JP2008093359A - Tufted pile rug - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a tufted pile rug the back stitch surface of which is flat and has little projections/recessions, is easily packed/kept by folding, and prevents folding wrinkles from being left in a pile surface when laid. <P>SOLUTION: Fiber webs 14 are laminated, where short fibers are accumulated on one surface of a base fabric 13 which is woven by using tape yarn with a flat cross-sectional shape composed of a polyolefin resin for weft yarn 12. Pile yarn 16 is inserted together with a needle 15 to the base fabric 13 from the lamination surface of the fiber webs 14 so as to implant piles 17 into the surface of the base fabric. The weight of the fiber web 14 is 20-120g/m<SP>2</SP>, and it is preferable that the color of the fiber web 14 is made to be the same as that of the pile yarn 16. An antislip resin is coated in the form dots on the back stitch surface. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a tufted pile rug in which pile yarn is inserted into a base fabric together with a needle to plant the pile.

  Woven fabrics and non-woven fabrics are used for the base fabric of tufted pile rugs. The woven fabric and the nonwoven fabric used as the base fabric may be used as a double base fabric by overlapping the woven fabric and the woven fabric, or by overlapping the nonwoven fabric and the non-woven fabric, or the woven fabric and the non-woven fabric (for example, , See Patent Documents 1 and 2).

The back stitch surface of the tufted pile rug, that is, the back surface opposite to the pile surface on which the pile stands is raised in accordance with the thickness of the back stitch pile yarn connecting the adjacent piles in the stitch direction. Convex and concave surfaces in which convex portions and concave portions recessed according to the thickness of the pile yarn between the back stitches and the back stitches of the adjacent stitch rows are alternately formed.
As one method for flattening the uneven surface by the back stitch, a method is known in which a fiber web is laminated on one side of a base fabric to be a back stitch surface and needle punching is performed (for example, see Patent Document 3).

JP 10-168735 A (Patent No. 3011892) Japanese Patent Laid-Open No. 08-317268 Japanese Patent Laid-Open No. 02-169862 (Japanese Patent No. 2756822)

In the method of laminating a fiber web on a base fabric and performing needle punching, the laminated fiber web is subjected to needle punching to reduce the bulk. Therefore, in order to make the fibers of the fiber web rise from the recesses between the back stitches so that the back stitch surface becomes flat, the fabric weight of the fiber web subjected to the needle punching is increased and the layers are laminated thickly.
However, if it does so, the whole base fabric including a fiber web will become thick, and a tufted pile rug will be hard-finished and it will become difficult to fold and to pack and store. Then, when the tufted pile rug is folded once and then spread, folding folds generated when folded are left on the pile surface, so that it is difficult to obtain a so-called simple rug that can be folded and spread for use and storage.

  In addition, when needle punching is performed, the warp and weft are joined by the fibers of the fiber web inserted by the needle punching needle as if the overlapped warp and weft are nailed, and the fabric misalignment hardly occurs between the warp and the weft. Thus, tufting needles are subjected to strong resistance from the base fabric, making tufting difficult.

  Therefore, the fiber web 14 just overlapped with the base fabric 13 is bristly opened even if its basis weight is light and small, and when the tufting needle 15 is inserted toward the laminated surface, 13 warp yarns 11 and weft yarns 12 are undisturbed by the fiber web 14 and the needle 15 is not subjected to a particularly strong resistance from the base fabric 13, and the misalignment creates a gap 19 between the weft yarns. While the cloth 23 is coarse and easy to fold, the gap 19 between the wefts is covered with the fiber web 14 so that there is no problem in appearance, and the cloth 23 is flexible and easy to fold. Thus, it was found that the concave portions between the back stitches were filled with the fibers of the fiber web 14, and it was easy to fold and pack and store, and a tufted pile rug with a flat back stitch surface was obtained.

  The tufted pile rug according to the present invention has been completed on the basis of such knowledge, and is short on one side of a base fabric 13 woven by using a flat cross-sectional tape yarn made of polyolefin resin as a weft 12. A fiber web 14 formed by accumulating fibers is laminated, and pile yarns 16 are inserted together with needles 15 from the laminated surface of the fiber web 14 toward the base fabric 13 so that a pile 17 is implanted on the surface of the base fabric. Is the first feature.

A second feature of the tufted pile rug according to the present invention is that, in addition to the first feature, the basis weight of the fiber web 14 is 20 to 120 g / m ² .

  A third feature of the tufted pile rug according to the present invention is that, in addition to any of the first and second features, the fiber web 14 and the pile yarn 16 are the same color.

  The fourth feature of the tufted pile rug according to the present invention is that, in addition to any of the first, second and third features, the back stitch 18 of the pile yarn inserted from the laminated surface of the fiber web 14 is exposed. The point is that a non-slip resin is applied to the back-stitched surface in the form of dots.

A fifth feature of the tufted pile rug according to the present invention is that, in addition to the fourth feature, the coating amount of the anti-slip resin is 150 g / m ² or less.

The fiber web 14 just overlapped with the base fabric 13 has a bulky hair even if its basis weight is 20 to 120 g / m ² , and when inserting the tufting needle 15 toward the laminated surface, The warp yarns 11 and the weft yarns 12 of the base fabric 13 are not displaced by the fiber web 14, and the needle 15 does not receive a particularly strong resistance from the base fabric 13.
Then, the gap 21 between the warp yarns of the base fabric 23 after tufting is narrowed by the misalignment corresponding to the thickness of the pile yarn 16 as compared with the gap 21 between the warp yarns of the base fabric 13 before tufting. However, even if the gap between the wefts after tufting becomes narrower due to misalignment corresponding to the thickness of the pile yarn 16 than the gap 20 between the wefts before tufting, the wefts have a flat cross-sectional shape. Therefore, it is compressed in the width direction of the weft and the width f is greatly reduced as compared with the warp.

In particular, the weft yarn 22 that is interposed between the pile 17a and the pile 17b that are adjacent to each other in the U shape via the back stitch 18 in the stitch direction is fastened between the pile 17a and the pile 17b that are adjacent in the stitch direction. Thus, the width f is reduced, and the gap n between the adjacent wefts 17 and the wefts 17 is widened through the pile 17 by the reduced amount. As a result, the base fabric 23 after tufting is more porous than the base fabric 13 before tufting, and is flexible and easy to fold. Since the pile 17 is locked to the porous and easy-to-fold base cloth 23 as described above, the tufted pile rug of the present invention is easily folded and packed and stored, and is easy to handle as a simple rug.
In this case, even if a large gap 19 occurs in the base fabric 23, the gap 19 is covered with the fiber web 14 on the back stitch surface, and therefore the commercial value of the tufted pile rug is not impaired by the gap 19. Absent.

  The fibers 24 of the fiber web 14 are stitched to the base fabric 23 by the back stitch 18. Therefore, even if the fiber 24 constituting the fiber web 14 is a short fiber, the back stitch surface is not unraveled, and the recesses between the back stitches are filled with the fiber 24 of the fiber web 14, folded and packed. A tufted pile rug that is easy to store and has a flat back stitch surface is obtained.

In the present invention, when the fiber web 14 and the pile yarn 16 have the same color, the sense of unity between the fiber web 14 and the back stitch 18 is strengthened, and the basis weight of the fiber web 14 is 20 to 120 g / m ^2. Even if there are some irregularities, it does not stand out and the back stitch surface is beautifully finished.

The warp yarn 11 may be a tape yarn having a flat cross-sectional shape made of a polyolefin resin (polypropylene resin) in the same manner as the weft yarn 12.
The fibers 24 of the fiber web 14 are securely stitched to the base fabric 23 by the back stitch 18, and the needle gauge G and the stitch gauge S are set to 2.54 mm (1/10 mm) to prevent the fibers 24 from being unwound. The basis weight of the fiber web 14 should be 100 g / m ² or less to 4 mm (5/32 mm), and the length of the fiber 24 of the fiber web should be 30 mm or more, more than 10 times the needle gauge G, preferably 20 times. That's it.
The reason why the basis weight of the fiber web 14 is 100 g / m ² or less is that the basis weight of the fiber web 14 exceeds 120 g / m ² and the number of fibers 24 that are bundled between adjacent piles 17 a and 17 b in the stitch direction. When the number of fibers 24 is too large, the binding force acting on the fibers 24 of the fiber web 14 from the adjacent piles 17a and 17b, the back stitch 18 and the base fabric 23 is finely dispersed according to the number of the fibers 24, and the individual fibers 24 This is because the restraining force acting on the is weakened.

The application of the non-slip resin to the back stitch surface in a dot-like manner not only makes the tufted pile rug placed and used on the floor surface difficult to slip, but also prevents the fibers 24 of the fiber web 14 from unraveling. It is also effective above.
However, if the coating amount of the anti-slip resin is 200 g / m ² or more, a film-like coating film in which the fiber 24 of the fiber web and the anti-slip resin are integrated on the back stitch surface can be formed. A two-layer laminated structure with the fabric 23 is formed, and it becomes difficult to fold and pack the tufted pile rug as in the case of the fiber web in Patent Document 3.
Therefore, the coating amount of the slip resistant resin (dry weight) of 100 g / m ² or less, preferably to 50 to 80 g / m ^2, is coated on dot-shaped.

In the present invention, “coating in the form of dots” means coating so that the fibers 24 of the fiber web and the anti-slip resin are not integrated into a film to form a continuous coating film, For this purpose, an anti-slip resin is applied to the back stitch surface by a gravure roll or spray.
As the anti-slip resin, natural rubber latex, synthetic rubber latex, ethylene vinyl acetate resin emulsion, polyurethane resin emulsion or the like is used.

The fiber web 14 is prepared by a spinning card device.
The fiber web 14 may be needle-punched to be temporarily fixed to the base fabric 13 as long as it does not hinder eye misalignment during tufting of the warp 11 and the weft 12.

It is a partially cut rear perspective view of the tufted pile rug according to the present invention. It is an expanded back view of the tufted pile rug which concerns on this invention.

Explanation of symbols

11: Warp 12: Weft before tufting 13: Base fabric before tufting 14: Fiber web 15: Needle 16: Pile yarn 17: Pile 18: Back stitch 19: Clearance between wefts after tufting 20: Tufting Gap 21 between front weft yarns: Gap between warp yarns 22: Weft yarn after tufting 23: Base fabric after tufting 24: Fiber

Claims (5)

  A fiber web (14) in which short fibers are accumulated is laminated on one side of a base fabric (13) woven using a tape yarn of a flat cross section made of polyolefin resin as a weft (12), and the fiber web A tufted pile rug formed by inserting pile yarn (16) together with a needle (15) from the laminated surface of (14) toward the base fabric (13) and planting pile (17) on the surface of the base fabric. Tufted pile rugs supra Claim 1 weight of the fiber web (14) is 20 to 120 g / m ^2.   The tufted pile rug according to any one of claims 1 and 2, wherein the fiber web (14) and the pile yarn (16) have the same color.   The anti-slip resin is applied to the back stitch surface where the back stitch (18) of the pile yarn inserted from the laminated surface of the fiber web (14) is exposed. Tufted pile rug described in any one. The tufted pile rug according to claim 4, wherein the coating amount of the anti-slip resin is 150 g / m ² or less.

Images