JPS5846144Y2 - Primary lining for tufted carpets - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a backing for tufted carpets that eliminates glinting and is easily penetrated by tufted needles.

Conventionally, jute, cotton sackcloth, etc. have been used as the backing material for tufted carpets, but due to problems such as stability against stress, chemical resistance, microbial resistance, and carpet fiberability, polypropylene stretched tape cloth, so-called PP backing, has been used. Crosses are often used.

However, in tufted carpets, there is a phenomenon called glinting where the primary backing can be seen through the pile due to coarse or irregular pile tuft density, pile wear, etc., and PP backing cloth has a glossy texture. The greening was emphasized and the quality of the product was significantly lowered.

As a second countermeasure, there are examples of laminating a nonwoven fabric on a PP backing cloth, but since the single fibers that make up the nonwoven fabric are highly stretched and oriented, it has high strength but lacks flexibility and is difficult to cut.

Therefore, when non-woven fabrics are laminated, the penetration of tufting needles is inhibited, reducing the weavability of the carpet, and the position of the pile tends to shift.

The present invention solves these problems, and the gist of the invention is to create a tufted carpet in which a woven fabric made of drawn thermoplastic resin fibers with a flat cross section is laminated with a thermoplastic resin undrawn expanded defibrated web. It's the lining.

The present invention will be explained below using the drawings.

The thermoplastic resin unstretched foamed web used in this invention is
A thermoplastic resin such as polypropylene is blended with one or more blowing agents that generate gases such as N2 and CO2 at its molding temperature in an amount of about 0.007 to 3% by weight, and the mixture is molded through a die slit with a gap of 0.1 to 2 mm. It is obtained by melt extrusion, applying a draft at a draft ratio of 5 or more, preferably 20 to 150, and defibrating it into a net shape.

Figure 1 is a plan view schematically showing the mechanism of this foaming and defibration. In the thermoplastic resin sheet 1a that has been stretched by a draft without substantially molecular orientation, the air bubbles 2a are also elongated. The fibers are split to form an unstretched, expanded, defibrated web of thermoplastic resin in which fine single fibers are connected in a network.

This web can be obtained simply by melt extruding a thermoplastic resin containing a foaming agent through a die slit and applying a draft, so it is significantly cheaper than conventional nonwoven fabrics.

That is, conventional nonwoven fabrics are expensive because they undergo various processes such as stretching, crimping, cutting, and carding.

Furthermore, most of the single fibers in this web are fine, about 5 to 20 deniers, and are substantially unstretched and have a strength of less than 1 g/d, which inhibits the penetration of tufting needles. Compared to conventional cloth fabrics, the web is laminated and the single fibers that make up the web are connected in a network, making it difficult to grind, and unevenness is formed on the surface of the single fibers due to foaming and fibrillation. This has the effect of maintaining the quality of the tufted carpet as a product, since light is diffusely reflected and greening is not noticeable.

The woven fabric made of stretched thermoplastic resin fibers having a flat cross section used in the present invention is made by strongly stretching polypropylene, polyethylene, etc. by a factor of 4 to 5 times or more to make it highly oriented.
, a tape-like material having a strength of 5 to 4 g/d or more, a flat monofilament, etc., as shown in the plan view of Fig. 2.
This is a woven fabric 5 woven using warp threads 3 and weft threads 4.

Since this woven fabric 5 has highly oriented warp yarns 3 and weft yarns 4, it is unstable against stress, unpleasant odors, water, and chemicals, and is susceptible to microorganisms, unlike conventional primary linings such as jute and rough cloth. There is no parasitism.

Further, since the warp threads 3 and the weft threads 4 have flat cross sections and are highly oriented, they have low penetration resistance to the tufting needle and are not likely to be cut.

Note that examples of adhesive means for laminating the woven fabric and the unstretched expanded defibrated web of thermoplastic resin include the use of an adhesive, the use of an adhesive film, and point heat fusion.

As shown in the plan view of FIG. 3, the tufted carpet lining 9 of the present invention has a woven fabric 5 made of thermoplastic resin fibers having a flat cross section, and a thermoplastic resin unstretched foamed web 6. Laminated.

FIG. 4 is a cross-sectional view of a tufted carpet using the primary backing of the present invention.

Warp yarn of thermoplastic resin drawn fibers having a flat cross section 3
A thermoplastic resin unstretched expanded defibrated web 6 is laminated on a woven fabric 5 made of a weft yarn 4 and a weft yarn 4 with an adhesive film 7 interposed therebetween.

The pile threads 8 pass through the primary lining 9 and are secured to the secondary lining 11 by means of an adhesive 10 such as latex.

As mentioned above, the tufted carpet lining of the present invention has excellent stress stability, chemical resistance, and microbial resistance, is inexpensive, improves carpet weavability, eliminates greening, and improves quality. This is to improve the decline.

[Brief explanation of the drawing]

Figures 1A, B, and C are plan views schematically showing the foaming and defibrating mechanism of the unstretched and defibrated thermoplastic resin web used in the present invention, and Figure 2 is a flat cross-sectional view used in the present invention. 3rd plan view of a woven fabric made of thermoplastic resin drawn fibers having
The figure is a plan view of the secondary lining for a tufted carpet of the present invention, and FIG. 4 is a sectional view of a tufted carpet using the primary lining of the present invention. The symbols in the figure are 1, 1 a, 1 b... melt-extruded thermoplastic resin sheet), 2, 2 a, 2 b
...Bubble, 3...Warp thread, 4...
... Weft thread, 5 ... Woven fabric, 6 ... Thermoplastic resin unstretched foamed web, 7 ... Adhesive film, 8 ... Pile Yarn, 9...Primary lining, 10...Adhesive, 11...Secondary lining.

Claims (1)

[Scope of utility model registration request] A lining for tufted carpets comprising a woven fabric made of stretched thermoplastic resin fibers having a flat cross section and a thermoplastic resin unstretched expanded defibrated web laminated.