Edgeless tufted carpet using needle punched base fabric

Abstract

To provide a tufted carpet with no edge processing using a needle punch base fabric, which does not require an edge processing step, can reduce the number of steps in carpet manufacturing, shortens the production time per carpet, eliminates the need for thread materials and machine maintenance for edge processing, and further eliminates labor costs, thereby reducing the overall production cost. [Solution] The borderless tufted carpet is composed of, from top to bottom, a yarn layer 2, a needle-punched base fabric layer 1, an emulsion layer 3, a binder layer 4, a backing fabric layer 5, and an anti-slip layer. The yarn layer is tufted onto the needle-punched base fabric layer. The needle-punched base fabric layer is a needle-punched nonwoven fabric and is integrated with the binder layer by either lamination with a binder or heat and pressure consolidation. The emulsion layer is evenly applied to the underside of the needle-punched base fabric layer. The binder layer is made of one of PE, EVA, PO, SBR, asphalt, PU, ​​or TPE.

Description

[Technical Field]

[0001] This practical example relates to the carpet technology field, and more particularly to a carpet that does not require edge stitching by using a needle-punched backing fabric. [Background technology]

[0002] Carpets are widely used in everyday life and commercial environments, providing dust protection, sound absorption, thermal insulation, and decorative features. Conventional tufted carpets typically use a base fabric, such as a warp-knitted fabric, which is tufted to form a yarn layer on the surface. A subsequent over-edge process is required to prevent fraying and fiber shedding around the carpet's perimeter. However, conventional over-edge processes have several major drawbacks. They require specialized sewing machines, sewing thread, and skilled workers, increasing production steps, reducing efficiency, and complicating the manufacturing process. They also require additional sewing thread, machine maintenance costs, and labor costs, resulting in higher costs. Furthermore, even with over-edge processing, conventional warp-knitted carpets are prone to accelerated fraying of the fibers at the base fabric edges with repeated washing, resulting in poor washability. To solve these problems, a tufted carpet with a needle-punched backing fabric and no border was designed. Summary of the Invention

[0003] This new commercial carpet aims to solve the problems of conventional carpets, such as the need for edge stitching, low production efficiency, high cost, and insufficient washability. Specifically, by modifying the needle-punched base fabric and applying tufting to it, the technology eliminates the need for edge stitching, and the carpet is also washable, simplifying the production process, reducing costs, and extending the carpet's service life.

[0004] This practical new model provides a tufted carpet with a borderless finish using a needle-punched base fabric, and its composition, from top to bottom, is a yarn layer, a needle-punched base fabric layer, an emulsion layer, a binder layer, a backing fabric layer, and an anti-slip layer. The yarn layer is tufted onto the needle-punched base fabric layer and is made of synthetic or natural fibers suitable for forming tufted pile, such as polypropylene, polyester, or nylon fibers. The fiber fineness is 3-30 dpf, the pile length is 3-50 mm, and the pile weight of the pile layer is 300-3000 g / m 2 is. The needle-punched base fabric layer is a needle-punched nonwoven fabric, and is integrated with the binder layer by either lamination with a binder or by heat and pressure integration. The emulsion layer is evenly applied to the underside of the needle-punched base fabric layer, and its material is either water-based EVA or water-based SBR, with a dry weight of 20 to 150 g / m². 2 is. The material of the binder layer is either PE, EVA, PO, SBR, asphalt, PU or TPE. The base fabric layer is made of needle-bunched polyester or polypropylene nonwoven fabric, and is heat-pressed and laminated to the bottom of the binder layer. The weight of the base fabric layer is 50-800g / m 2 is. The anti-slip particles in the anti-slip layer are formed by either hot melt adhesive, dotted anti-slip material, or TPE adsorbent anti-slip material. Furthermore, during tufting, the fibers of the yarn layer penetrate all layers of the needle-punched fabric layer and are fixed, and the fibers of the yarn layer hold the fibers of the needle-punched fabric layer. By tufting the fibers of the yarn layer through all layers, the fibers are fixed like "stitching" and the end fibers of the needle-punched fabric layer can be physically restrained. Furthermore, the needle-punched base fabric layer is formed by needle-punching chemical fibers, and has a basis weight of 60 to 200 g / m 2Its thickness is 0.3 to 1 mm, and its tensile strength in the machine and cross directions is two to three times that of a single-layer base fabric. Unlike conventional woven base fabrics, the needle-punched base fabric layer has an integral needle-punched structure, which prevents fraying and prevents deformation of the edges and thread loss due to washing or long-term use. Furthermore, the emulsion layer fixes the fibers between the yarn layer and the needle-punched base fabric layer, and the latex secures the pile base, further preventing the end of the yarn layer from falling off after cutting. Furthermore, another structure of edgeless tufted carpet using needle-punched base fabric is a form that comprises, from top to bottom, a yarn layer, a needle-punched base fabric layer, an emulsion layer, and a binder layer, and can be selectively processed according to market demand and customer requirements.

[0005] This practical new model has at least the following beneficial effects: It eliminates the need for a hemming process, reduces the carpet production process, shortens the production time per carpet, and improves production efficiency. At the same time, it eliminates the need for sewing threads, maintenance of sewing machines, and labor costs, reducing overall production costs. In addition, there is no loss of defective products due to poor hemming, making it economical. Furthermore, the high strength of the needle-punched base fabric layer, the pile fixing effect, and the characteristics of the base fabric material work together to achieve a low fray rate even without hemming. Even after long-term use and repeated washing, there is no obvious thread loss or deformation, and the carpet has a longer service life than conventional hemmed carpets. Large-sized carpets can also be produced, and unlike the small sizes of conventional carpet tiles, they can be freely designed to exceed 50 cm in both length and width. The entire carpet is flexible, allowing for free combination and cutting. Furthermore, thanks to the selection of water-resistant materials, a composite structure with high washability, and controlled dimensional stability, the carpet can be washed in a home washing machine and retains its performance even after washing. It is easy to clean and dries quickly, solving the problems of conventional carpets, such as difficulty in cleaning and the tendency for dirt to accumulate. It is particularly suitable for homes with children or pets, as well as office spaces with frequent use. Furthermore, the edgeless design eliminates the "seam lines" found in traditional carpets, resulting in simple, smooth carpet edges. It can be designed into various shapes, such as square, round, or irregular, as needed, to suit different interior styles. At the same time, by adding a base fabric layer or anti-slip layer as needed, it can be used in a variety of environments, including homes, offices, and commercial spaces. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. 1 is a schematic diagram of the laminated structure of this practical new model. [Figure 2] FIG. 2 is a schematic diagram of an enlarged structure of part A in FIG. 1 of this practical new model. [Figure 3] FIG. 3 is a schematic diagram of the bottom view of the structure of the present practical new model shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0007] The following disclosure provides embodiments or examples for realizing different structures of the present application. To simplify the disclosure of the present application, the following describes specific example components and configurations. Of course, these are merely examples and are not intended to limit the present application. Furthermore, while various specific construction methods and materials are shown as examples in the present application, those skilled in the art will recognize the application of other construction methods and / or the use of other materials. Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings and examples.

[0008] Example 1: As shown in Figures 1 to 3, this practical model provides a tufted carpet with a borderless finish using a needle-punched base fabric, and the structure includes, from top to bottom, a yarn layer 2, a needle-punched base fabric layer 1, an emulsion layer 3, a binder layer 4, a backing fabric layer 5, and an anti-slip layer 6. The yarn layer 2 is tufted on the top surface of the needle-punched base fabric layer 1 and is made of chemical or natural fibers suitable for forming tufted pile, such as polypropylene, polyester, or nylon fibers. The fiber fineness is 3 to 30 dpf, the pile length is 3 to 50 mm, and the pile weight of the pile layer 2 is 300 to 3,000 g / m 2 is. The needle-punched fabric layer 1 is a needle-punched nonwoven fabric, and is integrated with the binder layer 4 by lamination with an adhesive or by thermocompression integration. The emulsion layer 3 is uniformly applied to the underside of the needle-punched base fabric layer 1, and is made of either water-based EVA or water-based SBR. The weight per unit area after drying is 20 to 150 g / m 2 is. The material of the binder layer 4 is any one of PE, EVA, PO, SBR, asphalt, PU and TPE. The backing fabric layer 5 is made of a nonwoven polyester or polypropylene fabric and is heat-pressed and laminated to the bottom of the binder layer 4. The weight per unit area of ​​the backing fabric layer 5 is 50 to 800 g / m 2 is. The anti-slip layer 6 is composed of anti-slip particles, either hot melt adhesive, dotted anti-slip material or TPE adsorbent anti-slip material. As shown in Figs. 1 and 2, the needle-punched base fabric layer 1 is formed by needle-punching chemical fibers, and has a basis weight of 60 to 200 g / m 2 The thickness is 0.3 to 1 mm. The tensile strength of the needle-punched base fabric layer 1 in the vertical and horizontal directions is two to three times that of a warp-knitted base fabric, giving it a longer service life than conventional over-edged carpets. Furthermore, large-sized carpets can be produced, and unlike the small sizes of conventional carpet tiles, they can generally be made to exceed 50 cm in both length and width. There are no restrictions on length or width, and the overall flexibility allows for free combination and cutting. As shown in Figures 1 and 2, the emulsion layer 3 fixes the fibers between the yarn layer 2 and the needle-punched base fabric layer 1, and the latex bonds the pile base, preventing the pile ends from falling off, eliminating the need for hemming, and allowing for free cutting. As shown in Figure 3, during flocking, the fibers of thread layer 2 penetrate all layers of needle-punched base fabric layer 1 and are fixed in place, and the fibers of thread layer 2 hold the fibers of needle-punched base fabric layer 1. The fibers of the thread layer penetrate all layers and are tufted, fixing the fibers of the surface base fabric and base fabric layer together like a "stitch," and physically restraining the end fibers of needle-punched base fabric layer 1.

[0009] Example 2: As another structure based on Example 1, a tufted carpet with a borderless finish using a needle-punched base fabric is configured to include, from the top layer down, a yarn layer 2, a needle-punched base fabric layer 1, an emulsion layer 3 and a binder layer 4, and can be selectively processed according to market demand or customer requirements. [Explanation of symbols]

[0010] 1: Needle punched base fabric layer 2: Yarn layer 3: Emulsion layer 4: Binder layer 5: Lining fabric layer 6: Anti-slip layer

Claims

1. A tufted carpet with a borderless finish using a needle-punched base fabric, characterized by a structure including, from top to bottom, a yarn layer (2), a needle-punched base fabric layer (1), an emulsion layer (3), a binder layer (4), a backing layer (5), and an anti-slip layer (6). The yarn layer (2) is tufted on the top surface of the needle-punched base fabric layer (1), and is made of chemical or natural fibers suitable for forming tuft pile, such as polypropylene, polyester, or nylon fibers. The fiber denier is set to 3-30 dpf, the pile length is set to 3-50 mm, and the pile weight of the pile layer (2) is 300-3000 g / m. 2 The needle-punched base fabric layer (1) is a needle-punched nonwoven fabric, and is integrated with a binder layer (4) by lamination with a binder or by heat and pressure integration. The emulsion layer (3) is uniformly applied to the lower surface of the needle-punched base fabric layer (1). The material of the emulsion layer (3) is either aqueous EVA or aqueous SBR, and the weight per unit area after drying is 20 to 150 g / m. 2 The binder layer (4) is made of one of PE, EVA, PO, SBR, asphalt, PU, ​​and TPE, the nonwoven fabric material of the base fabric layer (5) is made of one of polyester and polypropylene, and the base fabric layer (5) is heat-pressed to the bottom of the binder layer (4), and the weight of the base fabric layer (5) is 50-800 g / m 2 and the anti-slip particles of the anti-slip layer (6) are either a hot melt adhesive, a dotted anti-slip material or a TPE adsorbent anti-slip material.

2. A tufted carpet with an edgeless finish using the needle-punched base fabric described in claim 1, characterized in that during tufting, the fibers of the thread layer (2) penetrate through the entire layer of the needle-punched base fabric layer (1) and are fixed, and the fibers of the thread layer (2) fix the fibers of the needle-punched base fabric layer (1) and physically restrain the edge fibers of the needle-punched base fabric layer (1).

3. A tufted carpet with an edgeless finish using a needle-punched base fabric as described in claim 2, characterized in that the emulsion layer (3) fixes the fibers between the yarn layers (2).

4. In the edgeless tufted carpet using the needle-punched base fabric according to claim 2, the needle-punched base fabric layer (1) is formed by needle-punching chemical fibers, and has a basis weight of 60 to 200 g / m 2 A tufted carpet with a borderless finish using a needle-punched base fabric, characterized in that the thickness is 0.3 to 1 mm.

5. In the edgeless tufted carpet using the needle-punched base fabric described in claim 1, another structural form is a edgeless tufted carpet using a needle-punched base fabric, characterized in that it has a structure including, from top to bottom, a yarn layer (2), a needle-punched base fabric layer (1), an emulsion layer (3) and a binder layer (4).

Images