JPS59195431A - Carpet having molding property and manufacture thereof - Google Patents

Abstract

PURPOSE:To eliminate packing treatment and to provide with size stability and molding property, by a method wherein a plushy layer is formed on the surface of a plastic sheet serving as foundation. CONSTITUTION:In a carpet 10, a plushy layer 2 is formed on the surface of a plastic sheet 1. The plastic sheet 1 is thermoplastic and is used in, for example, a car floor mat. Exposed parts 1A and formed on the plastic sheet 1, and this enables the sheet to form a heel mat and a side mat. A carpet is manufactured by the method wherein a web layer of synthetic fiber or natural fiber is formed on the back of the plastic sheet 1, a fleece layer is formed by felt needles, and with folk needles pierced through, a plushy layer is formed on the surface of the plastic sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a moldable carpet and a method for manufacturing the same.

Conventionally, carpets, especially needle carpets, are made by intertwining them with a web felting needle to form a fleece, and then raising the fleece with a 7 oak needle, but because the shape is maintained only by the intertwining of the fibers, it is easy to unravel. It has poor dimensional stability, and when used as an automobile floor covering, it must be molded into a shape that conforms to the shape of the automobile floor, but there is no moldability in this case.

Therefore, a rubber layer or a synthetic resin layer is usually formed by coating the back side of the carpet with rubber latex or synthetic resin emulsion and drying, thereby imparting dimensional stability and moldability to the carpet. This treatment of the back surface of the carpet is called backing, but backing treatment lengthens and complicates the carpet manufacturing process and is not desirable.

The present invention aims to eliminate the above-mentioned carpet banking process, and its main feature is to use a plastic sheet as the base of the carpet.

To explain the present invention using an embodiment shown in the drawings, in Carbela QO, (1) is a plastic sheet,
(2) is a nap layer formed on the surface of the plastic sheet (1). The plastic sheet (1) is made of polyethylene, polypropylene, ethylene ionomer, ethylene-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, polyvinyl chloride, acrylonitrile-butadiene-styrene copolymer, polyamide, polyester, etc. Made of plastic. The above examples are not intended to limit the invention. As shown in FIG. 2, the carpet αQ is used, for example, as an automobile floor covering, and is formed into a shape that conforms to the shape of the automobile floor. The dimensional stability and moldability of Carbella) QO are provided by the above plastic sheet (1) and no backing treatment is required, but when it is used as an automobile floor covering, heel mats and side mats are usually attached to the carpet surface. do.

However, in the case of the present invention, the raised layer (2) is not formed at the attachment position of the heel mat or side mat, and the exposed part (1) A of the plastic sheet (1) is provided. There is no need to use extra parts such as 9, and resources can be saved.

The most suitable method for manufacturing the carpet of the present invention is described below.

The method consists of the following three steps.

1. Step of laying a web layer on the back side of the plastic sheet 1゜2. Intertwining the web layer with a felt needle 7.
Step 2゜3 of forming a lithium layer; Step 3 of forming a raised layer on the surface of the plastic sheet by piercing the fork needle from the side of the 7th lithium layer; Step 1. In this case, recycled fibers, polyester fibers, acetate fibers, polyamide fibers, and acrylic fibers are used on the back side of the plastic sheet (1).

A web layer (2
) Laying A. This situation is shown in FIG. The web layer (2)A usually has a thickness of 5 to 8.

Step 2. In this step, the web layer (2) A is entangled with a felt needle (3) to form a fleece layer (2) B as shown in FIG.

Step 3. In this step, a fork needle (4) is pierced from the B side of the seven squirrel layers (2) as shown in FIG. 5 to form a napped layer (2) on the surface of the plastic sheet (1).

In order to partially form the napped layer (2) in the above method, for example, as shown in FIG. After forming the fleece layer (2) B with a fork needle (4), the raised layer (2) is partially formed with a fork needle (4)
) and also provide an exposed part (1)A, or as shown in Figure 7, a web layer (2)A is laid only on the part where the raised layer is formed on the back side of the plastic sheet (1), and 7 leases are formed in the same manner. There is a way to make the hair look soft and erect. In the former method, the portion B of the seven squirrel layers (2) other than the napped layer (2) functions as a cushion layer for the exposed portion (1) A of the plastic sheet (1).

The carpet of the present invention may be manufactured by methods other than those described above. For example, the web layer may be made into seven layers [7] and then laminated on a plastic sheet, or it may be manufactured by a tufted carpet method as shown in FIG. 8, other than the needle carpet method.

As described above, the present invention uses a plastic sheet as a base material and forms a napped layer on its surface, so the plastic sheet provides dimensional stability and moldability and eliminates the need for backing treatment. In addition, it is easy to partially form a raised layer to provide an exposed part of the plastic sheet, and there is no need to attach heel mats or side mats when applying force to the shape of a car floor. It becomes possible to save resources.

[Brief explanation of drawings]

The drawings show one embodiment of the present invention; Fig. 1 is a side sectional view, Fig. 2 is a perspective view of a molded product, and Fig. 3 and subsequent figures show manufacturing steps. ．． The side cross-sectional view of FIG. 4 shows step 2. 5 is a side sectional view of step 3.0,
Fig. 6 is a side sectional view of one embodiment of the carpet with a partially formed nap layer, Fig. 7 is a side sectional view of another embodiment, and Fig. 8 is a side sectional view of another embodiment of the carpet. be. In the figure, (1)...Plastic sheet, (1) A...
・;・Exposed part, (2)・・・・Pili layer, (2)A・・・・
・Web layer, (2) B...fleece layer, (3)...
... Felt needle, (4) ... Fork needle Patent applicant Ikeda Bussan Co., Ltd. Procedural amendment July 21, 1981 Special exemption Master and student No. 068786 2, Title of invention Moldable carpet and manufacture thereof Method 3 Relationship with the person making the amendment Patent applicant 4, agent address 32-6 Tsukimigaoka, Yatomi-cho, Mizuho-ku, Nagoya
The number of inventions that will be increased due to the amendment. Figures 1 to 8 are revised to the attached drawings. Death 1 Figure 2 Figure 3 Figure 5 Figure 6 Figure 7 Figure 8

Claims (1)

[Claims] 1. A moldable carpet having a raised layer on the surface of a plastic sheet. 2. Step of laying a web layer on the back side of the plastic sheet. 1. The web layer is entangled with a felt needle to form a fleece layer. Step 2: Step 3 of forming a raised layer on the plain surface of the plastic sheet by piercing the fork needle from the side of the 7-liss layer 1. ．． 2. ．． 8. A method for producing a moldable carpet comprising: 3. The moldable carpet according to claim 1, wherein the raised layer is partially formed to provide an exposed portion of the plastic sheet.