JP2008031582A - Edge treatment method for napped fabric and napped fabric using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an anti-fraying method which has a soft touch, can surely prevent fraying, has excellent design properties, and has excellent processing efficiency in fraying prevention processing of an edge of a napped fabric. It is an object.
[Means for Solving the Problems] As a result of intensive investigations to solve such problems, the present inventors have melted the pile yarn at the edge of the napped fabric, leaving the fibers in a pattern shape by high-frequency welding or ultrasonic welding. By solidifying and adhering to the base fabric, the inventors have found that a fraying prevention method that has a soft touch feeling, can surely prevent fraying, has excellent design properties, and has excellent processing efficiency has been achieved.
[Selection] Figure 2

Description

  BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for treating an edge of a napped fabric such as carpet, mat, or moquette and a napped fabric processed by using the method, and a processing method that replaces the conventional fraying prevention processing called overlock or tape lock. Is to provide. In the present invention, the edge of the napped fabric refers to a range of 1 to 3 cm from the end of the napped fabric, and the end of the napped fabric refers to the end of the napped fabric.

  Conventionally, as an anti-fraying process for the edges of raised fabrics such as carpets, mats, and moquettes, the edges of the raised fabrics are threaded with an overlock sewing machine, or tape-like fabrics or resin sheets are used as raised fabrics. Usually, the edges were sewn with a tape lock sewing machine to prevent the edges from fraying. These are important in terms of design because they give a certain performance and give a visual point to the edge of the raised fabric, and are excellent methods for processing the edge of the raised fabric. .

  However, since the above method requires labor and manpower, more efficient fraying prevention processing of the edge of the raised fabric has been demanded.

Therefore, Patent Document 1 discloses a method for treating a carpet edge that does not require an overlock sewing machine by melting and press-bonding pile yarn with a heating roller or a heater. In Patent Document 2, as a terminal treatment method for a floor carpet for a vehicle, a vehicle in which molten resin is supplied onto a carpet edge after being slit with a trim blade, the resin is sandwiched between upper and lower molds, and is crimped and fixed to the carpet edge. Disclosed is a terminal processing method for a floor car pet for use. Patent Document 3 proposes a technique for fusing and fixing a nap by moving the fabric in the horizontal direction while oscillating the press in high speed in a direction perpendicular to the surface of the fabric by a method of tumbling the napped mat. Has been.
Japanese Patent Publication 47-46633 JP-A-10-67270 JP2004-19068

  However, in Patent Document 1, since the melted resin of the pile yarn that has come into contact with the superheated roller is impregnated into the base fabric and is firmly fused, the touch feeling of the carpet edge becomes a stiff adhesive layer, and the pile yarn to be left Since the end part of this part melts partly and the pile yarn becomes hard, it cannot be said to be a preferable processing method. Moreover, in patent document 2, an installation became big and was unsuitable for processing a big area. In Patent Document 3, since the pile yarn is tilted and fixed, although there is a soft touch feeling, the adhesive force is weak and it is not good as a fray-proofing process. An object of the present invention is to provide an anti-fraying method that has a soft touch, can be reliably frayed, has excellent design properties, and is excellent in processing efficiency. Yes.

  As a result of intensive studies to solve such problems, the present inventors have melted the pile yarn at the edge of the napped fabric leaving high-frequency welder processing or ultrasonic welder processing while leaving the fibers in a pattern. It has been found that a fraying prevention method with a soft touch feeling and reliable fraying prevention, excellent design properties and excellent processing efficiency can be achieved by adhering to the present invention. The present invention provides the following means to achieve the above object.

  [1] In a raised fabric composed of a pile yarn, a base fabric, and a backing layer, the edge is treated by melting by leaving the fiber form of the pile yarn at the edge, and impregnating the base fabric to provide a molten adhesive layer. A raised fabric characterized by having

  [2] In the above-mentioned napped fabric, the melt adhesive layer melts leaving the fiber form of the pile yarn at the edge, and a pattern is formed on the surface of the melt adhesive layer in a concavo-convex shape so as to impregnate the base fabric. The napped fabric according to the above item [1], which is treated.

  [3] In the napped fabric, the melt adhesive layer melts the pile yarn at the edge by high-frequency welder processing or ultrasonic welder processing, leaving the fiber form of the pile yarn at the edge, and the surface of the melt adhesive layer The raised fabric according to the above item [1] or [2], wherein a pattern is provided in a concavo-convex shape and the edge is treated by impregnating the base fabric.

  [4] A raised fabric comprising a pile yarn, a base fabric and a backing layer, wherein the raised pile yarn is melted while leaving the fiber form of the pile yarn, impregnated into the fabric, and the edge treatment is performed. Fabric edge processing method.

  [5] In the edge treatment method for the raised fabric, the edge pile processing is performed by leaving the fiber form of the pile yarn at the edge, melting, patterning the surface of the molten adhesive layer in an uneven shape, and impregnating the base fabric. The method for treating an edge of a napped fabric according to the above item [4], wherein:

  [6] In the edge treatment method of the raised fabric, the pile yarn at the edge is melted by high-frequency welder processing or ultrasonic welder processing, leaving the fiber form of the pile yarn at the edge, and is applied to the surface of the melt-adhesive layer. The method for treating an edge of a napped fabric according to the item [4] or [5], wherein a pattern is provided on the unevenness and the edge is treated by impregnating the base fabric.

  According to the invention of [1], the fiber form of the pile yarn at the edge is melted and impregnated into the base fabric to be bonded. Therefore, the molten adhesive layer in which the resin in which the pile yarn is melted is impregnated in the base fabric is provided. It can be a raised fabric that is formed, firm and has a soft, frayed surface that is fibrous.

  According to the invention of [2], the melt-adhesive layer is melted leaving the fiber form of the pile yarn at the edge, and the surface of the melt-adhesive layer is patterned in an uneven shape, impregnated into the base fabric and solidified. Therefore, a fibrous soft uneven pattern is added to the melt-bonded layer, and a raised fabric with improved design can be obtained.

  According to the invention of [3], the melt adhesive layer melts the pile yarn at the edge by high-frequency welder processing or ultrasonic welder processing, leaving the fiber form of the pile yarn at the edge, and on the surface of the melt adhesive layer. Since a pattern is provided on the concavo-convex shape and impregnated into the base fabric and solidified, it is possible to obtain a napped fabric with high efficiency, high flexibility, and improved design.

  According to the invention of [4], the fiber form of the pile yarn at the edge is melted, impregnated into the base fabric, solidified and processed at the edge, so that the surface is solid and the fiber is soft and frayed. It can be set as the edge processing method of the napped fabric.

  According to the invention of [5], the molten adhesive layer is melted leaving the fiber form of the pile yarn at the edge, and the surface of the molten adhesive layer is provided with an uneven pattern, and impregnated into the base fabric and solidified. Since the edge treatment is performed, it is possible to provide an edge treatment method for a napped fabric that is efficient, rich in flexibility, and improved in design.

  According to the invention of [6], the melt adhesive layer melts the pile yarn at the edge by high-frequency welder processing or ultrasonic welder processing, leaving the fiber form of the pile yarn at the edge, and on the surface of the melt adhesive layer. Since the edge is treated by patterning the irregularities and impregnating the base fabric, it is possible to provide an edge treatment method for a raised fabric that is efficient, rich in flexibility, and improved in design.

  Next, the present invention will be described with reference to the drawings. FIG. 1 is a schematic cross-sectional view of a carpet 1 which is a kind of napped fabric. A pile yarn 2 is implanted in a base fabric 3, and a backing layer 4 is used to prevent the pile yarn from coming off easily. Furthermore, the second base fabric 5 is often laminated below the backing layer 4 for the purpose of protecting the backing layer 4 and providing cushioning and soundproofing properties. The carpet 1 manufactured in this way is cut into a required size and shape, and the edges are frayed by overlock or tape lock processing to obtain a final product. The present invention is provided as an alternative to this overlock and tape lock processing.

  In the high-frequency welder processing according to the present invention, the molecules of the pile yarn corresponding to the mold are rotated and vibrated to generate heat from the inside, melt from the inside first, and impregnate and adhere to the adherend with pressure from above by a press. In ultrasonic welder processing, ultrasonic vibration is transmitted to the edge, the pile melts from the base fabric side by frictional heat due to vibration, and the pile yarn is pressed by the pressure from above by the press. It is a technique used in various fields, with an adhesion method characterized by a beautiful finish of the processed part and a strong welding force.

  The pile yarn at the edge of the raised fabric according to the present invention is not particularly limited as long as it is a thermoplastic resin, and may be melted by high-frequency welding or ultrasonic welding. For example, polyester, nylon, acrylic, polypropylene fiber, etc. can be mentioned. Further, the thickness of the pile yarn, the pile length, the number of stitches, the pile basis weight, and the like are not particularly limited, and may be a raised fabric in which the pile yarn is implanted in the base fabric.

  Pile yarn made of thermoplastic resin by high-frequency welder processing or ultrasonic welder processing melts the part pressed against the mold 6 while maintaining the fiber shape of the pile while maintaining the fiber shape of the pile. By pressure bonding to the base fabric, a base fabric made of a woven or knitted base fabric or a nonwoven fabric is impregnated to form the melt-adhesive layer 7, and fraying is reliably prevented by the anchor effect. In addition, the high-frequency welder processing and the ultrasonic welder processing are characterized by forming a beautiful melt-adhesive layer 7 which is melted while leaving the fiber shape on the surface of the pile yarn. Is formed. Further, if an embossed mold having an uneven pattern is used as the mold 6, the surface of the melt adhesive layer 7 is rich in design, can be a fraying stopper having a beautiful finish and excellent processing efficiency. .

  The metal mold for high-frequency welder processing and ultrasonic welder processing is long and is about 20 to 30 cm. Therefore, this is repeated and applied to the edge of the napped fabric to melt the pile yarn to perform edge processing. . The time required for one shot may be determined while confirming the molten state according to the standard of the napped fabric. When the pile yarn is melted by pressing the mold for a long time, most of the melted pile yarn is impregnated into the inside of the base fabric, the texture becomes hard, and a heap-like texture is not preferable. On the other hand, since most of the pile yarn is not melted in a short time, the resin of the fusion bonding layer 7 is not impregnated in the base fabric, so that fraying is not stopped. The time required for one shot varies depending on the melting point of the fiber used in the pile yarn, the pile standard, the tuft standard, and the like, and therefore the time required for the one shot may be determined while checking the melted state. In the preferable edge treatment, it is preferable that the edge treatment is performed by leaving 1/3 to 1/2 of the fiber of the pile yarn on the surface of the melt adhesive layer 7 because a soft touch feeling can be obtained.

  It is preferable that the mold is embossed and the uneven pattern is carved. In a flat mold, although the melt-adhesive layer 6 can be formed as a seal, it tends to be a flat film shape, and therefore, it is preferable that the design is carved to improve the appearance quality.

  The pile yarn 2, the base fabric 3, and the backing layer 4 at the edge of the raised fabric according to the present invention are most preferably made of a thermoplastic resin, but any one of the pile yarn 2, the base fabric 3, and the backing layer 4 is used. If one kind is made of a thermoplastic resin, the processing of the present invention is possible. Therefore, as a material used for a raised fabric, what is used for normal raised fabrics may be used. For example, examples of the base fabric 3 include polyester, polypropylene, cotton, etc., and may be a woven / knitted base fabric or a non-woven fabric. The backing layer 4 is not particularly limited as long as it is a resin composition or a rubber composition that can fix the pile yarn 2 and the base fabric 3. For example, the resin component of the resin composition may be acrylic, urethane, poly Examples thereof include resins such as vinyl chloride, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer (EVA). Examples of the rubber component of the rubber composition include SBR (styrene-butadiene rubber), NBR (acrylonitrile-butadiene rubber), MBR (methyl methacrylate-butadiene rubber), and natural rubber.

Next, specific examples of the present invention will be described.
<Example 1>
As an embodiment of the present invention, materials used for carpets and processing methods are listed.
<Materials used and processing methods>
Base fabric: polyester spunbonded nonwoven fabric (110 g / m ² per unit area, apparent thickness is 0.3 mm).
Pile yarn: 2600 decitex polyester fiber yarn.
Tufting machine ... 1/8 cut machine.
Tuft standard: 30 stitches / 10 cm, pile length 8 mm, pile weight 780 g / m ² .
Backing layer: SBR latex was roller-coated and dried at 120 ° C. for 10 minutes. (Application amount 260 g / m ² )
Second base fabric: polyester needle punch nonwoven fabric (410 g / m ² per unit weight, apparent thickness: 8 mm).
Cutting: A 1 m square carpet was obtained from the original carpet with a circle cutter.
Anti-fraying process: Using a die-shaped embossing die as shown in Fig. 3, using a welder processing machine, a die with a width of 10 mm and a length of 200 mm is placed on the edge of the carpet cut into 1 m square for 2 seconds. The melted adhesive layer 7 was formed by pressing, and the above operation was repeated to prevent fraying while feeding the carpet in increments of 200 mm. The melt adhesive layer 7 had about half of the pile yarn fibers that did not melt on the surface, and the appearance was rope-like, so it seemed to be overlocked and could have a good texture.

<Example 2>
In Example 1, a flat mold having no handle was used, and fraying was performed in the same manner as in Example 1 except that the mold was pressed for 1 second. About half of the pile yarn is not completely melted, and the melt-adhesive layer 7 is formed while leaving the yarn form to some extent, so that a soft feel remains and a good texture can be obtained.

<Comparative Example 1>
Fraying prevention processing was performed in the same manner as in Example 1 except that the pressing time in Example 1 was 5 seconds. Most of the melt-adhesive layer 7 that was completely melted and adhered was immersed in the inside of the base fabric, and it was not preferable because of a paper-like texture.

Schematic cross section of napped fabric Schematic perspective view in which a mold is pressed against the edge of a napped fabric and welded. Embossed pattern example of mold

Explanation of symbols

1 carpet 2 pile yarn 3 base fabric 4 backing layer 5 second base fabric 6 mold 7 melt adhesive layer 8 embossed pattern

Claims (6)

  In a napped fabric comprising a pile yarn, a base fabric, and a backing layer, the edge portion is processed by melting by leaving the fiber form of the pile yarn at the edge, and impregnating the base fabric to provide a molten adhesive layer. A unique raised fabric.   In the raised fabric, the molten adhesive layer is melted leaving the fiber form of the pile yarn at the edge, and the surface of the molten adhesive layer is patterned in a concavo-convex shape, impregnated into the base fabric, and the edge treatment is performed. The napped fabric according to claim 1, wherein:   In the napped fabric, the melt adhesive layer melts the pile yarn at the edge by high-frequency welding or ultrasonic welder, leaving the fiber form of the pile yarn at the edge, and the surface of the melt adhesive layer is uneven. The raised fabric according to claim 1 or 2, wherein a handle is attached to the base fabric to impregnate the base fabric to treat the edges.   An edged fabric comprising a pile yarn, a base fabric, and a backing layer, wherein the edge of the raised fabric is melted while leaving the fiber form of the pile yarn at the edge, impregnated into the base fabric, and the edge is treated. Part processing method.   In the edge treatment method of the raised fabric, the edge pile processing is performed by leaving the fiber form of the pile yarn at the edge, melting the surface of the molten adhesive layer, and then impregnating the base fabric. The edge processing method of the napped fabric according to claim 4 characterized by things.   In the edge treatment method of the raised fabric, the pile yarn at the edge is melted by high-frequency welder processing or ultrasonic welder processing, leaving the fiber form of the pile yarn at the edge, and is unevenly formed on the surface of the molten adhesive layer. The edge treatment method for a napped fabric according to claim 4 or 5, wherein a pattern is provided and the edge is treated by impregnating the base fabric.