JP3014132U - Rug with backing layer - Google Patents

Abstract

(57) [Summary] [Purpose] To provide a rug that does not have a pile on the surface and is stable and laid comfortably. [Constitution] The present invention relates to a rug, which is made of warp and weft, and has a pile-free cloth as a surface layer and a felt or a soft foam as a backing layer, and laminates both layers.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 An object of the present invention is to provide a rug which does not have a pile on the surface thereof and which is stable in laying down and which is comfortable to walk on.

[0002]

[Prior art]

 From the past, attempts to use pile-free cloth (plain weave) composed of only wefts and warps as rugs have been made for a long time, and even now, they are forming a large market. These plain woven fabrics were designed to give weight and tension to the woven fabrics by thickening the yarns used to give the rugs properness.

On the other hand, from the viewpoint that flat woven fabrics are insufficient in imparting sufficient physical properties (weight, tension, walking feeling) as rugs, woven fabrics using pile yarns such as corrugated carpets and carpets are used. It has been developed and used as a rug. The pile yarn as the third component added thickness and weight to the woven fabric to improve the walking sensation and to impart the physical properties of the rug.

Further, since the plain woven rug described above uses only thick yarn, it has the following two drawbacks as fundamental problems. (1) The walking feeling was poor because the thickness was thin and the elasticity was insufficient. (2) As the rug walks due to insufficient weight, the edges of the rug are curled, wrinkled, and displaced from the position where it was placed.

[0005]

[Means for solving problems]

 The gist of the present invention is a rug having a backing layer, which is characterized in that a fabric surface layer (hereinafter referred to as a plain weave) composed of warp and weft without a pile and a backing layer of felt or soft foam are laminated. Then, the above problems are solved.

The present invention will be described below with reference to the drawings. 1 and 2 are perspective views of the rug of the present invention. In Fig. 1, the plain weave 1 used for the surface layer is not the one used conventionally, and the materials used for the warp and weft are natural materials such as wool, cotton, silk and hemp, and Using yarns made of nylon, acrylic, rayon, polyester, polypropylene, etc., or blended yarns thereof, weaving textures include hand weaving, machine weaving, plain weave, twill weave, satin weave, ventilation weave, jacquard weave, etc. Things can be used.

The thickness of the thread constituting the plain fabric 1 used for the surface layer varies depending on the material and the constitution, but is preferably 1000 to 9000 denier (1 to 5 count), and the weave density of the plain fabric 1 is also Depending on the material and composition of the thread, 10-20 threads / inch is preferred. However, it is not particularly limited.

For the felt-like nonwoven fabric used as the backing material 2 laminated on the back surface of the plain woven fabric, any fiber can be used as a material, but a polyester material is preferable. A polyester material with a thickness of 5 to 20 denier is preferable because of its durability (elasticity retention) and low cost, and wool and cotton materials are also preferred because they provide a unique walking feeling. Particularly important are the basis weight (basis weight) and the thickness, preferably the basis weight is 80 to 800 g / m ² , more preferably 200 to 500 g / m ² , and the thickness is preferably 3 to 20 mm, further preferably Is 5 to 12 mm.

The felt-like nonwoven fabric is manufactured by, for example, a spunbond method, a press-fusion method, a needle punch method, etc. The needle punch method is most suitable for obtaining a backing material of the present invention having a large thickness and weight. ing. In this way, the rug 3 of the present invention is obtained.

In FIG. 2, 1 is a plain weave fabric and 4 is a foam backing layer. Examples of the backing material foam include synthetic rubber foams typified by styrene-butadiene rubber and synthetic resin foams such as polyurethane and polyvinyl chloride. Examples of the method for forming the foam layer include a mechanical foaming method in which air is mechanically mixed, and a chemical foaming method in which a foaming agent is mixed in advance with a resin composition and foamed by heating. good.

There is also a method in which the foamed layer obtained above is bonded to the fiber surface layer using an adhesive, or a liquid foamable composition is applied onto the fiber surface layer and then heated and gelled. There is also a method of forming a foam backing layer. As an embodiment of the present invention, a method of directly applying a mechanically foamed liquid resin to the back surface of the front fabric and heating and drying it to form a foam layer is preferable. When a textile fabric is used as a rug, the fabric is constantly subjected to strong abrasion and friction during walking, and the fibers often fluff, pull out, play hair, etc. When the body resin composition is applied, it partially penetrates into the warp and weft constituting the fibrous fabric used for the surface layer, and acts as a binder that binds the individual fibers constituting the yarn. It has the effect of suppressing fuzz and play hair. Particularly, when the yarns forming the warp and the weft are spun yarns (spun yarns) having a short fiber length, a remarkable effect is obtained. Furthermore, by appropriately selecting the thickness of the foam formed on the back surface and the foaming multiplication factor, a more excellent walking feeling can be obtained, and the rug can be prevented from curling up and shifting during walking.

[0012] The feeling of walking in the rug of the present invention is due to elasticity, and if the foaming ratio is increased, the elasticity is increased and the feeling of walking is improved, but if it exceeds a certain point, the elasticity is too high and the foot adheres to the ground. Without being unstable and fluffy, a so-called seasickness phenomenon occurs. When the magnification is further increased, the elastic recovery force decreases and the elasticity is lost, causing a so-called bottom feeling. Further, when the expansion ratio is low, elasticity is not obtained and the walking feeling is poor. In the present invention, the expansion ratio is preferably 2 to 15 times, and particularly, 3.5 to 6 times is particularly excellent in walking feeling. The backing layer preferably has a thickness of 2 to 20 mm, more preferably 4 to 12 mm, which gives a particularly good walking feeling. With the above thickness, the backing layer can prevent the edge of the rug from curling up and shifting due to its own weight.

An adhesive is used for laminating the front surface layer and the back surface layer. As this adhesive, the SBR latex composition (synthetic rubber) is the best in terms of compatibility with the fiber, but other urethane adhesives, EVA hot melt adhesives and the like can also be used.

[0014]

[Action]

 In order to improve the fundamental defect of the plain woven fabric used in the rug, the rug of the present invention reduces the weight of the entire rug by attaching the felt-like non-woven fabric or foam of the back layer to the plain fabric used for the front layer. And improve the feeling of walking. Further, by impregnating a plain fabric with the liquid foam and then drying it, play hair and hair loss are eliminated.

[0015]

【Example】

 (Example 1) Surface layer A: warp (material, 100% wool, thickness W4 / 6) weft (material, 100% cotton, thickness CC10 / 4) texture 12 warps / inch (12) weft 18 / Inch (18 steps)

[Table 1] Lining material (felt) experiment No material Denier Weight (g / m ² ) Thickness (mm) Compressibility (%) Recovery rate (%) Walking feeling 1 PE 10 80 3.0 3.0 12.5 91.2 Poor elasticity 2 PE 10 100 3.0 3.0 15.3 90.3 Poor elasticity 3 PE 10 200 3.0 3.0 25.3 88.3 Good 4 PE 10 300 5.0 28.3 87.3 Good 5 PE 10 400 5.0 30.3 90.2 Very good 6 PE 10 800 8.0 8.0 38.2 80.2 Very good 7 PE 10 1000 10. 0 45.3 70.1 Too soft 8 PP 10 100 100 3.0 11.0 92.5 Poor elasticity 9 PP 10 400 5.0 20.8 82.3 Good However, PE is polyester and PP is polypropylene. Show. For the surface layer A, a polyester needle punch felt backing material having a denier, basis weight, and thickness shown in Experiment Nos. 1 to 9 of Table 1 was added with SBR latex adhesive (solid content: 76%) at a rate of 950 g / m ² . The rug of the present invention was obtained by coating and adhering with. Table 1 shows the compression ratio, the recovery ratio, and the feeling of walking of the obtained rug. The compression rate and the recovery rate depend on JIS L1022. As a result of this experiment, Experiment Nos. 3 to 6 and 9 provided good walking feeling. (Example 2) Surface layer B: warp (material: polyester filament 2400 denier) weft (material: polyester filament 2400 denier) texture plain weave (warp: weft = 1: 1) density 12 warps / inch (12) weft 24 lines / inch (24 steps) Back surface layer: A synthetic rubber (styrene-butadiene rubber) latex composition (solidification: 76%) was foamed, coated and dried in an oven to form a foam layer. (Foaming method: Mechanical foaming with aeration by Oaks mixer)

[Table 2] Lining material (foam) Experiment No Material Foaming ratio (times) Application thickness (mm) Compressibility (%) Recovery rate (%) Walking feeling 10 SR 1 6 10.6 95.2 Insufficient elasticity 11 SR 2 6 18.3 92.1 Poor elasticity 12 SR 3 6 20.6 91.0 Good 13 SR 4 6 25.1 91.8 Very good 14 SR 5 6 28.6 90.5 Very good 15 SR 6 6 30.6 90.5 Very good 16 SR 7 6 30.0 89.2 Good 17 SR 8 6 32.7 90.4 Good 18 SR 9 6 33.5 90.6 Good 19 SR 10 6 34.1 86.3 Good 20 SR 11 6 36.7 82.3 Good 21 SR 12 6 38.2 84.3 Seasickness state 22 SR 13 6 37.6 80.5 Seasickness state 23 SR 14 6 38. 6 77.8 Seasickness 24 SR 15 6 40.0 79.2 Seasickness 25 SR 16 6 41.3 80.1 Bottom feeling 26 SR 17 6 42.0 83.1 Bottom feeling 27 SR 18 6 42.2 80.0 Bottom feeling 28 SR 19 6 45.6 77.3 Bottom feeling 29 SR 20 6 45.3 77.8 Bottom feeling However, SR shows a synthetic rubber latex composition. Further, a foaming latex was obtained by the mechanical foaming method in which the SBR latex composition (solid content: 76%) of the foaming ratios of Experiment Nos. It was applied to a uniform thickness according to the conditions and solidified by heating to form a back surface layer to obtain a mat. Table 2 shows the compression ratio, the recovery ratio, and the walking feeling of the obtained rug. As a result, Experiment Nos. 13 to 15 were very good. (Example 3) Surface layer C: warp (material: 100% wool, thickness W4 / 6) weft (material: 100% cotton, thickness CC10 / 4) texture plain weave density warp 12 / inch (12) weft 18 Book / inch (18 layers) Back surface layer: A polyurethane composition emulsion solution (solid content: 82%) was air-mixed (mechanical foaming method) with an Oaks mixer and dried in an oven to form a foam layer.

[Table 3] Backing material (foam) Experiment No. Material Foaming ratio (times) Application thickness (mm) Wrinkles during walking Misalignment during walking 30 PU 4 1 × × 31 PU 4 2 △ × 32 PU 4 3 ○ △ 33 PU 4 4 ○ ○ 34 PU 4 5 ○ ○ 35 PU 4 6 ○ ○ 36 PU 4 7 ○ ○ 37 PU 8 1 × × 38 PU 8 2 × × 39 PU 8 3 Δ × 40 PU 8 4 ○ × 41 PU 8 5 ○ ○ 42 PU 8 6 ○ ○ 43 PU 8 7 ○ ○ However, PU means a polyurethane composition. The symbols for wrinkles during walking and deviations during walking have the following meanings. X: Many wrinkles (or deviations) occur. Δ: There are few wrinkles (or deviations). ○: No wrinkles (or deviations) occur. The plain weave of the surface layer C was foamed with a polyurethane emulsion having a foaming ratio shown in Table 3 (solid content: 82%) in the same manner as in Example 2 and coated and solidified at the coating thicknesses shown in Table 3, respectively. A rug was obtained in the same manner as. As a result, the rugs of Experiments Nos. 32 to 36 and 41 to 43 did not cause any deviation during walking, and Nos. 31 to 36 and 39 to 43 did not cause wrinkles during walking, and could be used comfortably.

[Effect of device]

 It had elasticity and good walking feeling. Even when walking on the rug, the end of the rug did not turn up. Walking on the rug did not cause wrinkles and did not shift. No play hair, hair loss, or fluffing occurred during walking.

[Brief description of drawings]

FIG. 1 is a perspective view of a rug according to the present invention in which the backing layer is felt.

FIG. 2 is a perspective view of the rug of the present invention in which the backing layer is a foam.

[Simple explanation of symbols]

1 ... A plain woven fabric used as a rug surface layer of the present invention. 2 ... Felt-like non-woven fabric used as a lining layer for the rug of the present invention. 3 ... The rug of the present invention in which the backing layer is a felt-like nonwoven fabric. 4 ... A foam used as a lining layer for the rug of the present invention. 5 ... The rug of the present invention in which the backing layer is a foam.

Claims (6)

[Scope of utility model registration request] 1. A rug having a backing layer, characterized in that a cloth surface layer composed of warp and weft and having no pile and a backing layer of felt or soft foam are laminated. 2. The rug of claim 1, wherein the backing layer is felt. 3. The rug of claim 1, wherein the backing layer is a soft foam. 4. The rug according to claim 1, wherein the felt is a polyester material. 5. The rug according to claim 1, wherein the foamed resin of the backing layer is partially impregnated into the fabric surface layer. 6. The rug according to claim 1, wherein the backing layer has a thickness of 2 to 20 mm.