JPS61193829A - Method of lining carpet - Google Patents

Abstract

PURPOSE:To provide a method of lining a carpet in an economical way wherein materials and energy are saved and the number of the steps is reduced, by pressing and sticking successively as a lining material a kneaded compound material in a heated and softened state and in the form of a sheet to the undersurface of a carpet. CONSTITUTION:As a carpet lining material, a heated and kneaded compound material (B) of a resin or rubbery material is continuously extruded downward into a form of a sheet from a die 16, is passed between thickness controlling rollers 17, and is brought in contact with the undersurface of a substrate of a carpet (A) that is heated and softened by pressing rollers 18a, 18b thereby the material (B) is successively pressed and stuck to the undersurface. A second lining material (C) that is rolled and supported by a delivery shaft 19 is delivered at a prescribed rate, is heated, if required, by a heater 21 to a suitable temperature, and is successively pressed and stuck by second pressing rollers 22a, 22b to the undersurface of the compound material (B) that is still at a high temperature and in a softened state.

Description

[Detailed description of the invention] B. Purpose of the invention [Industrial application field] The present invention relates to a method for backing carpets.

[Conventional technology]

Carpets are made by weaving or flocking pile (crystalline or loop-like hair) into a base fabric such as woven, knitted, or non-woven fabric. Depending on the weaving method, pile form, etc., carpets can be woven or tufted. There are many types of carpets, including carpets and flocked carpets.

Figure 1 shows a cross section of an example of a tufted carpet, where 1 is the base fabric and 2 is the pile woven into the base fabric.

The back surface of Carpella A is lined to provide rigidity, sound insulation, moldability, etc., and to prevent the pile threads from falling off or being pulled out. Conventionally, the backing process involves first applying adhesive 1, such as latex rubber, to the back side of the carpet base fabric.
Coating treatment 3 with vinyl paste sol red tar, pitch, etc., followed by a backer sheet (backing sheet material) 4 manufactured in advance and stocked in rolls, etc., for example, thick resin sheet such as vinyl chloride, calcium carbonate calcium High-density EVA resin or rubber sheets containing fillers such as these were reheated and bonded together.

[Problem that the invention seeks to solve]

However, the above-mentioned backing process consumes a large amount of adhesive. There are problems such as the need for a large amount of thermal energy to reheat the backer sheet during the backer sheet lamination process.
Therefore, the cost of carpet lining processing has been relatively high.

Furthermore, when tar or pitch is used as an adhesive, there is also the problem that it leaches through the base fabric to the carpet pile during the summer.

The present invention has been proposed in view of the above, and an object of the present invention is to provide an economical method for processing carpet backing using materials, energy saving, and process saving.

Summary: Structure of the Invention [Means for Solving the Problems] The present invention provides a method for discharging a heated kneaded compound material of resin or rubber material into a sheet using an extruder, or rolling it into a sheet using a rolling roll device. The sheet-like kneaded compound material, which has been extruded or rolled and is still in a thermally softened state and has sufficient kneading ripening energy, is transferred to a carpet 7.
The gist of this invention is a method for lining a carpet, which is characterized in that the backing material is sequentially pressed and bonded to the back surface of the carpet.

[For production]

As a backing material crimped to the back side of the carpet,
Immediately after being extruded or rolled, the sheet-like kneaded compound material is generally in a heat-softened state at a high temperature of 130 to 180°C, and has sufficient adhesiveness, so it can be attached to the back side of the carpet without using an adhesive. On the other hand, it adheres well with less internal stress, and a part of it penetrates into the carpet base fabric and becomes a biting state (anchor effect), so that even after cooling and hardening, the state of being fully bonded to the back side of the carpet is maintained. Ru. That is, lining processing can be performed without using an adhesive or requiring an adhesive application process. In addition, the sheet-like kneaded compound material, which has just been extruded or rolled and is still in a thermally softened state and has sufficient kneading thermal energy, is sequentially applied as a backing material to the back surface of the carpet and bonded and bonded. Because it is processed, it is extremely advantageous in terms of thermo-economics compared to the conventional method of reheating and reheating backer sheets that have been manufactured and stocked, and the process of reheating backer sheets can also be omitted. .

〔Example〕

In Fig. 1, A is a rolled carpet to be lined, which is rolled up with the back side facing outward, supported by a feeding shaft 10, and continuously fed and conveyed at a predetermined speed. .

Reference numerals 11-12 are carpet conveyance guide rollers, and 13 is a heater for heating the back surface of the carpet base fabric, which is disposed between the rollers 11 and 12, if necessary. 14 is a part of the extruder main body, 15 is the extruder head, and 16 is a die, from which the heated kneaded compound material B of resin or rubber material as a W-beating material is directed downward in the form of a sheet. Continuously extruded and discharged.

Sheet-shaped heat-kneaded compound material B extruded and discharged
is brought into contact with the back side of the base fabric of the carpet A via the pair of thickness adjusting rollers 17, and while it is still in a thermally softened state due to sufficient kneading thermal energy by the pair of compression rollers 18a and 18b, the back side of the carpet base fabric is The backing material is sequentially crimped and laminated onto the backing material.

Immediately after extrusion and discharge, the sheet-shaped kneaded compound material B is generally in a heat-softened state at a high temperature of 130 to 180°C, and has sufficient adhesiveness, so that it can be attached to the back side of the carpet A base fabric without the use of an adhesive. The Bt (Fig. 2) penetrates into the base fabric due to the pressure force and becomes stuck, and even after cooling and hardening, it remains fully bonded to the back side of the carpet base fabric. Retained.

Compound material B is a resin such as vinyl chloride resin, EVA resin, polyethylene resin, polypropylene resin, etc., and a filler such as calcium carbonate, talc, mica, barium sulfate, etc. in a total compound weight ratio of 30 to 30%. It is a high specific gravity blended resin containing about 300% blend, and is generally extruded and discharged as a sheet with a thickness of about 0.5 to 10 layers and laminated to the back side of the carpet base fabric. It is preferable that the base fabric 1 and/or the pile 2 of the carpella) A and the heat-kneaded compound material B, which is the backing material, have mutual adhesion affinity. When all or part of the constituent fibers in No. 2 are vinyl resin fibers such as vinyl chloride resin, the heat-kneaded compound material B is preferably a soft or semi-hard vinyl resin such as vinyl chloride resin.

When using a rubber material as compound material B, use a room-temperature vulcanization accelerator that allows vulcanization to proceed at room temperature, or carpet A.
Temperature that does not burn itself with heat, e.g. 60-100℃
A heating type vulcanization accelerator is blended in which vulcanization progresses by passing through a heating furnace.

The heat-kneaded compound material B, which is a rubbery material, adheres well to and integrates with the carpet base fabric in which all or part of the constituent fibers are cotton, human silk, polyester resin, etc.

Following the press-bonding process of the sheet-shaped heat-kneaded compound material B as a backing material to the back surface of the base fabric of the carpet A, the back surface of the bonded and kneaded compound material B is further coated as necessary for the purpose of preventing shrinkage, etc. A second backing material may be laminated.C in FIG. 102 is the second backing material, and is made of, for example, nonwoven fabric such as glass fiber or polyester fiber, hard or semi-hard vinyl chloride resin, etc. Mesh sheets (flat mesh materials), etc. 2 in Figure 1
The backing material C is wound into a roll, supported by a payout shaft 19, fed out and conveyed at a predetermined speed (20 is a conveyance guide roller), and is heated to an appropriate temperature by a heating device 21 as needed, so that it is already a carpet base fabric. The second pressure roller pair 22a and 22b sequentially performs a pressure bonding process on the back surface of the compound material B which is still in a high temperature/thermally softened state and whose back surface has been subjected to a pressure bonding process.

When the second backing material C is a mesh sheet.

The mesh sheet can also be applied in the form of being embedded within the thickness of the compound material B by adjusting the pressure of the pressure roller pair 22a and 22b. Also, as shown by the two-dot chain line C' in FIG. It can also be applied in an embedded form.

Furthermore, the second layer is lined with compound material B.
The carpeller (A) to which the backing material C has been laminated is then cooled through a cooling zone (not shown) and wound up into a roll, or sequentially cut into sheets of fixed length, or Subsequently, the product is transported to a processing zone such as a continuous vacuum forming apparatus and processed to be formed into a desired shape, for example, as an automobile floor mat or dash silencer sheet.

A rolling roll device is used in place of the extruders 14 to 16, and the material is rolled and delivered from the rolling roll device. This is a method in which a sheet-like kneaded compound material B made of resin or rubber material, which still has sufficient kneading thermal energy and is in a thermally softened state, is bonded to the back surface of the base fabric of the carpet A. There may be.

C. Effects of the Invention As described above, according to the present invention, carpet lining can be economically processed using materials and energy-saving processes.

[Brief explanation of drawings]

FIG. 1 is a schematic process diagram of one embodiment, FIG. 2 is a cross-sectional view showing the layer structure of a backing-treated carpet, and FIG. 3 is a cross-sectional view showing the layer structure of a carpet laminated with a backer sheet using an adhesive. A is the carpet, B is the backing layer, C is the second backing material,
l is the carpet base fabric, 2 is the pile, 3 is the adhesive layer, 4
is a backer seat.

Claims (8)

[Claims] (1) Heat-kneaded compound material of resin or rubber material is discharged in the form of a sheet by an extruder, or rolled and delivered in the form of a sheet by a rolling roll device, and the extruded or rolled material is still sufficiently kneaded. A carpet lining characterized in that a sheet-like kneaded compound material that retains thermal energy and is in a thermally softened state is sequentially pressed and bonded to the back side of the carpet as a backing material for the back side of the carpet. Processing method. (2) The method for lining a carpet according to claim 1, wherein the base fabric or pile of the carpet and the heat-kneaded compound material as the backing material have mutual adhesive affinity. (3) All or part of the constituent fibers of the base fabric or pile of the carpet are vinyl resin fibers such as vinyl chloride resin,
The carpet lining method according to claim 2, wherein the heat-kneaded compound material is a vinyl resin such as a soft or semi-hard vinyl chloride resin. (4) The carpet lining processing method according to claim 1, wherein the heat-kneaded compound material is a rubbery material containing a room temperature type or heat type vulcanization accelerator. (5) The heated kneading compound material contains calcium carbonate,
The carpet lining processing method according to claim 1, wherein the carpet lining is a high specific gravity material containing fillers such as talc, mica, and barium sulfate. (6) The carpet according to claim 1, wherein the second backing material is sequentially bonded to the back surface of the base fabric of the carpet at the same time as the sheet-shaped heat-kneaded compound material is bonded and bonded to the back surface of the carpet base fabric. lining processing method. (7) The carpet lining method according to claim 6, wherein the second lining material is a nonwoven fabric or a woven fabric such as glass fiber or polyester fiber. (8) The second backing material is a mesh member, and the second backing material is attached to the back surface of the sheet-shaped heat-kneaded compound material, or is embedded in the thickness of the sheet-shaped heat-kneaded compound material. The method for lining a carpet according to item 6.