JP2928272B2 - Molded rug and method of manufacturing the same - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a rug used as a floor material of an automobile or the like. More specifically, the present invention relates to a rug that can be easily formed three-dimensionally and can maintain a stable shape.

(Prior Art) Conventionally, rugs such as automobiles have a rug material in which pile yarn is planted by tufting or needle punching on a primary base cloth such as a woven fabric such as hemp yarn or polypropylene slit yarn or a spunbond nonwoven fabric. On the other hand, it is known that a secondary base cloth is adhered to the back surface with a binder such as latex or the like in which polyethylene is laminated in place of the secondary base cloth in order to prevent or remove hair removal. As the secondary fabric, the same woven fabric or nonwoven fabric as used for the primary fabric was used.

(Problems to be Solved by the Invention) In applications where the floor surface is uneven, such as an automobile, the rug must have an uneven shape that matches the floor surface in order to prevent sand etc. from entering under the rug. Is desired. However, in the case of a rug using a woven fabric as a secondary base fabric, it is easy to hot press mold into a desired shape, but the obtained rug (hereinafter referred to as a molded rug) is easily deformed. There was a drawback that the polyethylene layer was extremely thin at sharp bends and the pile base was exposed, resulting in poor moldability.

An object of the present invention is to eliminate the above-mentioned disadvantages of conventional rugs and to provide a rug having good moldability and good shape retention.

(Means for Solving the Problems) As a result of earnest research, the present invention uses a net made of a heat-adhesive composite monofilament as a secondary base fabric and adheres it with a binder or a low-melting thermoplastic resin to achieve the above object. Knowing that the intended purpose can be achieved by doing so, the present invention has completed the invention.

In the present invention, there is no particular limitation on the primary backing cloth and pile yarn used for the original rug, and any one can be used as long as it does not cause deterioration or deformation during hot press molding. A method of implanting pile yarn on the primary base fabric is also performed by a known method such as tufting or needle patching.

The heat-adhesive monofilament used for the secondary fabric in the present invention has a melting point of 20 ° C. or higher, preferably 20 ° C. or higher, and two different thermoplastic resins, and the low-melting thermoplastic resin (hereinafter, low-melting point component) is a fiber. At least part of the surface, preferably
Fineness obtained by compound spinning in parallel type or sheath-core type to form 30% or more continuously is 150 to 5,000 d / f,
Preferably, it is a monofilament of 200 to 4,000 d / f. Such a heat-adhesive monofilament is knitted or woven at a driving number of 5 to 50/25 mm to form a secondary base fabric. In order to prevent misalignment and fraying, this secondary base fabric can be heat-treated by a hot air drier or a hot calender roll, if desired, to adhere the intersections of the monofilaments. If the difference between the melting points of the two types of thermoplastic resin constituting the heat-bonding monofilament is 10 ° C. or more,
At the time of hot press molding described below, the secondary base fabric is formed into a predetermined uneven shape while the high melting point component keeps the fiber shape, and the low melting component fuses and fixes the intersection of the monofilaments constituting the secondary base fabric. . As a combination of such thermoplastic resins, polypropylene / polyethylene, polyester /
Examples thereof include polyethylene, polyester / copolyester, and nylon 6 / nylon 66. If the fineness of the heat-adhesive monofilament is less than 150 d / f, the rigidity of the rug becomes insufficient, and the molded rug becomes easily deformed, which is not preferable. Is not preferred.

The method of adhering the secondary base fabric to the back of the rug material may be according to the following method, and bonding with a binder such as SBR latex, vinyl acetate latex, vinyl chloride latex,
After laminating a low-melting thermoplastic resin such as polyethylene, ethylene-vinyl acetate copolymer, polypropylene, and low-melting polyester, a secondary fabric is thermally bonded thereto. After bonding the secondary fabric directly to the rug fabric, binder or laminating is performed.
A method such as using more than one layer can be used. The amount of binder or thermoplastic resin with low melting point is usually 50-20
00 g / m ² , preferably 80 to 1000 g / m ² .

The thus obtained rug of the present invention can be formed into a molded rug by hot press molding. The molding conditions are
Pressing pressure range of 1 to 10kg / c at the temperature between the melting points of the two types of thermoplastic resin constituting the heat-adhesive composite monofilament
m ² , the press time is about 10 seconds to 15 minutes.

(Effects of the Invention) In the rug of the present invention, the mesh made of the heat-adhesive composite monofilament used as the secondary base fabric has a low melting point component melted at the time of hot press molding and the intersection of the monofilaments,
The secondary base fabric and the binder layer or the secondary base fabric and the laminate layer are bonded and fixed, and the high melting point component retains a net-like shape to prevent the movement of the binder layer and the laminate layer. Due to the fact that the base is not exposed and the effect of reinforcing the high melting point component, the shape given by hot press molding can be stably maintained.

(Examples) The present invention will be described more specifically with reference to examples and comparative examples. The rug (molded rug) was evaluated by the following method.

Formability: Use a female mold with an inverted trapezoidal groove with a base of 160 mm, a top of 220 mm, and a depth of 200 mm and a corresponding male mold. The surface of the rug is convex and concave. Then, the back surface of the obtained molded rug is observed, and the one where the pile base is exposed or the binder layer or the laminate is thinned is judged to be defective, and the one which is not is judged to be good.

Shape retention: Measure the width of the upper side of the groove of the molded rug used for evaluation of moldability, calculate the deformation rate (Y = 100A / 220) from the difference (Amm) from the mold dimension (220mm), and Was determined to be good if less than 10%, acceptable if not less than 10% and less than 20%, and poor if not less than 20%.

Example 1 A polyester bulked yarn (2,000 g / m ² ) made of a polyester bulked yarn (2,000 g / m ² ) by a spunbond method
d / 100f) was tufted into a loop pile at 1/10 gauge to give a rug raw fabric having a basis weight of 430 g / m ² . On the back of this rug,
Polypropylene / polyethylene (sheath core type) heat-adhesive composite monofilament (1,000d / f)
Laminate a 5mm plain weave secondary fabric (A in Table 1)
In hot calender roll heated only secondary backing side 154 ° C., a linear pressure of 15 kg / cm, adhered under the conditions of speed of 3m / min, further coating the SBR latex in purity content only 100 g / m ² on the back surface Then, it was dried with a hot air dryer at 110 ° C. to obtain a rug of the present invention.

Next, the rug is heated from the back with a far infrared heater.
After heating at 40 ° C. for 40 seconds, it was pressed with a mold at room temperature for 5 seconds at 5 kg / cm ² G to form a molded rug.

Table 1 shows the constitution of the secondary fabric used, and Table 2 shows the test results.

Example 2 The original rug used in Example 1 and the secondary fabric shown in Table 1B were laminated and bonded in the same manner as in Example 1, and further, polyethylene was melt-laminated with 200 g / m ² on the back surface. Thus, a rug of the present invention was obtained.

Next, this rug was press-formed in the same manner as in Example 1 except that the heating conditions were 135 ° C. and 50 seconds. Second test result
It is shown in the table.

Example 3 Using the same rug raw material as in Example 1, melt-laminated polyethylene with 130 g / m ² on the back surface, cooled, laminated the secondary fabric shown in C in Table 1, and further cooled polyethylene with 130 g / m ^2. m ²
By the melt lamination, the rug of the present invention having the back surface reinforced in three layers was obtained. This rug was press-formed in the same manner as in Example 1 to obtain a formed rug of the present invention. Second test result
It is shown in the table.

Example 4 A rug of the present invention was obtained in the same manner as in Example 3 except that D in Table 2 was used as the secondary base fabric. This rug was subjected to hot press molding under the same conditions as in Example 2 to obtain a molded rug of the present invention. The test results are shown in Table 2 below.

Comparative Example 1 100 g / m ² of SBR latex was coated directly on the back of the rug used in Example 1, without laminating a secondary base fabric, and dried with a hot air dryer at 110 ° C for 15 minutes. To obtain a prior art rug. This rug was subjected to heat press molding in the same manner as in Example 1 to obtain a conventional rug. The test results are shown in Table 2.

Comparative Example 2 In Comparative Example 1, the polypropylene spunbonded nonwoven fabric (with a basis weight of 102 g / m ² ) shown in E of Table 1 was laminated and dried before drying after coating with SBR-based terrax.
Example 1 by drying with hot air at 15 ° C. for 15 minutes to obtain a rug of Comparative Example 2.
Heat press molding was performed in the same manner as described above. The test results are shown in Table 2.

Comparative Example 3 200 g / m ^{2 of} polyethylene was directly melt-laminated on the back of the rug used in Example 1 without laminating a secondary base fabric,
After cooling, hot press molding was performed in the same manner as in Example 1. The test results are shown in Table 2.

As is clear from the results shown in the table, the molded rug of the present invention is excellent in moldability and shape retention, and is very suitable as a rug used in an uneven place such as a car floor.

Claims (3)

(57) [Claims] 1. Two types of thermoplastic resins having melting points different from each other by 10 ° C. or more as a secondary base cloth are provided on the back of a primary base cloth (hereinafter sometimes referred to as an original rug) on which pile yarns are planted. Thermoplastic resin (hereinafter sometimes simply referred to as low melting point component)
Fineness 150 obtained by compound spinning in parallel type or sheath-core type so that at least a part of the fiber surface is continuously formed
A mesh formed by knitting or weaving a heat-adhesive composite monofilament of ~ 5000 d / f with a driving number of 5 to 50/25 mm,
Directly or via a binder layer or a laminate layer, the low melting point component of the composite monofilament constituting the net is adhered and fixed by melting, and the other thermoplastic resin of the composite filament (hereinafter simply referred to as high melting point) A molded rug, wherein the rug retains the reticulated shape. 2. Two kinds of thermoplastic resins having melting points different from each other by 10 ° C. or more as a secondary base cloth on the back surface of a primary base cloth (hereinafter, sometimes referred to as a rug original fabric) on which pile yarns are planted. Thermoplastic resin (hereinafter sometimes simply referred to as low melting point component)
Fineness 150 obtained by compound spinning in parallel type or sheath-core type so that at least a part of the fiber surface is continuously formed
A mesh formed by knitting or weaving a heat-adhesive composite monofilament of ~ 5000 d / f with a driving number of 5 to 50/25 mm,
The low melting point component of the composite monofilament constituting the network is directly adhered and fixed by melting, and the other thermoplastic resin of the composite filament (hereinafter sometimes simply referred to as a high melting point component) is formed in the mesh shape. A molded rug characterized by holding a rug. 3. Two kinds of thermoplastic resins having melting points different from each other by 10 ° C. or more as a secondary base cloth on the back surface of a primary base cloth (hereinafter sometimes referred to as an original rug) on which pile yarns are planted. Thermoplastic resin (hereinafter sometimes simply referred to as low melting point component)
Fineness 150 obtained by compound spinning in parallel type or sheath-core type so that at least a part of the fiber surface is continuously formed
A mesh formed by knitting or weaving a heat-adhesive composite monofilament of ~ 5000 d / f at a driving number of 5 to 50/25 mm,
Directly, or by laminating via a binder layer or a laminating layer, the resulting laminate, hot press molding at a temperature between the melting point of the low melting point component and the high melting point component of the heat-adhesive composite monofilament. A method of manufacturing a molded rug.