JPS6339243B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a tufted carpet and a method for manufacturing the same, and more specifically, the present invention relates to a tufted carpet and a method for manufacturing the same, and more specifically, the fluff on the adhesive surface of the secondary base fabric allows the bond between the secondary base fabric and the pile to be bonded. This invention relates to a tufted carpet that has very strong adhesion to the foot and primary base fabric, and a method for producing the same.

[Prior art and its problems]

Conventionally, in tufted carpets in which a secondary base is attached to a tufted primary base fabric,
Jute fabric is often used as the secondary base fabric, and other materials such as extremely light tortoiseshell gauze-like knitted fabrics and synthetic rubber foam rubber are also used, and these are tufted with an adhesive such as latex to create the primary fabric. It is attached to the back side of the base fabric, fixing the legs of the pile, hiding the legs of the pile, and giving volume to the carpet. However, when using these secondary base fabrics, the adhesion of the legs of the pile and the adhesion between the primary base fabric and the secondary base fabric may be insufficient, resulting in the pile falling out or the secondary base fabric peeling off. Easy to do.

SUMMARY OF THE INVENTION An object of the present invention is to provide a tufted carpet free from the above-mentioned defects and a method for manufacturing the same.

[Means to solve the problem]

In order to achieve the above object, the structure of the tufted carpet of the present invention is such that a tufted carpet is formed by bonding a secondary base fabric to the back side of a tufted primary base fabric with an adhesive. At least heat-fusible composite short fibers made of two or more composite components with a melting point difference of at least 20°C or more as
It is composed of a fiber assembly layer consisting of 15% (by weight) or more (by weight) of other short fibers and 85% (by weight) or less of other short fibers, and has fluff with a length of more than 0.5 mm on one side (hereinafter referred to as the inner surface) and on the other side (hereinafter referred to as the outer surface). ) is a nonwoven fabric that has been formed into a smooth surface or an embossed uneven surface by heat treatment, and is bonded on the inside surface, and the fluff of the secondary fabric that extends to the back side of the primary fabric, the legs of the pile, and its surroundings forms the pile. It is characterized by being embedded and fixed together with the legs in an adhesive.

The tufted carpet of the present invention will be explained in more detail.

The length of the fluff on the inner surface of the secondary base fabric used in the present invention must be 0.5 mm or more, and if it is too short (less than 0.5 mm), the effect will be poor. The state of fluff does not necessarily require a piloerection state, but a prone state,
It is sufficient that the fluff be in a state such as an entangled state where a considerable amount of fluff can sufficiently contact the foot of the pile or the back surface of the primary base fabric when laminated together. Therefore, as long as the shape of the base fabric is maintained, even if the fluff is long, it is preferably used. When a secondary base fabric is bonded to a tufted primary base fabric using an adhesive, the fuzz invades the dents and gaps everywhere such as the foot of the pile, its periphery, and the back side of the primary base fabric. Therefore, the fuzz reaches not only the legs of the pile, but also extends well enough to the back side of the primary base fabric itself, and is present in the adhesive together with the legs of the pile, in contact with or intertwined with these surfaces. It is buried and fixed. Therefore, the primary base fabric, the pile foot, and the secondary base fabric are extremely strongly bonded by a very large anchoring effect due to the synergistic effect of the adhesive filling between them and the fluff of the secondary base fabric. Therefore, the pile is extremely difficult to come off, and the secondary base fabric is also difficult to peel off. The bonded state of the tufted carpet of the present invention is shown in FIG. 1, and that of a conventional product is shown in FIG. In the figure, 1 is the primary base fabric, 2 is the secondary base fabric, 3 is the adhesive,
4 indicates the pile, 5 indicates the foot of the pile, and 6 indicates the fuzz of the secondary base fabric.

The adhesive may be a commonly used adhesive such as latex.

The condition of the outer surface of the secondary base fabric may be arbitrary depending on the type and purpose of the tufted carpet, but generally it is used to provide wear resistance or to prevent slipping on the floor surface. The fibers themselves are molded by heat-sealing in order to create unevenness and give stiffness to the carpet as a whole. In addition, a property generally required for secondary base fabrics is bulkiness that gives the carpet a sense of volume.

From this point of view, the secondary base fabric should be bulky, have a large amount of fluff on one side (inner surface), or be easily raised, and be easily molded on the other side (outer surface). is preferable, and a nonwoven fabric is preferably used as a material having such properties. In this case, there is also the effect that the thread does not come undone from the cut end.

In particular, at least 15% (by weight) or more preferably 30% (by weight) of heat-fusible composite short fibers made of two or more composite components with a melting point difference of at least 20°C or more.
The nonwoven fabric containing the above is very suitable because a stable and durable molded article having an uneven shape can be obtained by heat-treating its outer surface and self-adhering between the fibers by heat fusion. In addition, by adjusting the content of heat-fusible composite short fibers on the outer surface side, that is, the molding side, to be high, and the content of the heat-fusible composite short fibers on the inner surface side, that is, the fluffy side, to be small, the amount of composite short fibers can be reduced, the hardness of the molded product, and the fluffiness. As a result, it is possible to increase the amount of fibers as appropriate. Furthermore, by increasing the thickness of the nonwoven fabric and adjusting the content of heat-fusible conjugate short fibers, a secondary base fabric with high sponge-like cushioning properties can be obtained. In addition, when a nonwoven fabric containing such heat-fusible conjugate short fibers is used as a secondary base fabric, it is not easy to simply provide an uneven shape on the outer surface to prevent slipping, but it is also difficult to apply a non-woven fabric containing such heat-fusible conjugate staple fibers to a non-woven fabric, such as a carpet for an automobile. It is also possible to make a molded product with a shape that bends greatly, and the tufted carpet using this can be
It becomes possible to stably hold such a shape.

If composite fibers made of composite components with different melting points are bonded by heat treatment at a temperature below the melting point of the high melting point component and above the melting point of the low melting point component, the high melting point component will retain its fiber shape, so the composite fiber Webs that themselves also contain composite fibers can be made into non-woven fabrics without reducing their volume. In this case, if the melting point difference between the composite components is 20°C or more, it has the advantage of widening the selection range of heat treatment temperature.If the melting point difference is less than 20°C, even the high melting point components may melt or soften, leading to shrinkage of the web. arise. Also,
If the amount of heat-fusible conjugate short fibers in the web is less than 15%, the number of bonding points decreases, resulting in a decrease in the strength of the nonwoven fabric, which is undesirable. If necessary, the inner surface of the nonwoven fabric is subjected to a napping treatment to form a secondary base fabric. As heat-fusible composite short fibers, composite short fibers with a fiber length of about 20 to 120 mm, which are made of composite components mainly composed of polypropylene and polyethylene, are particularly suitable for ease of heat treatment, ease of fluffing, and durability. It is preferably used in

Other short fibers used in the present invention include cotton,
Examples include natural fibers such as hemp and wool, or synthetic resin fibers such as polyolefin, polyester, and polyamide, with a fiber length of about 20 to 120 mm.

As the tufted primary base fabric used in the present invention, conventionally used primary base fabrics may of course be used, or those with special textures or threads may be used.

In the above-described tufted carpet of the present invention, the legs of the pile are strongly fixed and will not come off, and the secondary base fabric will not peel off. In addition, those using a non-woven fabric with an uneven outer surface as the secondary base fabric have excellent rigidity, abrasion resistance, anti-slip properties on floors, volume, cushioning properties, durability, etc.

Next, as another aspect of the present invention, a preferred method for manufacturing the above-mentioned tufted carpet will be explained.

That is, the structure of the method for producing a tufted carpet of the present invention is that two materials having a melting point difference of at least 20°C or more are used.
At least 15% (by weight), preferably 30% (by weight) of heat-fusible composite short fibers consisting of more than one composite component.
and other short fibers preferably 70% (by weight) to form a web having fluff on at least one side (hereinafter referred to as the inner surface), and the other side of this web (hereinafter referred to as the outer surface). With the side heated to the heat fusion temperature, press it against the surface of a roll with a smooth or embossed surface (hereinafter referred to as a press roll), and the inner surface has fluff of 0.5 mm or more in length and the outer surface is a smooth surface. Alternatively, a secondary base fabric formed with embossed irregularities is obtained, and the inner surface of the secondary base fabric and the back side of the primary base fabric where the tufted pile legs are located are bonded together using an adhesive. .

The aggregated state of the fibers may be random, substantially uniformly oriented, intersecting, etc., as long as the fibers have an appropriate thickness as a web, but webs produced by the carding method tend to fluff easily and are preferred in terms of handling.

In order to provide a web with a gradient in the content of heat-fusible conjugate short fibers in the thickness direction, it can be obtained, for example, by laminating thinner layers of webs having different contents. This layer is formed by heating and molding the layer having a higher content of heat-fusible conjugate short fibers.

One method for pressing one side of the web against the roll surface is to press the outer circumferential surface of a rotating press roll and a part of the web using a felt-like multi-haired or fine-meshed material that moves at a constant speed while pressing against the surface. A method of inserting it between a porous belt such as a wire mesh, and
A method may be adopted in which the pressure roll and another pressure roll having a hairy or porous surface are inserted between rotating rolls in pressure contact with each other. Depending on the surface conditions of the pressure roll and other rolls, the rotation of the rolls may be made slightly faster to provide a napping effect. The web is pressed against the press roll while the heat-fusible composite short fibers are heated to the heat-fusion temperature (temperature between the melting points of both composite components). (2) Preheat to some extent before pressing and then heat at the same time as pressing with a heated press roll; (3) Only use heated press rolls without preheating. Therefore, various methods can be used, such as heating at the same time as pressing. In methods (1) and (2) above, one side of the web is heated using, for example, an infrared heater, but in the case of method (1), the temperature on the fluff side also becomes high and the fluff condition becomes poor. Because it's easy (2)
Method (3) is preferred. In the case of method (3), it is easier to handle if the web is lightly needle-punched in advance to improve its cohesiveness as a web.

In addition, as another method of pressing, the outer surface of the web may be made into a non-woven fabric by lightly pressing against a heated roll surface without using a belt.

After heating and pressing, it may be actively cooled if necessary. Further, in any of the above cases, the inner surface can be subjected to a nap treatment in order to further improve the fluff condition. The raising is performed by a commonly used method and device (for example, a wire raising machine).

The inner surface of the thus obtained secondary base fabric and the back surface of the tufted primary base fabric are bonded together using an adhesive such as latex, but when this adhesive dries, a simple web or When using a non-woven fabric, it tends to shrink due to heat and lose its balance with the primary base fabric, resulting in an irregular appearance and degrading the quality of the carpet, but when using this method, the secondary base fabric
Since the nonwoven fabric has undergone heat treatment, this phenomenon does not occur and the fabric is of excellent quality.

Examples will be shown below, and the apparatus used for manufacturing the secondary base fabric in each example is shown in FIGS. 3 to 6. In each figure, 7 is a pressure roll, 8 is a web,
9 is a belt for pressing, 10 is another roll for pressing,
11 is a web conveyor, 12 is a cooling roll, 13 is a napping device, 14 is a needle punching device, and 15 is a preheating roll.

Example 1 Side-by-side heat-fusible composite staple fibers (hereinafter abbreviated as PP-PE composite staple fibers) containing polyethylene and polypropylene as composite components (3d x 64
mm) and regular polypropylene staple fiber (3d×64mm)
A web with a basis weight of 100 g/m ² was made by blending 50 parts of each. A nonwoven fabric was made from this using the apparatus shown in FIG. In this apparatus, the surface of the press roll 7 was smooth and maintained at 140°C, the cooling roll was made of metal, and the temperature was not particularly low, but was used at room temperature. Also, the pressing belt 9
felt was used. The thus obtained nonwoven fabric (secondary base fabric) had a large number of fluffs of about 0.7 to 2 mm on the inner surface and a hard, flat outer surface.

The inner side of this secondary base fabric and the polyproflat yarn woven fabric are used as the primary base fabric and are made of nylon filament 1300.
When the back side of the tufted fabric obtained by tufting (5/32 inch gauge, 7 stitches/1 inch, pile length 8 mm) denier twin yarn as pile yarn was laminated with latex, the pile legs were extremely strong. The secondary base fabric is firmly attached and cannot be easily peeled off, and the bottom surface (outer surface of the secondary base fabric) has a good texture and is made of durable tufted material. A carpet was obtained.

Example 2 60 parts of the same PP-PE composite short fibers as in Example 1 were mixed with 40 parts of polyester short fibers (3d x 64 mm) to make a web with a basis weight of 120 g/ ^m2 , and this was placed in the apparatus shown in Figure 4. A non-woven fabric (secondary base fabric) was created.

In this device, a pressing belt is not used, and the inner surface of the web is brought into contact with a preheating roll 15 (170°C) before reaching the heated press roll 7 (140°C), and the web is partially unwoven, and the web is cut. At the final stage, the inner surface was subjected to a napping process using a napping device 13. The pressure roll surface is smooth. The obtained secondary base fabric has approximately 2
It had a fluff of ~10 mm and had a flat, hard outer surface.

Using this secondary base fabric, it was bonded to a tufted fabric in the same manner as in Example 1 to obtain an excellent tufted carpet.

Example 3 Two series of cards were arranged in parallel, and one card was used to create a web with a basis weight of 50 g/m ² consisting only of PP-PE composite short fibers as in Example 1, and the other card was made of the same PP-PE composite short fibers as in Example 1. A web with a basis weight of 50 g/m ² is made from a blend of 30 parts of PE composite short fibers and 70 parts of acrylic waste wool, and the former is wrapped as a lower layer and the latter is wrapped as an upper layer. We created webs with different content weights of 100g/ ^m2 ,
A nonwoven fabric (secondary base fabric) was made from this using the apparatus shown in FIG. In this device, a cotton roll was used as the other pressing roll 10 instead of the pressing belt. A metal hot press roll with emboss-like unevenness on the surface is used as the press roll 7,
It was maintained at 135°C (5Kg/cm ² ). The thus obtained nonwoven fabric (secondary base fabric) has a large number of approx.
It had fluff of ~6 mm, and the outer surface was hard with embossed irregularities.

Using the inner surface of this secondary base fabric and a tieper (manufactured by Dupont) as the primary base fabric, tufting was performed using 1300 denier nylon filament twin yarn as a pile yarn (gauge 1/10 inch, stitches 8 pieces/1 inch, pile length 8 mm). ) and the back side of the tufted fabric with latex, an excellent tufted carpet was obtained in which the pile did not come off, the secondary base fabric did not peel off, the bottom surface was firm, and the texture was good.

Example 4 40 parts of PP-PE composite staple fibers (6d x 76mm) and 60 parts of polypropylene staple fibers (6d x 76mm) were mixed to form a web with a basis weight of 150g/ ^m2 , which was processed using the apparatus shown in Figure 6. It was made into a nonwoven fabric (secondary base fabric). In this example, prior to heating and pressing the web, punching is performed in only one direction from the top (400 points/25 points).
mm x 25 mm, 600 rpm), the upper surface (outer surface of the secondary base fabric) became tight and the lower surface (inner surface of the secondary base fabric) had a lot of fuzz, which was heated and pressed. In this case, the press roll 7 was an embossing roll kept at 140°C, and the press belt 9 was made of felt. The secondary base fabric thus obtained has an inner surface of about 2 to
It had a fluff of 5 mm and the outer surface was hard with uneven embossments.

When the inner surface of this secondary base fabric and the back side of the same tufted fabric as in Example 3 were laminated with latex, a tufted fabric with a good texture and a firm bottom surface with no piles and no peeling of the secondary base fabric was obtained. A carpet was obtained.

[Brief explanation of drawings]

FIGS. 1 and 2 show the state in which a primary base fabric and a secondary base fabric of a tufted carpet according to the present invention and a conventional tufted carpet are bonded together, respectively. In each of the above figures, 1 is the primary base fabric;
2 is the secondary base fabric, 3 is the adhesive, 4 is the pile, 5 is the foot of the pile, and 6 is the fuzz of the secondary base fabric. FIGS. 3 to 6 show the apparatus used for manufacturing the secondary base fabric in each example. In each of the above figures, 7 is a pressure roll, 8 is a web, 9 is a pressure belt, 10 is another roll for pressure, 11 is a conveyor for transporting the web, 12 is a cooling roll, 13 is a napping device, and 14 is a needle punching device. The device, 15, indicates a preheating roll.

Claims (1)

[Scope of Claims] 1. In a tufted carpet formed by bonding a secondary base fabric to the back side of a tufted primary base fabric with an adhesive, two types of secondary base fabrics having a melting point difference of at least 20°C or more are used. It is composed of a fiber assembly layer consisting of at least 15% (by weight) of heat-fusible composite short fibers made of the above composite components and 85% (by weight) of other short fibers. A nonwoven fabric with fluff of more than 0.5 mm in diameter and the other surface (hereinafter referred to as the outer surface) is heat-treated to form a smooth surface or an embossed uneven surface is used, and the inner surface is bonded to the back surface of the primary base fabric and the foot of the pile. A tufted carpet characterized in that the fuzz of the secondary base fabric that has entered the surrounding area is embedded and fixed in an adhesive together with the legs of the pile. 2. The tufted carpet according to claim 1, wherein the secondary base fabric has a higher content of heat-fusible conjugate short fibers on the outer side and less on the inner side. 3. Mix at least 15% (by weight) of heat-fusible composite short fibers consisting of two or more composite components with a melting point difference of at least 20°C or more with 85% (by weight) or less of other short fibers, and at least one side ( A web having fluff with a length exceeding 0.5 mm is formed on the inner surface (hereinafter referred to as the inner surface),
The other side (hereinafter referred to as the outer surface) of this web is heated to a heat fusion temperature and then pressed against the surface of a roll with a smooth or embossed surface (hereinafter referred to as a press roll), so that the inner surface has fluff. A secondary base fabric whose outer surface is either smooth or embossed and uneven is obtained, and the inner surface of the secondary base fabric and the back side of the primary base fabric where the tufted pile feet are present are bonded together with an adhesive. A method for manufacturing a tufted carpet characterized by the following. 4. The method according to claim 3, in which the web has different contents of heat-fusible conjugate staple fibers on both sides, with the side with the smaller content serving as the inner surface and the side with the larger content serving as the outer surface. . 5 Pressing the web against the press roll surface is performed by inserting the web between the roll surface and a hairy or porous belt that moves at a constant speed along a part of the roll surface while pressing against the roll surface. Claim No. 3
The method described in section. 6. Pressing the web onto the press roll surface is carried out by inserting the web between rotating rolls in which the roll and another press roll having a hairy or porous surface are in pressure contact with each other. The method described in Section 3. 7. The method according to claim 3, wherein after the outer surface of the web is press-molded, the inner surface is further raised. 8. The method according to claim 3, wherein the outer surface of the web is heated while being pressed against a heated press roll surface. 9. The method according to claim 8, wherein the outer surface of the web is press-molded after being preheated to partially form a non-woven fabric. 10. The method according to claim 8, wherein the web is punched in advance and then its outer surface is heated and pressed.