JP2683373B2 - Terminal-treated carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention relates to a carpet subjected to terminal treatment for use in automobiles, houses, buildings and the like.

INDUSTRIAL APPLICABILITY The carpet according to the present invention is effective as, for example, a deck carpet arranged on a rear floor behind a rear seat of an automobile and a trunk carpet arranged on a floor of a trunk of an automobile.

[Prior Art] Conventionally, in a carpet such as a deck carpet used in an automobile, as shown in FIG.
It is known that the peripheral edge portion of 100 is subjected to an overlock thread 102 with an overlock thread 102, which is end-processed by overlock processing, that is, edging. In this way, the carpet that has been terminal-treated by overlocking is
It is possible to effectively prevent the pile yarn 103 in the peripheral portion of 0 from fraying, and also to ensure the appearance.

[Problems to be Solved by the Invention] By the way, in the above-mentioned carpet which is overlocked with the overlock yarn 102, the overlock yarn is
The 102 may be scratched or the overlock thread 102 may be broken due to the influence of frictional heat. In this case, the pile yarn 103 of the carpet body 100 is frayed from that portion. Thus, once the overlock yarn 102 is frayed, it spreads to the overlock yarn 102 of the entire carpet, and there is a problem that the terminal processing function of the overlock process is hindered.

The present invention has been made in view of the above problems, and an object thereof is to provide a terminal-treated carpet that is effective in preventing fraying of the peripheral edge of the carpet body.

[Means for Solving the Problem] As a result of intensive research on the end treatment of a carpet whose main material is a thermoplastic fiber, the present inventor melted and crushed the thermoplastic fiber in the peripheral portion of the carpet with a hot press type. Then, it was found that forming the flat crushed portion in a wide shape on the peripheral edge of the carpet is effective in preventing fraying of the peripheral edge of the carpet. However, in the case of a carpet in which a flat surface crushed portion is crushed in a wide state by a heat press type, a warp of about 1 to 3 mm occurs at the peripheral edge of the carpet, and when the carpet is laid on the floor, the floor and the carpet peripheral edge are There was a problem that a gap was created between the two and impaired practicality.

Therefore, as a result of further intensive research by the present inventor, a terminal molding portion having a structure in which thermoplastic fibers are cohesively bonded in a semi-molten state is provided on the peripheral portion of the carpet, and a flat crushed portion is provided inside the terminal molding portion. It was found that by arranging them in parallel, it is effective in preventing the fraying of the carpet, and moreover, the warp of the carpet can be suppressed so as not to hinder the practical use. The reason why the warp can be suppressed is not necessarily clear, but that the terminal molding part having a structure in which the thermoplastic fibers are cohesively bound in a semi-molten state is provided in parallel with the flat crushing part, and the terminal molding part is a kind. It is presumed that it has a rib effect. The present invention has been completed based on the above findings.

That is, the terminal-treated carpet according to the present invention,
Carpet main body mainly composed of thermoplastic fibers, at least a single terminal molding portion provided on the peripheral portion of at least one surface of the front and back surfaces of the carpet main body, wherein the thermoplastic fibers are cohesively bound in a semi-molten state, and terminal molding It is characterized in that it comprises a flat crushed portion which is located inside the portion and is provided in the carpet body in a continuous state or an interrupted state and in which thermoplastic fibers are crushed in a semi-molten or molten state.

The carpet body may be a tufted carpet, a needle punched carpet, or another type of carpet, as long as it has thermoplastic fibers as a main material. As the thermoplastic fiber, for example, nylon fiber, polyester fiber, polypropylene fiber or the like can be adopted. The carpet body may be formed of only the carpet material, or the backing layer may be formed on the back surface of the carpet material.

The terminal molding portion is a portion where thermoplastic fibers are cohesively bound in a semi-molten state by heat and are molded into a predetermined shape. Therefore, in the terminal molding portion, usually, the thermoplastic fibers are partially melted and the outer surfaces of the fibers are welded to each other, and the fibers themselves substantially remain. As means for forming the terminal molding portion, for example, welding by hot pressing,
Ultrasonic welding, high frequency welding, etc. can be adopted. The terminal molding portion may have a lateral cross-section, and may have a molding shape in which the surface is a curved surface bulging in an arcuate convex shape, as illustrated in Examples described later.

The flat surface crushed portion is located inside the terminal molding portion and is provided continuously or intermittently. The flat surface crushed portion is a portion in which the melting degree of the thermoplastic fiber is increased and the flat surface is crushed by a hot press mold or the like into a flat shape. The flat surface crushed portion can be formed by welding by hot pressing, welding by ultrasonic waves, or welding by high frequency, similarly to the terminal molding portion. In this case, the flat surface crushed portion and the terminal molding portion may be molded at the same time, or may be molded separately, but it is desirable to mold at the same time considering productivity and the like.

The processing temperature for melting the thermoplastic fibers is preferably in the range of -60 ° C to + 60 ° C with respect to the melting temperature of the thermoplastic fibers. For example, when the thermoplastic fiber is polypropylene fiber, the treatment temperature is preferably about 120 to 130 ° C, and when it is nylon fiber or polyester fiber, the treatment temperature is preferably about 200 to 230 ° C.

In addition, the width dimension of the terminal molding portion, the width dimension of the flat crushing portion,
The width of the terminal molding portion is 3 to 20 although it is appropriately set depending on the material of the thermoplastic fiber, the use of the carpet, etc.
mm, and the width dimension of the flattened portion can be 1 to 5 mm.

[Embodiment] An embodiment of the carpet of the present invention will be described with reference to Figs.
A specific description will be given with reference to FIG. The present embodiment is applied to a deck carpet. The carpet manufacturing process is shown in FIG. 1, the state of the main part of the manufacturing process is shown in FIG. 2, the perspective view of the entire deck carpet is shown in FIG. 3, and the perspective view of the main part of the deck carpet is shown in FIG. FIG. 5 shows a view taken along the line VV of FIG.

In this embodiment, as shown in FIG. 1, the carpet body 1 is composed of a carpet material 10 and a backing layer 11 attached to the back surface of the carpet material 10. Carpet
10 is formed by punching polypropylene fibers 13 as thermoplastic fibers with a needle punch and entwining polypropylene fibers 13 with SBR latex. Therefore, in the carpet material 10, the polypropylene fibers 13 are napped as shown in FIG. The backing layer 11 is formed by coating a polyethylene film (300 g / m ² ) on the back surface of the carpet material 10.

As shown in FIG. 4, the terminal molding portion 2 is continuously wound around the peripheral portion of the surface of the carpet body 1. A cross section of the terminal molding portion 2 is shown in FIG. Fifth
As shown in the figure, the terminal molding portion 2 is formed by only partially melting the outer surface of the polypropylene fiber 13 as the thermoplastic fiber of the carpet material 10 and binding the polypropylene fibers 13 in a semi-molten state in an aggregated state. Has been done. The terminal molding portion 2 has a molding shape. That is, as seen in its cross section, the upper surface 20 is an arcuate convex surface which bulges upward as shown in FIG. The width L1 of the terminal molding portion 2 is 10 mm.

Further, as shown in FIG. 5, a flat surface crushed portion 3 is continuously bored along the terminal molding portion 2 inside the terminal molding portion 2. The flat surface crushed portion 3 is a portion in which polypropylene fibers are melted and strongly pressed to be crushed, so that the flattened portion is thinner than the terminal molded portion 2. The width L2 of the flattened portion 3 is 2 mm.
It is.

Now, an apparatus used in the carpet manufacturing method according to this embodiment will be described. In this case, as shown in FIG.
The upper surface plate 50 and the lower surface plate 51 are used. The upper surface plate 50 is provided with a processing die 52 for hot pressing. A heater is built in the processing mold 52, and the processing mold 52 is heated by the heater. As shown in FIG. 2, the processing mold 52 has a sharp trim blade 53, a flat surface portion 54, a trim blade 53 and a flat surface portion.
54 and an arcuate concave surface 55 located between them. Here, the arcuate concave surface 55 is recessed with a predetermined curvature by a dimension M (see FIG. 2) than the flat surface portion 54. As shown in FIG. 1, the upper surface 57 of the lower surface plate 51 is a flat surface.

Next, a method of manufacturing the carpet according to this embodiment will be described. First, as shown in FIG. 1, the carpet main body 1 is unwound from the wound body W in which the carpet main body 1 is wound in multiple layers, and the heater of the processing mold 52 is heated so that the processing mold 52 is
The rewound carpet body 1 is positioned between the lower surface plate 51 and the upper surface plate 50 in a state where the temperature is increased to about 0 to 130 ° C. In this state, the upper surface plate 50 is lowered to heat press the carpet body 1.

When the carpet main body 1 is hot-pressed by the heating mold 52 thus heated, as shown in FIG. 2, a portion of the carpet material 10 which is hot-pressed by the flat portion 54 of the processing mold 52 is Since the polypropylene fiber 13 is melted and is strongly pressed and crushed, the flat crushed portion 3 is formed.

Further, the arc concave surface 55 of the processing mold 52 of the carpet material 10
Since the pressure of the heat-pressed portion is smaller than that of the flat portion 54 of the processing portion 52, the polypropylene fibers 13 are bound to each other in a semi-molten state, whereby the molding terminal molding portion 2 Becomes

When heat-pressed in this manner, the trim blade 53 causes the carpet material 10 of the carpet body 1 to have a predetermined size,
Trimmed to a predetermined shape. FIG. 2 shows a state where the processing mold 52 is raised after the carpet main body 1 is trimmed by the processing mold 52.

Unlike the conventional carpet, the carpet according to the above-described embodiment is not subjected to the overlock processing by the overlock yarn 102, so that the problem that the fray of the overlock yarn 102 spreads to the entire carpet can be solved. In the present embodiment, even if the terminal molding portion 2 is unraveled partially due to child's mischief or the like, it is possible to prevent the fraying from remaining in that portion and spreading to the entire terminal molding portion 2.

Furthermore, the carpet according to this example was laid on the floor surface and the warp thereof was examined, but there was almost no warp of the carpet. The reason why the warp can be suppressed is not necessarily clear, but the terminal molding portion 2 is formed by binding the polypropylene fibers 13 to each other in a semi-molten state, and the terminal molding portion 2 has a molding shape. It is inferred that it has a rib effect.

By the way, when the peripheral edge of the carpet is overlocked with the overlock yarn 102 as in the conventional case,
It is difficult to completely match the color of the overlock yarn 102 with the color of the carpet, and even if the same color is used, they do not practically match. In this respect, in this embodiment, since the carpet main body 1, the terminal molding portion 2 and the flat crushing portion 3 are made of the same material, color matching is easy and appearance can be secured.

Further, in this embodiment, in the step of pressing with the processing mold 52, three operations of forming the end forming portion 2, forming the flattened portion 3 and trimming step are performed simultaneously, thus simplifying the processing step and shortening the processing time. Is advantageous to.

[Other Embodiments] In the above-described embodiments, the terminal molding portion 2 has a structure in which the terminal molding portion 2 is wound around the peripheral edge portion of the carpet main body 1 in a single layer. However, instead of this, in the other embodiment shown in FIG. As described above, the terminal molding portion 2 may be doubled around the peripheral edge portion of the carpet body 1. In this case, the flat crushing portion 3 is formed between the terminal molding portions 2 that are adjacent to each other.

Furthermore, as in the other embodiment shown in FIG. 7, the terminal molding portion 2 may be tripled around the peripheral edge portion of the carpet main body 1 and attached. In this case as well, the flat surface crushed portion 3 is formed between the terminal molding portions 2 adjacent to each other.

Further, in each of the above-described embodiments, the terminal molding portion 2 is continuously wound around the peripheral edge portion of the carpet body 1, but the present invention is not limited to this, and the flat surface crushing portion 3 is provided as in other embodiments shown in FIG. It may be formed intermittently.

Others The present invention is not limited to the embodiments described above and shown in the drawings, but can be implemented with appropriate modifications without departing from the scope of the invention.

[Advantages of the Invention] According to the carpet subjected to terminal treatment according to the present invention, it is effective in preventing fraying of the carpet peripheral portion, and the problem of warpage can be improved.

[Brief description of the drawings]

1 to 5 show an embodiment of the present invention, FIG. 1 is a schematic side view showing a manufacturing process, and FIG. 2 is a schematic side view showing a state in which a processing mold obtained by trimming a carpet is raised. FIG. 3 is a perspective view of the entire deck carpet, FIG. 4 is an enlarged perspective view of a main portion of the deck carpet, and FIG. 5 is a view taken along the line VV of FIG. It is a figure which shows typically a terminal molding part and a plane crushing part. FIG. 6 shows another embodiment of the present invention, and is a schematic cross-sectional view of the main part of the carpet. FIG. 7 shows another embodiment of the present invention, which is a schematic cross-sectional view of the main part of the carpet. ,
FIG. 8 is a partial plan view of a carpet showing still another embodiment. FIG. 9 is a partial perspective view of a conventional carpet. In the figure, 1 is a carpet body, 10 is a carpet material, 11 is a backing layer, 13 is polypropylene fiber (thermoplastic fiber), 2 is a terminal molding portion, 20 is an upper surface, and 3 is a flat crushing portion.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yukio Chano 1-1, Shimoineba, Sotowara, Kisogawa-cho, Haguri-gun, Aichi Prefecture Inside Toyota Kako Co., Ltd. (56) Reference JP-A-60-22539 (JP, A) ) Actually open 54-127339 (JP, U) Actually open 51-82239 (JP, U) Actually open 49-8008 (JP, Y1)

Claims (1)

(57) [Claims] 1. A carpet body containing thermoplastic fibers as a main material, and at least a single layer of a carpet body provided on the peripheral portion of at least one of the front and back surfaces of the carpet body, wherein the thermoplastic fibers are cohesively bound in a semi-molten state. It comprises a terminal molding portion and a plane crushing portion which is located inside the terminal molding portion and which is provided in the carpet body in a continuous state or an intermittent state and in which the fibers are crushed in a semi-molten state or a molten state. A terminal-treated carpet characterized in that