CN1929764A - Carpet and process for producing the same - Google Patents

Abstract

A carpet comprising piles (2) provided on the upper face a base fabric (3) and a backing layer (4) formed below the lower face of the base fabric, wherein an allergen-reducing agent (10) is adhered to at least a part of an area (X) ranging from the upper face (3a) of the base fabric (3) to the pile foot. Owing to this construction, allergens such as mites entering the carpet, dead mites and pollen can be efficiently inactivated and the amount of allergens in the carpet can be lowered.

Description

Carpet and its manufacturing method

technical field

The present invention relates to a carpet having a function of inactivating allergens such as pollen and ticks adhering to the carpet and a method for producing the same.

Background technique

The heat insulation or airtightness of houses built in recent years has been significantly improved, and high-performance energy-saving houses have been developed, which use natural convection to replace indoor air for several times longer than conventional houses. However, in a house designed in this way, due to its high airtightness, it is easy to stay indoors, such as bad smell or dust called house dust (house dust), which become allergens that cause allergies, which will Induces symptoms of allergic diseases such as atopic dermatitis, bronchial asthma, and allergic rhinitis.

There are various types of allergens, such as ticks (body, carcass, shell, feces), mold, pets (hair, scalp), pollen, etc. These are considered to be the main causes of allergic diseases. For example, even if dust mites, which are allergens, are expelled by high temperature or chemicals, their dead bodies remain in the carpet, and it is believed that these dust mite dead bodies are scattered from the inside of the carpet when people walk, move, etc. on the carpet Indoor space is the problem (the dust mite dead body is particularly problematic due to its high allergenicity). Therefore, unless allergens such as ticks, tick carcasses, tick shells, and tick feces are removed from the carpet, it is difficult to prevent the induction of allergic diseases due to these causes.

Based on such a background, air conditioners, air cleaners, etc. have been widely used for deodorization and dust collection, and for example, a method of collecting allergens in the air by using a filter or the like has been proposed. This collection method using air conditioners, air purifiers, etc. is effective for collecting allergens floating in the indoor air, but it is basically ineffective for allergens attached to carpets. In order to remove allergens adhering to the carpet, it is considered effective to remove ticks by repeatedly vacuuming while beating the surface of the pile on the carpet with a vacuum cleaner or the like. However, although this method can remove allergens adhering to the surface of the carpet, it cannot completely remove allergens such as ticks and tick corpses that have entered the interior of the carpet. If the allergens such as ticks and tick corpses entering the carpet cannot be completely removed in this way, the chances of people using the carpet to come into contact with these allergens cannot be sufficiently suppressed, and it is still difficult to fully prevent the induction of allergic diseases. condition of the living environment.

On the other hand, in the descriptions of Patent Documents 1 to 3, articles that have an allergen-reducing function by adhering an allergen-reducing component to fibers or the like are proposed. That is, in Patent Document 1, a cleaning cloth for carpets constituted by impregnating a base material (woven fabric, nonwoven fabric, etc.) with an allergen-reducing component is described. Allergen-reducing fibers are chemically bonded to fibers or adhered to fibers. Patent Document 3 describes the method of printing inks containing allergen-reducing components on non-woven fabrics. Allergen-reducing nonwoven fabric constructed on at least one side.

Patent Document 1: JP-A-2003-10089

Patent Document 2: JP-A-2003-96670

Patent Document 3: JP-A-2003-313778

As described above, conventionally known allergen-reducing functional bodies in which fibers or base fabrics (woven fabrics, non-woven fabrics, etc.) are impregnated with allergen-reducing components and the like are adhered. However, the current status is that in a fiber aggregate of a special structure called a pile carpet having piles on the surface, that is, piles are planted on the upper surface of the base fabric and formed on the lower surface of the base fabric. Among the carpets composed of backing layers, there is no carpet of the type to which an allergen reducing agent is added, and it is not known at all which part of the pile carpet is most effective to carry the allergen reducing agent. Therefore, the previous pile carpets do not have the function of inactivating allergens such as pollen and ticks attached to the carpet. Therefore, it is still difficult for people who use carpets to fully prevent allergic diseases. The conditions of the induced living environment.

Contents of the invention

The present invention is proposed in view of the above-mentioned technical background, and its purpose is to provide a kind of allergen that can effectively inactivate the allergens such as ticks, tick corpses, pollen, etc. Carpet with allergen content and method for its manufacture.

In order to achieve the above object, the inventors of the present invention have found through painstaking research that if the pile carpet is used continuously, allergens such as ticks, tick corpses, and pollen accumulate in large quantities especially at the root of the pile head of the pile carpet. Therefore, in order to effectively inactivate the allergens attached to the pile carpet and reduce the amount of allergens, the key is to attach the allergen reducing agent to the roots of the piles or its vicinity, and then to carry out a detailed analysis of its specific structure. As a result of intensive research, the present invention has been accomplished. That is, the present invention provides the following means.

[1] A carpet comprising tufts planted on the upper surface of the base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that, from the upper surface of the base fabric to the pile The allergen reducing agent is attached to at least a part of the root region of the head.

[2] A carpet in which tufts are planted on the upper surface of the base fabric and a backing layer is formed on the lower surface of the base fabric, wherein the allergen-reducing allergens adhere to the upper surface of the base fabric. agent.

[3] A carpet in which piles are planted on the upper surface of the base fabric and a backing layer is formed on the lower surface of the base fabric, wherein the upper surface of the base fabric is integrally laminated with: Mesh layer with allergen reducer attached.

[4] The carpet according to the preceding item [3], wherein the base fabric and the mesh layer are laminated together by needle rings.

[5] The carpet according to any one of items 1 to 4 above, wherein the mesh layer has a unit weight of 10 to 100 g/m ² .

[6] The carpet according to any one of items 1 to 5 above, wherein the adhesion amount of the allergen reducing agent is 1 to 10 g/m ² .

[7] A carpet comprising tufts planted on the upper surface of the base fabric and a cushion layer formed on the lower surface of the base fabric, characterized in that the cushion layer is made of resin or/and rubber containing The composition of the allergen reducing agent is constituted, and a part of the composition is soaked and adhered to the root of the pile.

[8] The carpet according to item 7 above, wherein the backing layer contains 2 to 20 parts by mass of the allergen reducing agent based on 100 parts by mass of the main component composed of resin or/and rubber composition.

[9] The carpet according to item 7 or 8 above, wherein the adhesion amount of the allergen reducing agent is 2 to 15 g/m ² .

[10] The carpet according to any one of items 1 to 9 above, wherein an allergen reducing agent having a phenolic hydroxyl group is used as the allergen reducing agent.

[11] A method for producing a carpet, characterized in that a composition having a viscosity of 5,000 to 25,000 mPa·s is applied to the lower surface of a base fabric with piles planted on the upper surface, and then dried, the composition The allergen reducing agent is contained in an amount of 2 to 20 parts by mass with respect to 100 parts by mass of a main component composed of resin or/and rubber.

[12] The method for producing a carpet according to the above item 11, wherein the composition is applied to the lower surface of the base fabric by a roll coating method.

In the invention of [1], since the allergen reducing agent is attached to at least a part of the region from the upper surface of the base fabric to the root of the pile, a large number of ticks and ticks that gather at the root of the pile Allergens such as lice carcasses and pollen, the allergen reducing agent can effectively act, and as a result, can effectively inactivate a large amount of allergens existing in the root of the pile head, thereby sufficiently reducing the amount of allergens. Therefore, if this carpet is used, it will contribute to realization of the living environment which can fully prevent induction|induction of an allergic disease.

In the invention of [2], since the allergen-reducing agent is attached to the upper surface of the base fabric, the allergen-reducing agent can be used for allergens such as ticks, tick carcasses, pollen, etc. It can function efficiently, and as a result, it is possible to effectively inactivate a large amount of allergens present in the roots of the pile heads, thereby sufficiently reducing the amount of allergens. Therefore, if this carpet is used, it will contribute to realization of the living environment which can fully prevent induction|induction of an allergic disease.

In the invention of [3], since the net layer to which the allergen reducing agent is adhered is laminated integrally on the upper surface of the base fabric, a large number of ticks, tick corpses, pollen, etc. Allergens such as allergens, the allergen reducing agent can effectively function, and as a result, can effectively inactivate the allergens present in a large amount in the roots of the pile heads, thereby reducing the amount of allergens sufficiently. The invention of [3] can obtain a more excellent allergen reduction effect than the invention of [2]. This is because, since the net layer exists on the upper surface of the base fabric, the contact efficiency between the allergen reducing agent and the allergens present in large quantities at the roots of the pile is further improved.

In the invention of [4], since the base fabric and the mesh layer are laminated into one body by needle loop lamination, the mesh layer can be stably and firmly integrated with the base fabric layer.

In the invention of [5], since the net layer has an amount per unit of 10 to 100 g/m ² , it is possible to further increase the contact efficiency between the allergen reducing agent and the allergen.

In the invention of [6], since the adhesion amount of the allergen reducing agent is 1 to 10 g/m ² , the cost can be reduced and the amount of allergens in the carpet can be sufficiently reduced.

In the invention of [7], since a part of the allergen-reducing agent-containing composition constituting the backing layer passes through the base fabric, soaks and adheres to the roots of the pile, a large number of ticks that gather at the roots of the pile Allergens such as tick carcasses, pollen, etc., the allergen reducing agent can effectively function, and as a result, can effectively inactivate a large number of allergens present in the roots of the pile head, thereby reducing the amount of allergens sufficiently. Therefore, if this carpet is used, it will contribute to realization of the living environment which can fully prevent induction|induction of an allergic disease.

In the invention of [8], since the backing layer is composed of a composition containing 2 to 20 parts by mass of the allergen reducing agent relative to 100 parts by mass of the main component composed of resin or/and rubber, it is possible to further improve The effect of reducing the amount of allergens.

In the invention of [9], since the adhesion amount of the allergen reducing agent is 2 to 15 g/m ² , the effect of reducing the amount of allergens can be further enhanced.

In the invention of [10], since an allergen reducing agent having a phenolic hydroxyl group is used as the allergen reducing agent, the allergen reducing agent having a phenolic hydroxyl group has a particularly strong ability to inactivate the allergen, so further Reduce the amount of allergens in the carpet.

In the invention of [11], since the backing layer is formed by applying a composition having a viscosity of 5,000 to 25,000 mPa·s containing a predetermined amount of an allergen reducing agent on the lower surface of the base fabric, a part of the composition Drains through the base fabric and attaches to the root of the pile. The carpet produced by this manufacturing method can effectively inactivate a large amount of allergens present in the pile roots because the allergen reducing agent is attached to the pile roots, thereby reducing the amount of allergens sufficiently.

In the invention of [12], since the composition is applied by the roll coating method, the degree to which the composition permeates the pile roots (penetration height) can be controlled with high precision, thereby making it possible to produce an excellent texture of the pile surface. Carpet with stable allergen reduction function.

Description of drawings

Fig. 1 is a sectional view showing a first embodiment of a carpet of the present invention;

Fig. 2 is a sectional view showing a second embodiment of the carpet of the present invention;

Fig. 3 is a cross-sectional view showing a third embodiment of the carpet of the present invention.

In the figure: 1-carpet; 2-pile; 3-base fabric; 4-backing layer; 5-net layer; 10-allergen reducer; 21-pile root; The area at the root of the pile.

Detailed ways

The carpet 1 of the present invention is formed by planting piles 2 on the upper surface of the base fabric 3, and forming a backing layer 4 on the lower surface of the base fabric 3, and is characterized in that, from the upper surface of the base fabric 3 to the The allergen reducing agent 10 is adhered to at least a part of the region X of the root portion 21 of the pile 2 (see FIGS. 1 to 3 ).

According to the above-mentioned carpet 1, since the allergen reducing agent 10 is attached to at least a part of the region X from the upper surface of the base fabric 3 to the root portion 21 of the pile head 2, a large amount of the allergen reducing agent 10 accumulated on the wall of the root portion 21 of the pile head 2 Allergens such as lice, tick carcasses, pollen, etc., the allergen reducing agent 10 can effectively play a role, thus, can effectively make the allergen that exists in a large amount in the root portion 21 of pile head 2 inactive, thereby can fully Reduce the amount of allergens in the carpet 1.

In addition, the "pile root 21" refers to the area X of the pile 2 from the height corresponding to the upper surface of the base fabric to the bisecting position of the pile height h (see FIGS. 1 to 3 ).

Fig. 1 shows a first embodiment of a carpet 1 of the present invention. This carpet 1 is constituted by planting piles 2 on the upper surface 3a of the base fabric 3, and forming a backing layer 4 on the lower surface of the base fabric 3. In addition, the adhesion of allergens to the upper surface of the base fabric 3 is reduced. Agent 10.

In this embodiment, since the allergen reducing agent 10 is adhered and fixed on the upper surface 3a of the base fabric 3 by the adhesive resin, even if washing or the like is performed, the falling off of the allergen reducing agent 10 can be sufficiently prevented, thereby enabling Sufficiently maintains the allergen-reducing effect.

The above-mentioned carpet 1 shown in FIG. 1 is side-planted from the lower surface of the base fabric 3 using a tufting machine after the adhesive resin containing the allergen reducing agent 10 is attached to the upper surface 3a of the base fabric 3 by coating or the like. The pile yarn 2 is provided, and then, the lower surface of the base fabric 3 is laminated with a spacer material, whereby the pile yarn 2 is fixed on the base fabric 3 .

The method for attaching the allergen reducing agent 10 to the upper surface 3a of the base fabric 3 is not particularly limited, and examples include uniformly dispersing the allergen reducing agent in the binder resin solution, spraying, coating, etc. A method such as a coating method is applied to one side of the base cloth 3, followed by a method of drying to make it adhere. The drying of the binder resin solution is not particularly limited, and examples thereof include air drying, heat treatment, and the like, and drying by heat treatment is preferable in consideration of drying treatment efficiency. The above heat treatment temperature also depends on the raw material of the base fabric 3, but is preferably 100 to 180°C. By performing the heat treatment at a temperature in such a range, the adhesiveness with the base fabric 3 can be further improved, and the continuation durability of the allergen reduction performance can be further improved.

The aforementioned binder resin and allergen reducing agent are preferably applied in the form of an aqueous dispersion dispersed in water, or the like. The binder resin is preferably in an emulsion state with water. In addition, alcohol etc. can be used besides water as a dispersion medium, but water is more suitable. As the order of dispersion in water, it is preferable to further disperse the binder resin in the liquid in which the allergen reducing agent is dispersed in advance from the viewpoint of dispersing the allergen reducing agent and the binder resin more uniformly in each other. In addition, various additives such as a dispersant and a thickener may be added to the aqueous dispersion.

The binder resin is not particularly limited as long as it can attach the allergen reducing agent 10 to the base fabric 3, and examples thereof include urethane resins, self-crosslinking acrylic resins, methacrylic resins, and silicone resins. , Glyoxal resin, polyester resin, vinyl acetate resin, vinylidene chloride resin, butadiene resin, melamine resin, epoxy resin, acrylic-silicone copolymer resin, ethylene-vinyl acetate copolymer resin (EVA) , Isobutylene maleic anhydride copolymer resin, ethylene-styrene-acrylate-methacrylate copolymer resin, etc. In addition, the binder resin may be constituted by mixing two or more of these resins. Among these, EVA is more suitable from the viewpoint of excellent adhesive force.

Fig. 2 shows a second embodiment of the carpet 1 of the present invention. This carpet 1 is constructed by planting piles 2 on the upper surface of the base fabric 3, and forming a backing layer 4 on the lower surface of the base fabric 3, and integrally stacks the net layer 5 attached with the allergen reducing agent 10. The layer is formed on the upper surface of the above-mentioned base fabric 3 . In the present embodiment, the allergen reducing agent 10 is attached to the entire mesh layer 5 (inside and upper and lower surfaces), but it is not particularly limited to this form, and for example, the allergen reducing agent 10 may be attached to the mesh layer. The structure of the upper surface 5a of the mesh layer 5, or the structure in which the allergen reducing agent 10 is attached to the inside of the mesh layer 5, or the allergen reducing agent 10 is attached to the lower surface of the mesh layer 5 (the surface overlapping with the base cloth) structure.

Compared with the carpet 1 shown in the above-mentioned FIG. 1 , the carpet 1 shown in FIG. 2 can obtain a better effect of reducing allergens. This is because the allergen reducing agent 10 is present at a position closer to the root portion 21 of the pile head 2 by the presence of the net layer 5 to which the allergen reducing agent is attached on the upper surface of the base fabric 3, thereby increasing the allergen reducing agent. The contact efficiency of the allergen reducer 10 with the allergen.

In the above-mentioned carpet 1 shown in FIG. 2 , the mesh layer 5 is impregnated in the binder resin solution containing the allergen reducing agent 10 and dried, and then the mesh layer 5 and the base fabric 3 are laminated with needle loops to form a One, then use the tufting machine to plant the pile yarn 2 from the lower surface side of the base fabric 3, and then use the pad material to mount the lower surface of the base fabric 3, thereby fixing the pile yarn 2 to the base fabric 3 on.

In addition, in the case of adopting a structure in which the allergen reducing agent 10 is attached to the upper surface of the net layer 5, for example, as long as the net layer 5 and the base fabric 3 are laminated as a whole through needle loops, the net layer 5 The upper surface is coated with a binder resin containing the allergen reducing agent 10 and then dried.

As a method of attaching the allergen reducing agent 10 to the above-mentioned net layer 5, in addition to the above-mentioned method of impregnating the net layer 5 in the binder resin solution containing the allergen reducing agent 10 dispersed therein and then drying it, for example Examples include uniformly dispersing the allergen reducing agent in the binder resin solution, coating it on the surface of the mesh layer 5 by spraying, coating, etc., and then bonding it by drying. The drying of the above-mentioned binder resin solution is not particularly limited, and examples thereof include air drying, heat treatment, and the like, and drying by heat treatment is preferable in consideration of drying treatment efficiency. The above heat treatment temperature also depends on the raw material of the mesh layer 5, but is preferably 100 to 180°C. By performing heat treatment at a temperature in such a range, the adhesiveness with the mesh layer 5 can be further improved, and the continuation durability of the allergen reduction performance can be further improved. The aforementioned binder resin and allergen reducing agent are preferably impregnated, coated, etc. in the form of an aqueous dispersion dispersed in water. The binder resin is preferably in an emulsion state with water. In addition, alcohol etc. can be used besides water as a dispersion medium, but water is more suitable. As the order of dispersion in water, it is preferable to further disperse the binder resin in the liquid in which the allergen reducing agent is dispersed in advance from the viewpoint of dispersing the allergen reducing agent and the binder resin more uniformly in each other. In addition, various additives such as a dispersant and a thickener may be added to the aqueous dispersion.

As the binder resin, the same resins as those exemplified in the first embodiment can be exemplified.

In the above-mentioned second embodiment, the unit weight of the mesh layer 5 is preferably 10 to 100 g/m ² . By making it below 100g/ ² , allergens can easily enter the net layer 5, thereby further improving the contact efficiency of the allergen reducing agent 10 and allergens, and by making it more than 10g/m ² , it is possible to A sufficient amount of allergen reducing agent is attached to layer 5 .

In the above-mentioned first embodiment and second embodiment, the adhesion amount of the allergen reducing agent 10 is preferably set within the range of 1 to 10 g/m ² . By making it 1 g/m ² or more, a sufficient allergen reduction effect can be exhibited, and by making it 10 g/m ² or less, the cost can also be suppressed. Among them, the adhesion amount of the allergen reducing agent is more preferably set within the range of 3 to 7 g/m ² .

Fig. 3 shows a third embodiment of the carpet 1 of the present invention. The carpet 1 is formed by planting piles 2 on the upper surface of the base fabric 3, and forming a cushion layer 4 on the lower surface of the base fabric 3. The cushion layer 4 is made of resin or/and rubber containing allergens. The reducing agent 10 is composed of a composition, and a part of the composition adheres to the root portion 21 of the above-mentioned pile by impregnation.

In the carpet 1 of FIG. 3 , a part of the composition containing the allergen reducing agent 10 constituting the backing layer 4 permeates through the base fabric 3 and is soaked and impregnated to the roots 21 of the pile piles. Part 21 of allergens such as ticks, tick carcasses, pollen, etc., the allergen reducing agent 10 works effectively.

In the above-mentioned third embodiment, the backing layer 4 is preferably composed of a composition containing 2 to 20 parts by mass of the allergen reducing agent with respect to 100 parts by mass of the main component composed of resin and/or rubber. By setting it at 2 parts by mass or more, a sufficient allergen-reducing action can be exhibited, and by setting it at 20 parts by mass or less, aggregation of the allergen-reducing agent 10 in the composition can be prevented. Among them, the backing layer 4 is more preferably composed of a composition containing 4 to 10 parts by mass of the allergen reducing agent based on 100 parts by mass of the main component composed of resin or/and rubber. In addition, when the filler layer 4 contains a filler, it is preferable to contain the filler in an amount of 400 parts by mass or less with respect to 100 parts by mass of the main component composed of resin and/or rubber. In addition, the above-mentioned liner layer 4 may have a foam structure.

In addition, in the third embodiment described above, it is preferable to set the adhesion amount of the allergen reducing agent 10 within the range of 2 to 15 g/m ² . By setting it to 2 g/m ² or more, a sufficient allergen reduction effect can be exhibited, and by making it 15 g/m ² or less, cost can also be suppressed. Among them, the adhesion amount of the allergen reducing agent is more preferably set within the range of 3 to 8 g/m ² .

In the above-mentioned third embodiment, it is important that the composition constituting the backing layer 4 permeates (bleeds out) the pile roots 21 on the base fabric 3. From this point, the viscosity of the above-mentioned composition is preferably set at 5000 to 25000 mPa. Within the range of s. By making it 5000mPa·s or more, it is possible to prevent the padding material composition from reaching the upper part of the pile 2 due to the degree of penetration, and by making it 25000mPa·s or less, it is possible to prevent the padding material composition from reaching the pile due to difficulty in penetration. The condition of the root of the head 21. Among them, the viscosity of the composition is preferably set within a range of 10000 to 20000 mPa·s. Viscosity management immediately before coating the carpet, etc. is critical. In addition, the drying temperature of the composition also depends on the material of the base fabric, the material of the pile, and the application amount of the backing composition, but usually it is preferable to perform heat drying treatment at 100-180°C for 3-10 minutes.

In order to obtain a good skin feel that is not harsh when it comes into contact with the pile surface of the carpet, the key is that the pad material composition seeps out moderately from the roots 21 of the pile on the base fabric 3, and its penetration height is preferably from the upper surface of the base fabric 3. The surface is higher than 0.2 ~ 2.5mm.

In addition, the amount of the cushioning material composition exuding from the root portion 21 of the pile on the base fabric 3 also changes according to the rotation speed of the roller or the contact method of the sizing knife and the carpet in the case of the roller coating method, so care must be taken. . When the rotational speed of the rollers is increased and the sizing blades are strongly contacted, the amount of exudation (the amount of penetration) that exudes to the pile root 21 increases. The application amount of the backing material composition is preferably 300 to 650 mL/m ² in order to be able to respond to various shapes of back stitches. By setting the application amount to 300 mL/m ² or more, it is possible to prevent the occurrence of coating unevenness and to coat evenly, and by setting the application amount to 650 mL/m ² or less, it is possible to prevent the carpet from becoming hard. Among them, the coating amount of the gasket material composition is more preferably between 350 and 500 mL/m ² .

In the present invention, the allergen reducing agent 10 is not particularly limited as long as it can deactivate the allergen through denaturation or the like and suppress the antigen-antibody reaction. In addition to hydroxybenzoic acids such as extracts and 2,5-dihydroxybenzoic acid, vinylphenol, tyrosine, 1,2-bis(4-hydroxyphenyl)ethylene, and the like can be exemplified. Among them, from the viewpoint of coating processability, washing resistance, and colorability, it is preferable to use phenolic hydroxyl groups such as vinylphenol, tyrosine, and 1,2-bis(4-hydroxyphenyl)ethylene (phenolic OH). ) allergen reducer.

In the present invention, as the above-mentioned base fabric 3, as long as the allergen reducing agent 10 can be adhered, any material and form may be used. Examples of raw materials for the above-mentioned base fabric 3 include thermoplastic fibers such as polyester fibers, polyamide fibers, and polyolefin fibers, and composite fibers of these fibers, or semi-synthetic fibers such as acetate. , regenerated fibers such as man-made fibers, natural fibers such as hemp and cotton, or fibers blended with these fibers. Moreover, as the form of the said base fabric 3, a woven fabric, a nonwoven fabric, a knitted fabric etc. are mentioned, for example.

In addition, the raw material of the above-mentioned pile 2 is not particularly limited, and for example, piles made of polyester fibers, nylon fibers, polypropylene fibers, acrylic fibers, rayon fibers, etc. can be used suitably. Pile made of natural fibers such as hemp, cotton, wool, etc. is produced. The form of the said pile 2 is not specifically limited, either, For example, a cut pile, a loop pile, etc. are mentioned.

In addition, the cushion material constituting the cushion layer 4 is not particularly limited as long as it is resin or rubber capable of fixing the pile yarn to the base fabric. Examples of resins include acrylic resins, urethane resins, polyvinyl chloride, polyethylene, polypropylene, ethylene-vinyl acetate copolymer resins (EVA), and rubbers such as SBR (styrene-butadiene rubber), NBR ( Acrylonitrile-butadiene rubber), MBR (methyl methacrylate-butadiene rubber), natural rubber, etc. In addition, it is preferable to contain a filler in the above-mentioned gasket material. The filler is not particularly limited, and examples thereof include calcium carbonate, aluminum hydroxide, magnesium hydroxide, fly ash, and the like. In addition, additives such as dispersants, thickeners, antibacterial agents, flame retardants, and deodorants may be added to the above-mentioned gasket materials within the range that does not hinder the effects of the present invention. In addition, a second base fabric made of nonwoven fabric or woven fabric may be integrally laminated on the lower surface of the backing layer 4 .

Example

Next, specific examples of the present invention will be described.

<Example 1>

In 100 parts by mass of water, 50 parts by mass of tyrosine (allergen reducing agent) was dispersed, and 50 parts by mass of EVA resin was further dispersed to obtain an aqueous dispersion. Apply the aqueous dispersion to one side of the base fabric (flat yarn woven fabric made of polypropylene fibers, mesh weight 110g/m ² ) by spraying, and then dry it at 110°C for 3 minutes to obtain A base fabric with an allergen reducing agent attached to one side of the base fabric. At this time, the adhesion amount of the allergen reducing agent was 7 g/m ² . Then, a pile yarn (pile mesh: 700 g/m ² ) made of polyester fiber was planted from the other side of the base fabric (the side to which the allergen reducing agent was not adhered) using a tufting machine, thereby attaching The cut pile with a pile length of 7 mm was formed on the side with the allergen reducing agent, thereby obtaining a gray carpet fabric. Then, SBR latex (containing calcium carbonate as a filler) was applied to the non-pile side (lower surface) of the above-mentioned carpet fabric, and dried to obtain a carpet having the structure shown in FIG. 1 .

<Example 2>

A carpet having the structure shown in FIG. 1 was obtained in the same manner as in Example 1 except that the adhesion amount of the allergen reducing agent on the upper surface of the base fabric was 10 g/m ² .

<Example 3>

A carpet having the structure shown in FIG. 1 was obtained in the same manner as in Example 1 except that the adhesion amount of the allergen reducing agent on the upper surface of the base fabric was 1.2 g/m ² .

<Comparative example 1>

A carpet was obtained in the same manner as in Example 1 except that the allergen reducing agent was not adhered at all.

<Comparative example 2>

A carpet having the structure shown in FIG. 1 was obtained in the same manner as in Example 1 except that the adhesion amount of the allergen reducing agent on the upper surface of the base fabric was 0.9 g/m ² .

<Comparative example 3>

Instead of adhering the allergen reducing agent on the upper surface of the base fabric, the allergen reducing agent was sprayed from the pile side with an adhesion amount of 7 g/m ² and then dried. A carpet made by attaching an allergen reducing agent to the surface of the pile.

<Example 4>

In the liquid in which 50 parts by mass of tyrosine (allergen reducing agent) was dispersed in 100 parts by mass of water, 50 parts by mass of EVA resin was further dispersed to obtain an aqueous dispersion. The mesh layer (50g/m ² per mesh) and the base fabric (flat yarn woven fabric made of polypropylene fibers, 110g/m ² per mesh) are laminated together through needle loops, and impregnated with the above aqueous dispersion , and then dried at 110°C for 3 minutes. The adhesion amount of the allergen reducing agent on the mesh layer is 5 g/m ² . Then, pile yarns (pile mesh: 700 g/m ² ) made of polyester fibers were planted from the other side of the base fabric (non-lamination layer) using a tufting machine, thereby forming piles on the net layer side. Length is the cut pile of 7mm, thereby obtained carpet greige. Then, SBR latex (containing calcium carbonate as a filler) was applied to the non-pile side (lower surface) of the above-mentioned carpet fabric, and dried to obtain a carpet having the structure shown in FIG. 2 .

<Example 5>

A carpet having the structure shown in FIG. 2 was obtained in the same manner as in Example 1 except that the adhesion amount of the allergen reducing agent on the upper surface of the base fabric was 9 g/m ² .

<Example 6>

A carpet having the structure shown in FIG. 2 was obtained in the same manner as in Example 1 except that the adhesion amount of the allergen reducing agent on the upper surface of the base fabric was 1.5 g/m ² .

<Comparative example 4>

A carpet having the structure shown in FIG. 2 was obtained in the same manner as in Example 4, except that the adhesion amount of the allergen reducing agent on the net layer was 0.6 g/m ² .

[Table 1] Where the allergen reducer attaches Attachment amount of allergen reducing agent (g/m ² ) Evaluation results of allergen reduction performance Example 1 upper surface of base fabric 7 1 Example 2 upper surface of base fabric 10 1 Example 3 upper surface of base fabric 1.2 2 Comparative example 1 - 0 4 Comparative example 2 upper surface of base fabric 0.9 3 Comparative example 3 pile surface area 7 3 Example 4 network layer 5 1 Example 5 network layer 9 1 Example 6 network layer 1.5 2 Comparative example 4 network layer 0.6 3

<Example 7>

Use a tufting machine to plant pile yarns (700 g/m 2 ) made of polyester fibers from one side of the base fabric (flat yarn woven fabric made of polypropylene fibers, 110 g/m ² ) ^. ), thereby forming a cut pile with a pile length of 7mm, thereby obtaining a carpet gray cloth. Then, 350 parts by mass of calcium carbonate, 10 parts by mass of tyrosine (allergen reducing agent), and 2 parts by mass of a thickener were added and dispersed in 100 parts by mass of SBR latex (SBR content rate: 50 mass %) , the thus obtained pad composition with a viscosity of 20000mPa·s was expanded by 1.7 times, and 500g/m ² (490mL /m ² ), drying treatment was performed at 150° C. for 10 minutes, thereby obtaining a carpet having the structure shown in FIG. 3 . The backing composition was impregnated and impregnated at the root of the pile, and was impregnated and adhered to a height of 1.2 mm from the upper surface of the base fabric at the root of the pile. The adhesion amount of the allergen reducing agent was 7.5 g/m ² . In addition, the viscosity was measured using the BM viscometer on the conditions of No. 4 spindle and 6 rpm (the same applies hereinafter).

<Embodiment 8>

A carpet having the structure shown in FIG. 3 was obtained in the same manner as in Example 7, except that the adhesion amount of the allergen reducing agent was 10 g/m ² . In addition, the backing composition impregnated and impregnated the root of the pile, and was permeated and adhered to a height of 1.2 mm from the upper surface of the base fabric at the root of the pile.

<Example 9>

As the liner composition, a liner with a viscosity of 10000 mPa·s obtained by adding and dispersing 5 parts by mass of tyrosine (allergen reducing agent) to 100 parts by mass of SBR latex (SBR content rate: 50 mass %) was used. Except for the mat composition, a carpet having the structure shown in FIG. 3 was obtained in the same manner as in Example 7. The backing composition impregnated and impregnated the root of the pile, and was impregnated and adhered to a height of 1.8 mm from the upper surface of the base fabric at the root of the pile. The adhesion amount of the allergen reducing agent was 5 g/m ² .

<Comparative example 5>

As the pad composition, 350 parts by mass of calcium carbonate and 1.2 parts by mass of tyrosine (allergen reducing agent) were added and dispersed in 100 parts by mass of SBR latex (SBR content rate: 50 mass%). A carpet having the structure shown in FIG. 3 was obtained in the same manner as in Example 7, except that the amount of the allergen-reducing agent deposited was 0.9 g/m ² using the backing composition. In addition, the backing composition impregnated and impregnated the root of the pile, and was permeated and adhered to a height of 1.2 mm from the upper surface of the base fabric at the root of the pile.

<Comparative example 6>

As the pad composition, 350 parts by mass of calcium carbonate, 10 parts by mass of tyrosine (allergen reducing agent), 5 parts by mass of A carpet was obtained in the same manner as in Example 7, except that a pad composition having a viscosity of 32,000 mPa·s was obtained using a tackifier in one part. The pad composition is not completely impregnated and impregnated at the root of the pile, and the attachment position of the allergen reducing agent is limited to the pad layer. The adhesion amount of the allergen reducing agent was 7.5 g/m ² .

[Table 2] Where the allergen reducer attaches Attachment amount of allergen reducing agent (g/m ² ) Evaluation results of allergen reduction performance Example 7 Pile root and underlayment 7.5 1 Example 8 Pile root and underlayment 10 1 Example 9 Pile root and underlayment 5 1 Comparative Example 5 Pile root and underlayment 0.9 3 Comparative Example 6 Underlayment 7.5 3

Each carpet obtained as above was evaluated as follows.

<Evaluation method of allergen reduction performance (performance to inactivate)>

The allergen reduction performance of each carpet was evaluated using an allergen measuring device (manufactured by Asahi Beer & Pharmaceutical Co., Ltd., trade name "Daniscan"). First, 3 mg of garbage dust collected from a general carpet (not a product of the present invention) that has been used for 3 years is placed on each of the above-mentioned carpets (embodiments 1 to 9, comparative examples 1 to 5 cm) cut into 5 cm x 5 cm. 6) on the surface, and then spread it until no dust and dust can be seen on the surface, and then left it for 2 days under the condition of 25°C×70%R.H. Then cut off the piles of each carpet, use a dust collector to rub the surface after the piles have been cut off, and drip the developing solution of the measuring device on it. According to the shade and position of the red line, the tick pollution status is as follows 4 levels were evaluated. Evaluation "1" and "2" are acceptable.

(judgment criteria)

"1"...no tick allergen contamination

"2"...only slight tick allergen contamination

"3" Contaminated with tick allergens

"4" Tick allergen contamination is very serious.

It can be seen from the table that the carpets of Examples 1 to 9 of the present invention have excellent tick allergen reduction performance, and there is no or almost no tick allergen contamination. In contrast, the carpets of Comparative Examples 1 to 6 did not have the tick allergen reduction performance at all, or did not sufficiently have the tick allergen reduction performance, so they were contaminated with tick allergens.

This application enjoys the priority of Japanese Patent Application No. 2004-68978 filed on March 11, 2004 and Japanese Patent Application No. 2004-68979 filed on March 11, 2004. The content described therein directly constitutes a part of the present application.

The technical terms and descriptions used here are only for describing the embodiment of the present invention, and the present invention is not limited thereto. As long as the present invention is within the scope of the application and does not deviate from the spirit, various changes in design are allowed.

The carpet of the present invention can be used, for example, as a living room carpet, an electric blanket, a bathroom mat, a toilet mat, or a tile carpet.

claims

(Amended in accordance with Article 19 of the Treaty)

1. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that:

An allergen reducing agent is attached to at least a part of a region from the upper surface of the base fabric to the root of the pile.

2. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that:

An allergen reducing agent is attached to the upper surface of the base fabric.

3. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that:

A mesh layer to which an allergen reducing agent is adhered is laminated integrally on the upper surface of the base fabric.

4. The carpet of claim 3, wherein:

The base cloth and the net layer are integrated through needle loop lamination.

5. (After correction) The carpet according to claim 3 or 4, wherein

The unit weight of the mesh layer is 10-100 g/m ² .

6. The carpet according to any one of claims 1 to 5, wherein:

The adhesion amount of the allergen reducing agent is 1-10 g/m ² .

7. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that:

The backing layer is composed of a composition containing an allergen reducing agent in resin or/and rubber, and a part of the composition penetrates and adheres to the root of the pile.

8. The carpet of claim 7, wherein:

The backing layer is composed of a composition containing 2 to 20 parts by mass of the allergen reducing agent with respect to 100 parts by mass of the main component composed of resin or/and rubber.

9. Carpet according to claim 7 or 8, characterized in that,

The adhesion amount of the allergen reducing agent is 2-15 g/m ² .

10. The carpet according to any one of claims 1 to 9, characterized in that

As the allergen reducing agent, an allergen reducing agent having a phenolic hydroxyl group is used.

11. A method for manufacturing a carpet, characterized in that,

On the lower surface of the base fabric with piles planted on the upper surface, apply a composition with a viscosity of 5,000 to 25,000 mPa·s, and then dry it. The composition is made of resin or/and rubber relative to 100 parts by mass The main component contains 2 to 20 parts by mass of the allergen reducing agent.

12. The manufacturing method of carpet according to claim 11, characterized in that,

The composition was applied to the lower surface of the base cloth by a roller coating method.

Claims (12)

1. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that: An allergen reducing agent is attached to at least a part of a region from the upper surface of the base fabric to the root of the pile. 2. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that: An allergen reducing agent is attached to the upper surface of the base fabric. 3. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that: A mesh layer to which an allergen reducing agent is adhered is laminated integrally on the upper surface of the base fabric. 4. The carpet of claim 3, wherein: The base cloth and the net layer are integrated through needle loop lamination. 5. The carpet according to any one of claims 1 to 4, wherein: The unit weight of the mesh layer is 10-100 g/m ² . 6. The carpet according to any one of claims 1 to 5, wherein: The adhesion amount of the allergen reducing agent is 1-10 g/m ² . 7. A carpet comprising tufts planted on the upper surface of a base fabric and a backing layer formed on the lower surface of the base fabric, characterized in that: The backing layer is composed of a composition containing an allergen reducing agent in resin or/and rubber, and a part of the composition penetrates and adheres to the root of the pile. 8. The carpet of claim 7, wherein: The backing layer is composed of a composition containing 2 to 20 parts by mass of an allergen reducing agent with respect to 100 parts by mass of a main component composed of resin or/and rubber. 9. Carpet according to claim 7 or 8, characterized in that, The adhesion amount of the allergen reducing agent is 2-15 g/m ² . 10. The carpet according to any one of claims 1 to 9, characterized in that As the allergen reducing agent, an allergen reducing agent having a phenolic hydroxyl group is used. 11. A method for manufacturing a carpet, characterized in that, On the lower surface of the base fabric with piles planted on the upper surface, apply a composition with a viscosity of 5,000 to 25,000 mPa·s, and then dry it. The composition is composed of resin or/and rubber relative to 100 parts by mass The main component contains 2 to 20 parts by mass of the allergen reducing agent. 12. The manufacturing method of carpet according to claim 11, characterized in that, The composition was applied to the lower surface of the base cloth by a roller coating method.

Images