JP5051823B2 - Tile carpet and manufacturing method thereof - Google Patents

Description

  In the present invention, a pattern that repeats in the tuft direction is attached, and the pattern in any one direction of the patterns is larger than 1 times the maximum length of one side of the tile carpet and at intervals that do not become an integral multiple. Because it is given, making use of the difference in the pattern of each tile carpet, so-called design pasting is possible, significantly improving the design of the floor surface during construction and improving the degree of freedom of design grant It can relate to tile carpet.

  Conventionally, tile carpets formed in a predetermined shape have been widely used as floor carpets for buildings and general houses. As the demand for tile carpets has increased, there has been a strong demand for design improvements from the market. By applying a pattern to each tile carpet by printing, or by forming piles made of processed yarn that has been pre-colored Colored tile carpets are provided.

  However, most of the conventional tile carpets have a square shape with a side length of 300 mm to 500 mm, and when the tile carpet with a pattern is laid on the floor surface, it is a joint between the tile carpets. This is not desirable in terms of aesthetics. Therefore, in the tile carpet, the pattern to be applied is limited to a pattern that does not affect the shift and is not conspicuous. That is, it is only applied to each tile carpet or laying tile carpets having different colors for the purpose of improving the design of the floor surface. Furthermore, specifically, when it was laid on the floor surface by giving a pattern having a fine repeat pattern, it was devised so that there is no sense of incongruity of the pattern due to misalignment or the like in the joint portion.

In addition, when a pattern such as a joint displacement or a pattern between tile carpets as described above is applied, the pattern is applied in units of each tile carpet. Therefore, the tile carpet has a relatively large area such as a roll carpet. It is not possible to express a continuous pattern that completes with. Therefore, the tile carpet has a low degree of freedom of design assignment, and the design after laying is poor in quality compared to the design of the roll carpet.

  Furthermore, if only a part of a conventional tile carpet is replaced due to dirt or the like after construction, there will be a difference in appearance between the replaced tile carpet and the surrounding tile carpet, and there are many aesthetic problems. It was.

However, although various techniques for making the joints between the tile carpets inconspicuous are provided (Japanese Patent Application Laid-Open No. 2004-52124, etc.), the tile carpet represents a continuous pattern completed in a relatively large area such as a roll carpet. Technology that resolves the difference in appearance between the tile carpet that has been replaced and the surrounding tile carpet when the technology or a part of the technology in relation to the tile carpet pattern or a part of the tile carpet is replaced is still provided. Absent.

As a means for solving the above-mentioned problems, the present invention provides a tile carpet in which a pile is formed on a base fabric as set forth in claim 1 and a backing layer made of a thermoplastic resin is formed on the base fabric. The pattern that repeats in a direction substantially perpendicular to the tuft direction and the tuft direction is added, and the pattern has a dark color portion and a light color portion, and the dark color portion and the light color portion. Between the dark color and the light color with gradation gradually changing from light to light, and the pattern in any one direction of the patterns is more than 1 times the maximum length of one side of the tile carpet. The present invention provides a tile carpet characterized in that it is provided at intervals that are large and not an integral multiple. According to the first aspect of the present invention, the tile carpet patterns have different patterns, so that the tile carpet can be laid regardless of the direction of the tile carpet, and the floor surface design is imparted when the tile carpet is laid. The degree of freedom increases.

  In addition, the conventional tile carpet has eliminated the uncomfortable feeling of the pattern between the tile carpets by making the joint portion inconspicuous, but according to the present invention, it is 1 to 3 times the maximum length of one side of the tile carpet. Since each tile carpet has a repeat pattern of a certain pattern perpendicular to each other at intervals, the design of the floor surface is different by conspicuous the difference in the pattern between the tile carpets. It is also possible to improve the performance.

  The invention according to claim 2 is characterized in that, in addition to the feature according to claim 1, the tile carpet is rectangular, and the length of one side is 1 to 5 times the length of adjacent sides of the one side. The tile carpet characterized by the above is provided.

The invention according to claim 3 is tufted to form a pile made of an original yarn, and / or after forming a pile, the pile is dyed to form a tuft direction at regular intervals, and It is repeated in a direction substantially perpendicular to the tuft direction , has a dark color portion and a light color portion, and has a gradation having a gradation gradually changing from a dark color to a light color provided between the dark color portion and the light color portion . After providing a backing layer via a binder layer made of a thermoplastic resin on the back of the raw machine with a pattern made of color, the binder and the backing layer are stuck by solidifying the binder layer, and the rectangle is rectangular There is also provided a method for manufacturing a tile carpet, wherein a punching machine for punching is performed so that the length of at least two sides parallel to each other does not become an integral multiple of the repeat interval of the pattern. It is.

  The tile carpet according to the present invention has different patterns, so that it can be laid regardless of the direction of the tile carpet, and there is a degree of freedom in design assignment of the floor surface when laying the tile carpet. improves.

Moreover, traditional carpet tiles for floor design after laying, by as much as possible uniform, was to eliminate the uncomfortable feeling of the pattern between carpet tiles by the tile carpet is inconspicuous. However, according to the present invention, each tile carpet is provided with a repeat pattern of a certain pattern that is given at intervals that are larger than 1 times the maximum length of the tile carpet and not an integral multiple. It is also possible to improve the design of the floor surface and the degree of freedom of design assignment by making the patterns of the tile carpets different, and conspicuously the difference in the patterns between the tile carpets.

  The effect of the tile carpet of the present invention is particularly remarkable when the applied pattern is composed of light and shaded colors having gradation, and can embody a floor surface design that could not be expressed by a conventional tile carpet.

  According to the tile carpet manufacturing method of the present invention, the tile carpet according to any one of claims 1 to 4 can be manufactured, and even though it is a repeat pattern, a substantially similar pattern can be punched with a probability of 2% or less. It is very useful as a manufacturing method for imparting a pattern difference to each tile carpet.

Hereinafter, the present invention will be described in detail with reference to the drawings.
The tile carpet of the present invention is given a pattern that repeats in the tuft direction with respect to the pile formed on the base fabric. The pattern is not particularly limited as long as it repeats in the tuft direction. For example, a pattern that does not cause a certain idea, such as a geometric pattern or a decorative character, is preferable to a pattern that causes an idea such as a floral pattern. This is because the tile carpet of the present invention aims to improve the designability of the entire floor surface and the degree of freedom of design provision by laying the floor carpet at random.

In addition to the tuft direction, the pattern of the tile carpet of the present invention may be repeated in a direction substantially perpendicular to the tuft direction. When the pattern of the tile carpet of the present invention is provided with a pattern that repeats in a direction substantially perpendicular to each other, it is preferable from the viewpoints of design properties and improvement in freedom of design.

Of the patterns repeated in the tuft direction attached to the tile carpet of the present invention, any one of the patterns is given at an interval larger than 1 times the maximum length of the tile carpet and not an integral multiple. The reason is that the pattern attached to the tile carpet is larger than 1 times the length of the maximum side of the tile carpet and does not become an integral multiple, so that the attached pattern was a repeat pattern. However, the patterns applied to the tile carpets are different from each other, and by combining tile carpets having the different patterns as appropriate, it is not a monotonous design such as repeating the same pattern as in the past, but a novel design. You can embody the floor.

  In addition, the tile carpet of the present invention is not particularly limited as long as it is a shape that can be laid on the floor without a sense of incongruity. For example, in addition to a rectangle, it may be a hexagon, other polygons, or a combination thereof.

  The pattern of the tile carpet of the present invention may be applied by an original yarn, a pile colored by a space die yarn, may be applied by a printing device, or may be applied by both the original yarn and the printing device. There is no particular limitation.

  As a material constituting the tile carpet of the present invention, a material conventionally used for tile carpets can be used. First, the material of the base fabric consists of a sheet such as a woven fabric or a non-woven fabric, as long as the pile can be sufficiently planted and has a strength that does not cause breakage, such as polyester, polypropylene, polyethylene, A sheet made of a synthetic resin such as polyamide, polyvinyl alcohol, polyvinyl chloride, polyacrylonitrile, or polyurethane, natural fibers such as cellulose or wool, or a mixture of two or more materials, or a mixture of these. Etc. are exemplified.

  The pile material constituting the tile carpet of the present invention is a kind of synthetic resin such as polyester, polypropylene, polyethylene, polyamide, polyvinyl alcohol, polyvinyl chloride, polyacrylonitrile, polyurethane, natural fibers such as cellulose and wool, or The thing which mixed the 2 or more types of raw material, or the thing which mixed these is illustrated.

  Moreover, a polyvinyl chloride resin etc. can be mentioned as a backing layer which comprises this invention tile carpet, and resin which sticks the said backing layer and a base fabric.

  In addition, the shape of the tile carpet of the present invention is preferably rectangular from the viewpoint of easy construction of the floor surface. This is because a normal building is designed and constructed in units of modules, and when a tile carpet is laid on the floor of the building, a rectangular shape is easy to construct.

When the tile carpet of the present invention is rectangular, the length of one side of the tile carpet adjacent to each other is 1 to 5 times, more preferably 1 to 4 times the one side. The reason is that when the length of one side and the length of the adjacent side of the side are significantly different, it is easy to give designability and a novel design, but handling properties and laying work during construction are easy. This is because it may become difficult to cause problems in terms of workability.

More specifically, in the case of a square, the building on which the tile carpet of the present invention is laid is designed and constructed in module units, and from the viewpoint of workability such as handling when laying the tile carpet. In the case of a length of one side and a rectangle, the length of the longer side, preferably 100 mm to 1500 mm, more preferably 250 mm to 1000 mm.

Moreover, you may comprise the pattern attached | subjected to this invention tile carpet from the color of the shade which has a gradation. By constructing such a pattern from light and shaded colors having gradation, it is possible to embody a novel design that could not be expressed in the past. The color in the present embodiment is not particularly limited as long as it has gradation, and may be a single color or a plurality of colors may be mixed.

  In addition, when the pattern of the tile carpet of the present invention is composed of a light and shaded color having gradation, the tile is embodied on the floor surface from the viewpoint that a novel design can be given to the floor surface. A rectangular shape is preferable as the shape of the carpet, and it is particularly preferable that the length of one side is 500 mm to 1000 mm and the length of the side adjacent to the one side is 500 mm.

  Furthermore, from the viewpoint of suppressing the probability of producing a tile carpet having a substantially similar pattern to 2% or less, the repeat interval of the pattern is 3.6 times the length of one side in the tuft direction of the tile carpet. It is preferable.

  The tile carpet of the present invention can be produced by tufting a base fabric, forming a pile, and / or dyeing the pile after forming the pile, so that they are perpendicular to each other at regular intervals. After providing a backing layer through a binder layer made of a thermoplastic resin on the back of the raw machine to which a pattern to be repeated is applied, the binder and the backing layer are adhered by solidifying the binder layer, and the shape is fixed. A punching machine for punching is characterized in that at least two sides parallel to each other are punched so as not to be an integral multiple of the repeat interval of the pattern.

  In the method for producing a tile carpet of the present invention, a pile is first formed by tufting a substrate. From the viewpoint of preventing joint space of the tile carpet, it is preferable that the stitches of the tuft and the gauge are 11.0 or more and the gauge is 1/8 or more, respectively.

As described above, the material of the base fabric may be any material as long as it is made of a sheet such as woven fabric or non-woven fabric, and can sufficiently plant a pile and has a strength that does not cause breakage. From synthetic resins such as polyethylene, polyamide, polyvinyl alcohol, polyvinyl chloride, polyacrylonitrile, polyurethane, natural fibers such as cellulose and wool, or a mixture of two or more materials, or a mixture of these The sheet body etc. which become are illustrated.

  In addition, as for the material constituting the pile, one kind of a synthetic resin such as polyester, polypropylene, polyethylene, polyamide, polyvinyl alcohol, polyvinyl chloride, polyacrylonitrile, polyurethane, natural fibers such as cellulose, wool, or two or more kinds of materials. The thing which mixed these, or the thing which mixed these is illustrated.

  Next, a pattern is formed on the surface by a pile planted on the substrate. As described above, the pattern may be attached by an original yarn, a pile colored by a space die yarn, may be attached by a printing device, or may be attached by both the original yarn and the printing device. There is no particular limitation. Further, the direction of applying the pattern of the tile carpet of the present invention does not necessarily need to be parallel to or perpendicular to the pile tuft direction, and is arbitrary as long as the above requirements are satisfied.

Next, a binder such as polyvinyl chloride resin is applied to the surface of the backing layer of the backing layer made of one or more of polyvinyl chloride resin, polyethylene, polypropylene, and ethylene-vinyl acetate copolymer resin. Adhere by drying. As a drying method, any known drying method such as hot air drying or reduced pressure drying can be used.

Further, a punching machine for punching the base material bonded through the backing layer and the binder layer into a fixed shape is punched so that at least the length of two sides parallel to each other does not become an integral multiple of the repeat interval of the pattern. . Although the shape in the case of punching out the base material stuck through the backing layer and the binder layer is arbitrary, a rectangular shape is preferable from the viewpoint of easy handling such as storage of tile carpet.

EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.
Example 1
An original yarn (2540 dtex: 660 dtex / 30 f × 4 PLY-nylon 66) is applied to a base fabric (trade name: Marix-Unitika Ltd.) with a pattern repeat of 1800 mm in the tuft direction and 1800 mm in a direction perpendicular to the tuft direction. Thus, a pile was planted on the base fabric by a needle shift method. A plan view of the base fabric on which the pile is planted is shown in FIG. As shown in FIG. 1, a pile in which a pattern is planted on a base fabric by dark and light colors and gradations is attached. Next, the base fabric in which the pile is planted is applied by applying a backing layer of about 1 mm and a pasty polyvinyl chloride resin through a glass mat (weight per unit area: 30 g / m ² ) and gelling by overheating. I let you. Further, the tile carpet of the present invention was obtained by cutting at 500 mm square. In FIG. 2, a solid line represents a cut portion of the base fabric in which the pile to which the backing layer or the like is bonded is implanted.

(Example 2)
A tile carpet of the present invention was obtained in the same manner as in Example 1 except that a light-colored original yarn was used from Example 1 and that it was cut to 250 mm in a direction perpendicular to the tuft direction and 1000 mm in a direction parallel to the tuft direction ( The present invention tile carpet 1). In addition, by using a dark original yarn, it was darker than the tile carpet 1 of the present invention and was cut into 250 mm in a direction perpendicular to the tuft direction and 1000 mm in a direction parallel to the tuft direction. In the same manner as in No. 1, a tile carpet of the present invention was produced (invention tile carpet 2). Further, by using a dark original yarn, the tile carpet 2 of the present invention was made darker and cut to 500 mm square by the same method as in Example 1 to obtain the tile carpet of the present invention (this book) Invention tile carpet 3). Furthermore, by using a dark original yarn, the tile carpet 3 of the present invention was made darker, and was cut into 500 mm squares in the same manner as in Example 1 to obtain the tile carpet of the present invention ( The present invention tile carpet 4).
Further, the tile carpets 1, 2, 3, and 4 of the present invention were designed on the floor surface, and an example of the plan view is shown in FIG.
As can be seen from FIG. 3, by applying the design, a novel design that could not be expressed by the conventional tile carpet could be given to the floor surface.

The base fabric which comprises this invention tile carpet, Comprising: The top view of an example base fabric which planted the pile is shown The top view which illustrated the cutting part to the sheet-like material of an example to which the backing layer etc. were joined to the base fabric which planted the pile which comprises this invention tile carpet is shown. The top view of the state which applied the design tile of this invention tile carpet 1, 2, 3, and 4 to the floor surface was shown.

Explanation of symbols

1: base fabric 21 in which a pile is planted: sheet-like material 22 in which a backing layer or the like is joined to a base fabric in which a pile is planted 22: a cut portion 23: a tile carpet 35 of the present invention 35: a tile carpet 1 of the present invention
36: The present invention tile carpet 2
37: The present invention tile carpet 3

Claims (3)

A tile carpet in which a pile is formed on a base fabric and a backing layer made of a thermoplastic resin is formed on the base fabric,
By coloring the pile, a tuft direction and a pattern that repeats in a direction substantially perpendicular to the tuft direction are attached,
The pattern has a dark color portion and a light color portion, and is composed of a light and dark color having a gradation gradually changing from a dark color to a light color provided between the dark color portion and the light color portion ,
The tile carpet according to any one of the above-mentioned patterns, wherein the pattern in any one direction is provided at an interval that is larger than 1 times the maximum length of one side of the tile carpet and does not become an integral multiple.   2. The tile carpet according to claim 1, wherein the tile carpet is rectangular, and a length of one side is 1 to 5 times a length of adjacent sides of the one side. By tufting and forming a pile made of the original yarn, and / or after forming the pile, the pile is dyed to repeat the tuft direction at regular intervals and in a direction substantially perpendicular to the tuft direction. And a living machine having a dark color portion and a light color portion, and a pattern made of a light and dark color having a gradation gradually changing from a dark color to a light color provided between the dark color portion and the light color portion . After providing a backing layer on the back surface through a binder layer made of a thermoplastic resin, the binder layer is solidified to adhere the raw machine and the backing layer, and at least parallel to each other with a punching machine for punching into a rectangle A method for producing a tile carpet, wherein the two sides are punched so that the length of the two sides does not become an integral multiple of the repeat interval of the pattern.

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