JPS6127510B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to tufted products.
In the case of the tufted raw fabric before backing finishing, the pile is only held between the warp and warp threads that make up the base fabric, and there is a concern that it may come off during transportation to the backing finishing process or during storage. In order to increase the strength, a woven fabric with a high weft density is used as the base fabric.

In particular, when the pile yarn is a filament yarn, its surface is smooth and therefore a particularly dense base fabric is required. Furthermore, in the case of velour-like tufted carpets, which have recently become mainstream, the pile surface of the tufted carpet is scraped with a wire brush roll before finishing the backing. A high-density base fabric is used to prevent the pile from falling out during the splitting treatment of velor-like tufted carpets, and a backing agent (latex, resin emulsion, etc.) is applied sufficiently during the subsequent backing treatment. given.

For this reason, conventional tufted products have pile tips that are evenly aligned and do not change, and lack breathability and water permeability.When they are laid in a Japanese-style room, moisture accumulates under the floor, causing the tatami to corrode and become unusable. This caused inconveniences such as hygiene.

The present invention aims to solve this problem and provide a tufted product that gives a warmer feel.

That is, the tufted product 1 according to the present invention has
A coarse woven or knitted fabric 3 with continuous inter-yarn gaps 2 of 1.0 mm or more is used as a base fabric, and the tuft spacing b is 1.5 times or more than the arrangement spacing a of the yarn gaps in the longitudinal direction, and the fabric is twisted and set. A cut pile 4 is formed by tufting the pile yarn, and a backing agent is applied without continuously filling the valleys 6 between all the back stitches 5 on the back side of the tufted fabric. It is something.

Here, "gap between threads" is defined as a space between two threads that is far enough apart that the light from the front side of the base fabric to the back side can be clearly seen through the space between the threads forming the base fabric. means a gap.

The coarse woven or knitted fabric with continuous inter-yarn gaps of 1.0 mm or more in the vertical and horizontal directions used in the present invention has a coarse warp density and a weft density, and adhesive resin is applied to the intertwined parts of the warp and weft. A flat weave woven fabric that has been bonded and treated with resin, and/or a plain weave woven fabric that has been pressure-heated after weaving to set the intertwined points of the warp and weft, and Rui and gauze weave woven fabrics joined with yarn, warp knitted fabrics knitted using the weft insertion method, latsiel warp knitted fabrics with continuous chain stitches in the vertical and horizontal directions, and warp and weft yarns joined by marimo and arakune machines. Stitched cloth, etc., stitched together with stitched thread is used. For these base fabrics, filament threads of thermoplastic synthetic fibers, monofilament threads, threads coated with thermoplastic synthetic fibers, etc., having a thickness of 1000 denier or more, preferably around 2000 denier, are mainly used.

The inter-yarn gap c of the base fabric is preferably 1.5 to 5 m/m, preferably around 2 m/m, and the gap a is 2 to 7 m/m, preferably around 2.5 m/m. .

It is appropriate that the tuft spacing b, ie, the tuft gauge or the needle arrangement gauge, be at least 1.5 times the longitudinal arrangement spacing a of the inter-yarn gaps 2 of the base fabric, and should be an integral multiple of 2 or 3 times.

As the pile yarn, in addition to filament yarn and spun yarn, synthetic fiber ribbon tape yarn can also be used, and the material of these yarns does not matter.

To apply a backing agent that does not fill the valleys 6 between vertical rows of back stitches, apply a low-viscosity latex, resin emulsion, or resin solvent solution that does not contain much or no filler such as aluminum hydroxide or calcium carbonate by roller coating or spraying. The backing agent applied on the back stitches penetrates into the back stitches 5 and firmly adheres the back stitches 5 and the base fabric 3, and the backing agent applied on the valleys 6 between the back stitches The agent penetrates into the warp and warp fibers constituting the base fabric and reinforces them, further strengthening the joint at the intertwining point 7 of the warp and weft, and a part of it also penetrates into the root part 8 of the pile on the front side. It penetrates into the fibers that make up the pile, solidifying the binding at the base of the fibers and stabilizing their upright state.

Hair splitting treatment on the pile surface can be performed after this backing finish.

According to the present invention, tufting is carried out in an unstable state where the pile is held in an unstable manner by the stiff, net-like, coarse base fabric due to the intertwined points of the warp and weft, so that the ends of the cut pile are randomly uneven. It is fixed as it is by the backing finish, and
The twisted and set pile yarn is cut and opened at the end of the pile, leaving traces of twists set in random directions, so the overall pile surface is not smooth, but has a random uneven surface, giving a feeling of fluffy softness and warmth. This results in an even more desirable appearance and feel when subjected to hair splitting treatment.

Since tufting is performed with a tuft spacing that is at least 1.5 times the inter-yarn spacing of the base fabric, needles are not inserted into at least one of the left and right sides of the pile column, and therefore the yarn gaps that are not filled and sealed by the pile yarns are tufted. Application of a backing agent that leaves gaps in the tufted fabric and does not fill the gaps between backstitches will cause the remaining gaps between yarns to remain even after the backing is finished, resulting in poor air permeability and water permeability. It is possible to obtain a highly tufted product, and when it is laid indoors, it will not corrode tatami mats or floorboards, and when it is laid outdoors to make artificial lawns, it is easy to lay it because rainwater flows from the pile surface to the basement. Rainwater does not accumulate on the surface, and the gaps between the threads of the base fabric that remain in tufted products make it easy to remove dust attached to the base of the pile when cleaning tufted products. Tufted products can be used hygienically to facilitate drying.

The use of twisted pile yarns thus effectively affects the remaining inter-yarn gaps in the base fabric in tufted raw fabrics and tufted products. In other words, since the pile yarns are set in a twisted manner, even when they are inserted into the inter-yarn gaps together with the needles, they do not untwist within the inter-yarn gaps, and therefore the left and/or
Or, the gap between threads remaining on the right side is not pressed and closed.

In addition, since there is no filler and the backing is finished with a low-viscosity backing agent with a high resin content, even if the pile is tufted onto a net-like base fabric, it stands upright on the base fabric and is bonded on the front and back sides of the base fabric. Therefore, the suture removal strength is strong, and the base fabric itself is also reinforced to improve its dimensions (shape).
A tufted product with excellent stability and wear resistance can be obtained.

In addition, it is important to penetrate the backing agent into the base of the pile and leave gaps between the threads by applying a brush roll to the back surface or applying an air jet to penetrate the base fabric immediately after applying the backing agent. This will make the implementation of the invention more reliable and easier.

Furthermore, without impairing the features of the present invention, the foamed resin 10 may be formed into a grid, stripes, or dots so that at least a portion 9 of the remaining inter-yarn gaps 9 remain after the above-mentioned backing finish. Alternatively, by applying a second backing finish that is laminated in a broken line shape, it is possible to obtain a tufted product 1' that is heavy and has cushioning properties, and such embodiments fall within the technical scope of the present invention. .

[Brief explanation of the drawing]

1 and 2 are perspective views, respectively, of a tufted product according to an embodiment of the present invention, viewed from the back side. 1, 1'...Tufted product, 2...Gap between threads, 3...Base fabric, 4...Cut pile.

Claims (1)

[Claims] 1 Pile twisted with a coarse woven or knitted fabric with continuous inter-yarn gaps of 1.0 mm or more in the vertical and horizontal directions, and with a tuft spacing of at least 1.5 times the arrangement spacing of the yarn gaps in the vertical direction. A tufted product characterized by tufting yarn to form a cut pile yarn, and applying a backing agent to the back side of the tufted fabric without continuously filling the valleys between vertical rows of back stitches.