tufted carpet

Abstract

To provide a tufted carpet in which piles are unlikely to collapse and which has excellent thread removal strength. [Solution] The tufted carpet (1) comprises a base fabric (2), cut pile yarns (3) tufted into the base fabric, and an adhesive layer (4) applied to the back surface of the base fabric to prevent the cut pile yarns from coming loose. The pile length (L) of the cut pile yarns is 2 to 4 mm, and the density of the single yarns constituting the cut pile yarns is 6,000 to 80,000,000 threads / m. 2 is.

Description

[Technical Field]

[0001] This invention relates to tufted carpets, particularly flat carpets with low pile length. [Background technology]

[0002] Tufted carpets, for example, are used as indoor floor coverings in offices, hotels, and other spaces. In tufted carpets, pile threads are pierced into a base fabric with a sewing needle and fixed with an adhesive applied to the back of the base fabric. This results in excellent thread removal strength and durability. Furthermore, compared to hard flooring materials, tufted carpets offer superior cushioning and absorb shock when walking, reducing fatigue and being gentle on the feet.

[0003] A longer pile length in tufted carpet improves cushioning, but the pile tends to collapse more easily, which can reduce the mobility of carry cases, wheelchairs, etc. Generally, the pile length for loop pile is 3-6 mm, while that for cut pile is 5-15 mm.

[0004] Rugs with electrically implanted pile are known as floor materials with excellent caster mobility. For example, Japanese Patent Application Laid-Open No. 2004-142243 describes a rug with electrically implanted pile made of polytrimethylene terephthalate fibers, and claims that the rug allows wheelchairs to move easily on it. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-142243 Summary of the Invention [Problem to be solved by the invention]

[0006] In electric flocking, a base fabric coated with adhesive is placed on one of the opposing electrodes, and pile (short fibers) is then blown onto the base fabric from the other electrode side and flocked. This allows for the production of carpets with short pile lengths and high pile density (i.e., pile that is less likely to collapse). However, because the pile does not penetrate the base fabric and become caught on it, tufted carpets are superior in terms of thread removal strength.

[0007] Therefore, an object of the present invention is to provide a tufted carpet in which the pile is less likely to collapse and which has excellent thread removal strength. [Means for solving the problem]

[0008] The tufted carpet of this invention comprises a base fabric, cut pile yarns tufted into the base fabric, and an adhesive layer applied to the back surface of the base fabric to prevent the cut pile yarns from coming loose. The pile length of the cut pile yarns is 2 to 4 mm, and the density of the single yarns constituting the cut pile yarns is 6,000 to 8,000,000 threads / m. 2 is.

[0009] Preferably, the single yarn is a multifilament yarn, and the fineness of one filament is 3 to 30 dtex.

[0010] Preferably, the single yarn is a dope-dyed yarn or a white dope yarn that has been print-dyed.

[0011] Preferably, the single yarn is made of nylon-based fiber.

[0012] Preferably, the tufted carpet further comprises a cushion layer, which has a shock-absorbing function and is attached to the back surface of the adhesive layer.

[0013] Preferably, the tufted carpet is a floor mat for an automobile, and further comprises a resin layer made of a thermoplastic resin attached to the back surface of the adhesive layer. [Effects of the Invention]

[0014] According to the rug of the present invention, although it is a tufted rug, the pile length is short and the single yarns are highly dense, so the cut pile yarns are less likely to collapse and the yarn pull-out strength is excellent. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a schematic cross-sectional view of a tufted rug according to a first embodiment of the present invention. [Figure 2] FIG. 10 is a schematic diagram for explaining gauges and stitches. [Figure 3] FIG. 2 is a schematic cross-sectional view of a tufted rug according to a second embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0016] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will now be described in detail with reference to the accompanying drawings, in which like or corresponding parts are designated by like reference numerals and will not be described repeatedly.

[0017] <Embodiment 1> A tufted carpet (hereinafter referred to as "carpet") 1 according to a first embodiment of the present invention will be described with reference to Figures 1 and 2. The surface that faces the floor when carpet 1 is laid is called the back surface and is designated by the symbol A1.

[0018] As shown in Figure 1, the carpet 1 comprises a base fabric 2, cut pile yarns 3 tufted into the base fabric 2, and an adhesive layer 4 applied to the back surface of the base fabric 2 to prevent the cut pile yarns 3 from coming loose.

[0019] The manufacturing method of the carpet 1 is as follows: first, pile yarns are inserted into the base fabric 2 using a tufting machine (sewing needles) and implanted. At this time, the inserted pile yarns are cut to form cut pile yarns 3. Two cut pile yarns 31, 32 extend from one needle insertion hole. Note that in Figure 1, adjacent cut pile yarns 31, 32 are shown separated from each other in a schematic view.

[0020] Next, an adhesive is applied to the side opposite to where the cut pile yarns 3 have been cut (the back surface of the base fabric 2) to prevent the cut pile yarns 3 from coming loose. The adhesive is generally latex rubber. The adhesive then forms an adhesive layer 4, and a backing layer 5 is attached to the back surface of this adhesive layer 4.

[0021] The base fabric 2 is made of a material commonly used for carpets, and may be, for example, a woven or nonwoven fabric made of synthetic resin fibers such as polyester fibers or polypropylene fibers. The backing layer 5 may be made of, for example, jute or a nonwoven fabric.

[0022] The cut pile yarns 3 may be made of natural fibers such as wool, linen, or cotton, or synthetic resin fibers such as polyamide fibers (nylon fibers), polyester fibers, or polyacrylic fibers. From the standpoint of durability, nylon fibers are preferred, and nylon 6 and nylon 66 are particularly preferred.

[0023] The cut pile yarns 3 rise vertically from the surface of the base fabric 2. The length of the cut pile yarns 3 from the surface of the base fabric 2 to the tip of the cut pile yarns 3 is called the pile length L, and in this embodiment, the pile length L is 2 to 4 mm. This pile length L is shorter than the short pile length of brushed cut pile (5 to 10 mm).

[0024] It is extremely difficult to achieve a pile length L of less than 2 mm (for example, 1 mm) with mechanical equipment. On the other hand, a pile length L of more than 4 mm (for example, 5 mm or more) increases resistance, leading to poor caster travel.

[0025] In this embodiment, the single yarns constituting the cut pile yarns 3 are multifilament yarns made up of a large number of filaments. The number of filaments is, for example, 30 to 300. The fineness of one filament is, for example, 3 to 30 dtex. The density of the single yarns will be described below with reference to FIG. 2.

[0026] The density of the single yarn in carpet 1 is 60 to 80 million threads / m 2 This density is determined by the number of filaments, gauge, and stitches. Gauge refers to the number of needles (pile threads) per inch in the direction perpendicular to the tufting direction. Stitch refers to the number of threads per inch in the same direction as the tufting direction.

[0027] So, for example, if your gauge is 16 threads per inch, your stitches are 13 threads per inch, and your filament count is 120, 630 pieces / m x 512 pieces / m x 120 pieces x 2 ≒ 77.41 million pieces / m 2 Since two cut pile yarns are formed from one needle insertion hole, the above formula is multiplied by 2.

[0028] Single yarn density: 60 million threads / m 2 Less than (for example, 50 million units / m 2 ) makes the cut pile yarns more likely to collapse, increasing the resistance to the caster. On the other hand, the density of the single yarn is 80 million threads / m 2 It is extremely difficult to achieve this with mechanical devices.

[0029] According to the carpet 1 of this embodiment, the pile length L is short, 2 to 4 mm, and the density of the single yarn is 60 to 80 million yarns / m 2 The high density of the cut pile yarns 3 makes them less likely to collapse or be crushed, resulting in excellent caster running performance. In addition, as it is a tufted carpet, the thread removal strength is strong and the carpet is highly durable.

[0030] In addition, because the cut pile yarns 3 are packed at a high density, dust does not easily get between the cut pile yarns 3, making cleaning easy. Also, by using synthetic fibers for the cut pile yarns 3, excellent moisture resistance is achieved. Furthermore, because it is made using the tufting method, mass production is easy, allowing for cost reductions.

[0031] The design of the carpet 1 may be plain, using solution-dyed nylon for the cut pile yarn 3. Alternatively, white yarn may be used for the cut pile yarn 3, and a desired design may be applied by print dyeing (roll printing, screen printing, inkjet printing, etc.).

[0032] (Variation) The backing layer 5 attached to the back surface of the adhesive layer 4 shown in Fig. 1 may be a cushioning layer with shock-absorbing properties. The cushioning layer is formed, for example, from a cushioning material such as nonwoven fabric or urethane foam. In addition to good caster running properties, the cushioning properties make it suitable for use as a carpet for wheelchairs in nursing homes, hotel corridors, and carry-on luggage in airports.

[0033] <Embodiment 2> A tufted floor mat (an example of a tufted carpet, hereinafter referred to as "floor mat") 1A according to embodiment 2 will be described with reference to Fig. 3. The floor mat 1A is an automobile floor mat, and has a resin layer 6 bonded to the back surface of an adhesive layer 4. The resin layer 6 is formed of a lightweight thermoplastic resin such as polyethylene or polypropylene.

[0034] The floor mat 1A can be used as a car mat for the driver or passengers (for example, a mat for the driver's feet) that is removably placed on the floor carpet of the vehicle body. The other structures are the same as those of the first embodiment.

[0035] According to this embodiment, the pile length is short, so the pile weight is kept down, and by forming the resin layer 6 from a lightweight thermoplastic resin, it can be used as a lightweight floor mat, which is suitable for electric vehicles, where weight reduction is particularly desirable. In addition, the cut pile yarns 3 are packed at a high density, so it is easy to clean sand and dust from the vehicle interior.

[0036] The embodiments disclosed herein are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined by the scope of the utility model registration claims, not by the above description, and is intended to include all modifications within the meaning and scope of the utility model registration claims.

[0037] For example, the single yarns constituting the cut pile yarn may be spun yarn. Furthermore, the size and shape of the carpet 1 are not particularly limited, and it may be a rug mat or a carpet tile. [Industrial Applicability]

[0038] The present invention can be advantageously used as a tufted carpet. [Explanation of symbols]

[0039] 1 Tufted carpet, 1A floor mat, 2 base fabric, 3 cut pile yarn, 4 adhesive layer, 5 backing layer (cushion layer), 6 resin layer, L pile length

Claims

1. A base fabric and Cut pile yarn tufted into the base fabric; an adhesive layer applied to the back surface of the base fabric to prevent the cut pile yarns from coming off; The pile length of the cut pile yarn is 2 to 4 mm, The density of the single yarns constituting the cut pile yarn is 6,000 to 80,000,000 / m ２ That is, tufted carpet.

2. 2. The tufted carpet according to claim 1, wherein the single yarn is a multifilament yarn, and the fineness of one filament is 3 to 30 dtex.

3. 2. The tufted carpet according to claim 1, wherein the single yarn is a dyed yarn or a white yarn that has been subjected to print dyeing.

4. 2. The tufted carpet according to claim 1, wherein the single yarn is made of nylon-based fiber.

5. The tufted carpet according to claim 1, further comprising a cushioning layer having a shock absorbing function and attached to the back surface of the adhesive layer.

6. 2. The tufted carpet according to claim 1, which is a floor mat for an automobile, further comprising a resin layer made of a thermoplastic resin attached to the back surface of the adhesive layer.

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