JPH0742063A - Pile products - Google Patents

Abstract

(57) [Summary] [Purpose] A pile product that is highly stable in napped form, has bulkiness and appropriate hardness, has high compression elasticity, and has no napped fiber falling out, and is a lightweight pile product. And a secondary product using the pile product. In a pile product having raised fibers on one surface of a substrate, a pile product in which at least a part of the raised fibers is fixed with a flexible binder resin or a raised polymer surface of the pile product is provided with a flexible polymer coating. It is a given pile product.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight pile product having a stable napped form, a high bulkiness and an appropriate hardness, a high compression elasticity, and a napped fiber that does not come off. It relates to a secondary product using.

[0002]

2. Description of the Related Art Conventionally, pile products have been woven or knitted fabric with pile fibers implanted or woven, or their backs are lined with latex etc. There are woven fabric linings and the like, and these pile products are used for many applications from lightweight products such as upholstery to heavy products such as carpets. As a modification of these pile products, for example, fixing the roots of piles planted with a fixing agent made of synthetic rubber and a reactive thermosetting synthetic resin has a high melting point as disclosed in JP-A-1-272877. The low melting point fiber or the high melting point and low melting point composite fiber is mixed in the main fiber of the above, and a loop pile is formed on the mixed fiber web by needle processing, and the low melting point fiber is heat-shrinked to increase the length of the loop pile. Japanese Patent Publication No. 1-4759 for shortening and then melting the low melting point fiber to make a needle punched loop pile carpet.
Japanese Patent Publication No. 0-39757 proposes a pile carpet made of pile yarn having a fluororesin attached to its surface.

[0003]

SUMMARY OF THE INVENTION Conventional pile products are
Since it was difficult to increase the napped fiber density, the compression elasticity was insufficient, and the bulkiness and compression resistance could not be balanced. And, in the case where the napped fiber density is increased, the compression elasticity is improved but becomes heavy. Further, when the root of the napped fiber is fixed with a resin, the napped fiber can be prevented from coming off, but it is difficult to strengthen the napped fiber to improve its resilience and elasticity.

An object of the present invention is to provide a pile product which is highly stable in napped form, has bulkiness and an appropriate hardness, has high compression elasticity, and has no falling fiber, and is a lightweight pile product. And to provide a secondary product using the pile product.

[0005]

The present invention relates to a pile product having raised fibers on one surface of a substrate, wherein at least a part of the raised fibers is fixed with a flexible binder resin. Is.

Further, the present invention provides a pile product having napped fibers on one surface of a substrate, wherein at least a part of the napped fibers is fixed with a flexible binder resin, and a fluffed surface is provided with a flexible polymer film. It is a pile product that is characterized by being.

The core base fabric constituting the pile product is, for example,
At least one selected from the group consisting of synthetic fibers such as polyester fibers, polyamide fibers, polyolefin fibers, polyvinyl chloride fibers, polyacrylic fibers, and polyvinyl alcohol fibers, acetate fibers, regenerated cellulose fibers, plant fibers, animal fibers, etc. Knitted fabric or woven fabric obtained by weaving or knitting in the usual manner using various types of short fibers or long fibers, or a non-woven fabric made by a dry method or a wet method,
Examples include spunbond nonwoven fabric made of synthetic fibers. Further, the core base cloth may be a woven cloth of tape yarn made by splitting a polymer film such as polyester or polyolefin. Polyester fiber or polyamide fiber is preferably used as the synthetic fiber. The weight of this core base cloth varies depending on the use of the pile product, but generally the weight is 8
It is in the range of 0 to 1,000 g / m ² .

The napped fibers are, for example, polyester fibers, polyamide fibers, polyolefin fibers, polyvinyl chloride fibers, polyacrylic fibers, polyvinyl alcohol fibers, or other synthetic fibers or a mixture of two or more types of fiber-forming polymers. Multi-component fibers obtained by spinning or composite spinning, acetate fibers, regenerated cellulose fibers, plant fibers,
It is a spun yarn using one type or two or more types of short fibers selected from the group of animal fibers and the like or a filament processed yarn using long fibers. The total fineness of the napped fiber bundle is usually 1,
It is 000 to 5,000 denier. Napped fiber length,
The napped fiber bundle density etc. is determined from the desired product,
Generally, the napped fiber length is 3 to 30 mm, and the napped fiber bundle density is 30.
The range is from 300 lines / in ² . The napped fiber form of the pile product may be either loop pile or cut pile. Further, when easily dyeable fibers are used for the napped fibers and the fibers constituting the base fabric, it is possible to obtain a pile product having the same hue or a different color tone by dyeing the pile product and then dyeing.

Before or after applying the binder resin, the pile product may be colored by a dip dyeing method, a textile printing method, a printing method, or a finishing treatment such as a hair styling treatment, if necessary.

The pile product is treated with a flexible binder resin, and at least the napped fiber portion, preferably the whole napped fiber, is fixed with the binder resin. The binder resin used is, for example, polyurethane obtained by adjusting the amount of the soft segment or the type of the hard segment, an acrylic acid ester polymer or copolymer, a copolymer of acrylic acid ester and another polymerizable monomer. Coalescing,
It is at least one resin selected from vinyl chloride polymers or copolymers, acrylonitrile butadiene copolymers, styrene butadiene copolymers, melamine resins, epoxy resins, polyester resins and the like. A preferred binder resin for maintaining the bulkiness of the napped fibers and obtaining a napped fiber surface having high compression elasticity is that the 100% modulus measured by a dry film is 80 kg / cm ² or less, preferably 3
It is a resin in the range of up to 50 kg / cm ² . By fixing the napped fibers with this flexible binder resin, a pile product having a compression deformation rate of the napped fiber surface of 20% or less under a load of 1 kg / cm ² can be obtained.

The binder resin is used as a solution or a dispersion, or as a composition liquid to which a treating agent such as an antibacterial agent, an insect repellent, an antistatic agent, a flame retardant, an antioxidant or a light stabilizer is added, if necessary. It is given to pile products. The application method is a method of dipping a pile product in a binder resin liquid,
It can be carried out by a roll coating method, a spray coating method, a method of coating a certain amount of a binder resin liquid on a support and transferring it. The amount of the binder resin applied is determined depending on the state of the napped fibers, the napped fiber density, the pile product application, etc. Generally, the resin weight relative to the pile product weight is 5-10.
It is in the range of 0% by weight, preferably 10 to 80% by weight.
And 1kg / pile fiber surface of resin-processed pile products
The compressive deformation rate of pile products is 2 when a load of cm ² is applied.
It is preferably 0% or less in order to obtain a product that is lightweight and maintains bulkiness and has a high compression elastic modulus. The pile product may optionally be embossed on the napped fiber surface.

The pile product of the present invention can be further processed into a secondary product. For example, a thickness of 10 to 5 made of a flexible polymer such as polyurethane elastomer, polyester elastomer, polyamide elastomer, polyamide, plasticized polyvinyl chloride, and polyamino acid resin.
A pile product in which a porous or non-porous coating of 00 μm is applied to the napped fiber surface of the pile product can be obtained. The pile product may be subjected to a treatment such as coloring or embossing if necessary on the surface of the coating film to be a sheet material for interior decoration such as wall covering or floor covering.

The pile product of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic sectional view of a pile product, in which napped fibers 2 fixed by a flexible binder resin are planted in a core base cloth 1.

FIG. 2 is a partially enlarged schematic sectional view of a pile product. FIG. 2 (1) is a schematic sectional view of a cut pile, FIG. 2 (2) is a schematic sectional view of a loop pile, and a core base cloth 1 The napped fibers 3 are planted in, and the napped fibers are fixed with a flexible binder resin 4.

FIG. 3 is a schematic cross-sectional view of a secondary product obtained by subjecting the pile product of the present invention to a secondary process, in which a flexible polymer coating 6 is applied to the napped fiber surface of the resin-processed pile product 5. Next product 7.

[0016]

The pile product of the present invention is a pile product of high compression elasticity having the bulkiness of the napped fibers and an appropriate hardness by fixing the napped fibers with the flexible binder resin.

[0017]

EXAMPLES Next, embodiments of the present invention will be described with reference to examples. The parts and% in the examples relate to the weight unless otherwise specified.

Example 1 A plain woven fabric using spun yarn of polyethylene terephthalate fiber was used as a core base fabric, and spun yarn of polyethylene terephthalate fiber having a single yarn fineness of 10 dr (total fineness of about 1,500 dr) was used as napped fiber and planted. It was planted in a base fabric under the conditions of a density of 10 × 10 fibers / in ² and a napped fiber length of 7 mm to obtain a pile product raw machine (1) having a loop pile surface. This pile product greige is dyed in a tea-based disperse dye solution, and then an antibacterial agent and a flame retardant are added to an acrylic resin emulsion with a solid content of 8% (100% modulus measured with a dry film is 18 kg / cm ² ). Immersion treatment in the binder resin composition liquid prepared above, squeezing liquid at the target squeezing ratio of 130%, drying in a hot air dryer at 135 ° C, and then using an embossing roll of matte surface heated to 90 ° C, using a cylinder pressure The napped fiber surface was embossed at 2.5 kg / cm ² to obtain a product.

This pile product has an appropriate hardness, is bulky, has a swelling feeling, and has a good appearance. The surface was rubbed 1000 times with a load of 500 g, but the napped fibers did not come off. Further, the compressive deformation rate when a load of 1 kg / cm ² is applied to the napped fiber surface is 12.5%, which is a sufficiently high compressive elasticity. When this pile product was used as a carpet underlay, it was excellent in heat retention and sound insulation.

Comparative Example 1 A pile product obtained by finishing the pile product raw machine (1) of Example 1 without resin-processing, has a napped fiber surface of 5 with a load of 500 g.
When rubbed 00 times, the napped fibers often fell out or were cut. Further, the compressive deformation rate when a load of 1 kg / cm ² was applied to the napped fiber surface was 41.5%, and the stiffness was weak.

Example 2 The pile product raw machine (1) of Example 1 was dyed with a green disperse dye, and then a yellow-free modified polyester type polyurethane (100% modulus measured by dry film was 28.5 Kg / c).
a solid concentration of 10% emulsion of m ^2), 3.5% of a green pigment and 0.5% with respect to the polyurethane solid content weight
The dyed pile product was dipped in the binder resin composition liquid added with the light resistance stabilizer of Example 1, squeezed at a target squeezing rate of 130%, dried in a hot air dryer at 135 ° C, and then heated to 90 ° C. Using a matte surface embossing roll, the napped fiber surface was embossed at a cylinder pressure of 2.5 kg / cm ² to obtain a product.

This pile product was subjected to a friction test with a dynamic vibration type flat friction tester 1000 times with a load of 500 g, but there was no damage on the napped fiber surface of friction and the compressive deformation rate was 9 when a load of 1 kg / cm ² was applied. It was 5% and had a sufficiently high compression elasticity. When this pile product was used as a rug at a golf driving range, it could be used as an artificial turf that is bulky, has a bulge, and has a good appearance.

Example 3 A core-sheath composed of 80 parts of polyethylene terephthalate fiber having a fineness of 2 dr and a fiber length of 51 mm, 40 parts of polyethylene terephthalate having a fineness of 6 dr and a fiber length of 51 mm, and 60 parts of hexamethylene terephthalate copolymer as a sheath component. 20 parts of type composite fiber (heat binder fiber having a melting point of the sheath component of 135 ° C.) is mixed and the average weight is 120 g / m ² with a random webber.
Fiber web of No. 40, needle density # 140 on each side, needle punch density is 40 punches / cm ² , puncture depth is 10 mm
The fiber-entangled non-woven fabric needle-punched under the above conditions was used as the core base fabric. On the other hand, as napped fibers, a filament yarn of polyethylene terephthalate having a single yarn fineness of 15 dr is combined and twisted to form a filament processed yarn of 2250 dr / 150 fil, and then a planting density of 10 × 10 filaments / in ² , napped fiber length of 5 mm Then, heat treatment was performed in a heating zone of 155 ° C., and the fibers of the core base cloth were fixed with binder fibers to obtain a pile product raw machine (2).

On the other hand, non-yellowing polyether type polyurethane (100% modulus measured by dry film is 4
8.5 kg / cm ² ) isopropyl alcohol / toluene /
A binder resin composition liquid in which 0.5% of a hindered phenolic antioxidant and 0.5% of a light resistance stabilizer were added to a 8% concentration solution dissolved in a dimethylformamide mixed solvent based on the weight of the polyurethane solid content, was added. After adjusting, the pile product raw machine (2) is dipped, squeezed at a target squeezing rate of 100%, dried in a hot air dryer at 135 ° C., and then using an embossed roll of pear ground heated to 90 ° C. The napped fiber surface was embossed at a cylinder pressure of 2 kg / cm ² to obtain a product.

This pile product was a lightweight product having a sufficiently high compressive elasticity with a compressive deformation rate of 7.8% when a load of 1 kg / cm ² was applied. When this pile product was used for the lining of a helmet, it had a swelling feeling and a good tactile sensation.

Example 4 As a coating to be applied to the napped fiber surface of a pile product, a polycarbonate-based polyurethane elastomer solution containing a colorant and a light resistance stabilizer was coated on a release paper having a leather pattern embossed, dried and averaged. A film with a thickness of 18 μm is formed, a polycaprolactone-based polyurethane elastomer composition liquid containing a foaming agent, a colorant, and a light resistance stabilizer is applied thereon, and dried and foamed to form a porous layer with an average thickness of 100 μm. Then, a polyether-based polyurethane elastomer adhesive composition liquid was applied, and most of the solvent was removed to obtain a polyurethane laminated film. The polyurethane coating side was laminated and adhered to the napped fiber surface of the pile product obtained in Example 3, and the release paper was removed by curing to obtain a product having a colored polyurethane coating having a leather pattern appearance on the surface of the pile product. . This product had a calm appearance and soundproofing as an interior wall material.

[0027]

EFFECTS OF THE INVENTION The pile product of the present invention is highly stable in napped form, has bulkiness and appropriate hardness, has high compression elasticity and good restorability of napped fiber surface, and prevents falling fiber from falling out. It is an excellent and lightweight pile product suitable for heavy-weight applications.
Further, it can be dyed or washed, and there is almost no shrinkage or change in texture even after washing. Furthermore, since this pile product has good elasticity and has the effect of soundproofing and vibration damping, it can be used as a soundproofing material or heat insulating material for buildings or structures. Therefore, it can be used for applications utilizing these characteristics, for example, for wearing in a helmet, intermediate cushions such as bedding and beds, seats, artificial turf, and the like. Further, the secondary product can be a sheet material for interior decoration such as wall covering and flooring.

[Brief description of drawings]

FIG. 1 is a schematic sectional view of a pile product of the present invention.

FIG. 2 is an enlarged sectional schematic view of a pile product of the present invention.

FIG. 3 is a schematic cross-sectional view of a secondary product in which a coating is provided on the napped fiber surface of the pile product of the present invention.

[Explanation of symbols]

 1 core base cloth, 2 resin fixed napped fibers, 3 napped fibers, 4 binder resin, 5 pile products, 6 coating layers, 7 secondary products.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location D06M 101: 16

Claims (2)

[Claims] 1. A pile product having napped fibers on one surface of a base material, wherein at least a part of the napped fibers is fixed with a flexible binder resin. 2. A pile product having napped fibers on one surface of a substrate, wherein at least a part of the napped fibers is fixed with a flexible binder resin, and a fluffed surface is provided with a flexible polymer coating. Pile product characterized by.