JPH04150825A - Rug - Google Patents

Abstract

PURPOSE:To improve adhesive property between a secondary backing sheet and a rug, shape-sustaining ability and repulsive flexibility, attain easy laying, removing and carrying work, and produce the light rug having excellent washability and rug-to-floor non-slip characteristic, by a method wherein a web layer is sandwiched between the secondary backing sheet and the rug. CONSTITUTION:A rug 1 consists of a pile layer 2 and a baking sheet 3 which is laminated on the back of the pile layer 2 by adhesive. The pile layer 2 is composed of a backing cloth 6 and rug piles 9 which are tufted on the backing cloth 6. The backing cloth 6 is of a fabric 7 backed with a fiber web layer 8. The backing sheet 3 is of a sheathedcore contraction of a coarse woven fabric covered with an elastomer 5, and core components of the coarse woven fabric are made of fiber threads 4. The backing sheet 3 is hard and is excellent in repulsive flexibility and water-permeability as well because the texture or mesh of woven fabric is coarse enough. The fiber threads of the backing sheet 3 are impregnated and covered with the elastomer 5 and the backing sheet 3 forms a part of the rug. Therefore, the excellent characteristic of the backing sheet 3 improves the property of the rug.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Fields] The present invention relates to a mat that is laid at entrances to buildings, passageways, etc. and used to collect soil and dust attached to footwear. It is related to

[Prior Art] Conventionally, rugs are used to wipe and collect dirt and dust attached to footwear by placing them in passages, entrances, entrances, etc. of buildings to prevent them from being carried into the building as much as possible. Particularly, as entrance mats, mats are used in which a secondary backing material such as a rubber sheet or a synthetic resin sheet is placed on the back side of a carpet made of a primary base fabric such as a woven or non-woven fabric tufted with pile threads. Many of these mats are leased, and leasing companies install them at demand locations.
Generally, the work route is to collect the waste, perform recycling processes such as washing and processing with a dust absorbent, and then install it again at the customer.

[Problems to be Solved by the Invention] Since the secondary backing material of such conventional rugs is a rubber sheet or a synthetic resin sheet, they are heavy and difficult to lay.
The workability of collection and transportation was poor, and many complaints were heard from workers. Furthermore, since the rugs are heavy, only a small number of rugs can be washed at one time in the recycling process, resulting in poor washing efficiency.

The present invention solves these problems and provides a lightweight rug that is easy to install, collect, transport, etc., has high washing efficiency that allows a large amount of laundry to be washed at a time, and has excellent slip resistance against the floor substrate. This is what we intend to provide.

Further, according to the present invention, the adhesiveness between the carpet and the sheet-like secondary base material is high, and the effects of excellent durability and rebound resilience can be achieved.

[Means for Solving the Problems] In order to achieve the above object, the present invention employs the following configuration.

That is, the rug of the present invention has a base fabric in which a fibrous web is laminated and integrated with a woven fabric, and pile yarn is tufted so that the stitched portion is on the fibrous web side, and the fibrous web side is lined with a backing material. The carpet is characterized in that the fiber web side thereof is integrated with a sheet-like material made of a coarsely knitted fabric made of fiber threads covered with a covering layer made of an elastomer.

[Function] By interposing a backing web layer between the carpet and the sheet-like secondary base material, the present invention not only improves the adhesion between the two, but also improves shape retention and rebound resilience. It was completed with the unexpected effect of improving the quality of the product.

The present invention will be explained with reference to the drawings.

FIG. 1 is a sectional view of a rug 1 of the present invention. The rug 1 has a carpet layer 2 made by tufting pile yarns 9 onto a base fabric 6 made of a fabric 7 with a fiber web 8 integrated on the back side.
The sheet material 3 is integrally laminated on the fiber web 8 side with an adhesive.

The sheet-like material 3 has a core component composed of fiber threads 4 as shown in FIG.
A coarsely knitted fabric consisting of elastomer (sheath component)
Since it is a core-sheath structure coated (impregnated) with No. 5, it is hard and has excellent rebound resilience, and since the sheet has sufficiently open weaves or stitches, it has excellent water drainage properties. Although this sheet-like material 3 is light and coarse, it not only improves the shape stability of the rug 1 but also improves the repulsion elasticity.
Furthermore, it has the effect of increasing slip resistance with the subfloor.

FIG. 3 is a cross-sectional view of the carpet layer 2, in which the fiber web 8 favorably sinks the pile yarns 9, and the packing material 10 enhances its flatness.

One feature of the present invention resides in the above-mentioned sheet-like material that is a secondary base material for a rug.

In other words, this sheet-like material not only reduces the weight of the rug, but also
This significantly affects shape stability and rebound resilience. As mentioned above, this sheet has a structure in which the inside of the yarn is impregnated with elastomer, and the surface of the yarn is further coated, and although it is light, it is hard and extremely resilient, and has excellent washing durability. It has excellent characteristics.

By integrating such a sheet-like material into a carpet, the above-mentioned characteristics of the sheet-like material are reflected in the rug.

A coarsely knitted fabric made of fiber threads as a core component, which constitutes such a sheet-like article, is one in which the threads form a planar shape due to a knitted structure or a woven structure, and the planar shape created by the structure of the knitted fabric The area of the space is preferably 15% or more of the area of the knitted fabric, or the distance between adjacent yarns in the same direction constituting a plane like a woven fabric is preferably 0.2 mm. This is a mesh-like knitted fabric as described above.

More specifically, for example, in the case of a woven fabric using polyester long fibers, the yarn thickness is 500 to 5000D, and the weave density is 5 to 25 inches in each width in the plain weave structure, etc., according to the present invention. It is preferably used as a core component of the sheet-like material.

By using such a sheet-like material, the rug of the present invention does not change in size, wrinkle or warp during use, has extremely small dimensional change due to changes in humidity or temperature, and has the characteristics of being strong and lightweight. have

The fibers constituting the coarsely knitted fabric of the sheet-like material include commonly used fibers such as natural fibers, nylon, polyester, acrylic, vinylon, polyolefin, and aramid, monofilament or multifilament, processed yarn, and spun yarn. Yarn, mixed yarn, etc. can be used. It is also possible to use a mixture of two or more of these fibers. Among these fibers, synthetic fibers are preferred because of their small shrinkage and dimensional change when reused after repeated washing. In particular, polyester fibers or acrylic fibers are preferred.

Elastomers constituting the coating layer or sheath component include styrene-butadiene copolymer rubber, acrylonitrile-butadiene copolymer rubber, chloroprene rubber, ethylene-propylene copolymer rubber, acrylic rubber, chlorosulfonated polyethylene, and polyester rubber. , chlorinated polyethylene, mixtures thereof, and the like can be used. As these elastomers, elastomer compounds containing fillers, vulcanizing agents, vulcanization accelerators, anti-aging agents, and other compounding agents can be used as necessary.

As a method for coating the threads of the coarsely knitted fabric, which is the core component, with such an elastomer, a method such as dipping or coating with elastomer latex or an organic solvent solution of elastomer can be adopted. In that case, it is desirable that the elastomer be adhered to the coarsely knitted fabric as uniformly as possible.

The sheet-like material has a core-sheath structure, as illustrated in FIG. Despite having a large number of spaces, it is possible to provide a sheet with high strength and rebound resilience.

When a normal rubber sheet is provided with such a large number of spaces, its strength and repulsion elasticity become low, making it unsuitable for practical use.

For example, in a rug such as an entrance mat, if the weight of the secondary base material such as the sheet-like material is heavy, the workability of transporting, laying, etc. will be reduced. In addition, we collect them like doormats,
In applications where laundry is used repeatedly, there is a weight limit on the washing machine used in the washing process, and heavier items can only wash fewer items at once, reducing washing efficiency. Therefore, the light weight of the secondary base material is very advantageous for transportation, collection, washing efficiency, etc., and when the above-mentioned secondary base material of the present invention is formed into a rug, the work efficiency in each process is improved. It has characteristics that enhance

In addition, the sheet-like material has an uneven surface of the stitches or textures covered by the sheath component made of elastomer, which has the advantage that slipping between the sheet material and the floor substrate is less likely to occur.

In the rug of the present invention, the quality of dehydration during the washing process affects the washing efficiency. In other words, in the commonly used centrifugal dehydration method, in order to improve dewatering performance, water must be easily drained from the carpet layer to the back surface, and for this purpose, the secondary base material must have water permeability. Although necessary, the sheet-like secondary base material used in the rug of the present invention has extremely excellent water permeability, excellent dehydration properties in the washing process, and high washing efficiency.

In the rug of the present invention, the weight of the coarsely knitted fabric made of fiber yarns is preferably 100 to 500 g/-, and the weight of the covering layer or sheath component made of an elastomer is greater than the weight of the coarsely knitted fabric. Preferably 40-200%
In this case, the above-mentioned features are further improved.

That is, when the weight of the coarsely knitted fabric is less than 100 g/rIf, the mechanical strength of the secondary base material is too low and tends to be easily damaged during use.

Furthermore, if the weight of the coarsely knitted fabric exceeds 500 g/rl, the weight of the secondary base material becomes too heavy, making it difficult to achieve the object of the present invention.

Furthermore, if the weight of the coating layer or sheath component made of elastomer is less than 40% of the weight of the coarse knitted fabric, the thickness of the coating layer or sheath component will be too thin and will not suffer damage such as wear during use. It tends to be easier. Furthermore, if the weight of the coating layer or sheath component exceeds 200% of the weight of the coarsely knitted fabric, the weight of the secondary base material becomes too heavy, making it difficult to achieve the object of the present invention.

In order to achieve the above-mentioned effects, the rug according to the present invention uses a fabric in which a fiber web is laminated and integrated in advance as the base fabric of the carpet layer.

That is, a carpet is used in which pile yarn is tufted onto a base fabric so that the stitched portion is on the fibrous web side, and then the fibrous web side is lined with a backing material. Laminated and integrated.

By using a base fabric in which a fibrous web is integrated into a woven fabric, the adhesion between the sheet-like article and the base fabric can be significantly improved.

In other words, by using such a base fabric, it is possible to significantly reduce the unevenness on the back surface caused by the stitches of the pile yarn tufted into the base fabric, making it possible to form a highly flat carpet back surface. . When the pile yarn is tufted, the fiber web around the stitched portion is compressed and the stitched portion sinks into the fiber web, but unevenness can be controlled to that extent. When the fibrous web side is lined with a backing material, the backing material accumulates in the concave portions of the stitched portions, making it possible to further reduce the unevenness. Therefore, the sheet-like material could be strongly integrated.

Further, in the rug according to the present invention, the weight of the fabric constituting the carpet layer is preferably 100 to 400 g/d.
It is good to be.

When the weight of the fabric is less than 100 g/-, the fabric has low strength and is difficult to withstand as a rug, and tends to cause problems such as breakage during use. Also, the weight of the fabric is 40
If it exceeds 0 g/m, the weight of the carpet layer will not only become too heavy, but also the water permeability of the carpet layer will decrease, making it difficult to obtain sufficient dehydration properties after washing, making it difficult to achieve the purpose of the present invention as a rug. Become.

The fibers used for the warp and weft yarns constituting the fabric are preferably synthetic fibers in terms of dimensional stability and durability of the rug, such as filament yarns or spun yarns such as nylon, polyester, vinylon, polypropylene, acrylic, and polyethylene. is used. In the case of long fibers, the thickness of the weaving yarn is preferably in the range of 250 to 2000D.

Further, the weave structure of the fabric is not specified.

Next, the weight of the fiber web to be laminated and integrated with the woven fabric is preferably in the range of 50 to 300 g/-.

That is, if the weight of the fibrous web is less than 50 g/bottom, the stitched portions of the tufted pile yarns will not sink sufficiently into the fibrous web, and the unevenness on the back surface of the carpet layer will become large. This makes it difficult to achieve the above effect.

Furthermore, if the weight of the fiber web exceeds 300 g/rd, not only the weight of the carpet layer becomes heavy, but also the water permeability of the carpet/soto layer decreases.

The fibers of the fibrous web may be synthetic fibers such as those used in the above-mentioned woven fabric (the type of web may be either a short fiber web or a long fiber web. The thickness of the fibers of the fibrous web is usually 1 to A range of 20d is used.

Such a fibrous web is preferably one that has been subjected to a punching process, particularly one that has been subjected to an entanglement process using a water jet, since it has excellent water permeability.

The method for laminating and integrating the fabric and the fiber web is as follows:
A bonding method using an adhesive, a water jet punching method, a needle punching method, etc. can be used. Among these, a base fabric integrated by a water jet punching method is preferred. That is, since a large number of fine passageways are formed in the base fabric by water jet punching, it is possible to achieve the effect of improving the water permeability of the carpet layer. Note that one method is to use a web that has been preliminarily water-jet punched and entangled as the fiber web, and then integrate it with the fabric using a water-jet panning method; however, in this method, Since the web already has water passages formed therein, there is an advantage that the punching effect is high and the time required for processing can be shortened.

The backing material that lines the fiber web side on the back side of the carpet layer can be any commonly used material, but it is preferable to use a material similar to the elastomer used for the covering layer of the sheet material because of its adhesive properties. It is desirable from the point of view of improvement.

Methods for integrating the backing material layer (fiber web side) of such a carpet with a sheet-like article include a method of applying an adhesive to one side of the sheet-like article and adhering it, and a method of applying an elastomer of the same type as the backing material to the sheet. A method in which both elastomers are used as a coating material for a shaped object and bonded together under heat and pressure.In that case, both elastomers are formed in an unvulcanized or semi-vulcanized state, and when they are integrated, they are vulcanized and bonded. etc. can be adopted.

[Example code] The present invention will be further explained by examples.

In the examples, washing refers to washing in warm water at 60°C containing 0.2% industrial detergent for 30 minutes using a large washing machine, followed by centrifugal dehydration after washing with water, and then washing in a large tumbler. - One cycle consists of drying in a dryer at 90°C for 30 minutes.

Example 1, Comparative Examples 1 to 2 1000D polyester filament yarn was used for the warp and weft, and the weaving density was 20 threads/inch in the warp and 15 threads/inch in the weft.
By laminating a fabric with a fabric weight of 160 g/d with a plain weave structure of 1.5 inches and a fiber web with a fabric weight of 100 g/% made by carding polyester fibers with a single yarn fineness of 10 d1 and a fiber length of 68 tnm, and then needle-punching the fabric. They were integrated to form a base fabric.

Nylon pile yarn is tufted so that the fibrous web side of this base fabric becomes the stitched part, and then acrylonitrile-butadiene copolymer rubber latex is applied to the fibrous web side and dried at 120°C for 5 minutes to form a carpet. Created.

The latex used contained a compounding agent such as a vulcanizing agent, but the latex was maintained in an unvulcanized state.

Next, 2000D polyester filament yarn was used for the warp and weft, and the weaving density was 17 threads/inch for the warp and 1 thread/inch for the weft.
A coarse fabric with a plain weave structure of 6 fibers/inch and a basis weight of 260 g/- was impregnated and coated with the acrylonitrile-butadiene copolymer rubber latex containing the above-mentioned vulcanizing agent by a dipping method, and then dried in 120.5 minutes. Then, a sheet-like product was prepared in which the latex was kept in an unvulcanized state. The amount of rubber adhered to this sheet was 87% of the weight of the coarse woven fabric, and the woven fabric had holes through which water could sufficiently pass.

These carpet backing layers and the sheet-like material were laminated and pressed at 155°C for 18 minutes to vulcanize and adhere.
I created rug A.

Although this rug was lightweight at 1,560 glrd, it was hard (and stable) and showed strong repulsion against bending.Also, when I laid this rug and stepped on it, it did not slip. Furthermore, when the degree of drying was observed by centrifugal dehydration using a immersion machine in water, it was confirmed that the water drained well and the drying properties were excellent.

On the other hand, as a comparison, a rug B was prepared by adhering a rubber sheet to the above-mentioned carpet (Comparative Example 1).

That is, as the rubber sheet, an unvulcanized rubber sheet with a thickness of 1.5 mm is prepared by kneading acrylonitrile-butadiene copolymer rubber and adding and blending a vulcanizing agent, and this is used as the backing layer of the carpet. were laminated, vulcanized under the same conditions as in Example 1, and adhered to create a rug B.

The weight of this rug was 2920 g/i, which was extremely heavy. When this rug was centrifugally dehydrated using a dipping machine in the same manner as in Example 1 and the degree of drying was observed, it was found that the water drained poorly. Compared to Example 1, only 60% (number of sheets) could be washed.

Next, as another comparison, nylon pile yarn was directly tufted onto the same fabric as in Example 1 without laminating the fiber web, and the same rubber latex as in Example 1 was applied to the side of the stitched part. A carpet was created by applying and drying in the same manner.

The same sheet-like material as in Example 1 was laminated on the rubber latex-coated surface of this carpet, and vulcanized and adhered in the same manner to create Rug C (Comparative Example 2).

This rug C and the rug A of Example 1 were washed for one cycle using the method described above.

As a result, the sheet-like material of Rug C was partially peeled off. However, no peeling phenomenon was observed in Rug A.

So, when we washed it again and observed the peeling condition, we found that
Rug C had completely peeled off. Note that no peeling phenomenon was observed in Rug A even after washing the rug A a total of 20 times.

[Effects of the Invention] The present invention conveniently prevents slipping between the flooring and the subfloor at the installation site, has excellent workability in laying, collecting, and transporting, and can wash a large amount at one time. Furthermore, it is possible to provide a rug that dries quickly after washing.

[Brief explanation of drawings]

FIG. 1 is an example of a cross-sectional view of a rug according to the present invention, and FIG.
The figure shows an example of a perspective view of a sheet-like article constituting a rug according to the present invention. Moreover, FIG. 3 illustrates a cross-sectional view of a carpet layer constituting a rug according to the present invention. 1: Rug 2: Carpet layer 3: Sheet material 4: Fiber yarn (core component) 5: Elastomer (sheath component) 6: Base fabric 7: Fabric 8: Fiber web 9: Pile yarn 10: Lining backing material

Claims (6)

[Claims] (1) A carpet is made of a base fabric in which a fiber web is laminated and integrated with a woven fabric, and pile yarn is tufted so that the stitched portion is on the fiber web side, and the fiber web side is lined with a backing material. What is claimed is: 1. A rug comprising: a sheet-like article made of a coarsely knitted fabric made of fiber threads covered with a coating layer made of the above-mentioned fibrous web; (2) Claim in which the fiber thread is composed of synthetic fiber (
1) The rug mentioned. (3) The weight of the fabric that makes up the carpet is 100 to 4
The rug according to claim (1), characterized in that it has a weight of 00 g/m^2. (4) The rug according to claim (1), wherein the weight of the fibrous web is 50 to 300 g/m^2. (5) The rug according to claim (1), wherein the fibrous web is entangled by a water jet punching method. (6) The rug according to claim (1), wherein the woven fabric and the fiber web constituting the carpet are integrated by a water jet punching method.