JP2008274467A - Method for cutting napped fabric and napped fabric with edge treated thereby - Google Patents

Abstract

[PROBLEMS] To provide a new fraying prevention method which has a soft touch feeling and can be surely frayed without hurting a person in the fraying prevention processing of the edge of a napped fabric, and which is excellent in processing efficiency. It is an object.
As a result of intensive studies to solve the above problems, the raised fabric is melted by sandwiching the raised fabric between a horn that vibrates ultrasonically and the lower blade, and at the same time, the skin layer and the second base fabric layer are melted. By sticking to prevent the raised fabric from fraying, and making the cross-sectional angle of the second base fabric layer on the side opposite to the outer skin layer out of the cross-section of the melt-fixed portion of the raised fabric, the touch feeling is soft and human The present invention has been found that the pile pile at the edge can be surely affected without being damaged, and the fray can be softly frayed without affecting the pile.
[Selection] Figure 2

Description

  BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a napping fabric cutting method for carpets, mats, moquettes, etc. and a napping fabric processed using the method, and a new anti-fraying process that replaces the conventional anti-fraying processing method called overlock and tape lock A method is provided. In the present invention, the edge of the napped fabric refers to a range of 1 to 3 cm from the end of the napped fabric, and the end of the napped fabric refers to the end of the napped fabric.

  Conventionally, as an anti-fraying process for the edges of raised fabrics such as carpets, mats, and moquettes, the edges of the raised fabrics are threaded with an overlock sewing machine with a width of 10 to 30 mm, or tape-like fabrics. Ordinarily, the edge of the raised fabric is sewn to the edge of the raised fabric by a tape lock sewing machine to prevent the edge from fraying. These are important in terms of design because they give a certain performance and give a visual point to the edge of the raised fabric, and are excellent methods for processing the edge of the raised fabric. .

  However, in the above method, since a special sewing machine is used, labor and operator skill are required. Therefore, more efficient fraying prevention processing of the edge of the raised fabric has been demanded.

Therefore, Patent Document 1 discloses a method for treating a carpet edge that does not require an overlock sewing machine by melting and press-bonding pile yarn with a heating roller or a heater. In Patent Document 2, as a terminal processing method for a floor carpet for a vehicle, after slitting with a trim blade, molten resin is supplied onto the carpet edge, the resin is sandwiched between the upper mold and the lower mold, and is crimped and fixed to the carpet edge. A terminal processing method for a vehicle floor carpet is disclosed. Patent Document 3 proposes a technique for fusing and fixing a presser while moving the presser in a horizontal direction while oscillating at a high speed in a direction perpendicular to the surface of the base fabric by a method of tumbling the napped mat. ing. Patent Document 4 discloses a technique in which olefin resin sheets are overlapped and a minute amplitude is given by an ultrasonic horn, the sheet pressure contact surfaces are frictionally heated, the sheets are welded together, and the edges are cut. In addition, in the patent document 5, the applicant has proposed a method for treating the edge of the napped fabric using an ultrasonic processing apparatus.
Japanese Patent Publication 47-46633 JP-A-10-67270 JP2004-19068 JP 2000-37780 A Japanese Patent Application No. 2006-205471

  However, in Patent Document 1, the pile yarn in contact with the heating roller is melted and fixed to the base fabric. Therefore, in order to impregnate the base fabric with the molten resin of the pile yarn to prevent fraying, the root of the pile yarn is used. It is necessary to melt to the part of the carpet, the touch feeling of the carpet end becomes stiff and hard, and since the heating roller comes into contact with the end of the pile thread to be left, the part where the pile thread becomes hard appears and is preferable. It was not a processing method. Moreover, in patent document 2, an installation became big and was unsuitable for the carpet which processes a big area. In Patent Document 3, since the pile yarn is tilted and fixed, although the edge portion has a soft touch feeling, the adhesive force is weak and it cannot be used as a fray-proofing process. Patent Document 4 is used for a resin sheet and is not suitable for a thick raised fabric. Moreover, although the applicant has proposed about the processing method of the edge part of a napped fabric by the ultrasonic processing apparatus in patent document 5, there exists a possibility that the cross-sectional shape of an edge part may be sharp and may injure a person, and improvement is calculated | required. Yes. An object of the present invention is to provide a new anti-fraying method that has a soft touch and can be reliably frayed without fraying in the fraying prevention processing of the edge of the napped fabric, and is excellent in processing efficiency. Yes.

  As a result of intensive studies to solve such problems, the present inventors melted the napped fabric by sandwiching the napped fabric between the horn and the lower blade of the ultrasonic processing apparatus on the napped fabric, and at the same time, The melted cross-sectional shape is melted and fixed at an obtuse angle while leaving the form of the fibers of the napped fabric, so that the pile pile at the edge is hardly affected, the touch feeling of the pile remains as it is, and the melt-fixed surface is hardened and hardened. The present invention has been found out that a soft fray-proofing process can be performed without any problems. The present invention provides the following means to achieve the above object.

  [1] In a raised fabric comprising a skin layer made of pile yarn and a base fabric, a backing layer for fixing the pile yarn and the base fabric, and a second base fabric layer, the raised fabric is interposed between a horn and a lower blade that are ultrasonically vibrated. The raised fabric is blown by pinching the fabric, and at the same time, the skin layer and the second base fabric layer are melted and fixed to prevent fraying of the raised fabric, and the second base fabric layer in the cross section of the melted and fixed portion of the raised fabric A method for cutting a napped fabric characterized in that the cross-sectional angle on the anti-skin layer side is an obtuse angle.

[2] In the above-mentioned raised fabric, the raised fabric is blown by sandwiching the raised fabric between a horn that vibrates ultrasonically and a lower blade having a tip support portion thinner than the tip portion. The method for cutting the napped fabric according to the description.

  [3] In a napped fabric comprising a skin layer made of pile yarn and a base fabric, a backing layer for fixing the pile yarn and the base fabric, and a second base fabric layer, the ends are melt-fixed, and the cross section of the melt-fixed portion Among these, the raised fabric is characterized in that the cross-sectional angle of the second base fabric layer on the side opposite to the outer skin layer is an obtuse angle.

  According to the invention of [1], since the napped fabric is sandwiched between the ultrasonically vibrating horn and the lower blade, the heat generated by friction is concentrated on the lower blade, so that the napped in contact with the tip portion of the lower blade. A napping fabric cutting method in which the skin layer, the backing layer, and the second base fabric layer of the fabric are melted and the cross section of the napped fabric is melted and fixed at the same time to prevent fraying. Also, as the distance from the tip of the lower blade does not become enough to melt and fix the skin layer and backing layer, most of the pile yarns in the skin layer will not melt and become stiff, leaving the fiber form Therefore, the edge of the napped fabric can be a method for cutting a napped fabric that is firmly frayed while leaving a soft pile touch feeling. Furthermore, since the cross-sectional angle of the second base fabric layer on the side opposite to the outer skin layer is obtuse in the cross-section of the melt-fixed portion of the napped fabric, the touch feeling of the cross-section of the melt-fixed portion is soft, and people are damaged by the melt cross-section. It is possible to provide a method for cutting a napped fabric that can be reliably prevented from fraying.

  According to the invention of [2], since the napped fabric is sandwiched between a horn that vibrates ultrasonically and a lower blade having a tip support portion thinner than the tip portion, the resin blown by the lower blade is melt-fixed. Since it flows to the tip support part thinner than the tip part, the horn side cross-sectional angle of the cross-section of the melt-fixed part of the stand-up fabric becomes an obtuse angle, and it is a cutting method of the stand-up fabric that does not hurt people on the melt cross-section. Can do.

  According to the invention of [3], in the napped fabric comprising a skin layer comprising a pile yarn and a base fabric, a backing layer for fixing the pile yarn and the base fabric, and a second base fabric layer, the ends are melt-fixed. Since the cross-section angle of the second base fabric layer on the side opposite to the outer skin layer is an obtuse angle in the cross-section of the melt-fixed part, the touch of the cross-section of the melt-fixed part is soft, and a napped fabric that does not hurt people in the cross-section is obtained. be able to.

  Next, the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view of an example of a raised fabric and illustrates a carpet 1. Sealing is applied by a backing layer 5 so that the pile yarn 2 of the skin layer 4 in which the pile yarn 2 is implanted in the base fabric 3 is not easily detached from the base fabric 3, and at the same time, the second base fabric layer 6 is the backing layer 5. The carpet 1 is formed by bonding for the purpose of providing protection, soundproofing and cushioning. The carpet thus manufactured is cut into the required size and shape, and the edges are frayed by overlock or tape lock processing to obtain the final product. The present invention provides a method for cutting a napped fabric by cutting with an ultrasonic processing apparatus to melt and fix the cross section, thereby eliminating overlock and tape lock processing, and further preventing cutting of the hand at the melt cross section of the carpet. Is.

  FIG. 2 is a schematic view of an ultrasonic processing apparatus when fusing the carpet 1. The ultrasonic processing apparatus is composed of a horn (ultrasonic vibrator) 8 that vibrates ultrasonically, a lower blade 7 and a feed roll (not shown), and a narrow gap (interval is between the lower blade 7 and the horn 8). The carpet that has entered the gap of 0, the amplitude width of the horn is vibrated by the horn, is heated by friction, and is melted to melt and fix the cross section. The base fabric 3 and the second base fabric layer 6 of the raised fabric 1 according to the present invention are not particularly limited as long as they are thermoplastic materials used for ordinary raised fabrics. If a thermoplastic material is used for either the base fabric 3 or the second base fabric layer 6, the other material is not particularly limited. For example, when a cotton base fabric is used as the base fabric 3, a thermoplastic material such as polyester or polypropylene is used as the second base fabric layer 6, and a woven / knitted base fabric or a non-woven fabric base fabric may be used. . When a thermoplastic material is not used for the second base fabric layer 6, a base fabric such as thermoplastic polyester or polypropylene may be used for the base fabric 3, but if possible, both the base fabric 3 and the second base fabric layer 6 are thermoplastic. It is preferable to use those. In this case, since the backing layer 5 is melted by the second base fabric 6 and the base fabric 3 so as to be melted and fixed, the fraying can be more firmly prevented. In order to prevent fraying more firmly, it is preferable that the second base fabric 6 and the base fabric 3 are made of the same kind of thermoplastic resin.

  The backing layer 5 is not particularly limited as long as it is a resin composition or a rubber composition that can fix the pile yarn 2 and the base fabric 3. For example, the resin component of the resin composition may be acrylic, urethane, poly, or the like. Examples thereof include resins such as vinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber composition include SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber), MBR (methyl methacrylate-butadiene rubber), and natural rubber.

  In addition, the carpet can be turned upside down, the horn 8 side can be piled and the lower blade 7 side can be melted as the second base fabric layer 6, but the pile is often pushed by the horn and does not have a sharp melting section. Was not preferable.

  The size and strength of the fraying prevention portion are adjusted by the feed speed of the napped fabric, the shape of the lower blade 7, the output of the ultrasonic processing apparatus, and the like. The distance between the horn 6 and the lower blade 7 is 0, and is set by applying a slight contact pressure. If it is spread too much, the amount of heat generation will be reduced and it will not be possible to blow, and the fraying prevention effect may not be obtained. As the shape of the lower blade 7 is sharper, the sharper the angle of the tip portion, the easier the fusing, but the strength of the fray-preventing portion may not be obtained. In addition, as the angle of the tip portion becomes obtuse, the strength of the fray preventing portion is easily obtained, but the feed speed may have to be reduced. It is preferable to adjust the feed speed, the shape of the lower blade 7, the output of the ultrasonic processing apparatus, etc. in accordance with the standards of the raised fabric.

  FIG. 2 shows an enlarged view of the tip of the lower blade 7 in the enlarged portion. The shape of the lower blade 7 has a tip portion 9 and a tip support portion 10 that is thinner than the tip portion. By adopting such a shape of the tip portion, the resin melted at the tip portion flows and adheres to the inner side of the tip portion of the lower blade, so that the cross-sectional angle on the anti-skin layer side of the second base fabric layer becomes an obtuse angle. Therefore, even if you touch your hand strongly during handling, it will not be like cutting your hand.

  The pile yarn of the napped fabric according to the present invention is not particularly limited, but a thermoplastic resin fiber is more preferable because it is vibrated by the horn 6 and melted. For example, polyester, nylon, acrylic, polypropylene fiber, etc. can be mentioned. Further, the thickness of the pile yarn, the pile length, the number of stitches, the pile basis weight, and the like are not particularly limited, and may be a raised fabric in which the pile yarn is implanted in the base fabric.

  The most preferred form of the raised fabric is a raised fabric in which a pile yarn is implanted in a thermoplastic base fabric and backing is applied, and at the same time the thermoplastic second base fabric is laminated simultaneously with the backing, the base fabric and the second base fabric. Is a napped fabric made of the same kind of thermoplastic resin. By carrying out like this, the strong fraying prevention effect can be acquired with few fraying prevention parts.

Next, specific examples of the present invention will be described.
<Example 1>
As an embodiment of the present invention, materials used for carpets and processing methods are listed.
<Materials used and processing methods>
Base fabric: polyester spunbonded nonwoven fabric (110 g / m ² per unit weight, apparent thickness: 0.3 mm) pile yarn: 2600 decitex polyester fiber yarn.
Tufting machine ... 1/8 cut machine
Tuft Standard: 30 stitches / 10 cm, pile length 8 mm, pile weight 780 g / m ²
Backing layer: SBR latex was roller-coated and dried at 120 ° C. for 10 minutes. (Application amount 260 g / m ² )
Second base fabric: polyester needle punch nonwoven fabric (410 g / m ² per unit weight, apparent thickness 8 mm).
Anti-fraying process: First, using an ultrasonic processing device for the lower blade 7 which rotates as the width of the tip 2 mm as shown in FIG. Was set at an interval of 0, and the 1 m square carpet obtained above was frayed. The melted cross section was melt-fixed so that the polyester spunbond nonwoven fabric of the base fabric and the polyester needle punch nonwoven fabric of the second base fabric wrapped the backing layer, and the fraying stop had a width of about 1 mm. The pile yarn at the end did not melt and become hard, and a good texture could be obtained. Moreover, the cross-sectional angle of the anti-skin layer side of the second base fabric layer of the melt-fixed part was an obtuse angle of 95 °, and it was not like cutting a hand.

<Comparative Example 1>
In Example 1, a carpet cut to a size of 1 m square was subjected to fraying prevention processing using an ultrasonic processing apparatus having a lower blade (tip angle 60 degrees) that becomes narrower toward the tip as shown in FIG. Although a good melted cross section and fraying prevention could be obtained without the piles at the edges lying sideways than in Example 1, the cross-section angle on the anti-skin layer side of the second base fabric layer of the melt-adhered portion was 35 °. It was an acute angle and the hand seemed to break.

<Example 2>
In Example 1, the carpet was turned upside down, and the same processing as in Example 1 was performed. The pile pile at the edge lay sideways, and the pile yarn at the edge did not melt and become hard, and a good texture could be obtained. The cross-section angle of the second base fabric layer of the melt-fixed portion on the side opposite to the outer skin layer was an obtuse angle of 95 °.

Schematic cross section of napped fabric Schematic of the fusing part of the ultrasonic processing apparatus of the present invention Schematic of the fusing part of the ultrasonic processing apparatus of Comparative Example 1

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Carpet 2 Pile yarn 3 Base fabric 4 Skin layer 5 Backing layer 6 Second base fabric 7 Lower blade 8 Horn 9 Tip 10 Tip support

Claims (3)

  In a raised fabric comprising a skin layer made of pile yarn and a base fabric, a backing layer for fixing the pile yarn and the base fabric, and a second base fabric layer, the raised fabric is sandwiched between a horn and a lower blade that are ultrasonically vibrated. The raised fabric is melted by pressing, and the skin layer and the second base fabric layer are melted and fixed simultaneously to prevent fraying of the raised fabric, and the anti-skin of the second base fabric layer in the cross-section of the melt-fixed portion of the raised fabric A method for cutting a napped fabric characterized in that the cross-sectional angle on the layer side is an obtuse angle.   2. The raised fabric according to claim 1, wherein the raised fabric is melted by sandwiching the raised fabric between a horn that vibrates ultrasonically and a lower blade that has a tip support portion thinner than the tip portion. A method for cutting a napped fabric.   In a raised fabric comprising a skin layer comprising a pile yarn and a base fabric, a backing layer for fixing the pile yarn and the base fabric, and a second base fabric layer, the end portion is melt-fixed, and the second of the cross sections of the melt-fixed portion A napped fabric characterized in that the cross-sectional angle of the base fabric layer on the side of the anti-skin layer becomes an obtuse angle.