JPH06335420A - Tufted carpet - Google Patents

Abstract

PURPOSE:To provide a carpet which has flexibility to be easily folded and stored, fiber web of which is bonded to the back stitch firmly, fuzzing of the fiber web is suppressed and hard to be worn, which is hard to be slipped around when it is spread on a primary carpet, and has plenty of durability and cushion property. CONSTITUTION:Fiber web 13, fiber on the outside 18 to be the back face of a tufted carpet 14 of which is heat-set, the inside 15 to be a lamination face with a back stitch 11 of which is in a fuzzed state, and the fiber density of the outside 18 of which is denser than the inside 15, is lined to the back stitch 11 to make the tufted carpet 14.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufted carpet backed with a fiber web.

[0002]

2. Description of the Related Art A back stitch of pile yarn is lined on a back surface of an original fabric of a tufted carpet so as to form a loop. Therefore, at the time of the backing process for fixing the pile to the base fabric, the backing process is performed in which the secondary base fabric is overlaid on the surface of the adhesive for backing and the unevenness due to the backstitch is covered to finish it flat. Conventionally, a woven fabric has been used as the secondary base fabric, but when the tufted carpet is laid on a carpet laid in advance (hereinafter referred to as a primary carpet), the tufted carpet ( In order to prevent the secondary carpet from slipping on the primary carpet, a porous non-woven fabric that easily engages with the pile of the primary carpet is used as the secondary base fabric for the secondary carpet. Became.

[0003]

A non-woven fabric used as a secondary base fabric is disclosed in Japanese Utility Model Laid-Open No. 62-182681 (Japanese Utility Model Publication 4-3).
No. 7513), a non-woven fabric is used in which a woven fabric is entangled with a fiber web having a basis weight of 100 to 300 g / m ² based on fibers of 3 to 15 denier. However, in this case, the fibers of the fiber web are only entangled with the woven fabric, so that they tend to be rubbed against the pile of the primary carpet and scraped off during use, and the secondary carpet lacks durability. Therefore, JP-A-63-305819 (Japanese Patent Publication No. 31247/1992)
Is a non-slip anti-slip structure in which the front and back sides are connected by a perforation thread sewn on the fiber web at fine intervals and a resin with a large friction coefficient (hereinafter referred to as anti-slip resin) is applied and impregnated in dots to prevent fuzzing. A non-woven fabric is used as the secondary base fabric. However, the coating of anti-slip resin is rich in viscoelasticity and weak, and the binding force between fibers is poor, and when the machine is hooked, the fiber web becomes expensive and the fibers are bound by the perforation lines, so that the fiber web It is not suitable for lining a thick fibrous web that has a low bulkiness and is inflated to a high volume and has cushioning properties. In addition, in actual development Sho 63-189062 (actual fair 4-11581),
Laminate a fiber web on the coated surface of the adhesive for backing and press it,
The backing adhesive is permeated and extruded onto the outer surface of the fibrous web, and the permeating backing adhesive fixes the fibers on the outer surface of the fibrous web in a granular form. However, when the backing adhesive is permeable and extruded to the outer surface, the voids between all the fibers in the fiber web will be filled with the backing adhesive, so the entire fiber web becomes the backing adhesive. It is hardened and loses its cushioning properties, forming a hard resin sheet. For this reason, the tufted carpet obtained lacks cushioning properties and is difficult to wind up in a roll shape, and when it is folded, cracks are likely to occur in the folds on the back surface, which makes it difficult to fold and store the carpet.

[0004]

SUMMARY OF THE INVENTION Therefore, according to the present invention, in a tufted carpet 14 in which a fibrous web 13 is lined and laminated, the tufted carpet 14 can be easily rolled up in a roll shape and can be folded and flexibly finished so as to be easily stored. ,
Firmly bond the fiber web 13 to the back stitch 11,
In addition, the first purpose is to suppress fluffing of the fibrous web 13 on the back surface and make it difficult to wear. A second object of the present invention is to obtain a tufted carpet which is hard to be displaced by being laid on a primary carpet as a secondary carpet. A third object of the present invention is to make the backing laminated fibrous web 13 highly durable and cushioning.

[0005]

A tufted carpet 14 according to the present invention is formed by backing and laminating a fibrous web 13 with a backing adhesive 12 applied to a backstitch 11 and backing and laminating the fibrous web 13. The fibers on the outer surface side 18 of the fiber web 13 are heat set, and the fibers on the inner surface side 15 of the fiber web 13 to be bonded to the back stitch 11 are not heat set and are fluffed. The fiber density of the outer surface side 18 of the web 13 is denser than that of the inner surface side 15 of the fiber web 13.

[0006] The backing adhesive 12 does not permeate the fiber web 13 and exude to the outer surface side 18, and
It is applied so that it penetrates between the fibers on the inner surface side 15. In that case, since the fibers are not heat set and fluffed on the inner surface side 15 of the fiber web 13 which is the bonding surface with the back stitch 11, it is not necessary to increase the coating amount of the adhesive 12 for backing. Also, even if a large amount of a filler such as talc or calcium carbonate is added to the backing adhesive 12, the backing adhesive 1
The fibers of the inner surface side 15 are firmly adhered to the back stitch 11 by 2 and the backing adhesive 12 becomes difficult to penetrate into the inside 16 while being hindered by the fluffed fibers of the inner surface side 15. Since the fibers on the outer surface side 18 of the fiber web 13 are heat-set even if the bleeding does not occur, fluffing is less likely to occur and abrasion is less likely to occur.

For that purpose, the fiber web 13 is composed of at least two kinds of fibers having a melting point temperature difference of 50 ° C. or more, and the low melting point fiber therein is a heat-fusible fiber having a melting point temperature of 150 ° C. or less. Then, a heating roll is applied to the outer surface side 18 of the fiber web 13 to fuse the heat-fusible fibers to the other fibers on the outer surface side 18.

The fiber web 13 thus heat-set
Since the outer surface side 18 is smooth and slippery, a slip resistant resin 19 is applied to the surface thereof. The anti-slip resin 19 includes
A resin emulsion containing butadiene as a component such as styrene / butadiene / latex or styrene / butadiene / acrylic resin emulsion is used. In that case, the content of butadiene in the whole resin should be 65 to 80% by weight, and if it is less than 65% by weight, the slipperiness of the resin coating film 19 becomes poor, and it exceeds 80% by weight. Therefore, the resin coating film 19 is not suitable because it has tackiness (adhesiveness) and is easily soiled. Further, a filler may be blended in the backing adhesive 12, but it should not be blended in the antislip resin 19, and preferably the weight ratio of the filler to the antislip resin 19 is set to zero. Even if a functional filler is added in order to color 19 or make it flame-retardant,
The blending amount is set to be half or less of the weight ratio of the filler in the backing adhesive 12.

Prior to the application of the anti-slip resin 19, the outer surface 1 of the fiber web 13 attached to the back stitch 11
8 is preferably impregnated with an elastic adhesive 17 that forms a softer coating film that is more elastic than the backing adhesive 12. When the fibrous web 13 is bonded to the backstitch 11 as described above and then the elastic adhesive 17 is applied and impregnated prior to the slip resistant resin 19, the elastic adhesive 17 is applied to the backstitch 1.
1 penetrates into the inside of the fiber web without reaching the bonding surface (15) with 1, and bonds the fibers of the inside 16 to bond the fiber web 13
Can have a porous cushion structure. To this end, the elastic adhesive 17 is applied in such an amount that the voids 20 remain between the fibers in the interior 16 of the fiber web 13 and such voids 20 remain.
It is advisable to dilute 7 and spray the fibrous web 13 without pressing it, and apply the anti-slip resin 19 after that by spraying with the viscosity adjusted so as not to penetrate into the fibrous web 13. In order to make the fiber web 13 into a cushion layer having the voids 20 in the inside 16, the fiber web 13 has a bulk density of 0.7 or less and an apparent thickness of 2 or less.
mm or more, generally 2 to 10 mm. Here, the bulk density (M) of the fiber web 13 is the basis weight (W; g) of the fiber web.
/ M ² ) is calculated by dividing the specific gravity (δ; g / cm ³ ) of the fibers forming the fiber web 13 and the apparent thickness (t; cm) of the fiber web 13. That is, the bulk density (M) of the fiber web 13 is M = W (g / m ² ) ÷
[Δ (g / cm ³ ) × t (cm) × 10000 (c
m ² )].

[0010]

The tufted carpet 14 according to the present invention
Is a fibrous web 1 to be a surface to be bonded with the back stitch 11.
In the inner surface side 15 of 3, the fibers are not heat set and are in a fluffed state, and it is difficult for the backing adhesive 12 to permeate into the inside 16 due to the fibers of the fluffed inner surface side 15. Is firmly adhered to the back stitch 11 by the backing adhesive 12, and the coating amount of the backing adhesive 12 is small, while the backing adhesive 12 is small and the outer surface 18 of the fiber web 13 does not seep out. Since the fibers are heat-set, they are less likely to fluff and wear.

Since the application amount of the backing adhesive 12 is small as described above, the tufted carpet 14 can be easily rolled up in a roll shape, and can be folded to be easily stored, and can be easily stored. 13 is firmly adhered to the back stitch 11 and the backside fiber web 13
The fluff is suppressed and it becomes hard to wear. In particular,
The fiber web 13 is composed of at least two kinds of fibers having a melting point temperature difference of 50 ° C. or more, and the low melting point fiber therein has a melting point temperature of 150 ° C. or less.
When the low melting point fiber is fused to the other fiber on the outer surface side 18 of No. 3 by heat setting, the outer surface side 18 becomes less fluffy and has excellent abrasion resistance.

The fiber web 13 has an outer surface 18
Since the fluff is suppressed by heat setting, it has air permeability and does not prevent evaporation of water (volatile matter) of the backing adhesive 12.

Further, by coating the outer surface side 18 of the fiber web 13 with the anti-slip resin 19, it is possible to obtain a tufted carpet which is hard to be displaced by being laid on a primary carpet. Since the outer surface 18 is heat-set and smooth without fluffing, the amount of the anti-slip resin 19 applied is small, and the outer surface 18 of the heat-set fibrous web 13 is less fluffed and worn by the anti-slip resin 19. Difficult, smooth, and beautifully finished.

The elastic adhesive 17 is applied to the porous interior 16 which is not filled with the backing adhesive 12 and has voids 20 between the fibers, so that the fiber web 13 is porous and has elasticity equivalent to that of the foamed resin elastic body. The elastic structure of the fibrous web 13 integrated with the elastic adhesive 17 has voids formed by bubble cells surrounded by a thin resin film such as a foamed resin elastic body. However, since the voids 20 are surrounded by fibers that are much less likely to be broken than the resin film of the cell, unlike the foamed resin elastic body, it is difficult for the layers to be peeled off, thereby improving durability and cushioning properties. Rich tufted carpet 1
4 is obtained.

Thus, according to the present invention, the fiber web 13 is easily rolled up into a roll, has the flexibility such that it can be folded and stored easily, and the fiber web 13 is firmly adhered to the back stitch 11. The tufted carpet 14 having excellent durability and cushioning property can be obtained, in which fluffing is suppressed and it is hard to be worn, and it is hard to displace and move when laid on a primary carpet.

[Brief description of drawings]

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

[Explanation of symbols]

 11 Backstitch 12 Adhesive for Backing 13 Fiber Web 14 Tufted Carpet 15 Inner Surface of Fiber Web 16 Inner Surface of Fiber Web 17 Elastic Adhesive 18 Outer Surface of Fiber Web 19 Antiskid Resin 20 Void

Claims (2)

[Claims] 1. A tufted carpet 14 in which a fiber web 13 is lined and laminated with a backing adhesive 12 applied to a backstitch 11, and (b) the fiber web 13 has a melting point temperature difference of 50 ° C. or more. And the melting point temperature of the low melting point fiber is 150 ° C. or less, and (c) the outer surface side 18 of the fiber web 13 which is the back surface of the tufted carpet 14. The fibers having a low melting point are fused to other fibers by heat setting, and (d) the fibers on the inner surface side 15 of the fiber web 13 which is the bonding surface with the back stitch 11 are not heat set and become fluffy. (E) A tufted carpet characterized in that the fiber density of the outer surface side 18 of the fiber web 13 is denser than that of the inner surface side 15 of the fiber web 13. 2. The tufted carpet according to claim 1, wherein the surface of the outer side 18 of the fibrous web 13 according to claim 1 is coated with an anti-slip resin 19.