JP2684156B2 - Bonding method for hot carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a hot carpet or hot mat having a heat ray and a detection ray (hereinafter collectively referred to simply as "heat ray") between a surface layer and a back layer (in this specification, a hot carpet is a generic term. The present invention relates to an advantageous method for forming an adhesive.

[0002]

2. Description of the Related Art Conventionally, in the production of hot carpets, a heating wire is wrapped as a unit with a non-woven fabric, and a liquid adhesive such as urethane resin is sprayed on the front layer and the back layer by spraying. It has been practiced to sandwich them between the front and back layers and bond them from above and below by hot pressing.

[0003]

However, in the above-mentioned bonding method, since liquid adhesive such as urethane resin is sprayed on both the front layer and the back layer, it requires manpower and funds to manage and maintain the spray material. Further, since the hot pressing time is long, the adhesion efficiency is poor and the productivity of hot carpet production cannot be improved. Further, the liquid adhesive such as urethane resin has a risk of causing environmental problems such as safety and health and pollution.

The present invention has dealt with the above-mentioned situation and found that a hot melt sheet material is temporarily fixed to a non-woven fabric in advance, so that only a pressure bonding by a hot press can be performed without using a liquid adhesive such as urethane resin. The purpose of the present invention is to improve the productivity by shortening the pressure-bonding time and the labor required for the hot carpet bonding, and thereby improving the productivity.

[0005]

That is, the features of the method of the present invention which meet the above-mentioned object are that a surface layer made of a synthetic fiber non-woven fabric obtained by adhering and fixing a heat ray with an adhesive in the formation of adhesion of a hot carpet, and a spider web. -Shaped hot melt sheet is attached to the surface and a backing layer made of synthetic fiber non-woven fabric is polymerized with the heat wire side and spider web-like hot melt sheet side as the inner surface side, and heat and pressure are applied from a heat press to bond them together. It is to incarnate. Then, be secured lightly by needling to the hot-melt sheet presses the fluff of the nonwoven fabric surface when to fasten the hot melt sheet to the back layer of synthetic fiber non-woven fabric, heating by or hot pressing, pressure It is also an important feature to spray normal temperature water on the upper surface of the surface layer in advance .

Here, a part of the low melting point synthetic fibers is mixed with the synthetic fibers constituting the back layer nonwoven fabric, and at the time of heating and pressurizing with a hot press, at least a part of the low melting point synthetic fibers is melted and fused. It is more advantageous to increase the adhesive strength.

Further, according to the present invention, a back layer non-woven fabric including a part of the low melting point synthetic fiber is formed, a part of the low melting point synthetic fiber in the non-woven fabric is melted, and the cobweb type hot melt sheet is melted. It is also preferable to fuse it to the surface so as not to penetrate into the non-woven fiber, which is very effective for improving the adhesiveness of the front and back layers.

[0008]

In the above-mentioned forming method according to the present invention, the surface layer to which the heat wire is adhered and fixed, and the non-woven fabric back layer lightly fastened with the spider web-like hot melt sheet on one side are treated with the heat wire and the spider web-like hot melt. By heat-pressing each sheet as the inner surface side, it is possible to easily bond without using a liquid adhesive as in the past, reducing the number of steps required to bond the conventional hot carpet and shortening the time required for product production. At the same time, by not using liquid adhesive, safety and hygiene and working environment can be improved.

Further, when fixing the hot melt sheet,
To prevent fluff on the surface and fix it, or to mix low melting point synthetic fiber into the non-woven fabric, and to bond it to the non-woven fabric surface so that the cobweb hot melt sheet does not melt and penetrate, hot melt It is possible to more effectively exert the adhesive ability of the sheet. In addition, heat press
Room temperature water can be sprayed with room temperature water prior to heat and pressure.
Becomes water vapor and penetrates inside the surface layer, giving a moist heat effect,
Make the effect of heat pressing more effective.

[0010]

Embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a cross-sectional explanatory view showing an example of a joining mode of a hot carpet formed by the method of the present invention. In FIG. 1, 1 is a surface layer made of synthetic fiber nonwoven fabric containing synthetic fibers as a main component, and 2 is the surface layer 2. On one surface, the heat wire adhered to the lower surface side in the figure, 3 is one surface of the synthetic fiber non-woven fabric forming the back layer 4, and in the drawing, the fluff is not attached to the surface so that it does not come off These are hot-melt hot-melt sheets, which are heated and pressed by a heat press with the heating wire 2 and the hot-melt web 3 as inner surfaces, respectively, to melt the hot-melt web. The front and back layers 1 and 4 are bonded and integrated, and the heating wire 2 is sandwiched between the front and back layers 1 and 4 to prepare a hot carpet.

2 to 4 show a step of joining the front layer 1 and the back layer 4 in the process of manufacturing the above-mentioned hot carpet. Since the heat wire 2 is separately adhered and fixed to the front layer 1 with an adhesive. In FIG. 2, the step of attaching the web-shaped hot melt sheet 3 to the back layer 4 is illustrated.

That is, as in the case of the surface layer 1, a fiber web having a basis weight of 200 to 500 g / m ^{2 is} generally used as a base layer, and a needling 7, which alternates from above and below, is used as a base layer.
8 is applied to form the non-woven fabric of the backing layer 4, and at the same time as the needling process, the web-shaped hot melt sheet 3 is fed out through the tension rod 5 and the wrinkle prevention guide 6 to one surface thereof, and polymerized. Then, the needling 9 is applied to the back layer 4 and the back layer 4 is fixed to one surface of the non-woven fabric.

Known synthetic fibers such as polyester, nylon, acryl and polypropylene can be used as the synthetic fibers forming the non-woven fabric of the front layer 1 and the back layer 4, and polyester, nylon and the like are not necessarily limited to one kind, and can be thick. Two or more types having different lengths, lengths and properties are used. Above all, it is practical to mix and use polyester fibers having different lengths and thicknesses.

The web-shaped hot melt sheet 3 usually has a basis weight of 30 to 70 g / m ² , preferably 20 to 4.
It is a thin non-woven fabric of about 0 g / m ² and has a spider web structure, and has a melting point of approximately 110 ° C. to 160 ° C. and is generally made of a modified polyamide fiber.

Of course, other than the non-woven fabric made of the modified polyamide fiber, any hot-meltable sheet can be used. The spider web-shaped hot melt sheet 3 is fixed to one surface of the nonwoven fabric of the backing layer 4 made of the fiber web, but the hot melt sheet 3 is not embedded in the fiber layer of the nonwoven fabric, and It is attached to such a degree that it does not come off and presses the fluff on the surface of the nonwoven fabric, in other words, temporary fastening.

The purpose of fixing without fluffing is to increase the adhesive strength and reduce the bonding time when bonding by subsequent hot pressing or the like. So that there is no fuzz on the surface
In addition, in order to prevent temporary peeling and lamination, a needling is required for lamination, and the number of implants is 20 to 35 / cm.
² , preferably around 30 needles / cm ² with a needle penetration depth of 10-1
It is effective to perform needling under the condition of about 2 mm.

If the number of implants is too large, or if the depth of penetration exceeds 12 mm, the hot melt sheet 3 is embedded in the nonwoven fabric fiber layer, and fluff tends to stick out on the surface. Reduce the power.

On the other hand, it is not preferable that the number of punches is small and the penetration depth is less than 10 mm, because the hot melt sheet 3 is likely to peel off from the nonwoven fabric 1.

The above is the case where the fibers constituting the fiber web are ordinary synthetic fibers, but it is also effective to partially mix the synthetic fibers constituting the fiber web with a low melting point synthetic fiber.

FIG. 3 shows an example in which such a low melting point synthetic fiber is partially mixed to form a nonwoven fabric for the back layer 4.

This is because a part of the low melting point synthetic fiber is melted by subsequent heating to enhance the anti-pill property, and as shown in FIG. After wearing, it is passed through the heating device 10 for the melting process,
By utilizing this melting step, the cohesive web-like hot-melt sheet 3 which is fixed and composited is fused and wound on the surface of the backing layer 4 so as not to be melted and permeated into the nonwoven fabric layer. In this case, the melting step usually uses a dryer or the like in a backing device for backing the resin. The heating device 10 is this dryer.

A suitable temperature in the heating device 10 is about 15.
It is 0 to 190 ° C., does not penetrate into the non-woven fabric fiber of the backing layer 4, and by bonding the web-like hot melt sheet to the non-woven fabric surface, the adhesive force is increased in the hot press in the next step, and the adhesion time is shortened. can do. The heat treatment time is 40 to 45 seconds. As the low melting point synthetic fiber mixed in the fiber web, known fibers such as low melting point nylon, polyester and polypropylene can be used, but the most practical one is the low melting point (melting point 110 ° C to 160 ° C). It is a polyester fiber (PET fiber).

The mixing ratio of the low-melting synthetic fibers may be changed depending on the kind of hot carpet and the bonding conditions of the hot press machine after that, so that the surface is not fluffed by the above-mentioned needling without passing through the above-mentioned melting step. There is no problem in using the spider web-shaped hot melt sheet as the temporarily fixed back layer 4.

The back layer 4 thus fixed to the web-shaped hot melt sheet formed as described above is polymerized with the surface layer 1 of the hot carpet and subjected to the next hot pressing step and heated by the hot pressing machine. Pressed, glued together and made into a hot carpet.

FIG. 4 shows a case in which the front and back layers 1 and 4 are adhered to each other by using the press of the hot press machine to prepare a hot carpet. In FIG. 4, 11 is an upper hot platen.
12 is a lower heating plate, and the heating plate temperature is 180 ° C to 200 ° C. Also, 13 and 14 are spacers, and spacer 1
The gauge thickness of 3, 14 is usually about 6 to 7 mm, which is narrower by about 0.5 to 1.0 mm than the total thickness of the surface layer 1 and the back layer 4, and the heat wire 2 is formed on the surface layer 1 by an adhesive. It is fixed.

On the other hand, the above-mentioned nonwoven fabric is used for the back layer 4, and the web-like hot melt sheet 3 is temporarily laminated on the inner surface side.

Therefore, when the upper heating plate 11 is lowered to the upper surfaces of the spacers 13 and 14 from the state shown in FIG. 4 and stopped, the thickness of the spacers 13 and 14 is 6 to 7 mm, which is 0.5 to 0.5 from the total thickness of the surface layer 1 and the back layer 4. Since it is 1.0 mm narrower,
By the difference, the upper and lower heating plates 11 and 12 cause the front layer 1 and the back layer 4 to reach 160 to 60 degrees from the upper surface of the front layer 1 and the lower surface of the back layer 4, respectively.
Heated to a temperature of 200 ° C, usually 180 ° C to 200 ° C,
Pressed at the same time. Press time is usually 15-40 seconds,
It is preferably about 20 seconds, and the surface layer 1 is formed by this hot pressing.
The back layer 4 and the back layer 4 are completely adhered by the web-shaped hot melt sheet 3 to obtain a hot carpet containing the heating wire 2.

[0029] Incidentally, the surface layer 1 and the back layer 4 16~60g / m ² in advance from the upper surface of the surface layer 1 before setting the press machine, if sprayed with cold water at a ratio of 50 g / m ^2-position, Room temperature water sprayed by a hot press at 180 ° C. to 200 ° C. turns into water vapor, permeates into the surface layer, and gives a great effect by applying moist heat. Large peel strength can be obtained even by hot pressing.

In particular, since the fluff of fibers is not formed on the surface of the cobweb-shaped hot melt sheet 3 which is fastened to one surface of the backing layer 4 and is temporarily laminated, the cobweb-shaped hot melt sheet is formed by hot pressing. 3 is not hindered by fluff,
It has the effect of being able to sufficiently exhibit the bonding ability.

Next, the adhesion data of the front and back layers of the hot carpet with the urethane resin and the adhesion data using the web-like hot melt sheet according to the present invention are shown in Table 1 in comparison. Below margin

[0032]

[Table 1]

[0033]

INDUSTRIAL APPLICABILITY As described above, according to the present invention, in the production of hot carpets, in particular, in the formation of an adhesive, a spider web-like hot melt sheet is formed by a needling process on-line in the needling process. To prevent the hot melt sheet from sticking to the surface so that the hot melt sheet does not melt and penetrate into the fiber layer in the heat treatment step, and to prevent fluff from forming on the surface of the hot melt sheet, use the hot melt sheet. It is sent to the hot pressing step in a state where it is fused to the back layer nonwoven fabric surface, and is formed by joining it to the surface layer of the hot carpet,
The use of spider web-shaped hot melt sheets does not require the use of liquid adhesives as in the past, but simply hot pressing can produce hot carpet joint products, and also provides strong adhesion and adhesion. It has a remarkable effect that the work environment can be improved and the number of workers can be reduced while improving the process environment.

Further, the present invention improves the adhesion effect during hot pressing by spraying normal temperature water on the upper surface of the surface layer, shortens the pressure bonding time of the hot pressing machine, and improves productivity by 5 times or more as compared with the conventional method. The peeling strength can be enhanced and the product quality can be improved.

[Brief description of the drawings]

FIG. 1 is one of the joining modes of the hot carpet according to the present invention.
It is a partial cross-sectional schematic diagram which shows an example.

FIG. 2 is a schematic explanatory view showing a composite material manufacturing step of combining a spider web-shaped hot melt sheet with a back layer side nonwoven fabric in the present invention.

FIG. 3 is a schematic view showing a part of the manufacturing process of the nonwoven fabric composite material of FIG. 2 (after the heating process).

FIG. 4 is an explanatory view showing a hot carpet joint formation state according to the present invention.

[Explanation of symbols]

 1 Surface layer 2 Heat wire 3 Spider web hot melt sheet 4 Back layer 7,8,9 Needling 10 Heating device 11 Upper heating plate 12 Lower heating plate 13,14 Spacer

Claims (2)

(57) [Claims] 1. A surface layer made of a synthetic fiber non-woven fabric obtained by adhering and fixing a heating wire with an adhesive, and a cobweb-shaped hot melt sheet fixed to the non-woven fabric surface by needling so as to press the fluff on the non-woven fabric surface. The backing layer consisting of the synthetic fiber non-woven fabric is polymerized with the heat wire side and the spider web-like hot melt sheet side as the inner surface side, respectively, and after spraying room temperature water on the upper surface of the surface layer, heat and press with a hot press to bond them together. A method for forming an adhesive on a hot carpet, which is characterized by: 2. A layered composite comprising a surface layer made of a synthetic fiber nonwoven fabric obtained by adhering and fixing a heating wire with an adhesive, and a synthetic fiber nonwoven fabric containing a low melting point synthetic fiber, one surface of which is a spider web hot melt sheet. A part of the low melting point synthetic fiber in the non-woven fabric is melted, and the back layer is fused to the surface so that the cobweb hot melt sheet does not melt and penetrate into the non-woven fabric fiber. The upper side of the surface layer is polymerized with the side of the spider web-shaped hot melt sheet as the inner side.
After spraying room temperature water on, heat and press with a hot press,
A method for forming an adhesive on a hot carpet, characterized in that the adhesive is integrated.