JPS6047732A - Preparation of carpet - Google Patents

Abstract

PURPOSE:To integrally unite a foundation and a resin layer firmly by applying resin onto the back surface of the foundation and sending the foundation onto an embossing roller to form a number of projections. CONSTITUTION:A foundation 1 is shifted in the longitudinal direction by a conveyor 2, and the back surface of the foundation 1 is applied with synthetic resin 4 in sol state and then heated by a preheater 5 to form semigel state. Synthetic resin 6 in sol state is sent under pressure into an extruder 8 by a pump 7 and extruded in molten sol state from a die 9 and applied onto the resin 4 in semigel state. Then, the foundation 1 is introduced onto an embossing roller 10, and the back surface of the resin 6 layer is pressed, and a number of projections 11 are formed and then cooled.

Description

[Detailed Description of the Invention] (Technical Field) The present invention relates to a method for manufacturing a carpet that is used, for example, on the floor of a car and has a large number of anti-slip protrusions on the back side of a resin layer at the bottom of the base fabric. .

(Prior art) The conventional method for manufacturing this type of carpet is to pour synthetic resin such as vinyl chloride into a mold to form a resin layer with protrusions, and then press a base fabric onto the surface of the resin layer to integrate them. There are known ways to do this. However, since this method uses a mold, the size of the carpet is limited and one-piece production is required, making it unsuitable for mass production.

In order to eliminate such defects, a method has been proposed in which a long base fabric is moved in the longitudinal direction and a synthetic resin such as vinyl chloride is applied to the back surface of the base fabric. However, when a synthetic resin is applied to a base fabric in a vine state, the resin penetrates into the base fabric and gels, forming a resin layer that is firmly integrated with the base fabric, but the sol's viscosity and flow characteristics Due to this, the formation of protrusions by the enforcing roller etc. is not performed well. In addition, when the synthetic resin is applied to the base fabric in a molten gel state, protrusions are well formed, but the resin is difficult to penetrate into the base fabric, and the resin layer is firmly integrated with the base 11j. or not formed. Therefore, this synthetic resin application method 1-4 has not been put into practical use.

(Object of the invention) This invention has been made in view of the above points, and is based on
It is possible to form a strong and integrated resin layer on the resin layer, and it is also possible to easily form a large number of protrusions on the back side of the resin layer.
It is an object of the present invention to provide a new method for manufacturing a carpet, which can continuously form a long carpet, and can be adapted to mass production.

(Structure of the Invention) In order to achieve the above-mentioned object, the present invention moves the base fabric in the longitudinal direction with its back side up, coats the back side with a resin in a sol state, and then preheats them. , Apply a resin in a molten gel state to a predetermined thickness on top of the IL in which the resin is semi-gelled, and then apply these to an embossing roller or the like to form a resin layer (Example) Hereinafter, an example of the present invention will be described with reference to the drawings. do. Now, Figure 1 shows an example of a carpet manufacturing apparatus.
In this device, a group 10 (1) having a large number of naps (la) on its surface is placed on a conveyor (2) with its surface facing up.
) is moved in the longitudinal direction. A synthetic resin (4) such as vinyl chloride in a sol state is thinly and uniformly applied to the back surface of the base fabric (1) using a coating roller (3) or a coating knife. Then, the base fabric (1) coated with this resin (4) is heated by a preheater (5),
The resin (4) penetrates into the surface of the base 4J (1) and is firmly integrated, and the next step is carried out in a half-keled state.

In this next step, synthetic resins such as vinyl chloride (6
) is pumped in a sol state to an extruder (8) by a pump (7), and is kelized and melted in a molten gel state to a tie (9).
), and by the heat-induced plasticity of the molten gel, it is integrated and coated to a predetermined thickness on the semi-gelled resin (4) on the back side of the base fabric (1). Note that this coating thickness depends on the extrusion speed of the resin (6) from the extruder (8) and the conveyor (2).
) is adjusted by adjusting the moving speed of the base fabric (1). Furthermore, in this state, the base fabric (1) is transferred to the conveyor (
2) It is separated from above and guided onto an embossing roller (1O) which also serves as a cooling member, and is pressed against the back surface of the resin (6) layer to form a large number of protrusions (IX) there, and is cooled. In addition, since this protrusion (11) is formed on the back surface of the resin (6) which is in a molten gel state immediately after the extruder (8), it can be easily formed without losing its shape by being well separated from the enhancer roller (10). It is.

As shown in Fig. 2, the car vent manufactured in this way has a resin (on the back side) of the base fabric (1) having the nap (1a).
4) and (6) are formed, and a large number of anti-slip protrusions (11) are formed on the back surface of the elongated product. Therefore, by feeding the base fabric (1) on the conveyor (2), long car vents can be manufactured continuously, which are then cut into appropriate sizes to be used as carpets for automobiles, etc. can be used.

(Effects of the Invention) As described in detail above, the present invention moves the base 1fj in the longitudinal direction with its back side facing up, coats its surface with a thin layer of resin in a vine state, and then preheats them. It looks like the resin is semi-gelled! -1, the resin in a molten gel state was applied to a predetermined thickness on top of the base fabric, and then this was applied with an embossing roller to form protrusions on the back side of the resin layer, so the resin layer was firmly integrated with the base fabric. In addition, it is possible to easily form a large number of protrusions on the back side of the resin layer without deforming the shape, and it is also possible to continuously manufacture long carbents, making it suitable for mass production. It has the excellent effect of being able to

[Brief explanation of the drawing]

Figure 1 shows a carpet manufacturing device embodying this invention.
1 and ffl 2 ra are partial side views of a car vent manufactured using this apparatus. Explanation of symbols■...7.4 cloth, 3...coating roller, 4...
...Synthetic resin, 5...Preheater, 6...Synthetic resin, 8
... Extruder, 10... Embossing roller, 11...
protrusion. Patent applicant Daiwa Co., Ltd.

Claims (1)

[Claims] 'J='= Move h in the longitudinal direction with its back side up, apply a thin layer of sol-state resin on the back side, preheat them, and place the resin on top of it in a semi-gelled state. A method for manufacturing carpen i., which comprises applying resin in a molten gel state to a predetermined thickness, and applying the resin using an embossing roller or the like to form protrusions on the back surface of the resin layer.