JP2584850B2 - Manufacturing method of dust control mat - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial application field) The present invention lays at an entrance of an office, a house, a store, etc., and collects dust adhering to shoe soles and the like on a mat itself to be used indoors. The present invention relates to a method for producing a dust control mat for preventing carry-in, particularly a dust control mat in which a clear pattern composed of a secondary pile is formed on a pile surface of a pile fabric in which a primary pile is tufted on a base cloth.

(Prior art and its problems) Conventionally, as a method of forming a pattern on a mat such as a carpet having tufted pile, an adhesive is appropriately applied to the surface of the pile of the mat in a pattern form, and a flockey for electrodepositing colored fibers. In general, a cutting method in which a carpet as a base material and a carpet of a different color are cut out in a corresponding pattern shape and the latter cutout portion is fitted into a cutout hole portion of the former.

However, in both methods, although a clear pattern can be obtained, there is a problem that it takes a lot of time and labor to create and change the pattern, the processing cost is high, and the productivity is low. Furthermore, in the flocking method, the pattern portion is hardened with an adhesive, so that the texture as a pile is impaired. In the cutting method, the material loss is large and the strength is often poor.

In view of this, there has been proposed an over-tuffing apparatus in which a desired pattern is drawn by partially tufting the pile by overlapping it on a tufted fabric in which the pile is tufted (for example, Japanese Utility Model Publication No. 60-28706). .

However, in this over-taft device, the table frame for holding the tufted fabric (pile fabric) at the processing position and the base fabric base for feeding the tufted fabric can be moved in the width direction in synchronization with each other. By controlling the movement in the width direction of the base cloth and the feeding and rewinding of the base cloth in the base cloth base, a required patterning by over-taft is performed. Since the drive mechanism has the same configuration as that of a normal tufting machine, complicated and precise patterns or patterns that are totally or partially discontinuous cannot be formed, and both the heavy table frame and the base cloth base can be moved. Therefore, there has been a problem that the apparatus configuration has become complicated and large, enormous equipment costs have been required, operating costs have been high, and productivity has been low.

On the other hand, office, house, laid at the entrance of stores, etc., as a dust control mat that collects dust attached to the shoe sole etc. in the mat itself and prevents it from being brought into the room, especially to enhance dust removal, A pile yarn of a pile fabric as a base material is impregnated with a dust-adhesive oil agent such as a mineral oil, a synthetic oil, a vegetable oil, or the like (see, for example, JP-A-62-137028).
No.). However, even in a conventional dust control mat using such a dust-adhering oil agent, there is a problem that the pile yarn has poor impregnation with the oil agent, so that it is not possible to impart a sufficient dust-removing property.

(Means for Solving the Problems) In view of the above-mentioned circumstances, the present invention provides an extremely wide selection range of a pattern, and can freely form a complicated and precise pattern or a discontinuous pattern. It is an object of the present invention to provide a method capable of producing a dust control mat which is easy and has a high original dust-removing function and has both excellent design properties and dust-removing properties at high efficiency and at low cost.

That is, the method for producing a dust control mat of the present invention comprises the steps of: tufting a primary pile of a spun yarn consisting of a 15th to a 7th single yarn impregnated with a dust-adhesive oil agent to a base cloth; A plurality of needles each having an independent extension device are held in a non-contact state with the pile fabric, and only a needle corresponding to a pattern to be formed is moved by the extension mechanism by a signal input to a pattern control device. 7, and a required pattern is formed by over-tufting the secondary pile through the base fabric of the pile fabric with the elongated needle.

(Detailed Configuration and Operation of the Invention) FIG. 1 shows a cross section of a pile fabric 3 to be over-tufted. This pile fabric 3 is obtained by tufting a primary pile 2 made of a cut pile having a relatively short pile length or a loop pile (not shown) on a usual tuft base fabric 1 made of a nonwoven fabric or a flat yarn woven fabric. It is. Primary pile 2 is made of nylon, polyester,
1 to 5 spun yarns of 15th to 7th spun yarns made of acrylic or the like, particularly preferably 15 to 15th spun yarns 3 to 7th spun yarns Further, it is impregnated with a dust-adhering oil such as spindle oil, machine oil, liquid paraffin, alkylbenzene oil, alkylnaphthate oil, and the like. However, since the single yarn of the relatively thin spun yarn as described above has extremely good impregnation and absorption of the oil agent,
The primary pile 2 is in a state of holding the oil agent at a high impregnation amount.

FIG. 2 to FIG. 5 schematically show a configuration of a tufting device for performing patterning on the pile fabric 3 by over-tufting.

In these figures, reference numeral 4 denotes a rocker arm which holds a plurality of needles 5 for tufting the secondary pile in a hanging manner. The rocker arm 4 swings when a switch of the over-tuffing machine is turned on. Are moved up and down at high speed while being guided by the needle plate 6. The vertical movement of the needles 5 is performed in the range of a shown in FIG. 2, but since the bottom dead center is set slightly higher than the pile cloth 3, the tip 9 of each needle 5 is
Is held in a non-contact state with respect to the base fabric 1.

Thus, the extension device 7 corresponds to each of the needles 5.
When a signal is input to the extension device 7 based on preset pattern data, the corresponding needle 5 is extended downward, and the needle is piled as shown in the range A of FIG. The needle 5 is moved up and down at a high speed with a long stroke penetrating the base fabric 1 of the fabric 3 and the needle 5 is moved while the pile fabric 3 is moving.
Every time the pile thread passes through, the pile yarn passed through the tip is caught and cut by the looper 10 and the knife 11, whereby the secondary pile 12 is over-tufted on the pile fabric 3.

Various mechanisms and structures can be adopted as the extension device 7 for controlling the extension of the needle 5, and an example thereof will be described with reference to FIG. That is, in the extension device 7 shown in FIG. 4, a horizontal cylinder bar is arranged along the direction in which the plurality of needles 5 are arranged.
13, a plurality of latch cylinders corresponding to each needle 5
15 are provided, and each latch cylinder 15 is provided with a pneumatic pressure by a signal from a computer 18 which is a pattern control device.
16 is applied, and this pressure causes the latch pin 14 to protrude toward the needle 5. Thus, when the tufting machine is switched on, the cylinder bar 13 moves up and down via the push rod 17 with a stroke that makes the amount of downward movement of the needles 5... It is set as follows.

Then, necessary pattern data to be formed by over-taft is input to the computer 18, and a signal is input from the computer 18 to the decompression device 7 based on the pattern data. Only the latch cylinder 15 corresponding to the above operates independently, the latch pin 14 is fitted into the corresponding needle 5, the needle 5 and the cylinder bar 13 are locked, and the vertical movement of the needle 5 is the same as that described above. The stroke is converted to the stroke indicated by A in FIG. 3, and the tufting operation of the secondary pile 12 is performed.

When it is necessary to stop the tufting operation of each needle 5 based on the pattern, the latch cylinder 15 corresponding to the needle 5 is moved to the right side of the drawing by a signal from the computer 18, so that the latch pin 14 Leave 5 Therefore, the needle 5 is
Due to the accumulated force of the spring device 8, the spring device 8 moves upward and returns to the original state, and only moves up and down with a short stroke a at a distance above the panel fabric 3 as shown in FIG. The pile fabric 3 has a pattern 19 formed of the secondary pile 12.

In addition, instead of making the needles 5 stand by while moving up and down at high speed on the pile fabric 3 as described above, the needles 5 are pulled up to the upper position where the tips 9 are not in contact with the pile fabric 3 via a spring. In this state, only the needles 5 necessary for pattern formation are latched by the extension device 7 shown in FIG.
It is also possible to set the secondary pile 12 to be tufted through the pile fabric 3 by engaging the cylinder bar 13 which is moving up and down by the operation of.

As the pile yarn of the secondary pile 2, the same fiber material as that of the primary pile 2 can be used, but there is no restriction on the thickness, and it may be a plain dyed yarn or a space dyed yarn.

After the secondary pile 2 is over-tufted to form a required pattern, the back surface of the base fabric 1 is backed with synthetic rubber or synthetic resin. As this backing material, nitrile-butadiene rubber (NBR), styrene-butadiene rubber (SBR),
Chloroprene rubber, polyvinyl chloride (PVC) and the like are used.

FIG. 6 is a cross-sectional view in the flow direction of the dust control mat thus obtained. In this mat, a required pattern 19 composed of an over-tufted long secondary pile 12 is formed on a base cloth 1 on which a short primary pile 2 is tufted, and a backing layer 20 is provided on the back side of the base cloth 1. It has high dust removal performance based on a dust-adhesive oil agent impregnated in the primary pile 2 and excellent design properties with a clear pattern 19. In addition, this dust-removal performance is that when the mat is laid at the entrance of an office, a house, a store, or the like, dust adhering to shoe soles and the like adheres to the primary pile 2 itself of the mat and is collected. Dust is prevented from being brought into the vehicle.

So, such a dust control mat,
If necessary, the product may be fitted in a mat base made of a synthetic resin.

In the present invention, it is desirable to make the secondary pile 12 longer than the primary pile 2 in order to clarify the pattern, but if necessary, a portion longer than the primary pile 2 of the secondary pile 2 may be cut. . Primary pile 2 between patterns 19 and 19
It is also possible to set it as a region without any. Further, the primary pile 2 and the secondary pile 12 are not limited to the cut pile form as shown in the figure, and one or both of them may be in a loop pile form.

A base fabric consisting of (Example) Polyester fabric, a spun yarn consisting of 12th 4 children twisted acrylic fiber impregnated with spindle oil, height 12cm, and tufted such that the pile weight 710 g / m ³ To form a primary pile, and a pile fabric to be subjected to over-taft was prepared.

The pile fabric is set in an over-taft machine in which each of the needles described above can be individually extended and extended, and by computer control, the needles necessary for patterning are extended through an extending device based on the set pattern data. After a nylon filament pile yarn was over-tufted to form a pattern consisting of a secondary pile row having a height of 18 mm, the back surface of the base fabric was lined with NBR resin to obtain a dust control mat.

This dust control mat has excellent design with a clear pattern consisting of secondary piles, PV
When used as a store mat in a form fitted to a mat base made of C (polyvinyl chloride), high dust-removal properties were exhibited.

(Effect of the Invention) According to the method for manufacturing a dust control mat according to the present invention, a pile fabric in which a primary pile is tufted,
A clear pattern consisting of an over-tafted secondary pile can be formed efficiently and easily, and the selection range of the pattern is extremely wide, and a complicated and precise pattern and a whole or partial discontinuous pattern can be set freely. In addition, the pattern can be easily created and changed, and the primary pile can be held with a high amount of impregnating oil with a dust-adhering oil. By arranging a plurality of needles in the width direction so as to cover the pattern forming area of the pile fabric, the pile fabric only needs to be sent in one direction at a constant speed, and the pile fabric can be manufactured. There is an advantage that the device configuration on the machine side to be arranged becomes extremely simple, and both equipment costs and operation costs are reduced.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view showing an example of a pile fabric provided for over-tuffing in the method of the present invention, FIG. 2 is a longitudinal sectional view schematically showing a state before patterning by an over-tuffing machine,
FIG. 3 is a longitudinal sectional view schematically showing the same patterning state, and FIG.
FIG. 5 is a longitudinal sectional view of an essential part showing an example of a needle extension device of the over-taft machine, FIG. 5 is a schematic longitudinal sectional view showing a state after patterning by the over-tuft machine, and FIG. FIG. 2 is a longitudinal sectional view along an mat flow direction showing an example of a dust control mat to be obtained. 1 ... base cloth, 2 ... primary pile, 3 ... pile cloth, 4
... rocker arm, 5 ... needle, 6 ... needle plate, 7 ... extension device, 9 ... tip, 10 ... looper, 11 ... knife, 12 ... secondary pile, 16 ... computer (pattern Control device), 19 ... patterns.

Claims (1)

(57) [Claims] 1. A primary pile of a spun yarn consisting of a 15th to 7th single yarn impregnated with a dust-adhesive oil agent is tufted on a base fabric, and each of the obtained pile fabrics has an independent stretching device. Are held in a non-contact state with the pile fabric, and only a needle corresponding to a pattern to be formed is extended via the extension mechanism by a signal input to the pattern control device. A method for producing a dust control mat, wherein a required pattern is formed by over-tufting a secondary pile through a base fabric of the pile fabric with an elongated needle.