JPH1161629A - Tufted pile fabric reinforced in strength resistant to pulling of pile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent piles from slipping off from a primary base fabric, even when the tufted piles are not especially treated, after tufted. SOLUTION: This tufted pile fabric is obtained by tufting piles 20 on a primary base fabric 13 to whose back stitch surface a foamable resin composition 11 is coated and laminated and which has a thickness of >=1 mm. Even when the primary base fabric 13 does not have a sufficient elastic restoring force for closing needle penetration holes 25 formed by the slipping movements of fibers constituting the base fabric 13, the fibers around the needle penetration holes 25 are elastically bound to each other through the resin composition 11, and the elastic restoring force of the resin composition acts so as to close the needle penetration holes 25. Thereby, the piles 20 are surely engaged with the primary base fabric 13. Even when back stitches 15 are not adhered and fixed to the primary base fabric 13 with a latex emulsion resin, the tufted pile fabric 18 having a pile pulling-resistant strength required for practical uses is thereby obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to prevention of slippage of a pile from a primary base cloth of a tufted pile cloth in which a pile yarn is inserted into a primary base cloth by a needle to form a pile.

[0002]

2. Description of the Related Art Tufted pile fabric used for carpets, dust control mats, artificial turf, cushioning materials, sound absorbing materials, heat insulating materials, etc. has latex stitched on its back stitch surface to prevent the pile from slipping off from a primary base fabric.・ Apply emulsion resin or other liquid resin composition,
The back stitch is firmly adhered and fixed to the primary base fabric.

As a method of preventing the pile from slipping off from the primary base cloth, a method of mixing heat-fusible fibers in the primary base cloth, heating the heat-fusible fibers after toughening and fusing the fibers to the back stitches. (JP-A-6-146155 and JP-A-7-146)
250803) Also, two base cloths having different elasticities are overlapped to form a primary base cloth, and a shear stress from the base cloth is applied to the base of the pile due to a difference in expansion and contraction that appears after toughening on the two base cloths. Method (JP-A-7-30525)
8) has been proposed.

[0004]

The step of bonding and fixing the pile to the primary base cloth with the liquid resin composition or the heat-fusible fiber is a post-step of the tufting step, and the number of man-hours increases by the subsequent step. To provide a tufted pile fabric (quick order) in response to
In addition, since the heating of the liquid resin composition and the heat-fusible fibers is an essential means in the bonding and fixing step, deformation of the tufted pile fabric due to heat shrinkage, irregular pile lengths, and brittle discoloration of the pile surface are caused. It is easy to become a problem and cannot meet the demands of the age of energy saving.

[0005] In the above-mentioned method using two base fabrics having different elasticities in an overlapping manner, when a difference in expansion and contraction occurs between the two base fabrics overlapping with each other, a warp such as bimetal is formed on the primary base fabrics on which the base fabrics overlap. And it becomes difficult to obtain a tufted pile fabric having a stable shape.

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a tufted pile fabric having a pile pulling strength required for practical use without performing any special treatment after tufting.

[0007]

In the tufted pile fabric 18 according to the present invention, the pile 20 is tufted on the primary base fabric 13 having a thickness of 1 mm or more in which the foamed resin composition 11 is applied and laminated on the entire back stitch surface. This is a first feature.

The second feature of the tufted pile fabric 18 according to the present invention is that, in addition to the first feature, the expansion ratio of the foamed resin composition 11 is 2 to 7 times, Has a thickness of 1 to 5 mm.

A third feature of the tufted pile fabric 18 according to the present invention is that, in addition to any one of the first and second features, the primary base fabric 13 is formed by removing the fluff of the base fabric 12 having fluff. The foamed resin composition 11 foamed at a foaming ratio of 2 to 7 times is coated and laminated on the surface having the composition.

A fourth feature of the tufted pile fabric 18 according to the present invention is that, in addition to any of the first and second features, the primary base fabric 13 is laminated on the base fabric 12 and needle punched. The foamed resin composition 11 foamed at a foaming ratio of 2 to 7 times on the applied fiber web 14 is applied and laminated.

A fifth feature of the tufted pile fabric 18 according to the present invention is the back stitch 15 of the primary base fabric 13 in addition to any one or more of the first, second, third, and fourth features. Is that the thickness of the portion 19 where the overlaps is smaller (thinner) than the thickness between the adjacent back stitches 15.

A sixth feature of the tufted pile fabric 18 according to the present invention is that the first and second, third, fourth and fifth features are described above.
In addition to any one or more of the above characteristics, the foamed resin composition layer 11
However, a test piece prepared in the form of a non-foamed film using the resin composition and prepared in the form of a No. 2 dumbbell in accordance with JIS K 6301 "Testing method for vulcanized rubber properties" was picked up to 500 cm with an interval of 2 cm. Set to ± 25mm / min constant speed tensile tester, measure the load and elongation at break,
It has physical properties such that the breaking strength calculated by dividing the load at break by the cross-sectional area of the specimen is 33 kgf / cm ² or less and the elongation at break is 500% or less.

A seventh feature of the tufted pile fabric 18 according to the present invention is that, in addition to any one or more of the first and second, third, fourth, fifth and sixth features, a foamed resin The composition layer 11 is prepared by the resin composition 11 into a non-foamed film, 5 cm long, 5 cm wide, and 0.5 m thick.
m test piece is attached to the bottom surface of a square glass plate having a length of 5 cm, a width of 5 cm, and a height of 5 mm, and the test piece is placed on a horizontal glass plate with the test piece facing down, and the test piece is attached to the square glass plate. A 1 kg load is placed on the square, and the friction coefficient expressed by a tensile load when the square glass plate is horizontally pulled and started to move is 1700 g or more.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the tufting process, the primary base cloth 13 is continuously conveyed, and when the needle 22 is inserted, the needle 22 causes the primary base cloth 13 to be unloaded at the delivery side 23 of the primary base cloth 13. The needle 22 acts so as to stop and the needle 22 acts to pull the primary base cloth 13 against the tensile stress applied from the drawer roll on the pull-out side 24 of the primary base cloth 13, so that the needle through-hole 25 is elongated vertically and large. It becomes a gap.

The toughened pile 20 is locked by the elastic restoring force of the primary base cloth 13 which attempts to close the needle through-hole 25, but in the present invention,
Even if the resin composition layer 11 is applied and laminated on the primary base cloth 13, the primary base cloth 13 does not have a sufficient elastic restoring force to close the needle through-hole 25 formed by the displacement movement of the fiber constituting the primary base cloth 13. Since the fibers around the needle through-hole 25 are elastically connected via the resin composition 11 and the elastic restoring force of the resin composition 11 acts to close the needle through-hole 25, the pile is formed. 2
0 is firmly locked to the primary base cloth 13, and as a result, the back stitch 15
Pile fabric 18 having pile pull-out strength required for practical use without having to adhere and fix to the primary base fabric 13
Is obtained.

The reason why the thickness of the primary base cloth 13 is set to 1 mm or more is to improve the entanglement between the needle through hole 25 and the base of the pile 20, and the elastic restoring force of the resin composition 11 acts on the base of the pile 20. This is to make it easier. The resin composition 11 is foamed because the resin composition 11 penetrates deeply into the inside of the base cloth 12, all the fibers of the base cloth 12 are strongly bonded by the resin composition 11, and the primary base cloth 13 is hard and finished. As a result, the resistance received from the primary fabric of the needle is increased so that the tufting does not become difficult.

In order for the resin composition 11 to strongly adhere to the base cloth 12 without deeply penetrating into the inside, the resin composition 11 is mechanically foamed 2 to 7 times to obtain
The base cloth 12 is coated with a thickness of 5 mm, and the base cloth 12 is made of a fluffed nonwoven fabric, a raised woven fabric or knitted fabric, or a fibrous web 1.
It is preferable to use a needle-punched cloth obtained by laminating 4 and performing needle punching and entangled with the base cloth 12. Then, the foamed resin composition 11 elastically bonds between the fibers (14) on the surface of the base cloth without deeply penetrating into the base cloth, and when the needle 22 is inserted, the fibers (14) around the needle through hole 25 ( 14) is elastically spread to form the primary base cloth 13
When the needle 22 is pulled out, the space between the fibers (14) around the needle through hole 25 is elastically contracted as before, and the pile 2
The root of “0” is securely held in the needle through-hole 25. In order to elastically bond the fibers (14) on the surface of the base fabric with the foamed resin composition 11, the foamed resin composition 11 is applied to the fluffed surface of the base fabric 12 and the fibrous web 14 in the needle-punched fabric. It is effective to apply and laminate on the lamination surface of. The reason why the expansion ratio limit of the resin composition 11 is set to 7 times is that if the resin composition 11 is expanded at an excessively high magnification, the foamed resin composition which attempts to close the needle through-hole 25 acting between the fibers (14). This is because the elastic restoring force of the material layer 11 is reduced, and the root of the pile 20 cannot be securely held in the needle through-hole 25.

When the thickness of the resin composition layer 11 is 1 to 5 mm and 2
When foamed up to 7 times, the thickness of the pile yarn 21 usually used for carpet is about 1 mm, and the thickness of the thick pile yarn 21 used for artificial turf is 5 mm or less. 15 is buried in a groove 16 formed by cutting into the foamed resin composition layer 11, that is, between the back stitch 15 and the back stitch 15 where the thickness of the portion 19 where the back stitch 15 of the primary base cloth 13 overlaps is adjacent. Become less (thinner) than the thickness, back stitch 1
Since the contact surface between the layer 5 and the foamed resin composition layer 11 is increased, the thread pulling strength of the pile 20 is further improved.

In particular, the resin composition layer 11 is prepared in a non-foamed film form by the resin composition,
6301 A test piece prepared in the form of a No. 2 dumbbell in accordance with the “Vulcanized Rubber Physical Properties Test Method” was picked, and the interval between allowances was 2 cm.
The load at break was measured by measuring the load and elongation at break at a constant speed of 500 ± 25 mm / min, and the breaking strength calculated by dividing the load at break by the cross-sectional area of the specimen was 33 kg.
When the needle 22 acts so as to pull the primary base cloth 13 from the draw-out side 24 in the tufting process, the needle insertion is performed in a material having a physical property of not more than f / cm ^{2 and} an elongation at break of not more than 500%. A crack 26 was formed in the resin composition layer 11 along the large needle through hole 25 formed between the sending side weft (23) and the pulling side weft (24) before and after the location, and the crack 26 was formed. The back stitch 15 is buried deep in the groove 16 by the
0 is more difficult to slip off from the primary base cloth 13. FIG. 1 shows a needle through hole 25 which can be enlarged by being pulled by a needle 22 in a toughening process and a crack 26 of a resin composition layer 11.
In the figure, 27 is a looper, and 28 is a knife for cutting pile yarn.

Further, in order to make it difficult for the pile 20 to slip off from the primary base cloth 13, the resin composition
5 cm long prepared in the form of a non-foamed film by 1
A test piece having a width of 5 cm and a thickness of 0.5 mm is obtained by
cm, attached to the bottom of a 5 mm high square glass plate, placed on a horizontal glass plate with the test piece facing down,
A load of 1 kg is placed on a square glass plate to which a test piece is attached, and the coefficient of friction (hereinafter, referred to as the tensile load when the square glass plate is horizontally pulled and started to move)
It is simply called the coefficient of friction. ) Is preferably 1700 g or more. If the resin composition 11 having such a large coefficient of friction is used, the surface 17 of the resin composition layer 11 between the adjacent back stitches is preferably used. The raised to the height of the back stitch 15 also provides a tufted pile fabric having anti-slip properties.

Specifically, the resin composition 11 contains polyacrylate, vinyl acetate / ethylene copolymer, polyvinyl chloride, styrene / butadiene copolymer, polychloroprene, acrylonitrile / butadiene copolymer, methyl methacrylate. Butadiene copolymer, polyurethane, etc. are used, and calcium carbonate, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, barium hydroxide, basic zinc carbonate, basic lead carbonate, ferric hydroxide, silica sand, talc, clay Foaming agents such as sodium lauryl sulfate, sodium alkyl diphenyl ether disulfonate, sodium polyoxyethylene alkyl phenol ether sulfate, ammonium stearate, alkyl sulfosuccinate, and quaternary alkyl ammonium chloride; Acrylate, carboxymethyl cellulose, thickeners such as methyl cellulose, epoxy resins, melamine resins, isocyanate compounds, breaking strength by blending a crosslinking agent such as zinc resin composition layer 11, elongation,
The coefficient of friction is adjusted.

[0022]

Example 1 A 400d polypropylene tape yarn was used as a warp, a 930d polypropylene tape yarn was used as a weft, and the warp density was 22 yarns / inch and the weft density was 10
A woven fabric (12) having a weight per inch and a basis weight of 80 g / m ² was woven. On this woven fabric (12), a polyester fiber web (having a basis weight of 120 g / m ² ) was laminated and subjected to needle punching, and an acrylic resin emulsion (AE5 manufactured by Nippon Synthetic Rubber Co., Ltd.)
00, resin solids content of 60% by weight), 100 parts by weight of aluminum hydroxide, 5.1 parts by weight of a foaming agent and a thickener in a viscosity of 10,000 mPa.s. s (BM type 25
° C, No. 3-6 rpm) and a resin composition obtained by blending 1 part by weight of a crosslinking agent (epoxy resin) with 100 parts by weight of the compound (solid content: 65% by weight) was foamed to a thickness of 2 m.
m and a primary base cloth (13)
Was manufactured. The primary gauge cloth (13) with the resin composition layer (11) facing the backstick surface is provided with a needle gauge 1 /
An 8-inch acrylic fiber pile yarn having a total denier of 800 d was toughened with a pile density of 35 stitch gauges / 10 cm to obtain a cut pile tufted pile fabric (18) having a pile length of 8 mm. The two-pull pile pullout strength (JIS-L-440) of this tufted pile fabric
5) was a 5.8N / 2-drawing pile. The back stitch (15) of this tufted pile fabric cuts into and adheres to the resin composition layer (11) on the back surface of the primary base fabric (13), and the pile (20) does not slip off from the primary base fabric (13). The surface (1) of the resin composition layer (11) between the adjacent back stitches (15);
7) was raised to the height of the back stitch (15), and the tufted pile fabric (18) did not slip during laying as a doormat. 2 prepared by the resin composition (11) into a non-foamed film
No. dumbbell-shaped test piece has a breaking strength of 31 kgf / cm
^In Example ² , the elongation at break was 417%, and the coefficient of friction of a test piece having a length of 5 cm, a width of 5 cm, and a thickness of 0.5 mm prepared by the resin composition (11) into a non-foamed film was 1,730 g. Met.

[0023]

Example 2 A 930d polypropylene tape yarn was used as a warp, a 930d polypropylene tape yarn was used as a weft, and the warp density was 14 yarns / inch and the weft density was 14
A woven fabric (12) having a weight per inch and a basis weight of 114 g / m ² was woven. A polyester fiber web (having a basis weight of 100 g / m ² ) is laminated on the woven fabric (12) and subjected to needle punching. The resin composition prepared in Example 1 is foamed on the laminated surface (14) of the fiber web. 2mm thick
Were laminated to produce a primary base fabric (13). Acrylic fiber pile yarn having a total denier of 800d and a pile density of 1/8 inch needle gauge and 35 stitch gauge / 10 cm was tufted on a primary base cloth (13) having the resin composition layer facing the backstick surface, A cut pile tufted pile fabric (18) having a pile length of 8 mm was obtained. The two-pull pile pull-out strength (JIS-L-4405) of this tufted pile fabric is 5.
The pile was an 8N / 2-drawing pile, the pile 20 did not slip off from the primary base cloth 13, and the tufted pile cloth (18) did not slip during laying as a door mat.

[0024]

Comparative Example 1 The 400d polypropylene tape yarn used in Example 1 above was used as a warp, the 930d polypropylene tape yarn was used as a weft, and the warp density was 22 yarns /.
The coefficient of friction of the woven fabric (12) having an inch size and a weft density of 10 yarns / inch was 1070 g, and a pile having a needle gauge of 1/8 inch and a stitch gauge of 35 yarns / 10 cm as in the case of Example 1. With density, total denier 800d
The pile pulling strength (JIS-L-4405) of the cut pile tufted pile fabric having a pile length of 8 mm obtained by tufting the acrylic fiber pile yarn of (1) is 0.5.
It was an N / 2-drawing pile.

[0025]

Comparative Example 2 The 400 d polypropylene tape yarn used in Example 1 was used as a warp, the 930 d polypropylene tape yarn was used as a weft, and the warp density was 22 yarns /.
The friction coefficient of the fiber web lamination surface of a needle-punched fabric obtained by laminating a polyester fiber web (basis weight: 120 g / m ² ) on a woven fabric woven at an inch and a weft density of 10 yarns / inch was 500 g. A pile length of 8 mm obtained by tufting an acrylic fiber pile yarn having a total denier of 800 d with a needle gauge of 1/8 inch and a stitch gauge of 35 threads / 10 cm in the same manner as in Example 1 on the needle punched fabric. The two-pile pile pullout strength (JIS-L-4405) of the cut pile tufted pile fabric was 1.3 N / 2-draw pile.

[0026]

According to the present invention, the back stitch 15 bites into and adheres to the resin composition layer 11 on the back surface of the primary base cloth 13, preventing the pile 20 from slipping off from the primary base cloth 13 and backing after tufting. Since the process is omitted or simplified, and the resin composition layer 11 foamed between the back stitches 15 and 15 is raised in a bulky manner, the cushioning property is improved.
A tufted pile fabric having excellent functions such as heat insulation and sound absorption can be obtained economically.

The tufted pile cloth does not need to be coated with a resin composition on the back side to prevent the pile from slipping off.
Therefore, since the needle through hole formed during tufting is kept open, it has excellent air permeability and water permeability, it is easy to dry after washing with water, it is suitable for dust control mats and other small carpets, and there is no water pool on the pile surface It is also suitable for artificial grass.

Since the backing step for preventing the pile 20 from slipping out of the primary base cloth 13 is omitted or simplified, the heat shrinkage deformation of the primary base cloth which has conventionally been caused by the heating in the backing step after tufting, and the like. Problems such as uneven pile length and discoloration and embrittlement of the pile surface can be avoided, and it is possible to meet the demands of the age of energy saving.

In the tufted pile fabric of the present invention,
The back stitch surface of the primary base cloth 13 is a foamed resin composition 11
The surface 17 of the foamed resin composition layer 11 is raised between adjacent back stitches, so that the back stitch 15 is strongly adhered to the primary base cloth 13 by a backing adhesive such as a latex / emulsion resin. If you are going to fix it, the amount of backing adhesive used is small, and if you are going to attach a secondary fabric for reinforcement to the back stitch surface, the secondary fabric will be attached to the back stitch surface It can be used to make mats, carpets, tile carpets, etc. that are in close contact and do not come off.

When a heat-fusible resin such as a vinyl acetate-ethylene copolymer or polyvinyl chloride is used for the resin composition 11, a heat roll may be applied to the back surface of the tufted pile fabric 18 to finish it smoothly. The resin composition layer 11 can be fused to the back stitch 15, and the resin composition layer 11 appearing between the adjacent back stitches can be heated and melted to bond a secondary base fabric. Can be three-dimensionally formed into a vehicle floor material and a vehicle interior material by heating and softening the material.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view in a tufting process of a tufted pile fabric according to the present invention.

FIG. 2 is a sectional view of a tufted pile fabric according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 11 Resin composition layer 12 Base cloth 13 Primary base cloth 14 Fiber web 15 Back stitch 16 Groove 17 Surface 18 Tufted pile cloth 19 Overlapping point 20 Pile 21 Pile yarn 22 Needle 23 Sending side 24 Pull-out side 25 Needle through hole 26 Crack 27 Looper 28 Knife

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Haruhisa Kamata Okayama Prefecture Kiyoon-mura, Kiyoon-mura 2nd Kaminakajima Watanabe Industrial Co., Ltd. Satosho Factory Co., Ltd.

Claims (7)

[Claims] 1. A foamed resin composition 11 on a back stitch surface.
And a pile 20 having a thickness of 1 mm or more and a pile 20 toughened with a pile 20. 2. The foamed resin composition 1 according to claim 1.
1 has an expansion ratio of 2 to 7 times, and its resin composition layer 11
The tufted pile fabric according to claim 1, wherein the thickness of the tufted pile fabric is 1 to 5 mm. 3. The primary base fabric 13 according to claim 1,
2. The tufted material according to claim 1, wherein the foamed resin composition 11 foamed with a foaming ratio of 2 to 7 times is applied to the fluffed surface of the base fabric 12 having fluff. Pile fabric. 4. The primary base fabric 13 according to claim 1,
The foamed resin composition 11 foamed at a foaming ratio of 2 to 7 times is applied on a fiber web 14 which has been laminated on a base fabric 12 and subjected to needle punching. 3. The tufted pile fabric according to item 1. 5. The primary base cloth 13 according to claim 1, wherein the thickness of the portion 19 where the back stitch 15 overlaps is smaller than the thickness between the adjacent back stitch 15. Claim 1 as a feature
3. The tufted pile fabric according to item 1. 6. The foamed resin composition layer 11 according to claim 1 is prepared in the form of a non-foamed film using the resin composition, and the foamed resin composition layer 11 is prepared according to JIS K 6301 “Test method for vulcanized rubber properties”. A test piece prepared in the shape of a dumbbell was picked up and the interval between the picks was set at 2 cm, and 500 ± 25 mm / min.
The load at break and the elongation were measured by setting it in a constant-speed tensile tester, and the break strength calculated by dividing the load at break by the cross-sectional area of the sample piece was 33 kgf / cm ² or less, 2. The tufted pile fabric according to claim 1, having an elongation of not more than 500%. 7. A test piece having a height of 5 cm, a width of 5 cm, and a thickness of 0.5 mm, wherein the foamed resin composition layer 11 according to claim 1 is prepared as a non-foamed film by the resin composition 11, Affixed to the bottom surface of a square glass plate of 5 cm in length, 5 cm in width and 5 mm in height, placed on a horizontal glass plate with the test piece facing down, and placed a 1 kg load on the square glass plate on which the test piece was stuck. The tufted pile cloth according to claim 1, having a physical property such that a friction coefficient represented by a tensile load when the square glass plate is horizontally pulled and started to move is 1700 g or more.