JP2013017744A - Tufted carpet, carpet tile, and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a tufted carpet wherein various patterns, photographs, printed matter, or the like, are reproduced as patterns of the carpet by a method not causing blurring by walking without impairing the material feeling of the carpet, and to provide a carpet tile using the same, and a method for producing the tufted carpet.SOLUTION: The tufted carpet can be obtained by taking in, as image data, a pattern or the like to be reproduced as a pattern, converting the image data into tonal data, creating tuft data (pile height data) based on the tonal data, and performing tufting on a carpet base fabric at a pile height according to the data.

Description

  The present invention relates to a tufted carpet, a carpet tile and a manufacturing method thereof.

It is known to use surface patterns, photographs, printed matter, etc. of various things such as marble and wood for carpet patterns. As the method, a method of printing on a plain carpet by screen printing, an ink jet printer, thermal transfer or the like is employed (Patent Document 1).
According to this method, the original pattern or the like can be easily reproduced on the carpet. However, since it is printed, the texture of the carpet is impaired, and when walking on the carpet, the printing gradually fades, and the walking durability is low. There is a drawback.

JP 2006-322077 A

  The present invention is a tough design that reproduces various patterns, photographs, printed materials, etc. (hereinafter collectively referred to as “patterns”) as carpet patterns in a method that does not impair the texture of the carpet and does not cause blurring due to walking. An object of the present invention is to provide a ted carpet, a carpet tile using the ted carpet, and a manufacturing method thereof.

The above problems are solved by the following inventions 1) to 4).
1) A pattern or the like to be reproduced as a pattern is captured as image data, the image data is converted into tone data, tuft data (pile height data) is created based on the tone data, and based on the tuft data A tufted carpet obtained by tufting a carpet base fabric with a pile height corresponding to the tuft data.
2) A carpet tile produced using the tufted carpet described in 1).
3) A step of capturing a pattern or the like to be reproduced as a pattern as image data by an image capturing device, a step of converting the image data by a data conversion device into multi-step color tone data, and tuft data based on the color tone data (Pile height data), and using a tuft machine capable of adjusting the pile height based on the tuft data, tufting the carpet base fabric with a pile height corresponding to the tuft data. Tufted carpet manufacturing method.
4) The method for producing a tufted carpet according to 3), wherein in the step of converting the image data into multi-stage color tone data, the image data is once converted to gray scale and then converted into multi-stage color tone data.

  According to the present invention, a tufted carpet that reproduces various patterns, photographs, printed materials, etc. (patterns, etc.) as a carpet pattern in a method that does not impair the texture of the carpet and does not cause blurring due to walking. A carpet tile and a manufacturing method thereof can be provided. It is very useful because it can easily reproduce even complex patterns in nature.

The figure which shows the outline | summary of the production process of the tufted carpet of this invention, and a carpet tile using the same. Explanatory drawing of the reason a color change expresses by the height difference of a pile yarn. (A) When H1> H2, (b) When H1≈H2, (c) When H1 <H2. (A) The figure which shows the surface pattern of the original plate of the plastic tile used in Example 1. FIG. (B) The figure which shows the carpet tile produced in Example 1. FIG.

Hereinafter, the present invention will be described in detail.
The present invention intends to reproduce and use various patterns, photographs, printed materials (patterns, etc.) as carpet patterns. As will be understood from the description below, the pattern finally shown on the tufted carpet or carpet tile is obtained by data processing of the original pattern, etc. It means that the pattern is highly similar to the original pattern. In addition, when gray scale conversion described later is performed using a color pattern or the like, the brightness is reproduced, but the color as it is is not reproduced.

The outline of the manufacturing process of the tufted carpet of the present invention and the carpet tile using the same will be described with reference to FIG.
First, a pattern or the like to be reproduced as a pattern is captured as image data by an image capturing device such as a scanner or a digital camera. A pattern etc. are not specifically limited, What kind of surface pattern, a photograph, printed matter of various things, such as a marble and a timber, may be sufficient.
Next, the image data is converted into color tone data by a data conversion device such as a personal computer. At this time, it is preferable that the image data is once converted to grayscale and then converted to tone data. This is because, in the case of gray scale, only lightness processing may be performed. However, in the case of color image data, the amount of data increases due to the addition of data related to color, and processing may not be possible. Therefore, color image data may be processed as it is as long as the data amount can be processed. In this case, a color image can be reproduced by treating the color data as the color arrangement data of the yarn.

Conversion to color tone data is performed by using a personal computer or the like, correcting the color tone with brightness and contrast so that the pattern can be seen more clearly, and aligning with the color tone. That is, the number of colors at this time is set to 6 to 600 colors in consideration of later conversion to the pile height, and 6 to 600 tone data is obtained. By this operation, the color tone can be replaced from a continuous change amount to a step change amount. If it is less than 6 colors, the reproducibility of the original image will be poor. Further, even if the number of colors exceeds 600, the reproducibility of the original image is not improved, and 600 colors is the limit at present due to the performance of the tuft machine.
If the number of colors is large, it is possible to make the pattern expression fine, but 16 to 160 colors are preferable in the current tuft machine. In addition, by adjusting the contrast and making the outline unclear, it is possible to obtain a more realistic pattern expression when using a tufted carpet.
When a part of the initial pattern or the like is to be used, only a necessary part is cut out and used.
The colors in the above description include achromatic colors such as white, black, and gray.

Next, based on the color tone data, tuft data (pile height data) is created by a personal computer or the like.
It is desirable that the pile height is in a range of 600 steps with a pitch of 0.01 mm between 2.00 and 7.9 mm. The pile height during tufting is set to 2.00 mm or more in order to obtain reproducibility of patterns and the like and durability of walking. If it is less than 2.00 mm, walking durability will be low and the reproducibility of patterns and the like will be poor. On the other hand, if it is higher than 7.9 mm, pile sag due to walking may occur, which is not preferable. In addition, you may make it 60 steps which made 0.1 mm increments between 2.0-7.9 mm, and may change the width | variety of a step suitably.

Next, using a tuft machine that can adjust the pile height based on the tuft data, 2 to 10 colors of yarns are allocated to the odd and even needles of the tuft machine, and the tuft is applied to the base fabric based on the tuft data. To produce a tufted carpet that reproduces the original pattern and the like by continuous color change.
For example, if the original pattern is entirely gray, two threads, white and black, may be used. In addition, by appropriately adding a brown or red thread to the gray color, these colors can be expressed in the added portion.
Further, a carpet tile can be obtained by providing a tufted carpet with a backing layer made of a vinyl chloride resin or the like by a conventional method and then cutting it to an appropriate size.
Moreover, when making a carpet tile, it is preferable to make it a random pattern so that it may become a different pattern when it is cut.

The present invention reproduces the original pattern or the like as a pattern by adjusting a plurality of yarns having different colors and the pile height thereof, but as described below, the color changes due to the height difference of the pile yarns. To express.
That is, when the pile height is different when the pile yarn is tufted on the base fabric, for example, the state shown in FIG. 2 is obtained. FIG. 2 shows an example of how patterns appear when the heights of odd-numbered and even-numbered piles are changed. Since the area occupied by the pile yarn is larger in the portion where the pile height is higher than in the portion where the pile height is low, the color is conspicuous, and the original pattern or the like is reproduced by the contrast.
As shown in FIG. 2, when the pile color of the odd-numbered needle is black, the pile color of the even-numbered needle is light gray, the pile height of the odd-numbered needle is H1, and the height of the pile of the even-numbered needle is H2, If> H2, a black pattern such as (a) will be conspicuous, if H1≈H2, a pattern such as (b) will appear, and if H1 <H2, a gray pattern such as (c) will stand out. . By specifying H1 and H2 for each stitch (one stitch), the original image can be faithfully reproduced on the carpet.
The basic principle is the same even when the number of yarn colors is increased.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples.

Example 1
The surface pattern of the original plastic tile plate (plate before punching into the tile: 2 m long × 4 m wide) was captured with a digital scanner to create digital data of the image shown in FIG.
Next, the Adobe software Photoshop and NedGraphics software Textcell are used, the digital data is converted to gray scale by a personal computer, and the color tone is corrected so that the pattern can be seen more clearly with brightness and contrast. Aligned.
Next, using TuftWin made by Nakagawa Seisakusho, based on the above color tone data, tuft data (pile height data) with a pile height of 2.5 to 4.1 mm in increments of 0.1 mm is obtained. Created.
Next, using a tuft machine (manufactured by Nakagawa Seisakusho Co., Ltd.) capable of adjusting the pile height based on the tuft data, the pile yarn is arranged in one odd needle and one even needle (two colors in total) according to the above tuft data. A tufted carpet was prepared by tufting on a polyester base fabric.
Next, after laminating a vinyl chloride backing layer made of the following materials and a glass nonwoven fabric layer with a basis weight of 30 g / m ^{2 on} the tufted carpet, the surface pattern of the original plate was reproduced by cutting. FIG. A carpet tile as shown in FIG.
Comparing FIGS. 3A and 3B, it can be seen that the surface pattern of the original plate of plastic tile is reproduced.

<Material recipe for PVC backing layer>
・ PVC paste resin (manufactured by Kaneka Corporation: PSM-176) 100 parts by weight ・ Plasticizer (manufactured by JPLUS: DOP) 75 parts by weight (Stabilizers, etc.) 10 parts by weight

Example 2
A tufted carpet was produced by tufting a polyester base fabric in the same manner as in Example 1 except that the pile yarn was arranged in two odd-numbered needles and one even-numbered needle (one total of three colors).
By using two similar colors for odd-numbered needles, it was possible to reproduce a deeper pattern than with one-colored odd-numbered needles.

Claims (4)

  A pattern or the like to be reproduced as a pattern is captured as image data, the image data is converted into tone data, tuft data (pile height data) is created based on the tone data, and based on the tuft data, A tufted carpet obtained by tufting a carpet base fabric with a pile height corresponding to the tuft data.   A carpet tile produced using the tufted carpet according to claim 1.   A step of capturing a pattern or the like to be reproduced as a pattern as image data by an image capturing device, a step of converting the image data by a data converting device into multi-step color tone data, and tuft data (pile) based on the color tone data Tufted comprising: a step of creating height data), and tufting a carpet base fabric with a pile height corresponding to the tuft data using a tufting machine capable of adjusting the pile height based on the tuft data. Carpet manufacturing method.   4. The method for manufacturing a tufted carpet according to claim 3, wherein, in the step of converting the image data into multi-stage color tone data, the image data is once converted to gray scale and then converted into multi-stage color tone data.