JPH06173154A - Tufted carpet - Google Patents

Abstract

PURPOSE:To obtain a repeatedly washable soft and light-weight tufted carpet by tufting ground fabric comprising water-resistant resin yarn, coated with a thermally fusing material in a sheath state, with pile yarn and then fusing under heating. CONSTITUTION:Needle punched nonwoven fabric as ground fabric 2 using polypropylene yarn coated with a polyethylene as a thermally fusing material in a sheath state is tufted with pile yarn 1 by a tufting machine. Then, hot air is brought into contact with the back of the ground fabric 2 and the polyethylene is melted, cooled and solidified to fix the pile yarn 1 to the ground fabric 2. Backing cloth comprising a plain weave cloth of polypropylene is laminated to the back of the ground fabric 2 and integrated.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION This invention relates to tufted carpets, and more particularly to washable tufted carpets.

[0002]

2. Description of the Related Art Recently, rugs are often laid on doorways of rooms and floors of rooms in buildings. In addition, as the prevalence of electric carpets has increased, the demand for electric carpet covers has also increased. Conventionally, tufted carpets have been used as carpets used for the above applications.

FIG. 4 shows an enlarged view of a cross-sectional structure of a conventional general tufted carpet. Referring to FIG. 4, tufted carpets are generally polypropylene plain weave fabrics 2
The pile yarn 10 is inserted into 0 or the like by a tufting machine to form a pile, thereby forming the surface of the carpet.
The back surface of the carpet is backed to form a backing layer 30 for fixing the pile yarn 10 to prevent the pile yarn 10 from coming off.

The backing layer 30 is for preventing the pile yarn 10 from coming off. At the same time, when the carpet is laid on the floor, the coefficient of friction with the floor is prevented so as to prevent the carpet from being displaced. Large materials are required. Therefore, SBR latex is generally used for the backing layer 30, and the pile yarn 1
It is fixed in the state that 0 is densely hardened.

[0005]

The SBR-based latex is commonly used in the backing layer of carpets.
Although due to cost reasons, this SBR latex has the drawback of being weak in water. Therefore, if the carpet that is heavily soiled is washed several times, the backing layer will easily fall off, and the function of fixing the pile yarn, which is the original purpose of the backing layer, will be lost and the pile yarn will come off. There is.

This problem of water resistance can be solved by using NBR latex for the backing layer, but it is difficult to put it into practical use because the cost is about 2.5 times as high as that of SBR latex. is there. Further, the SBR latex is so-called rubber, and as described above, the pile yarns are densely hardened, so that there is a drawback that they are hard and heavy. Therefore, even if the carpet can be washed once or twice, there is a problem that the carpet cannot be easily rolled and put in the washing machine at the time of washing. More recently,
There is an increasing need to improve the decorative properties of carpets, such as embroidering patterns on the carpets with pile yarns, and the backing layer to prevent the pile yarns from coming off has been required more than ever. . Therefore, during backing, a large amount of latex is required to firmly fix the pile yarn, and the carpet becomes harder and heavier, which makes it more difficult to handle.

Further, the fixing strength of the backing layer is determined by the adhesive force for adhering the pile yarn to the backing layer and the rupture strength of the backing layer itself. However, it has a drawback that the latex itself has a weaker breaking strength. Therefore,
Even if the pile yarn is firmly attached to the backing layer, there is a problem that the pile yarn comes off so that the meat of the backing layer can be stripped off relatively easily.

[0008] As described above, the carpet in which the pile yarns have come off has a very poor appearance and cannot be used practically. Therefore, the object of the present invention is to
It is intended to provide a tufted carpet which is water resistant, washable, flexible and light, and which does not increase the cost as compared with the conventional tufted carpet.

[0009]

A tufted carpet according to a first aspect of the present invention comprises a pile yarn and a base fabric in which the pile yarn is planted, which is made of fibers made of a water-resistant resin.
The pile yarn is fixed to the fiber by a heat-sealing material contained in a base fabric, and the heat-sealing material is a sheath and a fiber coated on the surface of the fiber in advance. It is characterized in that it is formed by melting and solidifying a heat fusion material having a lower melting point.

According to a second aspect of the tufted carpet, the pile yarn, the base fabric in which the pile yarn is planted, and the fiber provided on the back surface of the base fabric and made of a water-resistant resin, The pile yarn is fixed to the fiber by a heat-sealing material contained in the backing cloth, and the heat-sealing material is pre-sheathed on the surface of the fiber. It is characterized in that it is formed by melting and solidifying a heat-sealing material having a lower melting point than the above-mentioned fibers and pile yarns.

[0011]

According to the tufted carpet according to the first aspect of the present invention, the base cloth is made of fibers coated with the heat-sealing material in advance, and the pile yarn is planted in the base cloth. When the base cloth is heated in this state, the heat fusion material is melted and adheres to the pile yarn. If it is then cooled, the adhered heat-sealing material is solidified and the pile yarn as a heat-sealing material can be fixed to the base cloth.

According to the tufted carpet according to the second aspect of the present invention, the backing cloth on the back surface side of the base cloth, which is composed of fibers coated with the heat-sealing material in advance after the pile threads are planted in the base cloth. When heated, the heat fusion material melts and adheres to the pile yarn. If it is then cooled, the attached heat-sealing material is solidified and the pile yarn can be fixed to the backing cloth as the heat-sealing material.

[0013]

Embodiments will be described in detail below with reference to the accompanying drawings showing embodiments. FIG. 1 is an enlarged view of a cross section of a tufted carpet (hereinafter referred to as “carpet”) according to an embodiment of the present invention. In this carpet A, the pile yarn 1 is inserted into the base cloth 2 by a tufting machine or the like, and the pile yarn 1
Is directly fixed to the base fabric 2 without forming a backing layer for fixing the.

The base fabric 2 is a non-woven fabric having a high breaking strength which is made of polypropylene 31 having water resistance, which will be described later, and is needle punched without weaving these fibers. As shown in FIG. 2, the polypropylene 31
The fiber made of is coated with polyethylene 32 in a sheath shape. Note that polypropylene 31 has a higher melting point than polyethylene 32.

The pile yarn 1 forms and decorates the surface of the carpet A and is an arbitrary fiber having a higher melting point than the polyethylene 31. Below, Carpet A
The manufacturing processes (1) to (4) will be described. (1) A non-woven fabric is manufactured by needle-punching a fiber made of polypropylene 31, which is previously coated with polyethylene 32 as a heat-sealing material.

(2) Using a tufting machine, the pile yarn 1 is directly tufted onto the base fabric 2 which is the non-woven fabric. (3) When the back surface of the base fabric 2 on which the pile yarn 1 is tufted is heated to a predetermined temperature by, for example, applying hot air, the polyethylene 32 has a melting point higher than that of the fiber made of the polypropylene 31 and the pile yarn 1. Since it is low, the polyethylene 32 melts first. As a result, the melted polyethylene 32 as the heat-sealing material adheres to the pile yarn 1.

(4) In this state, stop heating and cool
The molten polyethylene 32 is solidified. As the heat-sealing material, the melt-solidified polyethylene 32 adheres fibers made of polypropylene 31 constituting the base fabric 2, and fibers made of the polypropylene 31 and the pile yarn 1, respectively.

Through the above steps, the carpet A is manufactured. According to this embodiment, the pile yarn 1 is heat-fused to the fibers inside the base cloth 2 having a high burst strength, so that it is firmly fixed to the base cloth 2. Further, since there is no backing layer made of a conventional latex layer, the carpet is soft and light. Moreover, since the base cloth 2 has water resistance, the fixing force for fixing the pile yarn 1 of the base cloth 2 does not decrease even after washing with water. Therefore, the carpet can be easily rolled up and repeatedly washed with a washing machine or the like, and it is possible to provide a carpet having excellent washability, not only as a carpet as a rug but also as an electric carpet cover.

Further, since the base cloth 2 also has the function of the conventional backing layer, the backing layer is not necessary and the step of fixing the pile yarn 1 to the base cloth 2 is performed by the pile of the base cloth 2. Since it is only necessary to apply predetermined heat in the tufted state of the yarn 1, it is possible to manufacture the inexpensive carpet while suppressing the manufacturing cost. Next, an enlarged view of a cross section of a tufted carpet B according to another embodiment of the present invention is shown in FIG.

Referring to FIG. 3, in this carpet B, a backing cloth 3a for preventing the tufted pile yarn 1 from coming off is used on the back surface of the base fabric 4 tufted with the pile yarn 1. The base cloth 4 is a plain weave cloth shape using polypropylene which has been generally used conventionally.
The feature of this another embodiment is that the backing cloth 3a is not the conventional latex layer 30 shown in FIG. 4 but the one having the same structure as the base cloth 2 shown in the one embodiment.

According to this another embodiment, instead of the conventional backing layer using latex, the backing layer 3 having the same structure as the base fabric 2 shown in the above-mentioned one embodiment is used as it is.
Since it is used as a, the backing layer for firmly fixing the pile yarn 1 can be processed easily and inexpensively by the same steps as those shown in the above-mentioned embodiment in the backing processing. Further, the same effects as those shown in the above-described embodiment, that is, the effect that the carpet B that is soft and lightweight and can be easily washed with water can be produced, are provided, and a carpet and an electric carpet cover as a rug excellent in washability are provided. be able to.

When tufting the pile yarn 1, first, the pile yarn 1 is tufted on the base fabric 4, and then the backing fabric 3 is used.
The backing process may be performed by applying a, or the pile fabric 1 may be tufted after the base fabric 4 and the backing fabric 3a are overlapped, and then the back surface of the backing fabric 3a may be heated to perform the backing process. The present invention is not limited to the above-mentioned embodiment, and as the fiber whose surface is coated with the heat-sealing material, the heat-sealing material used as the covering material has a melting point higher than that of the material used as the core material. If it is low, a combination of arbitrary materials can be used.

For example, general polyester (melting point 263 ° C.) is used as the core material, and low melting point polyester (11
Fused fiber (manufactured by Toyobo Co., Ltd .; trade name Eslanal) using 0 ° C.) may be used. Further, a combination of PET resin and other resin may be used. Further, the base fabric 2 is not limited to the non-woven fabric, and may be plain weave or the like.

Further, as a heating method, in addition to the hot air treatment, a plate material or the like heated to a predetermined temperature may be pressed. In addition, various design changes can be made without changing the gist of the present invention.

[0025]

According to the tufted carpet of the first aspect of the present invention, since the pile yarn is heat-fused to the fibers inside the base cloth having high burst strength, it is firmly fixed to the base cloth. Further, since there is no backing layer made of a conventional latex layer, the carpet is soft and light. In addition, since the base cloth is made of fibers having water resistance, the carpet has water resistance, and there is no fear that the adhesion strength to the pile yarn will decrease due to washing with water. Therefore, the carpet can be easily rolled and repeatedly washed with water in a washing machine or the like.

Further, the conventional backing layer can be eliminated, and the pile yarn can be fixed to the base fabric only by applying predetermined heat in a state where the pile yarn is tufted on the base fabric. It is possible to manufacture inexpensive carpets by suppressing the above. According to the tufted carpet according to the second aspect, the pile yarn is heat-fused to the fibers inside the backing cloth having high burst strength, and thus is firmly fixed to the backing cloth.

Further, since a backing cloth composed of fibers having water resistance is used instead of the conventional backing layer composed of a latex layer, the carpet is soft and light. Moreover, since the backing cloth is made of fibers having water resistance, the carpet has water resistance, and there is no fear that the fixing force for fixing the pile yarn of the backing cloth is lowered by washing with water. Therefore, the carpet can be easily rolled and repeatedly washed with water in a washing machine or the like.

Further, since it is sufficient to apply a predetermined heat to the backing cloth at the time of the backing process, the manufacturing cost can be suppressed and an inexpensive carpet can be manufactured.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view of a tufted carpet according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of fibers constituting the base cloth.

FIG. 3 is an enlarged sectional view of a tufted carpet according to another embodiment of the present invention.

FIG. 4 is an enlarged cross-sectional view of a conventional tufted carpet.

[Explanation of symbols]

 1 Pile yarn 2 Base cloth 3a Backing cloth 31 Polypropylene (fiber) 32 Polyethylene (heat sealing material) A Carpet B Carpet

Claims (2)

[Claims] 1. A pile yarn (1) comprising a pile yarn (1) and a base fabric (2) comprising fibers (31) made of a water resistant resin and having the pile yarn (1) planted therein. Is adhered to the fibers (31) by a heat-sealing material contained in the base fabric (2), and the heat-sealing material is preliminarily sheathed on the surface of the fibers (31). A tufted carpet comprising a melt-solidified heat fusion material (32) having a lower melting point than the fiber (31) and the pile yarn (1). 2. A pile yarn (1), a base fabric (4) in which the pile yarn (1) is planted, and a fiber (31) provided on the back surface of the base fabric (4) and made of a waterproof resin. And a backing cloth (3a) having a pile thread (1) fixed thereto, wherein the pile thread (1) is fixed to the fiber (31) by a heat fusion material contained in the backing cloth (3a). The heat-sealing material comprises a heat-sealing material (32) having a lower melting point than that of the fiber (31) and the pile yarn (1), the surface of the fiber (31) being covered in a sheath shape in advance. A tufted carpet characterized by being made by melting and solidifying.