JP2001348769A - Method for producing tufted carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a printed figure pattern from deforming in a printing step. SOLUTION: A backing 4 for preventing pile yarns 3 from slipping off is applied to the back surface of a gray fabric 1 obtained by inserting tufts of the pile yarns 3 into a primary base fabric 2 in the form of a long belt and a secondary base fabric 5 is superimposed on the undersurface of the backing 4 to bond and integrate the gray fabric 1 with the secondary base fabric 5 using the backing 4. A suitable figure pattern is then printed by printing. An adhesive having water resistance and capable of holding >=1.5 kg/3 cm peel strength when wetted is used as the backing 4 and a polyester nonwoven fabric is used as the secondary base fabric 5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a tufted carpet to be laid and used on floors of offices, stores, houses and the like.

[0002]

2. Description of the Related Art Generally, tufted carpets in which pile yarn is tufted on the surface are used for carpets laid on floors of offices, stores, houses and the like.

In the conventional tufted carpet, a carpet material obtained by tufting pile yarns on a long-strip-shaped primary base cloth (surface base cloth) by a tufting machine, that is, a so-called greige machine, is supplied to a backing process, and the greige machine is formed in the process. After applying a backing to prevent the pile thread from coming off on the back side, supply it to the printing process, and in the process, continuously print the appropriate pattern and coloring on the surface of the greige machine with the printing machine, and then supply it to the backing process In this process, a secondary fabric (back fabric) is overlaid on the lower surface of the backing, and the greige fabric and the secondary fabric are bonded and integrated by backing. The finished product is cut into a predetermined size, for example, 2 or 3 tatami mats.

[0004]

In the above-mentioned conventional method for manufacturing a tufted carpet, the printing and printing of the greige machine after the appropriate pattern and coloring are continuously printed on the surface of the greige machine in the printing process. In addition, since the stiffness of the greige machine is low, the greige machine is distorted, and the printed pattern is easily deformed. Since it is difficult to correct the deformation of the print pattern or the like that occurs in such a printing process in a post-process, it is difficult for conventional tufted carpets to print a pattern in which the deformation is conspicuous, such as a multicolor frame pattern. Was shunned and limited in design.

An object of the present invention is to provide a method for manufacturing a tufted carpet that solves the above-mentioned conventional problems.

[0006]

According to the present invention, in order to achieve the above object, a backing for preventing pile yarns from being removed from the back surface of a greige machine formed by tufting pile yarns on a long band-shaped primary base cloth is provided. The greige fabric and the secondary base fabric are bonded and integrated by backing, and the appropriate pattern is printed by printing.

In the present invention, it is preferable to use an adhesive which has water resistance to the backing and can maintain a peel strength of 1.5 kg / 3 cm or more when wet. It is desirable to use

[0008]

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

FIG. 1 is a partial sectional view of a tufted carpet. In the same figure, reference numeral 1 denotes a green fabric in which a pile yarn 3 is tufted on a primary base cloth 2, 4 denotes a backing for preventing pile yarn coming off formed on the back surface of the green fabric 1, and 5 denotes an adhesive and integrated with the green fabric 1 by a backing 4. 2 shows a secondary base fabric.

The greige machine 1 is prepared by using a natural fabric, a synthetic fiber and other appropriate fiber materials on a primary base fabric 2 made of a woven or non-woven fabric made of natural fibers, synthetic fibers or other appropriate fiber materials. The pile yarn 3 is tufted. The pile yarn 3 may be a loop pile,
It may be a cut pile.

The backing 4 is made of an adhesive having water resistance and capable of maintaining a peel strength of 1.5 kg / 3 cm or more when wet. As this adhesive, for example, SBR
Known adhesives such as (styrene / butadiene rubber), MBR (methyl methacrylate / butadiene rubber), NBR (nitrile / butadiene rubber), acryl, urethane and the like.

The secondary base fabric 5 may be a woven or non-woven fabric made of natural fibers, synthetic fibers or other appropriate fiber materials, but it is necessary to consider that the fabric is washed and dried together with the greige 1 by printing. to, polyester fibers from the speed of drying it is effective, also, since the nonwoven fabric is effective from the ability to prevent deformation during washing and drying, the 30 to 200 g / m ² using a polyester fiber Polyester nonwovens having a fiber content are preferred.

Next, a method of manufacturing the tufted carpet will be described. First, a long band-shaped primary base fabric 2 is supplied to a tufting step. In this step, a pile yarn 3 is tufted on the primary base cloth 2 by a tufting machine to form a greige machine 1, and subsequently the greige machine 1 is supplied to a backing process. Then, a backing 4 for preventing pile yarn coming off is provided on the back surface of the greige machine 1 in this step. Next, the raw fabric 1 and the secondary fabric 5 are supplied to the backing process, the secondary fabric 5 is superimposed on the lower surface of the backing 4 in the process, the greige 1 and the secondary fabric 5 are bonded and integrated by the backing 4, and subsequently supplied to the printing process. In this process, an appropriate pattern and coloring are continuously printed on the surface of the greige machine 1 by a printing machine. After that, it is supplied to a finishing process, and a product subjected to final finishing such as brushing in the process is cut into a predetermined size, for example, 2 tatami mats or 3 tatami mats, thereby completing the production of the tufted carpet.

According to the method for manufacturing a tufted carpet of the present invention, the secondary fabric 5
Are laminated and adhered and integrated by the backing 4, the rigidity of the greige machine 1 increases, and
It is strong enough not to cause distortion even when dried. For this reason, even if an appropriate design is printed on the surface of the greige machine 1 in the printing process, the printed design can be prevented from being deformed even if it is washed and dried.

Further, since the backing 4 is made of an adhesive which has water resistance and can maintain a peeling strength of 1.5 kg / 3 cm or more when wet, the adhesion between the greige machine 1 and the secondary base cloth 5 is printed. Even if the secondary base cloth 5 is washed in the process, the strength is such that the secondary base cloth 5 does not peel off. Therefore, even if the secondary base cloth 5 is washed in the printing step, the secondary base cloth 5 does not peel off.

Further, since a polyester non-woven fabric is used for the secondary base fabric 5, when washing and drying are performed in the printing process, the polyester fiber is easily dried by the polyester fiber which dries quickly.
The distortion can be suppressed by the nonwoven fabric having the deformation preventing ability.

[0017]

As described above, the present invention prevents the deformation of the printed design without causing distortion in the printing process by bonding and integrating the secondary base cloth on the back surface of the greige machine before printing. can do. This makes it possible to print a multicolor picture frame pattern that has been avoided in the past, and it is possible to provide a tufted carpet with a high degree of freedom in design.

Further, the backing has water resistance, and
By using an adhesive capable of maintaining a peel strength of 1.5 kg / 3 cm or more when wet, it is possible to prevent peeling of the secondary base fabric during washing in the printing process.

Furthermore, by using a polyester non-woven fabric for the secondary base fabric, it is easy to dry in the printing process,
Distortion can be suppressed.

[Brief description of the drawings]

FIG. 1 is a partial cross-sectional view of a tufted carpet.

[Explanation of symbols]

 Reference Signs List 1 greige machine 2 primary backing 3 pile yarn 4 backing 5 secondary backing

 ────────────────────────────────────────────────── ─── Continuing from the front page (72) Inventor Katsumi Takeuchi 1-3-16 Kuroricho, Izumi-shi, Osaka F-term (reference) in Yamamoto Sangyo Co., Ltd. 3B120 AA04 AA14 BA03 BA18 BA19 CA12 CA13 DB01 DB02 EA02 EA04 EA11 EA12 EB14 EB19 4L044 CB08 CB09 CC01 CC02 4L047 AA21 BA16 CA04 CA05 CA08 CC16 DA00

Claims (3)

[Claims] 1. A backing for preventing pile yarns from being removed from the back of a greige machine formed by tufting pile yarns on a long band-shaped primary backing, and then overlaying a secondary backing on the lower surface of the backing to perform backing. A method for manufacturing a tufted carpet, wherein a greige machine and a secondary base fabric are bonded and integrated, and then an appropriate pattern is printed by a printing process. 2. The backing has water resistance, and
The method for producing a tufted carpet according to claim 1, wherein an adhesive capable of maintaining a peel strength of 1.5 kg / 3 cm or more when wet is used. 3. The method for producing a tufted carpet according to claim 1, wherein a polyester nonwoven fabric is used for the secondary base fabric.