JPH0330064Y2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to carpets, and is mainly applied to the finishing of the backing of tufted carpets, which have cushioning properties and breathability.

[Conventional technology]

The primary base fabric of a tufted carpet is often damaged by needles during the tufting process, so it is often reinforced by backing it with a secondary base fabric after tufting.

Further, in order to improve the cushioning properties caused by the pile of tufted carpet, and at the same time to prevent slips that are likely to occur during use, the carpet may be lined with foamed resin.

Conventionally, backing with this type of foamed resin has been achieved by coating and laminating a foamed resin composition on the back side of the carpet, or by bonding a preformed foamed resin sheet to the backing.

[Problem that the invention attempts to solve]

When coating and laminating a foamed resin composition, the proportion of the resin component in the composition is increased, so a non-breathable film is formed on the surface of the foamed resin layer.
Furthermore, the foamed resin sheet that is pre-formed and bonded to the backing is strong enough to withstand the tension in the backing process, and therefore does not have air permeability.

For this reason, conventionally available carpets lack breathability and prevent moisture from escaping from beneath the floor behind the carpet, resulting in the inconvenience of rotting the floorboards, tatami mats, etc.

Furthermore, the foamed resin layer that is lined with the carpet gradually expands under foot pressure during use of the carpet, while the primary base fabric stretches less than the foamed resin layer, so the relationship between the foamed resin layer and the primary base fabric is There has also been a problem in that the edge of the carpet is warped in a bimetallic manner due to the difference in expansion and contraction.

Furthermore, it cannot be expected that the foamed resin layer will stabilize the dimensions of the tufted carpet, and therefore, when attempting to impart dimensional stability to the tufted carpet as well as cushioning properties. This required two finishing steps: backing with a secondary base fabric and lamination with a foamed resin layer.

[Purpose of invention]

The purpose of the present invention is to solve the above-mentioned problems in the prior art, and to efficiently obtain a carpet that has cushioning properties and anti-slip functions, is breathable, and has excellent dimensional stability. It is.

[Structure of the idea]

The tufted carpet 12 according to the present invention is produced by tufting the pile 18 using a woven fabric made of polypropylene tape yarn as the primary base fabric 17, and applying an emulsion latex compound 19 containing a rather large amount of filler. The secondary base fabric 11 is lined with a weft 15 and a warp 1.
6 to form a woven or knitted structure, the weft 15 of which is composed of a core yarn 13 and a foamed elastic resin composition 14, and the foamed elastic resin composition 14 is It is characterized by a thick outer sheath that covers the surface of the membrane.

As the weft yarn 15 reinforced by the core yarn 13,
A core yarn 1 is made of a foamable resin composition 14 having elasticity such as polyurethane, vinyl chloride, natural or synthetic rubber, etc.
It is formed with a core-sheath structure formed by coating and foaming a foamed elastic resin sheet, or it has a twisted yarn structure in which a foamed elastic yarn 14 obtained by slitting a foamed elastic resin sheet and a core yarn 13 are combined and twisted. It is formed by

The knitting structure of the weft 15 and warp 16 is formed by a knitting machine, and the woven structure of the weft 15 and warp 16 is formed by a loom. When this is done by a knitting machine, a weft insertion type warp knitting machine is used, which chain-stitches the warp threads and knits the weft threads into each stitch.
If using a loom, it is recommended to use a water jet loom.

In addition, FIG. 1 shows a secondary fabric in which a core yarn 13 is passed through a foamed polyurethane resin composition, and a weft yarn 15 with a thick outer sheath formed by the foamed polyurethane resin 14 is woven into a warp yarn 16 using a weft insertion type warp knitting machine. Base fabric 11
A tufted carpet 12 lined with is shown.

[Effect of idea]

(1) The weft 15 of the secondary base fabric 11 in the present invention is
The foamed elastic resin 14 swells to a high degree of cushioning properties, and the warp yarns 16 forming a woven or knitted structure bite into the foamed elastic resin outer sheath 14 on the surface of the weft yarns 15.

Therefore, according to the present invention, a tufted carpet 12 that looks like it is backed by a foamed elastic resin sheet can be obtained.

(2) On the other hand, although the foamed elastic resins 14, 14', 14'' of the wefts 15, 15', 15''... are in close contact with each other, they are not continuous with the surface of the secondary base fabric 11. It does not form a film, but a certain gap is created between each weft 15 as a weave or stitch, and on the other hand, the emulsion latex compound 19 used for backing coating has ventilation holes due to moisture dissipation as it dries. I can do it.

Therefore, the tufted carpet 12 according to the present invention has air permeability.

(3) Secondary base fabric 11 having cushioning properties
Because the weft threads 15 and warp threads 16 extend in the longitudinal and transverse directions, the carpet does not expand or contract in the longitudinal and transverse directions. This eliminates the possibility of bimetallic warping during use due to differences in expansion and contraction, resulting in excellent dimensional stability.

(4) As described above, according to the present invention, the cushioning properties and anti-slip function are achieved by the foamed elastic resin 14 in the weft 15, and the weave or stitch structure between the wefts 15 of the secondary base fabric 11 provides the cushioning properties and anti-slip function. The core yarn 13 and the warp yarn 16 of the weft yarn of the secondary base fabric 11 are
Thus, a carpet 12 having cushioning properties, anti-slip properties, breathability, and dimensional stability is obtained through the conventional backing process of backing the secondary base fabric 11.

(5) Therefore, it cannot be said that the production efficiency of tufted carpet is reduced by implementing the present invention, and on the contrary, the foamed resin composition is not coated and laminated on the back surface in the backing process. Therefore, there are many industrial advantages of the present invention, such as increased production efficiency.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of the tufted carpet according to the present invention, viewed from the back. 11...Secondary base fabric, 1
2...Tufted carpet, 13... Core yarn, 1
4... Foamed elastic resin, 15... Weft, 16... Warp, 17... Base fabric, 18... Pile.

Claims (1)

[Claims for Utility Model Registration] (a) A pile 18 is tufted onto a primary base fabric 17, and an emulsion latex compound 19 is
(b) The secondary base fabric 11 is constructed by forming a woven or knitted structure with weft 15 and warp 16. (c) the weft 15 is composed of a core thread 13 and a foamed elastic resin composition 14; (d) the foamed elastic resin composition 14 covers the surface of the core thread 13; A tufted carpet characterized by forming a thick outer sheath.