JPS6314121B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to tufted technology,
The purpose is to provide a tufted carpet and a tufted artificial lawn that are highly breathable.

Immediately after tufting, the pile is only lightly held between the warp and weft that make up the base fabric, and there is a concern that it may come off during transportation or storage during the subsequent lining finishing process. To increase strength, a dense woven fabric with no gaps between the warp and weft is used as the base fabric. In particular, the pile yarn used for tufted artificial lawns is a plastic monofilament tape yarn with a smooth surface, which makes it easy to pull out from the base fabric. Therefore, especially high-density woven fabrics are used as the base fabric for artificial lawns. ing.

In this way, conventional tufted manhole lawns have a high-density woven base fabric, and the backing is finished by applying a large amount of resin composition to bond the pile to the base fabric, resulting in a lack of breathability. It was hot.

For this reason, when using conventional tufted artificial grass, moisture from underground accumulates on the back side.
On the other hand, puddles of rainwater form on the front side, and,
It has been pointed out that the use in a tie ground has disadvantages such as making it difficult to insert the tee, that is, pull up the tee.

Some attempts have been made to create ventilation holes by inserting needles into tufted artificial grass that has been lined, but this is not a practical solution due to production costs.

Therefore, the main object of the present invention is to efficiently and economically provide a tufted artificial lawn suitable for tea-up, and also to provide a tufted carpet with excellent air permeability.

That is, according to the first invention of the present application, in the tufted artificial lawn, warp yarns 1 and weft yarns 2 are intertwined with an arrangement interval, ', which is more than three times the thickness of each yarn, and are covered with synthetic resin 4 at the intertwining point 5. A coarse mesh fabric with bonded void holes 6 is used as a base fabric 7, and a plastic tape yarn 9 is tufted with a tuft gauge g that is 1.5 times or more the warp spacing, and remains on the back side 23 of the tuft original fabric. It is constructed by applying a small amount of the backing resin composition 12 such that all or part of the pores 11 of the base fabric remain even after the backing is finished.

Here, the term "tuft gauge" refers to the arrangement interval of a large number of needles arranged and mounted on the tufting machine, which determines the interval between the pile rows in the longitudinal direction of the tufted material, that is, the pile gauge.

A conventional loom is used to intertwine the warp and weft yarns constituting the base fabric, and the resulting coarse net-like fabric is immersed in a synthetic resin composition using the mesh as pores, and then pulled up as it is to intertwine the warp and weft yarns. A base fabric can also be produced by coating the surfaces of the weft yarns with the synthetic resin and simultaneously joining the warp yarns and the weft yarns at intertwining points.

In addition, the base fabric constituting the present invention is obtained by covering the surface with synthetic resin 4 in place of the synthetic fiber yarn 3 as a conductive wire in the conventional electric wire manufacturing technique of forming an insulating coating of synthetic resin on a conductive wire. In this way, the core-sheath (sheath core) yarn, in which the synthetic fiber yarn is used as the core 3 and the synthetic resin is used as the sheath 4, is coarsely woven as the warp 1 and the weft 2, and then heated and/or a solvent is applied. It can be made by softening or melting the synthetic resin 4 that is the sheath component and pressing it at the intertwined points.

The core yarn 3 is polyester filament yarn or spun yarn with a single denier of 10 to 20 d and a total denier of 500 to 1000 d, and the sheath component is made of polyvinyl chloride, etc., and the outer diameter of the warp and weft is 0.3 ~1.5m/m
You will get satisfactory results when you do this.

For the pile yarn 9 forming a grass leaf shape, approximately 750 d x 12 gently twisted plastic monofilament tape yarns made of polyvinylidene chloride, polypropylene, nylon, etc. are used.

The tuft gauge is 5/64× for the tufted machine.
25.4m/m, 5/32×25.4m/m, 5/16×25.4m/m
The warp spacing of the base fabric is 2/3 or less of the tuft gauge g, preferably 1/2 or less of the tuft gauge, and is one integer (x), that is,
1/x (x is an integer of 2 or more) or less.

However, when the warp spacing is 1.5m/m or less,
When finishing the backing after tufting, the pores in the base fabric remaining in the tufted fabric are likely to be filled with the backing resin composition and blocked, and if the warp spacing is 10 m/m or more, the foot pressure that the artificial lawn will receive during use will be reduced. Stress due to abrasion concentrates on individual warp threads and breaks the warp threads, or the pile surface 10 of the resin composition in backing finish
It is desirable that the spacing between warp and weft yarns be 1.5 to 5.0 m/m to avoid leaching and contamination.

In this way, when tufting is performed using a tuft gauge that is 1.5 times or more the warp spacing, at least one side of the left and right sides of the pile column 24 has inter-warp void holes 11 in the base fabric into which needles are not inserted and, therefore, the pile is not tufted. However, in order to make the pores of the base fabric that remain in the tuft original fabric remain even after the backing is finished, the backing resin composition is applied by roller coating with the pile side facing up. In this case, while the applied resin composition does not dry or become agglomerated, airflow is applied perpendicularly to the pile surface to seal the pores in the base fabric and remove the coated backing resin composition. good. Additionally/or, before the backing resin composition is dried or coagulated, a doctor having artificial grass-like flexible protrusions is brought into contact with the back side of the tuft material, and the backing resin composition adhering to the pores of the base fabric is removed. Destruction of the crossing membrane may also yield good results.

The tuft step, that is, the tuft interval h of the pile in the longitudinal direction, is set to match the arrangement interval ' of the weft yarns of the base fabric, but this is not essential to the present invention.

According to the first invention of the present application, (1) the warp and weft of the base fabric are made of a strong synthetic fiber core yarn and a heat fiber that is unstretched, non-oriented, non-crystalline, rich in viscoelasticity, and has a large coefficient of friction. Since the surface coating is made of plastic synthetic resin, the tufted pile will not fall off from the base fabric during the backing finishing process after tufting due to the clamping pressure of the core yarn and the frictional force of the surface coating.

(2) Even with a base fabric with such a large coefficient of friction,
Large void holes 6 that are three times or more thicker than the warp and weft are continuous in the tufting direction, and
Since tufting is performed with a needle gauge that is 1.5 times or more the warp arrangement interval, gaps 11 between the warp threads where no needles are inserted remain on at least one side of the left and right sides of the needles that are inserted into the base fabric. Therefore, the needle easily enters the mesh-like pores of the base fabric, and in the pierced state, the pores expand to the remaining adjacent pores 11, so that the needle provides strong resistance during tufting. This prevents damage to the needle and breakage of the pile yarn.

(3) Since the warp and weft yarns that form the pores in this network are fused and joined to each other, the pores are not destroyed by tufting, and in particular,
The mesh-like voids between the vertical rows of piles that are not penetrated by the needles remain as they are, and remain without being completely sealed even by the packing agent used in the backing finish, creating ventilation holes that penetrate through the front and back of the finished tufted artificial lawn. 14, thus providing an artificial lawn with air permeability, water permeability, and suitability for tear-up.

(4) The incomplete sealing of the network-like pores remaining in the base fabric by the backing agent is due to the relatively small amount of backing applied, but the surface of the base fabric also serves as the material for the backing agent. Because it is coated with a synthetic resin, the pile firmly adheres to the base fabric even with a small amount of backing agent that seeps out from the back pile yarn by the doctor, making the artificial lawn of the present invention similar to a sports stadium. Even when used in a place subject to strong foot pressure abrasion, the pile will not be pulled out and an artificial lawn with excellent thread removal resistance can be obtained.

(5) Unlike an injection-molded mesh structure, the base fabric has oriented and crystallized fibers interposed as core threads in the warp and weft threads that form the pores, so the resulting artificial lawn It also has excellent dimensional stability.

(6) Such polymer crystals are generally easily destroyed by ultraviolet rays, but in the present invention, the synthetic fibers serving as the core fibers are made of thermoplastic resin, similar to the power transmission metal wires coated with insulation. The areas where the warp and weft intertwine or intersect are completely coated, making them less likely to become brittle even when left outdoors.
Therefore, an artificial lawn with excellent weather resistance can be obtained.

In the second invention of the present application, the back surface of the tufted artificial lawn according to the first invention has an interval q that is not an integral multiple of the warp interval of the base fabric but is three times or more,
In addition, the second backing resin composition is applied in a striped manner so that unapplied concave valleys 16 having a width p equal to or larger than the warp spacing of the base fabric are formed, thereby forming convex ridges.

This second resin composition includes polyvinyl chloride,
A polyvinyl chloride copolymer resin composition or the like is used by appropriately adding a foaming agent or by mechanical foaming.

The convex ridges 15 may be continuous in the vertical direction, or they may be discontinuous by forming concave valleys 18 that divide the continuation. Therefore, it can be done easily.

Therefore, according to the second invention of the present application, in addition to the effects of the first invention, (1) Since the concave valley portion 16 has a width p that is greater than the warp spacing of the base fabric, the void holes 1 remaining after the first backing finish are
4 will remain in the concave valley.

(2) Since the spacing q between the concave valleys is not an integral multiple of the warp spacing of the base fabric but is more than three times, the rows of voids 14 that remain after the first backing finish are formed in the concave valleys. Appears in either
Therefore, the ventilation holes 17 that are the object of the present invention are definitely formed by the voids that are not sealed by the convex ridges 15.

(3) When laying and constructing tufted artificial grass, ventilation channels are formed between the back side of the artificial grass and the ground (construction surface) by the concave valleys, and the air holes in the tufted material Even if only a portion of the artificial lawn remains, the ventilation channels will provide ventilation throughout the artificial lawn.

It is thus clear that according to the present invention, high quality tufted artificial turf can be obtained efficiently and economically, and in its implementation, filament yarns or spun yarns customary for indoor carpets are used instead of plastic tape yarns. Therefore, it is possible to obtain a breathable tufted carpet that does not cause corrosion of floorboards or tatami mats due to moisture, or a tufted carpet that can be easily washed with water, and the practical value of the present invention is often great. .

In addition, in carrying out the second invention, even if the convex ridges formed on the back side meander from side to side,
Even if it is formed in the weft direction, the effects of the present invention are not hindered, and the technical scope of the present invention is not limited thereby.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of the base fabric according to the present invention, FIG. 2 is a rear perspective view of the tufted raw fabric according to the present invention, and FIG. 3 is a rear perspective view of the tufted artificial lawn according to the present invention.
FIG. 4 is a sectional view taken along line XX in FIG. 3, and FIG. 5 is a perspective view of the back side of the tufted artificial lawn according to the present invention. 1... warp, 2... weft, 3... core thread, 4...
Synthetic resin, 5...Intersecting point, 6, 11, 14, 17
... Void hole, 7 ... Base fabric, 10 ... Pile, 13
...Tufted artificial lawn, 15...Convex ridges, 16
... Utsuyabe, 23 ... Tufted raw fabric (gray fabric).

Claims (1)

[Scope of Claims] 1. Warp and weft intertwined at intervals of three times or more their thickness, and void holes where the warp and weft are covered with synthetic resin and joined at their respective intertwining points. A certain rough mesh fabric is used as the base fabric, and plastic tape yarn is tufted with a tuft gauge that is at least 1.5 times the warp spacing, and all or part of the voids in the base fabric remaining on the back side of the tufted fabric are lined. A tufted artificial lawn characterized by being formed by applying a small amount of a backing resin composition to the extent that it remains even after application. 2. In claim 1, the warp and weft are core-sheath yarns having a synthetic fiber yarn as a core and a thermoplastic synthetic resin as a sheath and having an outer diameter of 0.3 to 1.5 m/m. . 3. In claim 1, the spacing between the warp and weft is 1.5 to 5.0 m/m. 4. A coarse net-like structure in which the warp and weft are intertwined at intervals of at least three times their thickness, and the warp and weft are covered with synthetic resin and have void holes that are joined at each intertwining point. A plastic tape yarn is tufted using a fabric as a base fabric with a tuft gauge that is 1.5 times or more the warp spacing, and all or part of the pores in the base fabric that remain in the tufted fabric remain even after backing finishing. A small amount of the backing resin composition is applied to the base fabric, and the uncoated concave valleys have a spacing that is not an integral multiple of the warp spacing of the base fabric but is three times or more, and a width that is equal to or larger than the warp spacing of the base fabric. A tufted artificial lawn characterized by forming a second backing resin composition and applying a second backing resin composition in a striped manner, and forming convex ridges formed by the second backing resin composition in a striped shape. 5 In claim 4, the warp and weft are core-sheath yarns having a core made of synthetic fiber yarn and a sheath made of thermoplastic synthetic resin and having an outer diameter of 0.3 to 1.5 m/m. . 6. In claim 4, the distance between the warp and weft is 1.5 to 5.0 m/m.