JP3728628B2

JP3728628B2 - Permeable tufted pile fabric

Info

Publication number: JP3728628B2
Application number: JP30770092A
Authority: JP
Inventors: 寿夫森田
Original assignee: 森田産業株式会社
Priority date: 1992-10-20
Filing date: 1992-10-20
Publication date: 2005-12-21
Anticipated expiration: 2020-12-21
Also published as: JPH06128862A

Description

【０００１】
【産業上の利用分野】
本発明は、通気性と透水性に優れ、特に透水性人工芝生に適したタフテッドパイル布帛に関するものである。
【０００２】
【従来の技術】
タフテッドパイル布帛によって構成され、屋外に施工して雨天時に水溜りの出来ない透水性人工芝生を得るために、本発明者は、パイル糸をタフテイングする一次基布に経糸間隔や経糸間隔が粗くネット状に織成した織物を使用し、タフテイング後に一次基布の布目として残る経糸間の隙間を塞じることなく裏打用接着剤を裏打塗布する方法を発明し、特公昭６３−１４１２１・特開昭５８−２００７０６に開示している。
【０００３】
【発明が解決しようとする課題】
経糸間隔や経糸間隔を粗くして大きい布目隙間を形成したネット状織物では目ズレが起き易く、その目ズレ止めのために織物を高温加熱してプレスセット経糸と緯糸の交絡している接結点を付形セットするか又は樹脂加工をして接結点において交絡する経糸と緯糸の間を接着固定する必要があった。
【０００４】
しかし経糸と緯糸との接結点を固定セットすると、タフテイング時に目ズレが起き難く、タフテイング時に一次基布から受ける抗力によってニードルが押し曲げられ変形する危険がある。何故なら、タフテイング過程において一次基布は常に一定の速度で長さ方向に搬送されており、一次基布に垂直に差し込まれたニードルは一次基布の移動方向に押圧されるからである。
【０００５】
従って、ニードルが移動する一次基布から受ける抗力を緩和するには、一次基布の移動方向に目ズレが起きる方が寧ろ望まれる訳である。
【０００６】
そして又、接結点を固定セットした一次基布では、パイル糸が布目隙間よりも十分に太い場合は別として、そうでない場合、特に比較的細手のパイル糸ではタフテイングされたパイルが布目隙間に遊嵌し、パイルが前後左右の経糸間や緯糸間で確りと挟持されないことになるので、裏打用接着剤によって一次基布に接着固定されるまでの間、パイルは抜け易い不安定な状態におかれることになる。
【０００７】
【発明の目的】
そこで本発明は、一次基布の搬送方向にタフテイング時に一次基布に目ズレが起き易くし、そうすることによって搬送方向にニードルが一次基布から受ける抗力を緩和し、且つ、タフテイング後は目ズレによって生じた布目の弾性的復元力によってパイルが経糸間や緯糸間で確りと挟持されるようにし、而も、一次基布が透水孔となる大きい布目を有し、透水性人工芝生に適したタフテイングパイル布帛が得られるようにすることを目的とする。
【０００８】
【課題を解決するための手段】
本発明に係るタフテッドパイル布帛１６は、幅Ｗと厚みＴとの比率Ｗ／Ｔで示される扁平率が６以上であり、一次基布を構成してタフティング時のパイル糸挿通時に目ズレを起こし、その後該パイル糸を弾性復元力で把持することが出来る程度の厚みを有し、プラスチックフイルムを細長くテープ状に裁断した形状のテープヤーンをパイル糸の形成するバックステッチが連続するステッチ方向に直交するニードルゲージ方向に続くテープヤーンを緯糸１１とし、パイル糸の形成するバックステッチが連続するステッチ方向における緯糸打込間隔Ｋとテープヤーンの幅Ｗとの比率Ｋ／Ｗを１〜１．３とし、ステッチ方向に直交するニードルゲージ方向における経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄを２以上とし、経糸間の隙間（Ｈ−Ｄ）を０．３ｍｍ以上に設定して織成された一次基布１２に、ステッチゲージＳと緯糸打込間隔Ｋとの比率Ｓ／Ｋを１以上とし、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを１．２以上とし、パイル糸１３の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗが１以上となるパイル糸１３がタフテイングされており、タフテイング後の一次基布１２の少なくとも一部のパイル糸の挿通されていない布目１４を塞ぐことなく裏打用接着剤を裏打塗布してパイル１７を一次基布１２に固定したことを特徴とするものである。
【０００９】
慣用されるプラスチックフイルムを細長くテープ状に裁断した形状のテープヤーンに成る一次基布に関して検討するに、テープヤーン１１を用い隙間なく緻密に織成された織物１２が、仮令経糸配列間隔Ｈとなる経糸太さＤとの比率がＨ／Ｄが２以上で経糸間に配列間隔Ｈと太さＤとの差（Ｈ−Ｄ）に経糸太さＤの数倍ｎに及ぶ大きい隙間（ｎＤ＝Ｈ−Ｄ）をもって経糸１５が配列されていても、テープヤーンに成る緯糸間に隙間なく、前後する緯糸１１Ａ・１１Ｂが密着する程度に緯糸打込間隔Ｋを緻密に織成されている場合には、畳表や御座がそうであるように搬送過程等において織物１２に目ズレは起き難い。
又、表裏を軽く挟んで把持したテープヤーン１１をその幅方向に押圧すると、テープヤーン１１は幅方向に折り畳まれるように幅Ｗを縮めて加撚された紡績糸や合撚糸の如き非扁平断面の糸条へと変形し易い。一方、そのテープヤーン１１を幅方向への押圧から解くと、一次基布を構成してタフティング時のパイル糸挿通時に目ズレを起こし、その後該パイル糸を弾性復元力で把持することが出来る程度の厚みを有し、プラスチックフイルムを細長くテープ状に裁断した形状のテープヤーン１１の有する弾性回復力によって幅方向に伸びて元の扁平断面のテープヤーン１１へと復元し易い。
【００１０】
本発明は、かかるテープヤーン１１の性質を利用して完成されたものであり、かかるテープヤーン１１の性質を考慮するとき、緯糸打込間隔Ｋとテープヤーンの幅Ｗとの比率Ｋ／Ｗを１〜１．２とし、加撚された糸条を経糸１５に使用し、経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄを３以上とし、経糸間の隙間（Ｈ−Ｄ）を１．０ｍｍ以上に設定して一次基布１２を織成し、ステッチゲージＳと緯糸打込間隔Ｋとの比率Ｓ／Ｋを２以上とし、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを２以上とし、パイル糸１３の見掛け太さＭが、経糸間の隙間（Ｈ−Ｄ）とニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈとの関係において、（Ｈ−Ｄ）≦Ｍ≦（Ｈ−Ｄ）×｛（Ｇ／Ｈ）−１｝となり、パイル糸１３の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗが１以上となるパイル糸１３をタフテイングして、ニードルゲージ方向において隣り合うバックステッチ１８とバックステッチ１８との間に少なくとも２本の経糸１５Ａ・１５Ｂが介在するようにすることが望まれる。
【００１１】
即ち、テープヤーン１１を緯糸とし、その幅Ｗと打込間隔Ｋとの比率Ｋ／Ｗを１〜１．３とした織物１２では、前後して打ち込まれるテープヤーン１１Ａ・１１Ｂの間は略密着していている。このため織物全体は一見して隙間がなく緻密に織成されたかの如き観を呈し、それを一次基布１２とした場合には透水性タフテッドパイル布帛は得難く思われる。
しかし、経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄを２以上とし、経糸間の隙間（Ｈ−Ｄ）を０．３ｍｍ以上に設定して一次基布１２を織成し、それにステッチゲージＳと緯糸打込間隔Ｋとの比率Ｓ／Ｋを１以上とし、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを１．２以上とし、パイル糸１３の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗが１以上となるパイル糸１３をタフテイングとすると、ニードル１９が貫通してパイル１７が植設された箇所では、１個のパイル１７を構成する２個（一対）のパイル片はバックステッチ１８の続くステッチ方向に縦に重なって並び、そのパイル１７の植設された箇所で前後する２本のテープヤーン１１Ｃ・１１Ｄの間（１４）は、縦に重なった２個のパイル片によってテープヤーン１１Ｃ・１１Ｄがその扁平断面の幅方向に折り畳まれるように圧縮されて押し広げられ、その間に２個のパイル片の太さ分の長さＮ（２Ｍ）の隙間が出来ることになる。
【００１２】
例えば、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈが１．２（Ｇ／Ｈ＝１．２）の場合は、５ニードルゲージ（５Ｇ）即ちニードルゲージ方向（一次基布の幅方向）にバックステッチ５列につき１回の割合で隣り合うバックステッチ１８・１８の間に２本の経糸１５Ａ・１５Ｂが介在することになり、その２本の経糸１５Ａ・１５Ｂの間にはパイル片（１７）が介在しないことになるから、そこに前後の緯糸１１Ｃ・１１Ｄと左右の経糸１５Ａ・１５Ｂに囲まれたパイルの植設されない布目１４、即ち、パイル糸の挿通されていない布目１４が残ることになる。
そのパイル糸の挿通されていない布目１４は、前後する２本の緯糸１１Ｃと１１Ｄの間が左右に２個縦に並んだパイル片に押し広げられてパイル糸１３の見掛け太さＭの２倍分の長さＮ（Ｎ＝２Ｍ）の細長いスリット孔（１４）になり、そのように細長いパイル糸の挿通されていない布目１４では、塗布される裏打用接着剤の塗膜が左右の経糸１５Ａ・１５Ｂに沿って亀裂し易く、そのようにステッチ方向に続く何れかの細長い布目１４における裏打用接着剤の塗膜の亀裂によって仕上がったタフテッドパイル布帛に透水孔（１４）が出来、それによって透水性人工芝生（１６）を得ることが出来る。
【００１３】
このようにして一次基布に細長いスリット孔として出来る透水孔１４の長さＮは、一次基布にタフテイングされた状態でのパイル糸１３の見掛け太さＭによって設定されることになる。
従って本発明における「パイル糸の見掛け太さ」とは、パイル糸を無緊張状態に放置した状態での見掛け太さではなく、一次基布に差し込まれて貫通する一次基布の貫通孔内の周囲の繊維に囲まれた状態におけるパイル糸の見掛け太さを意味する。
【００１４】
このようにして出来る透水孔１４の幅は、経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄと経糸間の隙間（Ｈ−Ｄ）を大きくすることによって広くすることが出来、その透水孔１４の長さＮは、パイル糸１３の見掛け太さＭおよびパイル糸１３の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗを大きくすることによって長くすることが出来る。又、その透水孔１４の数（タフテッドパイル布帛における分布密度）は、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを大きくして増やすことが出来、例えば、その比率Ｇ／Ｈを２以上にすると各バックステッチ列とバックステッチ列の間に透水孔１４を形成することが出来る。
従って、経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄは３以上になるようにし、経糸間の隙間（Ｈ−Ｄ）を１．０ｍｍ以上に設定し、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを２以上とし、パイル糸の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗが２以上になるようにすることが望まれ、又、経糸１５には断面が非扁平の加撚された糸条を用い、更に好ましくは、ニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈを２以上とする場合、パイル糸１３の見掛け太さＭは、経糸間の隙間（Ｈ−Ｄ）とニードルゲージＧと経糸配列間隔Ｈとの比率Ｇ／Ｈとの関係において、（Ｈ−Ｄ）≦Ｍ≦（Ｈ−Ｄ）×｛（Ｇ／Ｈ）−１｝となり、パイル糸１３の見掛け太さＭとテープヤーン１１の幅Ｗとの比率Ｍ／Ｗが１以上となるようにすると効果的である。
【００１５】
具体的に説明すると、タフテッドカーペットの一次基布として慣用されているテープヤーン織基布のテープヤーンの如く、幅Ｗが２ｍｍのポリプロピレンテープヤーンを緯糸１１とし、緯糸打込間隔Ｋを２．２ｍｍとし、１５００デニールで加撚された見掛け太さＤが０．３ｍｍのポリエステル長繊維フイラメント糸を経糸１５とし、経糸配列間隔Ｈを２ｍｍとして織成された一次基布１２では、緯糸打込間隔Ｋとテープヤーンの幅Ｗとの比率Ｋ／Ｗは１．１となり、経糸配列間隔Ｈと経糸太さＤとの比率Ｈ／Ｄは約７となり、経糸間の隙間（Ｈ−Ｄ）は１．７ｍｍとなる。
この一次基布１２に、見掛け太さＭが２ｍｍの６０００デニールの塩化ビニリデンテープヤーンをパイル糸１３として、ステッチゲージＳと緯糸打込間隔Ｋ（２．２ｍｍ）の比率Ｓ／Ｋをｎとし、ニードルゲージＧと経糸配列間隔Ｈ（２ｍｍ）の比率Ｇ／Ｈをｍとしてタフテイングすると、ステッチ方向に続くパイルとパイルの間にはｎ本のテープヤーン１１が介在し、又、ニードルゲージ方向のバックステッチとバックステッチの間隔はｍ×（Ｈ−Ｄ）となり、バックステッチとバックステッチの間にパイル糸の見掛け太さを差し引いたｍ×（Ｈ−Ｄ）−Ｍだけの経糸間の隙間が残ることになる。
ここでニードルゲージＧが５／１６吋（約８ｍｍ）のタフテッド機においてステッチゲージＳを７ｍｍとしてタフテイングすると、ステッチゲージＳと緯糸打込間隔Ｋの比率Ｓ／Ｋ（ｎ）は約３となり、緯糸テープヤーン３本につき１回の割合で布目の緯糸テープヤーンの間がパイル糸の見掛けの太さＭの２倍（Ｎ＝２Ｍ）になり、ニードルゲージＧと経糸配列間隔Ｈの比率Ｇ／Ｈ（ｍ）は４となり、バックステッチとバックステッチの間にはｍ×（Ｈ−Ｄ）−Ｍ＝４×（２−０．３）−２＝４×１．７−２＝４．８ｍｍに相当する経糸間の隙間（Ｈ−Ｄ＝１．７ｍｍ）が残ることになる。
【００１６】
ところで、ニードルゲージＧと経糸配列間隔Ｈの比率Ｇ／Ｈ（ｍ）が４と言うことは、経糸４本につき１個の割合でパイルがタフテイングされると言うこと、つまり、ニードルゲージ方向の一次基布の布目４個につき１個の割合でパイルがタフテイングされ残りの３個のパイル糸の挿通されていない布目はパイルがタフテイングされずに残ることを意味し、バックステッチとバックステッチの間に４．８ｍｍに相当する経糸間の隙間（Ｈ−Ｄ＝１．７ｍｍ）が残ると言うことは、パイルがタフテイングされずに経糸間の隙間が元の１．７ｍｍとなっているパイル糸の挿通されていない布目が４．８÷１．７＝２．８個即ち少なくとも２個は残ると言うことを意味する。
そしてタフテイング箇所の横の布目の長さＮはパイル糸の見掛けの太さＭの２倍の４ｍｍになるから、そのタフテイングされずに経糸間の隙間が元の１．７ｍｍとなって残る２個のパイル糸の挿通されていない布目は、それぞれ長さＮが４ｍｍで幅（Ｈ−Ｄ）が１．７ｍｍの透水孔１４を構成することになる。
【００１７】
このようにして出来る細長いパイル糸の挿通されていない布目１４を塞ぐことなく裏打用接着剤を裏打塗布してタフテッドパイル布帛を仕上げるには、裏打用接着剤の裏打塗布面に高圧気流を当ててパイル糸の挿通されていない布目１４に出来る裏打用接着剤の塗膜を打ち破ってから加熱ゾーンに通して裏打用接着剤を固化するとよい。
その場合、裏打塗布する裏打用接着剤に塞がれないようにし、又、裏打用接着剤が塗着して塞がれても塗膜が亀裂してパイル糸の挿通されていない布目１４が透水孔として残るようにするためにも、経糸間の隙間（Ｈ−Ｄ）は少なくとも０．３ｍｍになるようにし、好ましくは０．５ｍｍ以上、更に好ましくは１ｍｍ以上に設定するとよい。
特に、ニードルゲージＧと経糸配列間隔Ｈの比率Ｇ／Ｈ（ｍ）を大きく設定した場合に、隣り合って出来る数個のパイル糸の挿通されていない布目１４が纏まった大きい透水孔を形成するようにするため、その隣り合う布目の間を仕切る経糸は加撚によって見掛け太さＤを経糸間の隙間（Ｈ−Ｄ）よりも細くなるようにするとよい。
そのためにもタフテイングされずに経糸間の隙間（Ｈ−Ｄ）が元のままに残るパイル糸の挿通されていない布目の数が２個以上、好ましくは３個以上になるようにニードルゲージＧと経糸配列間隔Ｈの比率Ｇ／Ｈ（ｍ）を４以上にし、又、経糸の見掛け太さＤと経糸間の隙間（Ｈ−Ｄ）との比率Ｄ／（Ｈ−Ｄ）は、０．５以下に、好ましくは０．３以下で概して０．５〜０．１になるようにするとよく、そうすることによって裏打用接着剤が経糸に塗着し難くなり、仮令裏打用接着剤が隣り合う数個の纏まったパイル糸の挿通されていない布目を塞ぐように塗着しても、その裏打用接着剤の塗膜は隣り合うパイル糸の挿通されていない布目の間を仕切る細い経糸の長さ方向に沿って亀裂し易くなり、裏打用接着剤の塗膜が亀裂して纏まった数個のパイル糸の挿通されていない布目による透水孔１４が出来易くなる。
【００１８】
緯糸に使用するテープヤーン１１は、プラスチックフイルムを細長くテープ状に裁断しただけのものでもよいし、稍々幅広くテープ状に裁断したものを幅方向に折り畳んで数重に重ねたものであってもよく、又、プラスチックフイルムの長さ方向にスリットを入れたスリットヤーンやスプリットヤーンであってもテープ状をなすものであればよい。一方、経糸１５は、紡績糸でもマルチフイラメント糸でもよいし、又、加撚された紡績糸やマルチフイラメント糸の如く断面が丸みを帯びたものであればスリットヤーンやスプリットヤーンでもよく、経糸の見掛け太さＤと経糸間の隙間（Ｈ−Ｄ）との比率Ｄ／（Ｈ−Ｄ）を０．５以下とし、経糸間の隙間（Ｈ−Ｄ）を０．３ｍｍ以上とする限り、テープヤーンを経糸１５に使用することも出来る。
本発明に係る基布は、経糸と緯糸が直交している織物であり、経糸は基布の長さ方向に連続しており、基布は経糸の連続する長さ方向にタフテッド機に向けて供給され、その基布にパイル糸が連続してタフテイングされる。このため、各パイル糸が連続して形成するパイルとバックステッチは、基布を構成している経糸の長さ方向に平行して連続することになる。従って、本発明の基布を構成している経糸とは、各１本のパイル糸がそれぞれ形成するバックステッチの連続する方向に長く続く糸条を意味し、基布を構成している緯糸とは、そのバックステッチの連続する方向に交叉する方向に長く続く糸条を意味し、基布を構成している経糸と緯糸の違いはバックステッチの連続の仕方によって識別される。
【００１９】
【発明の効果】
本発明によると、前記の通りテープヤーン１１を緯糸とし、テープヤーン１１Ａ・１１Ｂの間に隙間なく緻密に織成した織物１２では、仮令経糸配列間隔Ｈとなる経糸太さＤとの比率がＨ／Ｄが２以上で経糸間に配列間隔Ｈと太さＤとの差（Ｈ−Ｄ）に経糸太さＤの数倍ｎに及ぶ大きい隙間（ｎＤ＝Ｈ−Ｄ）をもって経糸１５が配列されていても搬送過程等の通常の状態では目ズレが起き難い一方、幅方向に押圧するとテープヤーン１１は幅Ｗを縮めて非扁平断面の糸条へと変形し易く、その幅方向への押圧を解くと押圧によって蓄積された弾性回復力によって幅方向に伸びて元の扁平断面のテープヤーン１１へと復元し易いので、タフテイング時に一次基布１２に差し込まれるニードル１９によってテープヤーン１１がステッチ方向に目ズレを起こし、その目ズレによってニードル１９のステッチ方向への撓みが緩和され、又、ニードル１９が抜き取られた場合には目ズレによって蓄えられたテープヤーン１１の弾性回復力によってパイル１７が強く把持される。
【００２０】
そして、緯糸打込間隔Ｋとテープヤーンの幅Ｗとの比率Ｋ／Ｗを１〜１．３とした一次基布１２では、畳表や御座がそうであるように通常の状態では目ズレは容易には起きないので、一次基布１２の布目の目ズレによってタフテイング密度が不規則になるようなことも起こらず、かくして、布目隙間が多く目粗なネット状一次基布にタフテイングした場合と全く同様に透水性タフテッドパイル布帛１６が得られる。
一方、目粗なネット状一次基布を用いる場合と異なり、本発明では一次基布１２の目ズレを防ぐための熱セット加工や樹脂による布目のセット加工が不要になるので経済的であるだけではなく、ニードル１９の一次基布１２から受ける抵抗が少なくなるので、タフテイング効率が向上する。
そして前記の通り、タフテイング直後のパイル１７が緯糸間１１Ｃ・１１Ｄで確りと挟持されるので裏打加工も簡略化される。
【００２１】
かくして本発明によると、透水性人工芝生に適したタフテッドパイル布帛１６が効率的且つ経済的に得られる。
【図面の簡単な説明】
【図１】本発明に係る一次基布とタフテッドパイル布帛のタフテイング箇所での拡大斜視図である。
【符号の説明】
１１緯糸（テープヤーン）
１２一次基布（織物）
１３パイル糸
１４布目・スリット孔（透水孔）
１５経糸
１６タフテッドパイル布帛（人工芝生）
１７パイル
１８バックステッチ
１９ニードル[0001]
[Industrial application fields]
The present invention relates to a tufted pile fabric which is excellent in air permeability and water permeability and particularly suitable for water permeable artificial grass.
[0002]
[Prior art]
In order to obtain a water-permeable artificial lawn that is constructed of tufted pile fabric and cannot be accumulated in rainy weather, the present inventor has a rough warp interval and warp interval on a primary base fabric that tufts pile yarn. Invented a method of using a woven fabric in a net shape and applying a backing adhesive without closing the gap between warp yarns remaining as the primary base fabric after toughing. Japanese Patent Publication No. 63-14121 This is disclosed in Japanese Patent Publication No. 58-200706.
[0003]
[Problems to be solved by the invention]
Net-shaped fabrics with large warp intervals and coarse warp intervals that form large fabric gaps are prone to misalignment. To prevent misalignment, the fabric is heated at a high temperature and the press set warp and wefts are entangled. It was necessary to shape-set the points or perform resin processing to bond and fix between the warp and weft entangled at the connection point.
[0004]
However, if the connection point between the warp and the weft is fixedly set, misalignment is unlikely to occur during toughing, and there is a risk that the needle will be bent and deformed by the drag received from the primary base fabric during toughing. This is because the primary base fabric is always conveyed in the length direction at a constant speed in the tufting process, and the needle inserted perpendicularly to the primary base fabric is pressed in the moving direction of the primary base fabric.
[0005]
Therefore, in order to alleviate the drag received from the primary base fabric on which the needle moves, it is desirable that the misalignment occurs in the moving direction of the primary base fabric.
[0006]
In addition, in the primary base fabric with fixed connection points, the pile yarn is not thick enough than the gap between the piles, otherwise the tufted pile is relatively tight in the case of relatively thin pile yarns. Since the pile is not loosely clamped between the front, back, left and right warps or wefts, the pile is easy to come off until it is adhered and fixed to the primary fabric with the backing adhesive. It will be placed in.
[0007]
OBJECT OF THE INVENTION
Therefore, the present invention makes it easy for the primary base fabric to be misaligned when tufting in the transport direction of the primary base fabric, thereby reducing the drag that the needle receives from the primary base fabric in the transport direction, and after the tufting, The pile is firmly clamped between warps and wefts by the elastic restoring force of the fabric caused by the displacement, and the primary fabric has a large fabric with water-permeable holes, making it suitable for permeable artificial grass An object is to obtain a tough piling pile fabric.
[0008]
[Means for Solving the Problems]
The tufted pile fabric 16 according to the present invention has a flatness ratio indicated by a ratio W / T of a width W and a thickness T of 6 or more , constitutes a primary base fabric, and is misaligned when pile yarn is inserted during tufting. Direction in which the back yarn forming the pile yarn is formed into a tape yarn having a thickness that allows the pile yarn to be gripped by an elastic restoring force and then cutting the plastic film into an elongated tape shape. The weft 11 is a tape yarn continuing in the needle gauge direction perpendicular to the needle gauge, and the ratio K / W between the weft driving interval K and the width W of the tape yarn in the stitch direction in which the back stitch formed by the pile yarn continues is 1-1. 3 and then, the ratio H / D of the warp arrangement interval H and the warp thickness D in the needle gauge direction perpendicular to the stitching direction and two or more, the gap between the warp yarns (H-D) The ratio S / K between the stitch gauge S and the weft driving distance K is set to 1 or more on the primary base fabric 12 woven with a setting of 0.3 mm or more, and the ratio G between the needle gauge G and the warp arrangement interval H. / H is 1.2 or more, and the pile yarn 13 in which the ratio M / W of the apparent thickness M of the pile yarn 13 to the width W of the tape yarn 11 is 1 or more is tufted, and the primary base fabric after tufting The pile 17 is fixed to the primary base fabric 12 by applying a backing adhesive without blocking the cloth 14 through which at least some of the pile yarns 12 are not inserted .
[0009]
In order to examine a primary base fabric which is a tape yarn having a shape obtained by cutting a conventionally used plastic film into an elongated tape shape, a woven fabric 12 which is finely woven without gaps using the tape yarn 11 has a temporary warp arrangement interval H. The ratio of the warp thickness D to H / D is 2 or more, and a large gap (nD = H) which is several times n of the warp thickness D in the difference (HD) between the arrangement interval H and the thickness D between the warps -D) even when the warp yarns 15 are arranged, if the weft driving interval K is densely woven so that the front and rear weft yarns 11A and 11B are in close contact with each other with no gap between the weft yarns forming the tape yarn As with the tatami mat and the throne, misalignment is unlikely to occur in the fabric 12 during the conveyance process.
When the tape yarn 11 held lightly between the front and back is pressed in the width direction, the tape yarn 11 is reduced in width W so as to be folded in the width direction, and a non-flat cross section such as a spun yarn or a twisted yarn twisted. It is easy to deform into a yarn. On the other hand, when the tape yarn 11 is released from the pressing in the width direction, the primary base fabric can be constituted to cause misalignment when the pile yarn is inserted during tufting, and then the pile yarn can be gripped with an elastic restoring force. The tape yarn 11 having a certain thickness and elongated in the width direction by the elastic recovery force of the tape yarn 11 having a shape obtained by cutting the plastic film into a tape shape is easy to restore to the tape yarn 11 having the original flat cross section.
[0010]
The present invention has been completed by utilizing the properties of the tape yarn 11, and when considering the properties of the tape yarn 11, the ratio K / W between the weft driving interval K and the width W of the tape yarn is set as follows. 1 to 1.2, twisted yarn is used for the warp 15, the ratio H / D between the warp arrangement interval H and the warp thickness D is 3 or more, and the gap (H−D) between the warps The primary fabric 12 is woven by setting it to 1.0 mm or more, the ratio S / K between the stitch gauge S and the weft driving interval K is set to 2 or more, and the ratio G / H between the needle gauge G and the warp arrangement interval H is set to And the apparent thickness M of the pile yarn 13 is (HD) ≦ M in the relationship between the gap (W−D) between the warps and the ratio G / H between the needle gauge G and the warp arrangement interval H. ≦ (HD) × {(G / H) −1}, the apparent thickness M of the pile yarn 13 and the tape thread The pile yarn 13 whose ratio M / W to the width W of the thread 11 is 1 or more is tufted, and at least two warp yarns 15A and 15B are provided between the back stitch 18 and the back stitch 18 adjacent in the needle gauge direction. It is desirable to intervene.
[0011]
That is, in the woven fabric 12 in which the tape yarn 11 is a weft and the ratio K / W between the width W and the driving interval K is 1 to 1.3, the tape yarns 11A and 11B driven back and forth are substantially in close contact with each other. Is doing. For this reason, the entire woven fabric appears to be densely woven at first glance, and when it is used as the primary base fabric 12, it is difficult to obtain a water-permeable tufted pile fabric.
However, the primary fabric 12 is woven by setting the ratio H / D between the warp arrangement interval H and the warp thickness D to 2 or more, and setting the gap (HD) between the warps to 0.3 mm or more. The ratio S / K between S and the weft driving distance K is 1 or more, the ratio G / H between the needle gauge G and the warp arrangement interval H is 1.2 or more, the apparent thickness M of the pile yarn 13 and the tape yarn. When the pile yarn 13 having a ratio M / W of 11 to the width W of 1 or more is used as tufting, at the place where the needle 17 penetrates and the pile 17 is implanted, two pieces constituting one pile 17 ( A pair of pile pieces are vertically overlapped in the stitch direction following the back stitch 18, and the space (14) between the two tape yarns 11C and 11D moving back and forth at the place where the pile 17 is implanted overlaps vertically. With two pile pieces Compressed been spread as down 11C · 11D are folded in the width direction of the flat cross section, so that during the possible gap of thickness portion of the two pile piece length N (2M).
[0012]
For example, when the ratio G / H between the needle gauge G and the warp arrangement interval H is 1.2 (G / H = 1.2), 5 needle gauges (5G), that is, the needle gauge direction (the width direction of the primary base fabric) ), There are two warp yarns 15A and 15B interposed between the adjacent back stitches 18 and 18 at a rate of once per five rows of back stitches, and a pile piece between the two warp yarns 15A and 15B. (17) does not intervene. Therefore, there is a cloth 14 not surrounded by the pile surrounded by the front and rear wefts 11C and 11D and the left and right warps 15A and 15B, that is, the cloth 14 where no pile thread is inserted. Will remain.
The fabric 14 in which the pile yarn is not inserted is doubled by the pile piece 13 in which the space between the two wefts 11C and 11D, which are front and rear, is arranged in two on the left and right, and the apparent thickness M of the pile yarn 13 is doubled. In the fabric 14 in which the elongated pile yarn is not inserted , the coating film of the backing adhesive applied to the left and right warp yarns 15A is formed into an elongated slit hole (14) having a minute length N (N = 2M). A permeable hole (14) is formed in the tufted pile fabric which is easily cracked along 15B and thus finished by cracking of the coating film of the backing adhesive on any of the elongated fabrics 14 following the stitch direction, thereby A water-permeable artificial lawn (16) can be obtained.
[0013]
The length N of the water permeable holes 14 that can be formed as elongated slit holes in the primary base fabric in this way is set by the apparent thickness M of the pile yarn 13 in a state of being tufted into the primary base fabric.
Therefore, the “apparent thickness of the pile yarn” in the present invention is not an apparent thickness in a state where the pile yarn is left in a non-tensioned state, but in a through hole of the primary base fabric that is inserted into and penetrates the primary base fabric. It means the apparent thickness of the pile yarn in a state surrounded by surrounding fibers.
[0014]
The width of the water-permeable holes 14 thus formed can be widened by increasing the ratio H / D between the warp arrangement interval H and the warp thickness D and the gap (HD) between the warps. The length N of the hole 14 can be increased by increasing the apparent thickness M of the pile yarn 13 and the ratio M / W between the apparent thickness M of the pile yarn 13 and the width W of the tape yarn 11. Further, the number of the water permeable holes 14 (distribution density in the tufted pile fabric) can be increased by increasing the ratio G / H between the needle gauge G and the warp arrangement interval H. For example, the ratio G / H can be increased. When the number is two or more, the water-permeable holes 14 can be formed between the back stitch rows and the back stitch rows.
Therefore, the ratio H / D between the warp arrangement interval H and the warp thickness D is set to 3 or more, the gap (H-D) between the warps is set to 1.0 mm or more, and the needle gauge G and the warp arrangement interval are set. It is desired that the ratio G / H to H is 2 or more, and the ratio M / W between the apparent thickness M of the pile yarn and the width W of the tape yarn 11 is 2 or more. Is a twisted yarn having a non-flat cross section, and more preferably, when the ratio G / H between the needle gauge G and the warp arrangement interval H is 2 or more, the apparent thickness M of the pile yarn 13 is: In the relationship between the gap between the warps (HD) and the ratio G / H between the needle gauge G and the warp arrangement interval H, (HD) ≦ M ≦ (HD) × {(G / H) − 1} so that the ratio M / W of the apparent thickness M of the pile yarn 13 and the width W of the tape yarn 11 is 1 or more. Then it is effective.
[0015]
More specifically, the weft 11 is a polypropylene tape yarn having a width W of 2 mm, like a tape yarn of a tape yarn woven base fabric commonly used as a primary base fabric of tufted carpet. In the primary base fabric 12 woven with a warp 15 of polyester filament fiber filament yarn having an apparent thickness D of 0.3 mm twisted at 1500 denier and a warp arrangement interval H of 2 mm, the weft driving interval is The ratio K / W between K and the width W of the tape yarn is 1.1, the ratio H / D between the warp arrangement interval H and the warp thickness D is about 7, and the gap between warps (HD) is 1 .7mm.
In this primary base fabric 12, a 6000 denier vinylidene chloride tape yarn having an apparent thickness M of 2 mm is used as a pile yarn 13, and a ratio S / K between a stitch gauge S and a weft driving interval K (2.2 mm) is n, When tufting with the ratio G / H between the needle gauge G and the warp arrangement interval H (2 mm) as m, n tape yarns 11 are interposed between the piles in the stitch direction and the back in the needle gauge direction. The interval between the stitches and the back stitch is mx (HD), and there is a gap between the warp yarns of mx (HD) -M, which is the back thickness between the back stitch and the back stitch, minus the apparent thickness of the pile yarn. It will be.
When tufting with a stitch gauge S of 7 mm in a tufted machine with a needle gauge G of 5/16 mm (about 8 mm), the ratio S / K (n) between the stitch gauge S and the weft driving distance K is about 3, and the weft The ratio between the needle gauge G and the warp arrangement interval H is G / H between the weft tape yarns of the fabric at a rate of once for every three tape yarns and twice the apparent thickness M of the pile yarn (N = 2M). (M) is 4, and between the back stitch and the back stitch, m × (HD) −M = 4 × (2-0.3) −2 = 4 × 1.7−2 = 4.8 mm A corresponding gap (H−D = 1.7 mm) between the warps remains.
[0016]
By the way, when the ratio G / H (m) of the needle gauge G to the warp arrangement interval H is 4, it means that the pile is tufted at a rate of 1 per 4 warps, that is, the primary direction in the needle gauge direction. The pile is tufted at a rate of 1 out of 4 of the fabrics of the base fabric and the remaining 3 pile yarns do not pass through the pile , meaning that the pile remains untoughed, between the back and back stitches. The gap between the warp yarns corresponding to 4.8 mm (HD = 1.7 mm) is left, which means that the pile yarn is not tufted and the pile yarn thread has the original 1.7 mm gap. This means that there are 4.8 ÷ 1.7 = 2.8 unfinished fabrics, ie at least two.
And since the length N of the fabric next to the tufting portion is 4 mm, which is twice the apparent thickness M of the pile yarn, the remaining two pieces without the tufting remain with the original 1.7 mm gap. Each of the fabrics through which no pile yarn is inserted constitutes the water-permeable holes 14 having a length N of 4 mm and a width (HD) of 1.7 mm.
[0017]
In order to finish the tufted pile fabric by applying the backing adhesive without closing the cloth 14 through which the long and thin pile yarn is not inserted , a high pressure air current is applied to the backing application surface of the backing adhesive. It is preferable to break the coating film of the backing adhesive that can be formed on the cloth 14 through which the pile yarn is not inserted, and then pass through the heating zone to solidify the backing adhesive.
In that case, the backing adhesive to be applied to the backing is not blocked, and even if the backing adhesive is applied and blocked, the coating 14 is cracked and the fabric 14 where the pile yarn is not inserted is formed. In order to remain as water-permeable holes, the gap (H-D) between the warp yarns should be at least 0.3 mm, preferably 0.5 mm or more, more preferably 1 mm or more.
In particular, when the ratio G / H (m) between the needle gauge G and the warp arrangement interval H is set to be large, a large water-permeable hole is formed in which a plurality of adjacent pile yarns 14 through which pile yarns are not inserted are gathered. Therefore, it is preferable to make the apparent thickness D of the warp partitioning between the adjacent fabrics thinner than the gap (HD) between the warps by twisting.
For this purpose, the needle gauge G and the needle gauge G are used so that the number of fabrics not inserted into the pile yarn that remains without being tufted and the gap (H-D) between the warp yarns remains unchanged is 2 or more, preferably 3 or more. The ratio G / H (m) of the warp arrangement interval H is 4 or more, and the ratio D / (HD) between the apparent thickness D of the warp and the gap (H-D) between the warps is 0.5. Below, preferably 0.3 or less and generally 0.5 to 0.1, which makes it difficult for the backing adhesive to be applied to the warp, and the temporary backing adhesive is adjacent. Even if a few pile yarns are applied so that they are not inserted , the adhesive coating for the backing is the length of a thin warp that separates the adjacent pile yarns that are not inserted The number of cracks that are easily cracked along the thickness direction Permeability hole 14 can be easily caused by the pile yarns of the insertion that are not weft of.
[0018]
The tape yarn 11 used for the weft may be one obtained by simply cutting a plastic film into a long and thin tape shape, or by frequently folding a wide range of tape shapes into a plurality of layers by folding them in the width direction. Also, a slit yarn or a split yarn having slits in the length direction of the plastic film may be used as long as it has a tape shape. On the other hand, the warp yarn 15 may be a spun yarn or a multifilament yarn, or may be a slit yarn or a split yarn if the cross section is round like a twisted spun yarn or a multifilament yarn. As long as the ratio D / (HD) between the apparent thickness D and the gap between warps (HD) is 0.5 or less and the gap between warps (HD) is 0.3 mm or more, the tape Yarn can also be used for the warp 15.
The base fabric according to the present invention is a woven fabric in which warp and weft are orthogonal, the warp is continuous in the length direction of the base fabric, and the base fabric is directed to the tufted machine in the length direction of the warp. The pile yarn is continuously tufted on the base fabric. For this reason, the pile and back stitch which each pile yarn forms continuously will continue in parallel with the length direction of the warp which constitutes the base fabric. Therefore, the warp constituting the base fabric of the present invention means a yarn that lasts long in the continuous direction of the back stitch formed by each one pile yarn, and the weft constituting the base fabric. Means a yarn that lasts long in the direction crossing the back stitch continuous direction, and the difference between the warp and the weft constituting the base fabric is identified by the back stitch continuous manner.
[0019]
【The invention's effect】
According to the present invention, as described above, in the woven fabric 12 in which the tape yarn 11 is a weft and is densely woven without gaps between the tape yarns 11A and 11B, the ratio of the warp yarn thickness D to the temporary warp arrangement interval H is H / The warp yarns 15 are arranged with a large gap (nD = HD) which is several times n of the warp thickness D in the difference (HD) between the arrangement intervals H and the thickness D between the warp yarns with D being 2 or more. However, in a normal state such as a conveyance process, misalignment hardly occurs, but when pressed in the width direction, the tape yarn 11 is easily deformed into a non-flat cross-sectional yarn by reducing the width W, and the pressing in the width direction is performed. When unraveled, the tape yarn 11 is stretched in the width direction by the elastic recovery force accumulated by the pressing and easily restored to the tape yarn 11 having the original flat cross section. Therefore, the tape yarn 11 is moved in the stitch direction by the needle 19 inserted into the primary base fabric 12 during tufting. Eyes The deflection of the needle 19 in the stitch direction is alleviated by the misalignment, and when the needle 19 is pulled out, the pile 17 is strongly gripped by the elastic recovery force of the tape yarn 11 accumulated by the misalignment. The
[0020]
In the primary base fabric 12 in which the ratio K / W between the weft driving distance K and the width W of the tape yarn is 1 to 1.3, the misalignment is easy in a normal state as in the tatami mat and the throne. Therefore, it does not occur that the tufting density becomes irregular due to the misalignment of the primary base fabric 12, and as a result, it is completely different from the case of tufting on a net-like primary base fabric with many interstices. Similarly, a water-permeable tufted pile fabric 16 is obtained.
On the other hand, unlike the case where a coarse net-like primary base fabric is used, the present invention eliminates the need for heat setting processing for preventing misalignment of the primary base fabric 12 and setting processing of the fabric with a resin, so that it is only economical. Instead, since the resistance received from the primary base fabric 12 of the needle 19 is reduced, the tufting efficiency is improved.
As described above, since the pile 17 immediately after tufting is securely held between the wefts 11C and 11D, the backing process is also simplified.
[0021]
Thus, according to the present invention, the tufted pile fabric 16 suitable for the permeable artificial lawn can be obtained efficiently and economically.
[Brief description of the drawings]
FIG. 1 is an enlarged perspective view of a primary base fabric and a tufted pile fabric according to the present invention at a tufting location.
[Explanation of symbols]
11 Weft (tape yarn)
12 Primary fabric (woven fabric)
13 Pile yarn 14 Cloth / Slit hole (Water-permeable hole)
15 Warp 16 Tufted pile fabric (artificial lawn)
17 Pile 18 Back stitch 19 Needle

Claims

The flatness indicated by the ratio W / T between the width W and the thickness T is 6 or more. The primary base fabric is constituted and misalignment occurs when the pile yarn is inserted during tufting, and then the pile yarn is elastically restored. The weft yarn ( 11) which has a thickness that can be gripped with a needle and is formed by cutting a plastic film into an elongated tape shape and continuing in the needle gauge direction perpendicular to the stitch direction in which the back stitch forming the pile yarn is continuous. ) , And the ratio K / W between the weft driving interval K and the width W of the tape yarn in the stitch direction in which the back stitch formed by the pile yarn is continuous is 1 to 1.3, and in the needle gauge direction orthogonal to the stitch direction. the ratio H / D of the warp arrangement interval H and the warp thickness D is 2 or more, the gap between the warp yarns (H-D) and is set to more than 0.3mm woven primary backing (1 A), the ratio S / K of the stitch gauge S and weft implantation interval K is 1 or more, the ratio G / H of the needle gauge G and the warp arrangement interval H is 1.2 or more, the pile yarns (13) The pile yarn ( 13 ) in which the ratio M / W between the apparent thickness M and the width W of the tape yarn ( 11 ) is 1 or more is tufted, and at least a part of the pile of the primary base fabric ( 12 ) after tufting A water-permeable tufted pile fabric, wherein the pile ( 17 ) is fixed to the primary base fabric ( 12 ) by applying the backing adhesive without blocking the cloth ( 14 ) through which the yarn is not inserted .

The flatness indicated by the ratio W / T between the width W and the thickness T is 6 or more. The primary base fabric is constituted and misalignment occurs when the pile yarn is inserted during tufting, and then the pile yarn is elastically restored. The weft yarn ( 11) which has a thickness that can be gripped with a needle and is formed by cutting a plastic film into an elongated tape shape and continuing in the needle gauge direction perpendicular to the stitch direction in which the back stitch forming the pile yarn is continuous. ) , And the ratio K / W between the weft driving interval K and the tape yarn width W in the stitch direction in which the back stitch formed by the pile yarn is continuous is 1 to 1.2, and in the needle gauge direction orthogonal to the stitch direction. the ratio H / D of the warp arrangement interval H and the warp thickness D is 3 or more, the gap between the warp yarns (H-D) to be set to 1.0mm or more woven primary backing (1 A), the ratio S / K of the stitch gauge S and weft hammering distance K is 2 or more, the ratio G / H of the needle gauge G and the warp arrangement interval H is 2 or more, the apparent diameter of the pile yarns (13) The pile yarn ( 13 ) in which the ratio M / W of the thickness M to the width W of the tape yarn ( 11 ) is 2 or more is tufted, and at least part of the pile yarn of the primary base fabric ( 12 ) after tufting A water-permeable tufted pile fabric characterized in that a backing ( 17 ) is fixed to the primary base fabric ( 12 ) by applying a backing adhesive without blocking the non-inserted fabric ( 14 ) .

The flatness indicated by the ratio W / T between the width W and the thickness T is 6 or more. The primary base fabric is constituted and misalignment occurs when the pile yarn is inserted during tufting, and then the pile yarn is elastically restored. The weft yarn ( 11) which has a thickness that can be gripped with a needle and is formed by cutting a plastic film into an elongated tape shape and continuing in the needle gauge direction perpendicular to the stitch direction in which the back stitch forming the pile yarn is continuous. ) , And the ratio K / W between the weft driving interval K and the width W of the tape yarn in the stitch direction in which the back stitch formed by the pile yarn continues is 1 to 1.3, and the twisted yarn is warp ( 15 ) , the ratio H / D between the warp arrangement interval H and the warp thickness D in the needle gauge direction orthogonal to the stitch direction is 2 or more, and the gap (H-D) between warps is 0.3 mm or less. The ratio S / K between the stitch gauge S and the weft driving distance K is set to 1 or more on the primary base fabric ( 12 ) set and woven, and the ratio G / between the needle gauge G and the warp arrangement interval H H is 2 or more, and the apparent thickness M of the pile yarn ( 13 ) is the relationship between the gap (H−D) between the warp yarns and the ratio G / H between the needle gauge G and the warp arrangement interval H (H− D) ≦ M ≦ (HD) × {(G / H) −1}, and the ratio M / W between the apparent thickness M of the pile yarn ( 13 ) and the width W of the tape yarn ( 11 ) is 1 or more. The pile yarn ( 13 ) to be used is tufted, and at least two warp yarns ( 15A and 15B ) are interposed between the back stitch ( 18 ) and the back stitch ( 18 ) adjacent to each other in the needle gauge direction. at least a part of the inter-warp (15A · 15B) to Gap between the warp yarns (H-D = 0.3 mm) or wider and plugging the apparent thickness twice the pile yarns (13) inserted through non weft pile yarn length of (2M) (14) A water-permeable tufted pile fabric characterized in that the pile ( 17 ) is fixed to the primary base fabric ( 12 ) by applying a backing adhesive.

The flatness indicated by the ratio W / T between the width W and the thickness T is 6 or more. The primary base fabric is constituted and misalignment occurs when the pile yarn is inserted during tufting, and then the pile yarn is elastically restored. The weft yarn ( 11) which has a thickness that can be gripped with a needle and is formed by cutting a plastic film into an elongated tape shape and continuing in the needle gauge direction perpendicular to the stitch direction in which the back stitch forming the pile yarn is continuous. ) , And the ratio K / W between the weft driving interval K and the width W of the tape yarn in the stitch direction in which the back stitch formed by the pile yarn is continuous is 1 to 1.3, and in the needle gauge direction orthogonal to the stitch direction. The ratio H / D between the warp arrangement interval H and the warp thickness D is 2 or more, the gap between the warps (HD) is 0.3 mm or more, and the gap between the warp thickness D and the warp ( To -D) ratio of D / (H-D) is a primary base cloth woven set to 0.5 or less (12), the ratio S / K of the stitch gauge S and weft hammering distance K The ratio G / H between the needle gauge G and the warp arrangement interval H is 1.2 or more, and the ratio M / W between the apparent thickness M of the pile yarn ( 13 ) and the width W of the tape yarn ( 11 ). The pile yarn ( 13 ) having a thickness of 1 or more is tufted, and the primary base fabric ( 12 ) after tufting has a gap (HD ) between warp yarns of 0.3 mm or more and an apparent thickness M of the pile yarn ( 13 ) . A fabric ( 14 ) that has not been passed through the pile yarn that has been spread out by a pile yarn ( 13 ) that is twice or more (2M or more) pile yarn ( 13 ) , and at least a portion of the fabric that has not been passed through the pile yarn ( 14 ) the pile (17) by backing coated backing adhesive without blocking Permeability tufted pile fabric, characterized in that fixed to is configured Tsugimotonuno (12).