JPH0120260B2 - - Google Patents
Info
- Publication number
- JPH0120260B2 JPH0120260B2 JP61144590A JP14459086A JPH0120260B2 JP H0120260 B2 JPH0120260 B2 JP H0120260B2 JP 61144590 A JP61144590 A JP 61144590A JP 14459086 A JP14459086 A JP 14459086A JP H0120260 B2 JPH0120260 B2 JP H0120260B2
- Authority
- JP
- Japan
- Prior art keywords
- layer
- carpet
- fiber
- weight
- fibers
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- 239000000835 fiber Substances 0.000 claims description 110
- 239000010410 layer Substances 0.000 claims description 49
- 239000000839 emulsion Substances 0.000 claims description 34
- 239000011230 binding agent Substances 0.000 claims description 33
- 238000002844 melting Methods 0.000 claims description 26
- 230000008018 melting Effects 0.000 claims description 25
- 229920005989 resin Polymers 0.000 claims description 25
- 239000011347 resin Substances 0.000 claims description 25
- 239000004745 nonwoven fabric Substances 0.000 claims description 23
- 229920005992 thermoplastic resin Polymers 0.000 claims description 23
- 239000002344 surface layer Substances 0.000 claims description 18
- 238000004519 manufacturing process Methods 0.000 claims description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 8
- 238000000465 moulding Methods 0.000 claims description 6
- 230000035515 penetration Effects 0.000 claims description 6
- 230000009477 glass transition Effects 0.000 claims description 4
- 239000007787 solid Substances 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims 1
- -1 polypropylene Polymers 0.000 description 16
- 239000004743 Polypropylene Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- 229920001155 polypropylene Polymers 0.000 description 9
- 229920001577 copolymer Polymers 0.000 description 8
- 238000000034 method Methods 0.000 description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 description 5
- 239000005020 polyethylene terephthalate Substances 0.000 description 5
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 4
- 229920002647 polyamide Polymers 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- 239000004952 Polyamide Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920000573 polyethylene Polymers 0.000 description 3
- 229920002994 synthetic fiber Polymers 0.000 description 3
- 239000012209 synthetic fiber Substances 0.000 description 3
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 description 2
- SOGAXMICEFXMKE-UHFFFAOYSA-N Butylmethacrylate Chemical compound CCCCOC(=O)C(C)=C SOGAXMICEFXMKE-UHFFFAOYSA-N 0.000 description 2
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- BWHLPLXXIDYSNW-UHFFFAOYSA-N ketorolac tromethamine Chemical compound OCC(N)(CO)CO.OC(=O)C1CCN2C1=CC=C2C(=O)C1=CC=CC=C1 BWHLPLXXIDYSNW-UHFFFAOYSA-N 0.000 description 2
- 239000000178 monomer Substances 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 229920002239 polyacrylonitrile Polymers 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 2
- 229920002554 vinyl polymer Polymers 0.000 description 2
- 210000002268 wool Anatomy 0.000 description 2
- GOXQRTZXKQZDDN-UHFFFAOYSA-N 2-Ethylhexyl acrylate Chemical compound CCCCC(CC)COC(=O)C=C GOXQRTZXKQZDDN-UHFFFAOYSA-N 0.000 description 1
- WDQMWEYDKDCEHT-UHFFFAOYSA-N 2-ethylhexyl 2-methylprop-2-enoate Chemical compound CCCCC(CC)COC(=O)C(C)=C WDQMWEYDKDCEHT-UHFFFAOYSA-N 0.000 description 1
- RUMACXVDVNRZJZ-UHFFFAOYSA-N 2-methylpropyl 2-methylprop-2-enoate Chemical compound CC(C)COC(=O)C(C)=C RUMACXVDVNRZJZ-UHFFFAOYSA-N 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- WOBHKFSMXKNTIM-UHFFFAOYSA-N Hydroxyethyl methacrylate Chemical compound CC(=C)C(=O)OCCO WOBHKFSMXKNTIM-UHFFFAOYSA-N 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-M Methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920002845 Poly(methacrylic acid) Polymers 0.000 description 1
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- JETSKDPKURDVNI-UHFFFAOYSA-N [C].[Ca] Chemical compound [C].[Ca] JETSKDPKURDVNI-UHFFFAOYSA-N 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- CQEYYJKEWSMYFG-UHFFFAOYSA-N butyl acrylate Chemical compound CCCCOC(=O)C=C CQEYYJKEWSMYFG-UHFFFAOYSA-N 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 229920006026 co-polymeric resin Polymers 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- SUPCQIBBMFXVTL-UHFFFAOYSA-N ethyl 2-methylprop-2-enoate Chemical compound CCOC(=O)C(C)=C SUPCQIBBMFXVTL-UHFFFAOYSA-N 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 230000005012 migration Effects 0.000 description 1
- 238000013508 migration Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 229920002401 polyacrylamide Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000004926 polymethyl methacrylate Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- LYBIZMNPXTXVMV-UHFFFAOYSA-N propan-2-yl prop-2-enoate Chemical compound CC(C)OC(=O)C=C LYBIZMNPXTXVMV-UHFFFAOYSA-N 0.000 description 1
- PNXMTCDJUBJHQJ-UHFFFAOYSA-N propyl prop-2-enoate Chemical compound CCCOC(=O)C=C PNXMTCDJUBJHQJ-UHFFFAOYSA-N 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 229910000859 α-Fe Inorganic materials 0.000 description 1
Description
【発明の詳細な説明】
〔産業上の利用分野〕
本発明は、自動車の内装材、家屋内の敷物とし
て有用なカーペツトの裏打方法に関する。DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for lining carpets useful as interior materials for automobiles and rugs in homes.
自動車のフロアーカーペツトとして樹脂水性エ
マルジヨンを含浸させた不織布繊維マツトや、高
融点の熱可塑性樹脂組成と100〜170℃の融点を有
する樹脂繊維バインダーとの混合繊維よりなる不
織布ウエブをエマルジヨン中の樹脂または樹脂繊
維バインダーの融点以上の温度に加熱し、次いで
プレス成形して自動車のフロアの形状に成形した
カーペツトは公知である。
Non-woven fiber mats impregnated with an aqueous resin emulsion are used as floor carpets for automobiles, and non-woven webs made of mixed fibers of a thermoplastic resin composition with a high melting point and a resin fiber binder with a melting point of 100 to 170°C are used as resin in the emulsion. Alternatively, carpets that are heated to a temperature higher than the melting point of a resin fiber binder and then press-molded into the shape of an automobile floor are known.
これらカーペツトは、それ自体のみでは豪華さ
に欠け、また、剛性、弾性、成形性の一方の性能
に欠けるため、このカーペツト表面にポリプロピ
レンのフラツトセーンクロス基布に繊維をループ
状等に起毛させた表層用のタフテツドカーペツト
をホツトメルト剤を用いて接着させている。 These carpets lack luxury on their own, and also lack performance in terms of rigidity, elasticity, and moldability, so fibers are raised in a loop shape on a polypropylene flat sane cloth base fabric on the surface of the carpet. The tufted carpet for the surface layer is attached using a hot melt agent.
このタフテツドカーペツトは高価であり、高級
車の内装材として使用されるが、一般大衆車用に
は、プレーンタイプのニードルパンチカーペツト
を表層とし、これに高融点の繊維と樹脂繊維バイ
ンダーとの混合繊維よりなる裏打用不織布ウエブ
を重ね合せ、ついで表層側より、70本／cm2以上の
割合で、かつ、ニードルの先端が裏打用不織布ウ
エブの表面をつき抜ける深さ（通常15mm、針入
度）までニードリングを行なつて表層用プレーン
カーペツト裏打用ウエブとの繊維同志の絡み合せ
を十分に行ない、ついで加熱して繊維バインダー
を溶融して繊維の固定をして表層のプレーンカー
ペツトと裏打用ウエブを一体化して安価な成型可
能な複層カーペツトを製造する方法が提案され
た。 This tufted carpet is expensive and is used as an interior material for luxury cars, but for cars for the general public, the surface layer is plain needle-punch carpet, which is coated with high-melting point fibers and a resin fiber binder. The backing nonwoven fabric web made of mixed fibers of The fibers are sufficiently intertwined with the plain carpet for the surface layer and the web for the backing layer by performing needling to a depth of 100 mm).Then, the fibers are heated to melt the fiber binder and fix the fibers to form the plain carpet for the surface layer. A method has been proposed for manufacturing an inexpensive moldable multilayer carpet by integrating the PET and backing web.
このものは、表層用プレーンカーペツトＡ層の
剥離強度が0.25Kg／５cm幅と弱く実用的でないの
で、ニードリング後に、樹脂水性エマルジヨンを
裏打用ウエブ側より塗布し、圧搾して表層近くま
でエマルジヨンを含浸させた後に、加熱してバイ
ンダーとエマルジヨン樹脂を溶融させて表層と裏
打用ウエブを１体化させる方法が実施されてい
る。 This is not practical because the peel strength of the plain carpet A layer for the surface layer is weak at 0.25 kg/5 cm width, so after needling, a water-based resin emulsion is applied from the backing web side and squeezed to coat the emulsion close to the surface layer. A method has been implemented in which the surface layer and the backing web are integrated by heating and melting the binder and emulsion resin.
このもののプレーンカーペツトＡの繊維の剥離
強度は約５Kg／５cmと高く、実用上十分耐えうる
ものである。 The peel strength of the fibers of Plain Carpet A is as high as about 5 kg/5 cm, which is sufficient for practical use.
この実用化された複層カーペツトは、ニードリ
ングの密度が約70〜90本／cm2と多いとともに第２
図に示すニードル１の第３〜４バーブ２部分まで
カーペツトに侵入（12〜15mm）するのでプレーン
タイプの表層カーペツトの表面には太い針の跡が
多数残りかつカーペツト層の繊維が多数下層側へ
取られ、実質上表装カーペツトが薄くなり外観が
そこなわれる。しかしながら、この為に上下層の
結びつき（強度）が大きくなり実用性が出てい
る。
This practical multi-layer carpet has a high needling density of about 70 to 90 needles/cm 2 and a second
As the needle penetrates into the carpet up to the 2nd part of the 3rd to 4th barb (12 to 15 mm) shown in the figure, many thick needle marks remain on the surface of the plain type surface carpet, and many fibers of the carpet layer fall to the lower layer side. The carpet will be removed, and the carpet will become thinner and its appearance will be spoiled. However, this increases the bond (strength) between the upper and lower layers, making it more practical.
本発明は、この外観の向上を目的とし、かつ、
実用上十分な繊維の固定された複層カーペツトを
提供するものである。 The present invention aims to improve this appearance, and
The present invention provides a multilayer carpet with practically sufficient fibers fixed therein.
本発明は、表層用の不織布カーペツトＡの裏面
に、目付量が６〜200ｇ／m2であつて、融点が90
〜200℃の熱可塑性樹脂製繊維バインダーの透水
性不織布Ｂを、次いで融点が95〜200℃の熱可塑
性樹脂製繊維バインダーが15〜50重量％と、該繊
維バインダーの融点よりも40℃以上高い融点を有
する合成繊維もしくは天然繊維85〜50重量％とよ
りなる繊維マツトをニードリングした裏打用ウエ
ブＣの重ね合せたものを、表層用不織布カーペツ
トＡ側からニードリングして不織布カーペツト
Ａ、透水性不織布Ｂおよび裏打用ウエブＣの各層
の繊維同志の絡み合せを行なつた後、裏打用ウエ
ブＣ側からガラス転移点が80℃以上の熱可塑性樹
脂の水性エマルジヨンを塗布し、表層用カーペツ
トＡ層を貫通しない範囲でエマルジヨン樹脂を含
浸させたのち、エマルジヨン樹脂の固化状態又は
未固化状態で表層用の不織布カーペツトＡの繊維
が溶融せず、不織布Ｂの繊維バインダーおよびウ
エブＣの繊維バインダーならびにエマルジヨンの
熱可塑性樹脂が溶融する温度以上に加熱したの
ち、圧縮して各層を接着一体化並びに成型させる
ことを特徴とする成形可能な複層カーペツトの製
造方法を提供するものである。
In the present invention, the back surface of the nonwoven carpet A for the surface layer has a basis weight of 6 to 200 g/m 2 and a melting point of 90 g/m2.
Water-permeable nonwoven fabric B made of a thermoplastic resin fiber binder with a temperature of ~200°C, followed by 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 95 to 200°C, which is 40°C or more higher than the melting point of the fiber binder. A superimposed backing web C in which a fiber mat consisting of 85 to 50% by weight of synthetic fibers or natural fibers having a melting point is needled is needled from the nonwoven carpet A side for the surface layer to form a nonwoven carpet A, water permeable. After intertwining the fibers of each layer of the nonwoven fabric B and the backing web C, an aqueous emulsion of a thermoplastic resin with a glass transition point of 80°C or higher is applied from the backing web C side to form the surface carpet A layer. After the emulsion resin is impregnated to the extent that it does not penetrate, the fibers of the nonwoven carpet A for the surface layer do not melt in the solidified or unsolidified state of the emulsion resin, and the fiber binder of the nonwoven fabric B, the fiber binder of the web C, and the emulsion resin do not melt. The present invention provides a method for manufacturing a moldable multi-layer carpet, which is characterized in that the thermoplastic resin is heated to a temperature higher than the melting temperature and then compressed to bond and mold the respective layers.
表装カーペツトＡと裏打用ウエブＣの接着は、
従来からニードルパンチによる上下層間の繊維絡
合によるため十分な針密度と、針入度（ニードリ
ングの深さ）が必要でありニードルの構造から、
交率的なニードリングとしては70〜100本／cm2、
12〜15mm深さとなり、表装カーペツトの繊維を多
量に下層に導くこととなり、表装繊維のロスか
ら、繊維量の低減が難かしく、かつ表面にニード
リングの跡が針穴及び表面の凸凹状ではつきり残
つてしまう。この為、プレーンタイプのみが使用
され、起毛状のものは使用できなかつた。 Adhesion of facing carpet A and backing web C is as follows:
Conventionally, needle punching involves fiber entanglement between the upper and lower layers, which requires sufficient needle density and penetration (needling depth), and due to the needle structure,
70 to 100 needles/cm 2 for alternating needling,
The depth is 12 to 15 mm, and a large amount of the fibers of the facing carpet are guided to the lower layer, and it is difficult to reduce the amount of fibers due to the loss of facing fibers, and there are needle holes and uneven surfaces due to needling on the surface. It lingers forever. For this reason, only the plain type was used, and the raised type could not be used.
本発明では、かかる問題を解決するために、表
装カーペツトＡと裏打用ウエブＣの間に、熱可塑
性樹脂製繊維バインダーの不織布Ｂ層を置き、Ａ
とＣの接着にＣを用いる為、Ａ側からニードリン
グは、ＡとＣの熱による接着までの仮止めで十分
である為、Ａ層の繊維ロスを減らす様に出来るか
ぎり少い針密度で、かつ、ニードルの構造から第
１バーブがＣ層に達すれば良いことになる。 In the present invention, in order to solve this problem, a nonwoven fabric B layer made of a thermoplastic resin fiber binder is placed between the facing carpet A and the backing web C.
Since C is used to bond C and C, temporary needling from the A side is sufficient until A and C are bonded by heat, so the needle density should be as low as possible to reduce fiber loss in the A layer. , and from the structure of the needle, it is sufficient that the first barb reaches the C layer.
しかしながら、ニードルの跡は針入度大の場合
に大きく残る為、針密度より針入度の外観の与え
る影響度が大きい。この為、針密度は通常の範囲
より低く、100本／cm2以下好ましくは25〜50本／
cm2へ、針入度は第一バーブがＣ層へ達することで
Ｃ層を貫通しない範囲とし「６mm＋（Ａ層＋Ｂ層）
の厚み」を越えて「６mm＋（Ａ層＋Ｂ層＋Ｃ層）
の厚み」を越えない範囲で十分である。 However, since a large needle mark remains when the needle penetration is large, the appearance of the needle penetration has a greater influence than the needle density. For this reason, the needle density is lower than the normal range, less than 100 needles/ cm2 , preferably 25 to 50 needles/cm2.
cm 2 , the penetration is within the range where the first barb reaches the C layer and does not penetrate the C layer.
6mm + (A layer + B layer + C layer)
It is sufficient that the thickness does not exceed .
（表層用不織布カーペツト）
表層用不織布カーペツトＡとしては、Ｂおよび
Ｃ層の繊維バインダーよりも高い融点を有する洋
毛、ナイロン、ポリアクリロニトリル、ポリアセ
テート、ポリエチレンテレフタレート等の繊維を
素材として得た主としてプレンタイプのニードル
パンチカーペツトを用いるが、本発明では起毛状
のニードルパンチカーペツトも使用できる。(Nonwoven fabric carpet for surface layer) The nonwoven fabric carpet A for the surface layer is mainly made of plain fibers obtained from fibers such as western wool, nylon, polyacrylonitrile, polyacetate, and polyethylene terephthalate, which have a higher melting point than the fiber binders of layers B and C. Although a type of needle punch carpet is used, a raised needle punch carpet can also be used in the present invention.
このニードルパンチタイプカーペツトＡの目付
量は100〜500ｇ／m2である。一般には200ｇ／m2
の目付量のものが使われるが本発明ではニードリ
ングによる表装から下層への移行が少ない為、従
来より少い繊維層が達成出来る。 The basis weight of this needle punch type carpet A is 100 to 500 g/m 2 . Generally 200g/m 2
However, in the present invention, since there is less migration from the facing layer to the lower layer due to needling, fewer fiber layers can be achieved than in the past.
（繊維バインダーの不織布）
熱可塑性樹脂繊維バインダーの不織布Ｂは、ポ
リエチレン、ポリプロピレン、線状ポリエステ
ル、ポリアミド等の繊維、ポリエチレン／ポリプ
ロピレン積層体繊維等の融点が90〜200℃、好ま
しくは90〜170℃、２〜12デニールの樹脂繊維を
スパンポンド法により絡み合せて得られる６〜
200ｇ／m2、好ましくは20〜60ｇ／m2の目付の通
気性のあるもので、肉厚は５〜500ミクロンのも
のである。(Nonwoven fabric of fiber binder) Nonwoven fabric B of thermoplastic resin fiber binder is made of fibers such as polyethylene, polypropylene, linear polyester, polyamide, polyethylene/polypropylene laminate fibers, etc., and has a melting point of 90 to 200°C, preferably 90 to 170°C. , 6~ obtained by intertwining 2~12 denier resin fibers by the spunpond method.
It is breathable and has a basis weight of 200 g/m 2 , preferably 20 to 60 g/m 2 , and a wall thickness of 5 to 500 microns.
また、この繊維バインダーは、ポリプロピレ
ン、ポリエステル、ポリアミド等の樹脂のペレツ
トを押出機を用いて溶融し、細い孔を多数有する
ダイよりトコロテン状に押し出し、これを風に乗
せて個々の繊維が収束しないように引出し、ダイ
の下方にあるスクリーン上に沈積させ、これを巻
き取り機で引きとつて製造したものであつてもよ
い。 In addition, this fiber binder is made by melting pellets of resin such as polypropylene, polyester, polyamide, etc. using an extruder and extruding them in a continuous shape through a die with many thin holes, which is then carried by the wind so that the individual fibers do not converge. It may also be produced by drawing it out, depositing it on a screen below the die, and pulling it off with a winder.
かかる繊維バインダー製不織布Ｂは水が通過で
きる間隙を多数有するもので、ダイアボンド工業
(株)よりメルトロンＷの商品名でポリアミド系のも
のがPAY―200，PAS―200、ポリエステル系の
ものがES―500、エチレン・酢酸共重合体系のも
のがY7のグレード名で、三井石油化学工業(株)よ
りポリプロピレン系のものがシンテツクスPK―
103，PK―106，PK―404，PK―408等の商品名
で、また、ポリエチレン系のものがアドメルの商
品名で、および呉羽センイ(株)より同様な不織布が
DYNACの商品名でLNS―0000，LNS―2000，
ES―00，Ｂ―1000，Ｂ―2000，Ｂ―3000等のグ
レード名を付して販売されている。 Such fiber binder nonwoven fabric B has many gaps through which water can pass, and is manufactured by Diabond Industries.
Mitsui Petrochemical Co., Ltd.'s Meltron W product name is PAY-200, PAS-200 for polyamide-based products, ES-500 for polyester-based products, and Y7 for ethylene-acetic acid copolymer-based products. Syntex PK is a polypropylene-based product from Kogyo Co., Ltd.
103, PK-106, PK-404, PK-408, etc. Polyethylene-based products are available under Admel's product names, and similar non-woven fabrics are available from Kureha Sen'i Co., Ltd.
DYNAC product name LNS-0000, LNS-2000,
It is sold with grade names such as ES-00, B-1000, B-2000, and B-3000.
又、ポリプロピレン繊維をニードルパンチ等に
より不織布としたものでも良い。 Alternatively, polypropylene fibers may be made into a nonwoven fabric by needle punching or the like.
（裏打材）
裏打材ウエブＣは、融点が90〜200℃の熱可塑
性樹脂製繊維バインダーが15〜50重量％と、該熱
可塑性樹脂の融点よりも40℃以上高い融点を有す
る合成繊維もしくは天然繊維85〜50重量％とより
なる繊維マツトをニードリングして得たウエブで
あり、このものは公知の不織布の製造方法で製造
される。即ち、1.2〜300デニール、繊維長25〜
150mmの熱可塑性樹脂製繊維バインダー15〜50重
量％と、1.2〜300デニール、繊維長25〜150mmの
熱加塑性樹脂製繊維バインダー15〜50重量％と、
1.2〜300デニール、繊維長25〜150mmの合成繊維
および／または天然繊維85〜50重量％とが十分に
混合、開繊されたものをウエブ形成装置に供給
し、該混合繊維より形成されたカードを目的とす
る繊維目付量になる様に積み重ねて得たウエブ
（繊維マツト）を垂直方向にニードリングして繊
維同志をからみ合せることにより仮止めしたもの
である。(Backing material) The backing material web C contains 15 to 50% by weight of a thermoplastic resin fiber binder with a melting point of 90 to 200°C, and synthetic or natural fibers having a melting point 40°C or more higher than the melting point of the thermoplastic resin. This web is obtained by needling a fiber mat consisting of 85 to 50% by weight of fibers, and is manufactured by a known nonwoven fabric manufacturing method. i.e. 1.2~300 denier, fiber length 25~
15-50% by weight of a 150 mm thermoplastic resin fiber binder; 15-50% by weight of a 1.2-300 denier thermoplastic resin fiber binder with a fiber length of 25-150 mm;
1.2 to 300 denier, fiber length 25 to 150 mm synthetic fibers and/or 85 to 50% by weight of natural fibers are sufficiently mixed and opened and supplied to a web forming device, and a card is formed from the mixed fibers. The web (fiber mat) is obtained by stacking the web (fiber mat) so that it has the desired fiber weight, and is temporarily fixed by needling in the vertical direction to entangle the fibers.
繊維バインダーは、繊維マツト重量の15〜50重
量％、好ましくは20〜40重量％の割合で使用され
る。15重量％未満であるとプレス成形して得られ
るカーペツトの剛性、寸法安定性の向上の寄与が
小さい。逆に50重量％を越えるとレジンフエルト
のようになり、繊維の風合が損われた硬く脆いも
のとなる。 The fiber binder is used in a proportion of 15 to 50% by weight, preferably 20 to 40% by weight of the fiber mat weight. If it is less than 15% by weight, the contribution to improving the rigidity and dimensional stability of the carpet obtained by press molding will be small. On the other hand, if it exceeds 50% by weight, it becomes like resin felt, hard and brittle with impaired fiber texture.
また、実質的に繊維マツトを構成する他方の繊
維である合成繊維の原料としてはポリエチレンテ
レフタレート、ポリアミド等の前記熱可塑性樹脂
製繊維バインダーの融点よりも40℃以上、好まし
くは70℃以上高い融点を有する熱可塑性樹脂が用
いられる。また、天然繊維としては木綿、麻、羊
毛等が用いられる。 In addition, the raw material for the synthetic fiber, which is the other fiber that substantially constitutes the fiber mat, has a melting point that is 40°C or more, preferably 70°C or more higher than the melting point of the thermoplastic resin fiber binder such as polyethylene terephthalate or polyamide. A thermoplastic resin having a Further, as natural fibers, cotton, linen, wool, etc. are used.
裏打材ウエブＣの繊維目付量は300〜2000ｇ／
m2、好ましくは500〜1000ｇ／m2である。この裏
打材ウエブＣ層は熱可塑性樹脂繊維を含む為、熱
成型性を示すが、シヤープな形状が得にくく、か
つ剛性が不十分である。 The fiber weight of the backing material web C is 300 to 2000 g/
m 2 , preferably 500 to 1000 g/m 2 . Since this backing material web C layer contains thermoplastic resin fibers, it exhibits thermoformability, but it is difficult to obtain a sharp shape and has insufficient rigidity.
（熱可塑性樹脂水性エマルジヨン）
成形と剛性を付与するために重ね合せたカーペ
ツトに塗布、含浸するエマルジヨンの熱可塑性樹
脂はガラス転移点が80℃以上、好ましくは100〜
180℃で、粒径が0.01〜５ミクロンのものである。
具体的にはスチレン・アクリル酸の低級エステル
（エステルの炭素数は２〜６）共重合体、メタク
リレート・アクリル酸の低級エステル共重合体、
塩化ビニリデン共重合体（塩化ビニリデン含量が
85重量％以上）、スチレン・ジエン共重合体等の
熱可塑性樹脂が挙げられる。(Thermoplastic resin aqueous emulsion) The thermoplastic resin used in the emulsion applied to and impregnated into the stacked carpets to provide molding and rigidity has a glass transition point of 80°C or higher, preferably 100°C or higher.
At 180°C, the particle size is between 0.01 and 5 microns.
Specifically, lower ester copolymers of styrene and acrylic acid (ester has 2 to 6 carbon atoms), lower ester copolymers of methacrylate and acrylic acid,
Vinylidene chloride copolymer (vinylidene chloride content is
85% by weight or more) and thermoplastic resins such as styrene/diene copolymers.
最適には、
(a) ポリメタクリル酸ｎ・プロピル（Tg81℃）、
ポリスチレン（100℃）、ポリアクリロニトリル
（100℃）、ポリメタクリル酸メチル（105℃）、
ポリメタクリル酸（130℃）、ポリイタコン酸
（130℃）、ポリアクリルアミド（153℃）等のホ
モ重合体の水性エマルジヨンの他、
(b) これらの重合体の原料であるビニル単量体50
〜100重量％、好ましくは65〜95重量％と、他
のビニル単量体、例えばアクリル酸２―エチル
ヘキシル（Tg85℃）、アクリル酸ｎ・ブチル
（−54℃）、アクリル酸エチル（−22℃）、アク
リル酸イソプロピル（−５℃）、メタクリル酸
２―エチルヘキシル（−５℃）、アクリル酸
ｎ・プロピル（８℃）、メタクリル酸ｎ・ブチ
ル（20℃）、酢酸ビニル（30℃）、アクリル酸ｔ
―ブチル（45℃）、メタクリル酸２―ヒドロキ
シエチル（55℃）、メタクリル酸エチル（65
℃）、メタクリル酸イソブチル（67℃）、塩化ビ
ニル（79℃）等もしくは塩化ビニリデン（−18
℃）50重量％以下、好ましくは35〜５重量％と
の共重合体の水性エマルジヨン〔この(b)項にお
いて、（ ）内に示されるTgは、これらビニル
単量体若しくは塩化ビニリデンのホモ重合体の
ガラス転移点である〕、
(c) Tgが＋80〜155℃の樹脂水性エマルジヨン50
〜97重量％、好ましくは55〜95重量％と、Tg
が−85〜＋80℃未満の樹脂水性エマルジヨン50
〜３重量％、好ましくは45〜５重量％との混合
物等が上げられる。このエマルジヨン中に、得
られる不織布に重量感を付与するために炭素カ
ルシウム、酸化鉄、フエライト、硫酸バリウム
等の充填材を配合することも、また、成形性を
付与させるために低密度ポリエチレンやポリス
チレン、エチレン・酢酸ビニル共重合体等の低
融点樹脂のパウダーを配合することも可能であ
る。 Optimally, (a) polyn-propyl methacrylate (Tg 81°C),
Polystyrene (100℃), polyacrylonitrile (100℃), polymethyl methacrylate (105℃),
In addition to aqueous emulsions of homopolymers such as polymethacrylic acid (130°C), polyitaconic acid (130°C), and polyacrylamide (153°C), (b) vinyl monomer 50, which is the raw material for these polymers.
-100% by weight, preferably 65-95% by weight, and other vinyl monomers such as 2-ethylhexyl acrylate (Tg 85°C), n-butyl acrylate (-54°C), ethyl acrylate (-22°C). ), isopropyl acrylate (-5℃), 2-ethylhexyl methacrylate (-5℃), n-propyl acrylate (8℃), n-butyl methacrylate (20℃), vinyl acetate (30℃), acrylic acid t
-Butyl (45℃), 2-hydroxyethyl methacrylate (55℃), ethyl methacrylate (65
), isobutyl methacrylate (67℃), vinyl chloride (79℃), etc. or vinylidene chloride (-18℃), etc.
°C) Aqueous emulsion of a copolymer with 50% by weight or less, preferably 35 to 5% by weight (c) Resin aqueous emulsion with Tg of +80 to 155°C 50
~97% by weight, preferably 55-95% by weight, Tg
Resin water-based emulsion 50 with a temperature of -85 to less than +80℃
-3% by weight, preferably 45-5% by weight, and the like. Fillers such as calcium carbon, iron oxide, ferrite, barium sulfate, etc. may be blended into this emulsion to give the obtained nonwoven fabric a sense of weight, and fillers such as low-density polyethylene or polystyrene may be added to give moldability. It is also possible to blend a powder of a low melting point resin such as ethylene/vinyl acetate copolymer.
しかして、重ね合せたカーペツトの繊維マツト
へのエマルジヨンの塗布、含浸手段としてはリツ
カーロール、絞りロール、吹付ガン、浸漬等が挙
げられる。一般に、繊維マツトへのエマルジヨン
の含浸を完全とするため、塗布されたエマルジヨ
ンは絞りロールによつて圧搾される。エマルジヨ
ンの塗布は裏打用の繊維マツトウエブＣ側面より
行う。エマルジヨンが塗布、含浸された繊維マツ
トは水分を除去するため80〜250℃に加熱され、
繊維が結合された複層ニードルパンチカーペツト
が製造される。この加熱乾燥工程の際、エマルジ
ヨン中の樹脂粒子は一部が粒子状態で繊維マツト
内に存在し、一部は皮膜を形成して、繊維同士の
絡合を強固にすると共に、カーペツトの繊維マツ
トには成形性と剛性が付与される。 The means for applying and impregnating the emulsion onto the fiber mat of the stacked carpet include a licker roll, a squeezing roll, a spray gun, dipping and the like. Generally, the applied emulsion is squeezed by squeezing rolls to completely impregnate the fiber mat with the emulsion. The emulsion is applied from the side of the fiber matte web C for backing. The fiber mats coated and impregnated with emulsion are heated to 80-250℃ to remove moisture.
A multilayer needle punch carpet with bonded fibers is produced. During this heating and drying process, some of the resin particles in the emulsion remain in the fiber mat in a particulate state, and some form a film that strengthens the intertwining of the fibers and also strengthens the fiber mat of the carpet. is given moldability and rigidity.
熱可塑性樹脂水性エマルジヨンは、カーペツト
のＡ層、Ｂ層およびＣ層の繊維重量の和100重量
部に対し、エマルジヨン中の樹脂固型分量で10〜
100重量部の割合で用いられる。 The aqueous thermoplastic resin emulsion contains 10 to 10 parts by weight of the resin solids in the emulsion, based on 100 parts by weight of the fibers in layer A, layer B, and layer C of the carpet.
It is used in a proportion of 100 parts by weight.
（裏打方法）
カーペツトＡへのウエブＣの裏打は、樹脂繊維
バインダー製不織布Ｂを接着剤として両者の間に
重ね合せ、次いでこの重ね合せたものをニードル
１を用いて、表層用カーペツトＡ側から20〜50
本／cm2、好ましくは25〜50本／cm2の割合でかつ、
ニードル１の深さは、Ａ，Ｂ，Ｃの各層の合計厚
み＋６mm以内、例えば７〜９mmの深さにニードリ
ング（第１図参照）して各層の繊維同志の絡み合
いを軽く行なわせ、ついで裏打用ウエブＣ側より
樹脂水性エマルジヨンを含浸し、90〜220℃、好
ましくは100〜160℃に加熱して水を乾燥させると
ともに、不織布Ｂの繊維バインダー樹脂およびウ
エブＣの繊維バインダー樹脂ならびにエマルジヨ
ン樹脂を溶融させ、これをプレス成形機または加
圧冷却ロールを用いて圧縮し、Ａ，ＢおよびＣの
各層を接着することにより一体化して裏打を完全
させるとともに成形も行う。(Backing method) To back the carpet A with the web C, use the nonwoven fabric B made of resin fiber binder as an adhesive and overlap them between the two, and then use the needle 1 to apply the web C to the carpet A for the surface layer. 20-50
at a rate of 25 to 50 strands/cm 2 , preferably from 25 to 50 strands/cm 2 , and
The depth of the needle 1 is within the total thickness of each layer A, B, and C + 6 mm, for example, 7 to 9 mm (see Figure 1) to lightly entangle the fibers in each layer, and then The backing web C side is impregnated with a resin aqueous emulsion and heated to 90 to 220°C, preferably 100 to 160°C to dry the water, and the fiber binder resin of nonwoven fabric B, the fiber binder resin of web C, and the emulsion resin are is melted and compressed using a press molding machine or a pressure cooling roll, and the layers A, B, and C are bonded and integrated to complete the lining and are also molded.
この一体化の場合、薄いカーペツトＡを作る時
Ｂを基本として使用し、まえもつてＡとＢの複合
体をＣと重ね、ニードリングして接合することも
良い。 In the case of this integration, it is also good to use B as a base when making a thin carpet A, and to first overlap the composite of A and B with C and join them by needling.
又、ウエブＣ層の片面に熱可塑性繊維量を増す
かＢを基本としてあらかじめＢとＣの積層体を得
たのち、これにＡを重さねて、ニードリング接合
するのも良い。 Alternatively, it is also possible to increase the amount of thermoplastic fibers on one side of the web layer C or to obtain a laminate of B and C in advance using B as a base, and then overlay A on this and perform needling bonding.
（効果）
本発明の複層カーペツトは成形可能であり、繊
維の固定も強力（剥離強度約7.5Kg／５cm幅）で
あり、プレーン並びに起毛状ニードルパンチカー
ペツトが使用でき、外観に優れ、通気性、剛性に
も優れる。(Effects) The multilayer carpet of the present invention can be molded, has strong fiber fixation (peel strength approximately 7.5 kg/5 cm width), can be used with plain or brushed needle punch carpet, has an excellent appearance, and has excellent ventilation. It also has excellent strength and rigidity.
実施例 １
15デニール、繊維長85〜120mmのポリエチレン
テレフタレート（融点264℃）繊維カードをラン
ダムに積み重ねた繊維マツト150ｇ／m2を素材と
するプレーンタイプのニードルパンチカーペツト
Ａの裏面に、三井石油化学工業(株)製ポリプロピレ
ン繊維バインダー製不織布Ｂ“シンテツクスPK―
100（商品名、目付30ｇ／m2、繊維径３デニール）
を、更にこの不織布Ｂの下に後述のようにして製
造したニードルカーペツトよりなるウエブＣを重
ね合せ、見かけの厚さが約12mmの三層積層体を得
た。Example 1 Mitsui Oil Co., Ltd. was applied to the back side of a plain type needle punch carpet A made of fiber mat 150 g/m 2 randomly stacked with polyethylene terephthalate (melting point 264°C) fiber cards of 15 denier and fiber length 85 to 120 mm. Polypropylene fiber binder nonwoven fabric B “Syntex PK” manufactured by Kagaku Kogyo Co., Ltd.
100 (Product name, basis weight 30g/m 2 , fiber diameter 3 denier)
A web C made of a needle carpet produced as described below was further superimposed on the nonwoven fabric B to obtain a three-layer laminate having an apparent thickness of about 12 mm.
ついで、この積層体の表層カーペツトＡ側よ
り、１cm2当り25本、積層体への針入深さ８mmの割
合でニードリングし、各層の繊維同志の絡み合せ
を行つた。 Then, needling was carried out from the surface carpet A side of this laminate at a rate of 25 fibers per cm 2 and a penetration depth of 8 mm into the laminate to entangle the fibers in each layer.
その後、この積層体の裏打用ウエブＣ側より、
ガラス転移点が90℃のスチレン・アクリル酸ブチ
ル共重合体の水性エマルジヨンを130ｇ／m2（固
型分）の割合で塗布、圧搾してウエブＣの1/2の
深さまで含浸させ、ついで80℃で乾燥して水分を
除去した後、更にこの積層体を190℃に加熱して
不織布ＢとウエブＣのポリプロピレン繊維バイン
ダー並びにエマルジヨンの共重合体樹脂を溶融さ
せたのち、プレス成形機を用いて加圧成形し、金
型に忠実な各層が一体化した厚み約9.5mmの敷設
材を得た。 Then, from the backing web C side of this laminate,
An aqueous emulsion of styrene-butyl acrylate copolymer with a glass transition point of 90°C is applied at a rate of 130g/m 2 (solid content) and squeezed to impregnate the web C to a depth of 1/2. After drying at ℃ to remove moisture, this laminate was further heated to 190℃ to melt the polypropylene fiber binder of nonwoven fabric B and web C, and the copolymer resin of the emulsion, and then using a press molding machine. By pressure molding, we obtained a laying material with a thickness of approximately 9.5 mm in which each layer was integrated, faithful to the mold.
この敷設材の表層剤の針穴は目立たず、平滑で
外観は良好で、表層用繊維の剥離強度は7.5Kg／
５cm幅であつた。このものの上に500ｇ荷重をの
せて摩耗テストを行なつてもピーリングは生じな
かつた。 The needle holes in the surface layer agent of this laying material are not noticeable, it is smooth and has a good appearance, and the peel strength of the surface layer fiber is 7.5 kg/
It was 5cm wide. Even when a 500g load was placed on this product and an abrasion test was performed, no peeling occurred.
ニードルカーペツトＣの製造法
15デニール、繊維長約100mmの回収ポリプロピ
レン（融点164℃）繊維バインダー20％と15デニ
ール、繊維長75〜125mmの回収ポリエチレンテレ
フタレート（融点264℃）繊維80％の混合繊維屑
をランダムに積み重ねた繊維マツト（700ｇ／m2）
を、15―18―32―3RBの針を用いて１平方セン
チ当り100本の割合でニードリングし、肉厚約7.1
mm、見掛密度0.10ｇ／cm3のニードルカーペツトＣ
を得た。Manufacturing method for Needle Carpet C A mixed fiber of 20% recycled polypropylene (melting point 164°C) fiber binder of 15 denier and approximately 100 mm fiber length and 80% recycled polyethylene terephthalate (melting point 264°C) fiber of 15 denier and fiber length 75 to 125 mm. Fiber mat (700g/m 2 ) made by stacking waste randomly
was needled using 15-18-32-3RB needles at a rate of 100 needles per square centimeter, and the wall thickness was approximately 7.1 mm.
mm, needle carpet C with apparent density 0.10g/ cm3
I got it.
比較例 １
実施例１において、繊維バインダー製不織布Ｂ
を用いず、かつ、積層体〔ＡとＣ〕へのニードリ
ングを70本／cm2、針入深さ14mmとする他は同様に
して得た敷設材の物性は次のようであつた。Comparative Example 1 In Example 1, fiber binder nonwoven fabric B
The physical properties of the laying material obtained in the same manner were as follows, except that the laminates [A and C] were needled at a rate of 70 needles/cm 2 and at a depth of 14 mm.
外観―プレーンカーペツトＡの表層には針跡が
はつきりと目立つ。 Appearance - Needle marks are clearly visible on the surface of plain carpet A.
Ａ層の剥離強度―0.25Kg／５cm幅
〔水性エマルジヨンを含浸してない場合〕
〃 ―5.5Kg／５cm幅
〔水性エマルジヨンを含浸した場合〕
耐まもう性―500ｇ荷重をのせてのまもうテス
トで容易にピーリング生じる。 Peel strength of layer A - 0.25Kg/5cm width [When not impregnated with water-based emulsion] -5.5Kg/5cm width [When impregnated with water-based emulsion] Resistance - resistance test with a 500g load Peeling occurs easily.
第１図は本発明のニードリングの状態を示す断
面図であり、第２図はニードルの平面図である。
FIG. 1 is a sectional view showing the needling state of the present invention, and FIG. 2 is a plan view of the needle.
Claims (1)
量が６〜200ｇ／m2であつて、融点が90〜200℃の
熱可塑性樹脂製繊維バインダーの透水性不織布Ｂ
を、次いで融点が95〜200℃の熱可塑性樹脂製繊
維バインダーが15〜50重量％と、該繊維バインダ
ーの融点よりも40℃以上高い融点を有する合成繊
維もしくは天然繊維85〜50重量％とよりなる繊維
マツトをニードリングした裏打用ウエブＣの重ね
合せたものを、表層用不織布カーペツトＡ側か
ら、ニードリングして不織布カーペツトＡ、透水
性不織布Ｂおよび裏打用ウエブＣの各層の繊維同
志の絡み合せを行なつた後、裏打用ウエブＣ側か
らガラス転移点が80℃以上の熱可塑性樹脂の水性
エマルジヨンを塗布し、表層用カーペツトＡ層を
貫通しない範囲でエマルジヨン樹脂を含浸させた
のち、エマルジヨン樹脂の固化状態又は未固化状
態で表層用の不織布カーペツトＡの繊維が溶融せ
ず、不織布Ｂの繊維バインダーおよびウエブＣの
繊維バインダーならびにエマルジヨンの熱可塑性
樹脂が溶融する温度以上に加熱したのち、圧縮し
て各層を接着一体化並びに成型させることを特徴
とする成形可能な複層カーペツトの製造方法。 ２ ニードリングの針密度が20〜100本／cm2であ
ることを特徴とする特許請求の範囲第１項記載の
製造方法。 ３ ニードルの重ね合せたカーペツトへの針先の
侵入深さが、Ａ層とＢ層の厚みの和に６mmプラス
した肉厚を越えてＡ層とＢ層とＣ層の厚みの和に
６mmプラスした肉厚以下であることを特徴とする
特許請求の範囲第１項記載の製造方法。 ４ 熱可塑性樹脂水性エマルジヨンは、カーペツ
トのＡ層、Ｂ層およびＣ層の繊維重量の和100重
量部に対し、エマルジヨン中の樹脂固型分量で10
〜100重量部の割合で用いられることを特徴とす
る特許請求の範囲第１項記載の製造方法。 ５ 表層用の不織布カーペツトＡの繊維目付量が
100〜500ｇ／m2であり、裏打用ウエブＣの繊維目
付量が300〜2000ｇ／m2であることを特徴とする
特許請求の範囲第１項記載の製造方法。[Claims] 1. On the back side of the nonwoven carpet A for the surface layer, a water permeable nonwoven fabric B having a basis weight of 6 to 200 g/m 2 and a thermoplastic resin fiber binder having a melting point of 90 to 200°C.
, followed by 15-50% by weight of a thermoplastic resin fiber binder with a melting point of 95-200°C, and 85-50% by weight of synthetic or natural fibers having a melting point 40°C or more higher than the melting point of the fiber binder. The backing web C, which is made by needling fiber mats, is needled from the surface nonwoven carpet A side to entangle the fibers in each layer of the nonwoven carpet A, the water-permeable nonwoven fabric B, and the backing web C. After laminating, an aqueous emulsion of a thermoplastic resin with a glass transition point of 80°C or higher is applied from the backing web C side, and the emulsion resin is impregnated to the extent that it does not penetrate the surface carpet A layer. When the resin is in a solidified or unsolidified state, the fibers of nonwoven carpet A for the surface layer do not melt, and the fiber binder of nonwoven fabric B, the fiber binder of web C, and the thermoplastic resin of the emulsion are heated to a temperature higher than that at which they are melted, and then compressed. A method for producing a moldable multi-layer carpet, which comprises bonding and molding each layer. 2. The manufacturing method according to claim 1, wherein the needle density during needling is 20 to 100 needles/cm 2 . 3 The depth of penetration of the needle tip into the overlapped carpet exceeds the thickness of layer A, layer B, and layer C plus 6 mm plus the thickness of layer A, layer B, and layer C. 2. The manufacturing method according to claim 1, wherein the thickness is less than or equal to . 4. The aqueous thermoplastic resin emulsion has a resin solid content of 10 parts by weight per 100 parts by weight of the fibers in layer A, layer B, and layer C of the carpet.
2. The manufacturing method according to claim 1, wherein the amount is 100 parts by weight. 5 The fiber weight of nonwoven carpet A for the surface layer is
100 to 500 g/m 2 , and the fiber basis weight of the backing web C is 300 to 2000 g/m 2 .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61144590A JPS6392765A (en) | 1986-06-20 | 1986-06-20 | Production of moldable double-layer carpet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP61144590A JPS6392765A (en) | 1986-06-20 | 1986-06-20 | Production of moldable double-layer carpet |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS6392765A JPS6392765A (en) | 1988-04-23 |
| JPH0120260B2 true JPH0120260B2 (en) | 1989-04-14 |
Family
ID=15365618
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP61144590A Granted JPS6392765A (en) | 1986-06-20 | 1986-06-20 | Production of moldable double-layer carpet |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS6392765A (en) |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH0730709Y2 (en) * | 1989-11-11 | 1995-07-12 | 東洋紡績株式会社 | Vehicle seat |
| ATE216314T1 (en) * | 1997-01-13 | 2002-05-15 | Quadrant Plastic Composites Ag | THERMOPLASTIC DEFORMABLE COMPOSITE BODY |
| US6786988B1 (en) | 2001-02-14 | 2004-09-07 | Mohawk Brands Inc. | Use of waste carpet as filler |
| US7045590B2 (en) | 2001-02-14 | 2006-05-16 | Mohawk Brands, Inc. | Use of waste carpet as filler |
| AU2003292604A1 (en) * | 2002-12-26 | 2004-07-22 | Eidaikako Co., Ltd. | Loose mat with excellent sound-absorbing/waterproof characteristics and method of producing the same |
| US6814826B1 (en) | 2003-03-03 | 2004-11-09 | Mohawk Brands, Inc. | Use of waste carpet as backing filler for floor coverings |
-
1986
- 1986-06-20 JP JP61144590A patent/JPS6392765A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS6392765A (en) | 1988-04-23 |
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