JPH0129700B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing carpet tiles.

Tile carpet is made by laminating and backing an asphalt-based composition to a predetermined thickness on the back side of various carpet raw materials, then layering a backing fabric on top of that, and after cooling, cutting or punching as required. Manufactured. Generally, they are square, rectangular, diamond-shaped, or more complexly shaped carpets, each with an area of about 0.05 to ^2m2 , and by using these in combination, they can be used in combination with other carpets to cover the floor without creating any gaps. It is something that can be laid down. These tile carpets have the advantage of being easier to install than regular carpets by simply arranging them on the floor and fixing them.
It also has the advantage of being able to create carpets with a variety of textures by combining the shapes and colors of the tile carpets. When these tile carpets are laid on the floor, it is necessary that they adhere sufficiently to the floor and that a portion of the carpet does not come off when walking. There are ways to do this, such as using adhesives or adhesives, and fastening with nails or rivets, but these methods have drawbacks such as being troublesome to install and requiring time to reposition. There is. As a method to improve these drawbacks, a tile carpet is known in which a backing material gives the tile carpet its own weight, and the tile carpet has fixation (placeability) due to its own weight. This backing material also serves the purpose of imparting various properties to the tile carpet, such as thread removal prevention, dimensional stability, and elasticity.

Therefore, the backing material for carpet tiles is
Not only must it satisfy the properties required of general carpet backing materials, but it must also have the ability to be placed stably just by placing it. Moreover, this ease of placement must be provided without using expensive materials.

The present invention improves the quality of the product by accurately correcting undesirable tendencies such as meandering, sagging, and wrinkles of the running carpet strip material and backing fabric during the lamination process in the method for producing carpet tiles. The purpose is to provide a manufacturing method that is expected to improve productivity.

The object of the present invention is to unwind a carpet original fabric from a carpet original fabric supply section, pass it through a roll guider on the upstream side of a transport conveyor, and place the carpet original fabric on one end of the upstream side of the transport conveyor. Then, the asphalt-based composition is transferred from the upstream side to the downstream side of the transport conveyor, and on the transport conveyor, the asphalt-based composition is fed out from the coater to form a laminated backing layer on the upper surface of the carpet original fabric. is formed on the upper surface of the carpet original fabric, and on the other hand, the back base fabric sent out from the back base fabric supply section is passed through a cross guider, transferred to the upstream side of the conveyor, and then transferred onto the conveyor. After passing the backing fabric through an expander roll located upstream of the pressure roll and placing the backing fabric on top of the asphalt-based backing layer, This is achieved by a method for manufacturing a tile carpet in which a laminate consisting of a raw carpet fabric, an asphalt backing layer and a backing fabric is formed by pressure bonding, and then the laminate is cooled and then cut into predetermined dimensions.

Regarding the various manufacturing methods of tile carpets, the constituent elements of these carpets, and other processing means cited in the text, please refer to Patent Application Nos. 56-32334, 54-49781, and 54-49781 by the applicant of the present invention.
Details can be found in No. 108221.

As mentioned above, the method for manufacturing a tile carpet according to the present invention is characterized by guiding the elements to be processed so as to properly arrange them, especially in the laminated region. The manufacturing method will be explained with reference to the following.

FIG. 1 schematically shows the basic process functions of a method for manufacturing carpet tiles according to the prior art.
The strip-shaped carpet raw fabric 1 that is pulled out from the strip-shaped carpet raw fabric supply unit 2 (for example, a roll-wound raw fabric) by the conveyor means (conveyor) 3 and run is made of an asphalt-based material disposed above the running raw fabric 1 in the conveyance section. After the backing material is applied to a predetermined thickness from the coater 6 containing the objects 7 and the like, the backing material 5 is guided from the backing material supply section 4 (for example, a roll) in parallel to the upper surface of the backing material via a roller. are laminated by a pressure roll 8 to form a laminated carpet strip 9 having a predetermined thickness and properties, and in a subsequent step, it is passed through a cooling device 10 and cut into predetermined dimensions by a cutting device 11 to produce a tile carpet product. 12 and eggplant.

In order to ensure the quality of the product in this series of processes, one of the things that requires extremely high consideration is to ensure that the running carpet strip and backing fabric accurately maintain their specified width and are perfectly centered in the processing area. It must be in a consistent state. As can be expected from FIG. 1, the strip carpet material roll and backing fabric have traveled a considerable distance, and the centers of the original roll and backing fabric roll are not necessarily perfectly aligned when they are first wound. Before reaching the lamination site, defects such as meandering, center deviation, width shrinkage, and wrinkles of the original fabric and backing fabric are unavoidable, which not only deteriorates the quality of the product tile carpet but also reduces accuracy. This also hinders the lamination work, which in turn causes inefficient post-processing of the product, leading to an increase in product prices.

As shown in FIG. 2, (1) In the traveling process of the strip-shaped carpet material, the upstream roll guider 13 that brings the material to the conveyor section 3,
(2) In the back base fabric running process, the back base fabric is passed through an expander roll 15 upstream and adjacent to the pressure roll 8 and (3) a cross guider 14 at an appropriate position upstream of the expander roll 15. Please,
It is an object of the present invention to provide a method for manufacturing a tile carpet that eliminates the above-mentioned problems latent in conventional equipment.

FIG. 3 is a schematic perspective view of an example of a known roll guider for correcting the meandering of the strip-shaped carpet material used in the method of the present invention. 16 continues to be in a stopped state (Fig. 4b), but when it meanders to either the left or right, the roll moves while tilting due to the reciprocating movement of the slide rails 17, 17', as shown in Figs. 4a and 4c, and this movement is controlled by the detection signal to immediately hold the original fabric 1 in a predetermined position and correct the meandering. In Figures 3 and 4a-c, 1
8 is a drive motor, and 19 is a detector.

FIG. 5 shows an example of a known cross guider 14 used in the manufacturing method of the present invention, and shows an example of a mounting base 20.
a pair of actuation rolls 21 adjustably mounted on the
It is composed of 22 sets of fixed rolls and accurately corrects the meandering of the back base fabric 5, as well as exhibits the functions of spreading the fabric and removing wrinkles. Various types of drive rolls, such as electric and pneumatic types, are currently in use for driving the actuating rolls.

FIG. 6 shows an example of a rubber expander roll of a known expander roll 15 used in the manufacturing method of the present invention, in which a flexible rubber structure is molded around a curved axis, and its usage is as shown in FIG. The backing fabric is always introduced from the concave portion and guided to the convex portion, and in addition to the spreading effect, the sagging of the backing fabric is corrected, the sagging of the ears is corrected, and incorrect tension is controlled.

The present invention is based on the method for manufacturing tile carpet as described above, and the raw carpet strip is passed through a roll guider on the upstream side of a conveyor along the running method, so that the raw carpet strip can be rolled on either the left or right side. Even if it meanders in the direction, the tapered carpet material can be immediately held in a predetermined position by the tilting movement of the roll guider, and the meandering can be corrected. In addition, since the backing fabric is passed through a cross guide and then through an expander roll, the center alignment of the backing fabric is perfected and the backing fabric is passed through to the laminated area of the original fabric and backing fabric of the tile carpet.
To prevent meandering and center deviation of the backing fabric, shrinkage of the width of the backing fabric, and generation of wrinkles in the backing fabric, as well as correct sagging of the backing fabric and control incorrect tension. This has the effect of improving the quality of the product tile carpet.

[Brief explanation of drawings]

Fig. 1 is a schematic diagram showing the manufacturing process of a tile carpet according to the prior art, Fig. 2 is a schematic diagram showing the manufacturing process of a tile carpet according to the present invention, Fig. 3 is a perspective view of an example of a roll guider, and Fig. 4a 4c are functional diagrams of a roll guider, FIG. 5 is a perspective view of an example of a cross guider, FIG. 6 is an elevational view of an example of an expander roll, and FIG. 7 is an example of how the expander roll is used. 1: Strip-shaped carpet raw fabric, 2: Carpet raw fabric supply section, 3: Conveyor, 4: Back base fabric supply section, 5:
back base fabric, 6: coater, 7: asphalt composition, 8: pressure roll, 9: laminated carpet strip material,
10: Cooling device, 11: Cutting device, 12: Tile carpet, 13: Roll guider, 14: Cross guider, 15: Expander roll, 1
6: Roll, 17, 17': Slide rail, 1
8: Drive motor, 19: Detector, 20: Mounting base, 21: Operating roll, 22: Fixed roll.

Claims (1)

[Claims] 1. After the carpet original fabric is fed out from the carpet original fabric supply section, the carpet original fabric is passed through a roll guider on the upstream side of the conveyor, and the carpet original fabric is placed on one end of the upstream side of the conveyor. The asphalt-based composition is transferred from the upstream side to the downstream side of the conveyor, and on the transport conveyor, the asphalt-based composition is fed out from the coater, and the asphalt-based backing layer is applied to the top surface of the carpet original fabric. On the other hand, the back base fabric sent out from the back base fabric supply section is passed through a cross guider and transferred to the upstream direction of the conveyor for conveyance, and then the back base fabric is formed on the conveyor for conveyance. The backing fabric is placed on top of the asphalt backing layer by passing through an expander roll located upstream of the pressure roll, and then crimped with a pressure roll located on the top surface of a conveyor to form a carpet. A method for manufacturing a tile carpet, which comprises forming a laminate consisting of a raw fabric, an asphalt-based backing layer, and a backing fabric, and then cutting the laminate into predetermined dimensions after cooling.