JP5300229B2 - Carpet and method for manufacturing carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carpet excellent in slip prevention, durability, and dust-removability. <P>SOLUTION: The carpet includes: a base fabric 2; a first pile areas 31 where first pile yarn 31 has been implanted in the base fabric 2; and a second pile areas 41 where second pile yarn has been implanted in the base fabric 2. The first pile yarn 3 is formed of a thermoplastic resin fiber, and is fused and hardened at least in the top parts. The pile length of the first pile areas 31 is equal to or more than the pile length of the second pile areas 41. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

  The present invention relates to a carpet excellent in slip resistance, durability and dust removal, and a method for producing the carpet.

  Conventionally, carpets in which piles are planted on a base fabric have been widely used. Carpets with such piles are not slippery depending on the application (slip resistance), piles do not drip even after long periods of use (durability), dust on the soles can be removed (dust removal), etc. Is required. In addition, the carpet is also required to have good design properties.

In Patent Document 1, a pile surface in which a heat-shrinkable pile yarn and a non-heat-shrinkable pile yarn are combined is formed on a base fabric, and the heat-shrinkable pile yarn is heat-shrinked, whereby heat shrinkage is achieved. A dust control mat is disclosed in which a difference in height is imparted between a heat-resistant pile yarn and a non-heat-shrinkable pile yarn.
However, the heat-shrinkable pile yarn of the dust control mat of Patent Document 1 cannot improve functions such as prevention of pile sag, elimination of slipperiness, and improvement of dust removal effect.

Patent Document 2 discloses a dust removal mat in which a pile forming portion and a pile non-forming portion are provided on a base fabric, and a synthetic resin backing material is provided on the back surface of the base fabric.
However, since the dustproof mat of Patent Document 2 has a pile non-forming portion, the pile forming portion is very easily piled up and is inferior in durability. Furthermore, the dustproof mat has no dust removal effect in the pile non-formed part and does not have sufficient dustproofness.
Japanese Utility Model Publication No. 7-20165 Japanese Utility Model Publication No. 2-86459

  An object of the present invention is to provide a carpet excellent in slip resistance, durability, and dust removal, and a method for producing the carpet.

A first means of the present invention relates to a carpet, a base fabric, a first pile region in which a first pile yarn is implanted in the base fabric, and a second pile region in which a second pile yarn is implanted in the base fabric. The first pile yarn is a cut pile, the second pile yarn is a loop pile, the first pile yarn is formed of a thermoplastic resin fiber, and the first pile yarn The entire first pile yarn is melt-cured into a rod shape while maintaining the fiber shape of the yarn.

In the carpet, at least a first pile region and a second pile region are formed on a base fabric, and the entire first pile yarn in the first pile region is melt-cured in a rod shape. The melt-hardened first pile region is hard and can protrude sharply like a bar tip. On the other hand, the second pile region is as flexible as a normal pile. Thus, since it has a hard area | region and a soft area | region, the frictional resistance with respect to a sole becomes high, Therefore, the carpet of this invention is excellent in slip resistance. Further, since the hard first pile region supports the side of the second pile yarn in the flexible second pile region, the flexible second pile yarn is difficult to sag, and therefore the carpet of the present invention is excellent in durability. . Furthermore, since the first pile yarn having at least the upper part melt-cured is included, mud on the sole is easily scraped off, and therefore the carpet of the present invention is excellent in dust removal.
Further, since the second pile yarn is a loop pile, the second pile region is excellent in flexibility. Accordingly, the carpet of the present invention also has a good feeling as a rug.

  In a preferred carpet of the present invention, the pile length of the first pile region is formed to be equal to or higher than the pile length of the second pile region. Such a carpet is excellent in durability because the first pile region supports the second pile yarn, and further, since the sole placed on the carpet is in strong contact with the upper portion of the first pile yarn, the slip resistance and dust removal are particularly good. Are better.

In a preferred carpet of the present invention, the pile length of the first pile region is formed lower than the pile length of the second pile region.
Such a preferred carpet is excellent in durability because the first pile region supports the second pile yarn. Furthermore, since the second pile region is not melted, it has excellent water retention, and the second pile region that is excellent in water retention has a high pile length, and therefore can retain a certain amount of moisture. On the other hand, since the first pile region is melted, it has poor water retention (that is, excellent drainage), and the pile length of the first pile region that is excellent in drainage is low, so that the water can be retained in the second pile region. No moisture is drained through the first pile area to the edge of the carpet. Therefore, the preferable carpet can prevent slipping due to excessive accumulation of moisture. In addition, the carpet has a three-dimensional appearance because the shadow difference is large at the boundary between the first pile region having a low pile length and melted and the second pile region having a high pile length and not melted. It is also excellent in design.
In conventional carpets, a difference in shading can be caused by planting pile yarns having different pile lengths so as to form a high pile region and a low pile region. In addition, there is a problem that a part of the pile yarn in the low pile region is easily removed at the time of planting. In the carpet of the present invention, since the first pile yarn in the first pile region is melt-cured, even if the pile length in the second pile region is formed high, the first pile yarn in which the pile yarn in the region is melt-cured It is difficult to get lost by being supported by the thread. Further, since the pile length of the first pile yarn in the first pile region is shortened by heat melting, a relatively long first pile yarn can be used at the time of planting. Therefore, it is possible to prevent part of the first pile yarn from falling off during planting.

The second means of the present invention relates to a carpet manufacturing method, wherein the first pile yarn formed of thermoplastic resin fibers is planted on a base fabric, and is formed of fibers having a melting point higher than that of the first pile yarn. After obtaining a pile planting base fabric having a first pile yarn made of a cut pile and a second pile yarn made of a loop pile by planting the second pile yarn on the base fabric, the pile planting base By heating the cloth at a temperature higher than the melting point of the first pile yarn and lower than the melting point of the second pile yarn, the entire first pile yarn is melt-cured in a rod shape while maintaining the fiber shape of the first pile yarn. It is characterized by that.

According to the above-described carpet manufacturing method, after the first pile yarn and the second pile yarn having a higher melting point than the first pile yarn are planted on the base fabric, only the first pile yarn is melted by heating it. Thus, a carpet having a first pile region that has been melt-cured and a second pile region that has not been melted can be manufactured.
In such a manufacturing method, a process of heating at a temperature higher than the melting point of the first pile yarn and lower than the melting point of the second pile yarn may be added to the conventional carpet manufacturing step, so that the carpet can be easily manufactured. it can.

In a preferred carpet manufacturing method of the present invention, the base fabric includes a thermoplastic resin having a melting point higher than the heating temperature.
According to such a preferred method for producing a carpet, when the pile planting base fabric is heated, the base fabric can be prevented from expanding or contracting or deforming, and further, the pile can be prevented from coming off.

The carpet according to the present invention is excellent in slip resistance, durability and dust removal. Moreover, it is also possible to provide the carpet which was excellent in the design by the preferable aspect.
Moreover, the carpet manufacturing method according to the present invention can easily manufacture a carpet excellent in slip resistance, durability, and dust removal.

Next, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a partial side view of an embodiment of the carpet of the present invention.
In FIG. 1, reference numeral 1 denotes a carpet having a base fabric 2 and pile yarns 3 and 4.
The carpet 1 of the present invention is used by being laid on the floor. The use of the carpet 1 is not particularly limited. For example, the carpet 1 is laid on a door entrance and the like, and mainly on a dust control mat that scrapes off mud on the soles, a tile carpet laid on an office floor or the like, or a stairs surface. It can also be used as a non-slip mat, a mat laid in a place around water such as a dressing room.

As the pile yarn, a first pile yarn 3 in which a thermoplastic resin fiber is formed into a yarn shape and a second pile yarn 4 in which a thermoplastic resin fiber or a natural fiber is formed into a yarn shape are used.
The first pile yarn 3 and the second pile yarn 4 are planted on the base fabric 2 using a known tufting machine or the like.
The first pile yarn 3 and the second pile yarn 4 can be respectively planted in an arbitrary range of the base fabric 2. A region where the first pile yarn 3 is planted is referred to as a “first pile region 31”, and a region where the second pile yarn 4 is implanted is referred to as a “second pile region 41”.

In the first pile region 31, at least the upper part (the side opposite to the base fabric) of the first pile yarn 3 is melt-cured. As for this 1st pile yarn 3, the whole part which protrudes from the base fabric 2 may be melt-hardened.
The carpet 1 has a hard region (first pile region 31) and a soft region (second pile region 41) because the first pile yarn 3 is melt-cured and the second pile yarn 4 remains fiber yarn (non-melted). Have For this reason, the carpet 1 is excellent in slip resistance and dust removal, and the second pile yarn 4 is difficult to sag and is excellent in durability.

  The degree of melting of the first pile yarn 3 is preferably such that the fiber shape remains. Specifically, as will be described later, the first pile yarn 3 is melted by being heated after planting the first pile yarn 3 on the base fabric 2, but by adjusting the heating time, the heating temperature, and the like, The degree of melting of the first pile yarn 3 can be adjusted. For example, if the heating time is very long, the first pile yarn 3 is almost completely melted, and the thermoplastic resin constituting the first pile yarn 3 becomes indeterminate. The 1 pile region 31 can be a hard sheet-like cured layer. On the other hand, when the heating time is set appropriately, the surface of the first pile yarn 3 partially melts, and when this is cooled and hardened, the fiber shape of the first pile yarn 3 (the first pile yarn 3). In the case of a cut pile, it is cured in a state of maintaining a rod shape, and in the case of the first pile yarn 3 being a loop pile).

The first pile yarn 3 and the second pile yarn 4 may be cut piles or loop piles.
The first pile yarn 3 is preferably a cut pile as shown in FIG. When the first pile yarn 3 is a cut pile, when this is melt-cured, the upper portion of the first pile yarn 3 projects sharply like the tip of the rod, and the frictional resistance against the sole increases, It is easy to scrape off mud on the soles.
The second pile yarn 4 is preferably a loop pile. The second pile yarn 4 is not melt-cured and has the flexibility of the fiber yarn itself. For this reason, by using the second pile yarn 4 as a loop pile, the second pile region 41 is particularly excellent in flexibility and cushioning properties and can provide the carpet 1 with a good feeling of use.

The pile length (projection length from the surface of the base fabric 2) of the first pile yarn 3 in the melt-cured state and the non-melted second pile yarn 4 is substantially the same as shown in FIG. It's okay. Further, as shown in FIG. 1B, the pile length of the first pile yarn 3 in a melt-cured state may be formed higher than the pile length of the non-melted second pile yarn 4, or As shown in FIG. 1C, the pile length of the first pile yarn 3 in the melt-cured state may be formed to be lower than the pile length of the non-melted second pile yarn 4.
The pile lengths of the melt-hardened first pile yarn 3 and non-melted second pile yarn 4 are each preferably about 2 mm to 10 mm, more preferably about 2 mm to 7 mm.
When the pile length of the first pile yarn 3 is higher than the pile length of the second pile yarn 4, the difference between the pile length of the first pile yarn 3 and the pile length of the second pile yarn 4 is not particularly limited. However, usually, the difference is preferably about 0.5 mm to 3 mm, and more preferably about 1 mm to 3 mm. When the difference in the pile length is 1 to 3 mm, a part of the first pile yarn 3 protrudes sufficiently from the second pile yarn 4, so that the melted first pile yarn 3 is more likely to contact the sole. Thus, the effects of slip resistance and dust removal can be further enhanced. Moreover, the carpet 1 which exhibits the texture which is unprecedented in which the texture of the 1st pile yarn 3 and the 2nd pile yarn 4 was mixed on the external appearance can be provided.
Further, when the pile length of the first pile yarn 3 is lower than the pile length of the second pile yarn 4, the difference between the pile length of the first pile yarn 3 and the pile length of the second pile yarn 4 is not particularly limited. However, usually, the difference is preferably about 0.5 mm to 3 mm, and more preferably about 1 mm to 3 mm. When the difference in the pile length is 1 to 3 mm, a part of the first pile yarn 3 is covered with the second pile yarn 4, and therefore, the first pile yarn 3 is visually recognized visually. Thus, since the said blurred part can be formed, the carpet 1 which exhibits the texture which is not in the past can be provided. Furthermore, when the difference in the pile length is 3.5 mm or more, more preferably 4 mm or more, the first pile yarn 3 is sufficiently covered with the second pile yarn 4, and therefore, in view of appearance, the non-melted fiber (first The texture of the two-pile yarn 4) can be emphasized. Accordingly, it is possible to provide the carpet 1 that is excellent in anti-slip property, durability, and dust removal property while maintaining the same texture as that of the conventional carpet in appearance.

  When the pile length of the first pile yarn 3 is equal to or higher than that of the second pile yarn 4, the first pile yarn 3 that is difficult to bend supports the standing state of the second pile yarn 4, so that it is flexible. The second pile yarn 4 can be prevented from sagging, and therefore the carpet 1 having excellent durability can be provided. Further, when the sole is placed on the carpet 1, the sole strongly contacts the upper portion of the first pile yarn 3, so that the frictional resistance against the sole is increased, and mud on the sole is scraped off. It becomes easy. Accordingly, it is possible to provide the carpet 1 that is particularly excellent in slip resistance and dust removal.

On the other hand, when the pile length of the first pile yarn 3 is lower than that of the second pile yarn 4, it is possible to provide the carpet 1 that is particularly excellent in durability and anti-slip property when wet with water, and further excellent in design.
Specifically, since the second pile yarn 4 in the second pile region 41 is not melted, it is excellent in water absorption and water retention. On the other hand, since the first pile yarn 3 in the first pile region 31 is melted, the water retention is low and water is easily discharged. If the pile length of the first pile region 31 is low, a step is generated between the first pile region 31 and the first pile region 31 serves as a drainage channel, and retains water in the second pile region 41. Moisture that cannot be discharged is discharged to the edge of the carpet 1 through the first pile region 31. Therefore, the carpet 1 having a low pile length in the first pile region 31 can be prevented from becoming slippery due to excessive accumulation of moisture. Similarly to the above, since the first pile yarn 3 that is not easily bent supports the standing state of the second pile yarn 4, it is possible to prevent the flexible second pile yarn 4 from sagging.
Furthermore, the melted first pile yarn 3 has a higher gloss appearance in appearance than the non-melted second pile yarn 4. If the pile length of the first pile yarn 3 is low and the pile length of the second pile region 41 is high, the shadow difference becomes large at the boundary between the two regions, so that the carpet 1 is excellent in design.

  In FIG. 1, the first pile region 31 has two first pile yarns 3 and the second pile region 41 has three second pile yarns 4. The number of tufts of the first pile yarn 3 and the second pile yarn 4 is not limited to this.

  The area ratio between the formation range of the first pile region 31 and the formation range of the second pile region is appropriately set. However, if the area ratio occupied by the first pile region 31 is too large, the carpet 1 has a poor feeling of use. May not. For this reason, the area of the formation range of the first pile yarn is preferably a ratio of 5 to 70, more preferably a ratio of 5 to 50, particularly preferably 10 when the area of the carpet 1 is 100. It is a ratio of ~ 30. In the remaining portion (a range other than the first pile region 31), the second pile region 41 and the like are formed.

  The formation pattern of the first pile region 31 and the second pile region 41 (planar shape and arrangement of the first and second pile regions 31, 41) is not particularly limited and can be set as appropriate. FIG. 2 is a reference plan view showing each example of the formation pattern. However, in FIGS. 2 and 3, the formation range of the first pile region 31 is indicated by “light ink”, and the formation range of the second pile region 41 is indicated by “shaded”.

In the carpet 1 shown in FIG. 2A, the first pile region 31 is provided so as to extend in a band shape in the width direction of the base fabric 2, and the second pile region 41 is the entire non-formation range of the first pile region 31. Is provided.
In the carpet 1 shown in FIG. 2B, two first pile regions 31 extending in a strip shape in the width direction of the base fabric 2 are provided substantially in parallel, and the second pile region 41 is the two first piles. The region 31 is provided over the entire non-formation range.
The carpet 1 in which the strip-shaped first pile region 31 is formed is preferably laid on, for example, a step surface. In this case, as shown in FIG. 3, if the carpet 1 is laid so that the belt-like first pile region 31 is positioned in the vicinity of the front corner of the staircase surface 10, it is particularly effective in preventing the staircase surface 10 from slipping. There is.
In addition, the width | variety of the strip | belt-shaped 1st pile area | region 31 is about 5 mm-50 mm, Preferably it is 10 mm-30 mm. If the width of the first pile region 31 is formed in the above range, the anti-slip effect is particularly excellent.

The carpet 1 shown in FIG. 2C is provided with first pile regions 31 and second pile regions 41 extending in a strip shape in the width direction of the base fabric 2 in a stripe shape (alternately).
The striped carpet 1 is particularly excellent in durability because the first pile region 31 supports the side of each second pile region 41. In the striped carpet 1, the width of the first pile region 31 may be sufficiently wider than the width of the second pile region 41, as shown in FIG. Such a carpet 1 has excellent caster traveling performance because the sinking of casters (wheels) in the first pile region 31 is small. In the striped carpet 1, the width of the first pile region 31 may be formed sufficiently narrower than the width of the second pile region 41 (not shown).

In the carpet 1 shown in FIG. 2E, the first pile regions 31 are provided in a circular shape, and the first pile regions 31 are regularly arranged.
In the carpet 1 shown in FIG. 2 (f), the first pile regions 31 are provided in a lattice shape.
Further, the first pile region 31 and the second pile region 41 may be arranged in a checkered pattern (not shown).
These carpets 1 are less slippery in all directions and particularly excellent in slip resistance.

  In addition, the first pile region 31 may be formed in a triangular shape or an arbitrary planar shape, and the first pile region 31 may be formed in a planar shape imitating the outer shape of a character or the like.

As the first pile yarn 3 and the second pile yarn 4, known yarns can be used. Examples of the fiber properties of the first pile yarn 3 and the second pile yarn 4 may include one type, a mixed yarn obtained by bundling a plurality of two or more types of multifilaments, or a twisted yarn obtained by twisting a plurality of yarns. The fiber properties of the pile yarns 3 and 4 are appropriately selected in consideration of the design properties and functions of the carpet. For example, by using monofilaments as the pile yarns 3 and 4, the brightness or the color contrast is increased, and a more prominent pattern can be expressed.
The thickness of the pile yarn is not particularly limited, but is preferably 500 dtex to 5000 dtex. By using the pile yarn having such a thickness, the three-dimensional feeling of the pile, the balance when forming the pattern, and the tuft workability are improved. When pile yarns of less than 500 dtex are used, tufting properties and patterns may not be formed in a desired region. On the other hand, if pile yarns of more than 5000 dtex are used, production may be hindered. .

As the first pile yarn 3, a fiber obtained by spinning a thermoplastic resin that melts when heated is used. The thermoplastic resin is not particularly limited, and examples thereof include polyethylene, polypropylene, polyvinyl chloride, acrylic resin, and polyurethane. As will be described later, the carpet 1 of the present invention can be easily manufactured by planting the first pile yarn 3 and the second pile yarn 4 on the base fabric 2 and then heating to melt only the first pile yarn 3. Therefore, the first pile yarn 3 is preferably a fiber of a resin (for example, polyethylene or polypropylene) having a relatively low melting point.
In addition, although melting | fusing point of polyethylene has a vertical difference by the difference in the density etc., it is the range of 100 to 145 degreeC in general. In addition, the melting point of polypropylene is approximately 150 ° C. to 170 ° C., although there are differences depending on the molecular structure and molecular weight.

On the other hand, the second pile yarn 4 is not limited to thermoplastic resin fibers, and natural fibers can also be used. As the second pile yarn 4, it is preferable to use a fiber that does not melt or deform at the heating temperature when the first pile yarn 3 is melted, and in particular, a resin fiber having a melting point higher than the melting point of the first pile yarn 3. It is more preferable to use
Such a second pile yarn 4 is relatively determined in relation to the first pile yarn 3. Therefore, when a polyethylene fiber is used as the first pile yarn 3, it is also possible to use a polypropylene fiber as the second pile yarn 4. Among these, the second pile yarn 4 is preferably a fiber having a relatively high melting point, and examples thereof include a polyamide resin such as nylon 66, an acrylic resin, and a polyester resin. Among these, polyamide resin fibers are preferable because they have a relatively high melting point and high self-restorability and rigidity.
The melting point of polyamide is approximately 210 ° C. to 270 ° C., although there is a difference in the upper and lower sides depending on the difference in structure such as nylon 66 and nylon 6.

The said base fabric 2 consists of sheet bodies, such as a woven fabric or a nonwoven fabric, and if it can fully plant a pile thread | yarn and is excellent also in intensity | strength, it will not specifically limit. Examples of the material of the base fabric 2 include synthetic resins such as polyester, polypropylene, polyethylene, polyamide, polyvinyl alcohol, polyvinyl chloride, polyacrylonitrile, and polyurethane, and natural fibers such as cellulose and wool. Moreover, when the base fabric 2 contains a thermoplastic resin, the resin preferably has a melting point higher than the heating temperature at which the first pile yarn 3 is melted. By using such a base fabric 2, it is possible to prevent the base fabric 2 from expanding or contracting or deforming when the carpet 1 is manufactured.
Preferably, the base fabric 2 is a polyester nonwoven fabric or a polyester woven fabric. This is because the polyester nonwoven fabric or the polyester woven fabric has a high melting point (usually 260 ° C. to 270 ° C.) and is excellent in properties as a base fabric. The base fabric 2 may be coated with an SBR-based, MBR-based, PVC-based latex, and / or EVA-based precoat agent.

  A backing layer 5 is usually provided on the back surface of the base fabric 2. The backing layer 5 can be formed of a known material, for example, a PVC base containing a paste vinyl chloride resin, an EVA base containing a vinyl chloride-vinyl acetate copolymer, an APP base containing an atactic polypropylene resin, Examples thereof include a PUR base composed of isocyanate and polyol. Further, from the viewpoint of dimensional stability and the like, a conventionally used glass mat, nonwoven fabric, canvas, net, or the like may be provided inside the backing layer 5. Examples of the net include a product name “Kurenet” manufactured by Kurashiki Boseki Co., Ltd.

  The carpet 1 of the present invention may be in the form of a tile carpet punched into a predetermined shape, or may be in the form of a roll carpet wound up in a roll shape. In the case of a roll carpet, the backing layer 5 is made of PVC paste, styrene-butadiene resin, ethylene-vinyl acetate copolymer, atactic polypropylene, hot melt resin such as amorphous poly-α-olefin, or the like. preferable. Various emulsions and latexes can also be used. Further, a jute woven fabric or non-woven fabric may be attached as a backing material together with the backing layer 5.

Since the carpet 1 of the present invention has the first pile region 31 that has been melt-cured, the carpet 1 is excellent in slip resistance, durability, and dust removal.
Furthermore, the carpet 1 of the present invention exhibits a different texture compared to a conventional carpet by appropriately adjusting the pile length of the first pile yarn 3 and the pile length of the second pile yarn 4. Furthermore, by appropriately adjusting the pile length and the melting degree of the first pile yarn 3, it is possible to change the appearance in various ways. Further, by combining the melting of the first pile yarn 3 and the lightness and color of the fiber itself, a pattern rich in variations with a high-class feeling and a three-dimensional feeling can be formed. Thus, the carpet 1 of the present invention can be given various patterns by the melted first pile yarn 3 and the non-melted second pile yarn 4.

(Carpet manufacturing method)
The carpet can be manufactured, for example, by the following method.
The first pile yarn and the second pile yarn are planted on the base fabric. As the base fabric, a fabric that does not substantially expand or contract or deform at the heating temperature when the first pile yarn is melted is used.
The order of planting the first pile yarn and the second pile yarn is not particularly limited, and either the first pile yarn or the second pile yarn may be planted first, or both may be planted simultaneously in parallel. May be.
The pile length at the time of planting the first pile yarn and the second pile yarn is not particularly limited, but is preferably about 3 mm to 10 mm, more preferably about 3 mm to 6 mm. When the pile length is less than 3 mm, pile yarns are likely to be lost (missed) during planting. On the other hand, if the pile length exceeds 10 mm, it may be difficult to manufacture due to disorder in the regularity of the pile planting direction. Note that the pile length of the first pile yarn may be less than 3 mm after being melted by heat, but in this case, the pile yarn is not lost, so there is no problem.
Moreover, it is preferable to plant the pile length of the first pile yarn so as to be higher than the pile length of the second pile yarn. This is because if the second pile yarn is high, it is blocked by the second pile yarn and it is difficult to apply heat to the first pile yarn.
The first pile yarn having a high pile length before melting is higher than the pile length of the second pile yarn after melting, or equal to the pile length of the second pile yarn, or the second pile yarn Lower than the pile length. Such adjustment of the pile length of the first pile yarn after melting can be appropriately controlled by the degree of heating or the like.

Next, the base fabric on which the first pile yarn and the second pile yarn are planted (referred to as “pile planted base fabric”) is heated.
The heating temperature is a temperature not lower than the melting point of the first pile yarn and lower than the melting point of the second pile yarn. For example, when the first pile yarn is polypropylene and the second pile yarn is nylon 66, the heating temperature is preferably 170 ° C to 190 ° C.
In addition, as described above, the degree of melting of the first pile yarn can be controlled by appropriately adjusting the heating time.

The heating means is not particularly limited, and heating using an oven can be exemplified as a simple means. For example, what is necessary is just to heat, installing an oven in the middle of the conveyor of a production line, and sending the said pile planting base fabric with a conveyor.
A heat medium such as an oven is preferably applied from above the pile forming surface of the pile planting base fabric.

Only the first pile yarn is melted by the heating. Thereafter, when the temperature is lowered by cooling by a cooling device such as a blower or natural heat radiation, the melted first pile yarn is cured again. Then, the backing layer 5 etc. are provided in the back surface of a base fabric. If necessary, the carpet can be obtained by cutting into a predetermined size.
According to the production method of the present invention, the carpet of the present invention excellent in anti-slip property, durability and dust removal property can be produced simply by adding the heating step to the conventional carpet production step.

  Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. However, the present invention is not limited to the following examples.

(Materials used)
(1) Base fabric:
As the base fabric, a polyester nonwoven fabric (product name “Marix spunbond” manufactured by Unitika Ltd.) was used.
(2) Pile yarn (P1):
Polypropylene fiber (Mitsubishi Rayon Co., Ltd.) was used. This fiber is a mixed yarn of polypropylene multifilament (total dtex: 2555 dtex / total number of filaments: 120).
(3) Pile yarn (P2):
Polypropylene fiber (Mitsubishi Rayon Co., Ltd.) was used. This fiber is a twisted yarn of polypropylene multifilament (total dtex: 2670 dtex / total number of filaments: 120).
(4) Pile yarn (N):
Polyamide fiber (Invista) was used. This fiber is a blended yarn of nylon 66 multifilament (total dtex: 2490 dtex / total number of filaments: 136).
(5) Pile yarn (E):
Polyethylene fiber (available from Ebara Industries Co., Ltd.) was used. This fiber is a 3720 dtex twisted yarn in which four 370 dtex polyethylene monofilaments and four 560 dtex polyethylene monofilaments are twisted.

Example 1
The pile yarn (P1) was planted in a plurality of straight lines on the entire base fabric using a 1 / 10G tufting machine. The pile yarn (P1) was a loop pile, and the pile length was set to 3.5 mm.
The oven was set so that the temperature of the pile forming surface of the base fabric on which the pile yarn (P1) was planted was about 170 to 190 ° C., and the pile forming surface was heated in the oven for 60 seconds.
Then, after leaving at room temperature for 10 minutes to dissipate heat, a backing layer made of a paste vinyl chloride resin having a thickness of about 3 mm was laminated on the back surface of the base fabric.
Finally, the carpet according to Example 1 was manufactured by punching into a square shape of length × width = 500 mm × 500 mm with a punching machine.
In this carpet, the pile yarn (P1) was melt-cured, and the pile length of the pile yarn (P1) after melt-curing was 2.5 mm.

(Example 2)
The pile yarn (P2) and the pile yarn (N) were alternately planted in a straight line on the entire base fabric using a 1 / 10G tufting machine. The pile yarn (P2) was a cut pile, and the pile length was set to 6.0 mm. On the other hand, the pile yarn (N) was a loop pile, and the pile length was set to 3.5 mm. The pile yarn (P2) and the pile yarn (N) were each planted in six strips in one region.
The oven was set so that the temperature of the pile forming surface of the base fabric in which the pile yarn (P2) and the pile yarn (N) were planted was about 170 to 190 ° C., and the pile forming surface was heated in the oven for 60 seconds. did.
Then, after leaving at room temperature for 10 minutes to dissipate heat, a backing layer made of a paste vinyl chloride resin having a thickness of about 3 mm was laminated on the back surface of the base fabric.
Finally, a carpet according to Example 2 was manufactured by punching into a square shape of length × width = 500 mm × 500 mm using a punching machine.
In this carpet, the pile yarn (P2) was melt-cured, and the pile length of the pile yarn (P2) after melt-curing was 4.0 mm. However, the pile yarn (N) was not changed in appearance and touch.

(Example 3)
The pile yarn (P1) and the pile yarn (N) were alternately planted in a straight line on the entire base fabric using a 1 / 10G tufting machine. The pile yarn (P1) was a loop pile, and the pile length was set to 3.5 mm. On the other hand, the pile yarn (N) was a loop pile, and the pile length was set to 3.5 mm. The pile yarn (P1) and the pile yarn (N) were planted alternately one by one.
The oven was set so that the temperature of the pile forming surface of the base fabric on which the pile yarn (P1) and the pile yarn (N) were planted was about 170 to 190 ° C., and the pile forming surface was heated in the oven for 60 seconds. did.
Then, after leaving at room temperature for 10 minutes to dissipate heat, a backing layer made of a paste vinyl chloride resin having a thickness of about 3 mm was laminated on the back surface of the base fabric.
Finally, the carpet according to Example 3 was manufactured by punching into a square shape of length × width = 500 mm × 500 mm with a punching machine.
In this carpet, the pile yarn (P1) was melt-cured, and the pile length of the pile yarn (P1) after melt-curing was 2.5 mm. However, the pile yarn (N) was not changed in appearance and touch.

Example 4
The pile yarn (P1) and the pile yarn (E) were alternately planted in a straight line on the entire base fabric using a 1 / 10G tufting machine. The pile yarn (P1) was a loop pile, and the pile length was set to 3.5 mm. On the other hand, the pile yarn (E) was a loop pile, and the pile length was set to 3.5 mm. The pile yarn (P1) and the pile yarn (E) were planted alternately one by one.
The oven was set so that the temperature of the pile forming surface of the base fabric on which the pile yarn (P1) and the pile yarn (E) were planted was approximately 140 to 150 ° C., and the pile forming surface was heated in the oven for 60 seconds. did.
Then, after leaving at room temperature for 10 minutes to dissipate heat, a backing layer made of a paste vinyl chloride resin having a thickness of about 3 mm was laminated on the back surface of the base fabric.
Finally, the carpet according to Example 4 was manufactured by punching into a square shape of length × width = 500 mm × 500 mm with a punching machine.
In this carpet, the pile yarn (E) was melt-cured, and the pile length of the pile yarn (E) after melt-curing was 2.0 mm. However, the pile yarn (P1) was not changed in appearance and touch.

(Comparative Example 1)
A carpet was produced in the same manner as in Example 1 except that the heat treatment was not performed.

(Comparative Example 2)
A carpet was produced in the same manner as in Example 1 except that the pile yarn (N) was used in place of the pile yarn (P1) and no heat treatment was performed.

(Comparative Example 3)
A carpet was produced in the same manner as in Example 2 except that the heat treatment was not performed.

(Comparative Example 4)
A carpet was produced in the same manner as in Example 3 except that the heat treatment was not performed.

(Dust removal test)
The carpets of Example 1 and Comparative Example 1 were subjected to a dust removal test.
In the dust removal test, sand (1 type of powder for JIS test) was sufficiently adhered to a wet 10 cm square rubber plate (with unevenness) and pressed against the pile surface of the carpet.
After pressing the rubber plate once, the weight of the carpet was measured to determine the carpet weight increase (g).
The above sand adhesion, rubber plate pressing, and weight measurement were repeated a total of 10 times. The results are shown in Table 2.
As is clear from Table 2, it can be seen that the carpet of Example 1 is excellent in sand scraping effect.

(Anti-slip test)
The carpets of Examples 1 and 2 and Comparative Examples 1 to 3 were tested for anti-slip properties.
The anti-slip test was conducted according to JIS A 1454.
Specifically, an OY / PSM tester (manufactured by Yasuda Seiki Co., Ltd.) is used, and a stocking, a slipper bottom and a shoe bottom are attached to the sliding piece, respectively, and a load of 80 kg is applied to the sliding piece in the carpet. Then, the sliding piece was pulled at a load speed of 80 kg / second, and the maximum tensile load at that time was measured.
C. represented by the following formula: S. The R value was used as an evaluation index for slip resistance. The results are shown in Table 3.
Formula: C.I. S. R value = maximum tensile load / loading amount (80 kg).
As evident from Table 3, the carpets of Examples 1 and 2 were C.I. S. It can be seen that the R value is high and the slip resistance is high.

(Durability test)
Durability tests were performed on the carpets of Examples 1 and 3 and Comparative Examples 1, 2, and 4.
The durability test was performed according to JIS L 4406.
Specifically, in the durability test, a caster having a weight of 90 kg was run 2000 times on the carpet pile surface, and then the pile length of the pile yarn was measured. In addition, about Example 3, the pile length of the area | region where the pile thread | yarn (N) which is not fuse | melted was planted was measured.
The dent amount and ratio represented by the following formula were used as evaluation indexes for durability. The results are shown in Table 4.
Formula: Depression amount = pile length before running on casters−pile length after running on casters.
Formula: Ratio (%) = (dent amount / pile length before running on casters) × 100.
As is apparent from Table 4, the carpets of Examples 1 and 3 have a low dent amount and high durability.

(Caster running test)
A caster running property test was performed on the carpets of Example 1 and Comparative Example 1.
In the caster running test, a shopping cart having a weight of 50 kg was placed on the pile surface of the carpet, and the cart was pulled. As a result, the carpet of Example 1 was able to move the cart with a smaller force than the carpet of Comparative Example 1.

(A) is a partially omitted side view showing an embodiment of the carpet of the present invention, (b) is a partially omitted side view showing another embodiment of the carpet, and (c) is another embodiment of the carpet. The partially-omitted side view which shows a form. (A)-(f) is a reference top view which shows the formation pattern of a 1st pile area | region and a 2nd pile area | region. The reference side view which shows the construction example of the carpet of this invention.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Carpet, 2 ... Base cloth, 3 ... 1st pile yarn, 31 ... 1st pile region, 4 ... 2nd pile yarn, 41 ... 2nd pile region, 5 ... Backing layer, 10 ... Stair surface

Claims (5)

A carpet having a base fabric, a first pile region in which a first pile yarn is planted on the base fabric, and a second pile region in which a second pile yarn is planted on the base fabric,
The first pile yarn is a cut pile, and the second pile yarn is a loop pile;
The carpet, wherein the first pile yarn is formed of a thermoplastic resin fiber, and the entire first pile yarn is melt-cured in a rod shape while maintaining the fiber shape of the first pile yarn.   The carpet according to claim 1, wherein a pile length of the first pile region is equal to or longer than a pile length of the second pile region.   The carpet according to claim 1, wherein a pile length of the first pile region is lower than a pile length of the second pile region. By planting a first pile yarn formed of thermoplastic resin fibers on a base fabric, and planting a second pile yarn formed of fibers having a higher melting point than the first pile yarn on the base fabric, After obtaining a pile planting base fabric having a first pile yarn made of cut pile and a second pile yarn made of loop pile ,
By heating the pile planting base fabric at a temperature not lower than the melting point of the first pile yarn and lower than the melting point of the second pile yarn, the entire first pile yarn is maintained while maintaining the fiber shape of the first pile yarn. A method for producing a carpet, characterized by melting and curing in a rod shape.   The carpet manufacturing method according to claim 4, wherein the base fabric includes a thermoplastic resin having a melting point higher than the heating temperature.

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