JP3101874B2 - Spotted carpet and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a needle punch carpet.

[0002]

2. Description of the Related Art The appearance of a conventional needle punch carpet is flat without volume and a single color or two to three.
It is a color in which fibers of three colors are opened and mixed, and most of the fibers are opened so that a plurality of mixed fibers are uniformly mixed. Therefore, the design is low and it is rarely used in ordinary households. In the past, there have been examples in which a pattern is to be applied to a needle punch carpet.

[0003] For example, a method in which various fibers in a pattern-forming portion are formed into a lump at the stage of cotton blending by a cotton lump manufacturing machine or fur note without passing through a carding process, and directly sprinkled on a substrate (JP-A-50-145670) ) And a method of pressing the lumpy fibers onto a substrate (Japanese Patent Application Laid-Open No. 49-573). In these methods, the width and flow Since there is a large variation in the adhesion in the direction, it has not been commercialized without a regular pattern.

[0004] Alternatively, a tow, sliver,
There is a method in which a fiber bundle such as a roving yarn is arranged in a pattern and punched (Japanese Patent Application Laid-Open No. 48-97664). However, the fiber bundle direction is only the flow direction, and the design variation is poor. At the time, the fiber bundle moves and does not become a regular pattern, furthermore, because the fiber bundle and the base material are different,
During punching and drying, phenomena such as bulging, waving, and meandering of the substrate occurred, and it was difficult to manufacture.

[0005] Further, there is a method of mixing a different-colored raw cotton at the time of carding, and forming a web in which unspread fibers are mixed by extremely coarsely opening the fiber (Japanese Utility Model No. 1065085). Because the fiber is also spread considerably,
There is no fibrous lump that forms a pattern, no contrast in hue, low design quality, and the pattern becomes a regular pattern flow pattern.When using multiple carpets, it is difficult to splice and the pattern becomes difficult. It was difficult to manufacture due to displacement or chipping.

A method using a special needle (Tokuto 92)
No. 3219) or a method using a heated and compressed drum with a pattern (Japanese Patent Application Laid-Open No. 51-82076), the surface of the needle punch carpet is provided with an uneven pattern. I could only get things.

[0007]

A conventional technique for imparting a color pattern or a three-dimensional pattern to a needle punch carpet to enhance the design is not to pass various fibers in a pattern portion through a carding process. , A method of sprinkling or extruding on a web sheet from another machine, a method of passing only the various fibers of the pattern part through the card, a method of punching another fiber bundle that becomes a pattern on the web sheet, etc. It has been. However, the variation in the portion where the pattern adhered in the width and the flow direction became large, and the pattern became faint and unclear. In addition, the carpet body had some structural defects such as bulging, waving, curling, and meandering, and the product had not yet been made into a product of commercial value.

[0008] In the technique of the present invention, during carding, there is almost no entanglement of fibers between different cotton ingots on the entire surface of the web sheet, and a web sheet in which single cotton ingots are continuously arranged is drawn. The present invention provides a needle punched carpet. That is, the pattern made by each cotton lump gives a hue contrast, and has a three-dimensional effect consisting of the unevenness of the grains of each cotton lump, making it possible to manufacture a carpet having a single-color or multiple-color mottled pattern on the entire surface. Thus, the present invention has been completed by giving a sense of quality, volume, and three-dimensional feeling not available in the conventional needle punch carpet.

Accordingly, the present invention is to solve the above-mentioned problems of the prior art, and has a single color or a plurality of colors, a pattern, and a three-dimensional effect which cannot be expressed by a conventional needle punch carpet. , To produce a new needle punched carpet.

[0010]

The inventor of the present invention has proposed that at least one or more colors of fibers to be blended form a granular cotton lump having an arbitrary size and shape for each fiber, which is continuously and almost completely filled. Such a web is not obtained, or the cotton lumps do not form a completely continuous sheet, and even if the web has a little gap between the cotton lumps, the cotton lumps are connected by punching. The web should be large enough to cover the entire surface of the material. That is, by drawing the web from a card obtained by partially improving a conventional card, a needle-punched carpet is provided with a one-color or multiple-color spot pattern having a three-dimensional effect to produce a new needle-punched carpet having a rich design. Make it possible,
The present invention has been completed.

That is, the present invention is such that the needle punch carpet can be patterned in only one process without using a separate process or another machine. An object of the present invention is to provide a method of manufacturing a carpet by using a method of pulling out a lump from cards. Still further, the present invention provides a patch carpet having a single color or a plurality of colors of a patch pattern in which a granular cotton lump covers the entire surface of the carpet.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings based on one embodiment of the present invention shown in FIG. FIG. 1 is a cross-sectional view of a preferred structure of the patchy carpet of the present invention. In the web sheet, the fibers of at least one color mixed are in a substantially continuous state of a cotton lump for each fiber,
There is almost no fiber entanglement between different cotton ingots, and the mixed fibers are drawn out of the card so as to form a cotton ingot-like layer A that is substantially independent for each fiber. Also, the size and shape of the cotton lump can be arbitrarily changed.

The fiber composition constituting the cotton-lumen layer A is not particularly limited, and may be any fiber such as synthetic fiber such as polypropylene, polyester and polyamide, regenerated cellulose fiber such as rayon, and natural fiber such as cotton thread. May be used alone or in combination of two or more, but from the viewpoint of design, a plurality of colors are more preferable. In that case, the appearance looks completely different even with the same pattern between the approximate color composition and the control color composition. In addition, when different fiber compositions and fiber diameters are combined, the texture, such as feel and elasticity, can be changed.

Further, the fiber diameter of the constituent fibers of the cotton-lumen layer A is usually about 1 to 30 d, preferably 3 to 3 in that the feeling, feel, abrasion resistance and pilling properties are excellent.
It is about 18d. When the fiber diameter is 1 d or less, the abrasion resistance deteriorates, and when the fiber diameter is 30 d or more, the feel becomes poor. Furthermore, the apparent density of the cotton-lumen layer A is usually 0.03 to 0.30 g / cm < ³ > in terms of excellent feeling, cushioning property, walking feeling, volume feeling, and three-dimensional feeling of the unevenness of the cotton-lumen.
Degree, preferably 0.05 to 0.25 g / cm ³
It is about. The basis weight of this cotton lump layer A is 200 g / m
And unevenness feeling of Watakatamari runs out When it is ² or less becomes flat carpet, so the manufacturing cost becomes 1000 g / m ² or more is higher, usually 200 to 1000 g / m ^2, preferably about 300 to 800 g / m ² .
According to the production method of the present invention, even if the conventional needle punch carpet has a basis weight of about 200 to 300 g / m ² , it is possible to obtain a sufficient cushioning property and a pattern unevenness that are not present in the conventional needle punch carpet.

Further, the cotton lumps in the cotton lumpy layer A have an apparent size on the surface and have a diameter of 5 mm from the viewpoint of giving a three-dimensional effect of the pattern and color tone of the entire carpet and the unevenness of each grain of the cotton lumps. Below this, each grain is crushed by punching, and the unevenness of the pattern is reduced. On the other hand, if it is 50 mm or more, there is a possibility that color variation may occur, and usually a diameter of about 5 to 50 mm is good,
More preferably, it is about 8 to 40 mm.

Furthermore, the apparent size of the cotton lumps may be uniform, or cotton lumps of different sizes may be mixed so that the weight per unit area and the overall balance of colors are not degraded in terms of increasing the number of pattern variations. May be. Furthermore, the shape of the cotton lumps can be selected according to the intended pattern, and when the appearance of the carpet is to be a clean circular continuation, all the cotton lumps are almost spherical and the appearance of the carpet is an abstract pattern It is good to make the shape of the cotton lump irregular. These appearances can be changed arbitrarily.

In this layer A, the constituent fibers are passed through a card. At this time, the web sheet is not opened so that the mixed cotton fibers are uniformly and sufficiently mixed as in usual carding. The conventional card is drawn from a partially improved card so that the cotton lump alone is arranged almost continuously every time.

The cotton lump layer A cannot be punched because the cotton lump falls down by itself, so that a separate base sheet is required on the back surface of the cotton lump layer A. The fiber composition constituting the base sheet is not particularly limited, and synthetic fibers such as polypropylene, polyester, and polyamide; regenerated cellulose fibers such as rayon; natural fibers such as cotton yarn; or core and sheath parts. May be any fiber such as a so-called sheath-core type composite fiber composed of fibers different from each other, and may be a single type thereof or a combination of two or more types. Further, the color is desirably about two colors of a single color and a single color plus a composite fiber. When the base sheet is laminated at a high punch density with a dark color, the fibers of the base sheet contain more fibers than the normal laminate in the cotton-lumped layer A, and the fibers are entangled and come out on the surface of the carpet. The hue of layer A is affected by the base sheet. Therefore, by changing the color of the base sheet, the hue of one cotton lump layer A can be changed in various ways.

Further, the fiber diameter of the constituent fibers of the base sheet is such that the cotton lumps of the cotton lumpy layer A are prevented from falling apart, and the carpet is excellent in dimensional stability, pilling properties and volume feeling. When the fiber diameter is 1 d or less, the volume feeling is low, and when the fiber diameter is 30 d or more, punch lamination with the cotton-lumen layer A becomes sweet, and there is a risk of delamination. Therefore, usually 1 to 30 d is used, but it is more preferable. Is 3
About 18d. Furthermore, the apparent density of this base sheet is the dimensional stability of the carpet, cushioning,
Normally 0.0
About 2 to 0.30 g / cm ³ is used, and more preferably about 0.03 to 0.20 g / cm ³ . When the basis weight of the substrate sheet is 50 g / m ² or less, the strength of the substrate sheet is reduced, and the cotton lump layer A cannot be held.
/ M ² or more, the production cost is high.
About 0 to 400 g / m ² is used, more preferably 1 to 400 g / m ^2.
It is about 00 to 300 g / m ² .

Further, the substrate sheet may be a laminated nonwoven fabric drawn out by a usual carding method, or a punched version of the laminated nonwoven fabric, a heat treatment after punching, or a commercially available spunbonded nonwoven fabric. Is mentioned. The fiber diameter of the heat-fusible fibers and the content of the heat-fusible fibers in the case of heat treatment are excellent in carpet rigidity, dimensional stability, body abrasion, pilling properties, prevention of fiber detachment, feeling, etc. Usually, the fiber diameter is about 1 to 30 d, more preferably about 3 to 18 d,
The content is about 10 to 70%, more preferably about 20 to 50%.

Further, the base sheet is bonded to the cotton lump layer A by a method such as punching. The punching conditions are as follows: the unevenness pattern of each grain of the cotton lump remains, the cotton lump layer A and the base sheet are easily bonded without peeling off, and the abrasion resistance, pilling property, dimensional stability, and wind of the carpet are further improved. If the punch density is good enough to provide good cushioning and volume, etc. May be slightly stretched in the flow direction, or the color of the base sheet may be exposed on the surface.

Further, according to the purpose of use of the carpet, a thermoplastic resin is applied to the back surface of the carpet to form a resin layer C in order to prevent the fiber from coming off of the carpet and to enhance the pilling property, cushioning property and dimensional stability. Sometimes. As the thermoplastic resin used for the resin layer C,
Known resins such as SBR can be used. There is no particular limitation on the method of application, and an extremely general method such as a roll coater or a foam coater may be used.
The coating amount of the thermoplastic resin, preventing loss of fiber, pilling, cushioning, from the viewpoint of dimensional stability of carpet is usually 50 to 500 g / m ^2, preferably about, 100 to 300 g / m ² approximately It is.

[0023] The method for producing a patch carpet according to the present invention is suitable for mass production and stable supply of a carpet having a pattern on the entire carpet, and can greatly reduce the production cost.

Since the patch carpet of the present invention thus obtained has excellent appearance and cushioning properties, the needle punch carpet of the present invention can be used not only in public floors and exhibitions, but also in ordinary households. It will be preferred. Furthermore, it can be used not only as a carpet but also as a center mat, a rug, or the like, and can be suitably used for various purposes. Hereinafter, the present invention will be specifically described with reference to examples of the present invention.

[0025]

Example 1 60% of a white polyester fiber having a fiber diameter of 6 denier and 40% of a white polyester-based fused fiber having a fiber diameter of 4 denier were blended. The web was pulled out in the usual carding manner. 160 / c for laminated web sheet
m ³ density punched in the apparent thickness of 0.2 mm,
A needle-punched nonwoven fabric having a basis weight of 150 g / m ² was obtained.
Next, 20% each of a blue / dark blue / green / black / white color was mixed with polypropylene fiber having a fiber diameter of 7 denier. Five color fibers were drawn out of the card in different sizes and into a cylindrical cotton lump vertically elongated in the flow direction. 500 g / m ^{2 was} laminated on the above-mentioned needle-punched nonwoven fabric, and the pattern was stretched in the flow direction while being laminated by high-density punching. Then 1
Heat treatment was performed at 50 ° C. to bond the fibers, and then 300 g / m ² of SBR resin was applied to the needle punched nonwoven fabric side.
The obtained needle-punched carpet was a patchy carpet in which five colors of blue / dark blue / green / black / white looked like a marble pattern.

[0026]

Example 2 Polyester fibers having a fiber diameter of 7 denier were blended with red / rose in a color of 25% each and acrylic fibers having a fiber diameter of 8 denier in pink / salmon pink with a color of 25% each. On the surface of the web sheet, four-color fibers of approximately the same size and a substantially spherical cotton lump were pulled out of the card. 150g /
After by stacking basis weight of 300 g / m ² on a polyester spunbond of m ^2, and more laminated with punching. 30 SBR resin on the spunbond side of the carpet
0 g / m ^{2 was} applied to obtain a patch carpet. The obtained patchy carpet has a fiber weight per unit area of 450 g / m, which is the same level as a conventional needle punch carpet.
^{When the two} were compared, the pattern features that were not found in the conventional needle punch carpet were obtained. That is, it was possible to simultaneously express both a pattern in which the color array was scattered almost like a polka dot of four colors of red / rose / pink / salmon pink, and a three-dimensional pattern in which each of the four cotton lumps was small.

[0027]

Example 3 A 7-denier dark brown polypropylene fiber was drawn out from the web by a normal carding method. The laminated web sheet was punched at a density of 160 / cm ³ to obtain a needle-punched nonwoven fabric X having an apparent thickness of 0.2 mm and a basis weight of 200 g / m ² . A 7-denier white polypropylene fiber having a fiber diameter of 7 denier was also subjected to the same steps as the needle-punched nonwoven fabric X to obtain a needle-punched nonwoven fabric Y. Next, 25% each of a polypropylene fiber having a fiber diameter of 7 denier and a color of yellow / beige / light brown / white was blended. Each cotton lump is made to have a different size, and the cotton lump layer Z drawn from the card so as to become a columnar cotton lump vertically long in the flow direction is placed on the above-mentioned needle-punched nonwoven fabric X at 350 g / m ² . It laminated so that it might become. This is laminated by high-density punching, and then heat-treated at 150 ° C. to bond the fibers.
Further, 300 SBR resin is applied to the needle punched nonwoven fabric side.
g / m ^{2 was} applied to obtain a mottled carpet x. The needle-punched nonwoven fabric Y is also laminated with the cotton lump layer Z through the same process as the needle-punched non-woven fabric X, and the patchy carpet y
I got The same cotton lump layer Z is used on the surface of the patchy carpet x and the patchy carpet y. / Dark Brown / Light Brown 4 colors, and the uneven carpet y is 4 in Light Yellow / Light Beige / Light Brown / White.
Color. When the patchy carpet x and the patchy carpet y were compared, patchy carpets having considerably different hues were obtained. This has made it possible to produce mottled carpets of different hues with the same cotton lumpy layer of raw cotton.

[0028]

[Comparative Example 1] A polypropylene fiber having a fiber diameter of 7 denier was mixed with yellow / beige / light brown / white in a ratio of 25% each, and a web was drawn out by a normal carding method. 20 for the laminated web sheet
A needle punch carpet having an apparent thickness of 0.5 mm and a basis weight of 400 g / m ² was produced by performing punching at a density of 0 / cm ³ . In addition, SB on the back of the carpet
R resin was applied at 300 g / m ² . The obtained needle punch carpet was a flat needle punch carpet with a yellowish beige one-color appearance, and did not have the color, three-dimensional, luxury, cushioning, and voluminous feelings as in the examples. .

[0029]

According to the patch carpet of the present invention, the fibers constituting the pattern are not attached to the carpet body later,
A web sheet is drawn from a card obtained by partially modifying a conventional card so that all fibers serving as a base of the needle punch carpet constitute a pattern. Therefore, the patch carpet of the present invention can diversify the surface without requiring a separate machine, in order to give a three-dimensional pattern of one or more colors to the entire carpet, which is not seen in conventional products. It is also advantageous in terms of cost. Further, it is excellent in performance as a carpet, for example, dimensional stability, cushioning property and the like.

Further, the appearance in which a small number of colors represented by a single color of the used fiber is blended is completely different from the appearance in which a large number of colors are blended. Also, the same color composition and the control color composition look completely different. Furthermore, when pulling out a lump-like web sheet from a card, the appearance in which cotton lump of the same size is continuous and the appearance in which cotton lump of different sizes are mixed are completely different. It becomes a pattern. Furthermore, the appearance of a cotton lump having a shape close to a sphere is almost completely different from the appearance of a cotton lump having a cylindrical shape or the like. Further, depending on the conditions of the punching, it is possible to connect the gaps between the cotton lumps or extend the shape of the cotton lumps to change the pattern. Furthermore, the hue of the web sheet on the front surface changes depending on the color of the needle-punched nonwoven fabric laminated on the back surface of the web sheet. Therefore, even if the number of colors of the raw cotton for the web sheet is limited, it is possible to increase the number of colors of the carpet by increasing the number of colors of the needle-punched nonwoven fabric. Can also be reduced.

Furthermore, the combination of the color, size, shape, and the color of the needle-punched nonwoven fabric laminated on the back surface of the cotton lump is infinite, and the production method of the present invention makes it possible to form various patterns. It is typical. Therefore, a carpet having a completely different taste from a conventional carpet can be manufactured, and can be used not only as a carpet, but also for interior goods such as center mats and rugs and various other uses.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view schematically showing an embodiment of a patch carpet of the present invention.

[Explanation of symbols]

 A cotton lump layer A B base sheet C resin layer C

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-8-238967 (JP, A) JP-A-7-315101 (JP, A) Japanese Utility Model 63-87133 (JP, U) (58) Survey Field (Int.Cl. ⁷ , DB name) A47G 27/02

Claims (4)

(57) [Claims] 1. A web sheet in which cotton lumps of at least one color are arranged almost continuously on the surface of a base sheet, and punched to leave a three-dimensional appearance consisting of irregularities of each grain of the cotton lumps. Wherein the entire surface of the carpet has a spot pattern of one or more colors. 2. When carding the web sheet according to claim 1, the web sheet has a structure in which fibers are hardly entangled between different cotton ingots, and each cotton ingot is continuously connected. The method for producing a mottled carpet according to claim 1. 3. The base sheet according to claim 1, wherein the base sheet is a nonwoven fabric which has been lightly punched or the like or a non-punched nonwoven fabric. A patch carpet characterized by being laminated. 4. The mottled carpet according to claim 1, wherein the resin composition is applied to the back side of the mottled carpet according to claim 1, 2 or 3.