JP2001087115A - Tile carpet and heater cutter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively produce a tile carpet which prevents loosening at peripheral edges without using a polyvinyl chloride paste sol, is light in weight and can be occasionally laundered. SOLUTION: The tile carpet is constituted by including a base fabric 11 and piles 12 projecting from this base fabric 11 and cutting pile fabric 14 which is continuous between the piles and piles adjacent to each other in one direction of the base fabric via back stitches 13. The fibers of >=30 wt.% constituting the base fabric 11, the piles 12 and the back stitches 13 are formed of synthetic fibers having hot meltability and the cut terminals of the hot meltable synthetic fibers 16 constituting the base fabric and back stitches appearing at the cut ports 15 are formed as molten lumps 17 and the cut terminals of at least a portion thereof are fused. A disk 24 which is rotatably driven and a heat cutter having a heating element 26 which is fixed to face the peripheral edge 25 of this disk are used for the cutting.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tile carpet constructed by laying the edges of the tile carpet together and a heat cutter used for manufacturing the tile carpet. Tile carpets are used by laying a large number on such a wide floor, and are easier to carry than large carpets spread over the floor and constructed, and easy to remove when not in use, like carpets It is not bulky and is widely used due to its convenient storage.

[0002]

2. Description of the Related Art At the beginning of the development of a tile carpet, it has a feeling of weight that does not move even if it is simply laid, flexibility to fit on the uneven surface of the floor, and anti-smearing property that does not easily come off from the periphery. It is considered necessary, and in order to satisfy these required characteristics, a vinyl chloride paste sol is applied to the back of the carpet, a heavy backing layer is laminated, and it is cut into a shape (usually rectangular) that can be laid. . Carpets include needle punched felt carpets, abbreviated as knee pans, woven carpets represented by Wilton carpets and Axminster carpets, and tufted carpets, abbreviated as tufts.

[0003] Woven carpets have a base fabric that is densely woven.
Since it is difficult to perform a backing treatment for preventing the base fabric from being loosened by applying and impregnating the adhesive on the back surface, it is not suitable for a tile carpet. In addition, knee pans lack cushioning and antifouling properties and have a poor three-dimensional appearance, and thus have not been recently used for tile carpets. For this reason, a tufted carpet that can prevent the pile or the base cloth from being loosened by an adhesive applied to the back surface is mainly used as the tile carpet.

[0004]

The vinyl chloride paste sol used for tile carpets contains a large amount of harmful plasticizers, and the vinyl chloride resin itself generates harmful combustion gases, which poses a problem in terms of pollution. There is. In addition, even tile carpets that have been thickly finished by applying a vinyl chloride paste sol can be sucked up by a vacuum cleaner, so recently the construction method of temporarily bonding tile carpets with an adhesive has become widespread. It is desired to reduce the weight of the tile carpet in terms of easiness, and it is no longer necessary to apply a thick vinyl chloride paste sol to give the tile carpet a sense of weight.

[0005]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a tile carpet that can be prevented from unraveling at the periphery without using a vinyl chloride paste sol, is lightweight, flexible, and can be washed at any time. It is another object of the present invention to provide a luxurious tile carpet using a Wilton carpet, an akisminster carpet and other woven carpets.

[0006]

The tile carpet of the present invention includes a base cloth 11 and a pile 12 protruding from the base cloth, and a back stitch is provided between piles adjacent to each other in one direction of the base cloth. The pile mass 14 which is continuous through the cutout 13 is cut, and the molten mass 17 of the hot-melt resin is formed only at the cutting end of the base fabric and the fiber 16 constituting the back stitch, which appear at the cutout 15 of the pile ground. The first feature is that the cut ends of at least some of the fibers 16 are fused via a molten mass 17.

A second feature of the tile carpet of the present invention is that, in addition to the above first feature, a base cloth 11 and a pile 12 protruding from the base cloth are provided, and are adjacent to each other in one direction of the base cloth. It is constituted by cutting a pile ground 14 which is continuous between piles via a back stitch 13,
30% by weight or more of the fibers constituting the base cloth 11, the pile 12 and the back stitch 13 are synthetic fibers having a heat-melting property, and the base cloth appearing at the cutout 15 of the pile ground and the heat-fusible synthetic material forming the back stitch. Only the cutting end of the fiber 16 forms a molten mass 17, at least a portion of which is fused between the cutting ends, and a peripheral portion 18 including the cutting opening 15.
And the thickness of the inner portion 19 surrounded by the peripheral edge thereof is uniform.

A third feature of the tile carpet of the present invention is that, in addition to any one of the first and second features, the pile fabric 14 is a pile woven fabric in which the base cloth 11 and the pile 12 are simultaneously woven or knitted. It consists of a knitted fabric.

A fourth feature of the tile carpet of the present invention is that, in addition to any one of the first and second features, the pile material 14 is obtained by laminating the fibers 21 on the interlining material 20 and performing needle punching. It is constituted by a tufted pile cloth in which a pile 12 is formed by inserting a pile yarn into a base cloth 11.

A fifth feature of the tile carpet of the present invention is that, in addition to any one of the first, second, third and fourth features, a backing layer 22 made of a hot-melt resin is provided on the back surface of the pile ground 14. Are laminated.

A sixth feature of the tile carpet of the present invention is that, in addition to any one of the first, second, third, fourth and fifth features, the base fabric 11 and the back stitch 13 are heat-meltable. This is because the resin adhesive is impregnated.

The heat cutter of the present invention is an apparatus for manufacturing the tile carpet 23 described above, and includes a disk 24 driven to rotate and a heating element 26 for heating a peripheral edge 25 of the disk.
Is a first feature.

The second feature of the heat cutter of the present invention is that
Two disks 24 and 27 that are rotationally driven are supported by rotating shafts 28 and 29 having their axes aligned in parallel, and the peripheral edges 25 and 30 of the two disks 24 and 27 are on the same plane. A heating element 26 for heating a peripheral edge 25 of one disk 24 and a peripheral edge 30 of the other disk 27
Is provided with a pointed tip.

A third feature of the heat cutter of the present invention is that
In addition to any of the first and second features, the heating element 2
6 is provided with a hot-melt resin replenishing device 40 for feeding hot-melt resin to the peripheral edge 25 of the disk 24 heated to 6.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION
When cutting with a dull circle cutter (rotary blade) with blade damage, frictional heat is generated and the fibers at the cutting opening are fused, and the ratio of thermoplastic synthetic fibers contained in the fiber aggregate is high, It has been found that if the fibers of the fiber aggregate are dense, the fibers in the cut are easily fused to each other, and the cut is hardened by the molten mass. The present invention has been completed based on such findings.

In order for the base cloth 11 constituting the peripheral edge 18 of the tile carpet 23 and the cut end of the fiber of the back stitch 13 to form and fuse the hot melt mass 17, a circle cutter (24, 27) is used. And actively heat the cutting edge without relying on frictional heat with the pile ground.
The pile material 14 is cut while being heated and melted by 5).
At the same time as the cutting, a fiber cutting terminal may be fused.
Because, in this case, even if the cutting edge (25) is damaged, the fiber 16 is melted by heat and breaks, and the cutting edge of the fiber vibrates by touching the rotating cutting edge to cut the other fiber. And a resin film 31 is formed at the cutout by the melt 17. Then, the melt 17 is a plastic of the same quality as the fibers (16) constituting the base cloth 11 and the back stitch 13, and the fibers are more firmly bonded than when an adhesive is applied. Unraveling is completely prevented. In this case, even if wool fibers or cellulosic fibers are interposed in the cutout 15, those non-heat-meltable fibers are cut at the cutting edge (25), and the cut non-heat-meltable fibers are cut. The molten mass 1 of the heat-meltable fiber 16
Since the fibers 7 are entangled and integrated, even if the non-heat-fusible fiber is interposed in the cutout 15, unwinding is prevented. For this reason, even if the pile material 14 is a Wilton carpet or an Axminster carpet that is hardly impregnated with an adhesive, the tile carpet 23 can be finished by preventing the pile material 14 from being unraveled at the cutout.

In order to prevent the cutting opening from being unraveled, a heater may be applied to the cut opening without heating to heat and melt the terminal of the cut fiber. However, even if a heater is applied to the cut formed once, the cut cannot be fused neatly, and a tile carpet having commercial value cannot be obtained. Because the thickness of the backing fabric including the back stitch is generally 2 in any carpet.
mm or less, it is extremely difficult to apply the heater only to the cutting terminals of all the fibers that appear in the thin cut, and depending on the condition of the heater applied to the cut, the molten mass extruded. Irregularities are formed, and the surrounding pile is melted and deformed by radiant heat from the heater, and the aesthetic appearance of the entire tile carpet is impaired. In order to evenly and accurately apply the heater to the thin cutout, it is necessary to manually perform the operation, and the two steps of cutting and heat melting by the heater itself increase the cost of the tile carpet.

The pile material 14 is cut using a heat cutter having a disk 24 driven in rotation and a heating element 26 fixed to the periphery 25 of the disk. The pile material 14 is cut not by the side but by the back surface of the pile material, and the edge 25 of the disk 24 is not deeply penetrated to reach the pile surface, but is penetrated shallowly to touch the root of the pile. Then,
The molten mass 17 of the heat-fusible resin is formed only at the cutting end of the base fabric appearing at the cutout 15 and the fibers 16 constituting the back stitch, or the heat-fusible material forming the backstitch and the base fabric appearing at the cutout 15 forms the back stitch. Only the cutting end of the synthetic fiber 16 forms the molten mass 17, and the base cloth 11 and the back stitch 13 alone can be neatly cut in one step without thermally deforming the pile 12 appearing at the cutting opening 15.
The pile with the molten mass at the tip does not protrude to the surface to impair the feel and feel of the tile carpet. As described above, the present invention is directed to cutting not only the base fabric and the back stitch but also the entire pile material including the pile layer with the heat cutter, but cutting only the base fabric and the back stitch without the pile layer with the heat cutter. There is a feature.

However, the disk 24 heated by the heating body 26
With a heat cutter having only a loop pile, it is not possible to cut off a pile material having a loop pile at a cutting edge. Two disks 24 and 27 that are rotationally driven are supported by rotating shafts 28 and 29 having their axes aligned in parallel, and the peripheral edges 25 and 30 of the two disks 24 and 27 are on the same plane. The heat cutters, which are arranged side by side and are provided with a heating element 26 for heating the peripheral edge 25 of one disk 24, and the edge 30 of the other disk 27 is provided with a cutting edge with a pointed cross section, the This is effective for cutting the pile ground 14 having the same. That is, when a heat cutter is used, the base cloth 11 and the back stitch 13 are cut by the disk 24 heated by the heating body 26 first, and then the loop pile is cut open by the disk 27 not heated by the heating body. In that case, the disk 27 that is not heated by the heating element is
0 is digged deep until it reaches the pile surface (FIG. 3).

The heat cutter having the two disks 24 and 27 is also effective for cutting a pile of cut pile. This is because the cutting opening immediately after the cutting, which is cut by the disk 24 heated by the heating element 26, is in a state where it is melted and has residual heat, and can be bound again via the molten mass 17, and it is bound. Sometimes you need a cutter to pull it apart. Also, the peripheral edge 25 of the disk 24
If you do not cut into the pile deep enough to reach the pile surface, but only to touch the root of the pile, it may not be possible to cut the pile ground 14 completely, and a cutter is necessary to separate the uncut portion become. In this regard, 2
In the heat cutter having the two disks 24 and 27, the disk 27 not heated by the heating body separates the cutting hole rebound by the molten mass 17 and the uncut portion of the disk 24 heated by the heating body 26. It is also effective for cutting pile piles of cut pile. This is because even though the hot-melted cuts facing each other may fuse due to residual heat, and even if the pile pieces cut by hot-melting from the base become foreign matter and fuse to the cuts, Is separated by the disk 27 after it is not heated.

As described above, it is preferable to attach the cutting edge (25) also to the peripheral edge of the disk 24 heated by the heating element. That is, by attaching the cutting edge (25) also to the heating disk 24, it is possible to cut the base cloth 11 and the back stitch 13 containing the non-heat-meltable fiber. However, base cloth 1
When the mixing ratio of the non-heat-fusible fibers contained in No. 1 or the back stitch 13 increases, the fusion of the fibers appearing at the cutting opening between the cutting terminals becomes insufficient. Therefore, the base cloth 11 and the pile 12
And 30% by weight of the fibers constituting the backstitch 13
Above, preferably at least 50% by weight is made of heat-fusible synthetic fibers. Since the cutting end of the fiber appearing at the cutting opening is rubbed and entangled with the disk 24, the heat-fusible synthetic fiber may be contained in either the base cloth 11 or the pile 12 (back stitch 13). The heat-fusible synthetic fibers may occupy 30% by weight or more, preferably 50% by weight or more of the entire fibers of the base cloth 11 and the pile 12 (back stitch 13) that appear.

In the present invention, the cutting edge of the pile ground, that is, the loosening from the periphery of the tile carpet, is caused by the fusion of the fiber cutting terminal thus appearing at the cutting edge (17.31).
Therefore, there are many hot-melt fibers appearing at the cutting opening, and the more densely the hot-melt fibers are present, the more effectively the unraveling is prevented. In this regard, in the pile weave (FIG. 2), the base fabric 11 is woven and knitted precisely together with the back stitch 13, so that it is easy to prevent unraveling. However, in the tufted pile fabric (FIG. 1), the back stitches 13 are protruded in a loop shape on the back surface of the base fabric 11, and the gaps (13, 13) between the adjacent back stitches (13, 13) in which the fibers of the pile yarn are not interposed are formed. ), And the molten mass 17 is formed only by the thin base cloth 11. Therefore, as the base cloth 11 of the tufted pile cloth, a needle-punched felt (so-called knee pan base cloth) obtained by laminating the fiber web 21 on the interlining 20 and performing needle punching is used, and the lamination surface of the fiber web 21A is back-stitched. Tough to the side. The fibrous web is preferably laminated to increase the density of the hot-melt fibers appearing at the cuts and increase the amount of the molten mass 17 that acts as an adhesive.
1B is also laminated on the pile surface side of the interlining 20 (FIG. 1).

By doing so, the back stitch 13 sinks into the fiber web layer 21A, and the fiber web 2
1A is raised between the back stitches 13 and 13 so that the back surface of the tufted pile fabric becomes flat and the fiber web 2
1 at the cutting opening 15 by the amount of lamination
6 becomes dense and the back stitches 13 are bonded via the molten mass 17 so that the cutout 1
5 is effectively prevented (FIG. 1). In the case of the base fabric in which the fiber web 21B is also laminated on the pile surface side of the interlining 20, the peripheral edge of the disk 24 is so small that the fibrous web 21B is not completely cut even when the interlining 20 is completely cut. 2
5 shallowly bite, the molten mass 1 of the fiber web 21A, the interlining 20, and the back stitch 13 on the back stitch side
7 is blocked by the remaining fiber web 21B and does not protrude into the pile surface, and the molten mass 17 that has been blocked and adhered to the fiber web 21B is cut into a disk 27 that is not heated by the heating element. So, the cut end is beautifully finished. The interlining 20 of the base cloth 11 may be a woven fabric, a nonwoven fabric, or a knitted fabric.

If the constituent yarns (warp or weft) and the backstitch of the back fabric approaching the cut are rubbed or hooked, they are pulled by the fibers and the cut is torn. There is a possibility that it will spread and be easily unraveled.
In order to avoid such a problem, in particular, in the pile woven fabric (14), a backing material (22) is laminated on the back surface, and the backing material (22) constitutes a base fabric. The yarn such as back stitch (pile yarn) is covered and protected, and the yarns constituting the base fabric are joined via the backing material (FIG. 2). Since this backing material (22) also constitutes a part of the cutout 15 when cutting the pile ground, a nonwoven fabric having a heat-meltable fiber or a heat-meltable resin is used for this.

The hot-melt resin used as the backing (22) is an adhesive type in which fine powder is dispersed and applied as an adhesive, a hot-melt type in which the resin is heated and melted, or a film. Any type of film type, which is formed and heat-sealed or bonded, may be used. When the backing material (22) is back-lined and laminated on the back surface of the pile ground 14, the back surface of the tile carpet is finished smoothly, and an adhesive is applied thereto to easily finish the tile carpet which is easy to perform temporary bonding.

A backing agent can be applied to the pile material 14 like a conventional tufted carpet to firmly adhere the base fabric and the back stitch. In this case, a hot-melt resin is used as the backing agent. As the heat-fusible fiber, many thermoplastic synthetic fibers such as nylon, polyester, polyolefin, vinylon, acetate, and polyvinyl alcohol are used, and these may be particularly those to which heat-fusing properties are imparted. The heat-fusible resin as the backing material includes plastics used as the material of these heat-fusible fibers, polyethylene vinyl acetate resin (EV)
A) Many other resins can be used.

The heat cutter may be provided with a cleaner 32 for scraping off the melt adhered to the disk 24. The cleaner 32 is preferably provided with a groove 33 into which the peripheral edge 25 of the disk 24 fits, and scrapes off the molten material at the groove edge (33). Remove from In addition, the heat cutter
A bed (press) 34 for preventing vibration of the pile ground is appropriately provided. In the figure, reference numeral 35 denotes a rotating shaft of the cleaner. In the heating disk 24, an opening 36 for heat radiation is opened so that the rotating shaft 28 is not excessively heated, and a blade for blowing air is attached to the opening 36 to conduct heat conduction from the peripheral edge 25 to the rotating shaft 28. Reduce.

In a preferred embodiment of the present invention, the heating element 26
Is to use a heat cutter provided with a hot-melt resin replenishing device 40 for feeding hot-melt resin to the peripheral edge 25 of the disk 24 to be heated. In such a heat cutter having the hot-melt resin replenishing device 40, even in the pile ground 14 in which neither the base fabric 11 nor the back stitch 13 contains hot-melt fibers or hot-melt resin at all, At the same time as being cut by the peripheral edge 25, a hot-melt resin is applied to the cut and the molten mass 17 of the hot-melt resin adheres the cutting ends of the fibers that appear in the cut, so that the cut is made at the cut. Unraveling is prevented.

A further preferred embodiment of the present invention uses a heat cutter provided with a hot-melt resin replenishing device 40 for feeding hot-melt resin to the peripheral edge 25 of the disk 24 heated by the heating element 26, and a pile. Non-thermofusible fibers such as wool fibers and hemp fibers are used for the yarns (pile 12 and backstitch 13), and heat-fusible fibers and resin are used only for the base cloth 11. Then, the back stitch 13 of the non-heat-fusible fiber such as wool fiber and hemp fiber
Appears, the molten mass 17 of the hot-melt resin supplied from the hot-melt resin supply device 40 is fused to the back stitch 13 together with the hot-melt fibers and the hot-melt resin of the base cloth 11 and cut. Unwinding at the mouth is prevented, and a high-quality tile carpet having a pile surface constituted by natural fibers such as wool fiber and hemp fiber can be obtained.

The disk to be heated by the heating element may project from the peripheral surface of a rotating body having the heating element provided therein. As described above, it is better to attach a cutting edge (25) to the periphery of such a disk. The hot-melt resin replenishing device may be a pad (tank) provided with a heating device, and in such a hot-melt resin replenishing device, the pad is heated in the pad (tank) and becomes fluid. The disk (24) is supported so that the periphery contacts the hot-melt resin.

[0031]

According to the present invention (claims 1 to 4), it is possible to prevent the tile carpet from being unraveled at the cutout without impregnating the adhesive into the base cloth or the back stitch.
Accordingly, Wilton carpets and Axminster carpets, for which it is practically impossible to impregnate the adhesive, can be economically provided as tile carpets.

According to the present invention (claims 5 and 6), a tile carpet that does not break the cutout even if the back surface is strongly rubbed and does not come off from the cutout can be obtained.

According to the present invention (claims 7 to 9), the fibers at the cut opening are heat-sealed at the same time as the cutting, and even if the non-heat-fusible fibers are mixed in the base fabric or the backstitch, the heat fusion is performed. The non-heat-fusible fiber is integrated with the molten mass of the conductive fiber, and the tile carpet which does not come off from the cutout can be efficiently obtained.

[Brief description of the drawings]

FIG. 1 is a side view of a main part of a tile carpet according to the present invention, which is partially enlarged and shown in a circle.

FIG. 2 is a perspective view of a main part of the tile carpet according to the present invention, and shows a part of the tile carpet in an enlarged manner surrounded by a circle.

FIG. 3 is a side view of a main part of the heat cutter according to the present invention.

[Explanation of symbols]

 REFERENCE SIGNS LIST 11 base cloth 12 pile 13 backstitch 14 pile ground 15 cutout 16 heat-meltable fiber 17 molten mass 18 peripheral portion 19 inner portion 20 interlining 21 fiber (web) 22 backing layer 23 tile carpet 24 disk 25 peripheral edge 26 heating element 27 Disk 28 Rotation shaft 29 Rotation shaft 30 Peripheral edge 31 Resin film 32 Cleaner 33 Groove 34 Bed 35 Rotation shaft 36 Opening 37 〆 Warp 38 Core warp 39 Weft 40 Hot melt resin supply device

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Toshiaki Hirotsu 5-4-20 Nagayoshi Dedo, Hirano-ku, Osaka Honey Steel Co., Ltd. F-term (reference) 3B120 BA24 BA28 CA04 DB03 DB04 EB15 EB16 3B154 AA06 AB24 AB34 BA32 BA47 BA49 BB12 BB54 BC31 BF12 DA18

Claims (9)

[Claims] A base cloth (11) and a pile (12) protruding from the base cloth, and a pile between piles adjacent to each other in one direction of the base cloth is continuous via a back stitch (13). The pile (14) is cut from the base material and the fiber (16) forming the back stitch at the cutting end (15) of the pile (15). ) Is formed, and a tile carpet in which at least a part of the cut ends of the fibers (16) is fused via a molten mass (17). 2. A base fabric (11) and a pile (12) protruding from the base fabric, and a pile between adjacent piles in one direction of the base fabric is continuous through a back stitch (13). 30% by weight or more of the base fabric (11), the pile (12) and the back stitch (13) are synthetic fibers having a heat melting property. The base cloth appearing at the cutting opening (15) of the pile and the cutting end of the heat-fusible synthetic fiber (16) constituting the back stitch form a molten mass (17), and at least a part of the fiber (16) is formed. A tile carpet with a fusion between cutting terminals. 3. The pile ground (14) according to claim 1,
The tile carpet according to claim 1, characterized in that the base cloth (11) and the pile (12) are pile woven knitted fabrics woven or knitted simultaneously. 4. The pile ground (14) according to claim 1,
Is a tufted pile fabric in which pile yarns are inserted into a base fabric (11) formed by laminating fibers (21) on an interlining (20) and performing needle punching to form a pile (12). The tile carpet according to claim 1, wherein 5. The pile ground (14) according to claim 1,
The tile carpet according to claim 1, wherein a backing layer (22) made of a hot-melt resin is laminated on the back surface of the tile carpet. 6. The tile carpet according to claim 1, wherein the base fabric (11) and the back stitch (13) according to claim 1 are impregnated with a hot-melt resin adhesive. 7. A heat cutter comprising a rotating disk (24) and a heating element (26) for heating a periphery (25) of the disk. 8. Two rotating disks (24 · 2)
7) are respectively supported by rotating shafts (28, 29) whose axes are aligned in parallel, and their two disks (24.2)
The peripheral edges (25 and 30) of 7) are arranged on the same plane,
A heating element (26) for heating the periphery (25) of one of the disks (24) is provided, and the periphery (3) of the other disk (27) is provided.
A heat cutter having a pointed tip in 0). 9. A rotating disk (24), a heating element (26) for heating a peripheral edge (25) of the disk, and a peripheral edge (25) of the disk (24) heated by the heating element (26). A heat cutter provided with a hot-melt resin supply device (40) for feeding hot-melt resin to the device.