JP2000273751A - Backing for tufted carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonwoven cloth having excellent tensile strength and modulus without inducing a moire pattern or interlayer peel off in tufting. SOLUTION: This backing for a tufted carpet is a filament nonwoven cloth comprising filaments composed of a thermoplastic polymer having >=170 deg.C melting point and having many heat-pressed contact points, >=50 piece/cm2 pressed contact point density, <0.4 mm2 pressed contact point area and 5-20% a pressed contact area fraction and the nonwoven cloth is characterized by having <=0.4 g/cm3 apparent density.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a base fabric for tufted carpet comprising a nonwoven fabric in which a group of long fibers is accumulated.

[0002]

2. Description of the Related Art Conventionally, a nonwoven fabric in which a group of long fibers is accumulated has been used as a base fabric for tufted carpet. This tufted carpet base fabric is used as a support when tufting pile yarn (planting pile yarn). A method for manufacturing a tufted carpet using such a tufted carpet base fabric is as follows. That is, an undyed pile yarn (for example, a pile yarn made of an undyed nylon yarn) is tufted on a tufted carpet base fabric, and then the pile yarn is adjusted to a desired color using a pad steam continuous dyeing machine or the like. After dyeing, it is further backed to give a tufted carpet.

[0003] Such a carpet base fabric has a tufted pile yarn arranged in an orderly manner without causing jumping or blinding, has an excellent pile grip force, has little dimensional change due to process tension in a dyeing process, and has a small dimensional change due to process tension in a backing process. It must have excellent dimensional stability.

As this kind of tufted carpet base cloth, a needle-punched non-woven cloth made of a long fiber is provided by bonding a thermoplastic resin thereto (Japanese Patent Publication No. 61-818).
No. 9), however, since the strength of the resin decreases at high temperatures, dimensional changes occur due to tensile stress during the secondary processing step, and the dimensional stability of the obtained product deteriorates. The lowering causes a problem that wrinkles are easily formed in the process. Further, in the case where the resin is applied by simply being entangled by a needle punch, there is a problem that the base fabric becomes bulky and a large amount of pile yarn is required, so that the cost increases and the base fabric becomes heavy. Was.

On the other hand, there has been proposed a carpet base fabric (Japanese Patent Application Laid-Open No. 3-104973) in which a composite fiber in which a part of the fiber is made of a low-melting polymer is thermocompressed with an embossing roll. Depending on the conditions, the fiber may be turned into a film, and the resistance of the tuft needle to penetrate the base fabric during tufting may increase.In addition, since only the surface layer of the nonwoven fabric is firmly bonded, delamination occurs in which the base fabric separates into layers in the tufting process. In some cases, the dyeing process may not be applied to the pin tenter, or the backing agent may not easily penetrate, and the carpet may not be rigid.

A carpet base fabric has been proposed in which a mixed fiber web of fibers made of a low-melting polymer and fibers made of a high-melting polymer is thermocompressed with an embossing roll.
Since different components are drawn and thinned at the same suction speed, spinning operability is inferior. In addition, since the mechanical performance is inferior, the width shrinkage in the dyeing process is large.

[0007] Further, the non-woven web which has been partially hot-pressed with an embossing roll using an embossing roll has a problem that a moiré pattern is generated in which the gauge or stitch of the pile yarn interferes with the embossed pattern applied to the non-woven fabric. is there.

[0008]

SUMMARY OF THE INVENTION The present invention solves such a problem and has good tufting properties, does not cause delamination or moire due to tufting, and has a high modulus strength that can withstand continuous dyeing. It is another object of the present invention to provide a rigid tufted carpet base fabric having good dimensional stability.

[0009]

Means for Solving the Problems The present inventors have made intensive studies to solve the above-mentioned problems, and as a result, have reached the present invention. That is, the present invention is a long-fiber non-woven fabric comprising a long fiber made of a thermoplastic polymer having a melting point of 170 ° C. or more and having a large number of hot-press junctions, and having a junction density of 50 pieces / cm ² or more and a contact area of 0 Less than 0.4 mm ² and pressure contact area ratio of 5
The present invention provides a tufted carpet base fabric, wherein the apparent density of the nonwoven fabric is 0.4 g / cm ² or less.

[0010]

DETAILED DESCRIPTION OF THE INVENTION The long fibers used in the present invention are:
It is made of a thermoplastic polymer having a melting point of 70 ° C. or more. As a thermoplastic polymer having a melting point of 170 ° C. or higher,
Examples thereof include polyester polymers such as polyethylene terephthalate and polybutylene terephthalate, polyamide polymers such as nylon 6 and nylon 66, and blends and copolymers of these polymers. If the melting point of the thermoplastic polymer constituting the long fiber is less than 170 ° C., the base fabric cannot withstand heat in the backing step, and a product having good dimensional stability cannot be obtained.

The form of the long fiber may be a single polymer or a composite of a plurality of polymers. Examples of the composite form include a core-sheath type, a side-by-side type, and a split type. When the composite fiber is used as the long fiber, it is composed of a low-melting polymer and a high-melting polymer having a melting point higher than the melting point of the low-melting polymer by 20 ° C. or more (both have a melting point of 170 ° C. or more). It is preferable to use a polymer in which a part of the low melting point polymer is present on the fiber surface. When such a composite form of long fiber,
In the hot pressing process, at the hot pressing junction, the low melting point polymer is softened or melted and the constituent fibers are fused and joined,
The high-melting polymer maintains the fiber form without being affected by heat, retains the mechanical properties such as shape retention and tensile strength of the long-fiber non-woven fabric, and becomes a highly flexible long-fiber non-woven fabric. Sometimes, the resistance of the tuft needle when it penetrates the heat-pressed portion is reduced, making it easier to penetrate.

Examples of the combination of the low melting point polymer and the high melting point polymer include copolymerized polyester / polyester, copolymerized polyamide / polyamide, and polyamide / polyester, and both polymers are preferably compatible.

[0013] The thermoplastic polymer used in the present invention includes:
Optional additives such as matting agents, pigments, flame retardants, defoamers, antistatic agents, antioxidants, and ultraviolet absorbers may be added as long as the objects of the present invention are not impaired.

The fineness of the nonwoven fabric used in the present invention is preferably 2 to 12 denier. When the fineness is less than 2 denier, the strength of the obtained long-fiber nonwoven fabric is low, and when performing needle punching or tufting a pile yarn, the long fibers are easily cut, and even if the fineness is larger, Even if the composite is formed, the tensile strength of the base fabric at the time of forming the tufted carpet tends to decrease. Also,
If it exceeds 12 denier, the number of constituent fibers per unit weight is reduced, the number of bonding points is reduced, the mechanical performance of the obtained long-fiber nonwoven fabric is impaired, or the bonding points between fibers are easily displaced. In addition, the base fabric itself becomes coarse and rigid, and the flexibility of the tufted carpet may be impaired, so that the required performance cannot be satisfied.

The long-fiber nonwoven fabric of the present invention has a large number of hot-press contacts, the constituent fibers are heat-fixed by the hot-press contacts, the press-contact density is 50 pieces / cm ² or more, and the press-contact area is It is less than 0.4 mm ² and the pressure contact area ratio is 5 to 20%.

If the pressure contact density is less than 50 pieces / cm ² , the adhesive strength becomes weak, and as a result, the strength of the base fabric becomes insufficient, and the base fabric is easily peeled off in layers.
The surface of the base fabric becomes fuzzy. The pressure contact area is 0.4m
When it is at least m ² , the flexibility of the base fabric is inferior, and the tuft needle easily penetrates the hot-press contact at the time of tufting, so that the tuft needle is easily damaged, and furthermore,
Not only the pierced portion is pierced but also the periphery of the needle hole is also torn, so that the tufted pile yarn is easily pulled out of the base fabric and the strength of the base fabric is reduced. In addition, when the pressure contact is large, the pressure contact pattern becomes conspicuous, the interference between the pressure contact of the base fabric and the arrangement of the pile yarns occurs, and a moiré pattern is easily generated.

If the pressed area ratio is less than 5%, the adhesive strength becomes weak, so that the mechanical strength of the base fabric is inferior, and the tensile stress during the secondary processing steps such as the tufting step, the dyeing step, and the backing step is reduced. Unable to obtain sufficient strength. On the other hand, 20%
Is exceeded, the degree of freedom of the fiber existing between the pressure junctions is reduced, so that the tufting needle stabs the fiber at the time of tufting, so that the fiber is cut and, as a result, the strength of the base fabric is reduced. Becomes

The shape of the pressure contact may be any shape such as a round shape, an elliptical shape, a diamond shape, a triangular shape, a T shape, a well shape, and a rectangular shape. Further, it is preferable that the pressure contacts are arranged at equal intervals.

The apparent density of the nonwoven fabric used in the present invention is 0.4.
g / cm ³ or less. If the apparent density exceeds 0.4 g / cm ³ , the base fabric becomes extremely hard, and the resistance when the tuft needle penetrates the base fabric becomes large, which is not preferable because it becomes difficult to penetrate. The lower limit of the apparent density is about 0.13 g / cm ^{3 in} consideration of the basis weight and thickness of the base fabric. If the apparent density is too small, the thickness of the base fabric is too large to obtain a base fabric having a basis weight sufficient to hold the tuft yarn, and the pile amount for obtaining the required pile height is required. Therefore, the carpet tends to be heavy and costly. A more preferable apparent density is 0.2 to 0.2.
35 g / cm ³ .

The nonwoven fabric used in the present invention is preferably a needlepunched nonwoven fabric in which fibers are entangled by needlepunching. Since the constituent fibers of the needle-punched nonwoven fabric are entangled not only in the two-dimensional direction but also in the thickness direction, the base fabric does not undergo delamination after tufting and can maintain its shape.

In the base fabric of the present invention, in order to improve stress and tensile strength at the time of elongation, it is preferable that a resin is adhered to the base fabric and the contact points of the constituent fibers are bonded with the resin. The attached amount of the resin (the attached amount of the solid content) is preferably 2 to 10% by weight based on the total weight of the tufted carpet base fabric. If the amount of the attached resin is less than 2% by weight, the effect of imparting the binder resin cannot be exerted. On the other hand, if the amount of the attached resin exceeds 10% by weight, the resin existing between the long fibers becomes too large, When tufting pile yarn,
The degree of freedom of the fibers is lost, the tufting needles are less likely to penetrate the base fabric, and the resulting tufted carpet tends to be less flexible.

As the resin used in the present invention, a desired combination of two or more monomers such as methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, acrylonitrile and styrene is used. It is preferable to employ a copolymer copolymerized in a molar ratio. Further, a cross-linkable binder resin in which the copolymer is cross-linked by a cross-linking agent may be used. As a crosslinking agent, a melamine resin, a phenol resin, a formaldehyde resin, or the like can be used.

The total weight of the tufted carpet base fabric of the present invention may be appropriately set, but is generally 50 to 50% by weight.
150 g / m ² is preferred. If the basis weight of the tufted carpet base fabric is less than 50 g / m ² , the mechanical strength of the base fabric decreases, and the holding force of the tuft yarn on the base fabric decreases due to the small amount of fibers in the base fabric. During the tufting, the tuft yarn easily comes off. On the other hand, if the basis weight exceeds 150 g / m ² , the fiber amount of the base fabric is large and the pile height becomes uneven, and the tuft interval tends to become uneven. In addition, it is not economical due to excessive physical properties. The basis weight of the tufted carpet base fabric is 50 cm x 50 c from the base fabric.
After 10 pieces of m were cut out to obtain equilibrium moisture, the weight of each sample was weighed, and the average value was converted to the weight per square meter.

Next, a preferred production method of the present invention will be described. First, a long fiber web formed by accumulating long fiber groups is prepared by a conventionally known method, for example, a spun bond method. That is, while collecting the long fiber group by the melt spinning method, the long fiber group is accumulated by being deposited on a moving collecting conveyor. Specifically, the thermoplastic polymer is melt-spun from a normal spinneret, the spun yarn is cooled, then drawn and thinned by air soccer, then spread by a known method, and then moved. It is deposited as a web on a deposition device.

The take-up speed at the time of towing by air soccer is preferably, for example, about 3000 to 6000 m / min. When it is less than 3000 m / min, the molecular orientation of the long fibers does not sufficiently increase, so that the tensile strength of the obtained long fibers tends to be insufficient, and as a result, the mechanical strength of the selected long fiber nonwoven fabric tends to be inferior. Becomes On the other hand, 6000
If it exceeds m / min, the spinnability during melt spinning tends to decrease.

Next, the obtained long fiber web is subjected to a needle punch to entangle the long fibers. The needle density of the needle punch is appropriately set depending on the type of needle used and the needle depth, but is generally 20 to 100 times / c.
m ² is preferred. If the needle density is less than 20 times / cm ² , the degree of entanglement between the long fibers is low, and the effect of needle punching is not exhibited. On the other hand, if the needle density is 100
When the number of turns / cm ² is exceeded, the entanglement between the long fibers becomes strong, but the long fibers are severely damaged by the needle and the fibers themselves become extremely low in strength. It tends to be inferior.

After the needle punching, the needle-punched non-woven fabric is passed through a hot embossing device and subjected to hot-pressing to form a hot-pressed contact on the non-woven fabric. The heat embossing device is composed of a heated uneven roll and a smooth roll, or a pair of heated uneven rolls,
When a nonwoven fabric is passed between the rolls, heat and pressure are applied to a portion of the uneven roll that comes into contact with the convex portion, and the long fibers in the portion are softened or melted, thereby forming a hot-press junction, and the constituent long fibers are connected to each other. It is heat-fixed by a hot-press junction.

The tip surface of the convex portion of the concave-convex roll is a portion where the nonwoven fabric is pressed, and depends on the area of the convex portion, the arrangement density, and the like.
The form of the heat and pressure contact applied to the long fiber nonwoven fabric is determined. Therefore, the form of the protrusions is also the same as the above-mentioned condition of the form of the thermal pressure contact, the arrangement density of the protrusions is 50 pieces / cm ² or more, the area of the tip surface of each protrusion is less than 0.4 mm ² , and The total area ratio of the tip surface of the projection to the roll surface area (the surface in a state where the projection is ignored) is 5 to 20%.

The heating temperature of the roll is set to a temperature lower than the melting point of the thermoplastic polymer constituting the long fiber, and is preferably set to a temperature lower than the melting point to a temperature lower by 60 ° C. than the melting point. When the long fiber is a composite fiber composed of a low-melting polymer and a high-melting polymer, the melting point of the low-melting polymer is used as a reference, and a temperature in a range of less than the melting point of the low-melting polymer to 60 ° C lower than the melting point. Is preferred. When the heating temperature of the roll is equal to or higher than the melting point, the softened or molten polymer in the portion that comes into contact with the projections adheres to the roll, and productivity is significantly reduced. If the temperature is lower than the melting point by more than 60 ° C., although depending on the linear pressure between the rolls, the heat fusion of the hot-press junction becomes insufficient, and it is difficult to obtain the desired mechanical strength of the nonwoven fabric.

The linear pressure between the rolls is 10 to 100 k
The range is preferably gf / cm ² , but is not particularly limited to this range, and may be appropriately selected in consideration of the basis weight of the nonwoven fabric to be subjected to the heat treatment. 10kgf / cm
^If it is less than ² , the adhesive force between the fibers at the hot-pressed contacts will be weakened, and it will be difficult to obtain a high-strength, high-strength base fabric for tile carpet at the time of stretching. On the other hand, 100kgf
If it exceeds / cm ² , the fiber is excessively pressed and the fiber is slightly damaged, so that the fiber at the boundary between the hot pressure contact and the non-heat pressure contact is easily cut and broken.

The processing speed depends on the pressing temperature and the roll linear pressure, but is preferably 5 to 30 m / min.

Next, in order to strengthen the bond between the constituent fibers of the base fabric, it is preferable to attach the above-mentioned resin. Examples of the attachment method include a known dipping method, foam impregnation method, spray method and the like. Adopt it.

To manufacture a tufted carpet, a pile yarn may be tufted and implanted in the tufted carpet base fabric according to the present invention. As pile yarn,
Nylon yarn, polypropylene yarn, polyester yarn and the like are used.

The longitudinal direction of the tufted carpet base fabric, that is, the flow direction at the time of manufacturing the base fabric, matches the longitudinal direction of the tufted carpet (the flow direction at the time of manufacturing the tufted carpet). Therefore, at the time of tufting, a relatively high load tends to be applied in the longitudinal direction of the base cloth and a relatively low load is applied in the lateral direction of the base cloth.

A backing agent is adhered to the back surface of the tufted carpet into which the pile yarn has been implanted, for the purpose of fixing the pile yarn and for holding the tufted carpet. Backing agent is polyvinyl chloride paste,
Polyethylene or the like is used.

[0036]

The present invention will be described below in detail with reference to examples. The evaluation in the examples was performed by the following method. (1) Apparent density (g / cm ³ ): The thickness of the base cloth was photographed with a stereoscopic microscope at a magnification of 40 times, and 10 cross-sectional photographs of the base cloth per 1 m of sample width were taken. Obtained as thickness (mm) by back calculation from magnification, and weight (g / m ² )
And the apparent density was calculated from the ratio. Apparent density = weight (g / m ² ) × 10 ⁵ / thickness (mm)

(2) KGSM strong (kgf / 5cm
Width); 5 cm in width and 3 in length using a constant speed elongation type tester Tensilon RTM-500 manufactured by Toyo Baldwin Co., Ltd.
A strip-shaped sample piece of 0 cm is measured according to the strip method described in JIS L 1096 at a gripping interval of 20 cm and a pulling speed of 20 cm / min. Then, the average value of 10 sample pieces was determined, and the value converted to the basis weight of 100 g / m ² was defined as the KGSM strength. The KGSM strength was determined for each of the MD and CD directions of the base fabric. In addition, MD
The direction is the longitudinal direction of the base fabric, that is, the flow direction when manufacturing the base fabric, and is the machine direction.
Therefore, it is abbreviated as MD direction. The CD direction is a direction perpendicular to the horizontal direction of the base cloth, that is, the vertical direction, and is also abbreviated to the CD direction because it is also referred to as Cross Direction.

(3) Stress at 10% elongation (kgf / 5c
m width); From the SS curve in the MD direction drawn in the above tensile test, a stress at 10% elongation was determined, and the average value was converted to a basis weight of 100 g / m ² , and the value was converted to 10% in the MD direction. The stress at the time of elongation (kg / 5 cm width) was used.

Example 1 Using a spinneret having a hole diameter of 0.4 mmφ, polyethylene terephthalate having a melting point of 256 ° C. was melt-spun from the die at a melting temperature of 285 ° C. The spinning speed is 5000m /
The polyester filaments were drawn while being stretched by air soccer to obtain polyester filaments having a fineness of about 8 denier.
The long fiber group was spread by a fiber opening device provided at the outlet of the air soccer, and then deposited on a moving wire mesh collecting conveyor to obtain a nonwoven web. An emulsion of dimethylpolysiloxane was applied to this nonwoven web so that the active ingredient was 0.5% by weight with respect to the constituent fibers.

Thereafter, the nonwoven web is heated to 220 ° C.
The arrangement density of the convex portions is 64 / cm ^Two, The surface area of the protrusion is
0.28mm^Two, Roll surface area (while ignoring protrusions)
Surface area) is 18%
Pass through a thermal pressure welding device consisting of a pair of embossing rolls,
Compress nonwoven web at 30kgf / cm, apparent density becomes
0.23g / cm^ThreeAnd have a hot-pressed contact
A non-woven fabric was obtained.

On the other hand, an acrylic ester-based binder resin solution was prepared, and the above-mentioned nonwoven fabric was impregnated with the binder resin solution so that the solid content was 5% by weight.
By performing drying and heat treatment, the basis weight is 100 g / m
^The base cloth for tufted carpet No. ² was obtained.

Example 2 The arrangement density of the projections was 51 / cm ² , and the surface area of the projections was 0.5.
31 mm ² , for a tufted carpet in the same manner as in Example 1 except that a pair of embossing rolls having a total area ratio of the leading end surface of the convex portion to the roll surface area (surface in a state where the convex portion is ignored) of 16% is used. A base cloth was obtained.

Example 3 The procedure of Example 1 was repeated except that needle punching was performed before passing through the hot pressing apparatus, the hot pressing conditions of the embossing roll were changed as follows, and the binder resin was not impregnated. Similarly, a tufted carpet base fabric was obtained.

That is, after obtaining a nonwoven web,
After dimethylpolysiloxane was applied and dried in the same manner as described above, the nonwoven web was passed through a needle punching machine in which needles of RPD36 # were implanted, and the needle density was 60 times / c.
Needle punching was performed at m ² . This needle-punched non-woven fabric has an arrangement density of convex portions heated to 200 ° C. of 100.
Pcs / cm ² , the surface area of the convex portion is 0.12 mm ² , and the total area ratio of the tip surface of the convex portion to the roll surface area (the surface in a state where the convex portion is ignored) is 12%. The needle-punched nonwoven fabric was compressed at a linear pressure of 50 kgf / cm to obtain a tufted carpet base fabric having an apparent density of 0.15 g / cm ³ .

Example 4 The needle-punched nonwoven fabric obtained in Example 3 was added
The arrangement density of the heated protrusions is 64 / cm ² , the surface area of the protrusions is 0.28 mm ² , and the total area ratio of the tip surface of the protrusions to the roll surface area (the surface in a state where the protrusions are ignored). Was passed through a hot pressing device consisting of 18% embossing rolls.
Further, an acrylic ester-based binder resin solution is prepared, and the above-mentioned nonwoven fabric is impregnated with the binder resin solution so that the solid content becomes 5% by weight. A base cloth for tufted carpet having m ² and an apparent density of 0.15 g / cm ³ was obtained.

Example 5 A non-woven web was used. Polyethylene terephthalate having a melting point of 256 ° C. was used as a high melting point component, and a melting point of 230 was used as a low melting point component.
Preparation of isophthalic acid 8 mol copolyester at ℃
A non-woven web was prepared by melt-spinning at a melting temperature of 285 ° C. using a core-shell type die at a core-sheath ratio (weight ratio) of 60/40, the embossing roll temperature was set to 200 ° C., and no binder resin was impregnated. Except for the above, a tufted carpet base fabric of the present invention was obtained in the same manner as in Example 1.

Example 6 A polymer constituting the nonwoven web was used.
Tufted carpet of the present invention in the same manner as in Example 5 except that polyethylene terephthalate at 56 ° C., 28 mol of adipic acid copolymerized polyester having a melting point of 195 ° C. as a low melting point component were prepared, and the embossing roll temperature was 170 ° C. A base fabric was obtained.

Comparative Example 1 The arrangement density of the projections was 44 / cm ² , and the surface area of the projections was 0.4.
14 mm ^2, except that using a tip surface embossing roll total area ratio of 6% of the projections with respect to the roll surface area (surface while ignoring the convex portion) is base fabric for tufted carpet in the same manner as in Example 1 I got

Comparative Example 2 The arrangement density of the projections was 22 pieces / cm ² , and the surface area of the projections was 0.
68mm ^2, except that the total area ratio of the front end surface of the convex portion with respect to the roll surface area (surface while ignoring convex portions) using 15% of the embossing roll, base fabric for tufted carpet in the same manner as in Example 1 I got

Comparative Example 3 The needle-punched nonwoven fabric obtained in Example 3 was provided with convex portions.
Installation density is 64 pieces / cm ^Two, The surface area of the projection is 0.42m
m^Two, The roll surface area (the surface without the protrusions)
Embossed with a total area ratio of 27%
Impregnated with binder resin
Except that the tufted camera was not
-A base fabric for pets was obtained.

Comparative Example 4 A tufted carpet base fabric having an apparent density of 0.1 g / cm ³ was obtained in the same manner as in Example 5, except that the surface temperature of the embossing roll was changed to 160 ° C.

The physical properties of the obtained tufted carpet base fabrics of Examples 1 to 6 and Comparative Examples 1 to 4 were measured, and the tufting described below was performed to evaluate the tufting properties. The results are shown in Table 1. Was. [Evaluation of Tuft Property] Obtained Examples 1 to 6 and Comparative Examples 1 to 4
Using a pile yarn made of 2800 denier nylon crimped yarn for the tufted carpet base fabric
Tufting was performed under the conditions of 0 threads / 1 inch, the number of stitches was 10/1 inch, and the height of the loop pile was 6 mm, and the following characteristics were evaluated.

(1) Tensile strength retention after tufting: After the tufting of the pile, the tensile strength (kg / 5 cm width) of the base fabric after tufting was measured by the method described above, and the strength retention after tufting was measured. It was calculated by the following equation. Tensile strength retention after tufting (%) = (tensile strength of base fabric after tufting / tensile strength of base fabric before tufting) × 100 The retention rate after tufting was determined and evaluated as the following three grades as retention after tufting. did. ：: 80% or more △: 55 to 80% ×: less than 55%

(2) Evaluation of Moiré Pattern: Judgment was made by visually observing the base fabric after tufting from all directions. ：: Moiré pattern not observed ×: Moiré pattern observed

(3) Evaluation of delamination: The pile was removed from the base fabric after tufting, and the state of the layers was visually determined. ○: No delamination at all ×: Layered separation or delamination

[0056]

[Table 1]

The tufted carpet base fabrics of Examples 1 to 6 are excellent in strength and stress at 10% elongation, and the base fabric can fix tufted piles efficiently and also has a high strength retention after tufting. It was good, there was no delamination, and no moiré phenomenon occurred.

When the pile yarn was removed from the base fabric of Example 1 and backing was carried out with a polyvinyl chloride paste, the backing agent had good permeability and good rigidity.

In Comparative Example 1, the pressure contact density was too low and the adhesion between the fibers was insufficient, the stress and strength at 10% elongation were low, the strength retention after tufting was poor, and delamination was observed. Was.

In Comparative Example 2, the area of the pressure contact was too large, and a moire pattern occurred at the tufting stage.

In Comparative Example 3, since the pressure contact area ratio was too large and the adhesion between the fibers was excessive, the degree of freedom of the fibers was lost.
The penetration resistance of the needle during tufting was large, the fibers were cut, and the retention after tufting was poor.

In Comparative Example 4, since the temperature of the embossing roll was low, it did not have a sufficient hot-press junction. When the physical properties of the base fabric were measured, the stress and tensile strength at 10% elongation were low. When the base fabric was tufted, the pile height was not uniform but uneven, and the so-called tuft was rough, resulting in poor appearance. Also, the retention after tufting was slightly lower.

Next, the tufting was performed on the tufted carpet base fabric of Example 1 by changing the gauge and stitch as shown in Table 2 among the tufting conditions, and the tufting property was evaluated. Table 2 shows the evaluation results.

[0064]

[Table 2]

The tufting property was good, and no delamination or moiré pattern occurred.

[0066]

According to the present invention, a long-fiber nonwoven fabric having a plurality of thermal compression point consists long fibers consisting of melting point 170 ° C. or more thermoplastic polymers, pressure point density of 50 / cm ² or more, pressure points The area is less than 0.4 mm ² and the pressed area ratio is 5
２０20% of footed carpet base fabric. That is, by setting the pressure contact density, pressure contact area, and pressure contact area ratio of the thermal pressure contacts of the tufted carpet base fabric in a specific range, the tensile strength and the modulus strength are excellent,
A product without delamination during tufting was obtained.

Further, by reducing the area of each pressure contact, at the time of tufting, a tuft needle is stuck into the pressure contact to form a hole in the pressure contact, and the pressure contact can contribute to the strength of the base cloth. Even if it disappears, since the pressure contact itself is small, the ratio of the pressure contact which contributes to the strength of the base fabric after tufting does not decrease, and the tensile strength and the stress at the time of elongation that can withstand in the secondary processing step can be maintained. However, for example, when the pressure contact area is large, when the tuft needle pierces the pressure contact, a hole is made in that part and the periphery thereof is also torn, so that the tufted pile yarn is easy to come off from the base cloth, Also, the pierced pressure contact itself cannot contribute to the strength of the base cloth, and after tufting, the ratio of the pressure contact area that contributes to the strength of the base cloth decreases, and as a result, the strength of the base cloth drops remarkably.

Further, since the pressure contact area is small, the pressure contact pattern is not conspicuous, the interference between the pressure contact of the base fabric and the arrangement of the pile yarns does not occur, no moire pattern is generated, and the appearance is excellent. Carpet is obtained.

Further, by limiting the apparent density of the base fabric to a specific range of 0.4 g / cm ³ or less, it is possible to reduce the penetration resistance of the tuft needle during tufting and to improve the tuft property. To play.

Claims (3)

[Claims] 1. A long-fiber non-woven fabric comprising a long fiber made of a thermoplastic polymer having a melting point of 170 ° C. or more and having a large number of hot-press contacts, a press-contact density of 50 / cm ² or more, and a press-contact area of 0.1 mm / cm ² or more. A base fabric for tufted carpet, characterized in that the base fabric has a press-bonded area ratio of less than 4 mm ² , a press-contact area ratio of 5 to 20%, and an apparent density of the nonwoven fabric of 0.4 g / cm ³ or less. 2. The toughness according to claim 1, wherein the long fiber is a composite fiber comprising a low melting point polymer and a high melting point polymer having a melting point higher than the melting point of the low melting point polymer by 20 ° C. or more. Base fabric for ted carpet. 3. The tufted carpet base fabric according to claim 1, wherein the long fiber nonwoven fabric is a needle punched nonwoven fabric.