JP2010162275A - Method for processing lining of tufted carpet and tufted carpet made from method for processing lining - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for processing a lining capable of obtaining a stable adhering strength (peeling strength) with a small applying quantity of adhesive in the lining processing of a tufted carpet. <P>SOLUTION: This invention is accomplished by finding out the method for processing the lining by which the stable adhering strength (peeling strength) can be obtained with a small applying quantity of the adhesive by adhering to each other after fluffing the adhering face of a second bath cloth before adhering a skin layer and the second bath cloth in the processing the lining of the tufted carpet. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a technique for backing a tufted carpet and a technique relating to a tufted carpet made by the backing process.

  A tufted carpet is manufactured by placing pile yarn on a tufted carpet base fabric with a tufting machine to create a skin layer, and applying a resin or rubber latex on the back side of the base fabric and pile yarn. A good method for producing tufted carpets that are fixed, and are piled with a second base fabric to protect the back of the skin layer, to provide dimensional stability, cushioning, etc. Are known.

  Further, as a method for enhancing the design of the skin layer of the tufted carpet, the skin layer is made by a method called needle shift, and as shown in FIG. 1 and FIG. Such a thing has come to be manufactured. In this case, as shown in FIG. 2, there is a back stitch 1 having a normal height A above the base fabric 3, and another back stitch 2 is overlaid on the upper side (height B). More latex was required than normal backing, and even when bonded to a second base fabric, there were many troubles such as low adhesive strength (peel strength). (In the present invention, the back stitch means a seam of pile yarn on the back surface of the skin layer of the tufted carpet.)

  For this reason, in Patent Document 1, there is a method in which a water-based primary adhesive is applied to the back stitch surface, and the float is lifted off from the back stitch by applying an iron, and the back processing is performed after reducing the bulk. It is disclosed.

  Further, Patent Document 2 discloses a tile carpet that uses a base fabric for tufted carpet that is punched to form a fluff layer, has high adhesion to a backing agent, and does not fray during cutting. ing.

  However, in these methods, since it is necessary to provide a heat process and a punching process for that purpose, it has become an expensive processing method.

Japanese Patent Laid-Open No. 10-085117 JP 2006-296501 A

  SUMMARY OF THE INVENTION An object of the present invention is to provide, at low cost, a backside processing method that can obtain a stable adhesive strength (peel strength) with a small amount of adhesive in the backside processing of tufted carpet.

  The present invention provides the following means in order to achieve the above object.

  [1] The back side of a tufted carpet characterized in that, in the reverse processing of the tufted carpet, before the skin layer of the tufted carpet and the second base fabric are bonded, the bonded surface of the second base fabric is fuzzed and bonded. Processing method.

  [2] The method for backing a tufted carpet as recited in the aforementioned Item 1, wherein the second base fabric is a woven base fabric.

  [3] The method for backing a tufted carpet according to the above item 1 or 2, wherein at least a part of the back stitches on the bonding surface of the skin layers of the tufted carpet overlap.

  [4] The method for backing a tufted carpet according to any one of items 1 to 3, wherein the second base fabric is a jute base fabric.

  [5] A tufted carpet made by the backing method according to any one of items 1 to 4.

  In the invention of [1], before the surface layer of the tufted carpet and the second base fabric are bonded, the bonding surface of the second base fabric is fluffed and then bonded, so that the adhesive strength is increased due to the anchor effect of the fluff, and there is little It can be set as the manufacturing method of the tufted carpet from which sufficient adhesive strength (peeling strength) is obtained with the amount of latexes. Moreover, if the process of making the second base fabric fluffy is performed immediately before the skin layer of the tufted carpet and the second base fabric are bonded together, it is efficient that no fluffing process is required in a separate process.

  In the invention of [2], since the second base fabric is a woven base fabric, the bonded surface of the second base fabric can be fluffed while maintaining the strength and width of the second base fabric.

  In the invention of [3], since at least a part of the back stitch on the surface of the skin layer of the tufted carpet overlaps, in an ordinary process, an attempt is made to ensure sufficient adhesive strength at the back stitch overlap. Then, a large amount of latex is required, but in the present invention, since the bonding surface of the second base fabric is fluffed and then bonded, the adhesive strength of the second base fabric increases due to the anchor effect of the fluff, and even in the overlapping portion of the back stitch Thus, a method for producing a tufted carpet in which sufficient adhesive strength (peel strength) can be obtained with a small amount of latex can be obtained.

  In the invention of [4], since the second base fabric is a jute base fabric, a tufted carpet that is easy to fluff and has excellent dimensional stability can be obtained.

  In the invention of [5], since it is a tufted carpet made by the manufacturing method according to any one of items 1 to 4, sufficient peel strength can be obtained, and it can be attached with a small amount of latex. Thus, a tufted carpet that is more flexible than the conventional one can be obtained.

  The present invention is a method for bonding a surface of a tufted carpet, which is made by fuzzing a bonding surface of a second base fabric before the surface layer and the second base fabric are bonded, and having a stable adhesive strength with a small amount of adhesive. The present invention provides a backing method capable of obtaining (peel strength).

  For example, as shown in the schematic diagram of the manufacturing process of tufted carpet in FIG. 3, latex 6 is applied by roll coater 5 on the back stitch side of skin layer 1 of tufted carpet, and then applied by raised roll 7. The mating surfaces are combined with the second base fabric 4 having a fluffed surface, pressed by a pressure-bonding roll 8, dried by a drier 9, bonded and integrated, and subjected to a tufted carpet backing.

  The raising roll 7 is generally known as raising process, and is used to rub the surface of the second base fabric by using a roll having a large frictional resistance wound on the surface, such as needle cloth, sand paper, emery (rubber sheet), etc. is there. The amount of fluffing may be appropriately determined while confirming the adhesive strength (peel strength), but may be 5 to 10 mm.

  The second base fabric is preferably a woven base fabric because its bonded surface is fluffed. Non-woven fabrics and knitted base fabrics are not preferable because the filaments come off and the width is not stable when fluffing. The material is not particularly limited, but it is preferable to use spun yarn for the weft. This is to make it easy to fluff within the tufted carpet lining process. Filament yarns and yarns such as tape yarns are not easily fluffed or fuzzy. This is because of this.

  The skin layer of tufted carpet is made by planting pile yarn on a tufted carpet base fabric using a tufting machine. To improve its design, the pile yarn is moved while moving the needle of the tufting machine left and right. May be planted on a base fabric. In particular, when there are two needle rows, as shown in FIGS. 1 and 2, the back stitch planted in the front row of needles may overlap the back stitch in the rear row, resulting in a rather bulky back stitch. More resin or rubber latex to be applied is required than usual backing processing, and there are many problems such as adhesion strength (peel strength) not being obtained even when bonded to a second base fabric.

  In the present invention, since the bonding surface of the second base fabric is fluffed and then bonded, the fluff of the second base fabric enters the resin or rubber latex layer applied to the back surface of the skin layer, and the anchor effect of the fluff works The adhesion can be increased, and the adhesion can be maintained even with a small amount of resin or rubber latex. Also, this method works effectively even when the back stitch height is normal or when the back stitch overlaps, and the amount of resin or rubber latex can be reduced, reducing the cost and toughness of the soft texture. A ted carpet can be obtained.

The method of pasting the skin layer and the fluffed second base fabric with resin or rubber latex is to apply the resin or rubber latex to the skin layer by a known method such as roll coater method, spray, direct coating method, etc. There is no particular limitation. The resin or rubber latex is not particularly limited, and examples of the resin include resins such as acrylic, urethane, polyvinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber latex include SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber), MBR (methyl methacrylate-butadiene rubber), and natural rubber. The application amount of the conventional resin or rubber latex in which the second base fabric is not fluffed is preferably 700 to 1000 g / m ^{2 in} the case of a general back stitch, and 1000 to 1500 g / m ^{2 in the} case where the back stitch overlaps. It was said. In the present invention, the amount of resin or rubber latex applied can be reduced by 10 to 15% by making the second base fabric fluffy. (In the present invention, the coating amount of the synthetic resin or rubber latex is wet weight and the solid content is 50 to 80% by mass.)

Next, although the carpet produced along the specific Example of this invention and its evaluation result are described, this invention is not limited by this. Moreover, the measurement and evaluation method of peeling strength and hardness were as follows.
Method for measuring peel strength The peel strength (kgf / 5 cm) was measured in accordance with JIS L1021. Accept 2.5 kgf / 5 cm or more.
Carpet hardness
A simple method was used, where the end of the carpet was held by hand and the one that could be bent easily was marked as ◯, and the one that was difficult to bend like a plate was marked as x.

As a skin layer, a base fabric made of a flat yarn of a plain weave structure with a warp density of 18 yarns / inch and a weft yarn density of 16 yarns / inch, and polyester yarn A (3000 dtex white) and polyester yarn B (3000 dtex black) as pile yarns It was threading the two alternating tufts standard, 32 stitches / 10 cm as the pile length 6.5 millimeter pile weight per unit area 890 g / ^{m 2,} needle epidermal layer tufted without moving (two rows sequence) to the left and right (no shift) Then, a tufted skin layer (with shift) was prepared by moving the needle left and right as shown in FIG. As the second base fabric, a (both warp and weft jute, plain weave, basis weight 198 g / m ² ), b (warp polyflopyrene flat yarn, weft polyester spun yarn, plain weave, basis weight 200 g / m ² ) and c ( A polyester needle punched nonwoven fabric having a basis weight of 90 g / m ² ) was prepared.

  As the reverse processing step, the step shown in FIG. 3 is performed. After the SBR latex 6 is applied as an adhesive layer to the back surface of the skin layer with the roller coating 5, the second base fabric 4 fluffed with the raised roll 7 is put together, and the pressure roll 8 And dried in a dryer 9 at 120 ° C. for 10 minutes to obtain a tufted carpet. The amount of SBR latex applied was wet weight and the solid content was 70% by mass.

<Example 1>
Using an epidermis layer (no shift), apply SBR latex at 1000 g / m ² , use a as the second base fabric, fluff 7 mm with a raised roll, overlay it on the epidermis layer coated with SBR latex, Pressurized and dried with a dryer to obtain a tufted carpet. The adhesive strength (peel strength) was 3.8 kgf / 5 cm and passed. Moreover, the hardness of the carpet was soft and good.

<Example 2>
A tufted carpet was obtained in the same manner as in Example 1 except that a skin layer (with shift) prepared by moving the needle to the left and right as shown in FIG. 1 was prepared as the skin layer. The adhesive strength (peel strength) was 3.0 kgf / 5 cm and passed. Moreover, the hardness of the carpet was soft and good.

<Examples 3-8><Comparative Examples 1-6>
Tufted carpets were obtained as described in Table 1, and adhesive strength (peel strength) and hardness were evaluated.

  As can be seen from Table 1, in the case of the jute base fabric, even in a small coating amount, in Examples 5, 6, 7, and 8 where fluffing was applied, the peel strength was ensured, and Comparative Example 1 where no fluffing was applied In 2, 3, and 6, the peel strength could not be secured. Similarly, in the case of a polyester spun yarn only in the weft, Example 3 and Example 4 where fluff was given could ensure the peel strength, and Comparative Example 2 where no fluff was given could not ensure the peel strength. In Comparative Example 4 in which the coating amount was increased, although there was no problem in the peel strength, the carpet became hard and was judged to be unacceptable. Further, in Comparative Example 5, the coating amount was too small, and the peel strength could not be ensured despite the fuzzing. In addition, although not described in Table 1, c (polyester needle punched nonwoven fabric) was used as the second base fabric, and fluffing was attempted with a raised roll. As a result, the fluffing process could not be performed.

  The technique of the present invention is not limited to tufted carpets, and is widely used as a technique for pasting textile products.

It is a figure which shows the overlap of the back stitch of the tufted carpet which concerns on one Embodiment of this invention. It is a figure which shows the cross section of the overlap of the back stitch of the tufted carpet which concerns on one Embodiment of this invention, and is a figure which shows the cross section in the circle | round | yen in FIG. It is the schematic which shows the process of the back process which concerns on one Embodiment of this invention.

1 ... Pile yarn A
2 ... Pile yarn B
DESCRIPTION OF SYMBOLS 3 ... Base cloth 4 ... Skin layer 5 ... Roll coating 6 ... Adhesive 7 ... Raising roll 8 ... Crimping roll 9 ... Dryer 10 ... Driving roller 11 ... Fluff A ... Back stitch height (low)
B ... Back stitch height (high)

Claims (5)

A method for backing a tufted carpet, wherein the surface of the tufted carpet and the second base fabric are pasted together by fuzzing the pasting surface of the second base fabric before the pasting of the tufted carpet. The method for backing a tufted carpet according to claim 1, wherein the second base fabric is a woven base fabric. 3. The method for backing a tufted carpet according to claim 1, wherein at least a part of back stitches on a bonding surface of the skin layers of the tufted carpet overlap each other. The method for backing a tufted carpet according to any one of claims 1 to 3, wherein the second base fabric is a jute base fabric. A tufted carpet made by the backing method according to claim 1.