Nothing has been proposed yet.
Japanese Patent Laid-Open No. 11-46965 JP 2003-336170 A JP 2005-198684 A Japanese Patent Application No. 2005-146111

  The present invention has been made in view of such a technical background, and it is possible to prevent diffusion of aldehyde gas generated from fabrics used in houses, automobiles, trains, passenger airplanes, etc. The goal is to keep it clean.

  As a result of intensive studies to solve such problems, the present inventors have generated the napped fabric by fixing the inorganic silicon compound carrying the polyamine compound to the pile yarn and / or the backing layer of the napped fabric. It has been found that diffusion of aldehydes can be reduced, and the present invention has been reached. In order to achieve the above object, the present invention provides the following means.

  [1] A raised fabric characterized in that an inorganic silicon compound carrying a polyamine compound is fixed to a pile yarn and / or mixed into a backing layer through a binder resin.

[2] The inorganic silicon compound carrying the polyamine compound has a particle size of 10 nm to 100 μm, and is fixed to 0.2 to 10.0 g / m ² (dry weight) pile yarn and / or mixed with a backing resin. The napped fabric according to item 1 above.

  [3] The raised fabric according to item 1 or 2, characterized in that the raised fabric is a moquette, nonwoven fabric, or carpet using a recycled material.

  According to the invention of [1], since the inorganic silicon compound carrying the polyamine compound is fixed to the pile yarn and / or mixed in the backing layer via the binder resin, a very small amount of aldehydes generated from the napped fabric It is possible to make a napped fabric that efficiently and effectively removes neutral gas. Moreover, since it adheres to the pile yarn via the binder resin and / or is mixed in the backing layer, it is possible to obtain a napped fabric that can sufficiently withstand washing.

According to the invention of [2], the inorganic silicon compound carrying the polyamine compound has a particle diameter of 10 nm to 100 μm and is fixed to the pile yarn and / or a backing resin of 0.2 to 10.0 g / m ² (dry weight). Napped to effectively remove the trace amount of neutral aldehydes generated from the napped fabric without any roughness and maintaining a good texture of the napped fabric. It can be a fabric.

  According to the invention of [3], even if the raised fabric is a moquette, non-woven fabric, or carpet using a recycled material, neutral gas diffusion of a trace amount of aldehydes generated from the raised fabric is suppressed, Indoor air can be prevented from being contaminated.

  Next, an embodiment of the napped fabric according to the present invention will be described. The raised fabric of this embodiment is not particularly limited, and examples thereof include a raised fabric such as a raised nonwoven fabric, a carpet, and a moquette. The fibers forming the napped fabric are not particularly limited, and those made of fibers such as polyester fibers, polyamide fibers, polypropylene fibers, acrylic fibers, rayon fibers, etc. can be suitably used, and other hemp, cotton, wool, etc. Those made of natural fibers can also be used. Among them, a very small amount of neutral gas of aldehydes may be generated from fibers regenerated by recycling, and the present invention is effective for these regenerated fibers.

  In the present invention, examples of the inorganic silicon compound carrying a polyamine compound include those carrying a polyamine compound on porous silicon dioxide, aluminum silicate, or the like. As the polyamine compound, any one of aliphatic amine, aromatic amine, and alicyclic amine can be used as long as it has one or more primary amino groups in the molecule. For example, diethylenetriamine, tetraethylenepentamine, etc. Can be mentioned. As a method for supporting a polyamine compound, for example, an aqueous solution of a polyamine compound is prepared, porous silicon dioxide is immersed in this aqueous solution, and this is heated and fired to obtain a silicon dioxide compound supporting the polyamine compound. .

  The particle size of the inorganic silicon compound carrying the polyamine compound is preferably 10 nm to 100 μm. Since the average particle diameter is 10 nm to 100 μm, it is possible to obtain a raised fabric having a good texture without receiving a feeling of roughness when it is carried on a pile portion. Among them, the average particle diameter is preferably 10 nm to 10 μm, and particularly preferably 10 nm to 5 μm.

The coating amount of the inorganic silicon compound carrying the polyamine compound is preferably 0.2 to 10.0 g / m ² (dry weight). Less than 0.2 g / m ² is not preferable because sufficient aldehyde removal performance cannot be obtained. Moreover, even if it exceeds 10.0 g / m < ² >, the removal performance of aldehydes will not be improved, and the cost will increase undesirably.

  The coating method of the inorganic silicon compound carrying the polyamine compound is prepared by first preparing a treatment liquid comprising an aqueous dispersion in which the inorganic silicon compound carrying the polyamine compound and a binder resin are dispersed in water. At this time, it is preferable to disperse the inorganic silicon compound carrying the polyamine compound and the binder resin as much as possible, and it is more preferable that the binder resin forms an emulsion state with water. In addition, it is preferable to disperse the binder resin after dispersing the inorganic silicon compound carrying the polyamine compound in water in advance before the preparation.

  As the binder resin, any resin can be used. For example, self-crosslinking acrylic resin, methacrylic resin, urethane resin, silicone resin, glyoxal resin, vinyl acetate resin, vinylidene chloride resin, butadiene resin, melamine resin, epoxy resin, acrylic-silicone copolymer resin, ethylene- Examples thereof include vinyl acetate copolymer resin, isobutylene maleic anhydride copolymer resin, and ethylene-styrene-acrylate-methacrylate copolymer resin. Two or more of these resins may be mixed to form a binder resin.

  Moreover, you may mix | blend various additives, such as a dispersing agent and a thickener, with the said process liquid for various characteristic improvement. The treatment liquid thus obtained is applied to a raised fabric such as a carpet or a moquette. The means for applying is not particularly limited, and examples thereof include a spray method, a dipping method, a coating method, and a padding method. In the case of carpet, the application time may be a single state of the pile yarn, the base fabric, and the backing layer, or the treatment solution may be applied in the form of a skin layer in which the pile yarn is laid on the base fabric. The skin layer and the backing layer may be applied in an integrated form. Alternatively, the backing layer may be formed by mixing an inorganic silicon compound carrying the polyamine compound in a backing agent and applying the mixture by spraying or roller coating.

  As described above, the treatment liquid is applied and then dried. As a drying means, a heat treatment method is preferable from the viewpoint of drying efficiency. The heat treatment temperature is preferably 100 to 180 ° C. By the heat treatment at this temperature, the sticking property of the inorganic silicon compound carrying the polyamine compound can be further increased, and the sustained durability can be further improved.

  In general, the fabric is often processed to impart various functionalities such as flame retardancy, insect repellency, and antifouling in addition to the deodorizing performance. By adding the processing, the PH value of the surface of the napped fabric is increased. The deodorizing effect may be deteriorated by swinging to the acidic side or basic. In the present invention, it is important to maintain the pH value of the fabric surface before the main processing at 6 to 8, and the PH value of the fabric surface may be shifted to the acidic side or become basic due to various functionalities. In the case of shaking, it is preferably neutralized by immersing in an aqueous solution of phosphate, citric acid or the like. By adjusting the PH value of the surface of the napped fabric to 6 to 8 and then applying a deodorizing process, a napped fabric with good deodorizing efficiency can be obtained.

  Further, as shown in FIG. 1, the backing layer 5 is fixed to the base fabric 3 so that the pile yarn 2 does not come off during use, and is not particularly limited as long as it is a resin composition or a rubber composition. Examples of the resin component of the resin composition include resins such as acrylic, urethane, polyvinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber composition include SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber), MBR (methyl methacrylate-butadiene rubber), and natural rubber. What is necessary is just to mix the inorganic silicon compound which carry | supported the polyamine compound in the backing agent which consists of these resin composition and rubber composition, and it apply | coats to the back surface of a napped fabric, and dries. Examples of the coating method include a roll coating method and a spray coating method.

The coating amount of the inorganic silicon compound 7 supporting the polyamine compound is preferably 0.2 to 10.0 g / m ² (dry weight) on the pile yarn 2 and / or the backing layer 5. Less than 0.2 g / m ² is not preferable because sufficient aldehyde removal performance cannot be obtained. Moreover, even if it exceeds 10.0 g / m < ² >, the removal performance of aldehydes will not be improved, and the cost will increase undesirably.

  In addition, a 2nd base fabric 6 made of a woven fabric or a non-woven fabric may be attached to the lower side of the backing layer 5 for the purpose of protecting the backing layer and providing further cushioning properties and soundproofing properties. Examples of the form include a woven base fabric made of tape yarn and the like, a spunbond nonwoven fabric, a needle punched nonwoven fabric, and a water punch nonwoven fabric. The material of the 2nd base fabric 6 may be any material, for example, thermoplastic fibers such as polyester fibers, polyamide fibers and polyolefin fibers, and composite fibers of these fibers, acetates and the like. Examples thereof include semi-synthetic fibers, regenerated fibers such as rayon, natural fibers such as hemp and cotton, and mixed cottons of these, and even recycled products of these various fibers can be used.

<Example 1>
As an embodiment of the present invention, materials used for carpets, processing methods, and test evaluation methods are listed.
<Materials used and processing methods>
Base fabric: polyester spunbonded nonwoven fabric (ordinary 1st base fabric, basis weight 110 g / m ^{2 and} apparent thickness 0.3 mm)
Pile yarn: 2600 decitex original polyester yarn.
Tufting machine ... 1/8 cut machine
Tuft Standard: 30 stitches / 10 cm, pile length 8 mm, pile weight 780 g / m ²
Backing layer: SBR latex was roller-coated and dried at 120 ° C. for 10 minutes. (Application amount 260 g / m ² dry weight)
2nd base fabric: Needle-punched non-woven fabric of polyester recycled fiber (410 g / m ² per unit weight, apparent thickness 8 mm)
Deodorization processing: 20 parts by mass of silicon dioxide having an average particle diameter of 10 μm carrying NS, which was supported by diethylenetriamine, was added to 80 parts by mass of water, and then stirred with a stirrer to obtain a dispersion. . 10 parts by mass of an acrylic silicon binder resin (solid content 25%) was further added to this dispersion, and the mixture was stirred well to obtain a uniform treatment liquid. Next, before applying the backing layer, 10 g / m ² of this treatment solution was applied to the pile yarn and dried simultaneously with the drying of the backing layer, and 1.8 g / m ² (dry weight) of silicon dioxide carrying diethylenetriamine. Supported.

<Test evaluation method>
A sample piece cut into a 10 cm square is placed in a 10 L inner bag, and after a certain amount of nitrogen gas is sealed and heated at 60-65 ° C. for 2 hours, the gas in the bag is collected in a collecting tube, Quantitative analysis was performed by liquid chromatography to measure the amount of aldehydes emitted. The amount of formaldehyde released was 0.5 μg / unit or less, and the amount of acetaldehyde was 0.5 μg / unit or less. In Example 1, the emission of formaldehyde was 0.10 μg / unit, and the emission of acetaldehyde was 0.15 μg / unit.

<Example 2>
A carpet was obtained in the same manner as in Example 1 except that the average particle size of silicon dioxide carrying diethylenetriamine was 20 nm. The amount of formaldehyde released was below the detection limit, and the amount of acetonitrile released was 0.05 μg / unit.

<Example 3>
In Example 1, silicon dioxide having an average particle diameter of 10 μm carrying diethylenetriamine was carried out in the same manner as in Example 1 except that 0.2 g / m ² was supported on the pile yarn by 0.1 g / m ² (dry weight). And got a carpet. The amount of formaldehyde released was 0.28 μg / unit, and the amount of acetoaldehyde released was 0.34 μg / unit.

<Example 4>
A carpet was obtained in the same manner as in Example 1 except that 8 g / m ² (dry weight) of silicon dioxide carrying diethylenetriamine was carried on the pile yarn. The amount of formaldehyde released was below the detection limit, and the amount of acetonitrile released was 0.09 μg / unit.

<Example 5>
A carpet was obtained in the same manner as in Example 1 except that in the pile yarn, silicon dioxide carrying diethylenetriamine was not carried on the pile yarn, but 1.8 g / m ² (dry weight) was carried on the backing layer. The amount of formaldehyde released was 0.12 μg / unit, and the amount of acetonitrile released was 0.22 μg / unit.

<Example 6>
A carpet was obtained in the same manner as in Example 1 except that silicon dioxide supporting diethylenetriamine was supported on the pile yarn at 4 g / m ² and the backing layer at 4 g / m ² (dry weight). The amount of formaldehyde released was below the detection limit, and the amount of acetonitrile released was 0.02 μg / unit.

<Example 7>
A carpet was obtained in the same manner as in Example 1 except that silicon dioxide carrying tetraethylenepentamine was used instead of silicon dioxide carrying diethylenetriamine. The amount of formaldehyde released was 0.11 μg / unit, and the amount of acetonitrile released was 0.14 μg / unit.

<Comparative Example 1>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that neither the pile yarn nor the backing layer supported silicon dioxide supporting diethylenetriamine. The amount of formaldehyde consumed was 0.58 μg / unit, and the amount of acetaldehyde was 0.69 μg / unit, which was unacceptable.

<Comparative example 2>
A carpet was obtained in the same manner as in Example 1 except that silicon dioxide supporting diethylenetriamine was supported on a pile yarn at 6 g / m ² and the backing layer was supported at 6 g / m ² (dry weight). The amount of formaldehyde released was below the detection limit and the amount of acetonitrile released was 0.02 μg / unit, which was acceptable. However, the effect of only increasing the loading was not obtained.

<Comparative Example 3>
In Example 1, a carpet was obtained in the same manner as in Example 1 except that the average particle diameter of silicon dioxide carrying diethylenetriamine was 120 μm, but the surface texture was rough and did not become a preferred product. .

It is a schematic sectional drawing which shows the deodorizing carpet which concerns on one Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Carpet 2 ... Pile thread 3 ... Base fabric 4 ... Skin layer 5 ... Backing layer 6 ... 2nd base fabric 7 ... Inorganic silicon compound which carry | supported polyamine compound

Claims (3)

An inorganic silicon compound carrying a polyamine compound is fixed to and / or backing to a pile yarn via a binder resin on a fabric whose PH value on the surface of the fabric is maintained at 6 to 8 before being mixed into the fixing and / or backing layer. A raised fabric characterized by being mixed in the layer.

The inorganic silicon compound supporting the polyamine compound has a particle size of 10 nm to 100 μm, and is fixed to 0.2 to 10.0 g / m ² (dry weight) pile yarn and / or mixed with a backing resin. Item 2. The napped fabric according to item 1.   The napped fabric according to claim 1 or 2, wherein the napped fabric is a moquette, non-woven fabric, or carpet using a recycled material.