JP2006175074A - Carpet hardly causing harmful gas - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carpet which has not only flame retardancy and fire-safety but also fire resistance and characteristics of hardly causing a harmful gas. <P>SOLUTION: The carpet A hardly causing the harmful gas is obtained by adhering a backing material layer 10 and a skin material layer 20 across an adhering material layer 30. The backing material layer 10 is a nonwoven fiber aggregate composed of fibers containing acrylic oxide fibers of 30 to 80 wt.% and synthetic fibers of 20 to 70 wt.%. The adhering material layer 30 consists of material hardly causing harmful gas composed of an EVA (ethylene-vinyl acetate) resin 32 containing a mesh base 31 composed of a polyester fiber. Regarding the skin material layer 20 composed of gray fiber, piles 22 are formed of pile yarns of 100% wool on the front surface of a primary ground fabric 21 consisting of a nonwoven fabric made of polyester fibers, and an adhesive 23 consisting of EV latex for preventing falling out of the yarns is applied to its rear surface. The carpet A hardly causing the harmful gas being the material hardly causing the harmful gas is composed of a carpet gray fiber to the front surface of which a liquid non-combustible agent is attached. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a carpet, and more particularly to a carpet that is flame resistant and flame retardant, and that hardly generates harmful gases even when heated.

  In order to reduce the damage caused by the occurrence of fire as much as possible, it has been proposed to use flame retardant and fire resistant materials for houses, furniture, rugs and the like.

  However, there is no end to human damage that has been delayed because houses, furniture, rugs, etc. have inhaled harmful gases generated by heating. Therefore, it is desired to use a flame retardant and fire resistant material that does not generate harmful gases. In particular, when a fire breaks out in a place where there is no escape, such as a ship, it will fall into a serious situation that will develop into a major disaster, so that not only flame resistance and fire resistance but also flame resistance and no harmful gases will be generated. There are strict standards.

  Accordingly, the present inventor has developed a carpet that is excellent in flame resistance as well as flame resistance and fire resistance and hardly generates harmful gases.

  The carpet having difficulty in generating harmful gas according to the present invention is formed by adhering a backing material layer and a skin material layer through an adhesive layer, and the backing material layer contains an oxidized acrylic fiber or carbon fiber and a synthetic fiber. It is a woven fiber assembly, wherein the adhesive layer and the skin layer are made of a material that generates no harmful gas.

  If comprised as mentioned above, the whole raw material will be a thing of the material which does not generate | occur | produce a harmful gas easily, and it will have flame resistance as well as flame retardance and fire resistance.

  Moreover, in the above-mentioned carpet that generates a harmful gas, the synthetic fiber combined with the backing material layer may be a fiber selected from the group consisting of polyester fiber and aramid fiber.

  In the present invention, the toxic gas-prone carpet refers to a carpet certified by a test method for smoke generation and combustion toxicity tests.

  If comprised in this way, the heat setting property will improve and since it will become a high density, the intensity | strength as a backing material will increase.

  And in the said noxious gas difficulty generating carpet, you may comprise so that an adhesive layer may consist of thermoplastic resin powder in which the mesh place which consists of polyester fiber was contained.

  If comprised in this way, adhesiveness will be favorable, dimensional stability will be high, and durability will increase.

  Further, in the above-mentioned carpet that generates a harmful gas, an adhesive for preventing a thread from coming off is formed on the surface of a primary base fabric made of polyester fiber non-woven fabric with a pile yarn of 100% wool. It is good also as a structure which is a carpet raw machine by which is applied.

  If comprised in this way, a skin material layer rich in cushioning properties can be obtained, and since the entire skin material layer is firmly integrated, thread dropout and breakage are unlikely to occur.

  Further, in each of the above-mentioned carpets that generate toxic gases, a liquid incombustible material may be attached to the surface of the skin material layer.

  If comprised in this way, nonflammability will improve further and a flame retardance, fire resistance, and flame resistance will improve further.

  Furthermore, it is good also as a structure formed by cutting said carpet which generate | occur | produces the noxious gas difficulty to predetermined size.

  If comprised in this way, it is convenient for laying a carpet, and it becomes possible to replace a carpet partially as needed.

  Moreover, the manufacturing method of the noxious gas difficulty generation carpet which concerns on this invention is manufactured by the following process AC.

  A. As the backing material, a non-woven fiber assembly is formed by intertwining fibers containing oxidized acrylic fibers or carbon fibers and synthetic fibers.

  B. As a skin material, a non-woven fabric made of polyester fiber is used as a primary base fabric, a pile is formed on the surface of the primary base fabric with a pile yarn of 100% wool, and an adhesive is applied to the back surface to prevent the thread from coming off. A carpet green machine is formed by adhering a liquid incombustible material to the surface.

  C. After spraying thermoplastic resin powder on the backing material and overlaying a mesh fabric made of polyester fiber, heating it to melt the thermoplastic resin powder, overlaying the skin material on it, pressurizing this Then, the shape and dimensions are stabilized by heating, and after pressing, the molten thermoplastic resin powder is solidified by cooling to bond the backing material and the skin material, and cut into a predetermined size.

  According to the present invention, it is possible to provide a carpet that has flame resistance as well as flame resistance and fire resistance and is less likely to generate harmful gases.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 1 is a partially cutaway perspective view of a carpet according to the present embodiment, FIG. 2 is a schematic sectional view of the carpet according to the present embodiment, and FIG. 3 shows a manufacturing process of the carpet according to the present embodiment. FIG.

  1 and 2, A indicates a carpet according to the present embodiment, and the carpet A is configured by bonding a backing material layer 10 and a skin material layer 20 via an adhesive material layer 30.

  The backing material layer 10 is a non-woven fiber assembly composed of fibers containing oxidized acrylic fibers and synthetic fibers.

  The oxidized acrylic fiber used for the backing material layer 10 is obtained by heat-treating a polyacrylonitrile (PAN) -based precursor fiber (precursor) in an oxidizing atmosphere. When this oxidized acrylic fiber is used, even if it ignites, the damage of the backing material itself due to combustion and melting is slight. In addition, since the oxidized acrylic fiber has appropriate strength and elongation, a non-woven fiber assembly can be formed in the manufacturing process.

  The non-woven fiber assembly in the present example uses a mixture of the above-mentioned oxidized acrylic fiber and synthetic fiber in order to enhance the heat setting property. In this manner, in the manufacturing process, heat setting is improved by shrinking and entanglement of the synthetic fiber by heating in the post-needling process, followed by pressure cooling, so that the density after pressing is kept high, and the dimensional stability At the same time, flame retardancy can be increased. Since the above-mentioned oxidized acrylic fiber alone is not sufficient in rigidity, it is difficult to maintain a high density state by itself, and the non-woven fiber assembly is maintained at a required density by blending synthetic fibers having high rigidity, and the backing Excellent performance as a material. Furthermore, the synthetic fiber is preferably a polyester fiber (including a heat-adhesive fiber), and when this fiber is used, sufficient heat setting properties can be obtained and relatively high heat resistance can be obtained. A disadvantage that impairs the heat resistance of the backing material can be avoided, and a backing material having a relatively high heat resistance such as a heat resistant temperature of 150 ° C. to 200 ° C. can be obtained.

  The blending ratio of the oxidized acrylic fiber and the synthetic fiber is desirably a weight ratio of 30 to 80% for the oxidized acrylic fiber and 20 to 70% for the synthetic fiber. When the blending ratio of the synthetic fiber is suppressed to such a level, a backing material can be obtained in which the heat setting property is remarkably improved without significantly reducing the flame resistance.

  If the backing material layer 10 of the carpet A is formed using the above-mentioned backing material, it has high flame resistance and flame resistance, so that no harmful gas is generated even when exposed to direct flame. In addition, since it does not burn by self-extinguishing instantaneously, it does not burn, so that even if an ignition occurs, damage due to combustion / melting of the backing material itself is minimal.

  The adhesive layer 30 is made of a harmful gas generation material made of EVA resin (ethylene-vinyl acetate resin) 32 in which a mesh base 31 made of polyester filament multifilament yarn is embedded.

  Since the polyester fiber has a high tensile strength and is difficult to stretch, a carpet A having high strength and excellent dimensional stability can be obtained.

  In addition, the mesh base 31 uses a plain weave made of multifilament yarns of polyester fibers, so that high strength and dimensional stability can be obtained in both the vertical and horizontal directions.

  When the adhesive layer of the carpet A is configured as described above, the adhesiveness is good due to the EVA resin 32, the tensile strength is large due to the mesh base 31 composed of the multifilament yarn of polyester fiber, and the dimensional stability is good. Carpet A having increased durability is obtained.

  In the skin material layer 20, a pile 22 is formed of a pile yarn of 100% wool on a surface of a primary base fabric 21 made of a polyester fiber nonwoven fabric, and an EVA (ethylene-vinyl acetate) latex is used on the back surface thereof to prevent the yarn from coming off. This is a carpet living machine made of a material that hardly generates harmful gas to which an adhesive 23 is applied.

  A liquid incombustible material is attached to the surface of the skin material layer 20 by spraying. As described above, when the skin material layer 20 of the carpet A is configured, a skin material layer having a high cushioning property is obtained, and the entire skin material layer is firmly integrated. In addition, nonflammability is further improved, and flame retardancy, fire resistance and flame resistance are improved.

  Next, based on FIG. 3, the process of manufacturing the carpet A of the present embodiment by bonding the backing material layer 10 and the skin material layer 20 configured as described above through the adhesive material layer 30 will be described.

  On the belt conveyor a, a long backing material 10 made of a non-woven fiber assembly made of fibers containing 30 to 80% by weight of oxidized acrylic fiber and 20 to 70% by weight of synthetic fiber made of polyester fiber is placed. It is transported at a constant speed from the left to the right in the figure.

  Next, the powder of the EVA resin 32 is spread on the backing material 10 on the belt conveyor a, and the powder is leveled with a doctor knife b. A mesh ground 31 made of polyester fibers is placed on the EVA resin 32 powder, which is averaged to a certain amount, and the EVA resin 32 powder sprayed on the backing material 10 is heated and melted using the heating device c.

  On this heat-melted EVA resin 32, a pile 22 is formed with a pile yarn of 100% wool on the surface of a primary base fabric 21 made of polyester fiber non-woven fabric. The surface of the skin material 20 coated with the agent 23 and having a liquid incombustible material attached thereto is pressurized with a pressure roll d.

  Thereafter, the polymer is heated through a dryer device e to stabilize the dimensions, is again pressurized with a pressure roll f in the dryer device e, is cooled with cold air with a cooling device g, and the molten powder is solidified with a cooling roll h. To do. Moreover, it cuts into tile carpet size with the cutting machine i as needed.

  In addition, Table 1 shows the test method of the smoke emission and combustion toxicity test and the test result of the measured toxic gas.

Test method The test is conducted according to Part 2 “Smoke and Combustion Toxicity Test” of “Code for Application of Fire Test Method (MSC 61 (67))” by the International Maritime Organization (IMO). A tile carpet (DS-TILE CARPET), ie the product described in the above example, was carried out as a specimen.

Test results Table 1 shows a summary of the test results and the reference values defined in the above test method. In accordance with the judgment criteria of Part 2 of the fire test method code, the above test specimens were judged to meet the smoke emission and toxicity standards of each material specified in the standards.

  Since the harmful gas flame generating carpet according to the present invention is excellent in flame retardancy, fire resistance and flame resistance, fire prevention of ships, airplanes, automobiles, etc. as well as places where fires are handled in ordinary households and factories where fires occur. Suitable for vehicles with severe standards.

It is a partially cutaway perspective view of a carpet according to an embodiment of the present invention. It is a schematic sectional drawing of the carpet based on the Example of this invention. It is the schematic which shows the manufacturing process of the carpet based on the Example of this invention.

Explanation of symbols

A ... Carpet 10 ... Backing material layer 20 .... Skin material layer 21 ... Primary base fabric 22 ... Pile 23 ... Adhesive 30 ... Adhesive material layer 31 ... Mesh 32 ... EVA resin a ...・ ・ Belt conveyor b ・ ・ ・ Doctor knife c ・ ・ ・ Heating device d ・ ・ ・ Pressure roll e ・ ・ ・ Dryer device f ・ ・ ・ Pressure roll g ・ ・ ・ Cooling device h ・ ・ ・ Cooling roll i ..Cutting machines

Claims (6)

  The backing material layer and the skin material layer are bonded via an adhesive layer, and the backing material layer is a non-woven fiber assembly containing oxidized acrylic fiber or carbon fiber and synthetic fiber, and the adhesive layer and A carpet for generating noxious gas flame, wherein the skin material layer is made of a noxious gas generating material.   The carpet for generating noxious gas according to claim 1, wherein the synthetic fiber combined with the backing material layer is a fiber selected from the group consisting of polyester fiber and aramid fiber.   The toxic gas flame generating carpet according to claim 1 or 2, wherein the adhesive layer is made of a thermoplastic resin powder in which a mesh ground made of polyester fiber is embedded.   It is a carpet raw machine in which a skin material layer is formed with a pile made of 100% wool pile yarn on the surface of a primary base fabric made of polyester fiber non-woven fabric, and an adhesive is applied to the back surface to prevent yarn from coming off. The toxic gas flame generating carpet according to any one of claims 1 to 3.   The toxic gas flame generating carpet according to any one of claims 1 to 4, wherein a liquid incombustible material adheres to the surface of the skin material layer.   6. A noxious gas flame generating carpet according to any one of claims 1 to 5, wherein the noxious gas flame generating carpet according to claim 1 is cut into a predetermined size.

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