JP4084337B2 - Manufacturing method of artificial tatami mat - Google Patents

Description

  The present invention relates to a method for producing an artificial tatami mat using forged grasses produced from a thermoplastic synthetic resin.

FIG. 6 is an explanatory diagram of a method for producing the forged grass and the method for producing an artificial tatami mat table using the imitation grass.
That is, in the production of a conventional artificial tatami mat, as shown in FIG. 6 (A), a thin film cylindrical body of a thermoplastic plastic such as P or P is formed by an inflation device through a feeder, a mold, and a cooling device. While running as a two-layer (two sheets) form of raw film with a roll, it is cut and divided into a tape piece of raw tape with a cutter, and each tape piece of the two-layer form of film is heated to a pinch roll. → Two stages of hot plate heating and stretching are applied by a heating device, and the film is wound on a winding roll as a tape raw yarn in the form of a two-layer film.

Next, as shown in FIG. 6 (B), the tape yarn from the take-up roll is randomly converged and heated by a converging device (nozzle) heated to 270 to 280 ° C. Molded into a prairie yarn consisting of epidermis, cooled with a blower, and then run in a hot water bath at 80-100 ° C for 3 seconds, convergence rate of about 0.35% (3.5mm / 1m) The “primary annealing” treatment for shrinkage is performed, and a fixed size is cut by a cutter through a cooling process to obtain imitation grass for a fragment loom.
This “primary annealing” process is a process of forming the tape raw yarn into the steppe yarn with a heat converging device. It is caused by fusing spots due to thermal expansion and explosion of the air that has entered the tape raw yarn, and uneven heat shrinkage. Because the prairie yarn is deformed or flattened, the outer shape of the molded prairie yarn is shaped by thermal expansion so that the cross-section is almost close to a perfect circle, giving straightness and the weft of the fragment loom. In order to make it usable as a strip, it is an indispensable process step in imitation grass production using a conventional heat converging apparatus.

Then, the imitation grass cut into a certain size was manually bundled into a imitation grass bundle, and as shown in FIG. 6 (C), it was put into the heat treatment space as “secondary annealing”, and the temperature was around 50 ° C. 6 for 12 hours, a residual shrinkage is manifested by shrinkage with a shrinkage of 0.65% (6.5 mm / 1 m), and then subjected to natural cooling treatment for about 4 hours to form a weft for weaving. As shown in (D), the product is supplied to a fragment loom and woven into an artificial tatami mat. As shown in FIG.
For floor heating tatami mats and the like that tend to shrink during use, the product lot is further subjected to heat relaxation treatment at around 50 ° C. for about 72 hours as necessary.
This “secondary annealing” treatment is to prevent the shrinkage of the imitation grass under a tolerable environment and impart commercial value to the artificial tatami mat, and is applied to the imitation grass that is thermoformed and manufactured with a plastic film. Is an essential processing step.
Japanese Patent No. 3195968 (JP-A-6-122163)

  In the process of forming the tape raw yarn into the steppe yarn using a heat converging device, the forged grass produced by the method of the conventional example (FIG. 6) is subjected to thermal expansion and explosion due to the air swallowed together with the tape raw yarn. In addition to causing flaws and flaws on the tape, an irregular heat-shrinking action occurs in the tape yarn, and the grassland yarn shrinks and becomes flattened. It is necessary to expand and shape the cross section so that it is almost a perfect circle.

In addition, even after cutting the forged weeds as wefts for weaving, as shown in FIG. 6 (C), a long-time secondary annealing process and a long-term natural cooling are required. When putting it in, it is necessary to manually arrange each bundle imitation grass so that it will not be disturbed and to bundle it. If the second annealing is performed, the fragment imitation grass is entangled with each other. As shown in FIG. Therefore, the handling work of the fragment imitation grass was a cumbersome and time-consuming work requiring attention.
Therefore, each of the essential primary annealing treatment and secondary annealing treatment is a significant reduction in the production cost of imitation grass in terms of heat energy consumption, thermal management, treatment time management, occupied space, required labor, etc. It was an inhibiting factor.

  The present invention relates to the production of artificial tatami mats using conventional forged grasses, high quality artificial tatami mats for all processes of imitation grass production, imitation grass shape stabilization treatment surface, weaving surface, It was completed through trial and error in research, experimentation, and implementation so that it could be manufactured reasonably and highly efficiently. At the manufacturing stage of imitation grass, the cross-section was almost a perfect circle and suppressed fusing spots. The imitation grass 22 was made into a large straightness imitation grass 22 which was made, and the secondary annealing before weaving was omitted, and the imitation grass was woven into an artificial tatami mat with heat shrinkage inherent. After weaving, the product lot stage Thus, an annealing process for removing the residual shrinkage is performed, and the production efficiency is high and a high-quality artificial tatami mat can be provided at low cost.

In the present invention, a tape raw yarn 12 made of a thermoplastic synthetic resin film stretched in the longitudinal direction is converged and inserted into a heated convergent molding nozzle 15 through an air vent hole 15P disposed in a constricted portion 15M of the convergent molding nozzle 15. Then, the air entrained with the tape yarn 12 is released and removed, so that molding is performed while suppressing the air explosion in the nozzle molding portion 15D, and the fusion of the fusion spot 22W is suppressed on the outer periphery of the core portion 22C. Weaving imitation grass 22 having a substantially round cross section and straightness, obtained by heat molding into a grassland yarn 17 provided with an epidermis skin 22S, as wefts with inherent heat shrinkage, In the state of the product lot 25 after weaving, heat relaxation treatment is performed to remove the heat shrinkability of the imitation grass 22 to obtain an artificial tatami mat product.
In addition, imitation grass refers to a state in which the imitation grass develops heat shrinkage due to the heating action in a durable environment as a tatami surface. This includes imitation grass that has undergone subsequent primary annealing.

“Large straightness” means that the piece loom has straightness that does not cause a horizontal insertion error. If the bending displacement is within 1 cm per 10 cm of the tip of the weft, it will fly. It is possible to run sideways, and if there is a bending displacement of 1 cm or more per 10 cm, that is, a weft that is displaced from the weft axis by 1 cm or more to the side, frequent flying mistakes occur.
That is, “large straightness” means that the straightness (10 cm long weft / cm bending displacement) is 10 or more.
Accordingly, the imitation grass 22 of the present invention may have improved cross-sectional roundness and straightness by the primary annealing treatment after the conventional I grass thread molding, but typically, as shown in FIG. By using the new convergent mold nozzle 15 shown in the figure, imitation grass that is formed in the grass step 17 by forming it into a grass portion 17 having a substantially round cross section and a straightness and cooling and solidifying the grass step 17. It is.

According to the present invention, secondary annealing (thermal relaxation treatment) in the state of imitation grass before weaving, which is a conventional essential processing step, can be simplified.
That is, when the imitation grass manufactured in the conventional example is adopted, the secondary annealing process before weaving which requires manpower and time can be omitted, and the imitation grass obtained with the new convergent molding nozzle of FIG. 3 is adopted. In this case, the primary annealing process and the secondary annealing process can be omitted.
In this case, by using the convergent molding nozzle 15 shown in FIG. 3, the air that has entered the nozzle throttle portion 15M together with the tape raw yarn 12 is thermally expanded. However, excess air in the throttle portion, that is, the front molding portion 15M, In other words, since the surplus air than the amount of air necessary to form the air void AV is eliminated by the imitation grass core portion 22C, the air explosion in the nozzle molding portion 15D can be extremely suppressed, and the The fusion coating of the grass thread becomes a beautiful fused skin 22S with suppressed fusion spots, and has a substantially round cross section with a high roundness (minor axis / major axis) and is excellent in straightness. 17 can be molded .
Therefore, an artificial tatami mat table with few scratches caused by fusing spots and less dirt due to fuzz and dust adhesion can be obtained .
In addition, after the weaving process, the morphological stabilization process as a woven fabric (artificial tatami mat) is performed by one thermal relaxation process, so the morphological distortion generated during the weaving process can be corrected at the same time, and after the morphological stabilization at the imitation rush stage. The product is more reliable than the woven fabric (artificial tatami mat).

  In other words, in the conventional heat relaxation treatment (secondary annealing treatment) at the imitation grass stage, the treatment is performed in a state where a certain amount of artificial imitation grass is manually gathered in a concentrated state. However, in order to generate a weft insertion error in a subsequent loom, the work of gathering together a certain amount of dissimilar pieces of imitation grass requires manual and careful work. The thermal relaxation treatment after the formation is a simple handling work in the form of a roll of fabric, so the thermal relaxation treatment after making the fabric (artificial tatami mat) from the work surface is also a piece before weaving. Much more labor saving and rationalization than the secondary annealing process in the imitation grass stage.

  Further, in the present invention, the imitation grass 22 discharges and removes the air entrained together with the tape yarn 12 through the air vent hole 15P disposed in the throttle portion 15M of the convergent molding nozzle 15, thereby forming the nozzle molding. It is preferable to perform molding while suppressing air explosion in the portion 15D, and to form the fusion skin 22S in which the fusion spots 22W are suppressed on the outer periphery of the core portion 22C.

In this case, by using the convergent molding nozzle 15 shown in FIG. 3, the air that has entered the nozzle throttle portion 15M together with the tape raw yarn 12 is thermally expanded. However, excess air in the throttle portion, that is, the front molding portion 15M, In other words, since the surplus air than the amount of air necessary to form the air void AV is eliminated by the imitation grass core portion 22C, the air explosion in the nozzle molding portion 15D can be extremely suppressed, and the The fusion coating of the grass thread becomes a beautiful fused skin 22S with suppressed fusion spots, and has a substantially round cross section with a high roundness (minor axis / major axis) and is excellent in straightness. 17 can be molded.
Therefore, an artificial tatami mat table with few scratches caused by fusing spots and less dirt due to fuzz and dust adhesion can be obtained.

Further, in the present invention, the grass yarn 17 drawn from the convergent molding nozzle 15 is made into the product imitation grass 22 in a state where it is drawn by the take-up rolls 20 and 21 through the cooling tank 19, and the imitation I It is preferable to use the grass 22 as a weft.
In this case, the grass thread 17 drawn from the nozzle 15 has a satisfactory shape for both the roundness of the cross section and the straightness, so that when it is cooled and solidified, the heat shrinkability is inherent, but it is used as a weft. It is possible to cut into pieces of fixed-size pieces and weave them with a piece loom like a conventional piece imitation grass or supply imitation grass to a loom in a continuous state. is there.

Therefore, the stepped yarn 17 can be used as a weft for weaving by cutting it into a fixed size or in a continuous state only by cooling. Circularity improving processing, that is, primary annealing is not required.
And, the present invention is woven with heat shrinkage inherent, and in order to heat-stabilize all at once in the state of the woven lot, omission of primary annealing in imitation grass production process, and after imitation grass production, Artificial tatami mats can be manufactured without omission of secondary annealing in the state of fragmented grass before weaving. Compared with the manufacture of conventional artificial tatami mats, thermal management and passage of primary annealing in the process of imitation rush production High-quality artificial tatami mats with higher quality than conventional methods, with significant advantages in manufacturing, such as speed management, rationalization of equipment space, and the delicate and complicated work of secondary annealing. Can be provided at low cost.

In the present invention, as shown in FIG. 1, it is preferable that the imitation grass 22 drawn by the take-up rolls 20 and 21 is directly supplied to the loom 23 through the relaxation zone Z in a continuous form.
In this case, the imitation grass 22 is continuously drawn at a constant speed by a take-up roll, and in the loom 23, it is cut and fed at every weft insertion opening of continuous wefts and is inserted at high speed intermittently. However, the consumption per hour (consumption length) as a weft in the loom and the take-up amount per hour (take-off length) of the imitation grass 22 on the take-up rolls 20 and 21 are set consistently. Accordingly, the imitation grass 22 can be produced and the weaving action of the imitation grass can be continued in the presence of the relaxation zone Z.
In addition, imitation grass in a continuous form drawn out as a product can be woven even if there are insufficient roundness and straightness, which is difficult to weave as a conventional fragment weft. By the thermal relaxation treatment after the tatami surface fabric is formed, an artificial tatami surface that can withstand use can be obtained.
Accordingly, the manual supply operation of the product imitation grass 22 to the loom 23 can be omitted, the process from the production of the imitation grass 22 to the weaving of the artificial tatami surface can be rationalized, and the imitation grass 22 to be manufactured is a product. Without any loss, the entire amount can be used and weaved as wefts, making it possible to provide artificial tatami mats at low cost.

In the present invention, it is preferable that the imitation grass 22 is woven in a wide width allowing for heat shrinkage.
In this case, if the grassland yarn 17 is cooled and woven into the weft, the heat shrinkage rate is about 2%. The heat shrinkage of the imitation grass 22 can be dealt with.
The imitation grass 22 is woven in a state where heat shrinkage is inherent, and after the weaving, imitation grass that omits primary annealing and secondary annealing, or imitation grass that omits only secondary annealing. If the amount of heat shrinkage of the imitation grass 22 used in advance is known, the heat-shrinkable removal by heat relaxation treatment only once at the time of product, a thermally stable tatami mat with a predetermined woven width Finished in the product, the generation of width cutting waste during folding can be suppressed to a minimum, and folding with good yield becomes possible.

In the present invention, the heat relaxation treatment is preferably annealing of the product lot 25 in a heat space of about 65 ° C. for 24 hours or more and 36 hours or less.
In this case, it is preferable to arrange the heat space in the form of a sealed chamber so that a large number of lots can be heated evenly by a straw rack, a wire mesh shelf, etc., and the heat source is a uniform heating of the room such as gas, electricity, steam, etc. I can do it.
In addition, one lot may be a normal roll-up (standard: 10 mm).
Further, the heat treatment time and the treatment temperature are important factors for preventing heat shrinkage in a range that does not cause discoloration and in a serviceable environment. It is a temperature that is not less than the upper limit of heating received in the environment and does not cause thermal alteration such as heat softening in imitation grass.
As a result of the sample experiment, in an environment of about 65 ° C., the 10-winding lot (normal lot) can be completely prevented from shrinking by treatment for 24 hours or more, and the treatment for 36 hours or more It was found that fading occurs on the outer surface.
Therefore, annealing at around 65 ° C. for 24 to 36 hours can impart complete heat shrinkage prevention to the product lot under a usable environment as a tatami mat without causing fading.

Further, in the present invention, the tape raw yarn 12 is formed by the heating rolls 7, 8, and 9 that guide the double-layer raw tape 61 of a film having a width of 23 to 30 mm and a thickness of 40 to 50 μm in a bent form. It is preferably a two-layered film having a film thickness of 7 to 10 μ stretched about 5 times in the longitudinal direction with some stretching in the width direction.
In this case, the two sheets of the raw film 61 may be overlapped by using a two-layered original film of a cylindrical film formed by an inflation device. Like the original film of the conventional example (FIG. 6), Preparation at low cost is possible.

  In addition, if a cylindrical film has an infinite number of vertical rods arranged on the surface with an inflation device, it is possible to avoid layering and integration of two tapes at the time of heat stretching treatment with the raw tape 61, In addition, the tape raw yarn is bulky even during the converging molding operation in the converging molding nozzle 15 and can reduce the frictional resistance with the inner peripheral surface of the nozzle molding portion 15D. An effect of suppressing the occurrence of spotting can be expected, which is advantageous for the formation of the uniform fused skin 22S and the formation of the uniform porous core 22C.

Further, as shown in FIG. 2 (B), when the heating and stretching rolls 7, 8, and 9 are arranged on the upper and lower sides and the original fabric tape 61 is bent and stretched, the original tape 61 and the heating rolls 7, 8, and 9 Due to the interfacial pressure, in the raw fabric tape 61, a slight expansion stress generated in the width direction causes the orientation of the constituent polymer in the width direction, and the fibrillation in the width direction is suppressed more than the uniaxially stretched film. Become.
Therefore, even if the film is stretched about 5 times to form a thin film, it is difficult to fibrillate against stress orthogonal to the stretching direction, and the product imitation grass can suppress the occurrence of fluff during its service life.

  If two film tapes having a film thickness of 7 to 10 μm and a width of 23 to 30 mm are stacked, the production of the tape raw yarn 12 can not only be rationally performed by slitting and hot roll drawing, but also instantaneous heat fusion. Although it is an ultra-thin tape that can be attached, it is possible to form a porous core portion 22C in which finely divided air voids AV are uniformly dispersed, and it is possible to instantaneously form a fusion skin 22S at the nozzle molding portion 15D. Become.

Further, in the present invention, the tape yarn 12 is relaxed between the heating roll 9 and the downstream annealing roll 10 after being stretched in the longitudinal direction with slight stretching in the width direction by the heating rolls 7, 8, 9. Those subjected to relaxation treatment at a rate of 6 to 12% are preferred.
In this case, a high relaxation rate of 6 to 12% is given to the heating roll device that guides the tape raw yarn 12 in a bent form by compactly arranging the water-cooled annealing rolls 10 as shown in FIG. 2B. It becomes possible.
If the internal thermal stress strain (residual strain) is eliminated by sufficient relaxation (relaxation) before being sent to the convergent molding nozzle 15, the thermal stress inhomogeneous action in the thermal molding by the nozzle 15 in the subsequent process is performed. In the thermoformed product (I prairie yarn), it is possible to suppress the occurrence of flattening and bending, and the shape of the straight line in the longitudinal direction and the high roundness (minor axis / major axis) imitation Igusa necessary for wefts for weaving And imitation grass that is easy to weave is obtained.

  In the present invention, imitation grass is woven in a state where heat shrinkage is inherent, and in the state of product lot 25 after weaving, the heat shrinkability of imitation grass 22 is fully expressed by a single thermal relaxation treatment. In order to prevent thermal contraction during the use as a tatami surface, the heat relaxation treatment step in the state of the imitation grass 22 can be omitted, and since the heat relaxation treatment (annealing) after weaving, imitation grass In addition to removing the heat shrinkability of the 22 itself, the morphological distortion generated during the weaving process can be corrected at the same time, and with one annealing (thermal relaxation treatment), an artificial tatami mat with high morphological stability and high quality reliability can be obtained. .

  Further, since the secondary annealing step as the imitation grass can be omitted, it is complicated and cumbersome to converge in a certain amount of parallel state of the separated fragment imitation grass 22 required in the secondary annealing step. Therefore, the heat relaxation treatment after weaving is handled in the wound lot of the fabric, so the workability of the heat relaxation treatment is better than the heat relaxation treatment in the state of the conventional fragment imitation grass 22. By improving productivity by rationalizing labor and time, it becomes possible to provide an inexpensive artificial tatami mat with high quality and reliability.

Further, the imitation grass 22 discharges and eliminates excess air from the amount of air required for forming the air void AV at the imitation grass core portion 22C during the convergence molding by the nozzle 15, and the air explosion in the nozzle molding portion 15D. , And forming into the stepped yarn 17 having high cross-sectional roundness and straightness, it becomes unnecessary to improve the roundness after molding, and even the primary annealing for imparting straightness. by adopting, than conventional imitation rushes process, manufacturing device space plane, thermal management of annealing, at a speed management plane or the like, much imitation Lee grass 22 is obtained by streamlined advantageous production method, conventional High-quality artificial tatami mats, combined with a final and complete annealing process in the product lot after weaving, instead of primary annealing and secondary annealing, is revolutionary productivity Improvement It can be produced in.

  Further, each film tape itself of the tape raw yarn 12 for manufacturing the imitation grass 22 is slightly stretched in the width direction when stretched in the longitudinal direction, and therefore, due to a slight air explosion generated during molding in the convergent molding nozzle 15. However, the fibrillation of the film is suppressed, and the fibrillation of the surface of the imitation grass is also suppressed by the frictional action during the durability as a tatami mat. Therefore, the generation of fuzz that causes dust adhesion and dirt is small. A high-quality artificial tatami mat table that has a clean appearance over a long period of time is obtained.

[Manufacture of tape yarn]
As shown in FIG. 2 (A), the raw roll 6 is made of a raw material in which a conventional anti-glare agent, pigment, and matting agent are mixed with polypropylene resin, as in the conventional example, and a film thickness of 40 to 60 μm (micron) is obtained by inflation processing. ) And a two-ply 600-900 mm wide original film 60 is scraped off.
As shown in FIG. 2B, the original film 60 is cut and divided into 20 to 35 mm widths (ex, 5400d: 34 mm, 3300 d: 21 mm) according to the fineness of the grass to be manufactured by a slitter 6 '. 61, the first heating roll 7, the second heating roll 8, the third heating roll 9 and the water-cooled annealing roll 10 installed vertically are heat-stretched and annealed.

Each heating roll 7, 8, 9 is heated to 130-140 ° C., and the raw fabric tape 61 is guided to bend up and down to be stretched three times between the first heating roll 7 and the second heating roll 8, and the second heating roll 8 The film is stretched twice between the third heating rolls 9 and taken at a drawing take-off speed of 70 mm / min, and relaxed by 6 to 12% between the third heating roll 9 and the water-cooled annealing roll 10, and the tape raw cheese roll 11 Get.
The wound original fabric tape 61 is in a state where two films are stacked, and the thickness of one film is 7 to 10 [mu] m, and the two stacked original fabric tapes 61 are 14 to 20 [mu] m.

  However, even when the tape yarn thickness is 20 μm, there is no problem in the production of thick count (thickness) imitation grass. Since the film 22) can be formed, the tape yarn 12 is formed to a thickness of 7 μm, which is the limit of the film (film) formation with the inorganic agent kneaded plastic, and the width of the tape yarn 12 corresponds to the fineness difference. Is better.

  Then, the tape yarn 12 is composed of the constituent polymer in the length direction of the tape by the pressure stress action with each roll at the time of the heat drawing action in the first heating roll 7, the second heating roll 8, and the third heating roll 9. In addition to the orientation in the length direction (orientation) by stretching, a slight orientation in the width direction is produced, so that it has anti-fibrillation characteristics (characteristics in which longitudinal tearing is less likely to occur) than a hot tape-stretched tape yarn.

[Manufacture of imitation grass]
As shown in FIG. 1, the tape yarn 12 is drawn from the tape yarn cheese winding 11, fitted in a heating device 16 set at 285 to 300 ° C., and heated to 270 to 285 ° C. It is inserted and molded into the grassland yarn 17, cooled and fixed with water (tap water) in a cooling tank 19 through an underwater roll 18, and a powerful take-up device composed of an opposing take-up upper roll 20 and take-up lower roll 21. Take it out at 50 m / sec and send it to the relaxation zone Z at the rear.

In this case, as shown in FIG. 3, the convergence molding nozzle 15 includes a funnel portion 15F for randomly converging the tape raw yarn 12, a constriction portion 15M as a pre-molding portion following the funnel portion 15F, and a subsequent molding portion 15D. An expanded air reservoir 15A is disposed between the pre-molded portion 15M and the molded portion 15D, and two air vent holes 15P communicating from the air reservoir 15A to the nozzle tip 15T are used. .
In addition, the underwater roll 18 guided to the cooling tank 19 has an arc-shaped cross-section guide groove for inserting the round bar-shaped grass meadow yarn 17 into the surface of the roll 18 so as not to flatten the grass grass yarn 17 immediately after molding (see FIG. The one in which (not shown) is arranged is adopted.

  In addition, each drive take-down lower roll 21 and take-up upper roll 20 pair as a powerful take-up device has a structure in which a corresponding arc groove (not shown) is arranged so that no pressing deformation occurs in the grassland yarn 17, Each take-up lower roll 21 on the drive side is made of metal and knurled to prevent slipping on the circumferential surface of the arc groove, and each take-up upper roll 20 is made of rubber so as to suppress the pressure deformation to the grassland yarn 17. While adopting a group of rolls to which a strong gripping force is applied, the grassland yarn 17 is taken up at a take-up speed of 50 m / sec.

  Supply of the tape raw yarn 12 to the converging nozzle 15 is, for example, when the imitation weave degree is 5400d, the nozzle forming hole diameter Ds: 1.09 mm, and the tape raw yarn (two layers of film) thickness: 14 μ (one piece) : 7μ), tape yarn width: 34mm, filling rate: 34%, at 4700d, nozzle forming hole diameter Ds: 0.95mm, tape yarn thickness: 14μ, tape yarn width: 30mm, filling rate : 60%, at 4000d, nozzle forming hole diameter Ds: 0.8mm, tape raw yarn thickness: 14μ, tape raw yarn width: 25mm, filling rate: 71%, at 3300d, nozzle forming hole diameter Ds: 0.66mm, Tape raw yarn thickness: 14μ, tape raw yarn width: 21 mm, filling rate: 86%

[Weaving]
As shown in FIG. 1, the imitation grass 22 drawn out by the take-up upper roll 20 and the take-down lower roll 21 is woven into a warp opening as a weft in a loom 23 through a relaxation zone Z and woven into an artificial tatami mat. To do.
The loom 23 used in the practice of the present invention is provided with a weft continuous feeding device, which was filed as Japanese Patent Application No. 11-666904 and published as Japanese Patent Application Laid-Open No. 2000-355852 by the applicant of the present application. As shown in FIG. 5, relaxation is performed using two imitation grasses running in parallel, which are taken up by the arrangement upper manufacturing apparatus 20, that is, the arrangement imitation grass production section by the take-up upper roll 20 and the take-down lower roll 21. The supply weft is inserted alternately into the loom via the zone Z.

In the relaxation zone Z, the amount of continuous take-up from the upper and lower take-up rolls 20 and 21 is detected while detecting the amount of relaxation of the weft, that is, the imitation grass 22 by the pair of optical sensors of the upper sensor and the lower sensor. And the intermittent weft insertion consumption in the weaving machine, and the weft cut and weaving into the warp opening by weaving and cutting the weft into the weft opening by intermittent contact and separation of the delivery roller to the delivery pulley, The imitation grass 22 drawn out at 21 is directly fed to the loom 23 through the relaxation zone Z.
In addition, when two wefts are inserted alternately, even if the imitation grass produced by each production apparatus has a slight color difference, it is possible to maintain the uniformity of the color mixture on the product tatami mat.

The inventors conducted various tests for confirming the effects of the present invention, and obtained the following test results.
[Imitation grass fluff]
Since the rip 22W on the surface of the grass is the one in which the tape yarn is stretched in the longitudinal direction, if the tear 22W is subjected to a frictional action, it becomes fibrillated and a flaw having a length of 3 mm or more generates fluff even by light friction.

Test conditions: Conventional hot plate stretching is used as the tape yarn.
A is a molded grass with a conventional convergent molding nozzle
In B, a scratch of 5 mm or more generated within 10 m length of the grass was counted by observation with a molding grass microscope (10 times loupe) with the convergent molding nozzle used in the present invention shown in FIG.

A: Scratches 5mm 6mm 7mm Total
4500d 4 1 2 7
4000d 2 3 3 8
3000d 4 2 3 9

B: Scratch 5mm 6mm 7mm Total
4500d 3 1 2 6
4000d 2 1 2 5
3500d 2 1 1 4

As a result, the nozzle used in the present invention can improve large scratches (fissures) of 5 mm or more that cause fluff generation by 66% at 3000d, 35% at 4000d, 15% at 4500d, and the conventional nozzle.
Scratches of 3 mm length or less, especially around 1 mm, occurred in orders of magnitude in the A product compared to the product of B, but such scratches were fluffed immediately when the product (textile) was used. In addition, since the counting operation is extremely difficult and complicated, it was excluded from the counting.
Therefore, even in the case of using a conventional hot tape-stretched tape yarn that is easily fibrillated, the use of a nozzle that is molded while suppressing air explosion in the nozzle molding portion 15D in FIG. It is extremely effective in suppressing scratches.

[Igusa fabric friction test]
In the imitation woven fabric formed by the convergent molding nozzle 15 of FIG. 3 of the present invention, a stretching method of hot plate stretching (5 times stretching) and roll stretching (5 times stretching) at the time of producing the tape yarn. A rubbing test (rubbing test) of the different fabrics was carried out for 15 minutes with a rubber roll having a hardness of 60 degrees, a weight of 500 g, and a width of 30 mm at a moving distance of 5 cm and 35 reciprocations / min.

Test piece: 4500d has a driving density of 176 pieces / 10 cm, 4000 d: 182 pieces / 10 cm, 3300 d: 194 pieces / 10 cm

4500d fabric 4000d fabric 3300d fabric Hot plate stretching 9 (defects) 10 8
Roll stretching 7 7 5

The defects were observed with a microscope (10-fold loupe), and fluff defects having a length of 7 mm or more on the fabric surface within 10 cm ² were counted.
As a result, roll stretching at the time of production of the tape yarn produces an effect of suppressing fibrillation rather than uniaxial stretching by hot plate stretching due to the occurrence of a slight width direction orientation in the tape constituent polymer.

[Thermal relaxation test]
(1) Maximum shrinkage measurement and change after folding No-annealing weft (product imitation grass 22 in which the grassland yarn 17 pulled out from the convergence molding nozzle 15 is pulled out by the take-up roll via the cooling tank 19) A sample of a tatami mat half width (approx. 1 m) with a weaving width (tatami surface width) of 90.3 cm was aged in a heat space by gas combustion (heat relaxation treatment) at 63 ° C for 72 hours (3 days). The heat shrinkage of the tatami mat was examined.

Imitation grass herb fineness Before aging (cm) After aging (cm) Error (cm)
5700d 90.3 88.4 1.9
4700d 90.3 87.6 2.7

Samples were folded on the above-mentioned heat-relaxed tatami surface, lines for detecting the shrinkage of the wefts were applied along the tatami edges, and re-introduced into the gas combustion heat space at 63 ° C. for 72 hours.
It was taken out after 72 hours, and it was visually checked whether or not the coating line was separated from the tatami edge. However, in both 5700d and 4700d products, separation from the tatami edge of the coating line could not be confirmed by visual observation.
That is, in an artificial tatami mat with a tatami mat width of 90.3 cm, woven with imitation grass of no annealing, if the heat shrinkage of 5700d to 88.4 cm and 4700d to 87.4 cm, As a result, it was found that the heat shrinkability of can be completely removed.

(2) Shrinkage measurement and discoloration in product lots 10 tatami rolls (standard lot) weaved with no-annealing wefts are placed in a cardboard box and aged at 63 ° C for 72 hours by gas combustion (thermal relaxation) Processing).
(A) The overall product lot evaluation is as follows:
Imitation grass herb fineness Before aging (cm) After aging (cm) Discoloration
5700d 90.3 88.2 Yes
4700d 90.3 88.1 Yes

(B) Product lot site evaluation is as follows:
Imitation moss fineness Part Before aging (cm) After aging (cm) Error (cm) Discoloration 5700d Inside 90.3 88.1 2.2 None
Intermediate 90.3 88.3 2 None
Outside 90.3 88.1 2.2 Somewhat 4700d Inside 90.3 88.4 1.9 None
Intermediate 90.3 88.2 2.1 None
Outside 90.3 88.2 2.1 Some

As described above, the outer side to which heat is directly applied and the ears (both ends) are discolored by the long-time treatment in the 63 ° C. heat space.

(3) Relationship between Aging Time, Shrinkage, and Discoloration Thirteen belt samples with a weaving width of 90.3 cm and a length (warp direction length) of 20 cm woven with no-annealing imitation grass were prepared. ) Is used as a reference for comparison with other samples. 2-NO. For each of the 13 samples, the aging time was increased every 6 hours to test changes in a 63 ° C. heat space.
The test results are shown in the table below.
As a result of the test, it was found that in heat relaxation treatment (aging) at 63 ° C., complete removal of heat shrinkability could be achieved in 24 hours or more, and discoloration in imitation grass was caused in 36 hours or more.

Sample time (h) Before aging (cm) After aging (cm) Discoloration NO. 1 0 90.3
NO. 2 6 90.3 88.7 No NO. 3 12 90.3 88.6 No NO. 4 18 90.3 88.5 No NO. 5 24 90.3 88.4 NO. 6 30 90.3 88.4 No NO. 7 36 90.3 88.4 Some NO. 8 42 90.3 88.4 Yes NO. 9 48 90.3 88.4 Yes NO. 10 54 90.3 88.35 Yes NO. 11 60 90.3 88.35 Yes NO. 12 66 90.3 88.35 Yes NO. 13 72 90.3 88.35 Yes

(4) Optimum aging in product lots Heat penetration was tested in the interior, middle, exterior, and each part of a product lot of an artificial tatami mat (standard: 10mm winding) woven with wefted imitation grass.
That is, thermocouples for temperature measurement were attached to the inside, outside, and middle part of the product lot, placed in a cardboard box, and inserted into a 63 ° C. heat space for measurement.
As a result, in the 10-winding lot, it was detected that the heat saturation in the middle part took the most time, and that reaching 63 ° C. in the middle part was delayed about 5 hours from the outside.
Therefore, the aging in the 10-winding product lot is over 29 hours, and the heat shrinkability can be completely removed without causing discoloration (thermal fading) of the outer surface portion.

It is a principal part schematic explanatory drawing of this invention. It is a schematic explanatory drawing of this invention, Comprising: (A) is formation of original fabric roll 6, (B) is a figure which shows formation of tape raw yarn cheese winding. It is explanatory drawing of the convergence shaping | molding nozzle used for this invention, Comprising: (A) is a top view, (B) is a vertical side view, (C) is a bottom view. It is imitation grass explanatory drawing obtained by this invention, Comprising: (A) is sectional drawing, (B) is a perspective view. It is explanatory drawing of the loom used for implementation of this invention, Comprising: (A) is a schematic perspective view of a weft sending mechanism, (B) is a schematic explanatory drawing of a relaxation zone. It is explanatory drawing of a prior art example, (A) is a tape raw yarn manufacturing process schematic, (B) is a imitation grass manufacturing process schematic, (C) is a secondary annealing schematic, (D) is a weaving schematic, (E ) Is a product lot schematic.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mixer 2 Extruder 3 Mold 4 Inflation apparatus 5 Pinch roll 6 Original fabric roll 6 'Slitter 7 1st heating roll (heating roll)
8 Second heating roll (heating roll)
9 Third heating roll (heating roll)
10 Annealing roll 11 Tape yarn cheese winding 12 Tape yarn 13, 14 Guide roll 15 Converging molding nozzle (nozzle)
15A Air reservoir 15D Molding part 15F Funnel part 15M Restriction part (pre-molding part)
15P Air vent hole 15T Tip (exit)
16 Heating device 17 Meadow yarn 18 Underwater roll 19 Cooling tank 20 Take-up upper roll (driven roll)
21 Take-down roll (drive roll)
22 Imitation grass (product imitation grass, product i grass)
22C core (core)
22S Fusion skin (fusion film, sheath)
22L, 22L '
22W Scratches
23 Loom 25 Product lot (weaving lot)
60 Original fabric film 61 Original fabric tape AV Air void Ds Molding hole diameter FL Film Ta Expansion taper Z Relaxation zone

Claims (7)

A tape yarn (12) made of a thermoplastic synthetic resin film stretched in the longitudinal direction is converged and inserted into a heated convergent molding nozzle (15), and is placed in the throttle portion (15M) of the convergent molding nozzle (15). The air entrained with the tape yarn (12) is released and removed through the hole (15P), so that molding is performed while suppressing air explosion in the nozzle molding part (15D), and the core part (22C) A large imitation grass with a substantially round cross section and straightness obtained by heat-molding it into a grass thread (17) having a fusion skin (22S) with suppressed fusion spots (22W) on the outer periphery. (22) is weaved using wefts with inherent heat-shrinking properties, and heat-relaxed in the product lot (25) after weaving to remove the heat-shrinking properties of the imitation grass (22). To make artificial tatami mats. The imitation yarn (17) drawn from the convergent molding nozzle (15) is drawn into the product imitation grass (22) in the state drawn by the take-off roll (20, 21) via the cooling tank (19), and the imitation using rushes (22) as Nukijo, preparation of artificial tatami facing of claim 1. The method for producing an artificial tatami mat according to claim 2 , wherein the imitation grass (22) drawn by the take-up roll (20, 21) is fed directly to the loom (23) through the relaxation zone (Z) in a continuous form. The method for producing an artificial tatami mat according to any one of claims 1 to 3 , wherein the imitation grass (22) is woven in a wide width allowing for heat shrinkage. The method for producing an artificial tatami table according to any one of claims 1 to 4 , wherein the thermal relaxation treatment is annealing the product lot (25) for 24 hours or more and 36 hours or less in a heat space of about 65 ° C. The tape raw yarn (12) is slightly heated by a heating roll (7, 8, 9) that guides the double-layer raw tape (61) of a film having a thickness of 23 to 30 mm and a thickness of 40 to 50 μm in a bent form. The method for producing an artificial tatami mat according to any one of claims 1 to 5 , which is a two-layered film having a film thickness of 7 to 10 µ stretched about 5 times in the longitudinal direction accompanied by stretching in the width direction. The tape yarn (12) is relaxed between the heating roll (9) and the downstream annealing roll (10) after being stretched in the longitudinal direction with slight stretching in the width direction by the heating roll (7, 8, 9). The method for producing imitation grass of artificial tatami mats according to claim 6 , wherein 6 to 12% is relaxed.

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