JP2013076282A - Manufacturing method of tatami facing - Google Patents
Manufacturing method of tatami facing Download PDFInfo
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本発明は、環境や人への負荷を低減させた畳表の製造方法に関する。 The present invention relates to a method for manufacturing a tatami mat with reduced load on the environment and people.
古くから、畳表は天然のイ草を編織して製造されているが、この天然のイ草は、その栽培が天候に左右され易いことから安定した供給が期待できず、価格変動も大きいと云うような欠点があった。そこで、従来、この天然のイ草に代わる物として、紙に撚りをかけた筒状抄繊糸を用いた畳表について研究開発が進められており、現に製品化が行なわれている（例えば、特許文献１参照）。 Traditionally, tatami mats have been manufactured by weaving natural rushes, but the natural rushes cannot be expected to provide a stable supply because the cultivation is influenced by the weather, and price fluctuations are also large. There were such drawbacks. Therefore, research and development has been conducted on tatami mats using a cylindrical fiber made by twisting paper as an alternative to this natural rush, and commercialization has been carried out (for example, patents). Reference 1).
この筒状抄繊糸は、幅約２０ｍｍ程度のテープ状の原糸を撚糸機にてコヨリ状に連続加工した後、その表面にアクリル系樹脂およびフッ素系樹脂の混合液などからなる撥水撥油剤を塗布して製造される物であり、このように工業的に生産が可能な筒状抄繊糸を畳表の素材とすることによって、より均一で品質のバラツキが少ない畳表を安定的に供給することができるようになる。 This cylindrical fiber-making yarn is a water-repellent and water-repellent material composed of a tape-like yarn having a width of about 20 mm, which is continuously processed in a twisted shape by a twisting machine, and then a mixture of an acrylic resin and a fluorine resin on its surface. This is a product manufactured by applying an oil agent. By using cylindrical fiber yarn that can be industrially produced in this way as a material for tatami mats, a more uniform tatami mat with less variation in quality can be supplied stably. Will be able to.
これまで筒状抄繊糸に塗布される撥水撥油剤用のフッ素系樹脂としてＣ８テロマーを原料とするものが使用されてきた。ここで、Ｃ８テロマーとは、パーフルオロアルキル基(ＣnＦ2n+1−)のうち炭素数が８のパーフルオロオクチル基(Ｃ8Ｆ17−)の構造を有する含フッ素化合物(短鎖重合体)のことであり、このＣ８テロマーを原料としたフッ素系樹脂で撥水撥油剤を製造すると、その製造工程で微量のＰＦＯＡ(パーフルオロオクタン酸：Ｃ7Ｆ15ＣＯＯＨ)が副生されることが知られていた。なお、Ｃ８テロマーから製造されるフッ素系樹脂は、非常に良好な撥水撥油性をもたらし、筒状抄繊糸からなる紙製畳表に優れた耐汚染性を付与すると共に、音鳴り現象(筒状抄繊糸に耐久性を与えるアクリル系樹脂等のバインダーによる筒状抄繊糸同士の密着が歩行などで剥がされた際に生じる異音)も抑制していた。 Until now, what used C8 telomer as a raw material as a fluorine-type resin for water- and oil-repellent agents applied to a cylindrical fibermaking thread has been used. Here, the C8 telomer is a fluorine-containing compound having a structure of a perfluorooctyl group (C 8 F 17 —) having 8 carbon atoms in the perfluoroalkyl group (C n F 2n + 1 —) (short chain heavy group). When a water- and oil-repellent agent is produced with a fluororesin using C8 telomer as a raw material, a small amount of PFOA (perfluorooctanoic acid: C 7 F 15 COOH) is by-produced in the production process. It was known. The fluororesin produced from C8 telomer provides very good water and oil repellency, imparts excellent stain resistance to the paper tatami mat made of cylindrical fiber, and produces a squealing phenomenon (cylinder). The abnormal noise generated when the cylindrical fiber yarns are peeled off by walking or the like by a binder such as an acrylic resin that gives durability to the fiber yarns is also suppressed.
しかしながら、近年、このＰＦＯＡは、人体へのリスクレベルは明らかになっていないものの、生体蓄積性が懸念されることや、環境残留性が高いことなどが明らかになってきており、国内メーカーにおいては、２０１２年を目処に、ＰＦＯＡが副生するＣ８テロマーの生産を取り止め、撥水撥油剤の原料となるフッ素系樹脂として実質的にＰＦＯＡを副生しないＣ６テロマーを原料とする物へと切替えが進められている。 However, in recent years, although the level of risk to humans has not been clarified, this PFOA has become clear that there are concerns about bioaccumulation and high environmental persistence. By 2012, the production of C8 telomer by-produced by PFOA will be canceled, and it will be switched to a C6 telomer that does not substantially produce PFOA as a fluororesin as a raw material for water and oil repellents. It is being advanced.
ここで、Ｃ６テロマーとは、パーフルオロアルキル基(ＣnＦ2n+1−)のうち炭素数が６のパーフルオロヘキシル基(Ｃ6Ｆ13−)の構造を有する含フッ素化合物(短鎖重合体)のことであり、Ｃ８テロマーに比べて「-ＣＦ2-」の鎖が２個少ないことから、一般的に撥水撥油性が劣っている。このため、Ｃ６テロマーを原料とするフッ素系樹脂で製造した撥水撥油剤では、従来のように耐汚染性・耐久性・静音性に優れた紙製畳表を製造するのが困難になると云う問題があった。 Here, the C6 telomer, perfluoroalkyl group (C n F 2n + 1 - ) carbon atoms 6 of perfluorohexyl group of (C 6 F 13 -) fluorine-containing compound having the structure of (Tankusarikasane In general, the water and oil repellency is inferior because there are two “—CF 2 —” chains less than the C8 telomer. For this reason, it is difficult to produce a paper tatami mat that is excellent in stain resistance, durability, and quietness with a water- and oil-repellent agent made of a fluororesin made from C6 telomer. was there.
それゆえに、本発明の主たる課題は、Ｃ６テロマーを原料とする撥水撥油剤を用いることで環境や人への負荷を低減させると共に、Ｃ６テロマーを原料とする撥水撥油剤を用いているにもかかわらず、従来のＣ８テロマーを用いたものと同様に耐汚染性・耐久性・静音性に優れた紙製畳表を製造できる畳表の製造方法を提供することである。 Therefore, the main problem of the present invention is to use a water / oil repellent made of C6 telomer as a raw material, to reduce the burden on the environment and to humans, and to use a water / oil repellent made of C6 telomer as a raw material. Nevertheless, it is to provide a method for producing a tatami mat that can produce a paper tatami mat that is excellent in stain resistance, durability, and silence as in the case of using a conventional C8 telomer.
本発明における第１の発明は、「（ａ）木質繊維から抄造された紙に撚りをかけて得られる筒状抄繊糸１０の表面に、主鎖或いは側鎖に架橋基を有する架橋性高分子からなるバインダー樹脂組成物２０を塗布した後、乾燥させて下塗り層１４を形成し、（ｂ）前記下塗り層１４の表面に、末端がパーフルオロヘキシル基で構成された側鎖と、末端が親水基で構成された側鎖とを有するフッ素系樹脂からなる撥水撥油剤２２を塗布した後、乾燥させて上塗り層１６を形成することによって筒状抄繊糸１０の表面に撥水撥油加工を施し、然る後（ｃ）撥水撥油処理済みの筒状抄繊糸１２を編織する」ことを特徴とする畳表の製造方法である。 The first invention in the present invention is “(a) a highly crosslinkable polymer having a crosslinkable group in the main chain or side chain on the surface of the cylindrical fibermaking yarn 10 obtained by twisting paper made from wood fiber. After the binder resin composition 20 composed of molecules is applied, it is dried to form an undercoat layer 14. (B) A side chain having a terminal composed of a perfluorohexyl group and a terminal on the surface of the undercoat layer 14. A water- and oil-repellent agent 22 made of a fluororesin having a side chain composed of a hydrophilic group is applied and then dried to form a top coat layer 16, thereby forming a water- and oil-repellent agent on the surface of the cylindrical fiber yarn 10. It is a method for producing a tatami mat, characterized in that it is processed and then (c) knitted with a water- and oil-repellent treated cylindrical fiber yarn 12 ".
本発明における第２の発明は、上記第１の発明において、「前記架橋性高分子が、アクリル樹脂である」ことを特徴とする畳表の製造方法である。 According to a second aspect of the present invention, there is provided a method for producing a tatami table according to the first aspect, wherein the crosslinkable polymer is an acrylic resin.
本発明における第３の発明は、上記第１又は第２の発明において、「前記フッ素系樹脂が、パーフルオロヘキシル基含有アクリルモノマー、ポリエチレンオキシド鎖含有アクリルモノマーおよび架橋性モノマーの共重合体である」ことを特徴とする畳表の製造方法である。 According to a third aspect of the present invention, in the first or second aspect of the invention, "the fluororesin is a copolymer of a perfluorohexyl group-containing acrylic monomer, a polyethylene oxide chain-containing acrylic monomer and a crosslinkable monomer. This is a method for manufacturing a tatami mat.
これらの発明によれば、下塗り層の表面に撥水撥油剤を塗設して上塗り層を形成する際、撥水撥油剤を構成するフッ素系樹脂の親水基が下塗り層を形成するバインダー樹脂組成物の架橋基と結合するようになるが、これと同時にフッ素系樹脂の末端がパーフルオロヘキシル基で構成された側鎖(＝このフッ素系樹脂はＣ６テロマーを原料としている)が親水基とは逆の方向、すなわち上塗り層の表面側へと配向するようになる。このため、下塗り層と上塗り層とを強固に結合させることができるのに加え、フッ素系樹脂の撥水撥油機能を担うパーフルオロヘキシル基を余すことなく上塗り層の表面側に配置させてその撥水撥油機能を無駄なく最大限発揮させることができるようになる。 According to these inventions, when forming the topcoat layer by coating the surface of the undercoat layer with a water / oil repellent, the binder resin composition in which the hydrophilic group of the fluororesin constituting the water / oil repellent forms the undercoat layer. At the same time, the side chain in which the terminal of the fluororesin is composed of a perfluorohexyl group (= this fluororesin is made from C6 telomer) is a hydrophilic group. They are oriented in the opposite direction, that is, toward the surface side of the overcoat layer. For this reason, in addition to being able to firmly bond the undercoat layer and the overcoat layer, the perfluorohexyl group responsible for the water- and oil-repellency function of the fluororesin is placed on the surface side of the topcoat layer without leaving any excess. Water and oil repellency can be maximized without waste.
したがって、Ｃ６テロマーを原料とする撥水撥油剤を用いることで環境や人への負荷を低減させると共に、Ｃ６テロマーを原料とする撥水撥油剤を用いているにもかかわらず、従来のＣ８テロマーを用いたものと同様に耐汚染性・耐久性・静音性に優れた紙製畳表を製造できる畳表の製造方法を提供することができる。 Therefore, the use of a water / oil repellent made from C6 telomer reduces the burden on the environment and people, and the conventional C8 telomer despite using a water / oil repellent made from C6 telomer. It is possible to provide a method for producing a tatami mat that can produce a paper tatami mat that is excellent in stain resistance, durability, and quietness as in the case of using the stencil.
本発明に係る畳表の製造方法は、筒状抄繊糸１０に撥水撥油処理を施して図１に示すような撥水撥油処理済みみの筒状抄繊糸１２を形成する「撥水撥油処理工程」と、この撥水撥油処理済みみの抄繊糸１２を編織して目的とする畳表を形成する「編織工程」とで大略構成されている。 The method for producing a tatami mat according to the present invention is a method for forming a tubular fiber yarn 12 having a water and oil repellent treatment as shown in FIG. The “water / oil repellent treatment step” and the “knitting step” in which the water-repellent / oil-repellent treated fibermaking yarn 12 is knitted to form a target tatami surface.
「撥水撥油処理工程」は、筒状抄繊糸１０の表面に撥水撥油処理を施して、より具体的には、筒状抄繊糸１０の表面に下塗り層１４と上塗り層１６とからなる撥水撥油層１８を形成して撥水撥油処理済みみの筒状抄繊糸１２を形成する工程である。 In the “water / oil repellent treatment step”, the surface of the tubular fiber yarn 10 is subjected to water / oil repellent treatment, and more specifically, the undercoat layer 14 and the overcoat layer 16 are applied to the surface of the tubular fiber yarn 10. This is a step of forming a water- and oil-repellent layer 18 having a water- and oil-repellent finish.
ここで、（撥水撥油処理前の）筒状抄繊糸１０は、針葉樹パルプなどの木質繊維を主体とする抄造紙を筒状に撚ったものであり、本実施例では、その外径が０．７〜１．５ｍｍ程度に設定されており、その中央部分には必要に応じて口径が０．２〜０．８ｍｍ程度の空洞が設けられている（勿論、中央部分に空洞ができないよう抄造紙を撚ることによって筒状抄繊糸１０を形成してもよい。）。 Here, the cylindrical fiber-making yarn 10 (before the water and oil repellent treatment) is obtained by twisting a paper made mainly of wood fiber such as softwood pulp into a cylindrical shape. The diameter is set to about 0.7 to 1.5 mm, and a cavity having a diameter of about 0.2 to 0.8 mm is provided in the center portion as necessary (of course, the cavity is formed in the center portion). The cylindrical fiber-making yarn 10 may be formed by twisting the paper-making paper so that it cannot be done.)
筒状抄繊糸１０を構成する抄造紙の種類や抄造紙の巻数は、特に限定されるものではないが、この実施例では、抄造紙としてＮＢＫＰ(針葉樹パルプ)を坪量１５〜３５ｇ／ｍ2程度で抄造した幅１５〜４０ｍｍ程度のテープ状のものが用いられ、その巻数は４〜１５巻程度に設定されている。 The type of papermaking paper constituting the cylindrical fibermaking yarn 10 and the number of windings of the papermaking paper are not particularly limited. A tape-shaped product having a width of about 15 to 40 mm made with about 2 is used, and the number of turns is set to about 4 to 15 turns.
撥水撥油層１８を構成している下塗り層１４は、筒状抄繊糸１０の表面にバインダー樹脂組成物２０を塗布することによって形成される。 The undercoat layer 14 constituting the water / oil repellent layer 18 is formed by applying a binder resin composition 20 to the surface of the tubular fiber yarn 10.
ここで、バインダー樹脂組成物２０は、架橋性高分子、水および必要に応じて後述する上塗り層１６と同じフッ素系樹脂などを加えて構成されている。 Here, the binder resin composition 20 is configured by adding a crosslinkable polymer, water, and, if necessary, the same fluororesin as the topcoat layer 16 described later.
架橋性高分子は、主鎖或いは側鎖に架橋性の官能基を有し、筒状抄繊糸１０の表面に後述する撥水撥油剤を固定化させるものである。この架橋性高分子としては、アクリル樹脂、酢酸ビニル樹脂、ウレタン樹脂、エチレン−酢酸ビニル共重合樹脂、アクリル−スチレン共重合樹脂等を例示でき、このうち、筒状抄繊糸１０に対する接着性(親和性)、撥水撥油剤との親和性等を考慮すれば、アクリル樹脂を用いるのが最も好適である。また、架橋性高分子を構成する「架橋性の官能基」としては、水酸基、カルボニル基、メチロール基、エポキシ基などを挙げることができる。 The crosslinkable polymer has a crosslinkable functional group in the main chain or side chain, and immobilizes a water / oil repellent described later on the surface of the cylindrical fiber yarn 10. Examples of the crosslinkable polymer include acrylic resin, vinyl acetate resin, urethane resin, ethylene-vinyl acetate copolymer resin, acrylic-styrene copolymer resin, and the like. In view of the affinity) and the affinity with the water / oil repellent, it is most preferable to use an acrylic resin. Examples of the “crosslinkable functional group” constituting the crosslinkable polymer include a hydroxyl group, a carbonyl group, a methylol group, and an epoxy group.
撥水撥油層１８を構成している上塗り層１６は、下塗り層１４の表面に撥水撥油剤２２を塗布することによって形成される。 The overcoat layer 16 constituting the water / oil repellent layer 18 is formed by applying a water / oil repellent agent 22 to the surface of the undercoat layer 14.
ここで、撥水撥油剤２２は、フッ素系樹脂および水を混ぜ合わせることによって構成されている。 Here, the water / oil repellent 22 is constituted by mixing a fluorine-based resin and water.
フッ素系樹脂は、Ｃ６テロマー、親水基含有モノマーおよび架橋性モノマーの共重合体で、末端がパーフルオロヘキシル基で構成された側鎖と、末端が親水基で構成された側鎖とを有する含フッ素化合物である。 The fluororesin is a copolymer of a C6 telomer, a hydrophilic group-containing monomer, and a crosslinkable monomer, and includes a side chain having a terminal composed of a perfluorohexyl group and a side chain having a terminal composed of a hydrophilic group. It is a fluorine compound.
上述のように下塗り層１４をアクリル樹脂で形成する場合には、このフッ素系樹脂として、図２に示すように、パープルオロヘキシル基含有アクリルモノマーとポリエチレンオキシド鎖含有アクリルモノマーと架橋性モノマーとの共重合体、つまりベース樹脂がアクリル樹脂のものを用いるのが好ましい。下塗り層１４と上塗り層１６とを共にアクリル系の樹脂とすることで、両層の層間を高い親和性で強固に結合させることができるようになるからである。 When the undercoat layer 14 is formed of an acrylic resin as described above, as shown in FIG. 2, the fluorine-based resin includes a purple cyclohexyl group-containing acrylic monomer, a polyethylene oxide chain-containing acrylic monomer, and a crosslinkable monomer. It is preferable to use a copolymer, that is, a base resin having an acrylic resin. This is because when both the undercoat layer 14 and the overcoat layer 16 are made of an acrylic resin, the layers of both layers can be firmly bonded with high affinity.
筒状抄繊糸１０の表面に撥水撥油処理を施す際には、図３に示すような撥水撥油処理装置３０が用いられる。 When performing the water / oil repellent treatment on the surface of the tubular fiber yarn 10, a water / oil repellent treatment apparatus 30 as shown in FIG. 3 is used.
撥水撥油処理装置３０は、複数のガイドローラ３２によって構成された搬送路３４を備えている。搬送路３４の始点には、搬送路３４に対して筒状抄繊糸１０を供給する供給装置３６が配置されており、搬送路３４の終点には、撥水撥油処理済みの筒状抄繊糸１２を巻き取る巻取装置３８が配置されている。なお、撥水撥油処理済みの筒状抄繊糸１２は、巻き取られずにイ草のように一定長さに切断されて堆積される場合もあり、この場合は、巻取装置３８の代わりに図示しない切断機が配置される。また、搬送路３４の途中には、第一浸漬槽４０、一次加熱装置４２、第二浸漬槽４４および二次加熱装置４６が配置されている。 The water / oil repellent treatment apparatus 30 includes a transport path 34 constituted by a plurality of guide rollers 32. A supply device 36 for supplying the cylindrical fiber 10 to the conveying path 34 is disposed at the starting point of the conveying path 34, and the water- and oil-repellent cylindrical paper-making process is disposed at the end of the conveying path 34. A winding device 38 for winding the fiber 12 is disposed. In addition, the cylindrical fiber yarn 12 that has been subjected to the water / oil repellent treatment may be cut and deposited in a certain length like grass without being wound, and in this case, instead of the winding device 38 A cutting machine (not shown) is arranged. Further, a first immersion tank 40, a primary heating device 42, a second immersion tank 44, and a secondary heating device 46 are disposed in the middle of the conveyance path 34.
そして、第一浸漬槽４０には、架橋性高分子、水(清水)および必要に応じてフッ素系樹脂などが加えられたバインダー樹脂組成物２０が収容されている。 The first immersion tank 40 contains a binder resin composition 20 to which a crosslinkable polymer, water (fresh water) and, if necessary, a fluorine-based resin are added.
また、第二浸漬槽４４には、Ｃ６テロマーと親水基含有モノマーとを原料とするフッ素系樹脂および水(清水)を混ぜ合わせることによって構成された撥水撥油剤２２が収容されている。 The second immersion tank 44 contains a water / oil repellent 22 constituted by mixing a fluororesin and water (fresh water) made from C6 telomer and a hydrophilic group-containing monomer as raw materials.
この撥水撥油処理装置３０を用いて筒状抄繊糸１０の撥水撥油処理を行う際には、供給装置３６から搬送路３４に対して筒状抄繊糸１０が供給され、この筒状抄繊糸１０が第一浸漬槽４０に浸漬される。そして、第一浸漬槽４０において、筒状抄繊糸１０の表面にバインダー樹脂組成物２０が付着する。なお、筒状抄繊糸１０の表面に付着したバインダー樹脂組成物２０の一部は、筒状抄繊糸１０の表層近く（図１の円中、Ａで示した表面から下の４層程度）まで滲み込んでいる。 When the water and oil repellent treatment of the tubular fiber 10 is performed using the water and oil repellent treatment apparatus 30, the tubular fiber 10 is supplied from the supply device 36 to the conveying path 34. The tubular fiber yarn 10 is immersed in the first immersion tank 40. And in the 1st immersion tank 40, the binder resin composition 20 adheres to the surface of the cylindrical fiber yarn 10. FIG. Part of the binder resin composition 20 adhering to the surface of the cylindrical fiber yarn 10 is close to the surface layer of the cylindrical fiber yarn 10 (about four layers below the surface indicated by A in the circle of FIG. 1). ).
第一浸漬槽４０を経た筒状抄繊糸１０は、一次加熱装置４２に与えられ、筒状抄繊糸１０の表面に付着しているバインダー樹脂組成物２０の表面が加熱乾燥され、抄繊糸１２の表面に下塗り層１４が形成される。なお、一次加熱装置４２における乾燥条件(乾燥温度や乾燥時間)は、バインダー樹脂組成物２０を構成している樹脂の種類や乾燥方法の違いによって適宜設定される(後述する二次加熱装置４６についても同様)。 The cylindrical fiber making yarn 10 that has passed through the first immersion tank 40 is given to a primary heating device 42, and the surface of the binder resin composition 20 adhering to the surface of the cylindrical fiber making yarn 10 is heated and dried to produce the fiber making. An undercoat layer 14 is formed on the surface of the yarn 12. The drying conditions (drying temperature and drying time) in the primary heating device 42 are set as appropriate depending on the type of resin constituting the binder resin composition 20 and the drying method (for the secondary heating device 46 described later). The same).
続いて、一次加熱装置４２を経た筒状抄繊糸１０は、自然冷却されながら第二浸漬槽４４へと搬送される。そして、第二浸漬槽４４において、下塗り層１４の表面に撥水撥油剤２２が塗布され、その表面が二次加熱装置４６で加熱乾燥されることによって下塗り層１４の表面に撥水撥油剤からなる上塗り層１６が形成され、撥水撥油処理済みの筒状抄繊糸１２が得られる。 Subsequently, the cylindrical fiber yarn 10 that has passed through the primary heating device 42 is conveyed to the second immersion tank 44 while being naturally cooled. Then, in the second immersion tank 44, the water / oil repellent 22 is applied to the surface of the undercoat layer 14, and the surface is heated and dried by the secondary heating device 46, whereby the water / oil repellent is applied to the surface of the undercoat layer 14. An overcoat layer 16 is formed, and the cylindrical fiber yarn 12 having been subjected to the water and oil repellent treatment is obtained.
ここで、下塗り層１４の表面に、撥水撥油剤２２を塗布して上塗り層１６を形成する際には、図４に示すように、撥水撥油剤２２を構成するフッ素系樹脂の親水基が下塗り層１４を形成するバインダー樹脂組成物２０(架橋性高分子)の架橋基と結合するようになるが、これと同時にフッ素系樹脂の末端がパーフルオロヘキシル基で構成された側鎖が親水基とは逆の方向、すなわち上塗り層１６の表面側へと配向するようになる。このため、下塗り層１４と上塗り層１６とを強固に結合させることができるのに加え、フッ素系樹脂の撥水撥油機能を担うパーフルオロヘキシル基を余すことなく上塗り層１６の表面側に配置させることができ、その後、二次加熱装置４６で該フッ素系樹脂をキュアすることにより、その撥水撥油機能を無駄なく最大限発揮させることができるようになる。 Here, when the top coat layer 16 is formed by applying the water / oil repellent 22 to the surface of the undercoat layer 14, as shown in FIG. 4, the hydrophilic group of the fluororesin constituting the water / oil repellent 22 is used. Is bonded to the crosslinking group of the binder resin composition 20 (crosslinkable polymer) forming the undercoat layer 14, but at the same time, the side chain in which the terminal of the fluororesin is composed of a perfluorohexyl group is hydrophilic. It is oriented in the direction opposite to the base, that is, toward the surface side of the overcoat layer 16. For this reason, the undercoat layer 14 and the overcoat layer 16 can be firmly bonded to each other, and the perfluorohexyl group responsible for the water- and oil-repellency function of the fluororesin is disposed on the surface side of the topcoat layer 16 without leaving any excess. After that, by curing the fluororesin with the secondary heating device 46, the water and oil repellency functions can be maximized without waste.
なお、筒状抄繊糸１０に下塗り層１４および上塗り層１６を形成する方法としては、上述の実施例のような浸漬法の他に、吹き付け法や流し塗り法などを用いてもよい。 In addition, as a method of forming the undercoat layer 14 and the overcoat layer 16 on the cylindrical fibermaking yarn 10, a spraying method, a flow coating method, or the like may be used in addition to the dipping method as in the above-described embodiment.
編織工程は、上述のようにして得られた撥水撥油処理済みの筒状抄繊糸１２を、図示しない編織機を用い、所定の織り込み密度で編織することにより目的の畳表を得る工程である。 The knitting process is a process of obtaining the desired tatami surface by knitting the water- and oil-repellent treated cylindrical fiber yarn 12 obtained as described above at a predetermined weaving density using a knitting machine (not shown). is there.
発明者等は、上述の方法にて得られた畳表の耐汚染性等について試験を行い、その実用性を検証した。以下には、その試験方法および試験結果について説明するが、本発明はこの実施例に限定されるものではない。 The inventors tested the contamination resistance of the tatami mat obtained by the above method and verified its practicality. The test method and test results will be described below, but the present invention is not limited to this example.
（１）実施例および比較例試料の調製
［実施例］
筒状抄繊糸として、ＮＢＫＰ(針葉樹クラフトパルプ)を坪量１８ｇ／ｍ2で抄造した幅２５ｍｍのテープ状の抄造紙を巻き数１０で撚りあわせたものを準備した。
(1) Preparation of Samples for Examples and Comparative Examples [Examples]
A cylindrical fiber-making yarn was prepared by twisting a tape-like paper with a width of 25 mm made from NBKP (conifer kraft pulp) at a basis weight of 18 g / m 2 at a winding number of 10.
次に、バインダー樹脂組成物を構成する架橋性高分子(バインダー樹脂)としてＤＩＣ社製のアクリル系樹脂を準備すると共に、撥水撥油剤を構成するフッ素系樹脂としてダイキン工業社製のものを準備した。そして、下表１に示す組成割合にてバインダー樹脂組成物および撥水撥油剤をそれぞれ調製した。なお、この実施例のバインダー樹脂は架橋基を有するものであり、フッ素系樹脂はＣ６テロマーを原料とし且つ側鎖に親水基を有するものである。 Next, an acrylic resin made by DIC is prepared as a crosslinkable polymer (binder resin) constituting the binder resin composition, and a product made by Daikin Industries is prepared as a fluorine resin constituting a water and oil repellent. did. Then, a binder resin composition and a water / oil repellent were prepared at the composition ratios shown in Table 1 below. The binder resin of this example has a crosslinking group, and the fluororesin has C6 telomer as a raw material and has a hydrophilic group in the side chain.
続いて、上記で準備した筒状抄繊糸に図３で示すような浸漬法により上記バインダー樹脂組成物の塗布を行なった。具体的には、バインダー樹脂組成物を浸漬槽に張り、筒状抄繊糸を当該バインダー樹脂組成物に０．３秒浸漬させた後、加熱装置に導入し、８０℃で３分間乾燥し、筒状抄繊糸の表面に塗布量７５ｇ／ｍ2の下塗り層を形成させた。 Then, the said binder resin composition was apply | coated to the cylindrical fiber yarn prepared above by the immersion method as shown in FIG. Specifically, the binder resin composition is stretched in a dipping tank, and the cylindrical fiber making yarn is immersed in the binder resin composition for 0.3 seconds, and then introduced into a heating device and dried at 80 ° C. for 3 minutes. An undercoat layer having a coating amount of 75 g / m 2 was formed on the surface of the cylindrical fiber-making yarn.
続いて、下塗り層の表面に、図３で示すような浸漬法により上記撥水撥油剤の塗布を行なった。具体的には、撥水撥油剤を浸漬槽に張り、表面に下塗り層が形成された筒状抄繊糸を当該撥水撥油剤に０．３秒浸漬させた後、加熱装置に導入し、１８０℃で１.５分間乾燥し、下塗り層の表面に塗布量２５ｇ／ｍ2の上塗り層を形成させた。 Subsequently, the water / oil repellent was applied to the surface of the undercoat layer by a dipping method as shown in FIG. Specifically, a water- and oil-repellent agent is stretched in a dipping tank, and a cylindrical fiber thread having an undercoat layer formed on the surface is immersed in the water- and oil-repellent agent for 0.3 seconds, and then introduced into a heating device. The coating was dried at 180 ° C. for 1.5 minutes to form an overcoat layer having an application amount of 25 g / m 2 on the surface of the undercoat layer.
そして、以上のようにして得られた撥水撥油処理済みの筒状抄繊糸を、織り込み密度０．８５ｋｇ／ｍ2で編織することにより実施例の畳表を得た。 And the tatami surface of the Example was obtained by knitting the cylindrical fiber yarn after water- and oil-repellent treatment obtained as mentioned above by the weaving density of 0.85 kg / m < 2 >.
［比較例１］
バインダー樹脂として架橋基を有さないアクリル系樹脂(コニシ社製)を用いると共に、フッ素系樹脂としてＣ６テロマーを原料としているが側鎖に親水基を有さないダイキン工業社製のものを用いたこと以外は上記実施例と同様な方法で比較例１の畳表を得た。
[Comparative Example 1]
As the binder resin, an acrylic resin (manufactured by Konishi Co., Ltd.) having no crosslinkable group was used, and as a fluororesin, a C6 telomer as a raw material but having a hydrophilic group in the side chain was used. Except for this, the tatami mat of Comparative Example 1 was obtained in the same manner as in the above Example.
［比較例２］
バインダー樹脂として架橋基を有さないアクリル系樹脂(コニシ社製)を用いたこと以外は上記実施例と同様な方法で比較例２の畳表を得た。
[Comparative Example 2]
A tatami mat of Comparative Example 2 was obtained in the same manner as in the above Example, except that an acrylic resin having no crosslinking group (made by Konishi Co., Ltd.) was used as the binder resin.
［比較例３］
フッ素系樹脂としてＣ６テロマーを原料としているが側鎖に親水基を有さないダイキン工業社製のものを用いたこと以外は上記実施例と同様な方法で比較例３の畳表を得た。
[Comparative Example 3]
A tatami table of Comparative Example 3 was obtained in the same manner as in the above example except that a fluorocarbon resin made of C6 telomer was used as a raw material, but a product made by Daikin Industries, Ltd. having no hydrophilic group in the side chain was used.
［比較例４］
バインダー樹脂として架橋基を有さないアクリル系樹脂(コニシ社製)を用いると共に、フッ素系樹脂としてＣ８テロマーを原料としており側鎖に親水基を有さないＤＩＣ社製のものを用いたこと以外は上記実施例と同様な方法で比較例４の畳表を得た。
[Comparative Example 4]
Other than using acrylic resin (manufactured by Konishi Co., Ltd.) having no cross-linking group as binder resin, and using DIC resin having C8 telomer as a raw material and having no hydrophilic group in the side chain as fluororesin. Obtained the tatami mat of Comparative Example 4 in the same manner as in the above Example.
［比較例５］
フッ素系樹脂としてＣ８テロマーを原料としており側鎖に親水基を有さないＤＩＣ社製のものを用いたこと以外は上記実施例と同様な方法で比較例５の畳表を得た。
[Comparative Example 5]
A tatami table of Comparative Example 5 was obtained in the same manner as in the above Example, except that the fluoric resin was C8 telomer as a raw material and the side chain had no hydrophilic group.
（２）各種特性評価試験の方法
［耐汚染性試験］
汚染物として約８０℃の緑茶とミルク入りコーヒーを用い、それぞれ適量滴下した後２時間後にふき取りを行い、汚れ跡を目視で２段階（○：汚れ跡なし，×：汚れ跡あり）に評価した。
(2) Various characteristic evaluation test methods [contamination resistance test]
About 80 ° C green tea and milk-filled coffee were used as contaminants, and after 2 drops each, wiped off 2 hours later, and the dirt marks were visually evaluated in two stages (○: no dirt marks, x: dirt marks present). .
［耐久性(耐摩耗性)試験の方法］
ＪＩＳ Ｌ−０８４９の摩擦に対する染色堅牢度試験方法に準拠し、学振型摩耗試験機を用いて実施例及び各比較例試料の表面を擦り、表面の状態を目視で２段階（○：変化なし，×：毛羽立ち或いは破れあり）に評価した。
[Durability (Abrasion Resistance) Test Method]
According to the dyeing fastness test method for friction of JIS L-0849, the surface of the sample of each of the examples and comparative examples is rubbed using a Gakushin type abrasion tester, and the surface condition is visually evaluated in two stages (○: no change) , ×: Fluffing or tearing).
［湿潤耐久性（耐洗浄性）試験］
水を含ませ硬絞りした日本手拭いで５００ｇの荷重で１００回摩擦させた後に、表面の状態を目視で２段階（○：異常なし，×：紙のめくれあり）に評価した。
[Wet durability (cleaning resistance) test]
After rubbing 100 times with a load of 500 g with a Japanese hand wipe containing water and hard-drawn, the surface condition was visually evaluated in two stages (◯: no abnormality, x: paper turned over).
［静音性］
試験片を６０℃で２時間、乾燥機中で加温した後常温に自然冷却し、試験片を折り曲げて開いた時の試験片の密着剥がれ音の発生を耳で聞いて２段階（○：異音なし，×：異音あり）に評価した。
[Silent]
The test piece is heated in a dryer at 60 ° C. for 2 hours, and then naturally cooled to room temperature. When the test piece is folded and opened, the test piece is peeled open and heard in two stages (○: No abnormal noise, x: abnormal noise).
（３）各種特性評価試験結果
上記各特性評価試験の結果を下表２に示す。
(3) Results of various characteristic evaluation tests The results of the above characteristic evaluation tests are shown in Table 2 below.
この表が示すように、バインダー樹脂が架橋基を有すると共に、フッ素系樹脂がＣ６テロマーを原料とし且つ側鎖に親水基を有する実施例の畳表は、従来のＣ８テロマーを原料としたフッ素系樹脂を用いた比較例４および５のものと同程度の耐汚染性、耐久性、及び静音性を有することが窺える。 As this table shows, the binder resin has a crosslinkable group, and the fluorine resin has a C6 telomer as a raw material and a hydrophilic group in the side chain. It can be seen that it has the same level of stain resistance, durability and quietness as those of Comparative Examples 4 and 5 using
これは、上述したように、下塗り層の表面に、撥水撥油剤を塗布して上塗り層を形成する際、図４に示すように、撥水撥油剤を構成するフッ素系樹脂の親水基と下塗り層を形成するバインダー樹脂組成物の架橋基とが結合すると同時に、フッ素系樹脂の末端がパーフルオロヘキシル基で構成された側鎖が親水基とは逆の方向、すなわち上塗り層の表面側へと配向することに起因するものと考えられる。 As described above, when the water- and oil-repellent agent is applied to the surface of the undercoat layer to form the topcoat layer, as shown in FIG. 4, the hydrophilic group of the fluororesin constituting the water- and oil-repellent agent and At the same time as the crosslinkable group of the binder resin composition forming the undercoat layer is bonded, the side chain in which the end of the fluororesin is composed of a perfluorohexyl group is opposite to the hydrophilic group, that is, to the surface side of the topcoat layer. This is considered to be caused by the orientation.
１０…(撥水撥油処理前の）筒状抄繊糸
１２…撥水撥油処理済みの筒状抄繊糸
１４…下塗り層
１６…上塗り層
１８…撥水撥油層
２０…バインダー樹脂組成物
２２…撥水撥油剤
３０…撥水撥油処理装置
３２…ガイドローラ
３４…搬送路
３６…供給装置
３８…巻取装置
４０…第一浸漬槽
４２…一次加熱装置
４４…第二浸漬槽
４６…二次加熱装置
DESCRIPTION OF SYMBOLS 10 ... Cylindrical fiber yarn 12 (before water / oil repellent treatment) ... Cylindrical fiber yarn 14 after water / oil repellent treatment ... Undercoat layer 16 ... Top coat layer 18 ... Water / oil repellent layer 20 ... Binder resin composition 22 ... water / oil repellent 30 ... water / oil repellent treatment device 32 ... guide roller 34 ... transport path 36 ... supply device 38 ... winding device 40 ... first immersion tank 42 ... primary heating device 44 ... second immersion tank 46 ... Secondary heating device
Claims (3)
前記下塗り層の表面に、末端がパーフルオロヘキシル基で構成された側鎖と、末端が親水基で構成された側鎖とを有するフッ素系樹脂からなる撥水撥油剤を塗布した後、乾燥させて上塗り層を形成することによって筒状抄繊糸の表面に撥水撥油加工を施し、然る後
撥水撥油処理済みの筒状抄繊糸を編織することを特徴とする畳表の製造方法。 After applying a binder resin composition composed of a crosslinkable polymer having a crosslinking group in the main chain or side chain to the surface of a cylindrical fiber yarn obtained by twisting paper made from wood fiber, it is dried. To form an undercoat layer,
The surface of the undercoat layer is coated with a water- and oil-repellent agent made of a fluororesin having a side chain whose end is composed of a perfluorohexyl group and a side chain whose end is composed of a hydrophilic group, and then dried. The surface of the cylindrical fiber yarn is subjected to water and oil repellent treatment by forming a top coat layer, and then the water and oil repellent treated cylindrical fiber yarn is knitted and woven. Method.
The method for producing a tatami mat according to claim 1 or 2, wherein the fluororesin is a copolymer of a perfluorohexyl group-containing acrylic monomer, a polyethylene oxide chain-containing acrylic monomer, and a crosslinkable monomer.
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| JP2016061096A (en) * | 2014-09-19 | 2016-04-25 | 大建工業株式会社 | Decorative material |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010168709A (en) * | 2009-01-26 | 2010-08-05 | Daiken Corp | Process for making tatami facing excellent in abrasion resistance |
| JP2010222746A (en) * | 2009-03-24 | 2010-10-07 | Konishi Co Ltd | Method for producing artificial rush and tatami facing |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2010168709A (en) * | 2009-01-26 | 2010-08-05 | Daiken Corp | Process for making tatami facing excellent in abrasion resistance |
| JP2010222746A (en) * | 2009-03-24 | 2010-10-07 | Konishi Co Ltd | Method for producing artificial rush and tatami facing |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2016061096A (en) * | 2014-09-19 | 2016-04-25 | 大建工業株式会社 | Decorative material |
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