Flame-retardant carpet made of nylon 6 pile, flame retardant, and method for manufacturing flame-retardant carpet

Abstract

Guanidine sulfamate or the like and a guanidine salt of an alkyl acidic phosphate ester are attached to achieve "flame retardancy imparted to a nylon 6 pile carpet" or the like. 【Solution means】The nylon 6 pile carpet 1 has a flame retardant X attached thereto, which is guanidine sulfamate as the first flame retardant X1 and a guanidine salt of an alkyl acidic phosphate ester as the second flame retardant X2. The base fabric 3 is made of polypropylene, and the first flame retardant X1 may also contain ammonium sulfate or the like. The ratio of the adhesion amounts of the first and second flame retardants X1 and X2 is 132:3 to 132:14. A penetrant Y such as acetylene glycol may also be attached. The flame retardant X has the first and second flame retardants X1 and X2. The first flame retardant X1 may also contain ammonium sulfate or the like, and the second flame retardant X2 may be a viscous substance at normal temperature. The manufacturing method of the carpet 1 may involve applying the flame retardant X, or the second flame retardant X2 may be a viscous substance at normal temperature, or the flame retardant X may be spray-coated.

Description

Technical Field

[0001] The present invention relates to a carpet (flame-retardant carpet) having a pile made of nylon 6 fibers and imparted with flame retardancy, a flame retardant, and a method for manufacturing the flame-retardant carpet.

Background Art

[0002] Conventionally, a flame-retardant tufted carpet has been known (Patent Document 1). This flame-retardant tufted carpet has a base fabric layer having a polypropylene fabric, a pile layer formed by adding a flame retardant to 66 nylon long fiber yarns and implanted on the surface of the base fabric layer, a flame-retardant rayon cotton layer disposed between the base fabric layer and the pile layer, and a back adhesive resin layer containing a flame-retardant resin disposed on the back surface of the base fabric layer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, in the pile layer of the flame-retardant tufted carpet described in Patent Document 1, long fiber yarns of 66 nylon (also referred to as "nylon 66") are used, but there are cases where piles are formed using nylon 6, which has a lower unit price. Comparing this nylon 6 with nylon 66, as shown in the following structural formulas (1) and (2), the number of "CH2", which is a part where a substance exhibiting flame retardancy is easily attached, is 10 in the structural formula (1) of nylon 66, but only 5 in the structural formula (2) of nylon 6. Therefore, a carpet having a pile made of fibers of nylon 6 resin (also referred to as "nylon 6 pile") is difficult to impart with flame retardancy.

[0005] [Chemistry]

[0006] [Chemistry]

[0007] Moreover, the differences in these structural formulas can also be said to appear as differences in melting points. Nylon 66 has a high melting point of 265°C, while nylon 6 has a low melting point of 225°C, which also makes it difficult to impart flame retardancy to carpets with nylon 6 pile.

[0008] In view of such points, the present invention provides a carpet having a pile of nylon 6 fibers, and by attaching sulfamic acid, which is a first flame retardant, Guanidine and a guanidine salt of an alkyl acidic phosphate ester, which is a second flame retardant, etc., to achieve "imparting flame retardancy to a carpet with nylon 6 pile", etc. The present invention aims to provide a carpet, a flame retardant, and a method for manufacturing a carpet. [Means for Solving the Problems]

[0009] The carpet 1 according to the present invention is a carpet in which a pile 2 is provided on a base fabric 3. The pile 2 is made of nylon 6 fibers, and at least the pile 2 is attached with a flame retardant X having a first flame retardant X1 and a second flame retardant X2. The first flame retardant X1 is a solid at room temperature contains sulfamic acid Guanidine and the second flame retardant X2 is a viscous substance at room temperature contains a guanidine salt of an alkyl acidic phosphate ester See, the ratio of the adhesion amounts of the first flame retardant X1 and the second flame retardant X2 is 132:3 to 132:14, and at least on the pile 2, a penetrant Y also adheres, and the penetrant Y contains an acetylene glycol-based penetrant which is the first feature.

[0010] The second feature of the carpet 1 according to the present invention is A carpet in which pile 2 is provided on a base fabric 3, wherein the pile 2 is made of nylon 6 fibers, and at least on the pile 2, a flame retardant X having a first flame retardant X1 and a second flame retardant X2 adheres, the first flame retardant X1 contains guanidine sulfamate which is a solid at room temperature, and the second flame retardant X2 contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous substance at room temperature that the base fabric 3 is made of polypropylene fibers, and the first flame retardant X1 is a solid at room temperature also contains a mixture of ammonium sulfate and , is a solid at room temperature a phosphorus-nitrogen-based onium salt, and the flame retardant X is attached to the pile 2 and the base fabric 3 , at least on the pile 2, a penetrant Y also adheres, and the penetrant Y contains an acetylene glycol-based penetrant which is the point.

[0011] The third feature of the carpet 1 according to the present invention is that, in addition to the above 2 feature, the ratio of the adhesion amount of the first flame retardant X1 to the second flame retardant X2 is 132:3 to 132:14. In addition, the numerical range of "132:3 to 132:14" in the present invention includes the boundary values of "132:3" and "132:14".

[0013] The flame retardant X according to the present invention is a flame retardant having a first flame retardant X1 and a second flame retardant X2, and the first flame retardant X1 is a solid at room temperature contains sulfamic acid Guanidine and the second flame retardant X2 is a viscous substance at room temperature contains a guanidine salt of an alkyl acidic phosphate ester See, the ratio of the dry weights of the first flame retardant X1 and the second flame retardant X2 is 132:3 to 132:14, and contains an acetylene glycol-based penetrant which is penetrant Y and is A flame retardant for nylon 6 characterized by the first feature.

[0014] The second feature of the flame retardant X according to the present invention is A flame retardant having a first flame retardant X1 and a second flame retardant X2, wherein the first flame retardant X1 contains guanidine sulfamate which is a solid at room temperature, the second flame retardant X2 contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous substance at room temperature, and the ratio of the wet weights of the first flame retardant X1 and the second flame retardant X2 is 25.000:0.568 to 25.000:2.652, and it is a flame retardant for nylon 6 containing an acetylene glycol-based penetrant which is penetrant Y A third feature of the flame retardant X according to the present invention is a flame retardant having a first flame retardant X1 and a second flame retardant X2, wherein the first flame retardant X1 contains guanidine sulfamate which is a solid at room temperature, and the second flame retardant X2 contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous substance at room temperature that the first flame retardant X1 is a solid at room temperature also contains a mixture of ammonium sulfate and , is a solid at room temperature a phosphorus-nitrogen-based onium salt See, and contains an acetylene glycol-based penetrant which is penetrant Y and is A flame retardant for nylon 6 characterized by this point.

[0016] The manufacturing method of the carpet 1 according to the present invention is a manufacturing method of a carpet in which the pile 2 is provided on the base fabric 3. The pile 2 is made of nylon 6 fiber, and at least the pile 2 is provided with a flame retardant X having a first flame retardant X1 and a second flame retardant X2. The first flame retardant X1 is a solid at room temperature contains sulfamic acid Guanidine and the second flame retardant X2 is a viscous substance at room temperature contains a guanidine salt of an alkyl acidic phosphate ester See, the ratio of the adhesion amounts of the first flame retardant X1 and the second flame retardant X2 is 132:3 to 132:14, and at least on the pile 2, a penetrant Y also adheres, and the penetrant Y contains an acetylene glycol-based penetrant and is characterized by the first feature.

[0017] The second feature of the manufacturing method of the carpet 1 according to the present invention is A method for manufacturing a carpet in which a pile 2 is provided on a base fabric 3, wherein nylon 6 fibers are used for the pile 2, and a flame retardant X having a first flame retardant X1 and a second flame retardant X2 is applied to at least the pile 2. The first flame retardant X1 contains guanidine sulfamate which is solid at normal temperature, and the second flame retardant X2 contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous substance at normal temperature. The base fabric 3 is made of polypropylene fibers. The first flame retardant X1 also contains a mixture of ammonium sulfate which is solid at normal temperature and a phosphorus-nitrogen-based onium salt which is solid at normal temperature. The flame retardant X adheres to the pile 2 and the base fabric 3, and a penetrant Y also adheres to at least the pile 2. The penetrant Y contains an acetylene glycol-based penetrant. characterized by this point. A third feature of the method for manufacturing the carpet 1 according to the present invention is that, in addition to the second feature, the ratio of the adhesion amount of the first flame retardant X1 to the second flame retardant X2 is 132:3 to 132:14.

[0018] The feature of the first 4 in the manufacturing method of the carpet 1 according to the present invention is that, in addition to the feature of the above first ~3 feature, the flame retardant X is applied to at least the pile 2 by spray coating.

[0019] Due to these features, in the nylon 6 pile carpet 1, by adhering (applying) a flame retardant X containing sulfamic acid as the first flame retardant X1 and a guanidine salt of an alkyl acidic phosphate ester as the second flame retardant X2, unlike Patent Document 1, not only sulfamic acid which is usually solid guanidine but also a guanidine salt of an alkyl acidic phosphate ester which is usually liquid is included. Therefore, the flame retardant X becomes sticky and adheres firmly to the pile 2 of nylon 6 with a small number of "CH2" and a low melting point, making it easier to impart flame retardancy. guanidine In addition, since the carpet 1 is a carpet with a pile made of nylon 6 fibers and imparted with flame retardancy, it can also be said to be a "flame retardant carpet with nylon 6 pile", and the manufacturing method of this carpet 1 can also be said to be a "manufacturing method of a flame retardant carpet".

[0020] Also, when polypropylene fibers with a low melting point and easy to burn are used for the base fabric 3 in the nylon 6 pile carpet 1, even if the combustion of the nylon 6 pile 2 is suppressed, there may be a two-stage combustion such as the subsequent combustion of the polypropylene fiber base fabric 3 starting. Even in this case, by further including ammonium sulfate and a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt as the first flame retardant X1, the combustion of the polypropylene fiber base fabric 3 can be suppressed, and as a result, flame retardancy can be imparted to the entire nylon 6 pile carpet 1.

[0021] guanidine Furthermore, sulfamic acid which is usually solid guanidine If the adhesion amount of the first flame retardant X1 such as is too large, the carpet 1 will turn white (the state where white powder is powdery). On the other hand, if the second flame retardant X2, which is usually a guanidine salt of an alkyl acidic phosphate ester in liquid form, is too much, tack (stickiness) may occur on the pile surface. Even in this case, by setting the ratio of the adhesion amounts of the first flame retardant X1 and the second flame retardant X2 to 132:3 to 132:14, in the carpet 1, both "whitening suppression" and "tack reduction" can be achieved.

[0022] In addition, by attaching the penetrant Y of the acetylene glycol-based penetrant to the nylon 6 pile carpet 1, the flame retardant X adheres more firmly not only to the tip side of the pile 2 but also to the base fabric 3 side of the pile 2. Therefore, even if the adhesion amount of the flame retardant X is not so large, the nylon 6 pile carpet 1 can be imparted with flame retardancy and "whitening suppression" etc. can be realized.

[0023] On the other hand, in the flame retardant X, guanidine By having the first flame retardant X1 containing sulfamic acid and the second flame retardant X2 containing a guanidine salt of an alkyl acidic phosphate ester, the flame retardant X becomes sticky and adheres firmly to the nylon 6 pile 2, making it easier to impart flame retardancy. Also, in the flame retardant X, since the first flame retardant X1 further contains ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt, even when the base fabric 3 uses polypropylene fibers and a two-stage combustion occurs where the combustion of the nylon 6 pile 2 is suppressed first and then the base fabric 3 of the polypropylene fibers starts to burn, the combustion of the base fabric 3 of the polypropylene fibers can be suppressed and flame retardancy can be imparted to the entire nylon 6 pile carpet 1. Furthermore, in the flame retardant X, since the second flame retardant X2 is a viscous substance (also referred to as a viscous body or viscous liquid) at room temperature as a whole including the guanidine salt of alkyl acidic phosphate ester, the entire flame retardant X becomes sticky, making it easier to impart flame retardancy to the carpet 1 such as nylon 6 pile. This is the same when the second flame retardant X2 is a viscous substance at room temperature in the manufacturing method of the nylon 6 pile carpet 1. In addition, in the manufacturing method of the nylon 6 pile carpet 1, when the carpet 1 is larger than a predetermined size, it may not enter the impregnation tank and it may not be possible to impregnate and impart the flame retardant X. Even in this case, by spray-applying the flame retardant X to the carpet 1, it becomes possible to impart the flame retardant X regardless of the size of the carpet 1.

Advantages of the Invention

[0024] According to the carpet, flame retardant, and manufacturing method of the carpet according to the present invention, by attaching sulfamic acid, which is the first flame retardant, guanidine and the guanidine salt of alkyl acidic phosphate ester, which is the second flame retardant, etc., it is possible to achieve "imparting flame retardancy to a nylon 6 pile carpet" and the like.

Brief Description of the Drawings

[0025]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0026] <Overall Structure of Carpet 1> Hereinafter, embodiments of the present invention will be described with reference to the drawings. In FIGS. 1 and 2, a carpet 1 according to the present invention is shown, and this carpet 1 has a pile 2 and a base fabric 3 which will be described later. At least the pile 2 of the carpet 1 has a flame retardant X attached thereto. The carpet 1 may have a penetrant Y (applied) attached thereto which will be described later, and in addition, may have a back coat portion 10 which will be described later. The "surface (fabric surface) 1a" of the carpet 1 in the present invention can also be said to be the surface on the side that is exposed when used for interior materials of railway vehicles and the like, seat covers covering seats (chairs), and the like. Conversely, the "back surface (fabric back surface) 1b" of the carpet 1 in the present invention can also be said to be the surface on the side that is not exposed when used for interior materials of railway vehicles and the like, seats, and the like.

[0027] The carpet 1 may have any configuration, for example, a pile fabric having warp and weft threads, a pile knitted fabric having only warp or only weft threads, a tufted carpet (tufted carpet) in which the pile 2 is implanted (tufted) on the base fabric 3, and the like. In particular, when the carpet 1 is a pile fabric, it may have any configuration. For example, a woven fabric woven with warp and weft threads in plain weave, twill weave, or satin weave may be used as the base fabric 3, and the pile yarn may be woven in the warp direction or the weft direction together with this base fabric 3 to form the pile 2. Incidentally, a pile fabric woven with pile yarn in the warp direction is also called a warp pile fabric, and a pile fabric woven with pile yarn in the weft direction is also called a weft pile fabric. Even when the carpet 1 is a pile knitted fabric, it may have any configuration. For example, a pile knit (a kind of weft knit which is a variation of plain knit, also called a pile loop knit or a plush knit) knitted with weft threads may be used. In this pile knit, pile yarn is added and knitted to the weft threads which are ground yarns, and the sinker loops of this pile yarn are enlarged to form the pile 2, and the plain knit ground woven with the weft threads of the ground yarn becomes the base fabric 3.

[0028] The thickness of the carpet 1 is not particularly limited. For example, it may be 1 mm or more and 100 mm or less. More specifically, the lower limit value may be 1 mm or more, preferably 3 mm or more, more preferably 5 mm or more, and the upper limit value may be 100 mm or less, preferably 70 mm or less, more preferably 40 mm or less. In addition, any of the lower limit values of this thickness may be combined with any of the upper limit values. In addition, the density of the yarn used for the carpet 1 is not particularly limited. However, when the carpet 1 is the above-mentioned warp pile fabric, the density of the pile yarn (pile 2) woven in the warp direction in the carpet 1 may be, for example, 50 yarns / 10 cm or more and 260 yarns / 10 cm or less. More specifically, the lower limit value may be 50 yarns / 10 cm or more, preferably 60 yarns / 10 cm or more, more preferably 70 yarns / 10 cm or more, and the upper limit value may be 260 yarns / 10 cm or less, preferably 240 yarns / 10 cm or less, more preferably 220 yarns / 10 cm or less. In addition, any of the lower limit values of this density may be combined with any of the upper limit values. Also, when the carpet 1 is a pile fabric, the density of the weft yarn forming the base fabric 3 may be, for example, 100 yarns / 10 cm or more and 260 yarns / 10 cm or less. More specifically, the lower limit value may be 100 yarns / 10 cm or more, preferably 120 yarns / 10 cm or more, more preferably 140 yarns / 10 cm or more, and the upper limit value may be 260 yarns / 10 cm or less, preferably 240 yarns / 10 cm or less, more preferably 220 yarns / 10 cm or less. In addition, any of the lower limit values of this density may be combined with any of the upper limit values. The basis weight of the carpet 1 is not particularly limited. For example, it may be 300 g / m 2 or more and 3000 g / m 2 or less. More specifically, the lower limit value may be 300 g / m 2 or more, preferably 450 g / m 2 or more, more preferably 600 g / m 2 or more, and the upper limit value may be 3000 g / m 2 or less, preferably 2000 g / m 2 or less, more preferably 1500 g / m 2The following (1018 g / m 2 etc.) may also be acceptable. Incidentally, each lower limit value of this basis weight may be combined with any of the upper limit values. Also, the basis weight, the adhesion amount, and the application amount (g / m 2 ) in the present invention usually mean values based on the dry weight. Hereinafter, carpet 1 will be mainly described as being a pile fabric (Axminster carpet) 1.

[0029] <Pile 2> As shown in FIGS. 1 and 2, pile 2 is provided on a base fabric 3 described later, and pile 2 may stand upright from base fabric 3. Pile 2 is made of nylon 6 fibers and has a flame retardant X described later attached thereto. Here, nylon 6 fibers (fibers of nylon 6 resin) are represented by the following structural formula (2) and are shown as follows.

[0030]

Chemical formula

[0031] This nylon 6 resin is a polymer having an amide bond in the repeating unit of the main chain (specifically, having "-C(=O)NH-" formed by the bond between one -C(=O)- part and the other -NH- part among adjacent repeating units), and is synthesized by ring-opening polymerization of caprolactam obtained by condensing and cyclizing a carboxylic acid amine as a raw material, and is also called a polyamide resin. Since the nylon 6 resin uses a carboxylic acid amine as a raw material, it is called an n-type. In the repeating unit, a total of 6 carbon atoms are included, which are 1 carbon atom of the -C(=O)- part and 5 carbon atoms of the -(CH2)5- part between the -C(=O)- part and the -NH- part. Therefore, it is a 6-type polyamide resin (nylon resin) and is named nylon 6 resin. On the other hand, nylon 66 is represented by the following structural formula (1) and is shown as follows.

[0032]

Chemical formula

[0033] This nylon 66 resin is also a polymer having an amide bond in the repeating unit of the main chain (specifically, having "-C(=O)NH-" in the center of the repeating unit and "-C(=O)NH-" formed by the bonding of one -C(=O)- part and the other -NH- part among adjacent repeating units). It is synthesized by condensation polymerization of a dicarboxylic acid and a diamine as raw materials, and is also called a polyamide resin. Since the nylon 66 resin uses a dicarboxylic acid and a diamine as raw materials, it is called the m,n type. In the repeating unit, a total of six carbon atoms in the -(CH2)6- part between two -NH- parts, six carbon atoms in the -(CH2)4- part between two -C(=O)- parts and those two -C(=O)- parts, so it has six and six carbon atoms, and thus is a 6,6 type nylon resin (polyamide resin), which is named nylon 66 resin.

[0034] In addition, the statement "pile 2 uses nylon 6 fibers" in the present invention means that at least nylon (polyamide) 6 fibers are used in pile 2. It does not only mean that only nylon 6 fibers are used, but also that fibers other than nylon 6 fibers may be used together with nylon 6 fibers. Here, fibers other than nylon 6 fibers include, for example, polyethylene terephthalate (PET) fibers which are thermoplastic fibers, and other fibers having an ester bond such as polytrimethylene terephthalate (PTT) fibers and polybutylene terephthalate (PBT) fibers. Additionally, polyolefin-based fibers such as polyethylene (PE) fibers and polypropylene (PP) fibers, rayon fibers, cupra fibers, acetate fibers, acrylic fibers mainly composed of polyacrylonitrile (PAN), polyvinyl alcohol (PVA) fibers (vinylon fibers), polyurethane (PU) fibers and other synthetic fibers may also be used. Moreover, glass fibers, wool, silk, etc. can be used, and these can be used alone or in combination. The following describes pile 2 as mainly using only nylon 6 fibers.

[0035] The yarn of such pile 2 may be multifilament yarn, monofilament yarn, or spun yarn. Moreover, the fineness of the fiber constituting pile 2 is not particularly limited. For example, in terms of the total fineness, it may be 20 dtex or more and 3000 dtex or less. More specifically, the lower limit value may be 20 dtex or more, preferably 50 dtex or more, and more preferably 100 dtex or more, and the upper limit value may be 3000 dtex or less, preferably 2000 dtex or less, and more preferably 1000 dtex or less. When the fiber constituting pile 2 is multifilament, the fineness of each filament is not particularly limited either. For example, it may be 0.1 dtex or more and 50.0 dtex or less. More specifically, the lower limit value may be 0.1 dtex or more, preferably 0.5 dtex or more, and more preferably 1.0 dtex or more, and the upper limit value may be 50.0 dtex or less, preferably 30.0 dtex or less, and more preferably 15.0 dtex or less. Incidentally, each lower limit value of these total fineness and single-filament fineness may be combined with any of the upper limit values. Pile 2 may be cut pile with its tip cut to form a feather shape, or loop pile formed by loops between adjacent piles 2. The following describes pile 2 mainly as cut pile.

[0036] The pile length of pile 2 is not particularly limited. For example, it may be 0.5 mm or more and 10.0 mm or less. More specifically, the lower limit value may be 0.5 mm or more, preferably 1.0 mm or more, and more preferably 2.0 mm or more, and the upper limit value may be 10.0 mm or less, preferably 8.0 mm or less, and more preferably 6.0 mm or less. Incidentally, each lower limit value of this pile length may be combined with any of the upper limit values. The pile height means the height from the surface of the base fabric 3 of the carpet 1 to the tip of the pile 2. More specifically, when the pile 2 stands upright (substantially upright) at a substantially right angle (substantially 90°) to the base fabric 3 (the angle θ formed by the pile 2 and the base fabric 3 is substantially 90°), it can be said that it is substantially equal to the pile length of the pile 2. Also, when the pile 2 is erected obliquely with respect to the base fabric 3 (the angle θ formed by the pile 2 and the base fabric 3 is less than 90° (for example, 80°, 70°, 60°, 45°, etc.)), the pile height is approximately equal to the pile length × sinθ. Such a pile height is not particularly limited, but for example, it may be 0.5 mm or more and 10.0 mm or less. More specifically, the lower limit value may be 0.5 mm or more, preferably 1.0 mm or more, and more preferably 2.0 mm or more, and the upper limit value may be 10.0 mm or less, preferably 8.0 mm or less, and more preferably 6.0 mm or less. Incidentally, each lower limit value of this pile height may be combined with any of the upper limit values. The basis weight of the pile 2 is not particularly limited, but for example, it may be 200 g / m 2 or more and 2500 g / m 2 or less. More specifically, the lower limit value may be 200 g / m 2 or more, preferably 350 g / m 2 or more, and more preferably 500 g / m 2 or more, and the upper limit value may be 2500 g / m 2 or less, preferably 2000 g / m 2 or less, and more preferably 1500 g / m 2 or less (such as 907 g / m 2 ). Incidentally, each lower limit value of this basis weight may be combined with any of the upper limit values.

[0037] <Base fabric 3> As shown in FIGS. 1 and 2, the base fabric 3 is provided with the above-described pile 2, and the pile 2 may stand upright from the base fabric 3. The base fabric 3 is made of polypropylene (PP) fibers, and may be adhered with a flame retardant X described later. Incidentally, "the base fabric 3 is made of polypropylene fibers" in the present invention means that at least polypropylene (PP) fibers are used in the base fabric 3, and not only polypropylene fibers are used, but also fibers other than polypropylene fibers may be used together with the polypropylene fibers. Here, examples of fibers other than polypropylene fibers include thermoplastic fibers such as polyethylene terephthalate (PET) fibers, and other fibers having an ester bond such as polytrimethylene terephthalate (PTT) fibers and polybutylene terephthalate (PBT) fibers. Additionally, nylon (polyamide) fibers such as nylon 6 fibers, nylon 66 fibers, nylon 11 fibers, and nylon 12 fibers, polyolefin fibers such as polyethylene (PE) other than polypropylene (PP) fibers, rayon fibers, cupra fibers, acetate fibers, acrylic fibers mainly composed of polyacrylonitrile (PAN), polyvinyl alcohol (PVA) fibers (vinylon fibers), polyurethane (PU) fibers, and other synthetic fibers. Moreover, glass fibers, wool, silk, etc. These may be used alone or in combination. The following describes the case where the base fabric 3 mainly uses only polypropylene fibers.

[0038] The yarns of such a base fabric 3 may be multifilament yarns, monofilament yarns, or spun yarns. Also, the fineness of the fibers constituting the base fabric 3 may be any value. For example, in terms of the total fineness, it may be 20 dtex or more and 3000 dtex or less. More specifically, the lower limit value may be 20 dtex or more, preferably 50 dtex or more, more preferably 100 dtex or more, and the upper limit value may be 3000 dtex or less, preferably 2000 dtex or less, more preferably 1000 dtex or less. When the fibers constituting the base fabric 3 are multifilament, the single fiber fineness of each filament is not particularly limited. For example, it may be 0.1 dtex or more and 50.0 dtex or less. More specifically, the lower limit value may be 0.1 dtex or more, preferably 0.5 dtex or more, more preferably 1.0 dtex or more, and the upper limit value may be 50.0 dtex or less, preferably 30.0 dtex or less, more preferably 15.0 dtex or less. Incidentally, any combination of the lower limit values and upper limit values of these total fineness and single fiber fineness is acceptable.

[0039] As described above, the base fabric 3 is a woven fabric, knitted fabric, or the like composed of warp and weft threads, and is in a sheet shape. Here, the "surface (base fabric surface) 3a" of the base fabric 3 in the present invention can also be said to be a surface close to the surface 1a that is exposed when the carpet 1 is used to cover the interior of a railway vehicle or the like, and the pile 2 is provided on this surface 3a side. Conversely, the "back surface (base fabric back surface) 3b" of the base fabric 3 in the present invention can also be said to be a surface close to the back surface 1b that is not exposed when the carpet 1 is used to cover the interior of a railway vehicle or the like (if the carpet 1 does not have the back coat portion 10, it is so to speak, the back surface 1b of the carpet 1 itself). The thickness of the base fabric 3 is not particularly limited, but for example, it may be 0.1 mm or more and 2.0 mm or less. More specifically, the lower limit value may be 0.1 mm or more, preferably 0.2 mm or more, more preferably 0.5 mm or more, and the upper limit value may be 2.0 mm or less, preferably 1.5 mm or less, more preferably 2.0 mm or less. Incidentally, each of these lower limit values of the thickness may be combined with any of the upper limit values. The basis weight of the base fabric 3 is not particularly limited, but for example, it may be 50 g / m 2 or more and 500 g / m 2 or less. More specifically, the lower limit value may be 50 g / m 2 or more, preferably 60 g / m 2 or more, more preferably 70 g / m 2 or more, and the upper limit value may be 500 g / m 2 or less, preferably 200 g / m 2 or less, more preferably 140 g / m 2 or less (such as 111 g / m 2 ). Incidentally, each of these lower limit values of the basis weight may be combined with any of the upper limit values.

[0040] <Flame retardant X> As shown in FIGS. 1 and 2, the flame retardant X is at least attached to the above-described pile 2, and may also be attached to the above-described base fabric 3. The flame retardant X has (contains) a first flame retardant X1 and a second flame retardant X2 described later. The flame retardant X may be in a colloidal state as a whole. Here, "colloidal state" in the present invention means a state like glue (regardless of the substances contained in the functional agent K), or a state of a highly viscous liquid. In addition, it can also be said to be gelatinous, jelly-like, gel-like, or jel-like. Further, the whole flame retardant X may be in a state of a dispersion liquid mixed with a penetrant Y or the like described later and dispersed in a dispersion medium such as water, or in a state of a dispersion liquid in which only the flame retardant X is dispersed in the dispersion medium without being mixed with the penetrant Y or the like.

[0041] The adhesion amount (also referred to as the application amount or coating amount) of the whole flame retardant X is not particularly limited. For example, in terms of dry weight, it may be 1.00 g / m 2 or more and 300.00 g / m 2 or less. More specifically, the lower limit value may be 1.00 g / m 2 or more, preferably 20.00 g / m 2 or more, more preferably 40.00 g / m 2 or more, and the upper limit value may be 300.00 g / m 2 or less, preferably 200.00 g / m 2 or less, more preferably 100.00 g / m 2 or less (40.00 g / m 2 or 52.80 g / m 2 or 66.00 g / m 2 or 67.32 g / m 2 or 67.95 g / m 2 or 69.30 g / m 2 or 71.28 g / m 2 or 72.60 g / m 2 or 75.90 g / m 2 or 89.10 g / m 2 or 132.00 g / m 2 etc.). The lower limit values of the adhesion amount of this dry weight may be combined with any of the upper limit values. Such a flame retardant X may be present discretely, in an island-like form in a sea-island structure, or in a substantially planar form of a predetermined size, when viewed in the normal direction of the fiber surface on the fiber surface of the fibers used in the pile 2 and the base fabric 3 of the carpet 1.

[0042] <First flame retardant X1> The first flame retardant X1 is a part of the above-mentioned flame retardant X and contains at least sulfamic acid guanidine (CH5N3·HSO3NH2). The first flame retardant X1 may also contain ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based (such as calcium-based) onium salt. That is, the first flame retardant X1 contains at least sulfamic acid guanidine and may further contain ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt. Note that the first flame retardant X1 may consist only of sulfamic acid guanidine or may consist of sulfamic acid guanidine and ammonium sulfate, or may consist of sulfamic acid guanidine and a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt. As a whole, the first flame retardant X1 may be solid at normal temperature (such as 20°C, 25°C, or between 20°C and 25°C). When the first flame retardant X1 is solid at normal temperature, at least sulfamic acid guanidine is solid at normal temperature (specifically, white lumps, etc.), and when ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt is included, ammonium sulfate, etc. may also be solid at normal temperature (specifically, orthorhombic crystals, granular crystals, etc.). Also, it can be said that the first flame retardant X1 is solid at the above-mentioned normal temperature and normal pressure (ordinary atmospheric pressure, such as 1 atm).

[0043] When the first flame retardant X1 is solid at room temperature, the first flame retardant X1 may be pulverized and in a particulate form, and the particulate form may be substantially spherical, or may be in the form of a lump, polyhedron, plate, needle, etc. When the first flame retardant X1 is solid at room temperature and in a particulate form and the particulate form is substantially spherical, its average particle diameter is not particularly limited, but may be, for example, 0.10 μm or more and 1.60 μm or less. More specifically, the lower limit value may be 0.10 μm or more, preferably 0.20 μm or more, more preferably 0.30 μm or more, and the upper limit value may be 1.60 μm or less, preferably 1.20 μm or less, more preferably 0.80 μm or less. Incidentally, each lower limit value of this average particle diameter may be combined with any of the upper limit values. When the first flame retardant X1 is solid at room temperature and in a particulate form, the first flame retardant X1 may be attached to the above-described pile 2 or base fabric 3 in a state of a solution dissolved in water or an organic solvent. The amount of adhesion (also referred to as the amount applied or the coating amount) of the first flame retardant X1 is not particularly limited, but may be, for example, 5.00 g / m 2 or more and 300.00 g / m 2 or less in terms of dry weight. More specifically, the lower limit value may be 5.00 g / m 2 or more, preferably 10.00 g / m 2 or more, more preferably 20.00 g / m 2 or more, and the upper limit value may be 300.00 g / m 2 or less, preferably 200.00 g / m 2 or less, more preferably 100.00 g / m 2 or less (40.00 g / m 2 or 52.80 g / m 2 or 66.00 g / m 2 or 82.50 g / m 2 or 132.00 g / m 2 etc.). Incidentally, each lower limit value of this dry weight adhesion amount may be combined with any of the upper limit values. When such a first flame retardant X1 is applied to the pile 2 or the base fabric 3 and adheres to the fiber surface used in the pile 2 or the base fabric 3, if the first flame retardant X1 is solid at normal temperature (or normal pressure) and in particle form, it can be said that it adheres to the fiber surface in the state of its particle form, directly or via the second flame retardant X2 described later (see Fig. 1).

[0044] <The second flame retardant X2> The second flame retardant X2 is a part of the above-described flame retardant X and contains at least a guanidine salt of an alkyl acidic phosphate ester. Incidentally, the second flame retardant X2 may consist only of a guanidine salt of an alkyl acidic phosphate ester. As a whole, the second flame retardant X2 may be liquid at normal temperature (such as 20 °C, 25 °C, 20 °C or more and 25 °C or less), and furthermore, it may be a viscous body (also referred to as a viscous body or a viscous liquid) at normal temperature. Also, it can be said that the second flame retardant X2 is a liquid (especially a viscous body) at the above-described normal temperature and normal pressure (ordinary atmospheric pressure, such as 1 atm). When the second flame retardant X2 is liquid at normal temperature, the second flame retardant X2 may be mixed with a solution obtained by dissolving the first flame retardant X1, which is solid at normal temperature and in particle form, in a solvent, and adhered to the above-described pile 2 or base fabric 3. The adhesion amount (also referred to as the application amount or coating amount) of the second flame retardant X2 is not particularly limited. For example, in terms of dry weight, it may be 0.10 g / m 2 or more and 30.00 g / m 2 or less. More specifically, the lower limit value may be 0.10 g / m 2 or more, preferably 1.00 g / m 2 or more, more preferably 1.50 g / m 2 or more, and the upper limit value may be 30.00 g / m 2 or less, preferably 20.00 g / m 2 or less, more preferably 10.00 g / m 2 or less (1.38 g / m 2 or 1.98 g / m 2 or 3.30 g / m 2 or 5.28 g / m 2 or 6.60 g / m 2, 9.90 g / m 2 It may be any of them (such as...). In addition, each lower limit value of the adhesion amount of this dry weight may be combined with any of the upper limit values. When such a second flame retardant X2 is applied to the pile 2 or the base fabric 3 and adheres to the fiber surface used in the pile 2 or the base fabric 3, if the second flame retardant X2 is a liquid (especially a viscous body) at normal temperature (or normal pressure), it can be said that it adheres to the fiber surface in a substantially layered manner in a side cross-sectional view and in an island shape in the sea-island or in a substantially planar shape of a predetermined size in a view in the normal direction of the fiber surface (see Fig. 1).

[0045] <Ratio of the adhesion amounts of the flame retardants X1 and X2> The ratio of the adhesion amount (or application amount or coating amount) of the first flame retardant X1 and the second flame retardant X2 described so far is not particularly limited. For example, it may be 132:3 to 132:14 (in other words, 132 / 14 (≈9.429) or more and 132 / 3 (=44.000) or less). More specifically, the lower limit value may be 132 / 14 or more, preferably 10.000 (=132 / 13.2) or more, and more preferably 11.000 (=132 / 12) or more, and the upper limit value may be 132 / 3 (=44.000) or less, preferably 40.000 (=132 / 3.3) or less, and more preferably 30.000 (=132 / 4.4) or less (such as 12.500). In addition, each lower limit value of the ratio of the adhesion amounts of the flame retardants X1 and X2 may be combined with any of the upper limit values.

[0046] <Other flame retardants> The flame retardant X is sulfamic acid, which is the specific flame retardant described above. guanidine It may also contain ammonium sulfate, a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt, or a flame retardant other than the guanidine salt of an alkyl acidic phosphate ester. For example, the flame retardant X may contain an alkyl metal phosphate such as aluminum tris(diethylphosphate), aluminum tris(methylethylphosphate), or aluminum tris(diphenylphosphate). In addition, the flame retardant X may contain ammonium polyphosphate, phosphorus-based flame retardants such as phosphate esters and tris(1-chloro-2-propyl) phosphate, metal hydroxide-based flame retardants such as aluminum hydroxide and magnesium hydroxide, non-halogen-based flame retardants, silicone resins, and the like. These flame retardants may be solid at normal temperature (or normal pressure), and in that case, they may be included in the first flame retardant X1. Also, these flame retardants may be liquid or viscous at normal temperature (or normal pressure), and in that case, they may be included in the second flame retardant X2.

[0047] <Penetrant Y> As shown in FIGS. 1 and 2, the penetrant Y is at least attached to the above-described pile 2 and may also be attached to the above-described base fabric 3. The penetrant Y contains at least an acetylene glycol-based penetrant. Here, the "acetylene glycol-based penetrant" in the present invention may be only acetylene glycol, or may be only an acetylene glycol derivative, or may be acetylene glycol and an acetylene glycol derivative. Incidentally, acetylene glycol can also be said to be a nonionic surfactant or the like. Also, the acetylene glycol derivative can be said to be an acetylene glycol EO adduct in which 10 to 80% of ethylene oxide (EO) is added to acetylene glycol. In addition to the above-described acetylene glycol-based penetrant, the penetrant Y may contain a nonionic surfactant such as polyoxyalkylene alkyl ether. Also, the penetrant Y can be said to be liquid at the above-described normal temperature and normal pressure (ordinary atmospheric pressure, such as 1 atm). The amount of attachment (also referred to as the amount applied or the coating amount) as the penetrant Y is not particularly limited. For example, in terms of dry weight, it may be 0.01 g / m 2 or more and 5.00 g / m 2 or less. More specifically, the lower limit value is 0.01 g / m 2 or more, preferably 0.05 g / m 2More preferably, it is 0.10 g / m or more 2 or more, and the upper limit value is 5.00 g / m or less 2 Preferably, it is 2.00 g / m or less 2 More preferably, it is 1.00 g / m or less 2 (0.40 g / m or 2 0.50 g / m, etc.) is also acceptable. Incidentally, each lower limit value of this adhesion amount may be combined with any of the upper limit values 2 The penetration agent Y described so far can be said to at least reduce the contact angle between the fiber back surface of the pile 2 and the flame retardant X, and promote wetting and penetration in the flame retardant imparting step P1 and the like described later (see Fig. 2, etc.) When such a penetration agent Y is applied to the pile 2 or the base fabric 3 and adheres to the fiber surface used in the pile 2 or the base fabric 3, if the penetration agent Y is liquid at normal temperature (or normal pressure), it can be said that it adheres to the fiber surface in a substantially layered manner in a side cross-sectional view and in an island shape in the sea-island or in a substantially planar shape of a predetermined size in a normal direction view of the fiber surface (see Fig. 1).

[0048] <Back coat portion 10> As shown in Figs. 1 and 2, the back coat portion 10 is a portion where a backing material (backing agent) is applied (back-coated) to the back surface 3b of the base fabric 3 described above, and may be in a layered form with a predetermined thickness The backing material of the back coat portion 10 is not particularly limited. For example, it may contain synthetic rubbers such as styrene butadiene rubber (SBR) and butadiene rubber (BR), and rubbers such as natural rubber (NR), or may contain urethane resins, vinyl chloride resins, etc. It may also contain a filler (for example, calcium carbonate (CaCO3), etc., also referred to as a filler). In addition, the backing material may contain a thickener (for example, resins such as acrylic acid and hydroxyethyl cellulose (HEC)), ammonia, or a cross-linking agent, etc ​Furthermore, if the backing material is a mixture of a plurality of materials, it is also called a compound. Also, the backing material may be applied in a latex state.

[0049] Here, the "surface (back coat surface) 10a" of the back coat portion 10 in the present invention can be said to be a surface close to the surface 1a that is exposed when the carpet 1 is used to cover the interior of a railway vehicle or the like, and it can also be said that the base fabric 3 is provided on the surface 10a side. Conversely, the "back surface (back coat back surface) 10b" of the back coat portion 10 in the present invention can be said to be a surface close to the back surface 1b that is not exposed when the carpet 1 is used to cover the interior of a railway vehicle or the like (if the carpet 1 has the back coat portion 10, it is so to speak, the back surface 1b of the carpet 1 itself). The adhesion amount of the entire backing material in the back coat portion 10 is not particularly limited. For example, in terms of dry weight, it may be 300 g / m 2 or more and 3000 g / m 2 or less. More specifically, the lower limit value may be 300 g / m 2 or more, preferably 600 g / m 2 or more, more preferably 900 g / m 2 or more, and the upper limit value may be 3000 g / m 2 or less, preferably 2000 g / m 2 or less, more preferably 1500 g / m 2 or less (such as 1285 g / m 2 or 1299 g / m 2 etc.). Furthermore, each lower limit value of this adhesion amount may be combined with any of the upper limit values. The thickness of the back coat portion 10 is not particularly limited. For example, it may be 0.1 mm or more and 10.0 mm or less. More specifically, the lower limit value may be 0.1 mm or more, preferably 0.5 mm or more, more preferably 1.0 mm or more, and the upper limit value may be 10.0 mm or less, preferably 5.0 mm or less, more preferably 3.0 mm or less. Furthermore, each lower limit value of this thickness may be combined with any of the upper limit values. Next, the method for manufacturing the carpet 1 described so far will be explained in detail.

[0050] <Method for manufacturing Carpet 1> As shown in FIG. 3, the method for manufacturing the above-mentioned Carpet 1 (hereinafter also referred to as "the manufacturing method") includes at least a flame retardant application step P1 described later. The manufacturing method may include a back coating step P2 and the like described later. Here, in the manufacturing method, when the flame retardant application step P1 is provided, it is the first embodiment, and when both the flame retardant application step P1 and the back coating step P2 are provided, it is the second embodiment. In addition, the first and second embodiments of the manufacturing method may include a carpet forming step described later before the flame retardant application step P1.

[0051] <Flame retardant application step P1> As shown in FIG. 3, the flame retardant application step P1 is a step of applying at least the above-mentioned flame retardant X to the above-mentioned Carpet 1 (at least the pile 2). The flame retardant X applied in this flame retardant application step P1 is such that the first flame retardant X1 is solid at normal temperature, the second flame retardant X2 is liquid (particularly, a viscous liquid) at normal temperature, or the entire flame retardant X may be in a colloidal state and applied to the Carpet 1. In addition, in the flame retardant application step P1, before being mixed with other flame retardants X and the like, the first flame retardant X1 (sulfamic acid guanidine etc. respectively) may be used in the state of a dispersion liquid dispersed in a dispersion medium such as water. In this case, the concentration of sulfamic acid guanidine etc. respectively ((weight of sulfamic acid guanidine etc. / (weight of the dispersion liquid combined with sulfamic acid guanidine etc. and the dispersion medium or the solution combined with the solvent))×100) can be any value. For example, it may be 10% by weight or more and 70% by weight or less. More specifically, the lower limit value may be 10% by weight or more, preferably 20% by weight or more, more preferably 30% by weight or more, and the upper limit value may be 70% by weight or less, preferably 60% by weight or less, more preferably 50% by weight or less (such as 40% by weight). In addition, each lower limit value of this concentration may be combined with any of the upper limit values. The same applies to the second flame retardant X2. Each of the guanidine salts of alkyl acidic phosphates, etc. before being mixed with other flame retardants X, etc. may be used in the form of a dispersion liquid dispersed in a dispersion medium such as water. In this case, the concentration of the guanidine salt of alkyl acidic phosphate, etc. ((weight of guanidine salt of alkyl acidic phosphate, etc. / (weight of dispersion liquid obtained by combining guanidine salt of alkyl acidic phosphate, etc. and dispersion medium or weight of solution obtained by combining solvent)) × 100) may be any value. For example, it may be 10% by weight or more and 70% by weight or less. More specifically, the lower limit value may be 10% by weight or more, preferably 20% by weight or more, more preferably 30% by weight or more, and the upper limit value may be 70% by weight or less, preferably 60% by weight or less, more preferably 50% by weight or less (such as 40% by weight). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values. Furthermore, the same applies to the penetrant Y. Each of the acetylene glycol-based penetrants before being mixed with other flame retardants, etc. may be used in the form of a dispersion liquid dispersed in a dispersion medium such as water. In this case, the concentration of the acetylene glycol-based penetrant ((weight of acetylene glycol-based penetrant / (weight of dispersion liquid obtained by combining acetylene glycol-based penetrant and dispersion medium or weight of solution obtained by combining solvent)) × 100) may be any value. For example, it may be 20% by weight or more and 90% by weight or less. More specifically, the lower limit value may be 20% by weight or more, preferably 40% by weight or more, more preferably 50% by weight or more, and the upper limit value may be 90% by weight or less, preferably 80% by weight or less, more preferably 70% by weight or less (such as 60% by weight). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values.

[0052] Here, the means for "applying" in the flame retardant application step P1 is not particularly limited. For example, it may be the spray method (also referred to as spray coating), or other methods such as the padding method (Dip-nip method), dipping method (Dipping method), kiss roll method, foam processing method, coating method, dropping method, or printing method may also be used. The addition of flame retardant X and the like in this flame retardant addition step P1 may be performed in an atmosphere at a predetermined temperature. Note that the predetermined temperature for the addition of flame retardant X and the like in the flame retardant addition step P1 is not particularly limited. Regarding the temperature of this addition, if we were to mention it specifically, for example, it may be 110°C or higher and 150°C or lower. More specifically, the lower limit value may be 110°C or higher, preferably 120°C or higher, and more preferably 125°C or higher, and the upper limit value may be 150°C or lower, preferably 140°C or lower, and more preferably 135°C or lower (such as 130°C). Note that each lower limit value of the temperature of this addition may be combined with any of the upper limit values.

[0053] Among the above-mentioned methods, taking the spraying method as an example for detailed explanation, in this spraying method, a dispersion liquid in which a mixture of flame retardant X and a liquid penetrant Y or the like is dispersed in a dispersion medium such as water at a predetermined concentration, or a solution dissolved in a solvent such as water, is atomized by spraying and sprayed (also referred to as coating or coating) onto the surface 1a side (also referred to as the pile 2 side or the pile surface side) and / or the back surface 1b side (the back surface 3b side of the base fabric 3 or the back surface 10b side of the back coat portion 10) of the carpet 1. Note that the application of the spraying method to the surface 1a side and the back surface 1b side of the carpet 1 may be performed on both the surface 1a side and the back surface 1b side, and the order may be from the surface 1a side to the back surface 1b side or from the back surface 1b side to the surface 1a side. In addition, it may also be only on the surface 1a side or only on the back surface 1b side, etc. Also, in the case of the spraying method, if the width of the carpet 1 is a long object of about 3.5 to 3.6 m (the width of approximately a 6-mat room), it can be said that it does not need to be placed in a water tank for immersion in a dispersion liquid or the like of a mixture such as flame retardant X (that is, the padding method or the immersion method cannot be used), but it can also be said that regardless of the width of the carpet 1, the application is possible as long as it is an application by the spraying method. In addition, as a means of "application", in the padding method, the carpet 1 is immersed in a dispersion liquid in which a mixture of flame retardant X and the like is dispersed in a dispersion medium such as water at a predetermined concentration, or a solution dissolved in a solvent such as water, and then the immersed carpet 1 is squeezed through between a pair of mangles (padding rolls). Note that the means of "application" may not necessarily be the padding method of squeezing with a mangle, and it may also be an immersion method of simply immersing the carpet 1 in a solution in which the mixture is dissolved.

[0054] Here, when dispersing the mixture after mixing a flame retardant X or the like by a spraying method or the like in the flame retardant imparting step P1 in a dispersion medium, etc., the concentration of the entire flame retardant X ((weight of the flame retardant X / (weight of the mixture of the flame retardant X or the like and the dispersion medium or the solution combined with the solvent)) × 100) can be any value. For example, it may be 5% by weight or more and 60% by weight or less. More specifically, the lower limit value may be 5% by weight or more, preferably 10% by weight or more, more preferably 15% by weight or more, and the upper limit value may be 60% by weight or less, preferably 50% by weight or less, more preferably 40% by weight or less (such as 20% by weight, 25% by weight, 50% by weight, etc.). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values. In addition, the concentration of only the first flame retardant X1 in this case ((weight of the first flame retardant X1 / (weight of the mixture of the flame retardant X including the first flame retardant X1 and the dispersion medium or the solution combined with the solvent)) × 100) can also be any value. For example, it may be 5% by weight or more and 60% by weight or less. More specifically, the lower limit value may be 5% by weight or more, preferably 10% by weight or more, more preferably 15% by weight or more, and the upper limit value may be 60% by weight or less, preferably 50% by weight or less, more preferably 40% by weight or less (such as 20% by weight, 25% by weight, 50% by weight, etc.). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values. Also, the concentration of only the second flame retardant X2 in this case ((weight of the second flame retardant X2 / (weight of the mixture of the flame retardant X including the second flame retardant X2 and the dispersion medium or the solution combined with the solvent)) × 100) can also be any value. For example, it may be 0.10% by weight or more and 10.00% by weight or less. More specifically, the lower limit value may be 0.10% by weight or more, preferably 0.20% by weight or more, more preferably 0.40% by weight or more, and the upper limit value may be 10.00% by weight or less, preferably 7.00% by weight or less, more preferably 4.00% by weight or less (such as 0.5% by weight, 0.75% by weight, 1.25% by weight, 2.00% by weight, 2.50% by weight, 3.75% by weight, etc.). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values. Furthermore, the concentration of only the penetration agent Y in this case ((weight of the penetration agent Y / (weight of the mixture of the penetration agent Y, the flame retardant X, etc. and the dispersion liquid combined with the dispersion medium or the solution combined with the solvent)) × 100) can be any value. For example, it may be 0.05% by weight or more and 10.00% by weight or less. More specifically, the lower limit value may be 0.05% by weight or more, preferably 0.50% by weight or more, more preferably 1.00% by weight or more, and the upper limit value may be 10.00% by weight or less, preferably 5.00% by weight or less, more preferably 3.00% by weight or less (such as 0.10% by weight). Note that each lower limit value of this concentration may be combined with any of the upper limit values.

[0055] In addition, in the flame retardant application step P1, after applying a mixture such as the flame retardant X to the carpet 1, the carpet 1 may be dried. The means for this "drying" is not particularly limited. For example, the carpet 1 may be dried at a predetermined drying temperature and a predetermined drying time by a dryer while being stretched on a pin tenter. The drying temperature is not particularly limited. For example, it may be 110°C or more and 150°C or less. More specifically, the lower limit value may be 110°C or more, preferably 120°C or more, more preferably 125°C or more, and the upper limit value may be 150°C or less, preferably 140°C or less, more preferably 135°C or less (such as 130°C). Note that each lower limit value of this drying temperature may be combined with any of the upper limit values. The drying time is not particularly limited. For example, it may be 0.1 minute (6 seconds) or more and 360.0 minutes or less. More specifically, the lower limit value may be 0.1 minute or more, preferably 0.2 minute (12 seconds) or more, more preferably 1.0 minute or more, and the upper limit value may be 360.0 minutes or less, preferably 10.0 minutes or less, more preferably 5.0 minutes or less (such as 2.0 minutes). Note that each lower limit value of this drying time may be combined with any of the upper limit values. In addition, the means for "drying" in the flame retardant application step P1 may be natural drying, blowing drying (air drying), or the like. Even when the means for "drying" in the flame retardant application step P1 is natural drying or the like, the drying temperature is not particularly limited. For example, it may be normal temperature (about 20 °C etc.), and the drying time may be until the moisture evaporates from the carpet 1 (for example, 24 hours etc.).

[0056] The amount of the entire flame retardant X applied after drying in the flame retardant application step P1 (that is, the dry weight of the flame retardant X on the carpet 1) is not particularly limited. For example, it may be 1.00 g / m 2 or more and 300.00 g / m 2 or less. More specifically, the lower limit value may be 1.00 g / m 2 or more, preferably 20.00 g / m 2 or more, more preferably 40.00 g / m 2 or more, and the upper limit value may be 300.00 g / m 2 or less, preferably 200.00 g / m 2 or less, more preferably 100.00 g / m 2 or less (40.00 g / m 2 or 52.80 g / m 2 or 66.00 g / m 2 or 67.32 g / m 2 or 67.95 g / m 2 or 69.30 g / m 2 or 71.28 g / m 2 or 72.60 g / m 2 or 75.90 g / m 2 or 89.10 g / m 2 or 132.00 g / m 2 etc.) may be acceptable. Note that each lower limit value of this application amount may be combined with any of the upper limit values. Note also that the amount of only the first flame retardant X1 applied after drying in the flame retardant application step P1 (that is, the dry weight of the first flame retardant X1 on the carpet 1) is not particularly limited. For example, it may be 5.00 g / m 2 or more and 300.00 g / m 2 or less. More specifically, the lower limit value may be 5.00 g / m 2More than 10.00 g / m 2 More preferably, 20.00 g / m 2 or more, or the upper limit is 300.00 g / m 2 Less than 200.00 g / m 2 More preferably, 100.00 g / m or less 2 Below (40.00g / m 2 or 52.80 g / m 2 , 66.00g / m 2 , 82.50g / m 2 , 132.00g / m 2 In addition, each lower limit value of the amount of application may be combined with any of the upper limit values. The amount of the second flame retardant X2 applied after drying in the flame retardant application step P1 (i.e., the dry weight of the second flame retardant X2 in the carpet 1) is not particularly limited, but may be, for example, 0.10 g / m 2 More than 30.00g / m 2 More specifically, the lower limit is 0.10 g / m or less. 2 More than 1.00 g / m 2 More preferably, 1.50 g / m 2 or more, or the upper limit is 30.00 g / m 2 Less than 20.00 g / m 2 More preferably, 10.00 g / m or less. 2 Below (1.38g / m 2 or 1.98 g / m 2 , 3.30g / m 2 , 5.28g / m 2 , 6.60g / m 2 , 9.90g / m 2 In addition, each lower limit value of the amount of application may be combined with any of the upper limit values. Furthermore, the amount of the penetrant Y applied after drying in the flame retardant application step P1 (i.e., the dry weight of the penetrant Y in the carpet 1) is not particularly limited, but may be, for example, 0.01 g / m 2 More than 5.00g / m 2 More specifically, the lower limit is 0.01 g / m or less. 2Preferably, it is 0.05 g / m or more 2 More preferably, it is 0.10 g / m or more 2 Or it is 5.00 g / m or less, preferably 2.00 g / m or less 2 More preferably, it is 1.00 g / m or less (it may be 0.40 g / m 2 Or 0.50 g / m, etc.). The lower limit values of this application amount may be combined with any of the upper limit values 2 Here, the application amount (adhesion amount) of the flame retardant X after drying in the flame retardant application step P1 can also be said to be the sum of the application amount (adhesion amount) of the first flame retardant X1 and the application amount (adhesion amount) of the second flame retardant X2 2 On the other hand, the application amount of the flame retardant X before drying in the flame retardant application step P1 (that is, the wet weight of the flame retardant X on the carpet 1) is not particularly limited. For example, it may be 10 g / m 2 Or it may be 3000 g / m or less. More specifically, the lower limit value is 10 g / m

[0057] Or it may be 3000 g / m or less, preferably 2000 g / m or less More preferably, it is 1000 g / m or less (it may be 660 g / m 2 Or 825 g / m, etc.). The lower limit values of the adhesion amount of this wet weight may be combined with any of the upper limit values 2 2 Or it may be 3000 g / m or less, preferably 2000 g / m or less 2 More preferably, it is 1000 g / m or less (it may be 660 g / m 2 Or 825 g / m, etc.). The lower limit values of the adhesion amount of this wet weight may be combined with any of the upper limit values 2 2 2 2 2 ​​​​​​In such a flame retardant application step P1, when the above-described first flame retardant X1, second flame retardant X2, etc. are applied to the pile 2 or the base fabric 3 and adhere to the fiber surface used in the pile 2 or the base fabric 3, if the first flame retardant X1 is solid and in particle form at normal temperature (or normal pressure), and the second flame retardant X2 is liquid (especially a viscous substance) at normal temperature (or normal pressure), <1> only the first flame retardant X1 is directly adhered to the fiber surface, <2> the first flame retardant X1 is directly adhered to the fiber surface, and the second flame retardant X2 adheres while surrounding the first flame retardant X1 in a substantially layered manner in a side sectional view, <3> the first flame retardant X1 adheres to the fiber surface through the second flame retardant X2 that is adhered in a substantially layered manner in a side sectional view, <4> only the second flame retardant X2 adheres to the fiber surface in a substantially layered manner in a side sectional view, <5> it can be said that there are states where nothing adheres to the fiber surface, etc. (see Fig. 1).

[0058] <Back coating step P2> As shown in Fig. 3(b), the back coating step P2 is a step of providing a back coating portion 10 in which a backing material containing rubber such as styrene-butadiene rubber and a filler is coated on the back surface 3b of the base fabric 3 in an atmosphere at a predetermined temperature after the above-described flame retardant application step P1. In addition, the predetermined temperature and the like for applying the backing material in the back coating step P2 are not particularly limited, but may be the same as those in the "application" in the above-described flame retardant application step P1.

[0059] Here, the means for "coating" in the back coating step P2 is not particularly limited. For example, it may be coating. Specific means of coating include coating with a brush, spray coating, in addition to comma direct method, gravure direct method, gravure reverse method, reverse roll coating method, air knife coating method, kiss coating method, etc., or a thin film coater, roll printing machine, inkjet printing machine, rotor dumping, etc. may be used. In addition, the means for "coating" may be kiss roll method, foam processing method, etc. When coating the backing material in the backcoating step P2, a dispersion obtained by dispersing a powdery backing material in a dispersion medium such as water at a predetermined concentration, or a solution obtained by dissolving the powdery backing material in a solvent such as water, is coated on the back surface 3b of the base fabric 3 by means such as spraying. Also, in the backcoating step P2, after coating the mixture, the carpet 1 may be dried. In this case, the means for "drying", the drying temperature, the drying time, etc. are not particularly limited, but may be the same as the means for "drying", the drying temperature, the drying time, etc. in the above-described flame retardant imparting step P1.

[0060] Here, in the backcoating step P2, among the backing materials, rubber such as styrene-butadiene rubber may be used in the state of a dispersion obtained by dispersing it in a dispersion medium such as water before being mixed with other fillers, etc. In this case, the concentration of rubber such as styrene-butadiene rubber ((weight of rubber such as styrene-butadiene rubber / (weight of dispersion obtained by combining rubber such as styrene-butadiene rubber and dispersion medium or solution obtained by combining solvent)) × 100) may be any value. For example, it may be 15% by weight or more and 75% by weight or less. More specifically, the lower limit value may be 15% by weight or more, preferably 25% by weight or more, more preferably 35% by weight or more, and the upper limit value may be 75% by weight or less, preferably 65% by weight or less, more preferably 55% by weight or less (such as 44% by weight). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values. This is the same for acrylic acid, which is a thickener among other backing materials. Before being mixed with other fillers or the like, the thickener may be used in the state of a dispersion liquid dispersed in a dispersion medium such as water. In this case, the concentration of the thickener ((weight of the thickener / (weight of the dispersion liquid combined with the thickener and the dispersion medium or the solution combined with the solvent)) × 100) can be any value. For example, it may be 10% by weight or more and 70% by weight or less. More specifically, the lower limit value may be 10% by weight or more, preferably 20% by weight or more, more preferably 30% by weight or more, and the upper limit value may be 70% by weight or less, preferably 60% by weight or less, more preferably 50% by weight or less (such as 40% by weight). Incidentally, each lower limit value of this concentration may be combined with any of the upper limit values.

[0061] The application amount of the backing material after drying in the backcoating step P2 (that is, the dry weight of the backing material on the carpet 1) is not particularly limited. For example, it may be 500 g / m 2 or more and 3000 g / m 2 or less. More specifically, the lower limit value may be 500 g / m 2 or more, preferably 700 g / m 2 or more, more preferably 900 g / m 2 or more, and the upper limit value may be 3000 g / m 2 or less, preferably 2000 g / m 2 or less, more preferably 1400 g / m 2 or less (such as 1285 g / m 2 or 1299 g / m 2 etc.). Incidentally, each lower limit value of this application amount may be combined with any of the upper limit values. Incidentally, the application amount of only the rubber such as styrene-butadiene rubber after drying in the backcoating step P2 (that is, the dry weight of the rubber such as styrene-butadiene rubber on the carpet 1) is not particularly limited. For example, it may be 50 g / m 2 or more and 2000 g / m 2 or less. More specifically, the lower limit value may be 50 g / m 2 or more, preferably 100 g / m 2 or more, more preferably 200 g / m 2or the upper limit is 2000 g / m 2 or less, preferably 1500 g / m 2 or less, more preferably 1000 g / m 2 or less (343 g / m 2 or 347 g / m 2 etc.) may be sufficient. In addition, each lower limit of this application amount may be combined with any of the upper limits. Further, the application amount of only the filler after drying in the backcoat step P2 (that is, the dry weight of the filler in the carpet 1) is not particularly limited. For example, it may be 100 g / m 2 or more and 3000 g / m 2 or less. More specifically, it may be 100 g / m 2 or more, preferably 200 g / m 2 or more, more preferably 500 g / m 2 or more, or the upper limit is 3000 g / m 2 or less, preferably 2500 g / m 2 or less, more preferably 2000 g / m 2 or less (942 g / m 2 or 952 g / m 2 etc.) may be sufficient. In addition, each lower limit of this application amount may be combined with any of the upper limits. Here, the application amount (adhesion amount) of the backing material after drying in the backcoat step P2 can be said to be the total value of the application amount (adhesion amount) of rubber such as styrene-butadiene rubber and the application amount (adhesion amount) of the filler.

[0062] In addition, the ratio of each of rubber such as styrene-butadiene rubber and filler in the backing material applied in the backcoat step P2 is not particularly limited. If expressed in parts by weight, first, the parts by weight of rubber such as styrene-butadiene rubber may be, for example, 15 parts by weight or more and 75 parts by weight or less. More specifically, the lower limit may be 15 parts by weight or more, preferably 25 parts by weight or more, more preferably 35 parts by weight or more, or the upper limit may be 75 parts by weight or less, preferably 65 parts by weight or less, more preferably 55 parts by weight or less (45 parts by weight etc.) may be sufficient. In addition, each lower limit of this parts by weight may be combined with any of the upper limits. Also, the parts by weight of a filler such as calcium carbonate are not particularly limited, and for example, they may be 25 parts by weight or more and 85 parts by weight or less. More specifically, the lower limit value may be 25 parts by weight or more, preferably 35 parts by weight or more, more preferably 45 parts by weight or more, and the upper limit value may be 85 parts by weight or less, preferably 75 parts by weight or less, more preferably 65 parts by weight or less (such as 55 parts by weight). Incidentally, each of these lower limit values of the parts by weight may be combined with any of the upper limit values. Furthermore, the parts by weight of a thickener such as acrylic acid are not particularly limited, and for example, they may be 0.1 part by weight or more and 10.0 parts by weight or less. More specifically, the lower limit value may be 0.1 part by weight or more, preferably 0.2 part by weight or more, more preferably 0.5 part by weight or more, and the upper limit value may be 10.0 parts by weight or less, preferably 5.0 parts by weight or less, more preferably 2.0 parts by weight or less (such as 1.0 part by weight). Incidentally, each of these lower limit values of the parts by weight may be combined with any of the upper limit values. And the parts by weight of ammonia are not particularly limited, and for example, they may be 0.01 part by weight or more and 5.00 parts by weight or less. More specifically, the lower limit value may be 0.01 part by weight or more, preferably 0.10 part by weight or more, more preferably 0.20 part by weight or more, and the upper limit value may be 5.00 parts by weight or less, preferably 2.00 parts by weight or less, more preferably 1.00 parts by weight or less (such as 0.50 part by weight). Incidentally, each of these lower limit values of the parts by weight may be combined with any of the upper limit values.

[0063] <Carpet forming step> The carpet forming step is a step of forming a carpet before the flame retardancy imparting step P1 described above. As described above, the carpet may be a pile fabric, a pile knitted fabric, or a tufted carpet. When the carpet is a pile fabric, it can be said that the carpet forming step is a pile fabric weaving step. When the carpet is a pile knitted fabric, it can be said that the carpet forming step is a pile knitted fabric knitting step. When the carpet is a tufted carpet, it can be said that the carpet forming step is a tufted carpet forming step.

[0064] Here, in the case of the pile fabric weaving process, the pile fabric woven in this process is, for example, between a pair of upper woven fabrics and lower woven fabrics woven with warp and weft in plain weave, twill weave, damask weave, etc., and the pile yarns are woven in the warp direction as connecting yarns together with these upper and lower woven fabrics, and then the connecting yarns may be cut (center cut) at approximately the center. As a result, two pile fabrics with the cut connecting yarns (pile yarns) each serving as pile 2 can be produced simultaneously with the upper woven fabric or the lower woven fabric as the base fabric 3. A pile fabric with such a configuration is also called a mockett. In this case, it is woven by a double mockett loom (such as a jacquard loom or a dobby loom). In addition, instead of weaving by connecting the upper and lower woven fabrics with pile yarns, the mockett may be one that weaves together with a single woven fabric while hooking the pile yarns in the warp direction on wires extending in the weft direction. In this case, it is woven by a wire mockett loom. Also, in the case of the pile knitting process, the pile knitted fabric knitted in this process may be, for example, a knitted fabric (a type of warp knitting, also called denim knitting or tricot) knitted with warp yarns on a knitting machine having a predetermined number of heddles (for example, 3 heddles), etc., as the base fabric 3, and the fluff formed by raising one or both sides of this base fabric 3 may be used as pile 2. Furthermore, in the case of the tufted carpet forming process, the tufted carpet formed in this process is formed, for example, by a tufting machine that tufts (plants) pile 2 on the base fabric 3 at predetermined intervals.

Examples

[0065] From here on, Examples 1 to 4, Example 1' of the carpet 1 according to the present invention, Comparative Examples 1 to 3, and Reference Examples 1 to 5 will be mentioned. Using these examples, comparative examples, and reference examples, Tests 1 and 2 described later are conducted.

[0066] <Example 1, Example 1'> The carpet 1 of Example 1 is a carpet in which only nylon 6 fibers are used for the pile 2 and only polypropylene fibers are used for the base fabric 3, and it is a pile fabric (mocket) woven in the carpet forming process (pile fabric weaving process). Incidentally, the basis weight of the entire carpet 1 is 1018 g / m 2 and the basis weight of the pile 2 is 907 g / m 2 and the basis weight of the base fabric 3 is 111 g / m 2 was. For this carpet, in the flame retardant application step P1, a first flame retardant X1 composed only of sulfamic acid guanidine (Nonnen WS-3 manufactured by Marubishi Yuka Kogyo Co., Ltd.) and a second flame retardant X2 composed only of a guanidine salt of an alkyl acidic phosphate ester (32 Han manufactured by Marubishi Yuka Kogyo Co., Ltd.) are mixed with a penetrant Y composed only of acetylene glycol (Olfin PD-002W manufactured by Nissin Chemical Industry Co., Ltd.). A dispersion obtained by adding water as a dispersion medium to the mixture was applied to the back surface 1b side of the carpet 1 by the spray method as an application means, and then applied to the front surface 1a side (pile 2 side) of the carpet 1. After that, the carpet was dried by a dryer while being stretched on a pin tenter. After the flame retardant application step P1, in the back coating step P2, a dispersion obtained by adding water as a dispersion medium to a backing material in which styrene-butadiene rubber and calcium carbonate as a filler are mixed is coated on the back surface 3b of the base fabric 3 of the pile fabric by coating to provide a back coating portion 10, thereby obtaining the carpet 1 of Example 1. Here, the application amount of the entire dispersion applied (coated) in the flame retardant application step P1 is 660.0 g / m 2 whereas, among the entire dispersion, the weight percentage of the entire flame retardant X is 27.00%, and the first flame retardant X1 (sulfamic acid guanidine The weight percentage of ) is 25.00%, the weight percentage of the second flame retardant X2 (guanidine salt of alkyl acidic phosphate ester) is 2.00%, the weight percentage of the penetrant Y is 0.10%, and the weight percentage of water as the dispersion medium is 72.90%. Incidentally, the application amount of the entire dispersion applied (coated) in the back coating step P2, and the weight percentages of styrene-butadiene rubber, calcium carbonate, and water in the entire dispersion are predetermined values. As a result, for the carpet 1 of Example 1, in terms of dry weight, the adhesion amount of the entire flame retardant X is 71.28 g / m 2 and the adhesion amount of the first flame retardant X1 is 66.00 g / m 2 and the adhesion amount of the second flame retardant X2 is 5.28 g / m 2 and the adhesion amount of the penetrant Y is 0.40 g / m 2 and the adhesion amount of the entire backing material is 1285.00 g / m 2 and the adhesion amount of styrene-butadiene rubber is 343.00 g / m 2 and the adhesion amount of calcium carbonate is 942.00 g / m 2 was obtained. In addition, in the carpet 1 of Example 1, a mixture containing only the flame retardant X and no penetrant Y was used. Among the entire dispersion applied (coated) in the flame retardant application step P1, the weight percentage of the penetrant Y was set to 0.00%, and the weight percentage of water as the dispersion medium was set to 73.00% to obtain the carpet 1 of Example 1'. As a result, compared with the carpet 1 of Example 1, for the carpet 1 of Example 1', in terms of dry weight, the adhesion amount of the entire flame retardant X is 71.28 g / m 2 and the adhesion amount of the entire first flame retardant X1 is 66.00 g / m 2 and the adhesion amount of the second flame retardant X2 is 5.28 g / m 2 which is the same, but the adhesion amount of the penetrant Y is 0.00 g / m 2 is different.

[0067] <Example 2> In the carpet 1 of Example 1, the first flame retardant X1 was replaced with sulfamic acid guanidine , and a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt (Nonnen WS-29 manufactured by Marubishi Oil Chemical Co., Ltd.). In the flame retardant application step P1, the weight percentage of the entire first flame retardant X1 in the total dispersion liquid to be applied (coated) is 25.00%, which is the same as in Example 1, but the weight percentage of sulfamic acid guanidine is set to 5.00%, and the weight percentage of the mixture of ammonium sulfate and the phosphorus-nitrogen-based onium salt is set to 20.00% to obtain the carpet 1 of Example 2. As a result, compared with the carpet 1 of Example 1, the carpet 1 of Example 2 has an adhesion amount of the entire first flame retardant X1 of 66.00 g / m in terms of dry weight 2 , which is the same, but the adhesion amount of sulfamic acid guanidine is 13.20 g / m 2 , and the adhesion amount of the mixture of ammonium sulfate and the phosphorus-nitrogen-based onium salt is 52.80 g / m 2 , which is different.

[0068] <Example 3> In the carpet 1 of Example 2, the application means of the dispersion liquid in the flame retardant application step P1 is only applied to the surface 1a side (pile 2 side) of the carpet 1 by the spray method, and the application amount of the total dispersion liquid to be applied (coated) in the flame retardant application step P1 is 825.0 g / m 2 to obtain the carpet 1 of Example 3. As a result, compared with the carpet 1 of Example 2, the carpet 1 of Example 3 has an adhesion amount of the entire flame retardant X of 89.10 g / m in terms of dry weight 2 , an adhesion amount of the entire first flame retardant X1 of 82.50 g / m 2 , an adhesion amount of sulfamic acid guanidine of 16.50 g / m 2 , an adhesion amount of the mixture of ammonium sulfate and the phosphorus-nitrogen-based onium salt of 66.00 g / m 2 , an adhesion amount of the second flame retardant X2 of 6.60 g / m 2 , and an adhesion amount of the penetrant Y of 0.50 g / m 2 , which is different.

[0069] <Example 4> In the carpet 1 of Example 2, the means for applying the dispersion liquid in the flame retardant application step P1 was only applied by the spray method to the surface 1a side (pile 2 side) of the carpet 1, and the carpet 1 of Example 4 was obtained. In addition, the carpet 1 of Example 4, compared with the carpet 1 of Example 2, in terms of dry weight, the adhesion amount of the entire first flame retardant X1, and sulfamic acid guanidine The adhesion amount of, and the adhesion amount of the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt were the same as those in Example 1.

[0070] <Comparative Example 1> In the carpet 1 of Example 1, the flame retardant X was only the first flame retardant X1 composed only of sulfamic acid guanidine Only, the means for applying the dispersion liquid in the flame retardant application step P1 was only applied by the spray method to the surface 1a side (pile 2 side) of the carpet 1, and among the entire dispersion liquid applied (coated) in the flame retardant application step P1, the weight percentage as the entire first flame retardant X1 was 20.00%, the weight percentage of water as the dispersion medium was 80.00%, and the application amount of the entire dispersion liquid in the back coating step P2, the weight percentage of styrene-butadiene rubber, the weight percentage of calcium carbonate, and the weight percentage of water were changed to obtain the carpet of Comparative Example 1. As a result, the carpet of Comparative Example 1, compared with the carpet 1 of Example 1, in terms of dry weight, sulfamic acid which is the entire flame retardant X guanidine The adhesion amount was 52.80 g / m 2 And the adhesion amount of the entire backing material was 1299.00 g / m 2 And the adhesion amount of styrene-butadiene rubber was 347.00 g / m 2 And the adhesion amount of calcium carbonate was 952.00 g / m 2 This was different.

[0071] <Comparative Example 2> In the carpet of Comparative Example 1, among the entire dispersion liquid applied (coated) in the flame retardant application step P1, the weight percentage as the entire first flame retardant X1 was 25.00%, and the weight percentage of water as the dispersion medium was 75.00% to obtain the carpet of Comparative Example 2. As a result, the carpet of Comparative Example 2 has a difference in that the adhesion amount of sulfamic acid, which is the entire flame retardant X, is 66.00 g / m in terms of dry weight compared to the carpet of Comparative Example 1. guanidine 2

[0072] <Comparative Example 3> In the carpet of Comparative Example 1, the weight percentage of the entire first flame retardant X1 was set to 50.00% and the weight percentage of water as the dispersion medium was set to 50.00% in the entire dispersion liquid applied (coated) in the flame retardant application step P1, thereby obtaining the carpet of Comparative Example 3. As a result, the carpet of Comparative Example 3 has a difference in that the adhesion amount of sulfamic acid, which is the entire flame retardant X, is 132.00 g / m in terms of dry weight compared to the carpet of Comparative Example 1. guanidine 2

[0073] <Reference Example 1> In the carpet of Comparative Example 2, the flame retardant X has not only sulfamic acid as the first flame retardant X1 but also a second flame retardant X2 composed only of a guanidine salt of an alkyl acidic phosphate ester. The weight percentage of the first flame retardant X1 is 25.00%, the same as in Example 1, the weight percentage of the second flame retardant X2 is 0.50%, and the weight percentage of water as the dispersion medium is 74.50% in the entire dispersion liquid applied (coated) in the flame retardant application step P1, thereby obtaining the carpet of Reference Example 1. guanidine As a result, the carpet of Reference Example 1 has a difference in that the adhesion amount of the first flame retardant X1 is 66.00 g / m in terms of dry weight, the same as that of the carpet of Comparative Example 2, but the adhesion amount of the entire flame retardant X is 67.32 g / m and the adhesion amount of the second flame retardant X2 is 1.32 g / m. 2 2 2

[0074] <Reference Example 2> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 was set to 0.75% and the weight percentage of water as the dispersion medium was set to 74.25% in the entire dispersion liquid applied (coated) in the flame retardant application step P1, thereby obtaining the carpet of Reference Example 2.​​​​​​​​ As a result, compared with the carpet of Reference Example 1, the carpet of Reference Example 2 had an adhesion amount of the entire flame retardant X of 67.98 g / m in terms of dry weight. 2 and the adhesion amount of the second flame retardant X2 was 1.98 g / m. 2 This was different.

[0075] <Reference Example 3> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the entire dispersion liquid applied (coated) in the flame retardant application step P1 was set to 1.25%, and the weight percentage of water as the dispersion medium was set to 73.75% to obtain the carpet of Reference Example 3. As a result, compared with the carpet of Reference Example 1, the carpet of Reference Example 3 had an adhesion amount of the entire flame retardant X of 69.30 g / m in terms of dry weight. 2 and the adhesion amount of the second flame retardant X2 was 3.30 g / m. 2 This was different.

[0076] <Reference Example 4> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the entire dispersion liquid applied (coated) in the flame retardant application step P1 was set to 2.50%, and the weight percentage of water as the dispersion medium was set to 72.50% to obtain the carpet of Reference Example 4. As a result, compared with the carpet of Reference Example 1, the carpet of Reference Example 4 had an adhesion amount of the entire flame retardant X of 72.60 g / m in terms of dry weight. 2 and the adhesion amount of the second flame retardant X2 was 6.60 g / m. 2 This was different.

[0077] <Reference Example 5> In the carpet of Reference Example 1, the weight percentage of the second flame retardant X2 in the entire dispersion liquid applied (coated) in the flame retardant application step P1 was set to 3.75%, and the weight percentage of water as the dispersion medium was set to 71.25% to obtain the carpet of Reference Example 5. As a result, compared with the carpet of Reference Example 1, the carpet of Reference Example 5 had an adhesion amount of the entire flame retardant X of 75.90 g / m in terms of dry weight. 2 and the adhesion amount of the second flame retardant X2 was 9.90 g / m. 2 This was different.

[0078] <Test 1 (Flammability Test)> In Test 1, for the carpets of Examples 1 to 3 and Comparative Examples 1 to 3 described above, a test was conducted in accordance with the Flammability Test for Railway Vehicle Materials (described in the Explanation Book of Vehicle Technical Standards of the Japan Railway Vehicle Machinery Technology Association, Incorporated Association, and the Ministry of Land, Infrastructure, Transport and Tourism, hereinafter referred to as "the said flammability test"). Whether the flame during alcohol combustion exceeds the upper end of the test piece, the presence or absence of afterglow and residue after alcohol combustion, and whether carbonization and deformation reach the upper end of the test piece (if not, the unit of the value: mm) were compared for pass / fail determination. In addition, if this pass / fail determination is a pass, it is indicated as "○" in Table 1, and if it is a fail, it is indicated as "×" in Table 1. In addition, for Example 1' etc. where penetrant Y was not used, the adhesion state of flame retardant X in pile 2 and base fabric 3 was confirmed by elemental distribution through fluorescent X-ray analysis evaluation to conduct a flammability determination. The measurement results of this Test 1 are shown in Table 1 below and FIG. 2.

[0079]

Table 1

[0080] <Evaluation of Test 1 (Flammability Test)> As shown in Table 1, in Comparative Examples 1 to 3, even though the adhesion amount of the first flame retardant X1 is significantly increased, since the second flame retardant X2 etc. are not used, the flame during alcohol combustion exceeds the upper end of the test piece, there is afterglow and residue after alcohol combustion, and carbonization and deformation reach the upper end of the test piece. Therefore, the said flammability test resulted in a "×" determination. In contrast, in Examples 1 to 3, although the adhesion amount of the first flame retardant X1 is not so large compared to Comparative Example 3, since the second flame retardant X2 and the penetrant Y are also used, as the entire flame retardant X, it firmly adheres to the pile 2 and the base fabric 3. Therefore, during alcohol combustion, the flame does not exceed the upper end of the test piece, there is no remaining flame or residue after alcohol combustion, carbonization and deformation do not reach the upper end of the test piece, and the generated carbonization and deformation are also 60 mm or less, and the flammability test has a judgment of "○". In particular, in Example 1, the first flame retardant X1 does not contain ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt, but consists only of sulfamic acid guanidine However, since the flammability test has passed, it can be seen that the first flame retardant X1 only needs to contain at least sulfamic acid guanidine . Also, in Example 1', although the adhesion amount of the first flame retardant X1 is not so large and the penetrant Y is not used, since the second flame retardant X2 is used, as shown in FIG. 2, sulfamic acid guanidine (containing sulfur (S), etc.) firmly adheres to the tip and base ends of the pile 2 and the surface side of the base fabric 3. Therefore, it can be said that in the same flammability test as in Examples 1 to 3, the judgment is "○". Note that in the middle part of the pile 2, the adhesion amount of sulfur, etc. seems small because although the dispersion liquid applied in the flame retardant application step P1 adhered to the middle part of the pile 2 before drying, due to migration (such as moisture movement) during drying, sulfur, etc. moves to the tip and base ends in the pile 2. However, even after drying, since a predetermined amount of sulfur adheres to the middle part of the pile 2, it can be said that there is no problem in the flammability test. Also, in Example 4, although the adhesion amount of the first flame retardant X1 is the same as that in Example 1, the means of applying the dispersion liquid in the flame retardant application step P1 is only to apply it to the surface 1a side of the carpet 1 by the spray method. Similar to Example 1', since the second flame retardant X2 is also used, sulfamic acid guanidineMoreover, since the mixture of ammonium sulfate and phosphorus-nitrogen-based onium salt adheres firmly to the tip and base ends of the pile 2 and the surface side of the base fabric 3, it can be said that the judgment will be "○" even in the same flammability test as in Examples 1 to 3. Therefore, by using not only the first flame retardant X1 but also the second flame retardant X2, it is possible to impart flame retardancy even to a nylon 6 pile carpet.

[0081] <Test 2 (Test for whitening suppression and tackiness)> In Test 2, for <whitening suppression>, the state evaluation of the generation of white powder is compared for the carpets of Reference Examples 1 to 5, Examples 1 to 4, Example 1', and Comparative Examples 1 to 3 described above. In addition, for this state evaluation, when the white powder is not generated on the pile surface (the surface formed by the tip sides of a plurality of piles) side of the carpet, it is judged as qualified (indicated as "○" in Table 2), and when it is generated, it is judged as unqualified (indicated as "×" in Table 2). For <tackiness>, similarly, the state evaluation of the pile surface is compared for the carpets of Reference Examples 1 to 5, Examples 1 to 4, and Comparative Examples 1 to 3. In addition, for this state evaluation, when there is no stickiness on the pile surface of the carpet, it is evaluated as "○", and when it occurs, it is evaluated as "×". The measurement results of this Test 2 are shown in Table 2 below.

[0082]

Table 2

[0083] <Evaluation of Test 2 (Test for whitening suppression and tackiness)> As shown in Table 2, for Comparative Examples 1 to 3 in which the second flame retardant X2 is not used, first, in Comparative Example 1, since the adhesion amount of the first flame retardant X1 is not so large, both the whitening suppression and the tackiness are evaluated as "○". However, in Comparative Examples 2 and 3, since the adhesion amount of the first flame retardant X1 has increased significantly, the whitening suppression is evaluated as "×". Among Comparative Examples 1 to 5 in which the second flame retardant X2 is used, in Comparative Example 1, since the adhesion amount of the second flame retardant X2 is small, the whitening suppression property is evaluated as "×", and in Comparative Example 5, since the adhesion amount of the second flame retardant X2 is too large, the tackiness is evaluated as "×". On the other hand, in Comparative Examples 2 to 4, since the adhesion amount of the second flame retardant X2 is appropriate with respect to the first flame retardant X1 (the adhesion amount ratio of the first flame retardant X1 to the second flame retardant X2 = 132:3 to 132:14), both the whitening suppression property and the tackiness are evaluated as "○". This is the same for Examples 1 to 4 and Example 1' in which the flammability test in Test 1 described above was judged as "○". In these examples, the adhesion amount ratio of the first flame retardant X1 to the second flame retardant X2 is within 132:3 to 132:14 (in particular, for Example 3, the adhesion amount ratio of the first flame retardant X1 to the second flame retardant X2 = 16.50 + 66.00:6.60 = 82.50:6.60 = 132.00:10.56, which is within the range of 132:3 to 132:14). Therefore, by setting the ratio of the adhesion amount of the first flame retardant X1 to the second flame retardant X2 to 132:3 to 132:14, it is possible to achieve both "whitening suppression" and "tack reduction".

[0084] <Others> The present invention is not limited to the above-described embodiments. Each configuration such as Carpet 1, the flame retardant X, the manufacturing method of Carpet 1, or the overall structure, shape, dimensions, etc. can be appropriately changed in accordance with the gist of the present invention. Carpet 1 may not have the back coat portion 10. The base fabric 3 may not use polypropylene fibers, and may be other polyolefin fibers such as polyethylene fibers, polyester fibers such as polyethylene terephthalate fibers, nylon (polyamide) fibers such as nylon 6 fibers and nylon 66 fibers, or the like, and these may be used alone or in combination. The first flame retardant X1 may not contain ammonium sulfate or a mixture of ammonium sulfate and a phosphorus-nitrogen-based onium salt. The base fabric 3 does not necessarily have the flame retardant X attached thereto. The ratio of the adhesion amounts of the first flame retardant X1 and the second flame retardant X2 does not necessarily have to be 132:3 to 132:14 (not less than 132 / 14 (≈9.429) and not more than 132 / 3 (=44.000)), and it may be less than 132 / 14 or greater than 132 / 3. The penetrant Y does not necessarily have to be attached to at least the pile 2 (that is, only the pile 2, or the pile 2 and the base fabric 3), and even when the penetrant Y is attached to at least the pile 2, the penetrant Y does not necessarily have to contain an acetylene glycol-based penetrant. The second flame retardant X2 does not necessarily have to be a viscous substance at normal temperature. In the method for manufacturing the carpet 1, the flame retardant X may be applied to at least the pile 2 by means other than spray coating, and may be applied by means such as padding or dipping. In the flame retardant application step P1, when the above-described first flame retardant X1, second flame retardant X2, etc. are applied to the pile 2 or the base fabric 3 and adhere to the fiber surface used in the pile 2 or the base fabric 3, if the first flame retardant X1 is a solid at normal temperature (or normal pressure) and has a particle shape, the second flame retardant X2 is a liquid (particularly, a viscous substance) at normal temperature (or normal pressure), and the penetrant Y is a liquid at normal temperature (or normal pressure), in addition to the above-described <1> to <5>, the second flame retardant X2 adheres to the fiber surface in a substantially layered manner in a side cross-sectional view, and the first flame retardant X1 adhered to the fiber surface directly or via the second flame retardant X2, or the penetrant Y adhered to the fiber surface in a substantially layered manner in a side cross-sectional view may cover them.

[0085] The carpet 1 may optionally use a material to which extender pigments or fillers (filler materials) such as titanium oxide and calcium carbonate are arbitrarily added, or to which deodorants, antibacterial agents, antifungal agents, flame retardants, water repellents, antifouling agents, colorants, fragrances, foaming agents, dispersants, etc. are added. Carpet 1 can have any color tone such as black, brown, blue, white, red, orange, yellow, green, purple, etc., and can have any value for chroma and lightness. Regarding the pattern of Carpet 1, it can be plain, a pattern of plants such as flowers and plants, an animal pattern, a geometric pattern, a pattern due to surface irregularities, etc.

Industrial Applicability

[0086] The carpet according to the present invention and the carpet manufactured by the manufacturing method of the carpet according to the present invention can be used as a floor material inside vehicles such as railway vehicles, automobiles (passenger cars), airplanes, ships, etc. (indoors), and in addition, can be used as a floor material inside buildings such as houses and buildings, etc. Furthermore, it may be used for industrial material applications, consumer material applications such as shoes and clothing. In addition to being able to be applied to carpets, the flame retardant according to the present invention can be applied to interior materials (such as inner wall materials, ceiling materials, floor materials, etc.) inside vehicles such as railway vehicles, automobiles (passenger cars), airplanes, ships, etc. (indoors), can be applied to the skin material (seat cover material) covering a chair (seat), and in addition, can be applied to interior materials (such as inner wall materials, ceiling materials, floor materials, etc.) inside buildings such as houses and buildings, furniture such as chairs and beds, and skin materials (cover materials) covering lighting fixtures, etc. Furthermore, it can be used for application to any material such as textile products, industrial materials, consumer materials such as shoes and clothing.

Explanation of Signs

[0087] 1 Carpet 2 Pile 3 Base fabric X Flame retardant X1 First flame retardant X2 Second flame retardant Y Penetrant

Claims

1. A carpet having a pile (2) attached to a base fabric (3), The pile (2) is made of nylon 6 fiber, A flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2) is attached to at least the pile (2), The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, the ratio of the amount of the first flame retardant (X1) to the amount of the second flame retardant (X2) attached is 132:3 to 132:14; A penetrating agent (Y) is also attached to at least the pile (2), The carpet according to claim 1, wherein the penetrating agent (Y) contains an acetylene glycol-based penetrating agent.

2. A carpet having pile (2) attached to a base fabric (3), The pile (2) is made of nylon 6 fiber, A flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2) is attached to at least the pile (2), The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, The base fabric (3) is made of polypropylene fibers, The first flame retardant (X1) also includes a mixture of ammonium sulfate, which is solid at room temperature, and a phosphorus-nitrogen-based onium salt, which is solid at room temperature; The flame retardant (X) is adhered to the pile (2) and the base fabric (3), A penetrating agent (Y) is also attached to at least the pile (2), The carpet according to claim 1, wherein the penetrating agent (Y) contains an acetylene glycol-based penetrating agent.

3. 3. The carpet according to claim 2, wherein the ratio of the amount of the first flame retardant (X1) to the amount of the second flame retardant (X2) attached is 132:3 to 132:

14.

4. A flame retardant comprising a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, the dry weight ratio of the first flame retardant (X1) to the second flame retardant (X2) is 132:3 to 132:14; A flame retardant for nylon 6, comprising an acetylene glycol-based penetrating agent (Y).

5. A flame retardant comprising a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, The wet weight ratio of the first flame retardant (X1) to the second flame retardant (X2) is 25.000:0.568 to 25.000:2.652; A flame retardant for nylon 6, comprising an acetylene glycol-based penetrating agent (Y).

6. A flame retardant comprising a first flame retardant (X1) and a second flame retardant (X2), The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, The first flame retardant (X1) also includes a mixture of ammonium sulfate, which is solid at room temperature, and a phosphorus-nitrogen-based onium salt, which is solid at room temperature; A flame retardant for nylon 6, comprising an acetylene glycol-based penetrating agent (Y).

7. A method for manufacturing a carpet having a pile (2) attached to a base fabric (3), comprising the steps of: The pile (2) is made of nylon 6 fiber, A flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2) is applied to at least the pile (2); The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, the ratio of the amount of the first flame retardant (X1) to the amount of the second flame retardant (X2) attached is 132:3 to 132:14; A penetrating agent (Y) is also attached to at least the pile (2), A method for producing a carpet, wherein the penetrating agent (Y) contains an acetylene glycol-based penetrating agent.

8. A method for manufacturing a carpet having a pile (2) attached to a base fabric (3), comprising: The pile (2) is made of nylon 6 fiber, A flame retardant (X) having a first flame retardant (X1) and a second flame retardant (X2) is applied to at least the pile (2); The first flame retardant (X1) contains guanidine sulfamate which is a solid at room temperature, The second flame retardant (X2) contains a guanidine salt of an alkyl acidic phosphate ester which is a viscous material at room temperature, The base fabric (3) is made of polypropylene fibers, The first flame retardant (X1) also includes a mixture of ammonium sulfate, which is solid at room temperature, and a phosphorus-nitrogen-based onium salt, which is solid at room temperature; The flame retardant (X) is adhered to the pile (2) and the base fabric (3), A penetrating agent (Y) is also attached to at least the pile (2), A method for manufacturing a carpet, wherein the penetrating agent (Y) contains an acetylene glycol-based penetrating agent.

9. The method for manufacturing a carpet as described in claim 8, characterized in that the ratio of the amount of the first flame retardant (X1) to the amount of the second flame retardant (X2) adhered is 132:3 to 132:

14.

10. 10. The method for manufacturing a carpet according to claim 7, wherein the flame retardant (X) is applied to at least the pile (2) by spray coating.

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