AU2001258388B2 - Method for producing textile products, in particular tufted products, provided with geometrical designs or not and resulting products - Google Patents

Abstract

To produce a material with a patterning of a geometric or non-geometric design, it incorporates at least two yarns in a uniform and repeated structure. A given pattern is laid of dye pastes in different colors with a particular affinity for each specific type of yarn. The fabric is produced on a tufting machine, using two bars or more with a relative longitudinal displacement between them. The tufted loops are of the same or different height levels, using the different yarn feeds. The tufted material is stabilized by a conventional coating, and is cut into tiles. The tiles are gathered by an index system at an assembly where dye pastes are applied in an accurate repeat color pattern, using an injection action to deliver the dyes of different colors into accurate locations on to the material surface and into its body mass.

Description

WO 01/81673 PCT/EP01/04890 METHOD FOR PRODUCING TEXTILE PRODUCTS, IN PARTICULAR TUFTED PRODUCTS, PROVIDED WITH GEOMETRICAL OR NON- GEOMETRICAL DESIGNS, AND RESULTING PRODUCTS Subject of the invention [0001] The present invention relates to a production method that allows to produce textile products, more particularly products of the tufted type, provided with designs, which may be geometrical or not.

[0002] The invention likewise relates to products obtained by such a method, preferably in the form of tiles provided with designs that can be perfectly joined together.

Technological background to the invention [0003] The production of textile-based floor covering products in the form of mats, carpets or tiles by techniques for printing patterns is well known, printing being defined as a local coloration (dying), generally achieved by means of impression rollers or frames supplied with coloured pastes that are locally deposited on a previously coloured or unbleached ground.

[0004] Other techniques are based on the use of yarns of different colours that form a continuous structure, starting from the different yarns according to a selected pattern.

[0005] Among these latter techniques, that of tufting allows to achieve coloured patterns by varying the arrangement of the yarns, generally of two to three different colours on the needle bar of the tufting machine.

WO 01/81673 PCT/EP01/04890 2 [0006] Owing to the very configuration of the needle bars, the patterns are strictly geometrical and extremely repetitive, but also very limited.

[0007] When the successive bars of a tufting machine allow a relative translational movement of the rows of needle bars with respect to the frame of the machine, offsetting effects of the patterns in each row of loops are possible, though without changing the repetitive geometrical character of the patterns.

[0008] More complex tufting machines, which are provided with feed control for each yarn, allowing the creation of different loop heights, have therefore been developed. The yarns used are likewise of two to three different colours and their arrangement on the needle bar, combined with the difference in the height of the loops, allows the creation of designs.

[0009] These designs are less systematically repetitive because certain loops, which are a different colour from their neighbours, may sometimes appear as a design if they are the same height as their neighbours, or may disappear if they have a smaller loop height, being concealed by their neighbours in this case.

(0010] The designs are formed on a textile cloth that is not stable, and it is therefore not possible to work on geometrical designs that can then be cut up into tiles since it is not possible to guarantee that such designs will be capable of being joined up. Because of this, all existing designs are of the "all-over" type for laying in the same direction or are geometrical but have to be laid in a chequered pattern, which limits the possibilities of decoration.

[0011] Moreover, this entails wear and, above all, preferential soiling of the tall loops.

[0012] Furthermore, the use of dyed yarn limits the adaptability of this method and, in the case where -3- O there is a change of colour or design, a minimum production quantity is required (1000 to 2000 m 2 depending on the products), since each change requires a change in the supply and hence replacement of a large number of yarn bobbins.

[0013] In addition, the density of material is not constant over the entire height, the shortest loops locally reducing this density.

00 00 M [0014] Finally, the type of patterns that can be achieved in this way is relatively 00 0 small in number and limits the creativity of the producers essentially to chind effects and the like.

N [0015] The use of yams with a differential affinity (substantivity) effect for the dyes has likewise already been proposed to create coloured effects, in particular for full-width dyeing of the padding type, possibly combined with resist effects. In this case too, the type of coloured patterns is very limited.

The preceding discussion of the background art is intended to facilitate an understanding of the present invention only. It should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was part of the common general knowledge in Australia as at the priority date of the application.

Aims of the invention [0016] The invention aims to avoid the disadvantages of the prior art. In particular, it aims to obtain structured textile products with designs in a manner that is of economic interest, in particular in the form of tiles that offer great freedom in terms of patterns but can nevertheless still be joined up.

Characteristic elements of the invention [0017] According to the present invention, what is proposed is a method for producing textile products provided with decoration in the form of geometrical or non-geometrical designs, preferably produced by tufting machines using at least two yarns with different affinity for the dyes in order to form uniform and regular structures, and different pastes of different WO 01/81673 PCT/EP01/04890 4colours and with specific affinity for each type of yarn are then deposited according to a pre-established pattern.

[0018] The type of tufting machine used according to the invention can be relatively simple and can be limited to producing a uniform geometrical pattern, without creating different loop heights, by displacing the needle bars in association with a yarn set-up (either unbleached with different affinities or as yarn that has been mass-dyed but always comprising polymers of different affinities).

[0019] However, it is likewise possible, according to the invention, to use tufting machines described above which influence the differences in the supply of yarn to the two bars so as to create a structured effect based on different loop heights, although still in a uniform and localised manner.

[0020] The yarns obtained starting from polymers that have different dyeing affinities are well known.

[0021] Acidic polyamide yarns and basic polyamide yarns with affinity for basic and acid dyes respectively may be mentioned, for example.

[0022] The different types of yarn used can be unbleached or can be mass-dyed.

[0023) The use of twisted yarn of different types is possible according to the invention.

[0024] The textile products obtained in this way can advantageously undergo conventional stabilisation coating and can be cut into tiles, which are then individually taken up in an indexed manner on the installation that allows said deposition of the different dye pastes according to designs that can be perfectly joined up for the different tiles.

[0025] The technique used is particularly suitable for dyeing performed by depositing dye pastes by means of a WO 01/81673 PCT/EP01/04890 machine for paste deposition fitted with a plurality of heads for injecting individual dye pastes onto the surface and into the body of the textile product.

[0026] Using an installation of this type to carry out the dyeing of tiles, it is perfectly possible to create designs that are geometrical or non-geometrical but can be perfectly joined up, since the operation is carried out on a finished product that is totally stable and the geometrical distribution of the different yarns of which is completely known.

[0027] In this way, there is no so-called "unidirectional" restriction on laying these designs.

[0028] Since this type of machine is generally capable of depositing six different colourings, it is possible to produce up to twelve colours on the finished product if each paste contains two types of dye.

[0029] Starting from a stock of unbleached tiles produced with tufting of different structures providing the bases for different effects, it is thus possible to produce any type of design and coloration in a very flexible manner with this type of machine, which can print very small minimum quantities of the order of a few square metres.

[0030] By means of this technique, it is possible to create effects that are in no case comparable with printing since each loop takes on the coloration corresponding to the affinity of its yarn. Original effects specific to this technique are thus obtained.

[0031] It may thus be considered that a "latent" design is first of all formed in the base material and this is then "revealed" by the pastes.

[0032] The invention will be described in greater detail with reference to the attached drawings, which relate to a preferred embodiment of the invention.

WO 01/81673 PCT/EPOI/04890 -6 Brief description of the drawings (0033] Figure 1 shows a schematic sectional view of a tufted product provided with designs in accordance with the prior art (gauge [0034] Figure 2 shows a similar schematic sectional view of a tufted product provided with designs according to the invention (gauge 1/10); [0035] Figure 3 shows a view of a tufted tile according to the invention before coloration; [0036] Figure 4 is a partial view of the tile after coloration and; [0037] Figure 5 illustrates the connection between the design of the tiles in Figure 4.

Description of a preferred embodiment of the invention [0038] According to the prior art, illustrated in Figure 1, a design can be obtained by means of an improved tufting installation. This machine allows to achieve differential tufting starting from yarns 1 of a first colour (black in the drawing) and yarns 2 of a second colour (white in the drawing).

[0039] In relation to the height of the loop obtained by means of yarn 1, the loops obtained by means of yarn 2 are respectively tall loops (2A) used for the design and short loops which are not visible.

[0040] In the case of the embodiment according to the invention in Figure 2, it is not necessary to resort to tufting machines capable of varying the height of the loops in the course of tufting (though this is not excluded).

[0041] According to the invention, the conventional tufting machine is supplied with basic yarns 1 (coloured grey) having an affinity for acid dyes and with acid yarns 2 (coloured black) having an affinity for basic dyes.

WO 01/81673 PCT/EP01/04890 7- [0042] After tufting, the product, which is preferably a tile, may have the pattern represented in Figure 3, for example.

[0043] Since each type of yarn has a different affinity for the dyes, it will react in a specific way when one or more dye pastes is/are deposited by a printing technique appropriate to the decorative effects that are desired to be obtained.

[0044] Provided that this printing is carried out in the manner referred to as indexed, i.e. while respecting the particular geometry of a tile, as done in Figure 4, for example, it is possible to continuously place tiles in such a way that they perfectly join up without limiting the direction of laying, as illustrated in Figure [0045] Although a specific embodiment of the invention has been described, it should of course be understood that this is only an illustrative example of the possibilities of the technique proposed.

[0046] The use of tufting machines that create loops of differential height, precisely consistent or not, and even random with respect to the coloured pattern that is desired to be created, is possible, as is the use of more than two yarns of different colours. Shades of the same colour are likewise possible, as are any other additional decorative, coloured, textured, structured or embossed effects etc.

Claims (6)

1. Method for producing textile products provided with decoration in the form of geometrical or non-geometrical designs comprising the steps of: 00 c00 producing uniform and regular structures starting from at least two yams; conventional stabilisation coating; C cutting the textile into tiles; individually taking up of said tiles in an indexed manner on an installation that allows deposition of different dye pastes according to designs that can be joined up perfectly; and deposition of different pastes of different colours and with specific affinity for each type of yarn.

2. Method according to Claim 1, characterised in that the textile structures are produced by means of tufting machines.

3. Method according to Claim 1 or 2, characterised in that the textile structures are produced by means of tufting machines with two or more bars, allowing longitudinal displacement relative to each other.

4. Method according to Claim 3, characterised in that the textile structures are produced by means of tufting machines without creating different loop heights.

5. Method according to Claim 3, characterised in that the textile structures are produced by means of tufting machines that allow the creation of different loop heights by means of equipment for supplying each yarn. -9- o

6. Method according to any of Claims 1 to 6, characterised in that the deposition of the dye pastes is performed by means of a machine for paste deposition fitted with a plurality of heads for injecting individual dye pastes onto the surface and into the body of the textile product. 00 00 rDated this Thirty-First day of March 2006. 00 cTarkett SAS Applicant 1 Wray Associates Perth, Western Australia Patent Attomrneys for the Applicant(s)