JP2018042722A - Tufted carpet and secondary base fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a secondary base fabric that solves a water shielding function of the secondary base fabric to an application surface of backing adhesives, and facilitates lining a back stitch surface of a tufted rolled material.SOLUTION: A secondary base fabric is made into a three-layer laminate structure of a fiber web 12, fabrics 11 and a fluff layer 13. The fluff layer 13 is formed by protruding filaments 32 of the fiber web 12 laminated on the fabrics 11. The fabrics are woven by an entwined woven texture in which any warp 15a in adjacent multiple pairs becomes the entwined warp and any other warp 15b becomes the ground warp to be entangled, and thereby the adjacent multiple warp 15a/15b forms one entwined yarn 19. In the fabrics, a texture gap 16 is formed in which a gap area occupancy ε of a gap area Sp occupying in the unit texture area St becomes 20% or more for facilitating the filaments 32 of the fiber web 12 to protrude and facilitating the backing adhesives to penetrate through.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a tufted carpet that is laminated and bonded to a coating surface 26 of a backing adhesive 27 applied to the surface of a back stitch 29 on the back surface of a tufted original fabric 23 in which a pile 20 is planted on a primary base fabric 21. This relates to the secondary base fabric (see FIG. 8).

The tufted carpet secondary base fabric used to improve the appearance of the tufted original fabric 23 and to provide dimensional stability and shape stability is a burlap fiber that is hard and difficult to stretch, has excellent tensile strength, and is stable in strength. Using 8 jute count (approx. 2066 dtex) burlap single yarn for warp 25 and weft 24, warp density 12 / 25.4mm, weft density 9 / 25.4mm, basis weight 237g / m ² (7 oz / square yard) Burlap fabric 31 is used (see FIG. 8).

  Burlap fiber is a kind of bast fiber like cedar bark used for roofing, even though cedar bark is hydrophilic and easy to absorb moisture, it lacks water permeability and is difficult to soak in water, hence it is used for roofing In addition, burlap single yarn is also used as a water shielding material for water-stop packing of water pipes.

  Unlike cedar bark, in which bast fibers are simply stacked, burlap monofilaments are spun yarns that are twisted and bundled. Thus, the fibers are firmly adhered to each other, and the oil agent used at the time of the softening treatment remains and gives off a strange odor. The remaining oil agent acts to repel water and enhance the water-insulating function of the burlap single yarn.

  For this reason, when used as the secondary base fabric 17 and superimposed on the application surface 26 of the backing adhesive 27, the backing adhesive 27 is difficult to become familiar with and swells when touched by the moisture of the backing adhesive 27. The adhesive 27 does not penetrate into the inside of the burlap single yarn, but is superficially bonded through the jute fluff 22 protruding to the surface (see FIG. 7).

  In particular, the burlap fiber is harvested when the flowering season is around 30 mm thick and grows up to a length of about 2 to 5 m. Leaves until the leaves fall, binds the trunk and leaves it in running water for 10 to 20 days. The bast is peeled and bundled, taken up from the water, dried on a cocoon, dried, and the bulk of the bundle is rolled and passed through a soft wire machine and taken out as a burlap fiber having a length of 2 to 3 m.

  The burlap fibers taken out in this way have a large variation in fineness due to the production method and the fiber length is as long as 2 to 3 m. The anchoring effect on the application surface 26 of the adhesive 27 is also slight.

  As a measure against burlap fabric to deal with these problems, a woven fabric fabric substitution method in which a woven fabric fabric using polyolefin flat yarn is substituted for a burlap fabric (for example, Patent Documents 1, 2, 3, 4, 5, 6) is considered.

  As another burlap fabric countermeasure, a burlap fabric raising method (for example, refer to Patent Document 7) that raises the throwing effect by raising the burlap fabric is considered.

JP-A-55-026251 Japanese Utility Model Sho 61-018079 JP 58-013738 (Japanese Patent Publication No. 02-35056) Japanese Utility Model Sho 62-175084 (Actual Fair 02-43892) Shokai 55-027463 JP 56-134255 A JP 2002-146660 (Patent No. 3465187)

  In the method of substituting a textured fabric using a split-fibre-opening polyolefin split yarn disclosed in the above-mentioned Patent Document 1, although the fluff is opened, it is a hydrophobic fiber, so that it is used for backing. Adhesives are not compatible with polyolefin split yarns, and it is not possible to obtain sufficient peel strength on the back stitched surface of the tufted original fabric.

  The above-mentioned Patent Document 2 discloses a method of raising a woven tissue fabric using polyolefin fibers and applying a sulfonate anionic surfactant in order to impart hydrophilicity. Since the adhesive is diluted and the adhesive strength is lowered, it does not seem to be a fundamental improvement measure to increase the peel strength.

  Patent Documents 3 and 4 describe a method of raising and raising a warp fabric using a polyolefin fiber and raising the fabric after weaving to increase the peel strength of the fabric. Although it is disclosed, the surface of the polyolefin flat yarn is hard and smooth regardless of how the fiber is opened, and thus it is difficult to raise the bulk like a short fiber spun yarn.

Patent Documents 5 and 6 disclose a method in which a short fiber spun yarn is used for one of the warp and the weft and a flat yarn is used for the other in order to easily raise the polyolefin fiber woven fabric.
However, in this case, the short fiber spun yarn is raised and the tensile strength decreases, and it becomes easier to stretch, while the flat yarn is not raised and the tensile strength is maintained. It is not possible to obtain a secondary base fabric that is mechanically stable.

  As a measure against burlap fabric, the burlap fabric raising method disclosed in the above-mentioned Patent Document 7 is a method of overlaying a fiber web (fiber thin film) on the burlap fabric, performing needle punching, and protruding a part of the web fiber on the opposite surface, and an adhesive for backing This is a method for enhancing the anchoring effect on the coated surface.

As explained at the beginning, 8 jute count (approx. 2066 dtex) burlap single yarn is used for the burlap fabric used to give dimensional stability and shape stability to the tufted original fabric, and its apparent thickness Is about 2mm thick, needle punching needles are hard to pierce the burlap monofilament, and the fiber web (fiber thin film) layered on the burlap woven fabric has a fabric gap surrounded by the warp 25 and the weft 24 where the needle is easy to pierce Will be sticking out.
In that case, although the anchoring effect by the fiber of the fiber web protruding from the fabric gap (16) is expected, the effect is the anchoring effect of the fiber web on the coated surface of the backing adhesive. Since it has a function, it is not expected to improve the peel strength of the burlap fabric itself with respect to the application surface of the backing adhesive.

This means that the warp density and the weft are such that the gap (16) surrounded by the warp 25 and the weft 24 is closed in order to increase the protrusion of the burlap 22 to the surface, which is an adhesive factor of the burlap fabric 31. It is the same even if the density is made fine.
Further, in order to increase the protrusion of the burlap fluff 22 that is a factor of the adhesiveness of the burlap fabric 31 to the surface of the burlap fluff 22, 12 jute count burlap single yarn is used for the warp 25 and the weft 24 to 12 warp density / 25.4 mm, I applied needle punching to a burlap fabric 31 with a weft density of 9 pieces / 25.4mm and a basis weight of 237g / m ² (7 ounces / square yard). The burlap fiber is a short fiber, but its fiber length is 2 to 3 m, and the fiber length is like a long fiber compared to 2 to 3 cm cotton fiber. Even if it is given, the number of exceptional burlap feathers does not increase, and the result is the same.

  From these facts, needle punching and raising rolls are not effective for the burlap fabric 31 formed of single jute yarn of 8 jute counts obtained by twisting burlap fibers, and the burlap fibers have a water shielding function. It was concluded that the burlap woven fabric 31 is not suitable for a tufted carpet secondary base fabric, and in particular, because the burlap fibers are thick and rigid, they are not suitable for tufted simple rugs that are folded and displayed in stores.

Then, this invention makes it the 1st objective to eliminate the water-blocking function of the secondary base fabric with respect to the coating surface of the adhesive for backing. The second object of the present invention is to increase the permeability of the backing adhesive to the secondary base fabric. The third object of the present invention is to form a smooth backing layer in which the secondary base fabric and the backing adhesive are integrated on the back stitch surface of the tufted original fabric.
The fourth object of the present invention is that a backing layer which does not impair the flexibility of the tufted original fabric can be laminated on the back stitch surface of the tufted original fabric, and the dimensional stability, shape stability and sound absorption are added to the tufted original fabric 23. It is to obtain a tufted carpet secondary base fabric suitable for imparting functionality such as heat resistance, heat insulation, cushioning, and shock buffering.
Accordingly, a fifth object of the present invention is to obtain a simple rug that can be folded and packed by covering the back stitch surface of the tufted original fabric with a flexible backing layer.

The tufted carpet secondary base fabric 17 according to the present invention is configured as a laminate of (a) a woven fabric 11 and a fiber web 12;
(B) For the weft 14 and the warp 15 of the fabric 11, a hydrophobic synthetic fiber filament yarn having a long fiber structure continuous in the fiber axis direction is used.
(C) A set of adjacent warps is divided into a warp 15a and a ground warp 15b with one or a plurality of wefts 14 in between, and the split warp and ground warp cross over the weft 14 A pair of warp yarns 19 that are twisted in the front and rear directions to bind the weft yarns 14 are formed (see FIGS. 2 and 3).
(D) The woven fabric is woven by a woven structure in which the kite yarn 19 and the weft yarn 14 are entangled,
(E) The fabric is formed with a fabric gap 16 surrounded by adjacent side threads 19 and 19 and adjacent wefts 14 and 14 (see FIG. 3).
(F) Occupied gap area occupied by the gap area Sp of the cloth gap 16 in the unit cloth area St shown as the product of the repeat Lw between the adjacent weft yarns 19 and 19 and the repeat Lf between the adjacent weft yarns 14 and 14 The rate ε is 20% or more,
(G) A fabric in which filaments (staples, fibers) 32 of the fiber web 12 include not only the fabric gaps 16 but also the individual wefts 14 and warps 15 by punching applied to the laminate from the fiber web 12 toward the fabric 11. The first characteristic is that a fluff layer 13 is formed on the surface of the fabric 11 so as to penetrate the entire fabric (see FIG. 1).

  The second feature of the tufted carpet secondary base fabric according to the present invention is, in addition to the first feature described above, (h) a flat yarn or a multifilament yarn having a flat cross-sectional shape in which the weft yarn 14 includes a split yarn. The warp yarn 15 is a flat yarn having a flat cross-sectional shape including split yarns, and the filament 32 of the fiber web 12 breaks through the individual flat yarns as well as the gaps between adjacent fibers of the multifilament yarn, and the fabric 11 The fluff layer 13 is formed on the surface.

  A third feature of the tufted carpet secondary base fabric according to the present invention is that, in addition to any of the first and second features, the fiber web 12 contains a heat-adhesive polymer.

The tufted carpet according to the present invention comprises: (1) the fluff layer 13 is opposed to the application surface 26 of the backing adhesive 27 applied to the back stitch 29 of the tufted original fabric 23, The secondary base fabric 17 is bonded to the tufted original fabric 23,
(2) On the critical surface between the back stitch 29 and the secondary base fabric 17, an inner film 34 is formed, in which the filament 32 of the fluff layer 13 and the backing adhesive 27 are united.
(3) The woven fabric 11 is nailed to the inner coating 34 by the fiber web 12 through the filament 32 penetrating the entire woven fabric as if the heel is a nail tip of the heel (see FIG. 4). ).

The second feature of the tufted carpet according to the present invention is that, in addition to the first feature, (4) the backing adhesive 27 permeates the fabric 11 and penetrates into the fiber web 12,
(5) An outer coating 33 in which the backing adhesive 27 and the filaments of the fibrous web 12 are integrally formed is formed on the critical surface of the fabric 11 and the fibrous web 12;
(6) The fabric 11 is in a pressure-bonded state as if the fabric 11 was nailed to the internal coating 34 by the external coating 33 through the filament 32 penetrating the entire fabric as if the nail tip of the kite (FIG. 5). reference).

According to the present invention, the secondary base fabric 17 having a three-layer laminated structure of the fiber web 12, the woven fabric fabric 11 and the fluff layer 13 is made of a synthetic fiber which is hydrophobic and does not swell hygroscopically substantially without twisting. It is formed of a filament yarn and is configured on the basis of the woven fabric fabric 11 having the fabric gap 16 having a gap area occupation ratio ε of the gap area Sp of 20% or more, and the backing adhesive 27 is easily transmitted.
Therefore, when the secondary base fabric 17 is overlaid on the application surface 26 of the backing adhesive 27 applied to the back stitch 29 of the tufted original fabric in the manufacturing process of the tufted carpet, as shown in FIG. On the critical surface of the stitch 29 and the secondary base fabric 17, there is formed an inner film 34 in which the penetration filament 32 of the fiber web 12 that has penetrated through the woven fabric fabric 11 and the backing adhesive 27 are integrally formed. The backing adhesive 27 that has permeated through the secondary base fabric 17 and oozed out into the fiber web 12 and the filament of the fiber web 12 are united with each other on the critical surface of the woven fabric fabric 11 and the fiber web 12 of the next base fabric 17. The weft 14 and the warp 15 of the woven fabric fabric 11 are formed between the inner film 34 and the outer film 33 as if the eyelet was attached to the cloth gap 16. It will be Rikyoji.
As a result, when the secondary base fabric 17 of the present invention is used, a tufted carpet, a tufted mat, a tufted tile carpet, etc., which are firmly bonded to the tufted original fabric 23 as if the secondary base fabric 17 were bound with eyelets. Will be obtained.

  The secondary base fabric 17 of the present invention is substantially untwisted and has many inter-fiber gaps unlike the twisted and bound burlap single yarn, and is bulkier than the twisted and bound burlap single yarn. Synthetic filament yarns, which are also hydrophobic and easily soaked with water between fibers, are used for the wefts 14 and warps 15 of the woven fabric fabric 11. The compounding amount of the main polymer of the adhesive 27 for tufted carpet backing is generally 30 to 65% by mass, and the viscosity of the backing adhesive 27 is generally 20000 to 30000 cps (BM type No. 4 rotor, 12 r.p.m.), which is substantially untwisted, bulky and has many inter-fiber gaps, and is hydrophobic and easily soaked into the wefts 14 and warps 15 which are readily accustomed to water.

In particular, in the thin woven fabric fabric 11 having a basis weight of 170 g / m ² or less, it is composed of a hydrophobic synthetic fiber and exhibits a dispersion function of diffusing the backing adhesive 27 like a dew or shower head. Therefore, the backing adhesive 27 is easy to permeate, and the backing adhesive 27 does not become spotted on the fiber web 12 and easily penetrates evenly.
In addition, in the weave fabric 11, the warp 15a in one set adjacent to each other becomes a warp and any other warp 15b is intertwined with one ground warp. On the other hand, the weft 14 is reduced in bulk by being bound to a set of warps 15a and warps 15b that are intertwined with each other, and the gap area occupying the gap area Sp in the unit cloth area St is 20% or more. A gap 16 is generated, and the backing adhesive 27 easily penetrates into the fiber web 12 through the cloth gap 16.

As such, the gap area occupying ratio ε of the fabric gap 16 is 20% or more, and the weft yarn 14 and the warp yarn 15 are substantially untwisted synthetic fiber filament yarns and laminated on the woven fabric 11 having a low needle stick resistance. When water punching by a high-pressure water flow or needle punching by a needle is applied to the fiber web 12, the filament 32 of the fiber web 12 penetrates the inter-fiber gap of the weave tissue fabric 11 to form the fluff layer 13, and the penetrated filament 32 Thus, the backing adhesive 27 can easily penetrate from the fluff layer side (13) to the fiber web side (12).
That is, the filament 32 penetrating through the inter-fiber gap of the woven fabric fabric 11 serves as a conduit for guiding the backing adhesive 27 from the back stitch surface of the tufted original fabric to the fiber web 12 on the back surface of the secondary base fabric 17. It is a translation that fulfills.

In this way, the backing adhesive 27 can easily permeate, so that when the secondary base fabric 17 of the present invention is used, the amount of the backing adhesive 27 used for bonding to the tufted original fabric 23 can be reduced. That's it.
Moreover, since the amount of application may be small, when the secondary base fabric 17 of the present invention is used, the applied backing adhesive 27 can be dried in a short time.

Traditionally, the burlap fiber used for the secondary fabric is plant fiber, and its production volume is greatly influenced by the climate, and the production area is outside Japan, and it is also greatly influenced by international politics. Is unstable.
However, the synthetic fibers used in the present invention in place of the burlap fibers are produced in Japan.
Therefore, according to the present invention, it is possible to stably supply the secondary base fabric in terms of quantity and price.

In the present invention, when flat yarns or multifilament yarns having a flat cross section including split yarns are used for the weft yarns 14, the weft yarns 14 are ejected from the fiber web 12 by the punching treatment because the weft yarn 14 is orthogonal to the conveying direction during the punching treatment. In the case of multifilament yarn, the filament 32 penetrates through the gap between adjacent fibers, and in the case of flat yarn, it penetrates through the coating having a flat cross-sectional shape. The fiber web 12 is anchored and locked to the weft 14 via the filament 32 by being pinched between the interfiber gaps and the fissure grooves.
The same applies to the case where flat yarns or multifilament yarns having a flat cross-sectional shape including split yarns are used as the warp yarns 15. However, since the transport direction of the fabric 11 and the warp yarns 15 are arranged in parallel during the punching process, the filament 32 However, when the multifilament yarn is used as the warp yarn 15, the multifilament yarn becomes fuzzy and easily breaks during the weaving process. Since the multifilament yarn does not easily pass through the reed mesh during the weaving process, the multifilament yarn is not used for the warp 15 and the surface is smooth and slippery and is folded in the width direction when passing through the reed. It is recommended to use a flat yarn that reduces the bulk for the warp 15.
In the present invention, “flat yarn having a flat cross-sectional shape including a split yarn” means that if the space between adjacent slits of the split yarn is enlarged, a flat cross-sectional shape is formed in the same manner as the flat yarn. Therefore, the flat yarn is a superordinate concept of the split yarn. And split yarn means included in the flat yarn as part of the flat yarn.

In the manufacturing process of the tufted carpet, the backing adhesive 27 is applied to the surface of the back stitch 29, and the tufted original fabric 23 in which the secondary base fabric 17 is superimposed on the application surface 26 is applied to the applied backing adhesive. In order to dry the agent 27, it is passed through a heat-drying pin tenter and heat-dried.
In that case, if the heat-adhesive polymer is mixed in the fiber web 12, the heat-adhesive polymer is heated and melted when passing through the heat-dried pin tenter to partially bond the filaments of the fiber web 12. become.

  Therefore, even if the fiber web 12 is fed from the spinning machine card and the filaments are in a free state, the backing adhesive 27 that has passed through the fabric 11 does not permeate the fiber web 12 and ooze out to the surface. Even if the uncoated layer (35) 27 in which no infiltration is applied remains on the fibrous web 12, a backing layer having excellent durability and no particular inconvenience is formed. On the contrary, the uncoated layer (35) is sound-absorbing. The effect of the layer, the heat insulating layer, the impact buffering layer 35, the cushion layer, etc. is exhibited and the quality of the tufted carpet is enhanced.

  The heat-adhesive polymer mixed in the fiber web 12 may be a heat-adhesive powder (fine particles), a heat-adhesive pellet (scale), a heat-adhesive filament, or a core sheath having a high melting point polymer as a core component. It may constitute the sheath component of the composite fiber.

The tufted carpet 10 of the present invention is configured by adhering the secondary base fabric 17 to the application surface 26 of the backing adhesive 27 applied to the back stitch 29 of the tufted original fabric 23 so that the fluff layer 13 faces. An inner film 34 in which the filament 32 of the fluff layer 13 and the backing adhesive 27 are integrally formed is formed on the critical surface of the back stitch 29 and the secondary base fabric 17.
The filament 32 is protruded from the fiber web 12 by a punching process. Even if one end of the filament 32 protrudes from the fabric 11, the other end is entangled in the fiber web 12 and securely locked.
One end of the filament 32 protruding from the woven fabric 11 does not come out by forming an inner film 34 that is firmly integrated with the backing adhesive 27, and the fiber web 12 and the inner film 34 pass through the filament 32. Since it is in the connected state, even if the backing adhesive 27 permeates the fabric 11 and does not ooze into the fiber web 12, the fabric 11 is pressed against the internal coating 34 by the fiber web 12, There is no peeling.

  Therefore, the backing adhesive 27 permeates the fabric 11 and oozes into the fiber web 12, and the backing adhesive 27 and the filament of the fiber web 12 are naturally integrated on the critical surface of the fabric 11 and the fiber web 12. When the outer coating 33 is formed, the fabric 11 is wrapped in the outer coating 33, and the outer coating 33 forms a part of the fiber web 12, so that the secondary base fabric 17 composed of the fabric 11 and the fiber web 12 is It is completely integrated with the tufted original fabric 23 and is difficult to peel off.

  And since the fiber web 12 covers the entire back surface of the tufted carpet 10, the back surface is smooth and beautiful, and when carrying, there is no damage by touching the skin, and when applying the construction adhesive, it is thin and uniform. Therefore, it is possible to obtain a tufted carpet in which the amount of the construction adhesive used is small, and the cost for the replacement can be reduced at the time of the replacement.

It is an expansion perspective view of the secondary base fabric concerning the present invention. It is an enlarged plan view of the fabric of the secondary base fabric according to the present invention. It is an expansion perspective view of the textile fabric of the secondary base fabric concerning the present invention. It is a partially cutaway enlarged perspective view of a tufted carpet according to the present invention. It is an expansion section perspective view of a tufted carpet concerning the present invention. It is a relationship figure of the cover factor Kf of a weft organization and a weave organization. It is an enlarged plan view of a conventional secondary base fabric. It is a partially cut-away enlarged perspective view of the conventional tufted carpet.

  The “tufted original fabric” referred to in the present invention means a tufted pile fabric in which the back stitch 29 is raised and exposed on the back surface, and a wide tufted machine in which 20 or more needles are implanted in the needle bar. A wide tufted pile production machine with a pile planted, a narrow tufted pile production machine with a pile planted by a small tufted machine with less than 20 needles implanted in a needle bar, and a hook gun having a single needle In addition to the hand tufting raw machines in which the piles are planted, any of the first backing fabric in which an adhesive is applied to the back surface of these raw machines and the back stitch is temporarily fixed to the base fabric may be used.

The first feature of the present invention resides in that a hydrophobic synthetic fiber due to non-hygroscopic swelling is used in place of the burlap fiber which exhibits hygroscopic swelling by absorbing moisture.
Therefore, the hydrophobic synthetic fibers include not only burlap fibers but also synthetic polyester fibers, especially hydrophobic polyester fibers or polyolefin fibers (polypropylene fibers / polyethylene fibers) that have a particularly low official moisture content and are close to zero (zero%). Recommended to use.
The polyolefin fiber may be either a polypropylene fiber or a polyethylene fiber, but is preferably a polypropylene fiber.

The second feature of the present invention is that, although the fiber length is relatively long, instead of the spun yarn of burlap fiber, which is an aggregate of a kind of short fibers, the fiber length is essentially as long as it is not necessary to twist. In particular, a synthetic fiber filament yarn of untwisted long fibers is used.
For example, monofilament yarns, multifilament yarns, flat yarns, split yarns, etc., have an infinitely long fiber length, and they do not need to be twisted without maintaining the form of yarn without breaking even in the untwisted state. It is suitably used as a fiber filament yarn. Among them, flat yarns or flat yarns having a flat cross-sectional shape having a flatness ratio of 500% or more, that is, a flatness ratio of 5 times or more shown as a ratio of width (w) to thickness (t) (100 × w / t), etc. The flat yarn has a higher rate of change in bulk when it is twisted than a flat yarn with a small flat rate.

And, the untwisting torque that acts from a flat yarn with a large change rate of the bulk that changes when twisted is compared with the untwisting torque that acts from a flat yarn with a small change rate of the bulk that changes when twisted. large.
Therefore, when the flatness of the flat yarn used for the warp yarn 15 is 500% or more, the multifilament yarn as the weft yarn 14 is strongly bundled by the strong untwisting torque that acts on the warp yarn 19 constituting the weave structure. Therefore, the gap area occupation ratio ε occupied by the gap area Sp of the fabric gap 16 of the weave texture is easily set to 20% or more.
As described above, the effect of the fabric gap 16 is that the filament 32 of the fiber web 12 protrudes from the fabric gap 16 to form the fluff layer 13 and is guided by the penetrated filament 32 so that the backing adhesive 27 is on the fluff layer side. It is easy to permeate into the fiber web side, and the anchoring effect of the backing adhesive 27 is increased according to the gap area occupation ratio ε.
Therefore, a preferred embodiment of the present invention is to make the gap area occupation ratio ε 40% or more, more preferably 50% or more.
Therefore, it is recommended to use flat yarns such as flat yarns and split yarns having a flatness ratio of 500% or more, preferably 1000% or more, more preferably 1500% or more for the warp yarn 15.
Thus, the use of a flat cross-sectional shape flat yarn having a ratio of width (w) to thickness (t) (= 100 × w / t) of 500% or more as warp yarn 15 means that the flat yarn does not fluff during the weaving process. As compared with the filament yarn, it is less likely to be worn, and this is a preferable embodiment for obtaining the textured fabric 11 efficiently and economically.

The third feature of the present invention is that a substantially untwisted filament yarn is used in place of the twisted yarn that promotes the water shielding function of the burlap fiber that absorbs and swells moisture.
Here, “substantially untwisted” means that the yarn is in an open state, and when performing a punching treatment with a high-pressure fluid or needle, the fibers are separated and the fibers are separated finely, making it easy for the high-pressure fluid or needle to It means that the filament 32 is likely to be entangled between the finely opened fiber gaps.
For example, in addition to flat yarns and split yarns, false twisted multifilament yarns and SZ alternating twisted multifilament yarns correspond to the substantially untwisted filament yarns referred to in the present invention.
The so-called sweet twist, which is inevitably twisted in the rewinding step of the preparation step before the weaving step of the knot-woven fabric 11, is generated in the filament yarn is "substantially untwisted".

The warp weave structure is based on a weft warp structure, which is a kind of changed plain weave structure, and a set of adjacent warps sandwiched between the weft weave structures sandwich one or more wefts in between The warp is divided into warp and ground warp, and the split warp and ground warp are twisted before and after the weft where the warp crosses the weft to constitute a set of a plurality of warps.
There are no particular restrictions on the number of warps that make up the warp and the warp.
FIG. 6 illustrates the relationship between the number of warps and the structure of the warp, and the warp weave structure illustrated in FIGS. 6a-1 to 6a-3 has two warps 15a and 15b adjacent to each other. Based on the matching 2/2 weft warp structure (fractional diagram 6a-2), the two warps are divided into warp warp, ground warp 15a and ground warp 15b to constitute the warp weave structure (fractional diagram 6a- 3).

  6b-1 to 6b-3 are based on a 3/3 weft structure in which three warps 15a, 15b and 15c are adjacent to each other (part 6b-2). A warp is divided into a single warp 15a and a pair of ground warps 15b and 15c to form a weaving structure (see Fig. 6b-3).

  6c-1 to 6c-3 are based on a 4/4 weft structure in which four warps 15a, 15b, 15c and 15d are adjacent (minute 6c-2), The four warps are divided into two sets of warps 15a and 15b and two sets of ground warps 15c and 15d to form a weave texture (minute figure 6c-3).

6D-1 to 6D-3 are based on a 5/5 weft structure in which five warps 15a, 15b, 15c, 15d, and 15e are adjacent to each other (see FIG. 6d-2). ), The five warps are divided into two sets of warps 15a and 15b and three sets of ground warps 15c, 15d and 15e to form a woven fabric structure (minute figure 6d-3).
As described above, the number of warps of a plurality of sets that constitute the warp divided into warp and ground warp is not particularly limited.

In the present invention, the fiber web 12 constitutes the skeleton of the inner coating 34 formed by the backing adhesive 27 on the critical surface of the tufted original fabric 23 and the secondary base fabric 17, and the filament is A skeleton of the outer coating 33 formed by the backing adhesive 27 is formed on the critical surface of the woven fabric fabric 11 and the fiber web 12, and a connecting material for connecting the filament 32 between the inner coating 34 and the outer coating 33 is provided. Applied to configure.
Therefore, the material and form of the fiber web 12 are not particularly limited, and the materials include polypropylene fiber, polyethylene fiber, polyester fiber, polyether fiber, acrylic fiber, nylon, rayon, acetate fiber, kenaf fiber, cotton fiber, etc. Either fiber or natural fiber can be used.
Moreover, the form is a melt-blown nonwoven fabric or spunbond nonwoven fabric in which spinning filaments discharged from a spinning nozzle are deposited, synthetic paper, a nonwoven fabric in which short fiber filaments are deposited in bulk, or a nonwoven fabric in which bulky deposited filaments are joined together Any of the punched nonwoven fabrics obtained by punching the bulky accumulated filaments and interlaced between the filaments may be used, and the punching may be either water punching by high-pressure water flow or needle punching by needles.

  However, in order to form the films 33 and 34 that are firmly integrated with the backing adhesive 27, hydrophobic synthetic fibers that are easily mixed with the backing adhesive 27 may be used as the material of the fiber web 12. Preferably, as shown in FIG. 5, in order to obtain a strong delamination strength between the inner coating 34 and the outer coating 33, a strong or stable polypropylene fiber or polyester fiber should be used for the fiber web 12. Is recommended.

  The total fineness of the weft 14 and the warp 15 is 600 to 3000 dtex, preferably the total fineness of the warp 15 is smaller than the total fineness of the weft 14, and the weft 14 is a filament yarn having a total fineness of 600 to 3000 dtex. The warp 15 is made of filament yarn having a total fineness of 600 to 1500 dtex, the weft density Nf of the weave fabric 11 is 7 to 16 / 25.4 mm, and the warp density Nw is 6 to 32 / 25.4 mm. (G) The cover factor K of the weave fabric 11 that is the sum of the weft cover factor Kf and the warp cover factor Kw is set to 400 to 1800, and (h) the filament 12 having a single fiber fineness of 10 dtex or less is formed on the fiber web 12. A filament having a single fiber fineness of 30 dtex or less is used.

  However, if the filament has a fine single fiber fineness, the needle puncture resistance received during punching is small, and a thin filament having a single fiber fineness is liable to be entangled with the weft 14 or the warp 15. Recommended to use.

A filament yarn having a total fineness of 600 to 3000 dtex is used for the weft yarn 14, a filament yarn having a total fineness of 200 to 1500 dtex is used for the warp yarn 15, the weft density Nf is 7 to 16 pieces / 25.4 mm, and the warp density Nw is 6 to 6 When 32 pieces / 25.4 mm, when the total cover factor K (= Kf + Kw) of the woven fabric, which is the sum of the weft cover factor Kf and the warp cover factor Kw, is 450 to 1800, the gap area Sp of the fabric gap 16 It becomes easy to efficiently weave the woven fabric fabric 11 having a gap area occupation ratio ε of 20% or more.
Here: In the present invention, the weft cover factor Kf is the product (Kf = Nf × D ¹ ) of the weft density Nf (line / 25.4 mm) and the square root (D ^1/2 ) of the total fineness D (drex) of the weft. ^{/ 2} ) is calculated.
Similarly, the warp cover factor Kw is the product (Kw = Nw × D ^1/2 ) of the warp density Nw (line / 25.4 mm) and the square root (D ^1/2 ) of the total fineness D (drex) of the warp. Calculated.

  A fourth feature of the present invention is that the weft yarn 14 is a multifilament yarn having a total fineness of 600 to 3000 dtex formed of filaments having a single fiber fineness of 30 dtex or less.

  In the present invention, a multifilament yarn having a single fiber fineness of 30 dtex or less, which is substantially untwisted and having many interfiber spaces, is used as the weft 14, and the filaments 32 of the fiber web 12 are finely divided between the interfiber spaces. A conduit that allows the backing adhesive 27 to enter is formed between the fiber gaps, and the multifilament, the filament 32 of the fiber web 12 and the backing adhesive 27 are mixed inside the weft 14. A solid material that is integrated into one piece is generated, and the anchoring effect of the backing adhesive 27 is enhanced.

The multifilament yarn of the weft 14 may be mixed with a heat-adhesive filament, and the multifilaments may be partially point-bonded via the heat-adhesive filament.
As described above, when the heat-adhesive filaments are mixed and the filaments are partially spot-bonded, the inside of the weft 14 has a three-dimensional network structure. Therefore, the anchoring effect of the filament 32 of the fiber web 12 and the backing adhesive 27 is achieved. Will increase.

  A fifth feature of the present invention is that one or both of the weft 14 and the warp 15 has a ratio (100 × w / t) of the width (w) to the thickness (t) of 300% or more, that is, the width is three times the thickness. The flat yarn (tape yarn, ie, flat yarn) having the above-described flat cross-sectional shape is.

  In the present invention, a flat yarn having a flat cross-sectional shape with a ratio (100 × w / t) of the width (w) to the thickness (t) of 300% or more is used for one or both of the weft 14 and the warp 15, and the weft 14 and warp 15 are torn, and the anchoring effect of filament 32 of fiber web 12 and backing adhesive 27 is increased, and weft 14 and warp 15 are folded in the width (w) direction to reduce the bulk, and the clearance area Sp A fabric gap 16 having a gap area occupancy ε of 20% or more is secured in the woven fabric fabric 11.

The basis weight of the fiber web 12 may be 10 g / m ² or more, and the upper limit is not particularly limited.

  The purpose of using the backing adhesive 27 on the tufted carpet 10 is that the filaments of the fiber web 12 and the backing adhesive 27 are placed on the critical surface of the textile fabric 11 and the fiber web 12, as shown in FIG. An internal coating 34 formed by mixing is formed, and the woven fabric fabric 11 and the fiber web 12 are firmly bonded through the internal coating 34, and the adhesive for backing is used until the back surface of the fiber web 12 is reached. It is not the case that the outer coating 33 in which the fiber web 12 and the backing adhesive 27 are mixed and integrated is formed on the back surface of the woven fabric fabric 11 by infiltrating and applying the agent 27.

Therefore, the thickness and basis weight of the fiber web 12 are not particularly limited.
And when using the fiber web 12 with a high basis weight exceeding 100 g / m ² , even if an uncoated layer (35) to which the backing adhesive 27 does not infiltrate is left on the fiber web 12, it is particularly inconvenient. On the contrary, the uncoated layer (35) exhibits the effects of a sound absorbing layer, a heat insulating layer, an impact buffer layer 35, a cushion layer, etc., and a high quality tufted carpet is obtained.
That is, even if an uncoated layer remains on the fiber web 12, a flexible and foldable tufted carpet can be obtained, and no inconvenience arises.
In FIG. 5, the code | symbol 36 shows the cavity produced | generated by the water | moisture content in the adhesive agent for lining evaporating.

  On the other hand, when the fiber web 12 has a small basis weight and the thickness becomes extremely thin, the backing adhesive 27 permeates the thin fiber web 12 and oozes out to the surface even if the coating amount is small ( FIG. 5). In that case, the exfoliated backing adhesive 27 forms a film between the filaments of the fiber web 12 due to the surface tension it has, and the back surface of the tufted carpet is a woven fabric 11 with a low basis weight, The woven tissue fabric 11, the fiber web 12, and the backing adhesive 27 are covered with a tough and flexible outer film 33, and a foldable simple rug is obtained.

Accordingly, the weave fabric 11 may have a low basis weight of about 30 g / m ² , and the fiber web 12 may also have a low basis weight of less than 30 g / m ^2. Even if the weight of the backing adhesive 27 is reduced, the inconvenience does not occur. Therefore, the present invention also includes a fiber web 12 having a low basis weight of about 10 g / m ² .
In the present invention, the basis weight of the fiber web 12 is 10 g / m so that a shoji paper having a basis weight of about 10 g / m ² and a lattice having a gap area occupation ratio ε of about 90% work as a shoji with a concealment rate of 100%. ^This is because even when the gap area occupancy ε of the weave fabric 11 is about 90%, the back stitch 29 is concealed and the aesthetic appearance of the tufted carpet is enhanced.

  In the tufted carpet according to the present invention, the secondary base fabric 17 is bonded to the back stitch 29 of the tufted original fabric 23 with the backing adhesive 27 with the fluff layer 13 facing (see FIG. 4).

  That is, the characteristics of the tufted carpet according to the present invention are as follows. (1) The secondary base fabric 17 having the above characteristics is bonded to the back stitch 29 of the tufted original fabric 23 with the fluff layer 13 facing. (2) On the critical surface between the tufted original fabric 23 and the secondary base fabric 17, the through filament 32 of the fiber web 12 that penetrates through the woven fabric fabric 11 and the backing adhesive 27 are stunned. An integrated inner film 34 is formed. (3) The secondary base fabric 17 is transmitted to the fiber web 12 through the critical surface between the woven fabric fabric 11 and the fiber web 12 of the secondary base fabric 17. An outer coating 33 is formed in which the exuding backing adhesive 27 and the filaments of the fiber web 12 are integrally formed. (4) The weft 14 and the warp 15 of the woven tissue fabric 11 are formed by the inner coating. 4 and is sandwiched between the outer coating 33 lies in interposed (see FIG. 5).

  The tufted carpet of the present invention is cut into a rectangular shape with a side length of 3 m or less to make a tufted mat, and is cut into a rectangular shape with a side length of 90 cm or less to make a tufted tile carpet. You can also.

As in the present invention, when a woven fabric structure is used for the woven fabric 11 serving as the base of the secondary base fabric 17, the clearance area occupation ratio ε occupying the unit fabric area St of the fabric clearance 16 is adjusted while satisfying the strength in the warp direction. The merit that can be done also arises.
This merit is a kind of changed plain weave structure and the weft weave cover factor Kw of the weft weave which is the base of the weave weave structure is the warp density (number / 25.4mm) of the number of warps Nw and the warp The warp cover factor Bw of the woven fabric is calculated as the product of the square root (D ^1/2 ) of the total fineness D (dtex) (Kw = Nw × D ^1/2 ). 25.4 mm), not the number Nw of warps, but the number Nb of warps composed of a plurality of warps (number / 25.4 mm) and the total fineness Nw × D (dtex) This is because it is calculated as a product of square root (Nw ^1/2 × D ^1/2 ) (Bw = Nb × Nw ^1/2 × D ^1/2 ).

Hereinafter, this point will be described in detail with reference to a specific example shown in FIG.
Temporarily, the warp cover factor Kw of the basic fabric of warp density D (dtex), warp density Nw / 1 / 25.4mm, 1/1 plain weave structure is Kw = 1 × (D1 ^{/ 2} ) = D. ^1/2 .
The weft of a 2/2 weft structure (FIG. 6a-1) in which the total fineness of the warp is D (dtex) which is the same as that of the basic fabric, and the warp density Nw of the basic fabric is double 2 / 25.4 mm The warp cover factor Kw of the woven fabric (FIG. 6a-2) is Kw = 2 × (D) ^1/2 = 2D ^1/2 .
However, the yarn density of the weave fabric (Fig. 6a-3), which is based on a 2/2 weft design (Fig. 6a-1), but constitutes one kite with two warp pairs, is One yarn / 25.4 mm, and the total fineness of the warp is 2D (dtex), which is the sum of the total fineness of the two warps, so the warp cover factor of the woven fabric (FIG. 6a-3) Bw is Bw = 1 × (2D) ^1/2 = 2 ^1/2 × D ^1/2 = 1.414D ^1/2 .
That is, the warp cover factor Bw of the weave fabric (FIG. 6a-3) based on the 2/2 weft texture (FIG. 6a-1) is the weft of the 2/2 weft texture (FIG. 6a-1). It is about 29% less than the warp cover factor Kw of the woven fabric (FIG. 6a-2) [(2-2 ^1/2 ) ÷ 2 = (2-1.414) ÷ 2 = 0.293≈29%].

Similarly, a 3/3 weft structure (FIG. 6b-1) having a total fineness of D (dtex), which is the same as that of the basic fabric, is 3 times 25.4 mm of the warp density Nw of the basic fabric. The warp cover factor Kw of the weft fabric (FIG. 6b-2) is Kw = 3 × (D) ^1/2 = 3D ^1/2 .
However, the warp density of the weave fabric (FIG. 6b-3), which is based on the 3/3 weft warp structure (FIG. 6b-1), but which constitutes one warp with one set of three warps, is the warp density. 1 / 25.4 mm, and the total fineness of the warp yarn is 3D (dtex), which is the sum of the fineness of the three warp yarns. Therefore, the warp cover factor Bw of the woven fabric (FIG. 6b-3) is Bw = 1 × (3D) ^1/2 = 1.732D ^1/2 .
That is, the warp cover factor Bw of the weave fabric (FIG. 6b-3) based on the 3/3 weft texture (FIG. 6b-1) is the weft of the 3/3 weft texture (FIG. 6b-1). It is about 42% less than the warp cover factor Kw of the woven fabric (FIG. 6b-2) [(3-31 / ² ) ÷ 3 = (3-1.732) ÷ 3 = 0.423≈42%].

Similarly, the total fineness is D (dtex) which is the same as that of the basic woven fabric, and the weft density of the basic woven fabric is 4 times 4/2 weft structure (FIG. 6c-1). The warp cover factor Kw of the cocoon fabric (FIG. 6c-2) is Kw = 4 × (D) ^1/2 = 4D ^1/2 .
However, the warp density of the weave fabric (FIG. 6c-3), which is based on the 4/4 weft warp structure (FIG. 6c-1), but constitutes one warp with one set of four warps, is the warp density. 1 / 25.4 mm, and the fineness of the warp is 4D (dtex), which is the sum of the fineness of the four warps. Therefore, the warp cover factor Bw of the woven fabric (FIG. 6c-3) is Bw = 1 × (4D) ^1/2 = 2.000D ^1/2
That is, the warp cover factor Bw of the weave fabric (FIG. 6c-3) based on the 4/4 weft design (FIG. 6c-1) is the weft of the 4/4 weft design (FIG. 6c-1). 50% less than the warp cover factor Kw of the woven fabric (FIG. 6c-2) [(4−4 ^1/2 ) ÷ 4 = (4-2) ÷ 4 = 0.5 = 50%].

Similarly, the total fineness is D (dtex) which is the same as that of the basic fabric, and the warp density of the 5/5 weft weave structure (FIG. 6d-1) is 5 times the warp density Nw of the basic fabric / 5 / 25.4 mm. The warp cover factor Kw of the woven fabric (FIG. 6d-2) is Kw = 5 × (D) ^1/2 = 5D ^1/2 .
However, the warp density of the weave fabric (FIG. 6d-3), which is based on the 5/5 weft warp structure (FIG. 6d-1) but forms one warp with one set of 5 warps, is the warp density. 1 / 25.4 mm, and the fineness of the warp is 5D (dtex), which is the sum of the fineness of the five warps, so the warp cover factor Bw of the warp woven fabric (FIG. 6d-3) is Bw = 1 × (5D) ^1/2 = 2.236D ^1/2
That is, the warp cover factor Bw of the weave fabric (FIG. 6d-3) based on the 5/5 weft design (FIG. 6d-1) is the weft of the 5/5 weft design (FIG. 6d-1). It is about 55% less than the warp cover factor Kw of the woven fabric (FIG. 6d-2) [(5-5 ^1/2 ) ÷ 5 = (5-2.236) ÷ 5 = 0.553≈55%].

  Thus, the warp cover factor Bw of the woven fabric (FIGS. 6a to 6d) gradually increases as the number of warps constituting one warp increases, but the increase rate is higher than the increase rate of the number of warps. Less. Therefore, even if the weft cover factor Kf is reduced by the increase of the warp cover factor Bw in order to keep the cover factor K of the entire fabric (11) constant, the decrease rate of the weft cover factor Kf can be suppressed to a small level.

  When the weft cover factor Kf is decreased, the weft density Nf is increased. However, if the weft density Nf is increased, the weaving efficiency of the fabric 11 is increased, so that no inconvenience occurs. This is because when weft density Nf is increased, the number of times weft is driven into the opening formed by the warp in the weaving machine for weaving the fabric in the warp direction to 25.4 mm increases, and the weaving efficiency decreases by the increased number On the contrary, when the weft density Nf is decreased, the number of times of weft is reduced in the opening formed by the warp in the loom for weaving the fabric in the warp direction by 25.4 mm. This is because the weaving time is shortened by the reduced amount.

(Tufted original)
A pile of wool fiber spun yarn with a total fineness of 2/5 meters is used as a pile yarn and a pile of 9 mm is piled on the primary base fabric 21 as a needle gauge 1/8 (25.4 cm) and stitch 10.6 (lines / 25.4 cm). 20 was planted to prepare a tufted original fabric 23 having a pile basis weight of 1130 g / m ² .

(Secondary fabric)
Polyester monofilament flat yarn with flatness of 2300% and single fiber fineness of 350 dtex is used as warp, and polyester multifilament yarn with single fiber fineness of 15 dtex and total fineness of 1100 dtex, and single-fiber fineness of 5 dtex and thermal adhesive binder multifilament with total fineness of 100 dtex are mixed. The multifilament yarn having a total fineness of 1200 dtex is used as a weft, the warp density Nw is 15.6 / 25.4 mm (warp yarn density 7.8 / 25.4 mm), and the weft density Nf is 6.35 / 25. 4 mm, basis weight 84 g / m ² , warp cover factor Kw 292, weft cover factor Kf 220, total cover factor K (= Kf + Kw) 512, unit fabric area St 7.5 mm ² , clearance area 16 Sp is 4.1mm ^2, the clearance area S The polyester fiber woven fabric (11) having a gap area occupancy ε of 54.7%, 70% by mass of polyester filaments having a single fiber fineness of 17 dtex, 25% by mass of polyester filaments having a single fiber fineness of 6.6 dtex, and a single fiber fineness of 4.4 dtex A polyester fiber web (12) having a basis weight of 70 g / m ² consisting of 5% by mass of a polyester fiber heat-bonding binder was laminated and subjected to needleching to protrude the polyester filament onto the surface of the polyester fiber fabric to form a fluff layer 13. A secondary base fabric 17 was prepared.

(Lining processing)
3490 parts by weight of styrene butadiene latex having a solid content of 50% by weight, 5640 parts by weight of calcium carbonate, 32.5 parts by weight of a thickener, 50 parts by weight of zinc white (crosslinking agent) having a solid content of 50% by weight, and 788 parts by weight of water. The back-stitched surface of the tufted original fabric 23 with a styrene-butadiene latex backing adhesive 27 prepared to a solid content of 74.43 mass% and a viscosity of 29000 cps (BM type No. 4 rotor, 12 rpm) (29) is applied at 1200 g / m ² (wet), the fluff layer 13 is directed to the application surface 26 and the secondary base fabric 17 is overlapped, and is passed through a heat-dried pin tenter at 120 ° C., and the backing adhesive 27 is applied. Heat-dried to finish tufted carpet 10 (FIG. 4).

(Comparative example)
Warp cover factor Kw using real twisted burlap single yarn of total fineness 2066dtex (8 jute count) for warp 25 and weft 24 is 547, weft cover factor Kf is 418, total cover factor K (= Kf + Kw) is 965, unit fabric area St is 5.9 mm ^2, clearance area Sp of weft gap 16 is 2.0 mm ^2, clearance area occupancy rate of clearance area Sp epsilon uses jute fabric 31 33.33 percent secondary backing 17 (FIG. 7).
(Lining processing)
1200 g / m ² (wet) of the styrene / butadiene / latex backing adhesive 27 used in the example was applied to the back stitch surface (29) of the tufted original fabric 23 used in the example, and a comparative example was applied to the coated surface 26. The secondary base fabric 17 (burlap woven fabric 31) was superposed, passed through a heat-dried pin tenter at 120 ° C., and the backing adhesive 27 was heat-dried to finish the tufted carpet 10 (FIG. 8).

(Evaluation)
In the peel test specified in JIS-L-1021 (9), the peel resistance of the secondary base fabric of the tufted carpet of the embodiment of the present invention (FIG. 4) is 47.1 N / 5 cm in length and 53.8 N in width. The peel-resistant strength of the secondary base fabric of the tufted carpet of the comparative example (FIG. 8) is 35.1 N / 5 cm in length and 42.3 N / 5 cm in width, whereby the tufted carpet of the present invention. The peel resistance was evaluated higher than the peel resistance of the tufted carpet of the reference example.

  The secondary base fabric 17 of the present invention can be diverted to a wall-covered fabric, a cover fabric, a packaging material, and the like by mixing the fiber web 12 with a heat-adhesive binder filament.

10: Tufted carpet 11: Woven fabric 12: Web 13: Fluff layer 14: Weft 15: Warp 16: Cloth gap 17: Secondary base fabric 19: Woven yarn 20: Pile 21: Primary base fabric 22: Burlap 23: Tufted original fabric 24: Weft 25: Warp 26: Application surface 27: Backing adhesive 29: Back stitch 31: Burlap fabric 32: Filament 33: External coating 34: Internal coating 35: Buffer layer 36: Air space Lf: Weft repeat Lw: Warp repeat Sp: Crevice area St: Cloth area

Claims (5)

(A) It is comprised as a laminated body of a textile fabric (11) and a fiber web (12),
(B) For the weft (14) and warp (15) of the woven fabric (11), a hydrophobic synthetic fiber filament yarn having a long fiber structure continuous in the fiber axis direction is used,
(C) A set of adjacent warps is divided into warps (15a) and ground warps (15b) with one or more wefts (14) in between, and the split warps and ground warps A set of warp yarns (19) which are twisted before and after the weft yarns (14) to cross the weft yarns to bind the weft yarns (14);
(D) The woven fabric is woven by a woven fabric in which the silk thread (19) and the weft thread (14) are entangled,
(E) The fabric is formed with a fabric gap (16) surrounded by adjacent weft yarns (19, 19) and adjacent weft yarns (14, 14),
(F) The cloth gap in the unit cloth area (St) shown as the product of the repeat (Lw) between the adjacent weft threads (19, 19) and the repeat (Lf) between the adjacent weft threads (14, 14) The gap area occupation ratio (ε) occupied by the gap area (Sp) of (16) is 20% or more,
(G) The filament (32) of the fiber web (12) is not only the fabric gap (16) but also the individual weft yarns (14) by the punching process applied to the laminate from the fiber web (12) to the fabric (11). ) And warp yarn (15), the tufted carpet secondary base fabric which penetrates the entire fabric and forms a fluff layer (13) on the surface of the fabric (11). (H) The weft yarn (14) is a flat yarn having a flat cross-sectional shape including a split yarn or a multifilament yarn, and the warp yarn (15) is a flat yarn having a flat cross-sectional shape including a split yarn. The fiber web (12) 2. The filament (32) of the multifilament yarn forms a fluff layer (13) on the surface of the woven fabric (11) not only through the gaps between adjacent fibers of the multifilament yarn but also through the individual flat yarns. Tufted carpet secondary base fabric. The tufted carpet secondary base fabric according to any one of claims 1 and 2, wherein (i) the fiber web (12) contains a heat-adhesive polymer. (1) The above-described claims 1 and 2, wherein the fluff layer (13) faces the application surface (26) of the backing adhesive (27) applied to the back stitch (29) of the tufted original fabric (23). 3 is bonded to the tufted original fabric (23),
(2) The inner film (34) in which the filament (32) of the fluff layer (13) and the adhesive (27) for lining are naturally integrated on the critical surface of the back stitch (29) and the secondary base fabric (17). ) Is formed,
(3) Tufted carpet in which the fabric (11) is pressed against the internal coating (34) by the fiber web (12) through the filament (32) penetrating the entire fabric. (4) The backing adhesive (27) penetrates the fabric (11) and penetrates into the fiber web (12),
(5) On the critical surface of the woven fabric (11) and the fiber web (12), an outer coating (33) is formed in which the backing adhesive (27) and the filament of the fiber web (12) are united. ,
(6) The tufted carpet according to claim 4, wherein the fabric (11) is pressed against the internal coating (34) by the external coating (33) through the filament (32) penetrating the entire fabric.

Images