JPH0312110A - Patterned matting and production thereof - Google Patents

Abstract

PURPOSE:To impart an adhesive effect and patterning effect to the matting in one stage by laminating an upper fiber layer and lower fiber layer consisting of materials different from each other, via a non-woven low melting hot melt fabric inserted therebetween, and embossing the laminate from above. CONSTITUTION:For example, the moquette formed by using polyester fibers is used as the upper layer. On the other hand, the needle punch felt formed by subjecting, for example, a fiber web of 500g/m<2> METSUKE consisting of 100% polyester fibers (250 deg.C m.p.) of 6 denier to needling alternately from above and below is used as the lower fiber layer. The non-woven low melting hot melt fabric (120 deg.C m.p.) of 50g/m<2> METSUKE consisting of modified polyester fibers is interposed and superposed between these two layers and the layers are tentatively laminated. The laminated fiber layers are placed in an oven and are heated at and for 200 deg.CX1min to melt the non-woven low melting hot melt fabric, by which the upper and lower fiber layers are welded. The laminate is thereafter subjected to the embossing for about 30 seconds at ordinary temp. from above by means of a patterned mold. The embossed patterns are thus formed on the surface of the fiber layers and the patterned matting is obtd.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to rugs such as electric carpets and commercially available car mats, and more particularly, to patterned rugs whose surfaces are provided with patterns by emboss press processing, and the like. Regarding manufacturing methods.

(Prior Art) Conventionally, patterned rugs have been made by combining different materials for the upper layer and the lower layer and giving them a pattern.
Alternatively, they were overlapped by sewing, and the skin of the patterned material was used in advance to form the pattern, and the pattern was created by means such as quilting.

(Problems to be Solved by the Invention) However, when using the above-mentioned resin adhesive to composite, it is unavoidable that the texture becomes hard over the entire surface, and when layered by sewing, it is difficult to maintain adhesive strength. In addition, it was time-consuming and had problems in terms of work efficiency.

In addition, the skin of the patterned material was used in advance, and operations such as quilting were required to form the pattern, which not only increased costs, but also restricted the selection of patterns, making it extremely difficult to create difficult patterns. .

In view of the above-mentioned circumstances, the present invention deals with each of these problems, and by using a low melting point hot melt nonwoven fabric and employing embossing press processing, it is possible to achieve a patterning effect and an adhesive effect at the same time, improve the texture, and The purpose is to diversify patterns and improve productivity.

(Means for Solving the Problems) Therefore, the features of the present invention that meet the above object are as follows: First, the invention according to claim 1 provides a pattern having a pattern formed by adhesion using the low melting point hot melt nonwoven fabric and embossing press. The mat is made of a low melting point hot melt nonwoven fabric interposed between an upper fiber layer and a lower fiber layer made of different materials, and the upper and lower fiber layers, and the upper and lower fiber layers are made of a low melting point hot melt nonwoven fabric. In addition to being fused and integrated by melting, an uneven pattern is formed on the surface by embossing press, and the embossed concave part has a patterning effect and an adhesive effect in place of sewing, while the part that is not forcibly pressed is made of hot melt nonwoven fabric. The point is that it has only an adhesive effect due to.

Further, the invention according to claims 2 and 3 relates to each manufacturing method for forming the above-mentioned patterned rug, and the former includes an upper fibrous layer and a lower fibrous layer made of different materials, and a low melting point hot melt nonwoven fabric between them. They are interposed and laminated, and at a temperature above the melting point of the hot-melt nonwoven fabric and below the melting points of the upper and lower fiber layers, an embossing press is applied from above using a Yunboss pattern to create an adhesive effect and patterning effect in the concave portion of the pressed part on the surface of the fiber layer. On the other hand, the patterned rug is formed by imparting an adhesive effect to the portions that are not pressed.

On the other hand, the latter is similar to the above, after laminating the upper and lower fiber layers and the intermediate low melting point hot melt nonwoven fabric, it is heated once at a temperature above the melting point of the hot melt nonwoven fabric and below the melting point of the upper and lower fiber layers, and then a pattern is added. Emboss press processing is performed from above at room temperature using a mold to create press depressions on the surface of the fiber layer for adhesion and patterning effects.

The point is that a patterned rug is manufactured by forming a non-pressed part that only has an adhesive effect.

(Function) First, in the above-mentioned rug of the present invention, a patterned effect and an adhesive effect are simultaneously imparted to the patterned concave portion by embossing press, and an adhesive effect is imparted to the non-pressed portion, so that the pattern design can be changed by sewing. In addition to being able to be removed easily, combined with the adhesion of the porous thin layer of low-melting point hot-melt nonwoven fabric, the rug has a good texture and a soft feel.

On the other hand, the manufacturing method according to claims 2 and 3 makes it possible to maintain adhesive strength by using hot-melt nonwoven fabric, and to achieve the adhesion effect and the patterning effect in one step, thereby omitting the labor of sewing and reducing the number of man-hours for patterning. This results in an overall reduction in the cost of manufacturing patterned rugs.

(Example) Hereinafter, embodiments of the present invention will be further described with reference to the accompanying drawings.

Fig. 1 is a schematic diagram of a patterned rug according to the present invention, and Fig. 2 is a partially enlarged view thereof. (3) is a low melting point hot melt nonwoven fabric interposed between the above two fiber layers (2); (4) is a nonwoven fabric made by embossing press processing; This is the embossed part, and as is clear from the figure, the upper fibrous layer (1), the low-melting hot melt nonwoven fabric (3), and the lower fibrous layer (2) are laminated in that order, and a mold with a pattern is used from the upper surface. Therefore, in the above structure, the fibers constituting each of the upper and lower fiber layers are not particularly limited, but it is important that the fibers have a melting point higher than the melting point of the low melting hot melt nonwoven fabric described below.
Besides synthetic fibers such as polyester fibers, wool.

Cotton is also used, and its basis weight is usually around 500 g/ld.

In particular, if a raised type fiber layer is used as the upper fiber layer, it will be more versatile.

On the other hand, low melting point hot melt nonwoven fabric is a nonwoven fabric known under the trade name Dynic, and is usually made of thin, porous spunbond nonwoven fabric with a basis weight of around 50 g/bore, and although there are some differences depending on the type and composition of fibers, - For boat fishing, the melting point is 90.
~150°C9 Usually made of modified polyester fibers at around 120°C.

By the way, when manufacturing the patterned rug of the present invention using these upper and lower fiber layers and the low melting point hot melt nonwoven fabric,
The following steps are performed.

That is, first, a moquette made of polyester fiber is used as the upper layer, and a fiber web made of 100% polyester fiber (melting point 250°C) of 6 denier (melting point 250°C) with a basis weight of 500 g/rrf is alternately formed from above and below as the lower fiber layer. A low melting point hot melt nonwoven fabric (melting point 120
°C) and temporarily laminated. The laminated fiber layers are then heated at 200°C for 1 minute in an open state to melt the low melting point hot melt nonwoven fabric and fuse the upper and lower fiber layers. Emboss press processing is performed for about 30 seconds at room temperature.

In this way, an embossed pattern is formed on the surface of the fiber layer, and the embossed recesses provide a patterning effect and adhesive effect, while the non-embossed portions provide an adhesive effect, resulting in the above-described patterned rug according to the present invention.

In the above method, the laminated fiber layers are heated in an oven and embossed using a cold press method. It is also possible to melt and fuse the hot-melt nonwoven fabric and perform embossing press processing using a hot press method, and similarly, it is possible to obtain a patterned rug that has a patterned effect and a good adhesive effect in the embossed portion.

In particular, even if the durable fiber layer is of a raised type, it is particularly advantageous that the texture can be maintained because it is partially embossed.

(Effects of the Invention) As described above, the present invention inserts a low melting point hot melt nonwoven fabric between the upper and lower fiber layers, fuses these upper and lower fiber layers and the low melting point hot melt nonwoven fabric together, and This is a rug with an embossed pattern formed by embossing press processing, and its manufacturing method.Since it is fused with a thin, porous, low-melting point hot-melt nonwoven fabric, it is similar to the use of conventional resin adhesives (which creates a hard texture). It is possible to maintain a soft texture, and even if the upper fiber layer is of the napped type, it has good adhesion, and because it is partially pressed by embossing press, the texture can be maintained sufficiently. Furthermore, since the pattern is processed by embossing press, it is possible to easily create a pattern that was difficult to sew in the past, and it has the effect of providing an extremely versatile rug.

In addition, in the methods according to claims 2 and 3, since the pattern is formed by embossing press processing as described above, in combination with the use of a low melting point hot melt nonwoven fabric, it is possible to simultaneously achieve the patterning effect and the adhesive effect in one step. Therefore, it is possible to simplify the process by omitting the labor of sewing and the number of man-hours of attaching the pattern, thereby achieving a reduction in production costs.

In particular, by performing partial pressing with an embossed pattern mold at a temperature above the melting point of the hot melt nonwoven fabric as described above, there is no need for conventional sewing. In addition to eliminating the need for overlocking, quilting also solves the problem of sewing at once, and the arrangement of pressed parts and non-pressed parts increases the variety of patterns, greatly contributing to the production of patterned rugs.

[Brief explanation of the drawing]

FIG. 1 is a schematic perspective view showing an example of a patterned rug according to the present invention, and FIG. 2 is a partially enlarged sectional view showing a mode of embossing press processing. (A) ...Patterned rug. (1)...Top fiber layer. (2)...lower fiber layer. (3)...Low melting point hot melt nonwoven fabric. (4)... Embossed part. 1. Indication of the case 1999 Patent Application No. 147499 2. Name of the invention Patterned rug and its manufacturing method 3. Person making the amendment Relationship with the case Name of patent applicant Representative of Kureha Chick Co., Ltd. Person: Tsuyoshi Oya 4, Agent residence: 3-9-10-6, Minamisenba, Chuo-ku, Osaka, subject of amendment: Column 7 of the detailed explanation of the invention in the specification, Contents of the amendment Tl) Specification, page 7, 7-8 ``Dynic'' in line ``
"Dinatsuku," he corrected.

Claims (3)

[Claims] 1. It consists of an upper fiber layer and a lower fiber layer made of different materials, and both fiber layers are fused and integrated by a porous thin layer of low-melting hot-melt nonwoven fabric, and a pattern is formed on the surface by emboss press processing. A patterned rug characterized in that the embossed part has a patterned effect and an adhesive effect in place of sewing, while the part that is not forcibly pressed has an adhesive effect by hot melt nonwoven fabric. 2. A porous thin layer of low melting hot melt nonwoven fabric is inserted between an upper fiber layer and a lower fiber layer made of different materials, and an embossed pattern is formed at a temperature that is above the melting point of the hot melt nonwoven fabric and below the melting point of the upper and lower fiber layers. A method for manufacturing a patterned rug, characterized in that embossing press processing is performed from above using a mold made of molds, thereby imparting an adhesive effect and a patterned effect to the surface of the fiber layer at the same time. 3. A porous thin layer of low melting point hot melt nonwoven fabric is inserted between an upper fiber layer and a lower fiber layer made of different materials, and after heating at a temperature higher than the melting point of the hot melt nonwoven fabric and lower than the melting point of the upper and lower fiber layers, a pattern is formed. A method for manufacturing a patterned rug, characterized in that embossing is performed from above at room temperature using a mold formed with the patterned pattern, thereby imparting an adhesive effect and a patterned effect to the surface of the fiber layer.