JP3619961B2 - Carpet manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method of manufacturing a carpet used for a house, a sports facility, a commercial facility, or the like.
[0002]
[Prior art]
A conventional carpet, for example, a tufted carpet, is manufactured by piercing a pile yarn on a primary base fabric with a tufting machine to form a pile, and bonding a secondary base fabric on the back side and drying.
[0003]
The secondary base fabric is used for the purpose of concealing the back stitch of the pile yarn to improve its appearance, imparting the strength to withstand the tension during construction, and improving the dimensional stability of the carpet in use.
[0004]
A jute, a nonwoven fabric, an elastomer film, or the like is used for the secondary base fabric, and conventionally, an adhesive such as foamed polyurethane or foamed latex is generally used to attach the secondary base fabric to the primary base fabric.
[0005]
Recently, carpets are required to have high cushioning, soundproofing, and heat insulation, and in order to satisfy these demands, it has been proposed to increase the thickness of the adhesive layer or the secondary fabric. Has been.
[0006]
[Problems to be solved by the invention]
For example, the proposal to increase the thickness of the adhesive layer can satisfy the above-mentioned demand, but the dryness is poor, the weight is increased, the cushioning property is lowered early, and there is a problem in incineration disposal. . On the other hand, the proposal for increasing the thickness of the secondary base fabric has a problem that jute has a poor cushioning property and is disadvantageous in terms of cost, and an elastomer film has a poor cushioning property, resulting in an increase in weight and cost.
[0007]
Therefore, it is effective to increase the basis weight of the nonwoven fabric, but this case also has the following new problems. That is, the nonwoven fabric used for the conventional secondary base fabric has a polyester fiber with an average thickness of 3 to 8 dtex and a basis weight of 70 to 150 g / m ^2, and is about 5 m / sec to a hot air drying furnace at a temperature of 140 to 150 ° C. However, if the fabric weight is increased and the thickness is increased, the drying property of the adhesive is remarkably lowered, and it is sufficient if the feed rate to the hot air drying furnace is not reduced to 1.5 m / sec or less. There was a problem that drying was impossible.
[0008]
As one of the causes of the above problem, when the fabric weight of the nonwoven fabric is increased and the secondary base fabric is thickened, it is predicted that the air permeability is lowered and the drying property of the adhesive is deteriorated. It is difficult to increase the hot air temperature with normal equipment. For this reason, there has been a problem that the production efficiency of the carpet is reduced to 1/3 or less compared to the conventional case, and the cost is increased accordingly.
[0009]
Accordingly, the present invention provides a method for producing a carpet that is excellent in cushioning properties, soundproofing properties, heat retaining properties, etc. while improving the drying property in the carpet production process, suppressing a reduction in production efficiency, and keeping costs low. The purpose is to provide.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides a carpet manufacturing method in which a secondary base fabric is bonded to the back surface side of a primary base fabric in which a pile is embedded with an adhesive and dried in a hot air drying furnace. , the secondary backing, using synthetic fibers of thickness 20 to 60 dtex, is characterized by being configured of a non-woven fabric which was basis weight 200 to 700 g / m ^2. By setting it as this structure, the thickness of the synthetic fiber of the nonwoven fabric which comprises a secondary base fabric increases 3 to 10 times compared with the past, air permeability and drying property improve, and the fall of the manufacturing efficiency of a carpet is suppressed. be able to. Moreover, the basis weight of the non-woven fabric constituting the secondary base fabric is also increased by about 1.5 to 10 times than before, and can be provided with sufficient cushioning properties, soundproofing properties, heat retention properties, etc. over a long period of time. Good cushioning properties can also be maintained. In addition, the thickness of the synthetic fiber used for the secondary base fabric is less effective for improving the drying property if it is 20 dtex or less, and the rigidity is excessive if it is 60 dtex or more. Further, when the weight of the nonwoven fabric of the secondary base fabric is 200 g / m ² or less, necessary cushioning properties and soundproofing properties cannot be obtained, and when it is 700 g / m ² or more, the material cost is increased and the drying property is deteriorated.
[0011]
The synthetic fiber of the nonwoven fabric which comprises the said secondary base fabric contains the core sheath type fiber which makes a core part a high melting point fiber, and makes a sheath part a low melting point fiber. By setting it as this structure, the low melting point fiber of a sheath part can fuse | melt at the time of hot air drying in a carpet manufacturing process, and the fibers of a core part can be fixed in an entangled state. In particular, even if the sheath fiber melts, the core fiber remains as it is, so that there is almost no change in the bulk density of the nonwoven fabric constituting the secondary base fabric, and the cushioning properties required for the secondary base fabric And strength and other functions can be maintained well.
[0012]
Further, a nonwoven fabric having a weight of 1 to 15 dtex, preferably an average of 3 to 8 dtex synthetic fiber and having a basis weight of 20 to 100 g / m ^2, preferably 60 to 80 g / m ² , is laminated on the lower surface side of the secondary base fabric which is the carpet back surface side. It is characterized in that the secondary base fabric is made into a two-layer structure having a thick main portion and a thin surface layer portion. With this configuration, the secondary base fabric of the main part that becomes the joint side with the primary base fabric is made thick with a thick synthetic fiber non-woven fabric, and the secondary base fabric of the surface layer portion that becomes the carpet back side with a thin synthetic fiber non-woven fabric Because it is thin, while maintaining high air permeability and dryness of the secondary base fabric, the lower side of the secondary fabric, that is, the nonwoven fabric on the back of the carpet is densified, and the feel is smooth and soft. And intrusion and adhesion of dust and foreign matter can be suppressed. The thickness of the synthetic fiber constituting the surface layer portion of the secondary base fabric is less than 1 dtex, and the effect of improving the feeling is lost when the thickness is 15 dtex or less. In addition, the basis weight of the nonwoven fabric constituting the surface layer portion of the secondary base fabric is less than 20 g / m ² , and the effect of improving the feel of the surface layer is poor, and if it is 100 g / m ² or more, the material cost is increased and the drying property is deteriorated. Note that the thin surface layer portion described above may be omitted if there is no request from the user.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an enlarged longitudinal sectional side view showing a schematic configuration when the present invention is applied to a tufted carpet.
[0014]
In FIG. 1, 1 is a pile, 2 is a primary base fabric, 3 is a secondary base fabric, and 4 is an adhesive.
[0015]
The pile 1 is formed by inserting an appropriate pile yarn into the primary base fabric 2 at a predetermined density using a known tufting machine. The primary base fabric 2 for piercing the pile 1 is composed of a synthetic fiber woven fabric or a non-woven fabric.
[0016]
The secondary base fabric 3 has a two-layer structure of a thick main body portion 3a occupying most and a thin surface layer portion 3b on the carpet back surface side.
[0017]
The thick main body portion 3a is formed of a nonwoven fabric having a synthetic fiber having a thickness of 20 to 60 dtex, preferably 30 to 50 dtex, and a basis weight of 200 to 700 g / m ^2, preferably 300 to 600 g / m ² . Moreover, the synthetic fiber of the nonwoven fabric which comprises this thick main-body part 3a is comprised with the core sheath type fiber which makes a core part a high melting point fiber, and makes a sheath part a low melting point fiber.
[0018]
The thin surface layer portion 3b is composed of a nonwoven fabric having a synthetic fiber having a thickness of 1 to 15 dtex, preferably 3 to 8 dtex on average, and a basis weight of 20 to 100 g / m ^2, preferably 60 to 80 g / m ² .
[0019]
The thick main body portion 3a and the thin surface layer portion 3b are overlapped in a web state in the nonwoven fabric manufacturing process to form a two-layer structure by needle punching, or one of 3a and 3b is made in advance. After that, the other web is placed on it and integrated into a two-layer structure by needle punching, or the one made previously in 3a and 3b is integrated into a two-layer structure by needle punching. It becomes. Then, in the carpet manufacturing process, the secondary base fabric 3 having a two-layer structure is joined with the adhesive 4 with the thick main body 3a on the back side of the primary base fabric 2, and is transported to a hot air drying oven and dried. The
[0020]
As the synthetic fiber constituting the secondary base fabric 3, a polyester fiber alone or a mixture of acrylic fiber, polypropylene fiber or the like is used. However, other fibers may be used.
[0021]
The adhesive 4 is made of foamed polyurethane, foamed latex or other appropriate adhesive material.
[0022]
In order to confirm the effect of the present invention, the main portion 3a is made of 40 dtex polyester fiber and has a basis weight of 280 g / m ² , and the surface layer portion 3b is made of polyester fiber having an average of 3 to 8 dtex and has a basis weight of 70 g / m ^2. A carpet (A) comprising a secondary base fabric 3 with a non-woven fabric having a structure and a carpet (B) comprising a secondary base fabric comprising a non-woven fabric having a single-layer structure with a basis weight of 350 g / m ² made of polyester fibers having an average of 3 to 8 dtex Were sent to a 140-150 ° C. hot air drying oven to perform a drying test, and the following results were obtained.
[0023]
For the carpet (A), a sufficiently satisfactory dry state was obtained when the feeding speed was set at 3 m / sec in consideration of a certain level of safety, and the speed could be increased a little more. On the other hand, with carpet (B), 1.5 m / sec is the limit, and the speed could not be increased.
[0024]
From the above results, in order to improve the drying property, it is desirable to configure the secondary base fabric 3 with thick fibers, and in this case, the main portion 3a occupying most of the secondary base fabric 3 is made of a thick fiber nonwoven fabric. It has been found that even if it is made thick and the thin portion of the surface layer portion 3b is made of a thin fiber non-woven fabric, the drying property is not adversely affected.
[0025]
In the above-described embodiment, the same polyester fiber is used for the main body portion 3a and the surface layer portion 3b of the secondary base fabric 3. However, by configuring the main body portion 3a with the core-sheath fiber as described above, The necessary cushioning properties and strength can be improved by bonding the fibers while maintaining the bulk density of the next base fabric 3. Moreover, it is possible to mix a core-sheath-type fiber also in the surface layer part 3b according to a use, an objective, or a user request | requirement. In addition, the secondary base fabric of this invention is applicable to the secondary base fabric of carpets other than a tufted carpet.
[0026]
【The invention's effect】
According to the present invention, the thickness of the synthetic fiber of the nonwoven fabric constituting the secondary base fabric is increased by 3 to 10 times compared with the conventional one, the air permeability and the drying property are improved, and the decrease in the production efficiency of the carpet is suppressed. Can do. Moreover, the basis weight of the non-woven fabric constituting the secondary base fabric is also increased by about 1.5 to 10 times than before, and can be provided with sufficient cushioning properties, soundproofing properties, heat retention properties, etc. over a long period of time. Good cushioning properties can also be maintained.
[0027]
The synthetic fiber of the nonwoven fabric constituting the secondary base fabric includes a core-sheath fiber having a high melting point fiber in the core part and a low melting point fiber in the sheath part. The low melting point fibers can be melted to fix the fibers in the core portion in an entangled state. In particular, even if the sheath fiber melts, the core fiber remains as it is, so that there is almost no change in the bulk density of the nonwoven fabric constituting the secondary base fabric, and the cushioning properties required for the secondary base fabric And strength and other functions can be maintained well.
[0028]
Further, a nonwoven fabric having a weight of 1 to 15 dtex, preferably an average of 3 to 8 dtex synthetic fiber and having a basis weight of 20 to 100 g / m ^2, preferably 60 to 80 g / m ² , is laminated on the lower surface side of the secondary base fabric which is the carpet back surface side. By integrating the secondary base fabric into a two-layer structure of a thick main portion and a thin surface layer portion, while maintaining high air permeability and drying of the secondary base fabric, the lower surface side of the secondary base fabric, That is, the structure of the nonwoven fabric fibers on the back of the carpet can be densified, the feel can be smooth and soft, and the intrusion and adhesion of dust and foreign matter can be suppressed.
[Brief description of the drawings]
FIG. 1 is an enlarged longitudinal sectional side view showing a schematic configuration when the present invention is applied to a tufted carpet.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Pile 2 Primary base fabric 3 Secondary base fabric 3a Main part 3b Surface layer part 4 Adhesive

Claims (3)

In the method of manufacturing a carpet in which the secondary base fabric is dried in a hot air drying oven in a state in which the secondary base fabric is bonded to the back side of the primary base fabric in which the pile is pierced with an adhesive, the secondary base fabric has a thickness of 20 using the synthetic fibers to 60 dtex, a manufacturing method of the carpet, characterized in that is constituted by nonwoven fabric with a basis weight 200 to 700 g / m ^2. The synthetic fiber of the nonwoven fabric which comprises a secondary base fabric contains the core sheath type fiber which makes a core part a high melting point fiber, and makes a sheath part a low melting point fiber, The manufacturing method of the carpet of Claim 1 characterized by the above-mentioned. . A non-woven fabric with a synthetic fiber having a thickness of 1 to 15 dtex and a basis weight of 20 to 100 g / m ² is laminated and integrated on the lower surface side of the secondary base fabric on the carpet back side to make the secondary base fabric a thick main portion and a thin surface layer portion. The method for producing a carpet according to claim 1, wherein the carpet has a two-layer structure.

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