JPS6250591B2 - - Google Patents

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for producing a carpet material suitable for exterior materials such as electric carpets. Furthermore, the present invention proposes a method of manufacturing carpet material that can be produced continuously at low cost using simple manufacturing equipment.

[Prior art]

Conventional carpet materials of this type are made by, for example, layering carded cotton made of fibers such as polypropylene on a base fabric made of polypropylene fibers, needle-punching the base fabric and carded cotton, and applying SBR resin from the base fabric side. It has a structure that is permeated and punched.

Therefore, it has poor flexibility, and its production requires a backing process using SBR resin, resulting in large bulky manufacturing equipment and low work efficiency.

As a method to solve this problem, attempts have been made to use a combination of needle punching and heat-sealing the fibers, but this method has not been able to produce carpet materials that have good airflow and less hair loss on the outer surface.

As a result of various research and trial production, the inventor of this application found that the conventional problems can be solved by increasing the amount of low melting point fiber on the lining side or by performing heat fusion on the front side at a lower temperature than on the back side. I got it.

The present invention has been made based on such knowledge, and aims to provide a carpet material that has a good air feel on the outer surface and less hair loss on the outer surface, and a method for manufacturing the same.

〔composition〕

The method for manufacturing a carpet material according to the present invention includes the first
A second fiber with a lower melting point than the first fiber is added to the fiber.
carded cotton for the outer material, which is a mixture of not more than 40% of the third fiber, and a carded cotton for the lining, which is a mixture of a third fiber that has a melting point similar to that of the second fiber, and a fourth fiber that has a higher melting point than the third fiber, which is a mixture of not more than 40% of the third fiber. are piled up and continuously fed to a needle punching device, and after being needle punched, the second fibers are passed between heated rolls and heated and pressurized to thermally fuse some or all of the second fibers to the first fibers, In addition, part or all of the third fiber is heat-sealed to the fourth fiber, and the part of the roll in which the carded cotton for the outer material is in contact is set at a lower temperature than the part in which the carded cotton for the lining material is in contact, and the heat-sealing is performed first. The carded cotton for the lining is brought into contact with the roll, and finally the carded cotton for the outer material is brought into contact with the roll.

〔Example〕

The present invention will be described in detail below based on drawings showing embodiments thereof. FIG. 1 is a schematic perspective view of a carpet material according to the present invention (hereinafter referred to as the product of the present invention).
In FIG. 1, 1 is the outer material and 2 is the lining material. The outer material 1 is made by mixing polypropylene fibers having a melting point of, for example, 148°C with polypropylene fibers having a lower melting point, for example, 80 to 120°C, in an amount of not more than 40% of the fibers, and has a thickness of about 2 mm. The lining 2 is made of polyester fibers with a melting point of, for example, 80 to 160°C and 40% of the polyester fibers with a melting point of 238°C.
It is a mixture of the following, and has a thickness of about 1 mm. In other words, the outer material has a low blending ratio of low-melting point fibers, and the lining has a high blending ratio. The outer material may have a blending ratio of low melting point fibers close to 0, and the lining material may have a blending ratio of high melting point fibers close to 0. In addition to the above-mentioned fibers, high-melting point nylon and low-melting point nylon can also be used, and natural fibers such as cotton can also be used as the high-melting point fibers.

If the content of low melting point materials exceeds 40% in the outer material, it will feel hard and the airflow will be impaired. Furthermore, if the content of high-melting-point materials in the lining exceeds 40%, sufficient heat fusion will not occur and the lining will not be able to function as a substitute for the base fabric of conventional carpet materials, resulting in increased hair loss on the outer material.

FIG. 2 is a schematic diagram of an apparatus for carrying out the method for manufacturing carpet material according to the present invention. 10 in the diagram
is a feed roll around which carded cotton 1a for forming outer fabric 1 is wound. This card cotton 10a
is made by mixing high melting point polypropylene fibers with 40% or less of low melting point polypropylene fibers. 11 is carded cotton 1 for forming lining 2
This is a feed roll that winds 1a. The carded cotton 20a is a mixture of low melting point polyester fiber and high melting point polyester fiber in an amount of 40% or less. These carded cotton 10a, 11a are in the form of a band with a width of 2 m and a thickness of about 15 mm. Each delivery roll 10, 11 is mounted on a trolley 10b, 11b, transported from the collection site of the rolls 10, 11, positioned at a predetermined location, or transported by another trolley, and then transported by a crane (not shown) or the like. It is mounted on carts 10b and 11b by means of the following. Carded cotton for outer material and lining material 10a and 11a fed out from each feeding roll 10 and 11 are guide plates 12 and 1
Both the carded cottons 10a and 11a are overlapped just before the pinch roll 13, and are pulled out by the pinch roll 13 at a predetermined speed. The carded cotton 10a and 11a, which are pulled out by the pinch roll 13 and overlapped, are passed through the needle punch device 1.
4, the carded cotton for the outer material 10a and the carded cotton for the lining 11a are intertwined with each other in an overlapping state. After needle punching, the carded cotton 10a, 11a is passed through a press roll 15 and compressed under a predetermined pressure. Next, the carded cotton 10a, 11a that has passed through the press roll 15 is introduced into a fusing device 16 for heat fusing processing.

The fusing device 16 has a large size within its housing 16a.
2 small calender rolls 17, 18, 19,
20 are arranged in this order with their center positions shifted upward and downward and in the moving direction of the carded cotton 10a, 11a, and each roll 17,
Gas burners 17a,
Two calender rolls 18a, 19a and 20a are arranged parallel to the central axis, and two calender rolls 17 and 1
Drive roller 1 for pressing against 8, 19, 20
A plurality of numbers 7b, 18b, 19b, and 20b are shown. Each gas burner 17a, 18a, 19
a, 20a have one end fixed to a supporting part (not shown), and each other end fixed to a calender roll 17,
18, 19, 20, and heats the rotating calendar roll 17 etc. from its inner peripheral surface,
Calendar rolls 17 and 19 are heated to around 180℃.
Further, the calender rolls 18, 20 are heated to and maintained at about 150°C.

Therefore, the carded cotton 1 introduced into the fusing device 16
0a and 11a, first, the surface of the carded cotton 11a for lining is wrapped around the outer cotton of the calendar roll 17,
The low melting point polyester fibers are melted and heat fused to the base fibers of the high melting point polyester fibers of the carded cotton 11a for the lining. Next, the carded cotton 10a for the outer material is wound around the calender roll 18, and the low melting point polypropylene fibers are melted and thermally fused to the high melting point polypropylene fibers. After this process is repeated on the calender rolls 19 and 20, the product is extracted from the housing 16a. The carpet material C that has come out of the housing 16a is passed through a cooler 21 and cooled to about 60°C to prevent recovery from heat shrinkage, and then passed through a looper 22 to a winding roll 23.
is wound up.

The looper 22 includes rolls 22b, 22c, and 22d arranged on the top of the stand 22a, and rolls 22e and 22f that are movable upward and downward on the stand 22a and that are always urged downward by a predetermined load.
The carpet material C is wound in a meandering manner upward and downward between the carpet material C, absorbs and relieves the slack and tension of the carpet material C due to variations in the moving speed of the carpet material C, and winds up the carpet material C while applying a predetermined tension. It is arranged to be wound onto a roll 23. The take-up roll 23 is pivotally supported by a stand 23a so as to be able to move upwardly and downwardly, and is rotated by a pair of drive rolls 23b, 23b which are in rolling contact with the outer peripheral surface of the stand 23a, thereby winding up the carpet material C. There is.

The carpet material C wound up on the winding roll 23 is transferred together with the winding roll 23 to another process, where it is cut to fit the width of the carpet. When an electric carpet is to be manufactured, a large number of heater wires are arranged and fixed in parallel at regular intervals on one side of the carpet.

[Effect] In the case of the method of the present invention as described above, by increasing the amount of low-melting fiber on the lining side compared to the outer side,
A carpet material with good airflow on the outer side and less hair loss on the outer side can be obtained. This is because, while the outer fabric side is less likely to become hard due to heat fusion, the lining side is firmly heat fused together with the needle-punched outer fibers in large quantities. Furthermore, the outer fabric side is heat-sealed at a low temperature and the lining side is heat-sealed at a high temperature.The lining side is heat-sealed first, and the lining side is preferentially heat-sealed, while the outer fabric side is heat-sealed last. This is because these are more effective in improving the airiness of the outer material and strengthening backing, that is, preventing hair loss. As described above, the present invention has excellent effects such as improving the airiness and preventing hair loss on the outer material, and also eliminating the need for a backing process using SBR and requiring no large-scale manufacturing equipment.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway perspective view of a carpet material manufactured by the method of the present invention, and FIG. 2 is a schematic side view showing the implementation state of the method of the present invention. 1... Outer material, 2... Lining, C... Carpet material, 10, 11... Feeding roll, 10a, 11
a...Card cotton, 13...Pinch roll, 14...
... Needle punch device, 15 ... Pressure roll, 1
7, 18, 19, 20... Calendar roll, 2
1... Cooler, 22... Looper, 23... Winding roll.

Claims (1)

[Claims] 1 Add a second fiber having a lower melting point to the first fiber.
Carded cotton for outer material made of a mixture of less than 40% fiber,
Carded cotton for lining made by mixing a third fiber with a melting point similar to that of the second fiber and a fourth fiber with a higher melting point of 40% or less of the third fiber is layered and continuously fed to a needle punch device. After needle punching, the second fibers are heated and pressed between heated rolls to heat-seal some or all of the second fibers to the first fibers, and some or all of the third fibers are bonded to the fourth fibers. The fibers are heat fused, and the roll makes contact with the outer carded cotton at a lower temperature than the lining carded cotton, and the heat fusion first brings the lining carded cotton into contact with the roll, and finally A method for producing carpet material, which comprises bringing carded cotton for the outer material into contact with a roll.