Primary base fabric for tufted carpet, and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-10876239-B2
Application number	US-201716090327-A
Country	US
Kind code	B2
Filing date	Apr 10, 2017
Priority date	Apr 11, 2016
Publication date	Dec 29, 2020
Grant date	Dec 29, 2020

Abstract

A primary base fabric for a tufted carpet includes a first non-woven web and a second non-woven web laminated on each other. The first non-woven web is constituted with a first constituent fiber formed with a first thermoplastic resin and containing carbon. The second non-woven web is constituted with a second constituent fiber formed with a second thermoplastic resin and having a carbon content lower than the carbon content of the first constituent fiber or containing no carbon. The primary base fabric is a product prepared by combining the first non-woven web and the second non-woven web through an emboss processing.

First claim

The invention claimed is:

1. A primary base fabric for a tufted carpet comprising a first non-woven web and a second non-woven web laminated on each other,
wherein the first non-woven web is constituted with a first constituent fiber formed with a first thermoplastic resin and containing carbon in addition to the first thermoplastic resin, thereby exhibiting a black color or a dark gray color due to the carbon;
the second non-woven web is constituted with a second constituent fiber formed with a second thermoplastic resin and containing carbon in addition to the second thermoplastic resin or containing no carbon in addition to the second thermoplastic resin;
the second non-woven web having a carbon content lower than the carbon content of the first constituent fiber or containing no carbon in addition to the second thermoplastic resin, thereby exhibiting a paler gray color due to the carbon or a white color; and
the primary base fabric is a product prepared by unifying the first non-woven web and the second non-woven web through an emboss processing.

2. The primary base fabric for a tufted carpet according to claim 1 ,
wherein in each of the first and second constituent fibers, a low-melting point resin having a lower melting point than the melting of the resin of a core is arranged around the resin of the core; and
in the primary base fabric, the constituent fibers are mutually bonded through the melting and the solidification of the low-melting point resin in emboss portions in emboss processing.

3. A method of manufacturing a primary base fabric for a tufted carpet,
wherein when the primary base fabric for a tufted carpet according to claim 2 is manufactured,
the first non-woven fabric and the second non-woven fabric are laminated on each other; and
the first non-woven web is arranged on the flat roll side and the second non-woven web is arranged on the emboss roll side, and then the laminated first non-woven fabric and the laminated second non-woven fabric are made to pass between the flat roll and the emboss roll to perform an emboss processing.

4. The primary base fabric for a tufted carpet according to claim 1 , wherein the peel strength between the first non-woven web and the second non-woven web is 2.0 N/50 mm width or more.

5. A method of manufacturing a primary base fabric for a tufted carpet,
wherein when the primary base fabric for a tufted carpet according to claim 4 is manufactured,
the first non-woven fabric and the second non-woven fabric are laminated on each other; and
the first non-woven web is arranged on the flat roll side and the second non-woven web is arranged on the emboss roll side, and then the laminated first non-woven fabric and the laminated second non-woven fabric are made to pass between the flat roll and the emboss roll to perform an emboss processing.

6. The primary base fabric for a tufted carpet according to claim 1 , wherein the surface of the first non-woven web has the processing traces due to a flat roll for an emboss processing, and the surface of the second non-woven web has the processing traces due to an emboss roll for the emboss processing.

7. A method of manufacturing a primary base fabric for a tufted carpet,
wherein when the primary base fabric for a tufted carpet according to claim 6 is manufactured,
the first non-woven fabric and the second non-woven fabric are laminated on each other; and
the first non-woven web is arranged on the flat roll side and the second non-woven web is arranged on the emboss roll side, and then the laminated first non-woven fabric and the laminated second non-woven fabric are made to pass between the flat roll and the emboss roll to perform an emboss processing.

8. A method of manufacturing a primary base fabric for a tufted carpet,
wherein when the primary base fabric for a tufted carpet according to claim 1 is manufactured,
the first non-woven fabric and the second non-woven fabric are laminated on each other; and
the first non-woven web is arranged on the flat roll side and the second non-woven web is arranged on the emboss roll side, and then the laminated first non-woven fabric and the laminated second non-woven fabric are made to pass between the flat roll and the emboss roll to perform an emboss processing.

Assignees

• Unitika Ltd

Inventors

• Chizuka Kenji

Classifications

• B60N3/04 Primary

  of floor mats {or carpets} · CPC title

• D04H1/5412

  sheath-core · CPC title

• A47G27/02

  Carpets; Stair runners; Bedside rugs; Foot mats (mat-like foot scrapers A47L23/22 {; doormats A47L23/26}) · CPC title

• D06N7/0068

  characterised by the primary backing or the fibrous top layer · CPC title

• B32B38/06

  Embossing · CPC title