JPH062260A - Tufted carpet - Google Patents

Abstract

PURPOSE:To reduce an amount of a backing agent applied to a tufted carpet as small as possible, to make tufted carpet lightweight, to diminish a manufacturing cost and to sufficiently prevent removal of pile. CONSTITUTION:The surface of a ground fabric 1 of plain weaves made of polypropylene is provided with a fiber-like sheet 2 made of thermally crimping polyester by needle punching in such a way that the fibers are piled on the ground fabric and are partially projected from the back of the ground fabric 1. Piles 4 are formed by tufting, the fibers on the projected part of the back of the ground fabric is thermally crimped and coated with a backing agent 5 to give a tufted carpet B.

Description

Detailed Description of the Invention

[0001]

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

[0002]

2. Description of the Related Art Generally, tufted carpets in which a pile is formed by piercing a base cloth with a thread using a tufting machine are widely used as bath mats, tile carpets, car mats or artificial grass materials and other rugs. It is known to be used. Among the above tufted carpets, a stretched film of polypropylene or the like is used as a base fabric, and this is knitted by plain weaving, etc., and a striped film of polypropylene or the like is tufted to form a cut pile. It is used as a carpet for outdoor laying because of its excellent properties and good drainage during washing.

Such a tufted carpet is usually coated with a backing agent such as a vinyl chloride resin or a latex compound on the back surface thereof, and if necessary, a net, jute, linoleum or the like is further laminated and adhered for durability. It was designed to improve the cushioning property and prevent the pile from falling out.

[0004]

However, in the above-mentioned conventional tufted carpet, a large amount of backing agent is necessary in order to prevent the phenomenon in which the tufted cut pile system is removed (hereinafter referred to as pile removal). Since they have to be laminated and adhered to each other, there is a problem that the weight increases, the handling is inconvenient, and the cost increases.

The present invention solves the above-mentioned problems and makes it possible to reduce the weight and production cost of tufted carpet by reducing the coating amount of the backing agent as much as possible. The task is to do so.

[0006]

In order to solve the above-mentioned problems, in the present invention, a heat-crimpable synthetic fiber cotton-like sheet is needle-punched on the surface of the base cloth so that a part of the fibers is backside of the base cloth. A pile is formed on this base cloth by tufting, and the back surface of the base cloth is heat-crimped on the back surface of the base cloth, and a backing agent is applied over it. It was adopted.

Alternatively, with a cotton-like sheet for tufted carpet, which is formed by stacking a heat-crimpable synthetic-fiber cotton-like sheet on the surface of the base cloth by needle punching so that a part of the fiber protrudes to the back surface 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 many places of the base cloth by needle punching, and the fibers protruding to the back surface side of the base cloth are further heat-crimped. Are entangled or fused with each other to form a fiber mass and engage with the back surface of the base fabric. At this time, the tissue of the base cloth is fixed to the cotton-like sheet, so that the tissue is less likely to loosen even when an external pressure such as a treading pressure is applied, and the pile is prevented from coming off.

The backing agent is easily held by the crimped fibers and can be applied efficiently, and the amount of the backing agent used can be reduced because the effect of preventing the pile from falling is improved.

[0010]

EXAMPLES The base fabric used in the present invention is not particularly limited in the material of the constituent fibers and the kind of its structure, and for example, synthetic fibers such as polypropylene, acrylic, polyethylene, nylon, polyester, cotton, wool and the like can be used. , Hemp, etc. can be adopted. Further, it may be a relatively woven knitted fabric knitted by a known method such as plain weave or satin weave, or a non-woven fabric joined by various methods. Among them, as the base fabric for the outdoor carpet, one obtained by plain-woven a strip-shaped yarn obtained by stretching polypropylene in one direction is excellent in mechanical strength and weather resistance and can be said to be particularly preferable.

Next, the cotton-like sheet used in the present invention employs a synthetic fiber having a heat crimping property. The term "heat-crimpability" as used herein means that when the fibers are heat-treated, the fibers are crimped in a wavy or spiral shape, and the fibers are partially fused to form a fiber mass. Therefore, the applicable synthetic fiber is a thermoplastic synthetic resin, for example, polyester fiber such as polyethylene terephthalate, nylon fiber, acrylic fiber, and the like,
Of these, those which have not been heat treated yet and whose fibers are not shrunk are used.

The backing agent used in the present invention is
Known compounds such as latex compounds, vinyl chloride resins, synthetic resins used for carpets and artificial grass, and synthetic rubber as a main component may be used.

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

As shown in FIG. 1, in the example, a stretched belt-shaped polypropylene yarn is used as a warp and a weft to form a base cloth 1 by plain weaving, and the surface of the base cloth 1 is made of polyester (polyethylene terephthalate 100%). The cotton-like sheet 2 composed of the short fibers of No. 1 is superposed with a uniform thickness and needle punched from the surface.

Needle punching uses a known needle punching machine which is also used for mechanical joining of nonwoven fabrics, and a large number of needles having downward small barbs are moved up and down at a high speed to remove the cotton-like sheet 2. It was performed by piercing the needle from above to below the base fabric 1. In this way, when the needle is pulled out, a small bundle 3 of synthetic fibers remains on the back surface of the base cloth 1 at, for example, 30 points / cm ² or more, and the heat-crimpable cotton-like sheet 2 and the base cloth 1 are separated from each other. After temporary attachment, a base fabric 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 inserting a polypropylene band-like thread into a cut pile on the surface of the base cloth 1 using a well-known tufting machine (not shown). did.

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

In this way, as shown in FIGS. 4 (a) and 4 (b), the synthetic fibers protruding from the weave of the base fabric 1 are heat-crimped and entangled, and the fibers are appropriately fused to each other. Te fiber mass 3
a was formed. Then, a required amount of backing agent was further laminated to obtain a tufted carpet B.

The tufted carpet B thus obtained has less pile loss, is excellent in dimensional stability before and after heat treatment, and is well compatible with the fibers on the back surface of the base cloth 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]

As described above, according to the present invention, a cotton-like sheet made of synthetic resin having a heat-crimping property is superposed on a base fabric by needle punching, and a part of the fiber is crimped to form a backing. Since the tufted carpet is treated with the agent, even if the backing agent is applied in a small amount, 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 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 cotton-like sheet according to an embodiment. (B) is a bottom view of the same.

FIG. 3 is a cross-sectional view showing a tufting example of the above embodiment.

FIG. 4 (a) is a cross-sectional view of the tufted carpet shown in FIG. 1 (b) is a bottom view of the above, showing the backing agent removed.

[Explanation of symbols]

 1 Base cloth 2 Cotton-like sheet 3 Small bundle of synthetic fiber 4 Pile 5 Backing agent

Claims (2)

[Claims] 1. A heat-shrinkable synthetic fiber cotton-like sheet is provided on the surface of a base cloth by needle punching so that a part of the fibers protrudes to the back surface of the base cloth, and a pile is tough on the base cloth. A tufted carpet which is formed by coating a backing agent on the back surface of the base fabric by heat-crimping the protruding portions of the fibers, and applying the backing agent on the crimped portion. 2. A cotton-like sheet for tufted carpet, comprising a cotton-like sheet made of heat-shrinkable synthetic fiber, which is superposed on the surface of the base cloth by needle punching so that a part of the fibers protrudes to the back surface of the base cloth. Base cloth.