JP2002275753A - Carpet and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a carpet having decreased weight. SOLUTION: The carpet is provided with a primary base cloth, piles planted on the surface of the primary base cloth and a nonwoven web layer bonded to the back surface of the primary base cloth. The fibers constituting the nonwoven web layer are entangled with the fibers constituting the primary base cloth. The fibers constituting the nonwoven web layer are entangled with each other. The fibers are preferably entangled with fibers constituting the base part of the piles. Accordingly, the nonwoven web layer is firmly bonded to the primary base cloth, etc., to prevent the falling off of piles and the nonwoven web layer has a sufficient function as the backing layer. Since the backing layer of the carpet is a nonwoven web layer holding a number of voids in the layer, the carpet has light weight compared with conventional resin sheet free from void.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a carpet with reduced weight and a method for manufacturing the carpet.

[0002]

2. Description of the Related Art Conventionally, a carpet in which a pile such as a loop pile or a cut pile is planted on a primary base cloth is provided with a backing layer made of a resin sheet such as natural rubber or elastic polyethylene on the back surface thereof. I have. This backing layer is firmly bonded to the primary base fabric and the base of the pile present on the back surface of the primary base fabric, and is for preventing the pile from falling off. In order to firmly join the backing layer and the primary base cloth, etc., a method of bonding a resin sheet with an adhesive or directly applying the liquid resin to the primary base cloth, etc., and drying or solidifying the liquid resin There is a method of forming a resin sheet as it is.

[0003] However, when the backing layer is made of a resin sheet, there is a disadvantage that the mass of the entire carpet becomes heavy. For this reason, the present inventor considered that the backing layer was composed of a fiber aggregate. That is, in the case of the fiber aggregate, since there is a gap between the fibers, the mass is lighter than that of the resin sheet having no such a gap, and therefore the mass of the entire carpet can be reduced. It was.

[0004] However, in the case of a fiber aggregate, it cannot be firmly bonded to a primary base cloth or the like as compared with a resin sheet. For example, even when a fiber aggregate such as a knitted fabric is bonded to a primary base cloth or the like with an adhesive, the mesh (voids between the yarns) of the knitted fabric is not bonded to the primary base cloth or the like, so that it is strong. Joining was difficult. If the strong joint is not made, the pile planted in the primary base cloth will fall off. That is, the fiber aggregate has a space between the fibers and is lightweight, but on the other hand, due to the presence of the space, it cannot be firmly bonded to the primary base fabric or the like and sufficiently prevents the pile from falling off. I can't do that.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to use a fiber aggregate as a backing layer and to firmly join the fiber aggregate to a primary base cloth or the like. Under such a problem, the present invention focuses on the fact that the primary base cloth and the pile are made of fibers, and entangles these fibers with the constituent fibers constituting the fiber aggregate as the backing layer, Strong bonding between the fiber aggregate and the primary base cloth was achieved.

[0006]

That is, the present invention provides a primary fabric, a pile planted on the surface of the primary fabric, and a nonwoven web layer joined to the back surface of the primary fabric. The present invention relates to a carpet, wherein the constituent fibers constituting the nonwoven web layer are intertwined with the fibers constituting the primary base fabric, and the constituent fibers are also intertwined with each other.

As the primary base fabric used in the present invention, any fabric can be used as long as it is made of fiber. For example, a nonwoven fabric obtained by accumulating long fibers or short fibers, a fabric knitted by filaments made of long fibers or short fibers, a cloth-like material knitted by flat yarn, or the like is used.

A pile is planted on the surface of the primary fabric. The pile may be a loop pile or a cut pile. The pile may be tufted with a pile yarn (also referred to as a tuft yarn) on the surface of the primary base fabric by a conventionally known method. As a result, a pile with long hair tips is planted on the surface of the primary base cloth. On the back side of the primary fabric, there is a root portion of the pile, and the pile is fixed to the primary fabric. As the pile yarn, a polyamide yarn, a polyester yarn, an acrylic yarn, a polypropylene yarn or the like is used.

[0009] A nonwoven web layer is bonded to the back side of the primary backing. The bonding state between the nonwoven web layer and the primary base fabric is
It is as follows. That is, the fibers constituting the nonwoven web layer and the fibers constituting the primary base fabric (long fibers, short fibers, flat yarns or the like) are entangled with each other, so that the fibers are firmly joined. The constituent fibers of the nonwoven web layer are as follows:
Not only the fibers constituting the primary base fabric, but also the fibers constituting the pile (polyamide fiber, polyester fiber, acrylic fiber, polypropylene fiber, etc.), particularly the fibers constituting the base of the pile present on the back surface of the primary base fabric, Is preferred. Further, the constituent fibers of the nonwoven web layer are also intertwined. This entanglement can prevent the constituent fibers from falling off the surface of the nonwoven web layer. The entanglement between the constituent fibers of the nonwoven web layer and the fibers constituting the primary base fabric and the like and the entanglement between the constituent fibers of the nonwoven web layer are means for entanglement between the fibers, such as a high-pressure water column treatment or a needle. It can be performed by a punching process or the like. In the present invention, the high pressure water column flow treatment is optimal.

As the constituent fibers of the nonwoven web layer, short fibers or long fibers are used. In order to improve the entanglement with the fibers constituting the primary base fabric or the like, short fibers having free ends exist. Preferably it is. For example, a fiber length of 10 to 10
Short fibers having a size of about 0 mm and a fineness of about 1 to 10 denier are preferred. As the material of the constituent fibers, any conventionally known materials such as polyester, polyamide and polyolefin can be used.

When a molding carpet is obtained, the composite fiber comprising a high-melting polymer and a low-melting polymer as constituent fibers of the nonwoven web layer, wherein the low-melting polymer forms at least a part of the surface. Preferably, fibers are used. The reason why the low melting point polymer forms at least a part of the surface of the constituent fibers is to fuse the constituent fibers to each other after molding.
As such constituent fibers, for example, a core-sheath type composite fiber having a high melting point polymer as a core component and a low melting point polymer as a sheath component, or a high melting point polymer and a low melting point polymer having a semicircular cross section are included. It is preferable to use a bonded side-by-side type composite fiber. When such a conjugate fiber is used, heat is applied to soften or melt the low melting point polymer in a state where the carpet is deformed into a predetermined shape (for example, a shape along the floor of an automobile). After cooling, the constituent fibers are fixed to each other in that state and formed into a predetermined shape. At this time, the high melting point polymer is hardly softened or melted, and the initial fiber shape is maintained, so that the nonwoven web layer can be prevented from becoming rigid.

The basis weight of the nonwoven web layer may be arbitrary, but is generally preferably about 50 to 500 g / m ² . The basis weight is 5
If it is less than 0 g / m ² , the entanglement with the fibers constituting the primary base fabric or the like becomes insufficient, and the pile may fall off. When the basis weight exceeds 500 g / m ² ,
As the whole carpet becomes thicker, the mass tends to be heavier.

The carpet according to the present invention can be rationally manufactured, for example, by the following method. That is,
After planting the pile on the surface of the primary base fabric, a fiber web layer is laminated on the back surface of the primary base fabric, and thereafter, a high-pressure water column flow is applied from the fiber web layer side, thereby forming the constituent fibers constituting the fiber web layer. And the fibers constituting the primary base fabric are entangled with each other.

First, a primary base fabric is prepared, tufting is performed using pile yarns, and a pile is planted. The fibrous web layer is laminated on the back surface of the primary base cloth on which the pile is planted (the surface where the pile with long hair ends does not exist and the surface where the root of the pile exists). In the fibrous web layer, the constituent fibers are entangled with each other to form a nonwoven web layer, but at this time, substantial entanglement is small. Thereafter, a high-pressure water column flow is applied from the fiber web layer side. The high-pressure water column flow generally uses an injection nozzle having a hole diameter of about 0.05 to 2.0 mm,
It can be obtained by spraying water at a water pressure of about 2 to 40 MPa. When this high-pressure water column flow is applied to the entire surface from the fiber web layer side, kinetic energy is given to the constituent fibers in the fiber web layer, and the constituent fibers and the fibers constituting the primary base fabric are entangled. In addition, the constituent fibers and the fibers constituting the base of the pile are entangled. Further, the nonwoven web layers are formed by entanglement between the constituent fibers.

The carpet according to the present invention as described above,
It is used for various applications such as carpets for cars and carpets for houses. In addition, the size and shape are arbitrary, and they are provided in the form of a scroll or a tile (tile carpet).
Furthermore, it is provided as a molded carpet provided with a predetermined uneven shape.

[0016]

Hereinafter, the present invention will be described based on examples, but the present invention is not limited to the examples. The present invention, the constituent fibers in the nonwoven web layer, which is the backing layer of the carpet, and the fibers constituting the primary base fabric and the like are entangled, whereby the nonwoven web layer and the primary base fabric are firmly joined, It should be understood that the pile is prevented from falling off.

Example 1 [Preparation of Primary Base Fabric] Polyethylene terephthalate having a melting point of 260 ° C. and a relative viscosity of 1.38 was used as a core component, and a copolyester (ethylene terephthalate) having a melting point of 215 ° C. and a relative viscosity of 1.35 was used as a sheath component. Was melt-spun to obtain a core-sheath composite long fiber. Then, after accumulating the core-sheath type composite filaments, the core-sheath type composite filaments are heat-welded with a pair of embossing rolls to partially adhere the core-sheath type composite filaments to each other, and the basis weight is 100 g.
/ M ² of primary nonwoven fabric.

[Pile Implantation] Using a polyamide yarn (nylon yarn) composed of polyamide filament, a gauge 8
Under the conditions of book / inch, stitch 8 / inch, and loop length 6 mm, tufting was performed on the primary base cloth, and a loop pile was planted on the primary base cloth.

[Joining of Non-Woven Web Layer] A polyethylene terephthalate short fiber having a fiber length of 51 mm and a fineness of 3 denier (on the back surface of the primary base cloth on which the loop pile is implanted (the surface where the loop pile having a long hair tip does not exist)) A fiber web layer (having a basis weight of 100 g / m ² ) on which polyester having a melting point of 260 ° C. and a relative viscosity of 1.38 was used was laminated. Then, the laminated body was placed on a conveyor formed of 50 mesh such that the loop pile surface was in contact with the conveyor. The conveyor was transported at a speed of 5 m / min, and a high-pressure water column flow was applied over the entire surface from the fiber web layer side. The high-pressure water column flow is obtained by jetting water at a pressure of 20 MPa from an injection nozzle having a hole diameter of 0.1 mm. The distance between the spray nozzle and the fiber web layer was 200 mm. By the above processing, the polyethylene terephthalate short fibers constituting the fibrous web layer are entangled with each other, and the short fibers and the core-sheath composite long fibers constituting the primary base fabric and the polyamide at the root of the loop pile are used. Polyamide filaments constituting the yarn were entangled, and the nonwoven web layer and the primary base fabric were firmly joined.

[Post-process etc.] After applying a high-pressure water column flow, excess water is removed with a mangle roll and dried with a dryer.
It was wound up to obtain a carpet. The carpet obtained as described above was lightweight, and the pile was less likely to fall off.

Example 2 [Preparation of primary base cloth, etc.] Melting point: 260 ° C., relative viscosity: 1.38
Was melt-spun to obtain polyethylene terephthalate long fibers. After accumulating the long fibers, needle punching was performed to obtain a primary base fabric made of a nonwoven fabric having a basis weight of 100 g / m ² .
Using this primary base cloth, a pile was planted in the same manner as in Example 1.

[Joining of non-woven web layer, etc.] A core-sheath composite having a fiber length of 51 mm and a fineness of 3 denier is formed on the back surface of the primary base fabric on which the loop pile is planted (the surface where the loop pile having a long bristle does not exist). Polyester staple fiber [melting point 26 as core component]
Polyethylene terephthalate having a relative viscosity of 1.38 at 0 ° C. was used, and a sheath component having a relative viscosity of 1.3 at a melting point of 215 ° C.
5 (using ethylene terephthalate copolymerized with isophthalic acid)] to form a fiber web layer (having a basis weight of 300 g / m ² ). Then, the laminated body was placed on a conveyor formed of 50 mesh such that the loop pile surface was in contact with the conveyor. At a conveyor speed of 10 m / min, a high-pressure water column flow was applied from the fiber web layer side to the entire surface. The high pressure water column flow is 30 MPa from the injection nozzle with a hole diameter of 0.1 mm.
It was obtained by squirting water at a pressure of. The distance between the spray nozzle and the fiber web layer was 200 mm.
By the above processing, the core-sheath type composite polyester short fibers constituting the fibrous web layer are entangled with each other, and the short fibers and the polyethylene terephthalate long fibers constituting the primary base fabric and the root portion of the loop pile are formed. Intertwined with polyamide filaments that make up the polyamide yarn,
The nonwoven web layer and the primary base fabric were firmly joined. Thereafter, a carpet was obtained through the same post-process as in Example 1. The carpet obtained as described above was lightweight, and the pile was less likely to fall off. further,
It also had excellent moldability as a molding carpet and was suitable as a carpet for automobiles.

[0023]

According to the carpet of the present invention, the constituent fibers in the nonwoven web layer disposed on the back surface are entangled with the fibers constituting the primary base fabric and the like, and the nonwoven web layer is firmly It is joined with a cloth or the like. Accordingly, the pile on the surface does not easily fall off, and the nonwoven web layer functions sufficiently as a backing layer, similarly to the conventional resin sheet. And
Since the nonwoven web layer has a large number of voids inside, the weight is reduced as compared with a conventional resin sheet having no such voids. Therefore, when used as a carpet for a car, there is an effect that the weight of the car can be reduced and the fuel efficiency can be reduced. Also, even when used as a carpet for homes, it is lightweight, so it is easy to carry,
In addition, there is an effect that the construction is easy, and especially when a tile carpet is used, these effects are further enhanced.

Claims (5)

[Claims] 1. A nonwoven web layer comprising: a primary base fabric; a pile planted on a surface of the primary base fabric; and a nonwoven web layer joined to a back surface of the primary base fabric. The carpet, wherein the constituent fibers are intertwined with the fibers constituting the primary base fabric, and the constituent fibers are also intertwined with each other. 2. The fiber constituting the nonwoven web layer is further intertwined with the fiber constituting the pile.
The described carpet. 3. A composite fiber comprising a combination of a high-melting polymer and a low-melting polymer, wherein the low-melting polymer forms at least a part of the surface. The carpet according to claim 1 or 2. 4. The carpet according to claim 3, wherein the conjugate fiber is a core-sheath type conjugate fiber or a side-by-side type conjugate fiber. 5. After planting a pile on the surface of the primary base cloth,
By laminating a fiber web layer on the back surface of the primary base fabric and thereafter applying a high-pressure water flow from the fiber web layer side, the constituent fibers constituting the fiber web layer are entangled, and the constituent fibers and the primary base fabric are entangled. A method for producing a carpet, comprising intertwining fibers constituting the carpet.