JPH01272877A - Pile floor covering and production thereof - Google Patents

Abstract

PURPOSE:To obtain a flexible raw fabric for pile fabrics without elution of a fixing agent in dyeing, by vertically setting pile yarns of a substrate sheet and adhering the base part thereof with the fixing agent consisting of styrene butadiene rubber and a specific thermosetting resin. CONSTITUTION:Piles 2, such as nylon, are vertically set in a substrate sheet 1 consisting of jute or synthetic fiber and a fixing agent 4 consisting of 80wt.% styrene butadiene rubber and 20wt.% aqueous chemical reactive type thermosetting resin (e.g., melamine resin) is continuously applied to the base part thereof, dried, then piece dyed and forcibly dried on a belt stretched parallel (the raw fabric is restored to a plane form at this time). The raw fabric restored to the plane form is then punched to a prescribed shape and a back side layer 5, such as natural rubber, is subsequently formed on the back side thereof to afford the aimed raw fabric for pile fabrics. Since the elution of the above- mentioned rubber in dyeing is suppressed with strong adhesion and accurate punching can be carried out in a state restored to the plane form by blending the afore-mentioned thermosetting resin as opposed to a conventional method, the accurate product is obtained.

Description

Detailed Description of the Invention (Field of Industrial Application) The present invention is directed to a process of processing a raw material obtained by tufting pile yarn onto a long base material sheet, in particular, to prevent stretching or warping of the raw material during rug punching. The present invention relates to a pile rug and a method for manufacturing the same, in which the pile is strongly fixed to a base sheet, and this fixing operation can be performed continuously, while providing the necessary conditions to make it possible to manufacture an accurate product.

[Conventional technology]

When manufacturing conventional pile rugs, such as entrance mats using cut pile, as shown in Figure 4, tufting is performed using pile fibers such as nylon on a textile base sheet made of woven fabric or synthetic fiber. , make a raw rug fabric, and arrange it in three rows of 90cm products, each fabric containing 1 piece of fabric.
Cut into pieces of about 2 cm, dye them in a batch dyeing tank, dry and tuft the roots of the cut pile with styrene-butadiene rubber (S, B, R,
After performing the so-called gluing using the method (abbreviated as ), as shown in FIG. 5, both sides of the web are secured to the tips of hooks a, and the web is moved through the drying oven C shown in the figure in a hollow supported state. After the product is force-dried and punched out to the size of the product, a so-called rubber layer is formed on the back side using natural rubber, polyvinyl chloride, or a mixture of natural rubber and polyvinyl chloride, and the product is obtained. was.

[Problem that the invention seeks to solve]

However, when pile rugs are manufactured by these methods, especially when drying after gluing the cut pile roots after tufting to the base material, when a planar conveying means such as a belt conveyor is used, S, B, R, adheres to the surface of the transfer means and the desired drying cannot be achieved.As a result, as a result of drying in a hollow supported state using hook a as shown in the illustration, the portion held by hook a has a width as shown in the example. The original fabric is stretched in the direction or the intermediate part thereof sag downward and hardens while being deformed, and as a result, the original fabric in the state before punching becomes elongated or wavy, and the product after punching does not have accurate dimensions, especially If the pile threads are not parallel, or if the surface is dyed with letters or designs, the part may be cut and the product may be defective. So S, B, R
, If the dyeing process is carried out after drying and curing in the post-hollow supported state, it will stretch in the width direction as described above during this dyeing process.
The present inventor conceived that an original fabric with high flatness in plan view could be obtained by heating the wavy portion in a dyeing solution, but S, B, and R are usually water-soluble emulsions. Because these types of cut piles are used, it has been found that they elute in the staining solution, making it impossible to obtain adhesion to the root of the cut pile.Therefore, it is necessary to glue S, B, and R before the dyeing process. The inventor has discovered that this is not possible. Naturally, instead of S, B, and R, it is also possible to use other materials that do not dissolve in the staining solution, such as EVA or urea resin, which is an ethylene vinyl acetate copolymer, but these materials are not suitable for the base material. After it is used in a sheet and cured, there is a problem that the base sheet itself becomes hard and loses its flexibility.In addition, when it is covered with rubber to form the back layer in the final process, chemical reactions with this rubber material occur. Poor compatibility,
The use of EVA or urea resin poses a problem. In addition, in the conventional manufacturing method and the manufacturing method obtained therefrom, the dyeing process is carried out in a batch process, and as a result, the processing length that can be dyed in one batch is about 120 Ir1. It is necessary to always cut the long original fabric to this length, and gluing to fix the roots of the cut pile after dyeing is unnecessary even though the process can be performed continuously. The situation forced continuous processing.

[Means for solving problems]

The present invention solves the problems associated with the conventional pile rug and its manufacturing method as described above, and provides a raw fabric that does not stretch or warp during punching, and also allows the pile to be strongly adhered to the base sheet and allows normal continuous operation. The aim is to provide something that can be made with a base material sheet, with pile threads planted upright on a base sheet, and the base of the pile made of styrene-butadiene rubber and water-based chemically reactive thermosetting synthetic resin. The subject matter is a pile rug characterized by being fixed with a fixing agent.

[For production]

As described above, the pile rug and the method for manufacturing the same according to the present invention, in the case of a pile rug, pile threads are planted upright on a base sheet and when fixing the root part, styrene-butadiene rubber and water-based chemical reaction type heat are used. It uses a fixing agent made of a curable synthetic resin.One of the fixing agents is a water-based emulsion type of styrene-butadiene rubber, while the other thermosetting synthetic resin is a water-insoluble one. Since S, B, and R are in the staining solution? This serves as a means to prevent the dye from leaking out, and allows it to be pasted before the dyeing process. Therefore, even if the original fabric with this fixative attached is stretched in the width direction in a hollow supported state or dried in a wavy state to fix the pile root, it will not be heated during the subsequent dyeing process. In addition to restoring the fabric to its original state, dyeing can be carried out without these fixatives eluting, and after dyeing, it can be dried on a transfer means that can be placed flat to create a pile. To provide a pile rug that allows accurate punching with the roots fixed, allows for continuous production, and has a strong fixing force at the pile roots, and a method for manufacturing the same.

[The detailed description of the invention will be explained in more detail.] That is, the pile rug according to the present invention is made by tufting pile threads such as nylon 6.6 on a base sheet made of woven fabric or other sheet material using jute, synthetic fibers, etc. To provide a pile fabric in which the root part of the pile yarn is fixed with a fixing agent, including a loop pile state or a cut pile state such as an entrance mat where mud, dust, etc. can be easily discharged. Here, the fixing agent used is one in which S, B, R, and a water-based chemical reaction type thermosetting synthetic resin coexist.As the water-based chemical reaction type thermosetting synthetic resin, melamine resin, urea Resins, phenolic resins, etc. are considered, and it is particularly desirable to use melamine resin from the viewpoint of cost, usage conditions, etc. S, B, R.

The amount of coexisting thermosetting synthetic resin is S, B, R, 70
The ratio is 10 to 30% by weight relative to ~90% by weight, and it is particularly preferable to use 80% by weight of S, B, and R and 20% by weight of the thermosetting synthetic resin. Usually, S,
B.

Ro is a water-soluble emulsion type and is used because it has flexibility, but since it is water-soluble, it is mixed with S and B before the dyeing process.

Even if R1 is used alone to fix the root of the pile yarn, it tends to be eluted into the dyeing solution and its fixing strength is reduced. On the other hand, when a thermosetting synthetic resin such as melamine resin is used and the base of the pile system is fixed with the resin alone, the base sheet itself, that is, the base sheet made by tufting the pile threads, is used. The flexibility of the raw material itself decreases,
Although it is in a hard state, thermosetting synthetic resins such as melamine resin are S because they are water-insoluble materials.

It becomes a material that prevents the elution of B and R, and when both components coexist, it is possible to adjust the degree of elution as well as the hardness.

When S, B, R, in the above range is 70% by weight or less, and the melamine resin is 10% by weight or less, it is not preferable to impart water-insoluble properties to S, B, R, and When the amount of thermosetting synthetic resin, typified by melamine resin, is 30% by weight or more, it is not preferable because the flexibility decreases.

By fixing the roots of the pile yarns planted on such a base material sheet with the fixing agent, gluing can be done before dyeing and dyeing can be carried out after fixing. It gives the original fabric a state without stretching or warping during punching, making it possible to make accurate cuts.In addition, even when immersed in the dyeing solution during the dyeing process, the fixative is eluted, reducing the adhesion to the base of the pile. There is nothing to do. Fig. 1 shows an explanatory view from below of the state in which the cut pile 2 is planted on the base sheet 1 and the fixing agent 4 is fixed to the root 3 part, and Fig. 2 shows the state after the cut pile 2 has been fixed with the fixing agent 4. This figure shows a cross-sectional state of a finished product formed by lining the back surface of the base sheet 1 with a back layer 5, for example, with natural rubber, polyvinyl chloride, or the like.

Next, we will discuss the method for manufacturing such pile rugs in Part 3.
A detailed explanation will be given based on the figures. That is, as shown in the flow sheet of FIG. 3, the present method for manufacturing pile rugs involves adding pile materials such as nylon 6 and nylon 6.6 to a base sheet made of jute or synthetic fiber fabric. A raw fabric is prepared by tufting the yarn in a conventional manner, and then a fixing process is performed on the three pile roots of the raw fabric. This fixing process involves applying a fixing agent containing 80% by weight of S, B, R, and 20% by weight of melamine resin to the pile root 3 which is exposed on the back side of the original fabric after the above-mentioned fabric preparation process. work that continuously adheres to
That is, gluing is done in a process, and then, similarly to the conventional method shown in FIG. It is hung to dry continuously. At this time, of course,
As in the conventional drying process, the original fabric is dried and hardened while being stretched, wavy, sagging, or deformed in the width direction due to its own weight. Next, the original fabric to which the root 3 of the pile yarn is fixed is cut into strips of about 120 m, which is the throughput capacity of one patch in the next dyeing process, and this is continuously immersed in the dyeing tank of the dyeing process in the usual manner. , perform the processing. During this dyeing process, similar to the conventional dyeing process, coloring is carried out called reverse dyeing, and printing is completed.During this process, the original fabric, which has been deformed during the drying process, is removed by the dyeing solution. Normally, the temperature is around 98°C, and as a result of staying inside for about 2 hours, even though S, B, R, and thermosetting synthetic resins are used, these fixing agents soften and the base material The sheet shrinks, and the original fabric itself recovers its flexibility and flatness at the same time. After taking it out of the dyeing tank, it is transferred to the next drying process. In this drying process, the material is placed on a transfer means that makes only partial contact with the material, such as a belt made of metal nets or wires stretched in parallel, and is force-dried in a drying oven. It is. That is, in this drying process,
Since the material is softened and restored to its original state and dried by placing it on a net or the like, it hardens without stretching or sagging like when using a hook. Next, in a punching process, the dyed original fabric is punched out into a predetermined shape. In this punching process,
The original fabric itself maintains its flatness and its dimensions have returned to those of the base sheet, so even if it is punched out, it will not be possible to cut it due to the pattern given to the pile itself or the pile system. It will never happen. Next, on the back side of the semi-finished product punched out in this way, a back layer 5 is shown in FIG. It is formed by coating or laminating as described above, and then undergoes a back layer forming process. As mentioned above, by using S, B, and R as the fixing agent, it has good compatibility with natural rubber and polyvinyl chloride resin, and among the thermosetting synthetic resins, melamine resin and urea Resins, phenolic resins, etc. do not interfere with their compatibility relatively, and moreover, they prevent S, B, R, and the like mentioned above from eluting in the dyeing solution, and do not impair flexibility as a whole. It is possible to create a state with less. The pile rug of the present invention is made by such a manufacturing method, but S, B, l? .

By mixing a thermosetting synthetic resin with the dye, S, B, and R themselves have the property of not being eluted in the dyeing solution, and at the same time,
A method for producing a pile rug is provided, which maintains the flexibility of the original fabric itself after tufting the pile system onto the base sheet 1, and also ensures the fixation of the pile base 3.

〔Effect of the invention〕

As described above, the pile rug according to the present invention and the method for producing the same can be applied to pile rugs planted upright on a base material sheet using a fixing agent made of S, B, R, and an aqueous chemically reactive thermosetting synthetic resin. Since the root part of the yarn is fixed, this fixing process is placed before the dyeing process to enable continuous gluing after fabrication, and at the same time, in the dyeing solution, S, Il, R,
It is possible to prevent the elution of the pile yarn and to create the original fabric for pile rugs without impairing the flexibility of the finished fabric, and it is also possible to achieve accuracy in flatness and width direction dimensions, so the pile yarn can be easily removed during punching. This makes it possible to punch out while accurately displaying the parallelism of the planted state and the patterns and designs formed on the surface.

[Brief explanation of the drawing]

The drawings show the product of the present invention and its manufacturing process, and Fig. 1 is a downward perspective view showing the cut pile of this rug in a planted state, Fig. 2 is a cross-sectional explanatory view of the finished product, and Fig. 3 4 is a flow sheet showing the manufacturing method of the present invention, FIG. 4 is a flow sheet showing the conventional manufacturing method, and FIG. 5 is an explanatory diagram showing the drying process in the conventional method. Base sheet, 2: Cut pile, 3: Root, 4: Fixing agent, 5: Back layer.

Claims (1)

[Claims] 1) Pile threads are planted on a base sheet, and the base of the pile is fixed with a fixing agent made of styrene-butadiene rubber and a water-based chemically reactive thermosetting synthetic resin. A pile rug characterized by: 2) The pile rug according to claim 1, which uses one selected from melamine resin, urea resin, and phenol resin as the water-based chemically reactive thermosetting synthetic resin. 3) The process of creating a pile rug by tufting the pile fibers onto a base sheet, and the aqueous chemical reaction type thermosetting synthesis of the root part of the pile planted on the base sheet with styrene-butadiene rubber. A process of fixing the base of the pile by fixing it with a fixative made of resin, a dyeing process of dyeing it in a dyeing solution, and a forced drying process by placing it on a transfer means that partially contacts the original fabric. A punching process in which the original fabric after dyeing is punched out into a predetermined shape, and a back layer forming process in which a back layer is formed from materials such as natural rubber or synthetic resin on the punched semi-finished product. and a method for manufacturing pile rugs. 4) A method for manufacturing a pile rug according to claim 3, which uses a metal net as a transport means in the drying process.