JP6021496B2 - Carpet manufacturing method - Google Patents

Description

  The present invention relates to a method of manufacturing a carpet having a backing layer on the back surface thereof in a carpet in which a pile is planted on a base fabric such as a hook carpet or a tuft carpet.

  Conventionally, a latex layer such as SBR or natural rubber is applied to the skin layer formed by piercing the pile fabric with a hook machine or tuft machine to prevent the pile thread from coming off, and then dried to form a backing layer. A carpet is known in which a pile is fixed. However, the conventional technique of bonding with latex has a problem that a drying process is required and further drying takes time.

  Patent Document 1 discloses a method for manufacturing a carpet in which a dispersion material in which hot melt adhesive powder is dispersed is spray-applied on the back surface of a carpet and then dried to form a buckling material scattered in the form of dots. Yes. However, the buckling material scattered in a dot shape is further heated and softened, and another sheet is superposed to perform pressure bonding or pressure bonding molding, and a heating step is required.

  Patent Document 2 discloses that a carpet and a nonwoven fabric are bonded by melting a random loop adhesive sheet. However, although the bonding state between the carpet and the nonwoven fabric is good, it is necessary to preheat one adherend separately.

JP 2000-14522 A JP 2007-07891 A

  The present invention has been made in view of such a technical background, and an object of the present invention is to provide a method for manufacturing a carpet that does not require a time-consuming drying step and is excellent in pile yarn pull-out strength.

  In order to achieve the above object, the present invention provides the following means.

  [1] In a carpet including a skin layer composed of a pile yarn and a base fabric, and a backing layer, after hot-melting a hot melt adhesive having a softening point in the range of 90 to 160 ° C., using a roll coater, By applying the molten hot melt adhesive to the base fabric side of the skin layer, at least a part between the stitch portion of the pile yarn and the base fabric, and / or the stitch portion of the pile yarn and the A method for producing a carpet comprising forming a backing layer comprising a hot melt adhesive that has been infiltrated into at least a part of fibers constituting a base fabric and then adhered by cooling and solidifying.

  [2] In a carpet including a skin layer made of pile yarn and a base fabric, and a backing layer, after hot-melting a hot melt adhesive having a softening point in the range of 90 to 160 ° C., using a roll coater, By applying the molten hot melt adhesive to the base fabric side of the skin layer, at least a part between the stitch portion of the pile yarn and the base fabric, and / or the stitch portion of the pile yarn and the Backing consisting of a hot melt adhesive and a secondary base fabric bonded by laminating a secondary base fabric while in contact with a pressure contact roll after being infiltrated into at least some of the fibers constituting the base fabric, and then cooling and solidifying. A method for producing a carpet, comprising forming a layer.

  [3] In the method in which the coating method by the roll coater method is applied by passing the base fabric side of the skin layer in contact with the roll coater, the rotational speed (A) of the roll coater and the skin layer 3. The method for producing a carpet according to item 1 or 2, wherein the value of the speed ratio (A / B) to the passing speed (B) is in the range of 1.2 to 3.0.

  [4] The hot-melt adhesive includes amorphous polyalphaolefin resin adhesive, EVA (ethylene-vinyl acetate) resin adhesive, SBS (styrene-butadiene block copolymer) resin adhesive, and SEBS (styrene). -Ethylene-butylene block copolymer) -based resin adhesive, SEPS (styrene-isoprene-styrene block copolymer) -based resin adhesive, an adhesive containing a tackifier, and a wax The method for producing a carpet according to any one of items 1 to 3, which is a urethane-based reactive hot melt adhesive.

  [5] The carpet according to any one of items 1 to 4, wherein the hot melt adhesive has a viscosity at 180 ° C. in the range of 300 to 5000 mPa · s according to a melt viscosity test method of JIS K 6862. Manufacturing method.

  In the invention of [1], after hot-melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the molten hot-melt adhesive is applied to the base fabric side of the skin layer using a roll coater. In combination with the fluidity (viscosity) of the hot melt adhesive melted by heating and the pushing force of the roll coater, at least a portion between the stitch portion of the pile yarn and the base fabric, and / or the pile yarn The hot melt adhesive can be infiltrated into at least a part of the fibers constituting the stitch portion and the base fabric. Thereafter, the pile yarn and / or the stitch portion of the pile yarn and the fibers constituting the base fabric can be firmly bonded by cooling and solidifying. That is, it is possible to manufacture a carpet that reliably bonds the pile yarn and the base fabric, has excellent pile yarn pull-out strength, and prevents the pile yarn from falling off the base fabric.

  In the invention of [2], after the hot melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the molten hot melt adhesive is applied to the base fabric side of the skin layer using a roll coater. Thus, in combination with the fluidity (viscosity) of the hot melt adhesive melted by heating and the pushing force of the roll coater, at least a part between the stitch portion of the pile yarn and the base fabric, and / or the pile Pile yarn by allowing hot melt adhesive to permeate at least a part of the yarn constituting the yarn stitch part and the base fabric, laminating a secondary base fabric while in contact with the pressure roll, and then cooling and solidifying it. And / or the fiber which comprises the stitch part of a pile thread | yarn, and a base fabric, and a secondary base fabric can be adhere | attached firmly. In addition, since the backing layer is composed of a hot melt adhesive and a secondary base fabric, the carpet is improved in appearance quality, and the protection performance, that is, the carpet in which the transition of the hot melt adhesive to flooring is suppressed is manufactured. Can do.

  In the invention of [3], the value of the speed ratio (A / B) between the rotational speed (A) of the roll coater and the passing speed (B) of the skin layer is defined in the range of 1.2 to 3.0. As a result, the molten hot melt adhesive can be pushed into the base fabric of the skin layer, and a carpet coated with a sufficient amount can be produced. If the value of the speed ratio (A / B) is less than 1.2, it is not preferable because uneven coating or blurring may occur. If it exceeds 3.0, the coating amount increases unnecessarily, and the hot melt adhesive is used as the skin layer. It is not preferable because it may be raised.

  In the invention of [4], the hot melt adhesive is an amorphous polyalphaolefin resin adhesive, EVA (ethylene-vinyl acetate) resin adhesive, SBS (styrene-butadiene block copolymer) resin adhesive, Contains at least one selected from SEBS (styrene-ethylene-butylene block copolymer) resin adhesive and SEPS (styrene-isoprene-styrene block copolymer) resin adhesive, a tackifier, and a wax Therefore, it is excellent in the fluidity | liquidity and adhesiveness after heat-melting, a melt | dissolution rate improves and it can adhere | attach fibers more reliably. Alternatively, a urethane-based reactive hot melt adhesive can be applied at a temperature in the range of 100 to 140 ° C., and a carpet in which fibers are securely bonded can be produced.

  In the invention of [5], the viscosity of the hot melt adhesive at 180 ° C. according to the melt viscosity test method of JIS K 6862 hot melt adhesive is in the range of 300 to 5000 mPa · s. Since the hot melt adhesive permeates into the fibers constituting the base fabric, it is possible to produce a carpet that prevents the pile yarn from falling off the base fabric and prevents the yarn constituting the pile yarn from slipping out. .

It is explanatory drawing which shows the manufacturing method of the carpet which concerns on one Embodiment of this invention. It is a schematic diagram of the pressure tester used for the transition test to the flooring of a carpet.

  The carpet manufacturing method according to the first aspect of the present invention is a carpet comprising a skin layer comprising a pile yarn and a base fabric, and a backing layer, and a hot melt adhesive having a softening point in the range of 90 to 160 ° C. After heating and melting, using a roll coater, by applying the molten hot melt adhesive on the base fabric side of the skin layer, at least a part between the stitch portion of the pile yarn and the base fabric, And / or forming a backing layer containing a hot-melt adhesive that is bonded to the stitch portion of the pile yarn and at least a part of the fibers constituting the base fabric by penetration and then solidifying by cooling. And

  According to the first invention, after the hot melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the molten hot melt adhesive is applied to the base fabric side of the skin layer using a roll coater. Thus, in combination with the fluidity (viscosity) of the hot melt adhesive melted by heating and the pushing force of the roll coater, at least a part between the stitch portion of the pile yarn and the base fabric, and / or the pile A hot melt adhesive can be infiltrated into at least a part of the yarn constituting the yarn stitch portion and the base fabric. Thereafter, the pile yarn and / or the stitch portion of the pile yarn and the fibers constituting the base fabric can be firmly bonded by cooling and solidifying. That is, it is possible to manufacture a carpet that reliably bonds the pile yarn and the base fabric, has excellent pile yarn pull-out strength, and can prevent the pile yarn from falling off the base fabric.

  The carpet manufacturing method according to the second invention is a carpet including a skin layer composed of a pile yarn and a base fabric, and a backing layer, and a hot melt adhesive having a softening point in the range of 90 to 160 ° C. After heating and melting, using a roll coater, by applying the molten hot melt adhesive on the base fabric side of the skin layer, at least a part between the stitch portion of the pile yarn and the base fabric, And / or hot melt bonded by laminating a secondary base fabric while in contact with a pressure roll, and then cooling and solidifying after permeating at least a part of the stitches of the pile yarn and the fibers constituting the base fabric A backing layer comprising an adhesive and a secondary base fabric is formed.

  According to the second invention, after the hot melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the hot melt adhesive is applied to the base fabric side of the skin layer using a roll coater. By combining the fluidity (viscosity) of the hot melt adhesive melted by heating and the pushing force of the roll coater, at least a part between the stitch portion of the pile yarn and the base fabric, and / or The pile yarn stitches and at least a part of the fibers constituting the base fabric can be infiltrated with hot melt adhesive, and the secondary base fabric is laminated while in contact with the pressure roll, and then cooled and solidified. The stitches of the yarn and / or pile yarn and the fibers and the secondary base fabric constituting the base fabric can be firmly bonded. In addition, since the backing layer is composed of a hot melt adhesive and a secondary base fabric, the carpet is improved in appearance quality, and the protection performance, that is, the carpet in which the transition of the hot melt adhesive to flooring is suppressed is manufactured. Is possible.

  In the present invention, the softening point of the hot melt adhesive is in the range of 90 to 160 ° C. When the softening point is within this range, the melted hot melt adhesive surely bonds the pile yarn 1 and the base fabric 2, and the pile yarn 1 has excellent pulling strength and prevents the pile yarn 1 from falling off the base fabric 2. be able to.

  In both the first and second inventions, as a coating method by the roll coater method, in the method of applying by passing the base fabric side of the skin layer in contact with the roll coater, the roll coater The value of the speed ratio (A / B) between the rotational speed (A) and the passing speed (B) of the skin layer is preferably in the range of 1.2 to 3.0. By defining within this range, it is possible to produce a carpet in which a molten hot melt adhesive is pushed into the base fabric of the skin layer and a sufficient amount is applied. When the value of the speed ratio (A / B) is less than 1.2, it is not preferable because uneven coating and blurring may occur just by transferring the hot melt adhesive to the base fabric of the skin layer. If it exceeds, the coating amount will increase unnecessarily, and the hot melt adhesive may rise to the skin layer, which is not preferable. The method for supplying the hot melt adhesive is not particularly limited. For example, the hot melt adhesive is supplied to the roll coater by a known method such as a method of pumping with a pump through a supply hose. Alternatively, a touch roll or the like may be provided in the roll coater, a liquid dam portion may be formed between the roll coater and the touch roll, and the hot melt adhesive may be supplied to the liquid dam portion. In addition, it is preferable to provide a touch roll in this manner because the supply amount of the hot melt adhesive to the application surface can be defined by the clearance between the roll coater and the touch roll. Moreover, it is preferable that the surface of the roll coater, the touch roll, and the pressure contact roll is subjected to fluororesin processing. By doing in this way, since it can suppress that the said hot-melt-adhesive adheres to a roller surface, it is preferable. The method for transporting the skin layer is not particularly limited, and examples thereof include transport by pins, transport by a belt conveyor or a roller conveyor. Moreover, the conveyance speed of the said skin layer has preferable 4-14 m / min, More preferably, it is 7-12 m / min.

  The hot melt adhesive includes amorphous polyalphaolefin resin adhesive, EVA (ethylene-vinyl acetate) resin adhesive, SBS (styrene-butadiene block copolymer) resin adhesive, and SEBS (styrene- An adhesive containing at least one selected from an ethylene-butylene block copolymer) -based resin adhesive and a SEPS (styrene-isoprene-styrene block copolymer) -based resin adhesive, a tackifier, and a wax; Or a urethane type reactive hot melt adhesive is preferable. By carrying out like this, while being excellent in the fluidity | liquidity and adhesiveness after heat-melting, a melting rate can improve and it can adhere | attach fibers more reliably. Alternatively, a urethane-based reactive hot melt adhesive can be applied at a temperature in the range of 100 to 140 ° C., and a carpet in which fibers are securely bonded can be produced.

  Furthermore, the viscosity at 180 ° C. of the hot melt adhesive according to the melt viscosity test method of JIS K 6862 is preferably in the range of 300 to 5000 mPa · s. By defining in this range, the hot melt adhesive penetrates into the stitch yarn of the pile yarn and the fibers constituting the base fabric, so that the pile yarn can be prevented from falling off from the base fabric and the yarn constituting the pile yarn can be prevented. It is possible to produce a carpet in which slipping is suppressed.

  Next, one embodiment of a carpet manufacturing method according to the first invention will be described with reference to FIG. In the carpet manufacturing method of this embodiment, the hot melt adhesive 4 having a softening point in the range of 90 to 160 ° C. was heated and melted, and then melted on the base fabric 2 side of the skin layer 3 using the roll coater 5. By applying the hot melt adhesive 4, at least a part between the stitch portion of the pile yarn 1 and the base fabric 2 and / or the fibers constituting the stitch portion of the pile yarn 1 and the base fabric 2. A carpet manufacturing method is characterized in that a backing layer 10 comprising a hot-melt adhesive 4 bonded by being infiltrated and then solidified by cooling is formed in at least a part of the carpet.

  And one Embodiment of the manufacturing method of the carpet based on 2nd invention is described based on FIG. In the carpet manufacturing method of this embodiment, the hot melt adhesive 4 having a softening point in the range of 90 to 160 ° C. was heated and melted, and then melted on the base fabric 2 side of the skin layer 3 using the roll coater 5. By applying the hot melt adhesive 4, at least a part between the stitch portion of the pile yarn 1 and the base fabric 2 and / or the fibers constituting the stitch portion of the pile yarn 1 and the base fabric 2. A backing layer 10 comprising a hot melt adhesive 4 and a secondary base fabric 9 which are bonded by laminating a secondary base fabric 9 while in contact with the pressure contact roll 8 and then cooling and solidifying. Is a method for manufacturing a carpet.

In the present invention, the material of the pile yarn 1 is not particularly limited, and those made of fibers such as acrylic fiber, polyamide fiber, polyester fiber, polypropylene fiber, rayon fiber, etc. can be suitably used. Hemp, wool, etc. can also be used. The pile yarn 2 may be a cut pile or a loop pile. The basis weight of the pile yarn 1 is preferably set to ²⁰⁰ to 2000 g / m ² . If it is less than 200 g / m ² , the function as a carpet is inferior, which is not preferable.

  In the present invention, the base fabric 2 is not particularly limited, such as a woven fabric, a knitted base fabric, or a non-woven fabric. Moreover, although it does not specifically limit as a raw material to comprise, For example, natural fibers, such as cotton and hemp, rayon fiber, polyester fiber, a polypropylene fiber, etc. can be mentioned.

  In the present invention, the hot melt adhesive 4 is not particularly limited, but is an amorphous polyalphaolefin resin adhesive, EVA (ethylene-vinyl acetate) resin adhesive, SBS (styrene-butadiene block copolymer). At least one selected from a resin adhesive, a SEBS (styrene-ethylene-butylene block copolymer) resin adhesive, and a SEPS (styrene-isoprene-styrene block copolymer) resin adhesive, and a tackifier An adhesive containing a wax or a urethane-based reactive hot melt adhesive is preferred. In addition, you may add various additives other than a ultraviolet absorber to the hot-melt-adhesive 4. FIG.

  Examples of the tackifier include, but are not limited to, synthetic resins such as petroleum resins, rosins such as rosin and rosin derivatives, terpene resins, terpene-phenol resins, aromatic modified terpene resins, hydrogenated terpene resins, and the like. Can be mentioned. Of these, a synthetic resin tackifier is preferred.

  Examples of the wax include petroleum-based oils such as paraffin wax and microcrystalline wax, and synthetic hydrocarbons such as Fischer Tropus wax and low-molecular polyethylene. Of these, paraffin wax is preferred.

In the present invention, the secondary base fabric 9 is not particularly limited, and examples thereof include woven fabrics, knitted fabrics, and non-woven fabrics such as Hessian and Tortoiseshell. The basis weight of the secondary base fabric 9 is 10 to 300 g / m ² , and the material is not particularly limited as in the case of pile yarn and base fabric. As shown in FIG. 1, the secondary base fabric 9 is laminated and integrated with a hot melt adhesive 4 to form a backing layer 10. Since the secondary base fabric 9 is laminated and integrated through the hot melt adhesive 4, the appearance quality can be improved and the protective performance, that is, the transition of the hot melt adhesive 4 to the flooring can be suppressed.

  The viscosity at 180 ° C. of the hot melt adhesive 4 according to the melt viscosity test method of the hot melt adhesive 4 is preferably in the range of 300 to 5000 mPa · s. That is, when the hot melt adhesive 4 is heated and melted, the hot melt adhesive 4 penetrates into the stitch portion of the pile yarn 1 and the fibers constituting the base fabric 2, so that the pile yarn 1 is removed from the base fabric 2. Can be prevented, and the thread constituting the pile yarn 1 can be prevented from slipping out. If the viscosity is less than 300 mPa · s, it is not preferable because it may permeate the pile yarn 1 of the carpet 11 too much. When it exceeds 5000 mPa · s, the stitches of the pile yarn 1 and the periphery of the base fabric 2 do not sufficiently penetrate, and there is a possibility that the pile yarn may come off.

  Next, specific examples of the present invention will be described, but the present invention is not limited to these examples. In addition, the carpet used as an Example of this invention, various measurement tests, and the determination method are as follows.

<Materials used>
Pile yarn: Acrylic yarn (5 ten-ply double yarn, cut pile length 15 mm, pile basis weight 1400 g / m ² )
Base fabric (primary): warp yarn: blended yarn 4.7 s aligned 12 pcs / inch, weft: blended yarn 6.0 s aligned 12 pcs / inch * Blended yarn: 35% cotton, 30% polyester, 15% rayon, others 20%
Backing layer:
Hot melt adhesive Secondary base fabric ... a) 100% rayon spun yarn (20 g / m ² basis weight),
B) Warp yarn: blended yarn 6.0 s aligned 15 pcs / inch, weft: blended yarn 4.7 s aligned 12 pcs / inch (125 g / m ² per unit area)
* Blended yarn: 35% cotton, 30% polyester, 15% rayon, 20% other

"Hot melt adhesive (A)"
Olefin copolymer 60%, tackifier (petroleum resin) 25%, wax (solid paraffin) 13%, additive (ultraviolet absorber) 2%, softening point 111 ° C., viscosity at 180 ° C. 760 mPa · s ( A-1 rotor, 10rpm)

"Hot melt adhesive (I)"
Olefin-based copolymer 55%, tackifier (petroleum resin) 40%, wax (solid paraffin) 3%, additive (ultraviolet absorber) 2%, softening point 130 ° C., viscosity at 180 ° C. 3000 mPa · s ( A-2 rotor, 2 rpm)

"Hot melt adhesive (U)"
Olefin copolymer 20%, tackifier (petroleum resin) 60%, wax (solid paraffin) 18%, additive (ultraviolet absorber) 2%, softening point 80 ° C., viscosity at 180 ° C. 760 mPa · s ( A-1 rotor, 10rpm)

"Hot melt adhesive (d)"
Olefin copolymer 60%, tackifier (petroleum resin) 38%, additive (ultraviolet absorber) 2%, softening point 170 ° C., viscosity at 180 ° C. 10,000 mPa · s (A-3 rotor, 4 rpm)

<Example 1>
The skin layer of the hook carpet which consists of the pile yarn and base fabric (primary base fabric) as described in the said use material was prepared. That is, pile yarn was planted on the base fabric (primary base fabric) with a hook machine to form a skin layer. As the hot melt adhesive 4, a hot melt adhesive (A) was used. As shown in FIG. 1, hot melt adhesive 4 that has been heated and melted to 170 ° C. in advance is supplied between roll coater 5 and touch-roll 6 (clearance 0.75 mm), and the rotational speed of roll coater 5 ( The base fabric 2 of the skin layer 3 is set between the coating roll 5 and the backup roll 7 (clearance 10 mm) by setting the speed ratio (A / B) between A) and the passing speed (B) of the skin layer 3 to 2.5. The hot melt adhesive 4 was applied to the back surface of the skin layer 3 with the coating roll 5 while passing through the skin layer 3 so that the side was in contact with the coating roll 5. The hot melt adhesive 4 penetrated into at least a part between the stitch part of the pile yarn 1 and the base fabric 2 and / or at least a part of the fibers constituting the stitch part of the pile yarn 1 and the base fabric 2. After that, the backing layer 10 made of the hot melt adhesive 4 adhered by natural cooling and solidification was formed. The carpet thus obtained had an application amount of hot melt adhesive 4 of 600 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 40N and passed. Both the pile yarn breakthrough strength test and the carpet flooring transfer test passed.

<Example 2>
The same skin layer and the same hot melt adhesive (A) as in Example 1 were used. As shown in FIG. 1, hot melt adhesive 4 that has been heated and melted to 170 ° C. in advance is supplied between roll coater 5 and touch-roll 6 (clearance 0.75 mm), and the rotational speed of roll coater 5 ( The base fabric 2 of the skin layer 3 is set between the coating roll 5 and the backup roll 7 (clearance 10 mm) by setting the speed ratio (A / B) between A) and the passing speed (B) of the skin layer 3 to 2.5. The hot melt adhesive 4 was applied to the back surface of the skin layer 3 with the coating roll 5 while passing through the skin layer 3 so that the side was in contact with the coating roll 5. The hot melt adhesive 4 penetrated into at least a part between the stitch part of the pile yarn 1 and the base fabric 2 and / or at least a part of the fibers constituting the stitch part of the pile yarn 1 and the base fabric 2. After that, as the secondary base fabric 9, the secondary base fabric a) is supplied to the application surface side of the hot melt adhesive 4, laminated and integrated by the press roll 8, and then bonded by natural cooling and solidification. A backing layer 10 composed of the agent 4 and the secondary base fabric 9 was formed. The carpet thus obtained had an application amount of hot melt adhesive 4 of 600 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 40N and passed. Both the pile yarn breakthrough strength test and the carpet flooring transfer test passed.

<Example 3>
In Example 2, the backing layer was the same as Example 2 except that the speed ratio (A / B) was 1.8 and the secondary base cloth (b) was used instead of the secondary base cloth (a). 10 was formed. The carpet thus obtained had an application amount of hot melt adhesive 4 of 430 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 32N and passed. Both the pile yarn breakthrough strength test and the carpet flooring transfer test passed.

<Example 4>
In Example 2, the backing layer was the same as Example 2 except that the clearance between the roll coater 5 and the touch roll 6 was 0.85 mm and the clearance between the coating roll 5 and the backup roll 7 was 8 mm. 10 was formed. The carpet thus obtained had an application amount of the hot melt adhesive 4 of 690 g / m ² . Moreover, the measurement result of the pull-out strength test of the pile yarn of the carpet was 45N and passed. Both the pile yarn breakthrough strength test and the carpet flooring transfer test passed.

<Example 5>
In Example 2, the hot melt adhesive (A) was used instead of the hot melt adhesive (A), and the clearance between the coating roll 5 and the backup roll 7 was changed to 8 mm. Thus, the backing layer 10 was formed. The carpet thus obtained had an application amount of the hot melt adhesive 4 of 550 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 35N and passed. Both the pile yarn breakthrough strength test and the carpet flooring transfer test passed.

<Comparative Example 1>
In Example 2, instead of the hot melt adhesive (a), EVA latex at 20 ° C. (ethylene-vinyl acetate copolymer latex, solid content 50%, viscosity at 20 ° C. 450 mPa · s (A-1 rotor, 10 rpm) )) Was applied to the back surface of the skin layer with a roll coater, and then the base fabric (secondary) (a) was laminated and integrated, and dried at 130 ° C. in a hot air circulation dryer as in Example 2. Carpet was manufactured. The coating amount of EVA latex was 600 g / m ² (dry). Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 20N and passed. Furthermore, both the pile yarn pull-out strength test and the carpet flooring transfer test passed. However, a time-consuming drying process is necessary.

<Comparative example 2>
In Example 2, the backing layer 10 was formed in the same manner as in Example 2 except that the hot melt adhesive (c) was used instead of the hot melt adhesive (a). The carpet thus obtained had an application amount of hot melt adhesive 4 of 600 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 40N and passed. The pile yarn breakthrough strength test was also passed. However, the carpet flooring transfer test failed.

<Comparative Example 3>
In Example 2, instead of the hot melt adhesive (a), the hot melt adhesive (d) was used, the clearance between the roll coater 5 and the touch roll 6 was set to 0.90 mm, and the coating roll 5 and the backup roll A backing layer 10 was formed in the same manner as in Example 2 except that the clearance between 7 was 6 mm. The carpet thus obtained had an application amount of hot melt adhesive 4 of 600 g / m ² . Moreover, the measurement result of the pull-out strength test of the carpet pile yarn was 25N and passed. The transition test to carpet flooring was also passed. However, the pile yarn pull-out strength test failed.

<Melt viscosity test>
The melt viscosity of each hot melt adhesive was measured at 180 ° C. using a Brookfield single cylinder rotational viscometer in accordance with JIS K 6862 A method.

<Softening point measurement test>
The softening point of each hot melt adhesive was measured according to JIS K 6863. A regular ring (19.8 mmφ) is filled with hot melt adhesive and held horizontally in a bath of glycerin (heat medium). When a ball of 3.5 ± 0.05 g and a diameter of 9.53 mm is placed in the center of the hot melt adhesive sample filled in the ring, the temperature of the glycerin bath is raised at a rate of temperature rise of 5 ° C./min. Measure the temperature when the sample touches the bottom plate of the ring base about 25.4 ± 0.2 mm below.

<Pull yarn pullout strength test>
Ten pull strengths of one pile were measured by a method according to JIS L 1021-8 (= 10 locations), and a minimum value of 9.8 N or more was determined to be acceptable.

<Peeling thread strength test>
Ten pull-out strengths of one yarn constituting the pile yarn were measured by a method according to JIS L 1021-8 (= 10 locations), and a minimum value of 1.5 N or more was regarded as acceptable.

<Transfer test to carpet flooring>
A test for promoting the transition of the carpet backing to the flooring will be described with reference to FIG. 2 (the pile yarn 2 is not shown).
1) A carpet 11 and a flooring material 13 each having a size of 100 mm and a width of 100 mm are prepared.
2) The carpet 11 and the flooring material 13 are stacked on the base 14 of the pressure tester 12.
3) A stainless steel round bar 15 of 4 cmφ is placed in the center of the carpet 11, and a flat plate 16 similar to the base 14 is passed through a bolt 18 as a support, and a push spring 19 and a flat plate 17 are stacked. Fix it lightly.
4) The weight 21 (70 kg) is placed while maintaining the balance so that a load of 76 kg in total including 6 kg of equipment above the 4 cmφ stainless steel round bar 15 is applied to the carpet.
5) Confirm that the pressing spring 19 is uniformly pressurized, and tighten the nut 20 to prevent the pressing spring 19 from returning.
6) The weight 21 is removed and the pressure tester 12 is placed in an oven (hot air circulating thermostat) and left to heat at a temperature of 80 ° C. for 168 hours.
7) Take out the pressure tester 12 from the oven, loosen the nut 20 and take out the carpet 11 and the flooring material 13. The carpet 11 and the flooring material 13 are peeled off, and the state of the surface (4 cmφ) of the flooring material 13 on which the 4 cmφ stainless polished round bar 15 is placed and is loaded is visually determined according to the “adhesion judgment standard”.
8) A cotton cloth (gold width 3) measuring 4 cm long and 10 cm wide is dipped in a 5% neutral detergent solution to make it 100% wet. The half of one side of the surface (4 cmφ) of the flooring material evaluated in 7) is rubbed 10 times with the wet cotton cloth wound around the fingertip to remove (wipe off) the deposits. The state of the removal surface is visually determined according to the “determination criteria after removal”.
“Adhesion criteria”: Grade 5 shows no adhesion at all, Grade 4 shows slight adhesion but is almost inconspicuous, Grade 3 shows adhesion clearly but less noticeable, grade 3 Slightly marked were rated as grade 2, and those with very significant adhesion and those that could not be peeled off were classified as grade 1. Grade 4 or higher was accepted and indicated by “◯”.
“Criteria for determining adhesion after removal”: Grade 5 where no adhesion was observed, Grade 4 where adhesion was slightly recognized but almost inconspicuous, and grade 3 where adhesion was clearly recognized but adhesion was less noticeable Grades that were slightly noticeable and adhered were classified as grade 2, and those that were markedly adhered and those that could not be removed were classified as grade 1. Grade 4 or higher was accepted and indicated by “◯”.

  The carpets of Examples 1 to 5 according to the present invention did not require a time-consuming drying step, and passed all tests including the strength of pulling out pile yarn. That is, it was a method for producing a carpet excellent in the pulling strength of pile yarn. On the other hand, in Comparative Example 1, a time-consuming drying process was required to dry the backing layer. In Comparative Example 2, the transition test to flooring failed, and in Comparative Example 3, the pile yarn pull-out strength test failed.

  INDUSTRIAL APPLICABILITY The present invention is a carpet in which piles are planted on a base fabric such as a hook carpet or tuft carpet, and as a method for producing a carpet having a backing layer on the back surface, a time-consuming drying step is not required and the pile yarn pulling strength is excellent. It is suitable as a method for manufacturing a carpet.

1. Pile yarn 2. Base fabric (primary base fabric)
DESCRIPTION OF SYMBOLS 3 ... Skin layer 4 ... Hot melt adhesive 5 ... Roll coater 6 ... Touch roll 7 ... Backup roll 8 ... Pressure contact roll 9 ... Secondary base fabric 10 ... Backing layer 11 ... Carpet 12 ... Pressure tester 13 ... Flooring 14 ... Base 15 ... 4cmφ stainless steel round bar 16 ... Flat plate 17 ... Flat plate 18 ... Bolt 19 ... Pressing spring 20 ... Nut 21 ... Weight

Claims (3)

In a carpet including a skin layer made of pile yarn and a base fabric, and a backing layer,
After the hot melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the pile yarn is applied by applying the melted hot melt adhesive on the base fabric side of the skin layer using a roll coater. Hot which is bonded by cooling and solidifying after permeating at least a part between the stitch part and the base fabric and / or at least a part of the pile yarn stitch part and the base fiber. Forming a backing layer comprising a melt adhesive ;
The hot melt adhesive is an adhesive containing an olefin copolymer, a tackifier, and a wax,
JIS K 6862 Viscosity at 180 ° C. of the hot melt adhesive according to the melt viscosity test method of the hot-melt adhesive, mosquito characterized ranges der Rukoto of 300~5000mPa · s - Pet manufacturing method. In a carpet including a skin layer made of pile yarn and a base fabric, and a backing layer,
After the hot melt adhesive having a softening point in the range of 90 to 160 ° C. is heated and melted, the pile yarn is applied by applying the melted hot melt adhesive on the base fabric side of the skin layer using a roll coater. After penetrating at least a part between the stitch part and the base fabric, and / or at least a part of the pile yarn stitch part and the fiber constituting the base fabric, the secondary base is in contact with the press roll. Forming a backing layer consisting of hot melt adhesive and secondary base fabric bonded by laminating the fabric and then cooling and solidifying ,
The hot melt adhesive is an adhesive containing an olefin copolymer, a tackifier, and a wax,
JIS K 6862 Viscosity at 180 ° C. of the hot melt adhesive according to the melt viscosity test method of the hot-melt adhesive, mosquito characterized ranges der Rukoto of 300~5000mPa · s - Pet manufacturing method. In the coating method by the roll coater method, in which the base fabric side of the skin layer is applied while being in contact with the roll coater, the rotational speed (A) of the roll coater and the passing speed of the skin layer ( The method for producing a carpet according to claim 1 or 2, wherein the value of the speed ratio (A / B) to B) is in the range of 1.2 to 3.0.