JPH10314007A - Carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a drinkable carpet with a draining function which has such a good compatibility with dents and protrusions/ups and downs, that is, ruggedness of a concrete ground as to be closely laid down and which can be laid on the ground without for its drain function being ruined by earth and sand. SOLUTION: A double warp-knitted ground cloth 27 consisting of an upper cloth constructed from upper yarns and a lower cloth constructed from lower yarns combined together by a combining yarn 24 with a specific space 31 in between, is pasted on the back surface of the carpet surfacing base material 34. The lower cloth is made as a netting construction having an opening surrounded by chain stitching rows 21 and the upper cloth is made as a plain stitched construction with spaces 22.22 of adjacent chain stitching rows being combined by insertion yarns 23. Each of the upper and lower chain stitching rows 21.22 and the combining yarn 24 are preferably covered by a coating film of a resin composition and as a combining yarn 24 a filament yarn of more than fifty deniers in a single yarn denier is preferable.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a rug mainly used outdoors.

[0002]

2. Description of the Related Art In a rug for outdoor use in which a pile is planted on a base cloth, high-pressure air is applied to a surface of an adhesive applied in a backing step of fixing the pile to the base cloth so that water does not pool on the surface. By spraying, the adhesive coating is opened with fine holes to impart water permeability, to facilitate the penetration of rainwater from the fine holes to the back surface, and to use a monofilament yarn with a flat cross section with good drainage for the pile, In consideration of drainage of rainwater that has passed through the base cloth, unevenness is provided on the back of the rug. In order to improve the drainage on the back of the rug, Japanese Utility Model Laid-Open No. 5-28627 discloses a plastic deck having a large number of legs projecting from the back of the substrate, laminated on the back of the rug surface substrate.

[0003]

Problems to be Solved by the Invention
In the case of a rug lined with a plastic deck as shown in (1), when laying it on concrete ground such as a parapet or veranda, drainage is secured between its legs, and although drainage is excellent, plastic Because the deck made by injection molding is hard and has excellent shape stability,
Without getting accustomed to the irregularities and undulations of the concrete ground, there is a gap between the concrete ground and the legs, and the rug floats, and the creaking noise generated by walking on it gives discomfort,
When it is laid on the ground, the legs bite into the ground, and the drains between the legs are closed with earth and sand.

[0004]

SUMMARY OF THE INVENTION Accordingly, the present invention provides a backing material which secures a space required for drainage on the backside of a rug, and the backing material can be closely laid on the unevenness and undulations of the concrete ground so that it can be closely laid and even if laid on the ground. It is an object of the present invention to obtain a rug that maintains a drainage function for a long period of time without the space on the back of the rug required for drainage being blocked by earth and sand.

[0005]

According to the present invention, there is provided a rug comprising an upper cloth composed of an upper thread and a lower cloth composed of a lower thread, with a certain space 31 provided between the upper cloth and the connecting thread 24. The first feature is that the double warp knitted fabric 27 connected by the above is bonded to the back surface of the rug surface base material 34.

A second feature of the rug according to the present invention is that, in addition to the first feature, the lower fabric has a net structure having an opening 28 surrounded by a chain stitch row 21.

A third feature of the rug according to the present invention is that, in addition to any one of the above-mentioned first and second features, the adjacent stitches 22 and 22 of the upper cloth are connected by an insertion thread 23. Is to be.

A fourth feature of the rug according to the present invention is that, in addition to any of the first, second and third features, a double warp knitted fabric 27 is provided.
The chain stitch rows 21 and 22 of the upper cloth and lower cloth and the connecting yarn 24 are
This is because the resin composition is covered with a coating film.

A fifth feature of the rug according to the present invention is that, in addition to any one of the first, second, third and fourth features, the connecting yarn 24 is a filament having a single yarn fineness of 50 denier or more. Filament yarn is used.

A sixth feature of the rug according to the present invention is that in addition to any of the first, second, third, fourth, and fifth features,
The surface substrate 34 is constituted by a pile fabric.

A seventh feature of the rug according to the present invention is that, in addition to any of the first, second, third, fourth, fifth, and sixth features, the surface substrate 34 has a flat cross section. In other words, the pile 32 is composed of fiber yarns.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The double warp knitted fabric 27 comprises a top cloth (22).
A double Raschel warp knitting machine is used in the same manner as the double Raschel warp knitting fabric, in which the pile yarn is cut (so-called center cut) between the upper and lower cloths (21) to form upper and lower cut pile cloths. The pile yarn is knitted as a connecting yarn 24.

In order to form the lower cloth into a net structure having an opening 28 surrounded by the chain stitch row 21, the lower thread constituting the lower cloth chain stitch row 21 is divided by one wale every several courses in the knitting process. Move to the left or right, and the two lower threads adjacent to each other
The composite chain stitch 29 may be formed together with the lower thread of the next wale that differs on the left and right every several courses. Then,
As shown in FIG. 2, an opening 28 is formed which is surrounded by a single chain stitch 30 formed solely by the lower thread adjacent to the left and right and a composite chain stitch 29 in which the adjacent lower thread is compounded. In order to connect the adjacent chain stitch rows 22 of the upper cloth with the insertion yarn 23, the insertion yarn 23 is moved left or right by one wale or several wale for each course in the knitting process of the upper cloth ( Lapping), and the insertion thread 23 may be engaged with the upper fabric chain stitch 22 formed by the upper thread at the folded position that moves left and right (FIG. 2).

The lower cloth is formed into a net structure having an opening 28 surrounded by the chain stitch row 21, and the lower cloth 22.
In the case where the connecting yarns 22 are connected by the inserting yarns 23, as shown in FIGS. Stitch row 2
Two connecting yarns 24a and 24b divided into two and two
Is formed on the upper side of the composite chain stitch 29 as the apex. The upper cloth is supported by two connecting yarns 24a and 24b constituting two sides of the space 31 having the inverted triangular shape, and the connecting yarn 24 is formed by the upper cloth chain stitch 22 and the lower cloth chain stitch 29. Reciprocating between them to form a loop structure similar to a loop pile, the upper end and the lower end of which are locked to the upper cloth and the lower cloth, respectively. For this reason, even if the upper cloth is depressed by being stepped on, if the pressing load is eliminated, the concave is eliminated by being pushed up by the connecting yarn 24, and the space 31 between the upper cloth and the lower cloth is elastically restored to the drainage groove. To restore its function.

The chain stitch rows 21 and 22 of the upper cloth and the lower cloth and the connecting yarn 24 are covered with the resin composition only between the connecting yarns (24 and 24) arranged upright between the upper cloth and the lower cloth. This is to close the minute gaps and the chain stitches of the upper cloth and the lower cloth so as to make it difficult for the double warp knitted fabric 27 to retain water. For this purpose, a filament yarn having a filament fineness of 50 denier or more is used as the connecting yarn 24, and the distance between adjacent connecting yarns (24.2) is used.
4) It is preferable to make a large gap that is difficult to hold water. Then, by using a filament having a single yarn fineness of 50 denier or more for the connecting yarn 24 and applying the resin composition to the chain stitch rows 21 and 22 and the connecting yarn 24, the double warp knitted fabric 27
, The space 31 serving as a drainage groove is secured for a long period of time, and the rug 20 is also rich in cushioning properties.

The resin composition is prepared by using a resin such as a natural rubber, a synthetic rubber, a vinyl chloride resin or an acrylic resin, and a plasticizer, an organic solvent, water, or another solvent to be used in a liquid state. In order to cover the chain stitch rows 21 and 22 and the connecting yarn 24 with the resin composition, the double warp knitted fabric 27 is dipped in the liquid resin composition, or the liquid resin composition is sprayed or sprayed with a roll coater or the like. After the application, it may be passed through a press roll. Then, the liquid resin composition sufficiently penetrates into the inside of the double warp knitted fabric 27, and all the fibers constituting the double warp knitted fabric 27 are covered with the liquid resin composition. Excess liquid resin composition in excess of the amount necessary to form a film on the surface of each fiber is squeezed out, and a space 31 serving as a drainage groove is secured. As described above, in order to easily recover the original space 31 after passing through the press roll, it is recommended to use a filament having a single yarn fineness of 50 denier or more for the connecting yarn 24.

As the surface substrate 34, a pile fabric, in particular, a pile fabric for artificial turf, in which a fiber yarn having a flat cross section is planted as a pile 32 on a coarse base cloth 33, may be used. When used, a needle punching felt can be used for the surface substrate 34. The adhesive 26 for bonding the surface base material 34 and the double warp knitted fabric 27 includes
A liquid adhesive, a heat-fusible resin prepared in a fibrous or powder form, a film or a non-woven form, or the like is used.

When the rug 20 is laid as a tile carpet cut into a tile of 30 to 100 cm square,
No particular water permeability is required between the surface base material 34 and the double warp knitted fabric 27. This is because rainwater permeates from the periphery of the tiled rug 20 to the back side, and it is difficult for water to collect on the surface.

[0019]

According to the present invention (claim 1), since a drain groove is formed on the back surface by a space 31 continuous in all directions between the upper cloth and the lower cloth, the rug is excellent in drainage and suitable for outdoor use. Is obtained.

Since the space 31 is formed so as to be surrounded by the connecting yarns 24 interposed in the upright state by connecting the upper cloth and the lower cloth, the double warp knitted fabric 27 has the same flexibility as the thick cloth. Having. For this reason, the rug of the present invention adheres well to the undulating concrete ground, walks on it without any discomfort, and the connecting thread 24 interposed in the upright state between the upper cloth and the lower cloth gives a cushion feeling. give.

Since the connecting yarn 24 is locked at both ends by the upper cloth and the lower cloth, it does not remain pushed down like the pile of the pile cloth protruding from the base cloth. Is maintained for a long time. Also, the connecting yarn 2
Since the lower end of 4 is locked to the lower cloth, even if the rug 20 is laid on the ground, it does not cut into the ground, and the lower cloth (21) prevents the intrusion of the earth and sand into the space 31.
1 The drainage function is maintained for a long time.

According to the present invention (claim 2), the connecting yarn 24
The lower end is pressed down to the lower cloth chain stitch row 21 which borders the opening 28, and the space 31 between the connecting yarns 24 which are in an upright state adjacent to each other between the upper cloth and the lower cloth can be increased, and the drainage thereof can be increased. Function can be enhanced.

According to the present invention (claim 3), since the surface of the upper cloth is a flat surface covered with the insertion yarn 23, the surface substrate 34
The penetration of the adhesive 26 to the inside of the double warp knitted fabric 27 is suppressed, the drainage function of the space 31 is not impaired by the adhesive 26, and the surface base material 34 and the double warp knitted fabric 2
7 are closely adhered on the entire surface and are firmly adhered.

When the lower cloth is formed into a net structure having an opening 28 surrounded by the chain stitch row 21, and the adjacent cloth stitch rows 22 of the upper cloth are connected by the insertion yarn 23, the connecting yarn 24 is used.
Since a and 24b form an inverted triangular space 31, the cushion effect of the connecting yarns 24a and 24b is further enhanced.

According to the present invention (claims 4 and 5), the inside of the chain stitch (21.22) and the inside of the connecting yarn (24.24)
Since the gap of the space 31 becomes large, the drainage function of the space 31 is improved, and the rug 20 has a good cushioning property.

According to the present invention (claim 6), the surface substrate 3
The water adhering to the surface of the pile 4 drips along the length direction of each fiber of the upright pile 32, and is easily drained through the space 31.

According to the present invention (claim 7), the surface substrate 3
Water adhering to the surface of No. 4 is easy to drip, and the rug 20 is easy to dry after rain or watering, so that bacteria are not propagated and sanitary.

[Brief description of the drawings]

FIG. 1 is a partially cut-away enlarged surface perspective view of a rug according to the present invention.

FIG. 2 is a rear perspective view of the rug according to the present invention, in which a part of the rug is encircled and enlarged.

[Explanation of symbols]

 Reference Signs List 20 rug 21 lower cloth chain stitch row 22 upper cloth chain stitch row 23 insertion thread 24 connecting thread 26 adhesive 27 double warp knitted fabric 28 opening 29 composite chain stitch row 30 single chain stitch row 31 space 32 pile 33 base cloth 34 Surface substrate

Claims (7)

[Claims] 1. A double cloth comprising an upper cloth composed of an upper thread and a lower cloth composed of a lower thread, which are connected with a connecting thread (24) with a certain space (31) opened between them. Warp knitted fabric (27)
Is bonded to the back surface of the rug surface substrate (34). 2. The rug according to claim 1, wherein the undercloth according to claim 1 forms a net structure having an opening (28) surrounded by a chain stitch row (21). 3. The rug as claimed in claim 1, wherein adjacent upper and lower stitch rows (22, 22) of the upper cloth are connected by an insertion thread (23). 4. The double warp knitted fabric (2) according to claim 1
7) The rug according to claim 1, wherein the chain stitch rows (21, 22) and the connecting yarns (24) of the upper cloth and the lower cloth are coated with a coating film of a resin composition. 5. The rug according to claim 1, wherein the connecting yarn (24) according to claim 1 is a filament yarn which is a filament having a single yarn fineness of 50 denier or more. 6. Surface substrate (34) according to claim 1,
The rug according to claim 1, wherein is a pile fabric. 7. The rug according to claim 1, wherein the pile (32) according to claim 1 is constituted by a flat-section fiber yarn.