KR101602838B1 - Carpet with improved coupling pile thread - Google Patents

Abstract

The present invention relates to carpet with improved coupling force of pile threads and a manufacturing method thereof, and more specifically, to carpet with improved coupling force of the pile threads which couples the pile threads to base threads constituting a base to maintain excellent morphological stability thereof as well as to prevent the pile threads from being lost from the base threads; and a manufacturing method thereof. The carpet comprises: the base formed by weaving the base threads; a plurality of pile threads coupled in the weft direction of the base threads, including upper twisted parts twisted and planted on the upper side of the base threads and a pile part extended from an end of the upper twisted parts to protrude to the upper side of the base; and pressing and fixating threads coupled in the warp direction of the base threads, including lower twisted parts twisted to the lower side of the base threads, and a pressing part positioned between the lower twisted parts to press and fixate the upper twisted parts.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a carpet,

The present invention relates to a carpet having improved cohesion of pile yarns and a method of manufacturing the same. More particularly, the pile yarn is firmly coupled to a bottom yarn forming a base so that there is no hair dropping at the bottom yarn, The present invention relates to a carpet having improved cohesion of pile yarn with excellent stability and a manufacturing method thereof.

In general, carpets are widely used for floor insulation, soundproofing and decoration.

Wherein the carpet uses a pile fabric, which is a fabric that has pile on one or both sides, that is, a fabric that is soft or has a loose (looped) or covered surface on the fabric surface.

That is, the pile refers to a soft gauze or lint covering the surface of the fabric, or a fabric with lint or lint. The above-mentioned pile fabrics have a loop formed by a warp (longitudinal thread) and a loop formed by a weft (transverse thread), and a loop formed is left as it is, and the former is a cut file, Or a loop file.

1A, a conventional carpet comprises a base 10 and a pile yarn 20 joined to the base 10. The base 10 is formed by knitting a bottom yarn 12 in a knitted fashion and the filament yarn 20 is composed of wool or the like and is joined to the bottom yarn 12. [ The plurality of pile yarns 20 protrude at a predetermined height from the base 10, so that the pile yarns 20 have soft touch.

Here, as shown in FIG. 1B, in the process of joining the pile yarn 20 to the bottom yarn 12, a plurality of pile yarns 20 are twisted down to the bottom yarn 12 to be planted.

However, in the conventional carpet, since the pile yarn 20 is twisted down to the bottom yarn 12 once and is planted in a simple combined structure, the binding force of the pile yarn 20 is weak and the pile yarn 20 And the life of the product is shortened, resulting in inconvenience in use due to the pile yarn 20 to be removed.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide a pile yarn which is firmly bonded to a bottom yarn as a base through a press- Which is excellent in the morphological stability of the carpet, and a method for manufacturing the carpet.

The above object of the present invention can be achieved by a method of manufacturing a semiconductor device, comprising: a base formed by weaving a bottom yarn; A plurality of pile yarns connected in a weft direction of the bottom yarn and having upper and lower twisted portions twisted to the upper side of the bottom yarn and a pile portion extending from an end of the upper twist portion and projecting upward from the base; A pressurizing fixing yarn which is joined in the weft direction of the bottom yarn and which is twisted to the lower side of the bottom yarn and is located at one side of the upward twist portion and a pressing portion formed between the downward twist portion and press- Wherein the pressurizing and fixing yarn is composed of a pressurizing yarn made of a high melting point polyester yarn and a joining yarn made of a low melting point polyester yarn, and when the pressurizing fixing yarn is heated, the joining yarn is melted, And the upper twist portions of the filaments are bonded to each other to prevent the filaments protruding from the bottom yarn from being separated from each other.

Also, an object of the present invention is to provide a method of forming a base, comprising: forming a base by weaving a bottom yarn; A pile forming step in which a pile yarn is twisted upward on the bottom yarn to form an upward twisted portion and a pile portion located at an end of the upward twisted portion is protruded upward from the base and a pile yarn is planted on the bottom yarn to form a pile portion; A step of press-fixing the pile yarn to the bottom yarn through a press-fixing yarn constituted by a pressurizing yarn made of a high-melting-point polyester yarn and a joining yarn made of a low-melting-point polyester yarn to the bottom yarn, A pressing step of forming a downward twisted part on one side of the part and a pressing part for pressing and fixing the upper twisted part between the downward twisted parts so that the pressing and fixing yarn presses the filament yarn; And a pile yarn attaching step of performing heat treatment at a temperature equal to or higher than the melting point of the joint yarn in the tentering process so that the joint yarn is melted in the pressurizing fixed yarn to adhesively bond the upward twisted portion of the press yarn, Can be achieved by providing a carpet manufacturing method with improved bonding strength of pile yarn.

According to the present invention, the pile yarn is firmly coupled to the bottom yarn as a base through a press-fixing yarn while being pressed and adhered thereto, so that there is no hair yarn dropping at the bottom yarn and excellent morphological stability of the carpet is maintained .

FIG. 1A is a view showing a conventional carpet,
1B is a view showing a structure in which a pile yarn is joined to a bottom yarn in a conventional carpet,
2 is a perspective view of a carpet according to the present invention,
3 and 4 are enlarged front views of a carpet according to the present invention,
5 is a process diagram showing a process of manufacturing a carpet according to the present invention.

Hereinafter, the present invention will be described in detail with reference to the accompanying drawings.

The carpet having improved binding force of the pile yarn according to the present invention is constructed such that the pile yarn is bonded to the bottom yarns 110 and 120 constituting the base 100 while being pressed and adhered through the press fixing yarn, 3 and 4, it includes a base 100, a pile yarn 200, and a pressurizing and fixing yarn 300.

The base 100 is formed by weaving bottom yarns 110 and 120. The bottom yarn 100 is formed by weft yarns 110 and weft yarns 120 that are weft- . Here, the bottom yarns 110 and 120 are formed of a known yarn, for example, polyester yarn, nylon or the like.

The pile yarn 200 is joined in the direction of the weft yarn 120 of the bottom yarn to form a soft knot or a napkin covering the surface of the base portion 100. The pile yarn 200 may be pine needled yarn, long fiber stretched yarn construction, terry yarn, or the like.

Here, the pine needle yarn applied to the present invention may be a bright yarn of wool (Bright yarn) containing titanium oxide (TiO2) which has a round cross section of the yarn and which controls gloss during polymer polymerization, And may be a spark yarn (Spark), which is formed in an irregularly angled state such as a triangle or the like and is caused to be twinkled by refraction of light. Further, the long fiber elongation yarn is also called DTY (Draw Textured Yarn), also referred to as Polyester Filament Draw Textured Yarn (DTY). The Yarn is a raw material for making fabrics and is obtained from natural fibers and man-made fibers in the form of filaments or staples. The filament yarn has a very long fiber length and includes silk fiber and synthetic fiber. Most of the fibers obtained in the natural state are short staple yarns, and among the synthetic fibers, there are staple yarns short cut to a certain length. Also, the terry yarn used in the present invention may be formed by cutting a ring-shaped terry yarn.

The pile yarn 200 may include an upper twist portion 210 that is twisted and bent to the upper side of the bottom yarn 120 and an upper twist portion 210 that extends from an end portion of the upper twist portion 210, And a protruding pile portion 220. A plurality of pile yarns (200) are woven and bonded to the bottom yarn (100).

The pressurized incursion 300 includes a downward twist 301 coupled to the bottom yarn 120 in a weft direction and twisted to the lower side of the bottom yarn 120 and positioned at one side of the upward twist 210, And a pressing portion 302 formed between the lower twist portions 301 to press and fix the upper twist portions 210. The pressing and fixing yarn 300 is twisted in the weft direction of the bottom yarn 120 so as to press the upper twist portion 210 of the filament yarn 200 to press the filament yarn 200 on the bottom yarn 120, As shown in FIG.

Specifically, the pressing and fixing yarn 300 is preferably composed of a pressing yarn 310 made of a high melting point polyester yarn and a joining yarn 320 made of a low melting point polyester yarn. That is, when heat is applied to the pressing and fixing yarn 300, the bonding yarn 320 is melted and the upper twisting portions 210 of the press yarn 310, the bottom yarn 120 and the pile yarn 200 are bonded So that the pile yarns 200 protruding from the bottom yarn 120 are prevented from falling off.

4, the bottom yarn 120, the pile yarn 200, and the press-fixing yarn 300 are woven to form a carpet. Then, in the tentering process, The upper yarn 210 of the press yarn 310, the bottom yarn 120 and the upper yarn 210 of the pile yarn 200 are adhered to each other while being fused in the press-fixing yarn 300, So that the file server is fixed firmly in the second place. Here, in the tenter process, when a heat fixing device for spraying hot air such as a tenter is used, the temperature of the hot air device is preferably set to be equal to or slightly higher than the melting point of the low melting polyester yarn, The ester is melted in the heat bonding process, and the shape disappears while the high melting point polyester is bonded.

The presser yarn 310 applied to the present invention is composed of polyester yarn having a melting point of 210 to 220 ° C, a fineness of 150 d / 48 to 180 d / 120 filament and a high melting point of DTY yarn, And a low melting point polyester yarn having a fineness of 70d / 24fila to 75d / 36fila.

That is, the high-melting-point polyester is a general polyester resin having a melting point inherent to the resin because it does not change the melting point. The high-melting-point polyester means that the melting point is relatively higher than that of the low- As the ester, polyethylene terephthalate, polynaphthalene terephthalate and the like can be applied. The low-melting-point polyester has a melting point lower by about 30 to 80 ° C than the melting temperature of the general polyester, and is applied to the heat-bonding application of the high-melting-point polyester yarn. In order to produce polyester yarns having such a low melting point, adipic acid or isophthalic acid may be added during the polymerization of polyester, and they may be used together. Polybutylene terephthalate, polylactic acid, and polyamide may be used. The low-melting-point polyester is preferably a mixture of the same kind of polyester as the high-melting-point polyester material with an additive. In the heat-bonding step, the low-melting-point polyester is melted to bond the high- It easily combines with the high-melting-point polyester which is the same material and works more effectively to improve the strength of the carpet.

If the melting temperature of the low melting point polyester yarn used as the bonding yarn 320 is too high above 190 deg. C, the thermal bonding temperature rises above 190 deg. C, and the tear strength of the base decreases, Carpets are easily torn due to a minute tension change in the post-processing, which causes quality defects. On the contrary, if the melting point of the low melting point polyester yarn used as the bonding yarn 320 is too low to be lower than 170 deg. C, the low melting point polyester yarn will melt during the subsequent process such as coating, And the width and length of the cafe finished product may be insufficient. Therefore, it is preferable that the bonding yarn 320 is made of a low-melting polyester yarn having a melting point in the range of 170 to 190 ° C.

It is preferable that the presser yarn 310 has a fineness of 150 d / 48 fila to 180 d / 120 fila. If the fineness below the numerical value is less than 150 d / 48 fila, the presser yarn 310 fails to support the filament yarn 200, And when the numerical value exceeds 180d / 120fila, it is too stiff to weave, which is the result of the test. Preferably, the presser yarn 310 is made of DTY yarn, DTY is an initial of Draw Textured Yarn (DTY Textile Yarn), and DTY is a stretch yarn or false twist yarn making the filament bulky and stretchable in a twisting process. In other words, by applying DTY yarn as a pressurizing yarn 310, the presser yarn 310 is pressed and fixed by pressing the bottom yarn 120 and the pile yarn 200 without further stretching in the heat bonding step of the joining yarn 320 .

The bonding yarn 320 is preferably made of a fineness of 70d / 24fila to 75d / 36fila. When the fineness below the numerical value is less than 70d / 24fila, the bonding yarn 320 is too thin, The pile yarn 120 and the pile yarn 200 can not be firmly coupled to each other through the joint yarn 320, , And when the number of stitches, which is a numerical value, exceeds 75d / 36fila, the bonding yarn 320 becomes too thick and the bonding yarn 320 does not melt when the bonding yarn 320 melts. Therefore, it is preferable that the pressing yarn 310 has a fineness of 150d / 48fila to 180d / 120fila, and the bonded yarn 320 has a fineness of 70d / 24fila to 75d / 36fila.

In addition, the present invention is characterized in that a plurality of upward twisted portions 210 of the pile yarn 200 to be twisted to the bottom yarn 120 are formed, and the upward twisted portions 210 are pressed through the press fixing yarn 300 So that the filament yarn 200 is more firmly fixed to the bottom yarn 120 through the press-fixing filament yarn 300.

To this end, the upper twist portion 210 of the pile yarn 200 includes a first upper twist 211, a second upper twist 212, and a third upward twist 212, which are sequentially twisted to the bottom yarn 120 And a lower bracket 301 of the pressing and fixing yarn 300 includes a first downward twist 301a formed at one side of the first upper twist 211, A second downward twist portion 301b formed at one side of the twist portion 212 and a third downward twist portion 301c formed at one side of the third upward twist portion 213. [ The pressing portion 302 of the pressing and fixing yarn 300 is formed on the upper side of the bottom yarn 120 between the first downward twist portion 301a and the second downward twist portion 301b, A first pressing portion 302a for pressing the first pressing portion 211 by pressing the second pressing portion 211 and a second pressing portion 302b formed above the bottom yarn 120 between the second downward twisting portion 301b and the third downward twisting portion 301c, A second pressing part 302b for pushing the part 212 and fixing the third upper twist part 213 formed on the other side of the third lower twist part 213 on the upper side of the bottom yarn 120, 3 pressure unit 302c.

 Therefore, the pile yarn 200 has three twists of the first upper twisting portion 211, the second upper twisting portion 212, and the third upper twisting portion 213, which are sequentially twisted to the bottom yarn 120 So that it is firmly fixed to the bottom yarn 120, and hair dropping phenomenon of the filament yarn 200 is reduced.

The first upper twisting portion 211, the second upper twisting portion 212 and the third upper twisting portion 213 of the pile yarn 200 are pressed against the first pressing portion 302a of the pressing and fixing yarn 300 The upward twist portions 211, 212 and 213 of the pile yarn are pressed through the pressing portions 302a, 302b and 302c of the pile yarn to the bottom yarn (second yarn end portion) through the second pressing portion 302b and the third pressing portion 302c, 120 of the pile yarn 200, and hair dropping phenomenon of the pile yarn 200 is remarkably reduced.

A method of manufacturing a carpet having improved binding force of pile yarns according to the present invention will be described.

A method of manufacturing a carpet with improved bonding strength of pile yarns according to the present invention includes a base forming step S1, a pile forming step S2, a pile pressing step S3, and a pile bonding step S4.

First, the base forming step S1 forms the base 100 by weaving the bottom yarns 110 and 120. Here, the bottom yarn is formed by the warp yarns 110 and the weft yarns 120 as a base 100 by being weft-wefted in a left-right symmetrical manner or knitted.

Next, the pile yarn forming step S2 forms an upper twisting portion 210 by twisting the pile yarn 200 upward in the bottom yarn 100 and forming a pile portion 210 located at an end of the upper twisting portion 210 220 are protruded to the upper side of the base 100. The upper twist portion 210 of the bottom yarn 120 may be formed a plurality of times so that the pile yarn 200 can be firmly coupled to the bottom yarn 120.

Next, the pressing step S3 is performed by pressing a pressurizing fixing yarn 300, which is composed of a pressurizing yarn 310 made of a high melting point polyester yarn and a joining yarn 320 made of a low melting point polyester yarn, The pressing and fixing yarn 300 is twisted down to the bottom yarn 120 so that the lower twist portion 301 is formed at one side of the upper twist portion 210 And a pressing portion 302 for pressing and fixing the upper twisted portion 210 is formed between the lower twisted portions 301. That is, the pressurizing and fixing yarn 300 is knitted to the bottom yarn 120 and presses the upward twist portion 210 of the pile yarn through the pressurizing portion 302 of the press-fixing yarn, So that the yarn 200 is fixed.

The joining step S4 of the joining yarn 320 is performed at a temperature higher than the melting point of the joining yarn 320 in the tentering process so that the joining yarn 320 is melted in the press- ), The bottom yarn 120 and the upper twist portion 210 of the pile yarn 200 to each other.

That is, in the tentering step S4, when the binder yarn 320 is melted and dried, the binder yarn 320 of the pressurizing and fixing yarn 300 is melted and the pressure yarn 310, the bottom yarn 120 And the upper yarn 210 of the filament yarn are adhered and bonded to each other, and the filament yarn 200 is adhered and fixed to the bottom yarn 120. Here, in the tenter process, when a heat fixing device for spraying hot air such as a tenter is used, the temperature of the hot air device is preferably set to be equal to or slightly higher than the melting point of the low melting polyester yarn, The ester is melted in the heat bonding process, and the shape disappears while the high melting point polyester is bonded.

The bonding yarn 320 is composed of a polyester yarn having a melting point of 210 to 220 DEG C and a fineness of 150 d / 48 to 180 d / 120 filaments and DTY yarns. The bonding yarn 320 has a melting point of 170 to 190 DEG C, a fineness of 70 d / It is preferable that the low melting point polyester yarn is composed of low melting point polyester yarn of 24fila to 75d / 36fila.

The carpet according to the present invention manufactured by such a method is configured such that the press-fixing yarn is twisted in the weft direction while pressing the upper twist portion of the filament yarn to the bottom yarn of the filament yarn base so that the filament yarn is primarily fixed to the bottom yarn And when the pressure fixing yarn is dried to a temperature not lower than the melting point of the joining yarn, the joining yarn of the pressing and fixing yarn is melted so that the press yarn, the bottom yarn and the upper twisted portion of the pile yarn are bonded and bonded to each other, do.

Therefore, the present invention is advantageous in that there is no hair dropping in the filament yarn in the bottom yarn, and the morphological stability of the carpet is excellent.

While the present invention has been particularly shown and described with reference to specific embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Anyone who can afford it will know.

100: Base 200: Files
300: Pressure fixing screw

Claims (5)

A base formed by weaving a bottom yarn;
A plurality of pile yarns connected in a weft direction of the bottom yarn and having upper and lower twisted portions twisted to the upper side of the bottom yarn and a pile portion extending from an end of the upper twist portion and projecting upward from the base;
A pressurizing fixing yarn which is joined in the weft direction of the bottom yarn and which is twisted to the lower side of the bottom yarn and is located at one side of the upward twist portion and a pressing portion formed between the downward twist portion and press- ≪ / RTI >
The pressurized fixing yarn is composed of a pressurizing yarn made of a high melting point polyester yarn and a joining yarn made of a low melting point polyester yarn,
Wherein when the pressing and fixing yarn is heated, the joining yarn is melted and the upward twisted portion of the press yarn, the bottom yarn and the pile yarn are bonded to each other to prevent the pile yarns protruding from the bottom yarn from being separated from each other. Carpets with improved bonding strength.
The method according to claim 1,
The pressing yarn is composed of a high melting point polyester yarn having a melting point of 210 to 220 DEG C, a fineness of 150 d / 48 to 180 d /
Wherein the bonding yarn is composed of a low melting point polyester yarn having a melting point of 170 to 190 DEG C and a fineness of 70 d / 24 to 75 d / 36 filaments.
The method according to claim 1,
The upper twist portion of the pile yarn comprises a first upper twist portion, a second upper twist portion, and a third upper twist portion which are sequentially twisted to the bottom yarn,
The downward twist portion of the pressure fixing yarn may include a first downward twist portion formed at one side of the first upward twist portion, a second downward twist portion formed at one side of the second upward twist portion, and a second downward twist portion formed at one side of the third upward twist portion. 3 downward twist portion,
The pressing portion of the pressing and fixing yarn is formed between the first downward twist portion and the second downward twist portion so as to form a first pressing portion formed on the upper side of the bottom yarn to press and fix the first upward twist portion, And a third pressing portion formed on the other side of the third downward twist portion to press and fix the third upper twist portion. The second pressing portion is formed on the upper side of the bottom yarn and fixes the second upper twist portion. Carpets with improved bonding strength.
A base forming step of weaving the bottom yarn to form a base;
A pile forming step in which a pile yarn is twisted upward on the bottom yarn to form an upward twisted portion and a pile portion located at an end of the upward twisted portion is protruded upward from the base and a pile yarn is planted on the bottom yarn to form a pile portion;
A step of press-fixing the pile yarn to the bottom yarn through a press-fixing yarn constituted by a pressurizing yarn made of a high-melting-point polyester yarn and a joining yarn made of a low-melting-point polyester yarn to the bottom yarn, A pressing step of forming a downward twisted part on one side of the part and a pressing part for pressing and fixing the upper twisted part between the downward twisted parts so that the pressing and fixing yarn presses the filament yarn;
And a pile yarn attaching step of performing heat treatment at a temperature equal to or higher than the melting point of the joint yarn in the tentering process so that the joint yarn is melted in the pressurizing fixed yarn to adhesively bond the upward twisted portion of the press yarn, A method of manufacturing a carpet with improved bonding strength of pile yarns.
5. The method of claim 4,
The pressing yarn is composed of a high melting point polyester yarn having a melting point of 210 to 220 DEG C, a fineness of 150 d / 48 to 180 d /
Wherein the joint yarn is composed of a low melting point polyester yarn having a melting point of 170 to 190 DEG C and a fineness of 70d / 24fila to 75d / 36fila.

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