JP3011892B2 - Water absorbent tufted carpet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a water-absorbent tufted carpet applied to a bathroom / kitchen carpet and a fabric for forming the pile.

[0002]

2. Description of the Related Art As shown in FIGS. 4 and 5, a conventional tufted carpet widely used for bath mats and the like is provided on a surface of a base cloth 5 woven in a plain weave or the like with a stretched belt-like polypropylene thread or the like. It is well known that the cut pile 8 is formed of a yarn having good water absorbency such as a cotton yarn.

[0003] Such a conventional tufted carpet C
Has a cotton-like nonwoven fabric 9 layered on the back surface of the base fabric 5 and integrated by needling to enhance cushioning properties. Further, a rubber layer 10 such as styrene-butadiene rubber (SBR) is applied to the lower surface thereof. It has a non-slip surface.

[0004]

However, the conventional tufted carpet described above absorbs water due to the hydrophilicity of the pile yarn and the capillary action of the fibers constituting the pile, and when the water is absorbed, the pile on the carpet surface is intensively large. Since the moisture is retained, the drying speed of the pile is low. For example, when such a tufted carpet is used for a bath mat (bathroom wiping mat), there is a problem in that the feel becomes poor and it cannot withstand continuous use. .

In order to solve such a problem, it is preferable to dry the pile yarn of the tufted carpet as soon as possible. However, if an acrylic pile yarn having low water absorption is simply employed, water will reach the back of the carpet. This is a problem because it penetrates and wets the floor.

The SBR anti-slip layer usually provided on the back of a conventional tufted carpet does not have a sufficient anti-slip function, and when applied thinly, the non-woven fabric for the cushion projects from the back to lower the waterproofness. There is also the problem of doing.

Further, since the heat resistance of the non-slip layer made of SBR is about 70 to 80 ° C., there is a problem that printing after thermal transfer cannot be performed after the anti-slip layer is provided on the carpet.

Accordingly, an object of the present invention is to solve the above-mentioned problems and to make the surface of the pile easy to dry while maintaining the water absorbing function of the water-absorbing tufted carpet, so that the feel is always good even when used continuously. It is to be.

Another problem of the present invention is that even when the above-mentioned problems are solved, it is possible to prevent water from penetrating to the back surface of the carpet and to wet the floor surface, and it is preferable that the anti-slip property is further improved. It is to be.

[0010] Still another object of the present invention is to make it possible to perform printing by thermal transfer after providing an anti-slip layer on a product.

[0011]

SUMMARY OF THE INVENTION In order to solve the above-mentioned problems of improvement in water absorption capacity and continuous use, in the present invention, a plurality of sheet-like rayon nonwoven fabrics are laminated on a base fabric.
A water-absorbent tufted carpet is obtained by forming a pile on the surface of the base fabric by inserting a hydrophobic pile yarn into the base fabric and the rayon non-woven fabric.

The rayon nonwoven fabric in the water-absorbent tufted carpet is preferably a sheet-like rayon nonwoven fabric having an embossed pattern.

As the cloth for the water-absorbent tufted carpet, a cloth for the water-absorbent tufted carpet in which a plurality of sheet-like rayon nonwoven fabrics are stacked on the back surface of the base cloth and integrated by needle punching can be adopted.

In addition to solving the above problems,
In order to solve the problems of water permeability to the back surface, anti-slip properties and printability, in the invention of the present application, a styrene resin and an EVA resin are used as main components on the back surface of the water-absorbent tufted carpet having the above configuration. That is, the mixed resin sheet is integrally provided.

The sheet-like rayon nonwoven fabric of the present invention is made of regenerated cellulose as a raw material and has good hydrophilicity. For example, a thin sheet nonwoven fabric having a thickness of about 0.1 to 1 mm is used. By using two or more sheets in a pile, they are used to form a large water-absorbing space between fibers and between layers.

To this end, it is preferable to form layers by stacking as many sheets of appropriate thickness as possible. Further, a sheet-like rayon nonwoven fabric having an embossed pattern is preferable for the present invention since a relatively large water-absorbing void can be formed between the superposed surfaces.

Since the pile formed on the surface of the base fabric is made of a hydrophobic pile yarn, its moisture retention when wet is low, and most of the water is absorbed and held by the rayon nonwoven fabric.

Accordingly, the water absorbing function of the water-absorbing tufted carpet is maintained, and the pile surface has a higher drying speed, that is, is easier to dry.

When a mixed resin sheet containing a styrene resin and an EVA resin as a main component is laminated and provided integrally on the back surface of such a water-absorbent tufted carpet, the nonwoven fabric does not protrude from the lower surface, so that waterproofness is obtained. In addition, water permeability to the back surface, non-slip properties and heat resistance (print processing property) are improved by the high coefficient of friction due to the properties of the EVA resin and the heat resistance properties of the styrene resin.

[0020]

Embodiments of the present invention will be described below with reference to the accompanying drawings. As shown in FIGS. 1 and 2, in the first embodiment of the present invention, four sheet-like rayon nonwoven fabrics 1, 2, 3, and 4 are superimposed on a plain-woven polypropylene yarn base fabric 5 and integrated by needle punching. This is a water-absorbent tufted carpet A in which a hydrophobic pile thread 6 made of acrylic fiber is stabbed into the formed water-absorbent tufted carpet cloth a by tufting to form a cut pile on the surface of the base cloth 5.

The rayon nonwoven fabrics 1, 2, 3, and 4 are artificial fibers having good hydrophilicity made from regenerated cellulose, and include, for example, nonwoven fabrics made of viscose rayon, cuprammonium rayon (cupra), saponified acetate human silk, and the like. Is a specific example.

The method for producing the nonwoven fabric is not particularly limited, and a web obtained by a well-known dry method or wet method is bonded by an adhesive, heat or mechanical bonding. Further, a material obtained by the spunbonding method (rayon spunbond) is formed into a thin sheet at a relatively low price, and preferable results are obtained by using the present invention.

Such a rayon nonwoven fabric has a thickness of 0.1 to 1
mm thin sheet (for example, 30 g /
m ² ) is preferable, and in particular, those in which fine uneven patterns are formed on both the front and back surfaces by embossing are preferable. As such an uneven pattern, for example, 0.5 × 0.5 mm
An example is a concavo-convex pattern in which approximately square concave portions are formed vertically and horizontally at intervals of 1 mm.

The base fabric 5 used in the present invention is not particularly limited in the material and woven structure of the yarn fibers constituting the base fabric 5, and may be, for example, other than synthetic fibers such as polypropylene, acrylic, polyethylene, nylon, polyester and the like. , Cotton, wool, hemp, etc. can be used. As the texture of the structure of the base cloth, it is preferable to adopt a coarse texture such as a plain weave or a satin weave in order to easily form a pile by tufting in a later step.

In the first embodiment shown in FIGS. 1 and 2, the fourth (lowermost) rayon nonwoven fabric 4
Adopts a relatively soft fiber with a long fiber length,
The fibers are easily entangled with other layers, that is, they are easily integrated by needle punching.

Nidol punching for the water-absorbent tufted carpet fabric a was performed by piercing a number of needles having downward barbs using a well-known needle punching machine.

The hydrophobic pile yarns 6 used in the present invention are exemplified by acrylic fibers (polyacrylonitrile fibers), but other known hydrophobic fibers may be employed. Other hydrophobic pile yarn fibers that can be used in the present invention include vinylon, polyester, nylon, polyurethane, polypropylene, polyethylene, and acrylic. Further, if a twisted wool-like pile yarn is used, the pile surface becomes dense and a soft texture can be obtained.

As shown in FIG. 2, the hydrophobic pile yarn 6 is
The tufting machine pierced the cloth a for water-absorbent tufted carpet and cut the trap pile to form a cut pile on the surface of the base cloth 5.

When the water-absorbent tufted carpet A produced as described above was used as a bath mat, most of the water was absorbed and retained in the sheet-like rayon nonwoven fabrics 1, 2, and 3 having an embossed pattern, and the hydrophobic pile was used. The surface of the carpet made of the yarn 6 was easy to dry and had a good touch even when used continuously.

As shown in FIG. 3, in the second embodiment of the present invention, a styrene resin and an EVA resin (ethylene-vinyl acetate copolymer) are used as main components on the back surface of the above-described water-absorbent tufted carpet. Is a water-absorbent tufted carpet B provided integrally with a mixed resin sheet 7 to be laminated (thermocompression bonding).

The styrene resin of such a mixed resin and EV
The compounding ratio of the resin A may be appropriately adjusted so that the coefficient of friction is appropriately increased and a material having heat resistance enough to withstand print printing in post-processing is used. It can also be blended.

The mixed resin sheet 7 has a thickness of about 300 g / m ² and a thickness of about 0.3 mm, and preferably has a heat-resistant temperature (heat deformation temperature) of 130 to 150 ° C. In this case, in the normal printing process, the thermal transfer is performed at about 90 to 110 ° C., so that the printing process can sufficiently withstand the printing process.

The styrene / EVA mixed resin has a high coefficient of friction and good water resistance, and is resistant to chlorine contained in tap water. No water permeated to the back surface, so that the floor surface was not wetted, the anti-slip property of the surface was improved, and the surface did not deteriorate even when wet with tap water.

[0034]

As described above, in the water-absorbent tufted carpet of the present invention, a plurality of rayon nonwoven fabrics are piled on a base cloth to form a pile on the surface thereof. There is an advantage that the surface of the pile is easily dried while being maintained, and the feel is always good even when used continuously.

Further, the invention employing a sheet-like rayon nonwoven fabric having an embossed pattern results in a water-absorbing tufted carpet having a relatively large water holding amount.

In the case where a predetermined resin sheet is integrally laminated on the back surface of the water-absorbent tufted carpet, the above-mentioned advantage can be prevented, and the adverse effect of water permeating the back surface of the carpet and wetting the floor surface can be prevented. In addition, there is an advantage that the anti-slip property is improved as compared with the conventional product, and that a print printing process by thermal transfer can be performed by post-processing.

[Brief description of the drawings]

FIG. 1 is a perspective view showing a first embodiment with a part cut away.

FIG. 2 is an enlarged sectional view taken along line II-II of FIG.

FIG. 3 is an enlarged sectional view of a main part of the second embodiment.

FIG. 4 is a perspective view showing a conventional example with a part cut away.

FIG. 5 is an enlarged sectional view taken along line VV of FIG. 4;

[Explanation of symbols]

 1, 2, 3, 4 Rayon nonwoven fabric 5 Base fabric 6 Hydrophobic pile yarn 7 Mixed resin sheet 8 Cut pile 9 Nonwoven fabric 10 Rubber layer a Fabric for water-absorbent tufted carpet A, B Water-absorbent tufted carpet C Conventional tufted carpet

Continuation of the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) D05C 17/02 A47G 27/02 101

Claims (3)

(57) [Claims] 1. A plurality of sheet-like rayon nonwoven fabrics having a thickness of 0.1 to 1 mm, each having an uneven pattern formed on both sides thereof by embossing, are laid on a base fabric, and a hydrophobic pile yarn is stabbed into the base fabric and the rayon nonwoven fabric. A water-absorbing tufted carpet formed by forming a pile on the surface of a base cloth. 2. A water-absorbent tufted carpet, wherein a mixed resin sheet containing a styrene resin and an EVA resin as main components is integrally provided on the back surface of the water-absorbent tufted carpet according to claim 1. 3. A cloth for water-absorbent tufted carpet, in which a plurality of sheet-like rayon nonwoven fabrics having a thickness of 0.1 to 1 mm and having a concavo-convex pattern formed on both sides thereof by embossing are laminated on a base cloth and integrated by needle punching. .