JP2796014B2 - Tufted carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufted carpet and a base fabric thereof which can be used as a rug indoors and outdoors, or particularly as a material for artificial turf and the like.

[0002]

2. Description of the Related Art Generally, tufted carpets in which a pile is formed on the surface by inserting a thread into a base cloth using a tufting machine are widely used as bath mats, tile carpets, car mats, artificial turf materials and other rugs. It is known to be used. Among the tufted carpets, a band-shaped stretched film of polypropylene or the like is used as a base cloth, which is knitted or woven by plain weaving or the like, and a band-like film of polypropylene or the like is tufted to form a cut pile. Because of its excellent properties and good drainage during washing, it is awarded as a carpet for outdoor laying.

[0003] Such a tufted carpet is usually coated with a backing agent such as a vinyl chloride resin or a latex compound on its back surface, and if necessary, further laminated and bonded with a net, a jute, a linoleum, etc., to provide a durable carpet. The properties and cushioning were enhanced and the pile was prevented from coming off.

[0004]

However, in the above-mentioned conventional tufted carpet, a large amount of the backing agent is required to prevent the phenomenon that the tufted cut-shaped pile system comes off (hereinafter referred to as "pile coming off"). Lamination must be performed, which causes problems such as increased weight, inconvenient handling, and increased cost.

The present invention has solved the above-mentioned problems, and has made it possible to reduce the weight and production cost of a tufted carpet by reducing the amount of a backing agent applied as much as possible, and to sufficiently prevent pile removal. The task is to make it.

[0006]

In order to solve the above-mentioned problems, according to the present invention, a part of the fiber is formed by needle punching a heat crimpable synthetic fiber cotton-like sheet on the surface of the base fabric. A pile is formed on the base fabric by tufting, and the protruding portion of the fiber is thermally crimped on the back surface of the base fabric, and a backing agent is applied thereon. It was adopted.

[0007] Alternatively, a cotton-like sheet for tufted carpet is obtained by needle-punching a cotton-like sheet made of synthetic fiber having heat crimp on the surface of a base cloth so that a part of the fiber protrudes to the back side of the base cloth. It may be a base cloth.

[0008]

In the tufted carpet according to the present invention, a part of the fibers of the cotton-like sheet is inserted into a large number of portions of the base fabric by needle punching, and the fibers protruding to the back side of the base fabric are further subjected to heat crimp. Entangled or fused together to form a fiber mass and engage with the back surface of the base fabric. In this case, the organization of the base fabric is fixed to the heat crimped cotton sheet, crimping
The removed fibers are less likely to fall out of the base fabric, so that the tissue of the base fabric is less likely to loosen even when subjected to an external pressure such as a treading pressure, and the pile is prevented from coming off .

[0009] The backing agent is used to form a fiber mass or a fiber bundle in which heat crimped fibers are entangled or fused at the time of application.
And around it. Small volume in this way
The backing agent to the concentrated fiber mass
And a pile yarn base cloth with a relatively small amount of backing agent
Can be fixed securely. In addition, the amount of the backing agent used can be reduced by the improvement in the effect of preventing the pile from being removed.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The base fabric used in the present invention is not particularly limited in terms of the material of the constituting fibers and the type of its structure. For example, in addition to synthetic fibers such as polypropylene, acrylic, polyethylene, nylon and polyester, cotton and wool , Hemp, etc. can be adopted. A relatively coarse knitted woven fabric woven by a known method such as plain weave or satin weave or a nonwoven fabric joined by various methods may be used. Among them, as a base cloth for an outdoor carpet, a plain weave of a belt-like yarn obtained by stretching polypropylene in one direction is excellent in mechanical strength and weather resistance, and is particularly preferable.

Next, the cotton-like sheet used in the present invention employs synthetic fibers having heat crimpability. Here, the term "heat crimpability" means that when the fiber is heat-treated, it shrinks in a wavy or spiral shape, and furthermore, the fibers partially fuse to form a fiber mass. Therefore, the synthetic fibers are thermoplastic synthetic resins, for example, polyester fibers such as polyethylene terephthalate, nylon fibers, acrylic fibers, and the like.
Among them, those which have not been heat-treated yet and whose fibers are not crimped are used.

Further, the backing agent used in the present invention comprises:
It may be a latex compound, a vinyl chloride resin, or a known backing agent mainly composed of a synthetic resin or synthetic rubber used for carpets and artificial turf.

An embodiment of the present invention will be described below with reference to the drawings.

As shown in FIG. 1, in the embodiment, a base fabric 1 is formed by plain weaving using a stretched belt-like polypropylene yarn as a warp and a weft, and polyester (polyethylene terephthalate 100%) is formed on the surface of the base fabric 1. The above-mentioned cotton-like sheets 2 made of short fibers are piled up at a uniform thickness and needle punched from the surface.

The needle-punching is performed by using a well-known needle-punching machine, which is also used for mechanical bonding of the nonwoven fabric, by moving a large number of needles having small downward barbs at a high speed up and down to form the cotton-like sheet 2. This was performed by piercing the needle from above to below the base cloth 1. In this manner, when the needle comes off, a small bundle 3 of synthetic fibers remains on the back surface of the base fabric 1 at, for example, 30 places / cm ² or more, and the heat crimping cotton-like sheet 2 and the base fabric 1 are separated. By temporarily attaching, a base cloth A with a cotton-like sheet for tufted carpet was obtained (FIG. 2).
(See (a) and (b)).

As shown in FIG. 3, the pile 4 is formed by using a belt-like thread made of polypropylene and piercing the surface of the base fabric 1 using a well-known tufting machine (not shown) so as to form a cut pile. did.

Next, as shown in FIG. 4A, a backing agent 5 made of synthetic rubber latex is coated on the back surface of the base fabric 1, and the hot air is heated at a heating temperature of 120 to 150 ° C. for about 3 minutes for drying. It passed through the dryer.

As a result, as shown in FIGS. 4 (a) and 4 (b), the synthetic fibers projecting from the weave of the base fabric 1 are crimped by heat crimping, and the fibers are appropriately fused to each other. Fiber lump 3
a was formed. Then, a required amount of a backing agent was further laminated to obtain a tufted carpet B.

The tufted carpet B obtained as described above has a small pile loss, excellent dimensional stability before and after heat treatment, and good compatibility between the fibers on the back surface of the base fabric and the backing agent 5. The coating amount could be reduced by about 15 to 20% by weight as compared with the conventional one.

[0020]

According to the present invention, as described above, a cotton-like sheet made of a heat-crimpable synthetic fiber is overlaid on a base fabric by needle punching, and a part of the fiber is crimped to form a backing. Since the tufted carpet to which the agent has been applied is used, even if the amount of the backing agent applied is small, it is possible to sufficiently prevent the pile from coming off, and there is an advantage that the weight can be reduced and the production cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a tufted carpet and a base fabric with a cotton-like sheet according to an embodiment.

FIG. 2 (a) is a cross-sectional view showing a base fabric with a flocculent sheet according to an embodiment, and (b) is a bottom view of the same.

FIG. 3 is a sectional view showing a state in which the embodiment is tufted.

4A is a cross-sectional view of the tufted carpet of FIG. 1. FIG. 4B is a bottom view of the tufted carpet with the backing agent removed.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base cloth 2 Cotton-like sheet 3 Small bundle of synthetic fibers 4 Pile 5 Backing agent

Claims (1)

(57) [Claims] 1. A heat-crimpable synthetic fiber cotton-like sheet is provided on the surface of a base fabric by needle punching so that a part of the fiber protrudes from the back surface of the base fabric, and a pile is toughened on the base fabric. A tufted carpet formed by forming a fiber mass by heat crimping the protruding portion of the fiber on the back surface of the base fabric, and applying a backing agent on the fiber mass .