JPS6211998Y2 - - Google Patents

Description

[Detailed Description of the Invention] This invention relates to a tufted carpet that has excellent mechanical properties even if the base is thin.

To manufacture tufted carpet, pile yarn is pierced through a first base fabric such as jute using a tufting machine, and adhesive is applied from the back side of the base fabric to fix the pile so that it does not fall out. is normal.
In such a normal backing method, the plateau is generally too thin to be firm, so it is often further backed with juute cloth or hexagonal gauze as a second base fabric, or foam rubber packing is performed. As a result, it is preferable to impart cushioning properties to the carpet and further increase heat insulation and sound absorption effects. However, if the plateau becomes thicker and the heat insulating effect increases, this is not preferable because the heat conductivity from the heater decreases when a planar heater is installed below the carpet and used as an electric heating carpet or its covering material. Furthermore, when used as a rug carpet, it is difficult to make the plateau thin and light for transportation and storage while maintaining certain mechanical properties.

This invention has been proposed to improve the above-mentioned problems regarding tufted carpet terraces. Therefore, the object of this invention is to provide a tufted carpet that has excellent mechanical properties even if the base is thin, by using a base fabric in which a synthetic fiber web is integrated with a fiber sheet. If the plateau can be made thin as in this invention, the heat generated from the planar heater can be transferred upwards when used as an electric heating carpet or its cover material, and it is also advantageous in terms of transportation and storage when used as a rug carpet.

This invention will be explained based on the drawings. FIGS. 1 and 2 respectively illustrate a tufted carpet 1 according to this invention. In order to construct the base fabric 2, a synthetic fiber web 4 is spread on the back side (FIG. 1) or the front side (FIG. 2) of the fiber sheet 3, and the two are integrated by needle punching. Examples of the fiber sheet 3 include jute or cotton twill fabric, polypropylene slit yarn plain woven fabric, and polypropylene or polyester spunbond fabric. In addition, the synthetic fiber web 4 is manufactured from polyester, polypropylene, etc., and the amount of spread cotton is 40~
Preferably it is 200g/ ^m2 . At this time, if the amount of spread cotton is less than 40g/ ^m2 , it will not be sufficient to increase the mechanical strength of the base fabric ² , and if it exceeds 200g/m2, the base fabric 2 will become too thick, making it difficult to increase the mechanical strength of the base fabric 2 during tufting. This increases the physical burden and is disadvantageous in terms of manufacturing costs. The synthetic fiber web 4 may be placed on the front or back surface of the fiber sheet 3, but in order to further increase the strength of the pile in the base fabric 2, it is preferable to spread the synthetic fiber web 4 on the back surface of the fiber sheet 3. Even if the synthetic fiber web is spread on both sides of the fiber sheet 3, the practical benefits are not great.

To form a pile on the base fabric 2, the base fabric is turned inside out and sent to a known tufting machine (not shown).
The pile yarn 5 is inserted by the tufting machine. The pile made with the tuft machine is cut pile 5a (first
(Fig.) or loop pile 5b (Fig. 2).
Alternatively, it may be a mixed pile of both, or a sheaggy with a long pile. Examples of the material for the pile yarn 5 include nylon, acrylic, polyester, rayon, wool, and blended yarns thereof. Next, apply an appropriate adhesive 6 to the back side of the base fabric 2, put it in a drying room, and dry it at high temperature to form a pile 5.
a and 5b are held on the base fabric 2. Adhesives are typically compounds based on SBR latex, PVC paste, vinyl acetate latex, EVA latex, etc. The long carpet thus obtained may be subjected to post-processing such as brushing, cut to a certain size, and then selvedge 7 (see FIG. 4) is performed using an overlock sewing machine.

In addition, in order to perform the sheargy border processing as shown in Fig. 3, after cutting the long carpet into a certain size, another pile thread is inserted using a sewing machine (not shown) to form the long pile 8. let This sheargy border processing is also called overtuft processing. Although the long piles 8 may be colored differently from the piles 5 and can be embroidered in various patterns, they are usually arranged in a band around the carpet. In the insertion part of long pile 8,
An adhesive 9 similar to that described above is further applied to the back surface of the base fabric 2 and dried to fix the long pile 8 to the base fabric 2.

In order to use the carpet of this invention as a cover material for an electric heating carpet, after cutting the carpet into a long piece or processing the above-mentioned shaggy border, four pieces of elongated trapezoidal cloth 11 (FIG. 4), which is generally made of non-woven fabric, are prepared. . Next, at each corner of the back surface of the base fabric, the trapezoidal cloths 11 are arranged so that both sides of the trapezoidal cloths 11 match the periphery of the cover material, and then the trapezoidal cloths 11 are simultaneously sewn together using the selvage stitches 7. As a result, only both sides of each trapezoidal cloth 11 are sewn to the cover material 10, so when each corner of the electric heating carpet 12 (see the dashed dot line in FIG. 4) is inserted under the trapezoidal cloth 11,
An electric heating carpet 12 can be held under the cover material 10. Such cloth 11 may be triangular instead of trapezoidal, or two T-shaped cloths may be used that are sewn on both long sides and one short side around the cover material.

The tufted carpet according to this invention uses a single base fabric made by integrating a synthetic fiber web into a fiber sheet, so that even though the base itself is considerably thinner than conventional carpets, the tear strength and pile removal strength of the carpet are improved. It has excellent mechanical properties and is also preferred in terms of carpet weight and morphological stability. In particular, it is advantageous when applying a sheer border finish to a carpet as an accent using a sewing machine to improve the appearance and feel of the carpet and increase its commercial value. When the carpet of this invention is used as an electric heating carpet or its cover material, the plateau is made of a single layer of base fabric, so it is thin and the heat generated from the sheet heater placed on the bottom side is well conducted upward, increasing the thermal efficiency of the electric heating carpet as a whole. is excellent. As a cover material for electric heating carpets, even if the trapezoidal cloth is sewn to the back of the base fabric at the same time as the selvage, the trapezoidal cloth can be firmly attached at each corner, and the trapezoidal cloth can be detached during use. Almost nothing happens. Furthermore, when the carpet of this invention is used as a rug carpet, it becomes thinner overall, lighter, and relatively easy to bend, which is advantageous when transporting or storing the carpet.

Next, this invention will be explained with reference to examples.

Example 1 For the purpose of manufacturing a cover material for an electric heating carpet, 100 g/m ² of a synthetic fiber web made of 100% polyester fiber of 6 denier and fiber length of 76 mm was applied to the back side of a polypropylene slit yarn plain woven fabric (product name: Polyback). The base fabric 2 is obtained by integrating by needle punching. 1500 denier double-twisted nylon BCF yarn was used as the pile yarn, and the tufting conditions were 1/8 inch gauge, 6 mm stitches, and 15 mm pile length. After tufting the cut pile, apply EVA compound to the back of the base fabric with solid content.
Apply 900g/ ^m2 and dry at high temperature. The obtained long carpet was cut into a rectangle of 1000 x 2000 mm.

Next, using acrylic thread as the pile thread for the sewing machine hook, a shaggy border is processed in a strip around the cover material under the following conditions: 10 rows of piles, 1/8 inch gauge, 5 mm stitches, and 25 mm pile length. A solid portion of EVA compound (150 g/m ^{2 )} is further applied to the back side of the base fabric in the pile-embedded area and dried. At the time of selving 7 using the same pile yarn as the main body, a trapezoidal cloth 11 of polyester nonwoven fabric is sewn to each corner at the same time to obtain a cover material 10 for an electric heating carpet.

Comparative example 1 Nylon directly applied to plain woven fabric (product name Polybag)
The BCF thread is tufted and then a sheared border is created using a sewing machine.

Comparative Example 2 Spunbond polypropylene to directly attach nylon to a nonwoven fabric (trade name: Typer, manufactured by Dupont)
The BCF thread is tufted and then a sheared border is created using a sewing machine.

Examining the sewing strength of the trapezoidal cloth sewn at the same time as the selvedge, it was found that the sewing strength of the trapezoidal cloth of Example 1 with a width of 5 cm was 15.
kg, 4 kg in comparative example 1, and 5 kg in comparative example 2. In addition, the pile thread removal strength of the sewing machine hook part is
3 kg per pile in Example 1, 1 kg in Comparative Example 1
kg, Comparative Example 2 is 0.5 kg. With respect to the mechanical properties of the carpet, the covering material of Example 1 is therefore superior to that of Comparative Examples 1 and 2.

Example 2 For the purpose of manufacturing a rug carpet, 80 g/m ² of a synthetic fiber web made of 100% polypropylene fiber of 6 denier and fiber length of 64 mm was integrated on the back side of a 3.7 oz/square yard nonwoven fabric (product name: Typer) by needle punching. to obtain a base fabric 2. 1050 denier double-twisted nylon BCF as pile yarn
The tufting conditions were 1/10 inch gauge, 4.5 mm stitches, and 7 mm pile length. After tufting the loop pile, apply SBR to the back of the base fabric.
Apply the compound at a solid content of 900g/m ² and dry at high temperature. The obtained long carpet is 950 x 1850.
Cut into mm rectangles.

Next, using acrylic thread as the pile thread for the sewing machine hook, a shaggy border is processed around the carpet in the form of a band under the conditions of 8 rows of piles, 1/8 inch gauge, 5 mm stitches, and 25 mm pile length. On the back side of the base fabric where this pile is embroidered,
Furthermore, apply 150g/m ² of EVA compound in solid content and dry. Then, use the same pile thread as the main body to overlay the ears to obtain a rug carpet.

The pile thread removal strength of the sewing machine hook portion is 3 kg/piece in Example 2, which is greater than the thread removal strength of Comparative Examples 1 and 2, and is excellent in terms of mechanical properties.

[Brief explanation of drawings]

Figures 1 and 2 are partial cross-sectional views illustrating the tufted carpet according to this invention, Figure 3 is a side view showing the carpet after a shear border has been processed by a sewing machine, and Figure 4 is a side view of the carpet according to the invention. It is a back view of the cover material for electric heating carpets which is an example. 1...Tufted carpet, 2...Base fabric, 3
... Fiber sheet, 4 ... Synthetic fiber web, 5 ... Pile thread, 6 ... Adhesive, 7 ... Overlock, 8 ... Long pile, 10 ... Covering material for electric heating carpet, 1
1...Trapezoidal cloth.

Claims (1)

[Claims for Utility Model Registration] 1. A synthetic fiber web of 40 to 200 g/m2 is spread on the front or back ^side of a fiber sheet and integrated by needle punching as a base fabric, and the desired pile yarn is added to this base fabric. Then, apply an appropriate adhesive to the back of the base fabric and dry it to form a relatively short pile. After cutting this long carpet to a certain size, another pile thread is inserted using a sewing machine. A tufted carpet characterized by forming a relatively long pile by applying a sheargy border and then applying an adhesive to the back side of the base fabric at the embroidered part and drying it. 2. The carpet according to claim 1, wherein the synthetic fiber web spread on the fiber sheet is made of polyester fiber.