JP2009112358A - Nonwoven fabric backing for carpet which has shift preventing function, and its manufacturing method - Google Patents

Nonwoven fabric backing for carpet which has shift preventing function, and its manufacturing method Download PDF

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JP2009112358A
JP2009112358A JP2007285640A JP2007285640A JP2009112358A JP 2009112358 A JP2009112358 A JP 2009112358A JP 2007285640 A JP2007285640 A JP 2007285640A JP 2007285640 A JP2007285640 A JP 2007285640A JP 2009112358 A JP2009112358 A JP 2009112358A
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nonwoven fabric
fabric backing
split
fibers
fiber
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JP2009112358A5 (en
JP5306633B2 (en
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Kohei Yamada
耕平 山田
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Shoei Co Ltd
Daiwa KK
Yachiyo Co Ltd
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Shoei Co Ltd
Daiwa KK
Yachiyo Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To lower the cost of nonwoven fabric backing by providing a shift preventing function in a series of manufacturing processes of the nonwoven fabric backing and reducing the labor and time conventionally required for providing the shift preventing function in the nonwoven fabric backing, and to provide the nonwoven fabric backing whose shift preventing function is not easily damaged even when used for a long period of time, and its manufacturing method. <P>SOLUTION: In the nonwoven fabric backing 12 for a carpet, split type very thick composite fibers are included in the nonwoven fabric backing 12, and the split fibers 21a of the split type very thick composite fibers are projecting on the back surface side of the nonwoven fabric backing 12. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

本発明は、例えば自動車や列車、航空機などの乗り物の床面に敷設されるカーペットやマット、建物の室内や廊下の床面に敷設されるカーペットやマット、コンピュータのオペレーション用チェアマット、部屋の出入口に敷設される床面用マット、エレベータ内やエレベータホールの開閉扉前に敷設される床面用マット、玄関マットなどに適用されるカーペットに好適なズレ防止機能を有する不織布バッキング及びその製造方法に関する。   The present invention is, for example, a carpet or mat laid on the floor of a vehicle such as an automobile, train or aircraft, a carpet or mat laid on the floor of a building or hallway, a chair mat for computer operation, a room entrance / exit The present invention relates to a floor mat to be laid on a floor, a floor mat to be laid in an elevator or in front of an opening / closing door of an elevator hall, a nonwoven fabric backing having a displacement prevention function suitable for a carpet applied to an entrance mat, and the like, and a method of manufacturing the same. .

従来、カーペットの裏側に設けられるズレ防止機能を有する不織布バッキングとしては、例えば図５〜図７に示すように、不織布バッキング１の裏面側に、表面と裏面とを有する縦編み横糸挿入編物の前記表面と裏面とを接続するループ状縦糸をカットした編物２が一体化されていて、前記縦糸のカット端３が係止部として繊維質バッキング１の裏面側に突出するようにしたものがある（特許文献１参照）。
特開２００３−１０２６１１号公報 Conventionally, as the nonwoven fabric backing having a displacement preventing function provided on the back side of the carpet, for example, as shown in FIGS. 5 to 7, the warp knitting weft insertion knitted fabric having a front surface and a back surface on the back surface side of the nonwoven fabric backing 1. The knitted fabric 2 obtained by cutting the loop warp connecting the front surface and the back surface is integrated, and the cut end 3 of the warp yarn protrudes to the back side of the fibrous backing 1 as a locking portion ( Patent Document 1).
JP 2003-102611 A

ところが、図５〜図７に示すカーペット用不織布バッキングにあっては、当該不織布バッキング１にズレ防止機能を持たせるに、縦編み横糸挿入編物のループ状縦糸をカットして編物２を作製し、この編物２を不織布バッキング１の裏面側に接着などの手法によって接合一体化する必要があり、その分、多くの手間と時間がかかり、さらにはコスト高を招いていた。   However, in the nonwoven fabric backing for carpets shown in FIGS. 5 to 7, in order to give the nonwoven fabric backing 1 a function of preventing deviation, the loop-shaped warp of the warp knitting weft insertion knitted fabric is cut to produce the knitted fabric 2, This knitted fabric 2 needs to be joined and integrated to the back side of the nonwoven fabric backing 1 by a technique such as adhesion, which requires much labor and time, and further increases the cost.

また、このカーペット用不織布バッキング１にあっては、接着などの手法によって編物２を接合一体化しているため、該カーペットのクリーニングなど、長期に使用するにつれて、編物２が不織布バッキング１から剥がれ落ちてズレ防止機能が損なわれる恐れもあった。   Further, in the nonwoven fabric backing 1 for carpet, since the knitted fabric 2 is joined and integrated by a technique such as adhesion, the knitted fabric 2 is peeled off from the nonwoven fabric backing 1 as the carpet is cleaned and used for a long time. There was also a risk that the function of preventing displacement was impaired.

本発明は、このような事情に鑑みなされたものであり、不織布バッキングの一連の製造過程の中でズレ防止機能を持たせることができ、従来、不織布バッキングにズレ防止機能を持たせるために要していた手間と時間を削減し、もって該不織布バッキングの低コスト化を実現することができ、さらに長期に使用してもズレ防止機能が損なわれ難い不織布バッキング及びその製造方法を提供することを目的とするものである。   The present invention has been made in view of such circumstances, and can provide an anti-slipping function in a series of manufacturing processes of a non-woven fabric backing. Conventionally, the non-woven backing is required to have an anti-slip function. The present invention provides a nonwoven fabric backing that can reduce the labor and time required, reduce the cost of the nonwoven fabric backing, and prevent the displacement prevention function from being impaired even when used for a long time, and a method for producing the same. It is the purpose.

上記目的を達成するため、請求項１記載の発明は、カーペット用不織布バッキングであって、当該不織布バッキング中に分割型極太複合繊維が含まれており、前記不織布バッキングの裏面側に前記分割型極太複合繊維の分割された繊維が突出していることを特徴とするズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   In order to achieve the above object, the invention described in claim 1 is a nonwoven fabric backing for carpet, wherein the nonwoven fabric backing includes a split-type very thick composite fiber, and the split-type very thick backing is provided on the back side of the nonwoven fabric backing. The gist of the nonwoven fabric backing for carpets having an anti-displacement function, characterized in that the split fibers of the composite fiber protrude.

請求項２記載の発明は、分割型極太複合繊維が融点の異なる少なくとも２種のポリマー成分からなることを特徴とする請求項１記載のズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   The gist of the invention according to claim 2 is the nonwoven fabric backing for carpets having an anti-slipping function according to claim 1, wherein the split-type very thick composite fibers are composed of at least two polymer components having different melting points.

請求項３記載の発明は、不織布バッキングの裏面側に分割型極太複合繊維が高密度に含まれていることを特徴とする請求項１又は２のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   The invention according to claim 3 is for carpets having an anti-displacement function according to any one of claims 1 and 2, characterized in that the split-type very thick composite fibers are contained at a high density on the back side of the nonwoven fabric backing. The gist of nonwoven fabric backing was used.

請求項４記載の発明は、不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項１〜３のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   The invention according to claim 4 is characterized in that, while the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, the fineness of the divided fiber of the split type very thick composite fiber is 50 to 300 dtex. The non-woven fabric backing for carpets having a displacement preventing function according to any one of claims 1 to 3 was used as the gist thereof.

請求項５記載の発明は、不織布バッキングの構成繊維中に分割型極太複合繊維と共に、前記分割型極太複合繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維が含まれていることを特徴とする請求項１〜３のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   The invention according to claim 5 is characterized in that the constituent fiber of the nonwoven fabric backing includes a split type very thick composite fiber and a fiber that is thinner than the split type extremely thick composite fiber and thicker than the constituent fiber of the nonwoven fabric backing. The non-woven fabric backing for carpets according to any one of claims 1 to 3, which has a function of preventing misalignment, was used as the gist thereof.

請求項６記載の発明は、不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５００〜１０００デシテックスであり、前記分割型極太複合繊維の分割された繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項５に記載のズレ防止機能を有するカーペット用不織布バッキングをその要旨とした。   In the invention according to claim 6, the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, whereas the fineness of the divided fiber of the split-type extra-thick composite fiber is 500 to 1000 dtex, and the split-type extra-thick 6. The nonwoven fabric backing for carpets having an anti-slipping function according to claim 5, wherein the fineness of the fibers which are finer than the divided fibers of the composite fiber and thicker than the constituent fibers of the nonwoven fabric backing is 50 to 300 dtex. Was the gist.

請求項７記載の発明は、カーペット用不織布バッキングの製造方法であって、当該不織布バッキングを構成する繊維ウェブを形成し、次いで、前記不織布バッキングの構成繊維ウェブ上に融点の異なる少なくとも２種のポリマー成分からなる分割型極太複合繊維からなる複合繊維ウェブを形成し、次いで、絡合処理を施すことにより、前記不織布バッキングの構成繊維ウェブ及び複合繊維ウェブのそれぞれの繊維相互、並びに不織布バッキングの構成繊維ウェブと複合繊維ウェブの繊維相互を結合し、この後、前記不織布バッキングを前記分割型極太複合繊維の高い融点のポリマー成分よりも低く、低い融点のポリマー成分と同じか若しくは高い温度で加熱することで、前記分割型極太複合繊維を分割させたことを特徴とするズレ防止機能を有するカーペット用不織布バッキングの製造方法をその要旨とした。   The invention according to claim 7 is a method for producing a nonwoven fabric backing for carpet, wherein a fiber web constituting the nonwoven fabric backing is formed, and then at least two polymers having different melting points on the constituent fiber web of the nonwoven fabric backing By forming a composite fiber web composed of split-type very thick composite fibers composed of components, and then performing an entanglement treatment, the constituent fiber web of the nonwoven fabric backing and the respective fibers of the composite fiber web, and the constituent fibers of the nonwoven fabric backing The fibers of the web and the composite fiber web are bonded to each other, and thereafter, the nonwoven fabric backing is heated at a temperature lower than the high melting point polymer component of the split ultrathin composite fiber and at the same or higher temperature as the low melting point polymer component. And having a function of preventing misalignment, characterized in that the split very thick composite fiber is split. The method for manufacturing carpet nonwoven backing which has its gist.

請求項８記載の発明は、不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項７に記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法をその要旨とした。   The invention according to claim 8 is characterized in that, while the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, the fineness of the divided fiber of the split-type very thick composite fiber is 50 to 300 dtex. The gist of the method for producing a nonwoven fabric backing for carpets having an anti-slipping function according to claim 7.

請求項９記載の発明は、不織布バッキングの構成繊維ウェブを形成した後、分割型極太複合繊維からなる複合繊維ウェブを形成する前に、前記分割型極太複合繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維のウェブを形成することを特徴とする請求項７記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法をその要旨とした。   According to the ninth aspect of the present invention, after forming the constituent fiber web of the nonwoven backing, and before forming the composite fiber web composed of the split very thick composite fibers, the structure of the nonwoven backing is thinner than the split very thick composite fibers. The gist of the method for producing a nonwoven fabric backing for carpets having an anti-displacement function according to claim 7, wherein a web of fibers thicker than the fibers is formed.

請求項１０記載の発明は、不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５００〜１０００デシテックスであり、前記分割型極太複合繊維の分割された繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項９に記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法をその要旨とした。   The invention according to claim 10 is that the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, whereas the fineness of the divided fiber of the split-type extra-thick composite fiber is 500 to 1000 dtex, and the split-type extra-thick The nonwoven fabric backing for a carpet having a function of preventing misalignment according to claim 9, wherein the fineness of the fibers which are finer than the divided fibers of the composite fiber and thicker than the constituent fibers of the nonwoven fabric backing is 50 to 300 dtex. The manufacturing method of was made the summary.

本発明のカーペット用不織布バッキングにあっては、当該不織布バッキング中に含まれる分割型極太複合繊維の分割された繊維が前記不織布バッキングの裏面側に突出し、カーペットが敷設される床面に食い込むことで、カーペットのズレが防止されるようになっていることから、構造が簡単であり、しかも優れたズレ防止機能を有すると共に、従来のカーペット用不織布バッキングのように長期にわたる使用でズレ防止機能が損なわれる恐れも少ないという効果を奏する。   In the nonwoven fabric backing for carpet according to the present invention, the divided fibers of the split-type very thick composite fiber contained in the nonwoven fabric backing protrude to the back side of the nonwoven fabric backing, and bite into the floor on which the carpet is laid. Since the slippage of the carpet is prevented, the structure is simple and it has an excellent slippage prevention function, and the slippage prevention function is impaired by long-term use like the conventional nonwoven fabric backing for carpets. There is an effect that there is little fear of being caught.

また、本発明のカーペット用不織布バッキングの製造方法にあっては、当該不織布バッキングを構成繊維ウェブを形成し、次いで、融点の異なる少なくとも２種のポリマー成分からなる複合繊維ウェブを形成し、次いで、絡合処理を施し、この後、分割型極太複合繊維の高い融点のポリマー成分よりも低く、低い融点のポリマー成分と同じか若しくは高い温度で加熱することで、前記分割型極太複合繊維を分割させ、該カーペット用不織布バッキングを製造することができるため、不織布バッキングの一連の製造過程で不織布バッキングにズレ防止機能を付与することができる。このため、従来の不織布バッキングのように、ズレ防止機能を持たせるために要していた手間と時間を削減し、もって該不織布バッキングの低コスト化を実現することができる。   In the method for producing a nonwoven fabric backing for carpet according to the present invention, the nonwoven fabric backing is formed into a constituent fiber web, then a composite fiber web composed of at least two polymer components having different melting points, and then formed. After the entanglement treatment is performed, the split type very thick composite fiber is divided by heating at a temperature lower than the high melting point polymer component of the split type thick composite fiber and at the same or higher temperature as the low melting point polymer component. Since the nonwoven fabric backing for carpets can be produced, a slip prevention function can be imparted to the nonwoven fabric backing in a series of production processes of the nonwoven fabric backing. For this reason, like the conventional nonwoven fabric backing, the labor and time required for providing the function of preventing misalignment can be reduced, and the cost of the nonwoven fabric backing can be reduced.

以下、本発明のカーペット用不織布バッキング及びその製造方法を図面に示した位置実施の形態に従ってさらに詳しく説明する。尚、本発明のカーペット用不織布バッキングの製造方法については、本発明のカーペット用不織布バッキングを説明する過程で共に説明することとする。   Hereinafter, the nonwoven fabric backing for carpet and the method for producing the same according to the present invention will be described in more detail according to the position embodiment shown in the drawings. In addition, about the manufacturing method of the nonwoven fabric backing for carpets of this invention, we shall explain together in the process of explaining the nonwoven fabric backing for carpets of this invention.

図１は、表面繊維基材１３の裏側に不織布バッキング１２を設けたカーペット１１を示すものである。表面繊維基材１３としては、特に限定されないが、図１に示す表面繊維基材１３は、不織布、紙、布、フェルトあるいはこれらの複合物からなる繊維シート１３ａにパイル糸１３ｂを所定のボリュームで略U字状となるように打ち込んだものである。尚、表面繊維基材１３は、パイル糸１３ｂを打ち込まない繊維シート１３ａのみからなるものであっても良い。   FIG. 1 shows a carpet 11 in which a nonwoven fabric backing 12 is provided on the back side of a surface fiber substrate 13. The surface fiber base material 13 is not particularly limited, but the surface fiber base material 13 shown in FIG. 1 has a pile yarn 13b at a predetermined volume on a fiber sheet 13a made of nonwoven fabric, paper, cloth, felt, or a composite thereof. It was typed into a substantially U shape. In addition, the surface fiber base material 13 may consist only of the fiber sheet 13a which does not drive the pile yarn 13b.

また、図１に示す表面繊維基材１３には、パイル糸１３ｂの抜け止めのためにプレコート層１４が設けられている。またさらに表面繊維基材１３のプレコート層１４の裏側には接着層１５が設けられている。図１に示す接着層１５は、例えば前述のポリアミド系ホットメルト樹脂、ポリスチレン系ホットメルト樹脂、ポリエチレン系ホットメルト樹脂、ＥＶＡ系ホットメルト樹脂などのホットメルト樹脂からなり、その形態は蜘蛛の巣状となっており、表面繊維基材１３と不織布バッキング１２とを部分接着できるようになっている。この接着層１５を介して不織布バッキング１２が接着されている。   Further, the surface fiber base 13 shown in FIG. 1 is provided with a precoat layer 14 for preventing the pile yarn 13b from coming off. Further, an adhesive layer 15 is provided on the back side of the precoat layer 14 of the surface fiber base 13. The adhesive layer 15 shown in FIG. 1 is made of a hot-melt resin such as the above-mentioned polyamide-based hot melt resin, polystyrene-based hot melt resin, polyethylene-based hot melt resin, EVA-based hot melt resin, and the form thereof is a spider web shape. Thus, the surface fiber base material 13 and the nonwoven fabric backing 12 can be partially bonded. The nonwoven fabric backing 12 is bonded through the adhesive layer 15.

不織布バッキング１２には、例えばポリプロピレンやポリエチレンなどのポリオレフィン系繊維、ポリエチレンテレフタレートなどのポリエステル系繊維、ナイロン６、ナイロン６６などのポリアミド系繊維、ポリアクリロニトリルなどのアクリル系繊維、或いはポリビニルアルコール系繊維から選ばれる１種若しくは２種以上を構成繊維とする不織布を用いることができる。   Nonwoven fabric backing 12 is selected from, for example, polyolefin fibers such as polypropylene and polyethylene, polyester fibers such as polyethylene terephthalate, polyamide fibers such as nylon 6 and nylon 66, acrylic fibers such as polyacrylonitrile, or polyvinyl alcohol fibers. The nonwoven fabric which uses the 1 type (s) or 2 or more types as a constituent fiber can be used.

この不織布バッキング１２を構成する構成繊維２０中には分割型極太複合繊維２１が含まれている。分割型極太複合繊維２１は、分割されることで極太の分割繊維或いはその分割繊維束が得られる。この分割型極太複合繊維２１は、極太の分割繊維或いはその分割繊維束に分割できるように、融点の異なる二種類以上のポリマー成分の組み合わせからなる。異なる二種類以上の組み合わせを構成するポリマー成分の融点の差は１５℃以上、好ましくは２０℃以上であり、このようなポリマーの組み合わせとしては、例えばポリエステル／ポリオレフィン、高融点ポリエステル／低融点ポリエステル、ポリアミド／ポリオレフィン、高融点ポリアミド／低融点ポリアミド、ポリプロピレン／ポリエチレン、高融点ポリエチレン／低融点ポリエチレン等が挙げることができる。   The component fibers 20 constituting the nonwoven fabric backing 12 include split-type very thick composite fibers 21. The split type very thick composite fiber 21 is split to obtain a very thick split fiber or a split fiber bundle thereof. The split-type very thick composite fiber 21 is composed of a combination of two or more types of polymer components having different melting points so that the split-type very thick composite fiber 21 can be split into extremely thick split fibers or split fiber bundles thereof. The difference in melting point of polymer components constituting two or more different combinations is 15 ° C. or more, preferably 20 ° C. or more. Examples of such polymer combinations include polyester / polyolefin, high-melting polyester / low-melting polyester, Polyamide / polyolefin, high melting point polyamide / low melting point polyamide, polypropylene / polyethylene, high melting point polyethylene / low melting point polyethylene, and the like.

この分割型極太複合繊維２１は、高い融点のポリマー成分（以下、「高融点成分」という）よりも低く、低い融点のポリマー成分（以下、「低融点成分」という）と同じか若しくは高い温度で加熱することにより、低融点成分が溶融し、高融点成分が分割された繊維として残存するようになっている。   The split ultrathin composite fiber 21 is lower than a high melting point polymer component (hereinafter referred to as “high melting point component”) and at the same or higher temperature as a low melting point polymer component (hereinafter referred to as “low melting point component”). By heating, the low melting point component melts and the high melting point component remains as a divided fiber.

この分割型極太複合繊維２１の断面形状としては、例えば図２に示すように、高融点成分２１ａと低融点成分２１ｂとを交互に層状に積層したものや、図３に示すように、高融点成分２１ａと低融点成分２１ｂとを交互に放射状に並べて菊花状の繊維断面としたものなどを使用できる。   As the cross-sectional shape of the split-type very thick composite fiber 21, for example, as shown in FIG. 2, a high melting point component 21a and a low melting point component 21b are alternately layered, or as shown in FIG. The component 21a and the low-melting-point component 21b that are alternately arranged radially to form a chrysanthemum-like fiber cross section can be used.

また、不織布バッキング１２の構成繊維２０には、繊度が１〜２０デシテックスのものが望ましく、これに対し分割型極太複合繊維２１の分割された繊維２１ａには、繊度が５０〜３００デシテックスのものが望ましい。   The constituent fiber 20 of the nonwoven fabric backing 12 preferably has a fineness of 1 to 20 dtex, whereas the divided fiber 21a of the split type very thick composite fiber 21 has a fineness of 50 to 300 dtex. desirable.

図１に示すカーペット用不織布バッキング１２は、例えば図４に示す方法によって製造することができる。図４に示す方法では、まず図１及び図４に示すように、図４中矢印方向に移動するメッシュ３０上に第１ホッパー３１から当該不織布バッキング１２を構成する構成繊維２０を投入して繊維ウェブ３１を形成する。次いで、前記不織布バッキング１２の構成繊維ウェブ３１上に第２ホッパー３３から融点の異なる少なくとも２種のポリマー成分からなる分割型極太複合繊維２１からなる複合繊維ウェブ３４を形成する。   The nonwoven fabric backing 12 for carpet shown in FIG. 1 can be manufactured, for example, by the method shown in FIG. In the method shown in FIG. 4, first, as shown in FIGS. 1 and 4, the constituent fibers 20 constituting the nonwoven fabric backing 12 are introduced from the first hopper 31 onto the mesh 30 moving in the direction of the arrow in FIG. A web 31 is formed. Next, a composite fiber web 34 composed of split very thick composite fibers 21 made of at least two polymer components having different melting points is formed from the second hopper 33 on the constituent fiber web 31 of the nonwoven fabric backing 12.

次いで、ニードリング又は水流によって絡合処理３５を施すことにより、前記不織布バッキング１２の構成繊維ウェブ３２及び複合繊維ウェブ３４のそれぞれの繊維２０、２１相互、並びに不織布バッキング１２の構成繊維ウェブ３２と複合繊維ウェブ３４の繊維２０と繊維２１の相互を結合する。この絡合処理により、不織布バッキング１２の一方面側、すなわち複合繊維ウェブ３４側には、分割型極太複合繊維２１が高密度に存在することになる。   Next, by performing an entanglement treatment 35 by needling or water flow, the constituent fiber web 32 of the nonwoven fabric backing 12 and the fibers 20, 21 of the composite fiber web 34 and the constituent fiber web 32 of the nonwoven fabric backing 12 are combined with each other. The fibers 20 and 21 of the fiber web 34 are bonded to each other. By this entanglement treatment, the split-type very thick composite fibers 21 are present at a high density on one surface side of the nonwoven fabric backing 12, that is, on the composite fiber web 34 side.

この後、絡合処理３５によって繊維相互が結合した不織布バッキング１２をヒーター３６によって、前記分割型極太複合繊維２１の高融点成分の融点よりも低く、低融点成分の融点と同じか若しくは高い温度で加熱することで、例えば図２又は図３に示す前記分割型極太複合繊維２１の低融点成分２１ｂを溶融させて分割させ、残存する高融点成分からなる繊維２１ａが放射状に分割し、図１に示すように該不織布バッキング１２の裏面側に分割型極太複合繊維２１の分割された繊維２１ａが突出することになる。   Thereafter, the nonwoven fabric backing 12 in which the fibers are bonded together by the entanglement process 35 is lowered by the heater 36 at a temperature lower than the melting point of the high melting point component of the split-type very thick composite fiber 21 and equal to or higher than the melting point of the low melting point component. By heating, for example, the low-melting-point component 21b of the split-type very thick composite fiber 21 shown in FIG. 2 or 3 is melted and split, and the remaining high-melting-point component 21a is radially split into FIG. As shown, the split fiber 21a of the split very thick composite fiber 21 protrudes on the back side of the nonwoven fabric backing 12.

また、加熱によって溶融した低融点成分２１ｂは、分割型極太複合繊維２１の分割された繊維２１ａが絡み合った不織布バッキング１２の構成繊維２０間を結合すると共に分割型極太複合繊維２１の分割された繊維２１ａ相互を結合し、不織布バッキング１２の裏面側に突出する分割型極太複合繊維２１の分割された繊維２１ａの根本が固められ、不織布バッキング１２の裏面側の形態の安定化を図ることができるようになっている。   Further, the low melting point component 21b melted by heating binds the constituent fibers 20 of the nonwoven fabric backing 12 in which the split fibers 21a of the split-type very thick composite fibers 21 are intertwined, and the split fibers of the split-type very thick composite fibers 21 The roots of the split fibers 21a of the split-type very thick composite fibers 21 that are bonded to each other and project to the back side of the nonwoven fabric backing 12 are solidified, so that the configuration of the back side of the nonwoven fabric backing 12 can be stabilized. It has become.

次に、図５に示す不織布バッキングについて説明する。図５に示すカーペット４１は、表面繊維基材４３の裏側に不織布バッキング４２を設けたものであり、不織布バッキング４２の構成繊維５０中に分割型極太複合繊維５１と共に、前記分割型極太複合繊維５１よりも細く、前記不織布バッキング４２の構成繊維５０よりも太い繊維５２が含まれていることを特徴とするものである。   Next, the nonwoven fabric backing shown in FIG. 5 will be described. The carpet 41 shown in FIG. 5 is provided with a nonwoven fabric backing 42 on the back side of the surface fiber base material 43, and the divided very thick composite fibers 51 together with the divided very thick composite fibers 51 in the constituent fibers 50 of the nonwoven fabric backing 42. The fibers 52 are thinner and thicker than the constituent fibers 50 of the nonwoven fabric backing 42.

尚、図５に示すカーペット４１における表面繊維基材４３、プレコート層４４、接着層４５、不織布バッキング４２の構成繊維５０、分割型極太複合繊維５１については、図１に示すものと同じであるため、ここでの説明は割愛する。   Note that the surface fiber base material 43, the precoat layer 44, the adhesive layer 45, the constituent fiber 50 of the nonwoven fabric backing 42, and the split-type very thick composite fiber 51 in the carpet 41 shown in FIG. 5 are the same as those shown in FIG. I'll omit the explanation here.

図５に示すカーペット４１における不織布バッキング４２の場合、不織布バッキング４２の構成繊維５０中には、構成繊維５０及び分割型極太複合繊維５１のほかに、前記分割型極太複合繊維５１よりも細く、前記不織布バッキング４２の構成繊維５０よりも太い繊維５２が含まれている。   In the case of the nonwoven fabric backing 42 in the carpet 41 shown in FIG. 5, in the constituent fibers 50 of the nonwoven fabric backing 42, in addition to the constituent fibers 50 and the split-type very thick composite fibers 51, they are thinner than the split-type very thick composite fibers 51, Fibers 52 that are thicker than the constituent fibers 50 of the nonwoven fabric backing 42 are included.

不織布バッキング４２の構成繊維５０の繊度としては１〜２０デシテックスが望ましく、これに対し、分割型極太複合繊維５１の分割された繊維５１ａの繊度は５００〜１０００デシテックスが望ましく、前記分割型極太複合繊維５１の分割された繊維５１ａよりも細く、前記不織布バッキング４２の構成繊維５０よりも太い繊維５２の繊度としては５０〜３００デシテックスが望ましい。   The fineness of the constituent fiber 50 of the nonwoven fabric backing 42 is preferably 1 to 20 dtex, whereas the fineness of the divided fiber 51a of the split type very thick composite fiber 51 is preferably 500 to 1000 dtex, and the split type very thick composite fiber The fineness of the fibers 52 that are thinner than the divided fibers 51a and thicker than the constituent fibers 50 of the nonwoven fabric backing 42 is preferably 50 to 300 dtex.

図５に示すカーペット用不織布バッキング４１は、例えば図６に示す方法によって製造することができる。図６に示す方法では、まず図５及び図６に示すように、図６中矢印方向に移動するメッシュ６０上に第１ホッパー６１から当該不織布バッキング４２を構成する構成繊維５０を投入して繊維ウェブ６１を形成する。次いで、前記不織布バッキング４２の構成繊維ウェブ６１上に第２ホッパー６３から分割型極太複合繊維５１の分割された繊維５１ａよりも細く、前記不織布バッキング４２の構成繊維５０よりも太い繊維５２を投入して繊維ウェブ６４を形成する。次いで、繊維ウェブ６４上に融点の異なる少なくとも２種のポリマー成分からなる分割型極太複合繊維５１を投入して分割型極太複合繊維５１からなる複合繊維ウェブ６５を形成する。   The carpet nonwoven fabric backing 41 shown in FIG. 5 can be manufactured, for example, by the method shown in FIG. In the method shown in FIG. 6, first, as shown in FIGS. 5 and 6, the constituent fibers 50 constituting the nonwoven fabric backing 42 are introduced from the first hopper 61 onto the mesh 60 moving in the direction of the arrow in FIG. A web 61 is formed. Next, fibers 52 that are thinner than the split fibers 51a of the split-type very thick composite fiber 51 and thicker than the constituent fibers 50 of the nonwoven fabric backing 42 are introduced from the second hopper 63 onto the constituent fiber web 61 of the nonwoven fabric backing 42. Thus, the fiber web 64 is formed. Next, split-type very thick composite fibers 51 made of at least two kinds of polymer components having different melting points are put on the fiber web 64 to form a composite fiber web 65 made of the split-type very thick composite fibers 51.

次いで、ニードリング又は水流によって絡合処理６６を施すことにより、前記不織布バッキング４２の構成繊維ウェブ６１、繊維ウェブ６４、及び複合繊維ウェブ６５のそれぞれの繊維５０、５２、５１相互、並びに不織布バッキング４２の構成繊維ウェブ６１、繊維ウェブ６４、及び複合繊維ウェブ６５の繊維５０と繊維５２、繊維５１の相互を結合する。この絡合処理により、不織布バッキング４２の一方面側、すなわち複合繊維ウェブ６５側には、分割型極太複合繊維５１が高密度に存在することになる。   Next, by applying an entanglement process 66 by needling or water flow, the fibers 50, 52, 51 of the constituent fiber web 61, the fiber web 64, and the composite fiber web 65 of the nonwoven fabric backing 42, and the nonwoven fabric backing 42, respectively. The fibers 50, 52, and 51 of the constituent fiber web 61, the fiber web 64, and the composite fiber web 65 are bonded together. By this entanglement treatment, the split-type very thick composite fibers 51 are present at a high density on one surface side of the nonwoven fabric backing 42, that is, on the composite fiber web 65 side.

また、この形態の場合、繊度が互いに近い繊維５０、繊維５２、繊維５１の３種類の繊維を用いているために、各繊維５０、５２、５１の相互が絡み易く、シート形態がより安定なものとなり、分割型極太複合繊維５１の分割された繊維５１ａの抜けをより確実に防止することができる。   In addition, in the case of this form, since the three types of fibers 50, 52, and 51 having fineness close to each other are used, the fibers 50, 52, and 51 are easily entangled with each other, and the sheet form is more stable. Therefore, it is possible to more reliably prevent the split fibers 51a from falling out of the split very thick composite fiber 51.

この後、絡合処理６６によって繊維相互が結合した不織布バッキング４２をヒーター６７によって、前記分割型極太複合繊維５１の高融点成分の融点よりも低く、低融点成分の融点と同じか若しくは高い温度で加熱することで、分割型極太複合繊維５１の低融点成分を溶融させて分割させ、残存する高融点成分からなる繊維５１ａが放射状に分割し、図５に示すように該不織布バッキング４２の裏面側に分割型極太複合繊維５１の分割された繊維５１ａが突出することになる。   Thereafter, the nonwoven fabric backing 42 in which the fibers are bonded together by the entanglement process 66 is lowered by the heater 67 at a temperature lower than the melting point of the high melting point component of the split type very thick composite fiber 51 and equal to or higher than the melting point of the low melting point component. By heating, the low melting point component of the split-type very thick composite fiber 51 is melted and divided, and the remaining fiber 51a composed of the high melting point component is radially divided, and the back side of the nonwoven fabric backing 42 as shown in FIG. In other words, the split fiber 51a of the split-type very thick composite fiber 51 protrudes.

また、加熱によって溶融した低融点成分は、分割型極太複合繊維５１の分割された繊維５１ａが絡み合った不織布バッキング４２の構成繊維５０及び繊維５２間を結合すると共に分割型極太複合繊維５１の分割された繊維５１ａ相互を結合し、不織布バッキング４２の裏面側に突出する分割型極太複合繊維５１の分割された繊維５１ａの根本が固められ、不織布バッキング４２の裏面側の形態の安定化を図ることができるようになっている。   Further, the low melting point component melted by heating bonds the constituent fibers 50 and the fibers 52 of the nonwoven fabric backing 42 in which the split fibers 51 a of the split very thick composite fibers 51 are intertwined with each other and splits the split very thick composite fibers 51. The fibers 51a are bonded to each other, and the roots of the split fibers 51a of the split-type very thick composite fiber 51 protruding to the back surface side of the nonwoven fabric backing 42 are solidified, thereby stabilizing the shape of the back surface side of the nonwoven fabric backing 42. It can be done.

尚、本発明のカーペット用不織布バッキングは、例えば繊度又は繊維長の異なる複数の分割型極太複合繊維を用いて、カーペットの適用される用途や使用状態に応じたズレ防止効果を調整するなど、特許請求の範囲に記載された範囲で自由に変更することができる。   The carpet nonwoven fabric backing of the present invention uses, for example, a plurality of divided ultra-thin composite fibers having different fineness or fiber lengths to adjust the anti-displacement effect according to the application and use state of the carpet. Changes can be made freely within the scope of the claims.

本発明のカーペット用不織布バッキングを示す要部拡大断面図である。It is a principal part expanded sectional view which shows the nonwoven fabric backing for carpets of this invention. 本発明のカーペット用不織布バッキングに含まれる分割型極太複合繊維の繊維断面を示す模式図である。It is a schematic diagram which shows the fiber cross section of the split-type very thick composite fiber contained in the nonwoven fabric backing for carpets of this invention. 本発明のカーペット用不織布バッキングに含まれる分割型極太複合繊維の別形態の繊維断面を示す模式図である。It is a schematic diagram which shows the fiber cross section of another form of the split-type very thick composite fiber contained in the nonwoven fabric backing for carpets of this invention. 図１に示すカーペット用不織布バッキングの製造工程を示す模式図である。It is a schematic diagram which shows the manufacturing process of the nonwoven fabric backing for carpets shown in FIG. 本発明のカーペット用不織布バッキングを示す要部拡大断面図である。It is a principal part expanded sectional view which shows the nonwoven fabric backing for carpets of this invention. 図５に示すカーペット用不織布バッキングの製造工程を示す模式図である。It is a schematic diagram which shows the manufacturing process of the nonwoven fabric backing for carpets shown in FIG. 従来のカーペット用不織布バッキングを用いたカーペットを示す要部拡大断面図である。It is a principal part expanded sectional view which shows the carpet using the conventional nonwoven fabric backing for carpets. 従来のカーペット用不織布バッキングの製造過程を示す要部拡大断面図である。It is a principal part expanded sectional view which shows the manufacturing process of the conventional nonwoven fabric backing for carpets. 従来のカーペット用不織布バッキングを示す要部拡大断面図である。It is a principal part expanded sectional view which shows the conventional nonwoven fabric backing for carpets.

符号の説明Explanation of symbols

１２、４２・・・不織布バッキング
１３、４３・・・表面繊維基材
１４、４４・・・プレコート層
１５、４５・・・接着層
２０、５０・・・構成繊維
２１、５１・・・分割型極太複合繊維
２１ａ、５１ａ・・・分割された繊維 12, 42 ... Non-woven fabric backing 13, 43 ... Surface fiber base material 14, 44 ... Precoat layer 15, 45 ... Adhesive layer 20, 50 ... Constituent fiber 21, 51 ... Split type Extra-thick composite fiber 21a, 51a ... split fiber

Claims (10)

カーペット用不織布バッキングであって、
当該不織布バッキング中に分割型極太複合繊維が含まれており、前記不織布バッキングの裏面側に前記分割型極太複合繊維の分割された繊維が突出していることを特徴とするズレ防止機能を有するカーペット用不織布バッキング。 Non-woven backing for carpet,
For carpets having a function of preventing misalignment, wherein the nonwoven fabric backing includes split-type very thick composite fibers, and the split fibers of the split-type very thick composite fibers protrude on the back side of the nonwoven fabric backing Nonwoven backing. 分割型極太複合繊維が融点の異なる少なくとも２種のポリマー成分からなることを特徴とする請求項１記載のズレ防止機能を有するカーペット用不織布バッキング。   The nonwoven fabric backing for carpets having an anti-displacement function according to claim 1, wherein the split-type very thick composite fibers are composed of at least two polymer components having different melting points. 不織布バッキングの裏面側に分割型極太複合繊維が高密度に含まれていることを特徴とする請求項１又は２のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキング。   The nonwoven fabric backing for carpets having a displacement preventing function according to any one of claims 1 and 2, characterized in that split-type very thick composite fibers are contained at a high density on the back surface side of the nonwoven fabric backing. 不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項１〜３のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキング。   The fineness of the constituent fibers of the nonwoven fabric backing is 1 to 20 dtex, whereas the fineness of the divided fibers of the split-type very thick composite fiber is 50 to 300 dtex. The nonwoven fabric backing for carpets which has a gap prevention function described in 1. 不織布バッキングの構成繊維中に分割型極太複合繊維と共に、前記分割型極太複合繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維が含まれていることを特徴とする請求項１〜３のいずれかに記載のズレ防止機能を有するカーペット用不織布バッキング。   The fibers of the nonwoven fabric backing contain fibers that are thinner than the segmented very thick composite fibers and thicker than the components of the nonwoven fabric backing, together with the segmented very thick composite fibers. The nonwoven fabric backing for carpets which has the gap prevention function in any one. 不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５００〜１０００デシテックスであり、前記分割型極太複合繊維の分割された繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項５に記載のズレ防止機能を有するカーペット用不織布バッキング。   While the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, the fineness of the divided fiber of the split-type very thick composite fiber is 500 to 1000 dtex, which is more than the split fiber of the split-type very thick composite fiber. The nonwoven fabric backing for carpet according to claim 5, wherein the fineness of the fibers which are thinner and thicker than the constituent fibers of the nonwoven fabric backing is 50 to 300 dtex. カーペット用不織布バッキングの製造方法であって、
当該不織布バッキングを構成する繊維ウェブを形成し、次いで、前記不織布バッキングの構成繊維ウェブ上に融点の異なる少なくとも２種のポリマー成分からなる分割型極太複合繊維からなる複合繊維ウェブを形成し、次いで、絡合処理を施すことにより、前記不織布バッキングの構成繊維ウェブ及び複合繊維ウェブのそれぞれの繊維相互、並びに不織布バッキングの構成繊維ウェブと複合繊維ウェブの繊維相互を結合し、この後、前記不織布バッキングを前記分割型極太複合繊維の高い融点のポリマー成分よりも低く、低い融点のポリマー成分と同じか若しくは高い温度で加熱することで、前記分割型極太複合繊維を分割させたことを特徴とするズレ防止機能を有するカーペット用不織布バッキングの製造方法。 A method of manufacturing a nonwoven backing for carpet,
Forming a fibrous web constituting the nonwoven backing, and then forming a composite fiber web composed of split very thick composite fibers composed of at least two polymer components having different melting points on the constituent fibrous web of the nonwoven backing, By performing an entanglement treatment, the constituent fiber web and the composite fiber web of the nonwoven fabric backing are bonded to each other, and the constituent fiber web of the nonwoven fabric backing and the fibers of the composite fiber web are connected to each other. Displacement prevention characterized in that the split-type very thick composite fiber is split by heating at a temperature lower than the high melting point polymer component of the split-type very thick composite fiber and at the same or higher temperature as the low melting point polymer component The manufacturing method of the nonwoven fabric backing for carpets which has a function. 不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項７に記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法。   8. The deviation prevention according to claim 7, wherein the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, whereas the fineness of the divided fiber of the split-type very thick composite fiber is 50 to 300 dtex. The manufacturing method of the nonwoven fabric backing for carpets which has a function. 不織布バッキングの構成繊維ウェブを形成した後、分割型極太複合繊維からなる複合繊維ウェブを形成する前に、前記分割型極太複合繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維のウェブを形成することを特徴とする請求項７記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法。   After forming the constituent fiber web of the nonwoven backing, and before forming the composite fiber web composed of the split-type very thick composite fibers, the web of fibers that are thinner than the split-type very thick composite fibers and thicker than the constituent fibers of the nonwoven backing The method for producing a nonwoven fabric backing for carpets having a function of preventing deviation according to claim 7. 不織布バッキングの構成繊維の繊度が１〜２０デシテックスであるのに対し、分割型極太複合繊維の分割された繊維の繊度が５００〜１０００デシテックスであり、前記分割型極太複合繊維の分割された繊維よりも細く、前記不織布バッキングの構成繊維よりも太い繊維の繊度が５０〜３００デシテックスであることを特徴とする請求項９に記載のズレ防止機能を有するカーペット用不織布バッキングの製造方法。   While the fineness of the constituent fiber of the nonwoven fabric backing is 1 to 20 dtex, the fineness of the divided fiber of the split-type very thick composite fiber is 500 to 1000 dtex, which is more than the split fiber of the split-type very thick composite fiber. The method for producing a nonwoven fabric backing for carpet according to claim 9, wherein the fineness of the fibers which are thinner and thicker than the constituent fibers of the nonwoven fabric backing is 50 to 300 dtex.
JP2007285640A 2007-11-02 2007-11-02 Non-woven backing for carpet, method for producing the same, and carpet having anti-slip function using non-woven backing Expired - Fee Related JP5306633B2 (en)

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013113067A (en) * 2011-11-30 2013-06-10 Kureha Ltd Soundproof floor material
JP2015042540A (en) * 2013-07-25 2015-03-05 株式会社大和 Method of manufacturing nonwoven fabric backing for carpet,nonwoven fabric backing for carpet manufactured by the method, and carpet with nonwoven fabric backing

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JP2000096345A (en) * 1998-09-21 2000-04-04 Chisso Corp Split-type conjugate fiber, nonwoven cloth and absorbing material thereof
JP2001064861A (en) * 1999-06-17 2001-03-13 Kanebo Ltd Cushion material and its production
JP2002004163A (en) * 2000-06-22 2002-01-09 Japan Vilene Co Ltd Method for producing backfabric for floor mat, and floor mat
JP2003038333A (en) * 2001-08-03 2003-02-12 Suminoe Textile Co Ltd Tufted carpet

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Publication number Priority date Publication date Assignee Title
JP2000096345A (en) * 1998-09-21 2000-04-04 Chisso Corp Split-type conjugate fiber, nonwoven cloth and absorbing material thereof
JP2001064861A (en) * 1999-06-17 2001-03-13 Kanebo Ltd Cushion material and its production
JP2002004163A (en) * 2000-06-22 2002-01-09 Japan Vilene Co Ltd Method for producing backfabric for floor mat, and floor mat
JP2003038333A (en) * 2001-08-03 2003-02-12 Suminoe Textile Co Ltd Tufted carpet

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2013113067A (en) * 2011-11-30 2013-06-10 Kureha Ltd Soundproof floor material
JP2015042540A (en) * 2013-07-25 2015-03-05 株式会社大和 Method of manufacturing nonwoven fabric backing for carpet,nonwoven fabric backing for carpet manufactured by the method, and carpet with nonwoven fabric backing

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