JP2016198200A - Method for manufacturing carpet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently manufacture a carpet that is rich in breathability and flexibility, and superior in handleability and workability, though an anti-slip is provided in the back side.SOLUTION: A long carpet A is manufactured which is made by sticking a secondary base fabric 5 comprising a non woven fabric on the back side of a primary base fabric 2 of a carpet main body 1 formed by tufting of pile yarn 3 to the primary base fabric 2 comprising a woven fabric or the non woven fabric through adhesives. Then, this long carpet A is conveyed in a tension state while holding both end ears by a tenter in a state where the secondary base fabric 5 is directed to the upper side. In the conveyance, an anti-slip coating composition is supplied on the secondary base fabric 5. This anti-slip coating composition is made to pass with the conveyance of the long carpet A through a plurality of holes 21 provided in the lower end of a plate 20 for forming the anti-slip projection disposed so as to come in contact with the secondary base fabric 5. Thereby, multiple anti-slip projections 6 are formed on the secondary base fabric 5.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a method for manufacturing a carpet having a non-slip surface on the back surface.

  A carpet with a non-slip on the back surface is widely known so that when the carpet is laid on the floor, the carpet does not slip on the floor and the elderly or infant falls. As a method for producing such a carpet, for example, as described in Patent Document 1, an adhesive is applied to the back surface of the carpet mainly formed by tufting to a primary base fabric made of a long sheet-like woven fabric or nonwoven fabric. After the application, a secondary base fabric made of non-woven fabric is backed on the primary base fabric through this adhesive layer, and then a rubber latex is sprayed on the back surface of the secondary base fabric to form an anti-slip layer. Things have been done.

JP-A-7-308255

  However, according to the method for manufacturing a carpet having a non-slip on the back surface as described above, a rubber latex is applied to the entire back surface of the secondary base fabric to form a non-slip rubber layer with a certain thickness. The rubber layer impairs the air permeability of the carpet and may cause the floor surface to become wet and easily corrode, and the flexibility and flexibility are impaired, causing problems in terms of handling and construction.

  The present invention has been made in view of such problems, and the object of the present invention is to provide air permeability, flexibility, and weight reduction despite the fact that the back surface is provided with a slip stopper. An object of the present invention is to provide a carpet manufacturing method that can efficiently and high-quality manufacture a carpet having excellent handling properties and workability.

  In order to achieve the above object, the carpet manufacturing method according to the present invention is the carpet main body formed by tufting pile yarn on a long sheet-like primary base fabric made of woven fabric or non-woven fabric. Is continuously conveyed on the coating roll with the back surface of the primary base fabric facing downward, and an adhesive is applied to the back surface of the primary base fabric by the coating roll, and then the long sheet-like 2 A process for producing a long carpet which is supplied after the secondary base fabric is superposed on the back side of the primary base fabric, and is adhered to the back side of the primary base fabric with the above-mentioned adhesive, and then dried. The fabric is fed over the tenter with the back side facing up, and is transported while holding the ears on both sides by the tenter, and slips at regular intervals in the width direction on the back surface of the secondary base fabric during transportation. Characterized in that it consists of a slip ridge forming step of drying after forming the ridged slip ridges consisting because the coating composition.

  In the anti-slip ridge forming step in the carpet manufacturing method according to claim 1 configured as described above, the invention according to claim 2 includes a lower end on the secondary base fabric so as to be orthogonal to the conveying direction of the carpet. An anti-slip ridge forming plate having a non-slip ridge forming hole at a predetermined interval is provided in the section, and the anti-slip ridge forming plate is disposed on the secondary base fabric upstream of the carpet conveyance with respect to the anti-slip ridge forming plate. The anti-slip coating composition is supplied to the back of the secondary base fabric by passing the anti-slip coating composition through the anti-slip ridge forming hole as the carpet is transported. A plurality of hook-shaped anti-slip ridges having the same cross-sectional shape as the hole are applied and formed.

  The invention according to claim 3 is a non-slip ridge forming step different from the invention according to claim 2, and is provided at regular intervals in the width direction of the secondary base fabric on the back surface of the secondary base fabric. An anti-slip coating composition extrusion nozzle is provided, and the anti-slip coating composition extruded from the nozzle forms ridge-like anti-slip ridges at regular intervals in the width direction on the back surface of the secondary base fabric. Features.

  According to a fourth aspect of the present invention, in the long carpet manufacturing process according to the first aspect, after drying, the long carpet is folded into a laminated state while being shaken down or wound into a roll, and the following anti-slip It is characterized in that a long carpet folded in this laminated state or a rolled long carpet is fed out while facing the back surface of the secondary base fabric upward during the ridge forming step.

  According to the first aspect of the present invention, a carpet main body formed by tufting pile yarn on a long sheet-like primary base fabric made of woven or non-woven fabric is coated with the back surface of the primary base fabric facing downward. After transporting continuously onto a roll and applying an adhesive to the back of the primary base fabric with this coating roll, a long sheet-like secondary base fabric made of non-woven fabric is pasted on the back of the primary base fabric with the above adhesive. Even if a secondary base fabric with a relatively thin thickness is used, the back surface is flattened by this secondary base fabric and has excellent dimensional stability, and it is lightweight and flexible, bendable and breathable. It is possible to efficiently produce a long carpet rich in size.

  Furthermore, in the step of forming the anti-slip ridge on the back surface of the secondary base fabric of the long carpet, the long carpet is fed out on the tenter with the back surface of the secondary base fabric facing upward. Since it is transported while holding the ears on both sides with a tenter, even if the nonwoven fabric forming the secondary base fabric is thin, the secondary base fabric is stretched and stretched uniformly in the width and length directions. So that the back surface of the secondary base fabric facing upward can be transported while being held on a flat surface, and the anti-slip coating composition is drawn on the back surface of the tensioned secondary base fabric. By supplying, it is possible to reliably apply and form a plurality of hook-shaped non-slip protrusions having a certain height and a certain width in a parallel state.

  In this way, since the hook-shaped non-slip ridges having a certain height and width are applied and formed on the back surface of the secondary base fabric in the long carpet, the non-slip ridges allow the air permeability and flexibility of the long carpet. It is possible to efficiently produce a lightweight and easy-to-handle carpet that is foldable and flexible from adjacent anti-slip ridges, with almost no hindrance. It is possible to provide a tile-like carpet and a sheet-like carpet excellent in laying on the floor surface and workability.

  In the anti-slip ridge forming step in the carpet manufacturing method according to claim 1, the invention according to claim 2 as a method of applying and forming a plurality of anti-slip ridges on the back surface of the secondary base fabric, An anti-slip ridge forming plate having anti-slip ridge forming holes provided at regular intervals at the lower end is arranged on the secondary base fabric so as to be orthogonal to the carpet conveying direction. The anti-slip coating composition is supplied onto the secondary base fabric upstream of the carpet conveyance with respect to the ridge forming plate, and the anti-slip ridge formation hole is formed along with the conveyance of the carpet. By passing, a plurality of hook-shaped non-slip ridges having the same cross-sectional shape as the anti-slip ridge forming holes are applied and formed on the back surface of the secondary base fabric, so it is constant on the back surface of the secondary base fabric. Multiple anti-slip ridges with width and width Accurately and efficiently applied to the column state can be formed.

  In addition, instead of the anti-slip ridge forming plate in the invention according to the second aspect, as in the invention according to the third aspect, on the back surface of the secondary base cloth at regular intervals in the width direction of the secondary base cloth. An anti-slip coating composition extrusion nozzle may be provided, and ridge-like anti-slip ridges may be formed at regular intervals in the width direction on the back surface of the secondary base fabric while extruding the anti-slip coating composition from the nozzle. .

  According to a fourth aspect of the present invention, in the long carpet manufacturing process of the carpet manufacturing method according to the first aspect, the long carpet is folded into a stacked state while being shaken off after being dried, or wound in a roll shape. Since the long carpet that is folded into this laminated state at the time of the next anti-slip ridge formation process or the long carpet that is rolled is turned out with the back surface of the secondary base fabric facing upward, When applying and forming anti-slip ridges on the back side of the secondary base fabric of the long carpet, while feeding the back side of the secondary base fabric of the long carpet facing upward so that the application and formation are easy The anti-slip ridge can be formed smoothly and reliably.

The simplified perspective view of the tile-like carpet obtained by parting the elongate carpet manufactured by this invention. The perspective view seen from the back side. Cross section of a carpet. The simplified side view which shows the manufacturing process of a long carpet. Sectional drawing of a part of the carpet main body. Sectional drawing of a part of carpet which adhere | attaches a secondary base fabric on the back surface. The simplified side view which shows a slip prevention protrusion formation process. Sectional drawing of a part of carpet conveyed with the back surface of a secondary base fabric facing up. The perspective view of the plate for slip prevention protrusion forming. The perspective view of the state which has apply | coated and formed the slip prevention protrusion.

  A specific embodiment of the present invention will be described with reference to the drawings. FIG. 1 to FIG. 3 show a long carpet A (described later) manufactured by the method of the present invention in a certain dimension in the width direction and the length direction. In the carpet main body 1 obtained by tufting the pile yarn 3 on the primary base fabric 2 as shown in the sectional view of FIG. 3, the tile-like carpet A ′ obtained by cutting is shown. An adhesive layer 4 is applied to the back surface of the primary base fabric 2, and the surface of the secondary base fabric 5 is adhered to the back surface of the primary base fabric 2 through the adhesive layer 4 and the secondary base fabric 2 is bonded. Applying and forming, in parallel, bowl-shaped anti-slip ridges 6, 6, 6... 6 having a constant width and a constant height that are long in the longitudinal direction at regular intervals in the width direction on the back surface of the base fabric 5. ing.

  As the primary base fabric 2, either a woven fabric or a non-woven fabric having air permeability may be adopted, but the secondary base fabric 5 is a non-woven fabric. The material for the pile yarn 3 is not particularly limited, and a pile yarn made of synthetic fiber, natural fiber, regenerated fiber, or the like can be used. As an adhesive for forming the adhesive layer 4, a rubber component such as styrene-butadiene rubber, acrylonitrile-butadiene rubber, or natural rubber is mainly used, and unvulcanized latex of this rubber component is added with calcium carbonate, aluminum hydroxide, or the like. It is possible to employ a liquid rubber obtained by mixing the filler.

  The anti-slip ridge 6 is formed by applying a non-slip coating composition on the back surface of the secondary base fabric 5 in a hook shape. As such an anti-slip coating composition, the coating composition has a viscosity that can be retained in the shape of a bowl when applied on the secondary base fabric 5, and can form a coating film that exhibits an anti-slip effect. If it exists, it will not specifically limit, A well-known anti-slip coating material can be used. The anti-slip coating is obtained by dispersing or dissolving a resin component in a solvent. Examples of the resin component include acrylic resins, urethane resins, epoxy resins, vinyl acetate resins, and silicone resins. Examples of the solvent include water, alcohol, ethyl acetate, toluene, xylene and the like. A commercially available product can be used as the non-slip coating. As a commercial item, the product name "Raditex MF-1470" (Anti-slip paint formed by dispersing an acrylic copolymer in water) manufactured by Higashi Chemical Co., Ltd. and the like can be mentioned.

  Next, the manufacturing method of the long carpet A will be described with reference to the drawings. First, the carpet is obtained by tufting the pile yarn 3 on a long sheet-like primary base fabric 2 made of a woven or non-woven fabric having a certain width. The main body 1 (a partial cross section is shown in FIG. 5) is manufactured. Next, as shown in FIG. 4, the carpet main body 1 is transported toward the backing process portion in the carpet manufacturing process, and a secondary base cloth 5 is attached to the back surface of the primary base cloth 2.

  In the carpet manufacturing process, a first tenter 10 is formed by projecting a large number of pins 10b each having a sharp tip on the surface of an endless belt 10a at a small interval. Are arranged so that the belts 10a, 10a on both sides extend below the ears on both sides of the long carpet A, and the projecting pins 10b, 10b of both the belts 10a, 10a are arranged on both sides of the carpet main body 1. By rotating the front and rear sprocket wheels 10c and 10d, which are pierced from the bottom surface into the end ears and spanned by the belt 10a, the carpet main body 1 is moved downstream (forward) in a state where tension is applied to the carpet main body 1 in the width direction. Transport.

  On the downstream side of the first tenters 10, 10, the coating roll 11 slidably in contact with the back surface (lower surface) of the primary base fabric 2 of the carpet main body 1 is in a state in which the lower half is immersed in the adsorbing tank 12. The adhesive roll 4 is applied to the entire back surface of the primary base fabric 2 of the carpet main body 1 that passes over the coating roll 11 by the coating roll 11. Is provided.

  Further, a guide roll 13 is rotatably disposed in the vicinity of the downstream side of the coating roll 11 so as to be in contact with the lower surface of the carpet main body 1, and a secondary base fabric made of a thin non-woven fabric through the guide roll 13. 5 is stuck on the back surface of the primary base fabric 2 of the carpet main body 1 in a superposed state via the adhesive layer 4 (see FIG. 6). The secondary base fabric 5 has the same width as that of the primary base fabric 2 and is also formed into a long sheet. The long carpet A is manufactured by sticking to the back surface.

  In the vicinity of the downstream side of the guide roll 13 into which the secondary base fabric 5 is fed, there is a second tenter 14 along the lower side of both side end ears of the long carpet A with the secondary base fabric 5 attached to the back surface. It is arranged. The structure of the second tenter 14 is similar to the first tenter 10 in that a large number of pins 14b each having a sharp tip on the surface of an endless belt 14a are projected at small intervals. By rotating the front and rear sprocket wheels 14c, 14d that pierce the belts 14a, 14a of the belts 14a, 14a on both sides of the second tenter 14 from the lower surface of both ends of the long carpet A from the lower surface, The long carpet A is conveyed toward the downstream side in a state in which the long carpet A is stretched in the width direction.

  A drying chamber 15 is provided on the way the long carpet A is conveyed in the length direction toward the downstream side by the second tenter 14, and the long carpet A is passing through the conveyance chamber 15, After the adhesive layer 4 bonding the primary base fabric 2 and the secondary base fabric 5 is dried, the adhesive layer 4 is transported from the delivery guide roller 16 disposed on the conveyance end side and temporarily stored.

  The long carpet A is stored in a state in which the long carpet A fed from the guide roller 16 is folded into a stacked state while being shaken off by a swing-off arm (not shown), or in a roll shape. Put it in a wound state. Next, the long carpet A in this storage form is transferred to the next anti-slip ridge forming step.

  In the anti-slip ridge forming step, as shown in FIG. 7, the first tenter 17 is provided on the upstream side and the downstream side in the conveying direction of the long carpet A, as in the manufacturing process of the long carpet A. A second tenter 18 is provided. The structures of the first and second tenters 17 and 18 are the same as those of the first and second tenters 10 and 14 used in the manufacturing process of the long carpet A, and both end ears of the long carpet A are used. Endless belt 17a arranged along the lower part of the belt; a large number of pins 17b; 18b with a sharp tip on the surface of 18a are projected at small intervals, and these belts 17a, 18a The front and rear sprocket wheels 17c, 17d; 18c, 18d are rotated by the rotation of the front and rear sprocket wheels 17c, 17d; It is configured to convey toward the downstream side (front side) with tension applied in the width direction.

  Further, a drying chamber 19 is disposed in the middle of the conveyance of the long carpet A by the second tenter 18. Accordingly, the first and second tenters 17 for carrying out the anti-slip ridge forming step without changing the first and second tenters 10 and 14 and the drying chamber 15 employed in the manufacturing process of the long carpet A are used. , 18 and used in the drying chamber 19.

  Between the first tenter 17 and the second tenter 18 for carrying out the anti-slip ridge forming step, is located above the long carpet A conveyed from the first tenter 17 toward the second tenter 18. On the back surface of the secondary base fabric 5 in the long carpet A, an apparatus for forming the hook-shaped anti-slip ridges 6 made of the anti-slip coating composition at regular intervals in the width direction is disposed.

  As shown in FIGS. 9 and 10, this device has a non-slip ridge that penetrates in a tunnel shape by cutting out the lower end portion into a triangular shape, an arc shape, or the like at regular intervals in the length direction. The anti-slip ridge forming plate 20 formed with the forming hole 21 is brought into contact with the secondary base fabric 5 facing upward in the long carpet A conveyed from the first tenter 17 toward the second tenter 18. The longitudinal direction of the long carpet A is arranged so as to be orthogonal to the conveying direction of the long carpet A, and the upstream side of the long carpet A (slip prevention) A supply pipe 22 for supplying the non-slip coating composition 6 'is disposed on the secondary base cloth 5 of the long carpet A on the back side of the ridge forming plate 20).

  In the anti-slip ridge forming step in which the anti-slip ridge forming device configured as described above is disposed, the long carpet A in the above-described storage form is fed out so that the back surface of the secondary base fabric 5 faces upward. However, the belt is fed onto the first tenter 17 and the pins 17b projecting from the belts 17a and 17a on both sides of the first tenter 17 are elongated from the surface of the primary base fabric 2 facing the lower side of the long carpet A. The long carpet A is moved by the belt of the first tenter 17 while the long carpet A is pierced at both ends of the carpet A to give the long carpet A tension in the width direction and the length direction. Transport to.

  When the long carpet A is conveyed to the front of the anti-slip ridge forming plate 20 in the anti-slip ridge forming device, the anti-slip coating composition 6 'is long from the supply pipe 22 disposed above the long carpet A. The carpet A is fed onto the secondary base cloth 5 facing upward, and the anti-slip coating composition 6 'is spread in the width direction of the secondary base cloth 5 by its fluidity, so that the long carpet A progresses. Accordingly, a plurality of non-slip ridge forming plates 20 are pressed against the back surface facing the upstream side of the anti-slip ridge forming plate 20 and provided at the lower end of the anti-slip ridge forming plate 20 while staying in the dammed state on the back surface. On the secondary base cloth 5 of the long carpet A which passes through the anti-slip ridge forming hole 21 of the long carpet A as it travels and is conveyed downstream from the anti-slip ridge forming plate 20. Anti-slip ridge having the same cross-sectional shape as the non-slip ridge forming hole 21 Continuously coating formed on the rib of. An intermediate tenter for tensioning the long carpet A or an extension of the first tenter 17 may be provided at the position where the anti-slip ridge forming plate 20 is disposed.

  In this way, the anti-slip ridges 6 are applied and formed in parallel at regular intervals on the secondary base cloth 5 facing upward in the long carpet A by the anti-slip ridge forming plate 20 on the downstream side. A large number of pins 18b projecting from the belts 18a, 18a on both sides of the second tenter 18 are placed on the both ends of the long carpet A on the lower side. It is stabbed from the surface of the primary base fabric 2 facing and passed through the drying chamber 19 in a state where the long carpet A is stretched in the width direction and the length direction, and the anti-slip ridge 6 is dried to the transport end side. It is unloaded from the disposed unloading guide roller 23 and folded into a stacked state while being shaken down or wound into a roll.

  A long carpet A provided with a plurality of anti-slip ridges 6 continuous in the length direction on the back surface thus manufactured is cut at a predetermined interval in the width direction and the length direction to obtain a sheet carpet (FIG. Or a tiled carpet A ′ as shown in FIGS. 1 and 2 can be obtained.

  In the above embodiment, as a device for applying and forming the anti-slip ridge 6 on the secondary base cloth 5 on the back surface of the long carpet A, a plurality of anti-slip ridge forming holes 21 are provided at the lower end. The anti-slip ridge forming plate 20 is employed, but the anti-slip coating composition extrusion nozzle (on the traveling direction of the long carpet A is arranged at regular intervals in the width direction of the long carpet A). (Not shown) in an open state toward the long carpet A side, and the long anti-slip coating composition pushed out from the nozzle causes the long carpet A to be attached to the back surface of the secondary base fabric 5. As the carpet A travels, a plurality of ridge-like anti-slip ridges 6 that are continuous in the length direction at regular intervals in the width direction may be formed.

A Long carpet 1 Carpet main body 2 Primary base fabric 3 Pile yarn 4 Adhesive layer 5 Secondary base fabric 6 Non-slip ridge
10, 14, 17, 18 tenter
20 Anti-slip ridge forming plate
21 Anti-slip ridge forming hole

Claims (4)

  Carpet main body made by tufting pile yarn on a long sheet-like primary base fabric made of woven fabric or non-woven fabric is continuously conveyed on the coating roll with the back side of the primary base fabric facing downward. After applying the adhesive to the back of the primary base fabric with a coating roll, supply a long sheet-like secondary base fabric made of non-woven fabric so as to overlap the back of the primary base fabric. The process of manufacturing a long carpet that is attached to the back side and then dried, and the long carpet is fed out on the tenter with the back side of the secondary base fabric facing upward, and the ears on both sides are held by the tenter. The anti-slip ridge forming step of transporting and forming a hook-like anti-slip ridge made of a non-slip coating composition at regular intervals in the width direction on the back surface of the secondary base fabric during conveyance Method for manufacturing a carpet, characterized in that it consists of.   In the anti-slip ridge forming step, anti-slip ridge forming holes are formed on the lower surface of the secondary base fabric with the back surface facing upward at regular intervals so as to be orthogonal to the conveying direction of the carpet. An anti-slip ridge forming plate is provided, and the anti-slip coating composition is supplied to the anti-slipping ridge forming plate on the secondary base fabric on the upstream side of the carpet conveyance. By passing the composition through the anti-slip ridge forming hole along with the conveyance of the carpet, a plurality of ridge-like anti-slip of the same cross-sectional shape as the anti-slip ridge forming hole is formed on the back surface of the secondary base fabric. The method for producing a carpet according to claim 1, wherein the protrusions are applied and formed.   In the anti-slip ridge forming step, anti-slip coating composition extrusion nozzles are arranged at regular intervals in the width direction of the secondary base fabric above the secondary base fabric with the back surface facing upward. The method for producing a carpet according to claim 1, wherein hook-like anti-slip ridges are formed at regular intervals in the width direction on the back surface of the secondary base fabric by the anti-slip coating composition extruded from the nozzle. .   In the long carpet manufacturing process, after drying, the long carpet is folded into a laminated state while being shaken down or wound into a roll, and is folded into this laminated state during the next non-slip ridge process. The method for producing a carpet according to claim 1, wherein the carpet or the rolled up long carpet is fed out with the back surface of the secondary base fabric facing upward.

Images