JPS6237971B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a carpet in which a polymer film is provided on the back side of the carpet to prevent slipping, and a method for manufacturing the same. to provide
Another object is to enable manufacturing by a method suitable for mass production.

Conventionally, when a partial-sized carpet (place-down carpet) is laid on top of the shag carpet that has been laid in a room, the carpet may move or sag due to the pressure of people stepping on it during use. It was happening.

In addition, electric carpets are now widely used in households, but in order to prevent the surface from getting dirty, another carpet (covering material) is often placed on top of the carpet. The same phenomenon as above occurs in this case as well.

Various measures have been considered to prevent this. For example, an uneven coating of polymeric material may be formed on the back surface of a carpet to increase the coefficient of static friction with the surface of the underlying carpet.

However, although such a thing is theoretically possible, it has not been realized in practice. This is due to the fact that it is difficult to mass produce, and simply adding unevenness to the back surface of the carpet does not prevent slipping.

Another conventional example is to coat the back surface of a carpet with a polymeric material having soft rubber elasticity to adhere particles to form irregularities.

However, conventionally, the packing process on the back side of carpets is done by rolling latex compounded by adding fillers, anti-aging agents, dispersants, thickeners, etc. to SBR or EVA (ethylene-vinyl-acrylic copolymer). It is applied to the back side of the carpet by a coater, but if granules are mixed into this latex, the granules will settle in the coater bath, preventing the granules from sticking to the roll and making uneven finishing impossible. If the granules are too light, it will not be possible to uniformly create unevenness on the back surface of the carpet. In addition, conventional roll coating is generally performed using a single roll coater, and in such cases, depending on the viscosity of the latex and the particle size of the particles, it is necessary to scrape off an appropriate amount of latex on the back side of the carpet with a doctor knife after applying the latex. When dropping, only particles are scraped off, or latex with a low moisture content is scraped off, resulting in changes in the moisture content of the latex in the coater bath, resulting in changes in viscosity and changes in the blending ratio of particles, etc. As time passes, it becomes impossible to apply latex to the back side of the carpet, making mass production impossible.

The present invention was made in view of such problems.
On the back side of the carpet material with pile formed on the surface.
A carpet coated with a latex layer such as SBR or EVA is characterized in that large, angular rubber particles with small, angular rubber particles on the surface are formed on the surface of the latex layer. The manufacturing method is as follows:
A latex made by mixing fillers, dispersants, thickeners, water, etc. with SBR, EVA, etc. is roll coated onto the original carpet, and the amount of coating is adjusted by removing the excess part of the coated latex. A first coating step, and a second coating step in which a latex is prepared that has a specific gravity similar to that of the latex and contains angular large and small rubber particles, and the excess portion of the latex is removed to adjust the coating amount. a coating step, and the latex coating surface after the second coating step is raised to form large, angular rubber particles on the surface of the latex layer, with small, angular rubber particles on the surface; This is a carpet manufacturing method characterized by the following steps: The following description will be given with reference to an embodiment. FIGS. 1 and 2 show a tufted carpet as an example.

1 is the base fabric, PP (same as polypropylene and below)
Nonwoven fabrics such as cloth, PP typer, and polyester spunbond are used. 2 is pile, which is made of nylon, acrylic, polyester, wool, or a blend thereof. The greige raw fabric 3 tufted in the tufting process is first coated with the latex 4a in the first bath _Y1 by the first roll coater 5a. As the latex 4a, a compound obtained by compounding SBR, EVA, etc. with a filler, a dispersant, a thickener, water, etc. is used, and here, an EVA compound was used. A high viscosity material with a viscosity of 20,000 to 30,000 cps is used. Excess latex 4a coated with the roll coater is removed with a doctor knife 6a to adjust the coating amount. Here, the high viscosity latex 4a is used in the roll coater in the second second bus _Y2 to coat the rubber particles 8b and 8c. In addition, it can be applied in proportions,
This is to ensure that the latex 4a is exposed outside the base fabric 1 as much as possible so that the latex does not soak into the base fabric too much and the carpet becomes too hard.
By forming the latex 4a layer as shown in Figures 3a and 3b, the rubber particles tend to adhere to the back surface of the carpet, and unlike the conventional example, only the particles are scraped off with a doctor knife, causing a change in the concentration of the latex in the coater bath. This eliminates the problem of particles not sticking uniformly. Daiichi bus
The carpet roll coated in Y ₁ is sent in the X direction to a second bus Y ₂ where latex 4
b is applied. Latex 4b is the first bus
Latex 8a similar to that used in Y ₁
Particles 8b and 8c (here, rubbery granules) are mixed in. The conditions for the particles to be mixed are as follows:
It must have a specific gravity similar to that of the latex 8a so that it does not settle or become airborne during manufacture. Regarding the particle size, if the protrusion _t1 on the back surface of the carpet used as a cover material is too large as shown in Fig. 5, it will not have any anti-slip effect because it will get stuck in the pile 10 of the primary carpet 9, and as shown in Fig. 6. If the shape of the protrusion _t2 is round as shown in FIG. In addition, if the protrusion is soft, as shown in Fig. 7a, when the pile 10 knocked down by treading pressure recovers, it will flip off the protrusion _t3 , causing the pile 1 of the primary carpet to
0, the cover material does not return to its original position and slips, resulting in displacement as shown in Figure 7b.

Therefore, in the present invention, rubber granules 8b having a slightly large and angular shape and rubber granules 8c having a slightly small diameter and an angular shape are used.

The reason why the large grains 8b are used here is because, as can be seen from FIGS. This is because when latex is applied to the back side, it will not have an anti-slip effect unless the protrusions are higher than this height.

Therefore, as shown in FIG. 9, small particles 8c were attached to the surface of large rubber particles 8b. A ratio of large particles to small particles of about 2:1 by weight is effective for preventing slipping. Moreover, a mixing weight ratio of latex and rubber particles of 10:3 to 4 is effective.

In addition, in order to harden the protrusions on the back side, the EVA stock solution of Latex 8a is mixed with slightly harder EVA, X _A , and slightly softer EVA, X _B , and the mixing ratio is X _A :X _B is 2: A ratio of 8 was effective in preventing slipping.

In addition, this mixing ratio determines not only the hardness of the protrusions but also the hardness of the entire carpet.
As shown in the figure, if the carpet is made hard, the area near where the foot steps on it will lift up and have no anti-slip effect. This percentage is set.

The state of the back surface of the material that has passed through the doctor knife 6b after being roll coated in the second bath _Y2 is shown in FIGS. 4a and 4b. Here, on the latex 4a layer, rubber particles 8b and 8c are adhered to the back surface of the carpet while being covered by the latex 8a. However, in this state, large, angular rubber particles with small, angular rubber particles on the surface are not formed.
In order to form large, angular rubber granules with small, angular rubber granules on the surface,
I made it possible to cause latex with Tatsuchirol 7. This is one of the major features of the present invention, and in order to achieve this, the viscosity of the latexes 4a and 4b is made considerably strong. As shown in Figure 2, when the tutti roll 7 is rotating in accordance with the flow of the carpet, when the tutti roll 7 and the latex surface on the back of the carpet are about to separate, the viscosity of the latex is increased so that a string is pulled. As the latex stretches, protrusions are formed at that time. Figure 8 a, b
In this case, the difference h between the height of the pile on the back surface of the carpet and the height of the protrusion becomes effective as an anti-slip agent.

Carpets made using this manufacturing method can be tufted by 7 to 8 cm after 400 steps when a commonly manufactured unlined tufted carpet such as jute is laid on a needle-punched loop pile. The carpet has moved. On the other hand, when the tufted carpet of the present invention was laid on the same needle punch and walked 400 steps, the distance traveled was about 2 cm.

Further, when the tufted carpet of the present invention was laid on a tufted loop pile and walked 400 steps, the distance traveled was 1 cm or less.

By performing this processing, the cover material will not wrinkle when walking, and the cover material will not slip and fall.

The present invention can be applied not only to tufted carpets but also to anti-slip carpets whose entire back is treated with polymer.

As described above, according to the present invention, SBR and EVA are applied to the back side of the carpet material with pile formed on the surface.
A carpet coated with a latex layer, characterized in that large, angular rubber particles are formed on the surface of the latex layer, with small, angular rubber particles on the surface. By doing this, if there are only small angular rubber granules, they will be buried in the pile and will not get entangled with the pile of carpet laid underneath, and only large angular rubber granules will be present. However, to prevent this, the small, angular shaped rubber granules are made to entangle well with the pile of carpet that is laid below, so that it does not get tangled in the pile of carpet that is laid down. A carpet with excellent anti-slip effect can be obtained even when placed on the underlying carpet.Also, latex, which is a mixture of SBR, EVA, etc. with fillers, dispersants, thickeners, water, etc., can be applied to the original carpet. A first coating step in which the coating amount is adjusted by roll-coating and removing an excess portion of the coated latex, and large and small angular rubber particles having a specific gravity similar to that of the latex. a second coating step in which an excess portion of the latex is removed to adjust the coating amount, and a small, angular rubber granule is formed by raising the surface of the latex coated after the second coating step. The method for manufacturing a carpet is characterized by comprising a tatsuchiroll step of forming large, angular rubber particles on the surface of the latex layer, whereby the latex in the first coating step is Because of this formation, the rubber particles of the latex in the second coating process are easy to adhere to, and the rubber particles are evenly adhered to the latex layer containing large and small rubber particles in the second coating process. It works effectively as a non-slip carpet because it is raised using a Tatsuchi Roll to form large, angular rubber particles on the surface of the latex layer with small, angular rubber particles on the surface. The angular protrusions are obtained continuously, making it a useful manufacturing method for forming the backing material of this type of carpet.

[Brief explanation of the drawing]

The figures show an example of the method for manufacturing a carpet according to the present invention, in which Figure 1 is a production process diagram and Figure 2a is a
Figure 2b is an enlarged view of the original fabric in section A, Figure 2b is a sectional view taken along line a-a in Figure 2a, Figure 3a is an enlarged view of section B in Figure 1, and Figure 3b is an enlarged view of Figure 3a. bb sectional view,
Figure 4a is an enlarged view of part C in Figure 1, and Figure 4b is an enlarged view of section C in Figure 1.
Fig. 5 is a cross-sectional view taken along the line CC in Fig. a; Fig. 5 is a diagram showing a combination of a raw fabric and a primary carpet showing one embodiment of the inconvenient protrusion; Fig. 6 is a diagram showing another embodiment of the inconvenient protrusion. , Figures 7a and 7b are views showing other embodiments of the same inconvenient protrusion, Figure 8a is an enlarged view of section D in Figure 1,
Fig. 8b is a sectional view taken along the line dd in Fig. 8a, Fig. 8c is an enlarged view of the raised part of the Tatsuti Roll, Fig. 9 is a view showing the combination of the protrusion and the primary carpet, and Fig. 10 is a view of the carpet. FIG. 3 is a diagram illustrating undesirable warpage.

Claims (1)

[Scope of Claims] 1. In a carpet in which a latex layer such as SBR or EVA is applied to the back side of a carpet material with piles formed on the surface, large-grained and angular rubber particles with small and angular shaped rubber particles on the surface. 1. A carpet characterized in that rubber particles in a shape of a vat are formed on the surface of the latex layer. 2 Roll-coat a latex made by mixing fillers, dispersants, thickeners, water, etc. with SBR, EVA, etc. on the original carpet, and adjust the coating amount by removing the excess part of the coated latex. A first application step is performed, and a second step is to prepare a latex having a specific gravity similar to that of the latex and containing angular large and small rubber particles, and to adjust the amount of application by removing an excess portion of the latex. 2 coating step, and the latex coated surface after the second coating step is raised to form large, angular rubber particles on the surface of the latex layer, with small, angular rubber particles on the surface. A method for manufacturing a carpet, comprising a tatsuchiroll process for forming the carpet.