JP2727097B2 - Rug - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a rug having good water permeability used in a veranda, a terrace, a bathroom, or the like.

[Conventional technology]

For conventional rugs, pile yarn is tufted or needle-punched onto a primary backing such as woven fabric such as hemp yarn or polypropylene slit yarn or a spunbonded non-woven fabric, and a secondary backing is applied on the back surface to prevent hair protection and reinforce. Adhesion with a binder such as rubber thread latex or lamination of a polyethylene sheet has been used.

[Problems to be solved by the invention]

Such conventional rugs have poor water permeability,
When used on a veranda or the like, there is a drawback that the rain that falls falls on the rug for a long time.

[Means for solving the problem]

The present inventor has conducted intensive studies to solve the above-mentioned problems of the conventional rug, and as a result, used a mesh material made of a heat-adhesive composite monofilament for a primary fabric or a secondary fabric, or a primary fabric and a secondary fabric. The present inventors have found that the intended purpose can be achieved by fusing and fixing the base of the pile yarn to this net by heat treatment, and have completed the present invention.

The heat-adhesive composite monofilament used in the present invention is composed of two types of thermoplastic resins having different melting points of 10 ° C. or more, preferably 20 ° C. or more. As a result, a composite yarn having a fineness of 150 to 8000 d / f, preferably 200 to 4000 d / f is used. When the melting points of the two types of thermoplastic resins are 10 ° C. or higher, the high melting point component of the heat-adhesive composite monofilament forms the base fabric without losing the fiber shape by the heat treatment described below, and the low melting point component is pile yarn by fusion. Can be fixed. Such thermoplastic resin combinations include polypropylene / polyethylene,
Examples thereof include polypropylene / ethylene vinyl acetate copolymer, polyester / polyethylene, polyester / copolyester, and nylon 6 / nylon 66. If the fineness of such a monofilament is less than 150 d / f, thread breakage of the base fabric is likely to occur at the time of flocking, and the quality of the rug deteriorates.
On the other hand, if the fineness exceeds 8000 d / f, the monofilament becomes stiff and weaving becomes difficult.

The above-mentioned heat-adhesive composite monofilament is driven 5 to 50
/ 25 mm, knitted or woven, and heat-bonded the intersections of the filaments using a hot-air drier or a hot calender roll, etc., to obtain a mesh used in the present invention.
The optimum value of the number of driving differs depending on the fineness of the monofilament. However, when the number is too large, the water permeability of the rug decreases, and when the number is too small, the ability to fix the pile yarn is reduced.

The method of implanting pile yarns into the mesh material or the primary backing according to the prior art is by a known method such as tufting or needle punching. As the pile yarn, any of natural fibers and synthetic fibers may be used as long as the pile yarn does not deteriorate by the heat treatment described below. The net-like material is laminated as a secondary base fabric on the back surface of the planted primary base fabric, and heat-treated at a temperature between the melting points of two types of thermoplastic resins constituting the heat-adhesive composite monofilament. For the heat treatment, known devices such as a hot air dryer and a hot calender roll can be used alone or in combination. When the primary base fabric is a net made of a heat-adhesive composite monofilament, the use of the secondary base fabric can be omitted.

〔The invention's effect〕

The rug of the present invention has good water permeability or air permeability because no binder coating or polyethylene lamination is performed,
In addition, since the base of the pile yarn is fixed to the primary or secondary base fabric or both the primary and secondary base fabrics by the fusion of the low melting point component of the heat-adhesive composite monofilament, the pullout strength is reduced. large. Furthermore, the mesh used for the base cloth is a thick fiber (monofilament) made of thermoplastic resin.
Since the rugs are fused and fixed to each other at the intersections, the obtained rug can be formed into a corrugated shape, a box shape, or the like by a method such as hot press molding.

〔Example〕

The present invention will be described more specifically with reference to examples and comparative examples. The physical properties of the rug were measured by the following methods.

Thread pulling strength: Measured according to the method of measuring pile thread pulling strength in JIS L 1021.

Peel strength: Measured according to JIS L 1021 for measuring the peel strength of a backing material.

Permeability: A test specimen of 15 cm x 15 cm is placed horizontally on a 6 cm diameter funnel and a beaker is placed under the funnel. Add 25 ml of water from a buret whose tip is in contact with the center of the sample.
Allow to flow over a period of 30 minutes. After standing for 30 seconds, weigh the water remaining in the peaker.

Air permeability: According to the Frazier method of JIS L 1018.

[Base cloth] A thermoadhesive monofilament (fineness of 25) with a composite ratio of 50/50 using crystalline polypropylene (melting point 169 ° C) as a core component and high-density polyethylene (melting point 131 ° C) as a sheath component.
0, 500, 1000, 5000 d / f) to make various plain weaves, 1
The resultant was treated with a hot air dryer at 36 ° C. to obtain a net-like material in which the intersections of the filaments were fused. The structure of these nets is
It is shown in the table. Further, a web obtained by spinning crystalline polypropylene by a spun bond method was treated with a hot calender roll at 140 ° C. to obtain a nonwoven fabric. The structure of this is the first
Also shown in the table.

[Pile yarn] (A) Polypropylene bulky processed yarn (2000
d / 136f), (B) polypropylene flat yarn (2000
(d / f) and (C) wool (four counts of four-count double yarns were bundled).

Examples 1-3 Using nets a, b and d shown in Table 1 as a primary base fabric, using a bulky polypropylene yarn A as a pile yarn, tufting with a 1/10 inch gauge tufting machine, hot air penetration type Heat treatment was performed at 140 ° C. for 110 seconds using a heat treatment machine to obtain a cut pile carpet having a basis weight of 420 g / m ² . Table 2 shows the physical properties of this carpet.

Examples 4 to 7 The nets c and d shown in Table 1 were used as primary base cloths and tufted with variously changed pile yarns, pile shapes, gauges and pile lengths. Heat treatment is performed by a heat treatment machine, and a net d is laminated on the back surface as a secondary base fabric.
Heat treatment was performed at 4 ° C. and a linear pressure of 15 kg / cm) under the conditions of 3 m / min to obtain a rug of the present invention. The physical properties of these rugs are shown in Table 2.

Examples 8 to 11 The spunbonded nonwoven fabric e shown in Table 1 was used as a primary base fabric, and a polypropylene bulky yarn A or a wool spun yarn C was used as a tuft. The rugs were laminated as a base cloth and treated with a heat calender roll (157 ° C. only on the secondary base cloth side, a linear pressure of 2525 kg / cm) at 5 m / min to obtain a rug of the present invention. The physical properties of these rugs are shown in Table 2.

Comparative Example 1 The spunbonded nonwoven fabric e was used as the primary base fabric, the polypropylene bulky yarn A was piled as a pile yarn, tufted with a 1/10 inch gauge, and the back surface was coated with 98 g / m ² of SBR latex by weight after drying. And dried with a hot air dryer at 110 ° C. to obtain a rug without a secondary backing. Table 2 also shows the physical properties of the rug.

Comparative Example 2 Spunbonded nonwoven fabric e was used as a primary base fabric, wool spun yarn C was used as a pile yarn, tufted with a 5/64 inch gauge, and spunbonded nonwoven fabric e was SBRW-based latex (dry weight 98 g / m ² ) on the back surface. And dried with a hot air drier at 110 ° C. to obtain a conventional rug with a secondary base fabric. The physical properties of this rug are shown in Table 2.

From the results shown in Table 2, it can be seen that the rugs by the conventional method treated with the SBR latex on the back side (Comparative Examples 1 and 2) have high thread removal strength and peel strength, but low water permeability and air permeability. It can be seen that all of the rugs of the present invention have practically sufficient thread pulling strength and peel strength and good water permeability and air permeability. The rugs obtained in these examples were preferably used for verandas, entrance mats, artificial turf and the like.

Claims (1)

(57) [Claims] 1. A parallel type or a sheath-core type in which two kinds of thermoplastic resins having melting points different by 10 ° C. or more are formed so that the low melting point thermoplastic resin forms at least a part of the surface of the fiber continuously. The heat-adhesive composite monofilament with a fineness of 150 to 8000 d / f obtained by composite spinning into
Knitted or woven at 50 strands / 25 mm, the heat-fused mesh at the intersection of the monofilaments is used as a primary or secondary fabric, or as a primary and secondary fabric, A rug, wherein the base of the pile yarn is fixed to the mesh by fusing a low-melting component of a heat-adhesive composite monofilament.