JPH0316535Y2 - - Google Patents

Description

[Detailed Description of the Invention] "Industrial Application Field" The present invention relates to a tufted carpet that has cushioning properties comparable to felt grippers and does not cause any flare.

``Prior Art'' Conventionally, general tufted carpets involve implanting pile threads into a primary base fabric using the tufting method, fixing the tail of the pile to the primary base fabric from the back side with adhesive, and then attaching a secondary base fabric. It is a pasted structure.

A woven or nonwoven fabric is used as the primary base fabric, and a woven fabric such as jute is generally used as the secondary base fabric. Styrene-butadiene (SB) latex compound, acrylic resin compound, etc. are used as the adhesive.

The tufted carpet construction products made in this way are transported to the construction site in the form of rolls and laid down, but this construction method can be roughly divided into two types: It is divided into the direct underlay method and the felt gripper method.

The former construction method is a method in which the entire surface is pasted with adhesive directly to the flooring base, such as a mortar base or wood base. This is a method of laying the carpet by fixing it to the flooring using nails, etc., and then hooking the end of the carpet to the protruding pins of the gripper board and stretching it like the skin of a drum. An underlay felt or similar cushioning material is inserted between the carpet and the subfloor to provide cushioning properties.

The direct underlay construction method is applied directly to a hard floor base such as mortar or wood, so the cushioning properties are not good, so it is used in spaces such as offices, but it is not suitable for luxury spaces such as office reception rooms, hotels, and residences. The felt gripper construction method is often used in spaces that require cushioning to improve cushioning when walking.

By the way, the felt gripper construction method requires more skill in the installation work than the direct underlayment construction method, and the gripper pins protrude from the edge of the carpet, which is dangerous. Because the carpet is not stretched properly, the carpet becomes loose and flares occur over time after installation, and it may be necessary to re-stretch it several times using a stretcher.

``Problems that the invention attempts to solve'' The inventors of the present invention conducted extensive research in order to provide a tufted carpet that can be applied directly under the carpet and has the same cushioning properties as the felt gripper method. It has been found that even if thick felt is fully bonded to the base fabric, it is sufficiently practical, and that the primary base fabric and the thick felt are unexpectedly well bonded, and a carpet with no flare can be obtained. This led to the completion of this invention.

``Means for Solving the Problems'' That is, the present invention is a tough fabric made of felt or needle punched felt with a thickness of 1.5 mm or more and a fiber density of 0.16 g/cm ³ or less applied as an underlay to the back side. It is a woven carpet.

The present invention is a tufted carpet having a structure in which, instead of the secondary base fabric of the tufted carpet, a felt used for an underlay or a needle punched felt having approximately the same thickness is attached.

The felt or needle-punched felt used for the underlay is intended to enhance cushioning properties, so it needs to be at least 1.5 mm thick, preferably 2 mm or more thick. Therefore, it is clearly different from a flat scrim of 1 mm or less of nonwoven fabric with no cushioning properties, which is sometimes used in place of a woven fabric such as jute as a secondary base fabric.

According to the present invention, felt or needle punched felt with an underlay function is already bonded to the back side of the tufted carpet, so when laying this carpet, even if it is a direct underlay construction method, the underlay of felt etc. The same cushioning effect as the felt gripper construction method that inserts a lay can be obtained, and compared to the felt gripper construction method, there is no risk of the pins protruding at the end of the carpet after installation, and because it is laid directly under the carpet, felt gripper construction is possible. Unlike the method, there is no flaring after installation, so it has extremely good installation workability and maintenance performance after installation.

In addition, in terms of manufacturing costs, there is no need for a secondary base fabric such as conventional jute, and the construction cost is lower than that of the felt gripper construction method, and the costs of both materials and construction are synergistic. Therefore, the cost can be reduced and it is extremely economical.

Conventionally, there are carpets that use foam cushioning materials such as rubber, urethane, and polyethylene instead of the secondary base fabric, but these have poor peel-up properties when reupholstered next time, and have poor walking feel. Because the elastic recovery when walking is as fast as that of a spring, it is impossible to obtain the feeling of stepping on felt, which is a three-dimensional aggregate of fibers.

There are also examples of using thin non-woven fabrics as the secondary base fabric;
This is simply replacing a woven fabric such as jute with a non-woven scrim, and in order to provide cushioning properties, a felt gripper construction method must be used.

The tufted carpet made by pasting and bonding felt or needle-punch felt as referred to in the present invention is used only during installation, that is, when installing a felt gripper, a felt-like material equivalent to an underlay to be inserted between the carpet and the subfloor is tufted. The tufted carpet structure is entirely new, as it is a bonded structure in place of the secondary base fabric of the tufted carpet.

A schematic cross-sectional view of the tufted carpet of the present invention is illustrated in FIG. 1. Reference numeral 1 indicates the pile, 2 the primary base fabric, 3 the adhesive layer, and 4 the felt layer.

The thickness of the felt or needle-punch felt layer used in the present invention is at least 1.5 mm or more, preferably 2 mm or more, and the density is expressed by the density of felt fibers only, and the boundary is not clear, but it is 0.06 to 0.16.
g/cm ³ , which is the appropriate density range for underlay felt used during carpet installation.

Also, in Figure 1 it is called cut pile,
Of course, a loop pile or a mixture of these may also be used.

Further, in order to maintain the morphological stability of the felt layer, part or all of the felt layer may be impregnated with a resin, a binder agent, etc., but only to the extent that the cushioning properties of the fiber aggregate are not lost.

[Effect of idea]

Thickness of 1.5mm or more and fiber density of 0.16
Since it uses felt or needle punched felt with a weight of less than g/cm ³ , it has cushioning properties comparable to conventional felt grippers.

Moreover, the primary base fabric and the above-mentioned felt or needle-punch felt stick together unexpectedly well, and since the felt itself has almost no directionality, it exhibits excellent form stability. As a result, there is no occurrence of flare.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view of the tufted carpet of the present invention. 1 is a pile, 2 is a primary base fabric, 3 is an adhesive layer, and 4 is a felt layer.

Claims (1)

[Scope of utility model registration request] A tufted carpet made by attaching felt or needle punched felt with a thickness of 1.5 mm or more and a fiber density of 0.16 g/cm ³ or less to the back side as an underlay.