JPH11301330A - Tufted carpet and manufacture of it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To eliminate inconvenience in which the number of processes is increased and productivity is deteriorated caused by fixing of a pile yarn to a ground fabric layer by a backing layer. SOLUTION: A nonwoven fabric layer 1 is formed by mixing a low melting point binder fiber of the same material as a high density nonwoven fabric on the high density nonwoven fabric, pile yarns of the same material as the nonwoven fabric layer 1 is tufted, and the root of the pile yarns 2 are fixed to the nonwoven fabric layer 1 by binder fibers. Since the roots of the pile yarns 2 can be fixed to the nonwoven fabric layer 1 without providing any backing layer, a process for forming the backing layer is not required.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tufted carpet used for a floor carpet of an automobile and a method for manufacturing the same.

[0002]

2. Description of the Related Art Tufted carpets in which pile yarns are planted on a base cloth are often used as floor carpets conventionally laid on the floor of automobiles.

As this kind of tufted carpet, for example, one described in Japanese Patent Application Laid-Open No. 9-175247 is known.

[0004] The tufted carpet disclosed in the above publication has a structure in which a nonwoven fabric mainly composed of thermoplastic resin fibers is laminated on the back surface, and a pile yarn is tufted from the side on which the nonwoven fabric is laminated to form a pile on the surface of the fabric. After standing, the base fabric is heated from the side on which the nonwoven fabric is arranged to form a fusion layer (backing layer) of nonwoven fabric constituent fibers, and the root of the pile yarn is fixed by the backing layer. This has the effect of enabling the carpet to be backed with excellent properties, moldability and soundproofing.

On the other hand, a tufted carpet having another structure is, for example, one in which a pile yarn is implanted in a base fabric, a backing layer is provided on the back side of the base fabric, and the base of the pile yarn is fixed to the base fabric with the backing layer. There is also.

[0006]

However, the above-mentioned conventional tufted carpets have a structure in which the root of the pile yarn is fixed by a backing layer made of a thermoplastic resin such as polyethylene to prevent the pile yarn from coming off. Has adopted.

For this reason, a process such as laminating for forming a backing layer is required, which results in poor productivity and high cost.

[0008] Polyester is usually used for the pile yarn and the base cloth, while polyethylene is used for the backing layer. Therefore, when recycling the used tufted carpet, the material is not used. Although it is necessary to separate the backing layer from a different pile yarn or base fabric, it is almost difficult to remove the hardened backing layer, so that there are disadvantages such as difficulty in recycling.

The present invention has been made in order to solve such a conventional problem, and provides a tufted carpet in which the base of pile yarn is fixed without providing a backing layer, and a method for manufacturing the same. It is intended to facilitate recycling.

[0010]

Means for Solving the Problems To achieve the above object, the invention according to claim 1 comprises mixing a low melting point binder fiber of the same material as the high density nonwoven fabric with a high density nonwoven fabric to form a nonwoven fabric layer, A pile yarn of the same material as that of the non-woven fabric layer is tufted to the non-woven fabric layer, and the base of the pile yarn is fixed to the non-woven fabric layer by the binder fiber.

According to the above configuration, since the nonwoven fabric layer and the pile yarn can be fixed without providing the backing layer, the step of forming the backing layer becomes unnecessary, and the number of steps can be reduced to improve the productivity.

Since the nonwoven fabric layer and the pile yarn are of the same material,
Used tufted carpets can also be easily recycled.

In order to achieve the above object, the invention according to claim 2 is that a cushion layer made of the same material as the nonwoven fabric layer is formed on the back surface of the nonwoven fabric layer.

According to the above configuration, a tufted carpet having a cushioning property can be easily obtained.

According to a third aspect of the present invention, a nonwoven fabric layer is formed by mixing a low melting point binder fiber of the same material as the high density nonwoven fabric with a high density nonwoven fabric. After tufting a pile yarn of the same material as the layer, the nonwoven fabric layer is heated to melt the binder fiber,
The non-woven fabric layer and the pile yarn are fixed with a molten binder fiber.

According to the above-mentioned method, the pile yarn can be fixed to the nonwoven fabric layer without providing the backing layer, so that the step of providing the backing layer is not required, thereby improving the productivity by reducing the number of steps.

[0017]

Embodiments of the present invention will be described in detail with reference to the drawings.

FIG. 1 is a cross-sectional view of a tufted carpet, in which 1 indicates a nonwoven fabric layer and 2 indicates a pile yarn tufted to the nonwoven fabric layer 1.

The nonwoven fabric layer 1 has a basis weight of 200 to 100.
A high-density nonwoven fabric having a thickness of 1 to 4 mm and a binder fiber made of a low-melting thermoplastic resin of the same material mixed with a nonwoven fabric of 0 g / m ² polyester resin. A pile yarn 2 made of polyester is tufted.

After the tufting of the pile yarn 2, the nonwoven fabric layer 1 is heated to the melting temperature of the binder fiber, and the root of the pile yarn 2 is fixed to the nonwoven fabric layer 1 by the melted binder fiber. The pile yarn 2 can be fixed to the nonwoven fabric 1 without providing the backing layer.

Next, a method of manufacturing the tufted carpet constructed as described above will be described. First, a pile yarn 2 of the same material as the high-density nonwoven fabric forming the nonwoven fabric layer 1 is set on a tufting machine (not shown). Non-woven fabric layer 1
Then, tufting of the pile yarn 2 is started.

At this time, the tufting method is the pile yarn 2
The method may be any of a loop pile in which the tip of a loop pile is formed or a cut pile in which the tip of a looped pile yarn is cut with a knife.

As described above, the pile yarn 2 is
Is tufted, the tufted carpet is removed from the tufting machine, and the nonwoven fabric 1 is heated from the back side to the melting temperature of the binder fiber to melt the binder fiber. Since the nonwoven fabric 1 is formed of a high-density nonwoven fabric, the root of the pile yarn 2 can be fixed to the nonwoven fabric layer 1 with a small amount of binder fiber.

And the obtained tufted carpet is
Since the root of the pile yarn 2 is firmly fixed to the nonwoven fabric layer 1, there is no fear that the pile yarn 2 will come off during use.

In the above embodiment, the case of the tufted carpet in which the pile yarn 2 is tufted on the nonwoven fabric layer 1 has been described. However, as shown in FIG.
A cushion layer 3 made of, for example, polyester of the same material as the nonwoven fabric layer 1 may be formed on the back surface of the carpet to give the tufted carpet cushioning properties. Further, in the above-described embodiments, no base fabric layer is provided, but a base fabric layer made of the same material as the nonwoven fabric layer 1 may be provided.

[0026]

As described in detail above, the present invention tufts a pile yarn of the same material as a nonwoven fabric layer on a nonwoven fabric layer made of a high density nonwoven fabric mixed with a low melting point binder fiber, and then heats the nonwoven fabric layer. Since the binder fibers are melted and the base of the pile yarn is fixed to the nonwoven fabric layer by the binder fiber, the pile yarn can be fixed to the nonwoven fabric without forming the binder layer.

This eliminates the need for a laminating step for forming the backing layer, thereby improving the productivity by reducing the number of steps and making it possible to provide a tufted carpet at a low cost by reducing the number of steps.

Since the same material resin is used for the non-woven fabric layer and the pile yarn, when the used tufted carpet is recycled, there is no need to separate the carpet, thereby facilitating the recycling. .

Further, by forming a cushion layer of the same material as the nonwoven fabric layer on the back surface of the nonwoven fabric layer, a tufted carpet having cushioning properties can be easily obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view of a tufted carpet according to an embodiment of the present invention.

FIG. 2 is a sectional view of a tufted carpet according to another embodiment of the present invention.

[Explanation of symbols]

 Reference Signs List 1 nonwoven fabric 2 pile yarn 3 cushion layer

Claims (3)

[Claims] 1. A non-woven fabric layer is formed by mixing a low-melting-point binder fiber of the same material as the high-density non-woven fabric with the high-density non-woven fabric, and a pile yarn of the same material as the non-woven fabric layer is tufted on the non-woven fabric layer. A tufted carpet, wherein a root of a pile yarn is fixed to a nonwoven fabric layer by the binder fiber. 2. The tufted carpet according to claim 1, wherein a cushion layer of the same material as the nonwoven fabric layer is formed on the back surface of the nonwoven fabric layer. 3. A non-woven fabric layer is formed by mixing a low-melting-point binder fiber of the same material as the high-density non-woven fabric with the high-density non-woven fabric, and a pile yarn of the same material as the non-woven fabric layer is tufted on the non-woven fabric layer. And heating the non-woven fabric layer to melt the binder fiber, and fixing the non-woven fabric layer and the pile yarn with the melted binder fiber.