JP5230695B2 - Pile structure material and method and apparatus for manufacturing the same - Google Patents

Description

  The present invention relates to a pile structure material that can be widely used for carpets, various mats, various interior materials such as wall materials and ceiling materials, decorative materials such as wall hangings, and the like, and a manufacturing method and apparatus therefor.

  For example, in a carpet whose surface is made of a pile, a so-called tile-type carpet having a square of several tens of centimeters in width and width appears, for example, instead of the conventional Wilton carpet or Akisminster carpet. In such a tile-type carpet, as exemplified in Patent Document 1 below, a pile length is formed on the surface of a plate-like or thick sheet-like substrate formed of a woven or non-woven fabric, a rubber material, a synthetic resin material, or the like. Accordingly, it has been proposed that a large number of pile yarns cut to a certain length according to the above are bent at the central portion and planted by bonding the bent portions.

  In the case of Patent Document 1, two pile rows in one vertical and horizontal direction are set as a set, and pile yarns for each row are held in a state of being aligned in a horizontal row, which is pulled out in a parallel state, and fixed. The pile yarn is planted by cutting it into lengths, bending the cut pile yarns at the center thereof, and bonding the bent portions to the surface of the substrate. In this case, the folding direction of the pile yarns in each row, that is, the parallel direction of the two pairs of piles in which the pile yarns are bent is the same direction.

  Also, in the case of Wilton carpet and Akisminster carpet, each pile yarn planted on the base fabric is folded in parallel in one vertical and horizontal direction, and a pair of folded two piles is in the same direction, for example, It is common that they are juxtaposed in the vertical direction.

  Therefore, in the case of a conventional carpet, a pile yarn that is bent and planted in parallel in the vertical and horizontal directions has two bent piles in parallel in one vertical and horizontal direction (for example, the vertical direction) and the other direction ( In the horizontal direction, for example, only one of the two folded piles is arranged in parallel. Therefore, the pile density in the horizontal direction is reduced.

  That is, when the pile yarn is cut to a certain length, bent, and planted, a pair of the two piles P1, P1 bent are arranged in the same direction as shown in FIG. Therefore, the pile density in the parallel direction of the pair of piles P1, P1 is higher than the pile density in the other direction. For example, when the pile yarn bonding interval is the same in both the vertical and horizontal directions, the pile density in the vertical direction is twice the pile density in the horizontal direction.

  Therefore, the pile pile in the vertical direction appears on the surface of the pile in a bowl shape, and a dent or a gap may be formed between the bowl and the bowl. In particular, the same scissors-like streaks appear on the surface of the pile after the shearing process, which is unusable and not particularly suitable for use where a high-class feeling is required.

  In order to solve the above problem, it is conceivable to narrow the interval in the direction intersecting the parallel direction of the two pairs of piles to make the overall pile density uniform. There is a limit to narrowing the gap in the horizontal direction due to the planting mechanism, etc., and the pile density in the weft direction is inevitably coarser than the warp direction, and the pile density in the vertical and horizontal directions is made uniform. Was difficult.

Japanese Patent Laid-Open No. 6-189845

  The present invention has been made in view of the above, and provides a pile structure material in which vertical and horizontal pile densities can be made uniform and no ridge-like or striped streaks occur on the surface of the pile. A manufacturing method and a manufacturing apparatus for obtaining a pile structure material are provided.

The present invention for solving the above-mentioned problems is that a pile yarn cut into a predetermined length is bent on the surface of a plate-like or sheet-like base material so as to form a pair of two piles, A pile structure material that is bonded and planted in parallel in the vertical and horizontal directions at the bent portion, and each of the pile yarns is located at one place in each of the vertical and horizontal rows of pile yarns arranged in the vertical and horizontal directions. At each planting position , the two piles of bent piles are bonded in different directions so that the parallel direction of the piles intersects vertically and horizontally, and the pile density is uniform across the entire surface of the pile It is characterized by having become. As a result, the pile density in the vertical and horizontal directions on the pile surface becomes uniform.

Further, according to the present invention, in the method for manufacturing a pile structure material described above, the pile yarn cut into a predetermined length according to the pile length is formed on the surface of the plate-like or sheet-like base material. A method of manufacturing a pile structure material which is bent at a central portion so as to be formed, and is bonded and planted in parallel in a vertical and horizontal direction at the bent portion, and a pile yarn supplied above the base material The pile yarns that are cut in a predetermined length and are bonded to the surface of the base material while bending the cut pile yarns at the center portion so as to form a pair of two piles. In both the vertical and horizontal rows of planting positions, for each planting position , the direction of bonding is changed so that the parallel direction of the pair of folded two piles alternately intersects vertically and horizontally. and a characterized Rukoto to uniform the pile density of the vertical and horizontal over the entire pile surface That.

Thereby, the pile structural material which made the vertical and horizontal pile density uniform can be obtained. In particular, the parallel direction of the pair of bent two piles is arranged so as to intersect vertically and horizontally alternately in both directions of the background at each position where the pile yarns are arranged in parallel in both the vertical and horizontal directions. the by adhered changes direction, so that it more uniform the pile density of the vertical and horizontal directions over the whole surface. Furthermore, the pile yarn to be supplied is a pile yarn that is selected and sent from the pile yarn selection / delivery section for each planting position according to the pattern on the pile surface, so that the pile density in the vertical and horizontal directions is uniform. Thus, a pattern with a good surface condition can be expressed.

  Moreover, this invention is a manufacturing apparatus of the said pile structure material, and mounts a base material on this xy table which can control movement to the height and width which can mount a plate-shaped or sheet-shaped base material. A porous guide board which is supported so as to be movable together with the xy table at a necessary interval and in which a plurality of through holes for bonding guides are formed in parallel in the vertical and horizontal directions at an interval corresponding to the pile pitching pitch; Above the guide board, a plurality of yarn introduction holes for holding a plurality of types of pile yarns supplied from the pile yarn supply unit so as to be capable of being sent in the horizontal direction are arranged in parallel in one vertical and horizontal direction and in the parallel direction. A pile yarn selection / delivery unit that is movably arranged and can select one yarn introduction hole and stop it at a predetermined delivery stop position; and in front of the delivery stop position of the pile yarn selection / delivery unit , Selected A pile yarn holding portion having a pair of openable and closable clamping members that nips the pile yarn sent out from the yarn introduction hole portion in the horizontal direction with a pressing guide space in the center and sandwiched from both sides, and the pile yarn A cutter device that cuts the pile yarn that is fed from the selected yarn introduction hole and sandwiched between the clamping members into a predetermined length between the holding unit and the pile yarn selection and delivery unit, and the pile yarn holding unit The bar-shaped pressing member supported by the pressing drive means at a position corresponding to the upper side of the pressing guide space between the holding members is lowered, and the lower end portion of the pressing member crosses the guide space by the lowering of the pressing member. The pile yarn is engaged with the held pile yarn, and the pile yarn is extracted downward from the pile yarn holding portion, inserted into one adhesive guide through hole of the guide board, bent, and the folded Before music pressing adhesive means provided so as to press and adhere to the surface of the substrate on the xy table, and the pressing member of the pressing adhesive means is lowered by the pressing drive means in a non-rotating state, and lowered It is characterized in that it can be controlled appropriately and selectively when it rotates at a predetermined angle.

  As a result, the pile yarn selected and delivered from the pile yarn selection / delivery section is cut into a predetermined length, and the cut pile yarn is pressed by the pressing adhesive means to form a pair of two piles. For each required number of pile yarn planting positions arranged in parallel in the vertical and horizontal directions, the direction of bonding is changed so that the parallel direction of the pair of piles alternately intersects in the vertical and horizontal directions. It is possible to manufacture a pile structure material in which the vertical and horizontal pile densities are uniform.

  In the pile structure material manufacturing apparatus, the pressing adhesive member is selectively controlled by a rotary actuator to descend in a non-rotating state or to descend by a quarter rotation. Can do.

  In the pile structure material manufacturing apparatus, the pressing drive means is a rotary actuator capable of appropriately and selectively controlling a case where the pressing member is lowered in a non-rotating state and a case where the pressing member is rotated by a predetermined angle during the lowering. Those are preferred.

  In the pile structure material manufacturing apparatus, in the pile yarn supply path from the pile yarn supply unit to the pile yarn selection / delivery unit, a portion corresponding to the pile yarn sending length is drawn from the linear running unit to the side. It is preferable that a length measuring holding unit including a drawing roller for holding is provided.

  The pull-out roller of the pile yarn length measuring holding unit is connected to and supported by an air cylinder having spring means for pressing and urging in one direction, and the pile thread is linearly resisted by the spring means by the operation of the air cylinder. It can be provided so as to be pulled out from the traveling unit to the side holding traveling unit.

  In the pile structural material manufacturing apparatus described above, a pile yarn feeding length is provided in which a pile yarn pressing means for restricting the sending of the pile yarn is provided between the length measuring holding unit and the pile yarn selecting and sending unit. It is preferable for keeping the thickness constant.

As described above, according to the pile structure material of the present invention, pile yarns that are cut to a predetermined length, bent at the center, and bonded to the surface of the base material in parallel in the vertical and horizontal directions are arranged in both vertical and horizontal directions. In each of the planting positions , the parallel direction of two pairs of piles is alternately arranged in the vertical and horizontal directions, and the vertical and horizontal pile density is uniform over the entire surface. Also in the direction, no wrinkle-like streaks or stripes due to density difference are generated, and the pile surface is very clean and has a good appearance. For example, high-grade in carpets, mats, interior materials and other various applications. It gives a feeling. Moreover, it can also be suitably used as a decorative item such as a wall hanging with a patterned pile surface.

  Moreover, the pile structure material manufacturing method and apparatus according to the present invention makes it possible to uniformly produce pile structure materials having a good surface state without any problems, since the pile density in the vertical and horizontal directions is uniform over the entire surface as described above.

1 is a schematic perspective view showing a pile structure material according to an embodiment of the present invention. It is a partial expanded sectional view of the pile structure material same as the above. It is a schematic plane explanatory drawing of the arrangement state of the pile yarn of a pile structure material same as the above. It is a schematic plan view of one Example of the apparatus which manufactures a pile structure material same as the above. It is the top view which notched a part of xy table same as the above and a guide board part. It is sectional drawing same as the above. It is the top view (a) of the support plate on an xy table, and sectional drawing (b) of 1 part of a frame-shaped member. It is sectional explanatory drawing which shows the supply state of the base material on a support plate same as the above. It is a simplified front view of the planting mechanism part same as the above. It is a schematic vertical side view before pile yarn delivery of the planting mechanism part same as the above. It is a schematic vertical side view at the time of pile yarn delivery same as the above. (A) (b) It is a plane explanatory view of a pile yarn sending out and pinching state same as each of (c). It is the front view (a) and side view (b) of a press bonding means. It is sectional explanatory drawing of the state which clamped the sent pile yarn. (A) It is sectional explanatory drawing of the pile thread | yarn by the pressing action of the pressing member same as each of (b) and (c), and the adhesion state. It is sectional drawing in the case of changing and changing the direction of pile yarn same as the above alternately. It is a schematic plane explanatory drawing of the arrangement state of the pile yarn of the conventional pile structure material.

  Next, embodiments of the present invention will be described based on examples shown in the drawings.

1-3 has shown the outline of the pile structure material A of this invention. This pile structure material A is cut to a predetermined length on the surface of a plate-like or sheet-like substrate 1 and a large number of pile yarns P form a pair of piles P1, P1 at the center. And bent and bonded in parallel in the vertical and horizontal directions at the bent portion P2. Reference numeral 3 denotes an adhesive layer made of, for example, a synthetic resin for heat sealing.
The pile structure material A of the present invention is bent as shown in FIG. 2 and FIG. 3 for each planting position in each of the vertical and horizontal rows of the piled positions of the pile yarns P arranged in parallel in the vertical and horizontal directions . Further, the pile yarns P are bonded to the surface of the base material 1 by changing the direction so that the parallel direction of the pair of piles P1, P1 is alternately arranged vertically and horizontally. That is, as shown in FIG. 3, each point of the implanted position of the pile yarn P in parallel to the vertical and horizontal, i.e. for each one in each pile yarn P, and parallel bent the two pair of pile P1, P2 The direction (bending direction of the pile yarn P) is glued and planted in different directions so as to form an array in which the direction and the direction intersect each other alternately in the vertical and horizontal directions.

Te each column odor aspect of implanted position of the pile yarn P, for example every two or three of the pile yarn P, in parallel direction vertically and horizontally alternately the two pair of pile P1, P1, which is bent Although it can be arranged so as to form a crossing direction, in terms of uniformity of the pile density on the entire pile surface, appearance of the surface after shearing, beauty, etc., as in the present invention shown in FIG. to, to leave this as implanted changes direction alternately every planting設位of one position of the pile yarn P.

  The vertical and horizontal planting pitches of the pile yarn P can be set as appropriate according to the material, thickness, usage, etc. of the pile yarn P, but are set so as not to cause streaks due to hair cracking on the pile surface after shearing. Is preferred.

  As the pile yarn P, natural fibers made of wool or other spun yarn, synthetic fibers such as acrylic and polyester, regenerated fibers such as rayon, and other various materials can be used. Furthermore, if necessary, a pile yarn in a state in which a large number of thin yarns are gathered without being twisted can be used. As the plate-like or sheet-like substrate 1, at least one of a woven fabric, a nonwoven fabric, a synthetic resin material, a rubber material, and a paper or wood board is selected and used depending on the application. In the case of a tile type carpet, it is cut into a square having a predetermined length and width, and an adhesive is applied to the surface for use. A backing material may be laminated on these base materials 1 as necessary.

  The outline of the manufacturing apparatus used for manufacture of the pile structure material A of this invention is demonstrated based on FIGS. In the figure, reference numeral 10 denotes an xy table that can be moved vertically and horizontally, and a plate-like or sheet-like substrate 1 is placed at a predetermined position by a known moving means using a servo motor or the like in the xy direction, that is, vertically and horizontally. It is movable and can be controlled to move to any position. Usually, it is controlled so as to move vertically and horizontally in accordance with the spacing of the pile yarn P planting positions set by a through-hole for adhesion guide of the guide board described later.

  On the xy table 10, above the base material 1 placed on the xy table 10, a required interval smaller than the length of the pile yarn P to be planted, for example, an interval of about 2 to 3 mm is provided. A guide board 11 for bending and bonding guides is supported in parallel so as to be movable together with the xy table 10. Reference numeral 12 denotes a support leg, and the guide board 11 is fixed on the support leg 12 by fastening means 13 such as a flat head screw.

  The guide board 11 differs depending on the length of the pile yarn P to be planted. For example, the thickness of the guide board 11 is 5 to 25 mm, preferably 10 to 20 mm. The pile yarn P is bent at the center as will be described later, and has a number of through holes 14 for bonding guides that can be bonded while maintaining the bent state. It consists of a perforated plate formed in parallel. Although the said through-hole 14 changes with the pile form of the pile structure material A to be manufactured, the pile density, the thickness of the pile yarn P, etc., for example, a diameter is 1.5-5.0 mm, More preferably, it is 2.0. It is formed at an interval of 1.7 to 5.5 mm so as to leave a thickness of about 0.15 mm, preferably about 0.2 to 0.3 mm between the through holes. Of course, the present invention can also be carried out by forming at a diameter and arrangement interval other than those described above.

  Although the base material 1 can be placed directly on the xy table 10, in the illustrated embodiment, the base material 1 is heated between the guide board 11 on the xy table 10. A support plate 15 that also serves as a heat plate for receiving and supporting is disposed so as to be movable up and down with the support leg 12 as a guide. The support plate 15 is connected to and supported by appropriate vertical movement imparting means (not shown) such as an air cylinder disposed between the xy table 10 and the outside of the xy table 10. During the bonding operation, the surface of the substrate 1 (the surface of the adhesive layer 3) placed as shown by the solid line in FIG. 8 is held at a position having a gap of 2 to 3 mm with the lower surface of the guide board 11. Along with the completion of the planting of the pile yarn P on the entire base material 1, the planted pile yarn P is provided so as to be lowered by about 2 cm, for example, to a position where it is removed from the through hole 14 of the guide board 11. (The chain line in FIG. 8).

  The base material 1 is supplied to the support plate 15 from the side of the xy table 10. At this time, the base material 1 is placed on the preheating section 16 provided on the side of the xy table 10 as shown in FIG. Then, the adhesive layer 3 applied to the surface of the base material 1 is preliminarily heated, and the heated base material 1 is supplied onto the support plate 15 by heating on the support plate 15. Time can be shortened, which is preferable. 16a shows the opening / closing part of the preheating part 16 which makes | forms a chamber.

  In the case of the illustrated embodiment, a frame-like member 17 for positioning and holding the base material 1 supplied from the side in a fixed position is provided on the upper surface of the support plate 15 so as to surround the four sides. . As schematically shown in FIG. 7, a member 17 a on one side of the frame-shaped member 17 that faces the preheated portion 16 is provided so as to be raised and lowered with respect to the support plate 15. When the base material 1 is supplied, the base plate 1 is provided in such a manner that it is lying down in the recess 18 on the upper surface of the support plate 15 to receive the base material 1 and stand up after being received. In addition, the support member 15b can be placed on the opposite side of the member 17b opposite to the member 17a so that the base material 1 after the pile yarn P has been planted, that is, when the pile structure material A is taken out. Can be provided up and down freely. The base material 1 after the planting is completed can be sent out to the opposite side by the supply action of the new base material 1. Further, the members 17c and 17c in a direction orthogonal to the both members 17a and 17b are supported by an air cylinder or the like so as to be displaceable, and are provided so that the interval between the members 17c and 17c can be adjusted appropriately.

  Reference numeral 20 in the drawing denotes a pile yarn selection / delivery unit installed at a required position slightly above the guide board 11. As shown in FIGS. 9 to 11, the pile yarn selection / delivery unit 20 forms a pattern on the pile surface of the pile structure material A to be manufactured from a pile yarn supply unit (not shown) such as a creel stand, for example. A plurality of yarn introduction holes 21 for holding various kinds of multi-colored pile yarns P that are pulled out in response to each other so as to be able to be sent out individually in the horizontal direction are arranged in parallel in one vertical and horizontal direction and appropriately moving means 22. The yarn introduction hole 21 of any selected pile yarn P is arranged with reference to the bending position of the pile yarn P and the pressing position for bonding by the pressing bonding means 50 described later. , So as to be able to stop at a predetermined sending stop position set corresponding to the pressed position. In the case of the figure, the yarn introduction holes 21 are arranged in an L-shape so as to be integrally formed so that the pile yarn P supplied from above can be turned in the horizontal direction and sent out.

  The moving means 22 for moving each yarn introduction hole 21 to the sending stop position includes a moving body 22a that can reciprocate in one direction by rotation of a ball screw by a servo motor. 21 is attached to and supported by a horizontal plate portion of a mounting plate member 23 connected in parallel to the moving body 22a, and the moving body 22a is moved by a command from a control section (not shown). By controlling, the yarn introduction hole portion 21 of the pile yarn P of an arbitrary yarn type (color or material) can be selectively stopped at the sending stop position.

  Each yarn introduction hole portion 21 is provided with an air introduction portion 24 for introducing and introducing air into a horizontal passage portion, for example, and the air is introduced into the horizontal passage portion and ejected from the delivery side end portion 21a. By doing so, the pile yarn P inserted through the yarn introduction hole 21 can be fed forward in the horizontal direction.

  In addition, a part of the supply path of each pile yarn P from the pile yarn supply unit to the yarn introduction hole 21 of the pile yarn selection / delivery unit 20, for example, the mounting plate immediately before the pile yarn selection / delivery unit 20 In the portion along the member 23, a length measuring holding unit 27 including a drawing roller 26 for individually pulling out the pile yarn P from the linear traveling unit 25a to the side and holding it is provided. ing.

  The pulling roller 26 in the length measuring and holding section 27 of the pile yarn P is connected to an air cylinder 28 including a spring means 28a such as a push spring that presses and urges the pile yarn P in one direction, and is supported so as to freely advance and retract. During normal time when P is not sent out (non-sending time), the pile yarn P is pulled out from the linear running part 25a to the side holding running part 25b by the tensile action against the spring means 28a by the operation of the air cylinder 28. 10 (the state shown in FIG. 10), and when the pile yarn P is delivered, the air cylinder 28 is released and the spring means 28a does not act on the pile yarn P due to the urging force of the spring means 28a. (The state shown in FIG. 11). As a result, the pile yarn P returns to the position of the linear traveling portion 25a, and the pile yarn P having a length corresponding to the pulling-out length of the holding traveling portion 25b can be sent out. Therefore, the delivery length of the pile yarn P can be adjusted and set by adjusting the holding length of the pile yarn P drawn by the drawing roller 26.

  Further, the pile yarn selection / delivery unit 20 is provided between the length measurement holding unit 27 of each pile yarn P and the pile yarn selection / delivery unit 20, particularly at a lower position of the length measurement reservation unit 27 of the pile yarn P. The pile yarn pressing means 30 for restricting the delivery of the pile yarn P is provided except when the pile yarn P is delivered from the yarn introduction hole 21. In the pile yarn pressing means 30, a pressing member 31 that presses the pile yarn P against the mounting plate 23 or the like is connected to an air cylinder 32 that includes a spring means 32a such as a pulling spring that pulls and biases in one direction. It is provided so as to be able to advance and retreat, and is basically provided to perform a pressing action except when the pile yarn P is delivered from the yarn introduction hole 21.

  The air cylinder 28 of the length measuring holding portion 27 and the air cylinder 32 of the pressing means 30 are installed in a part of the mounting plate member 23 and are provided so as to move with the yarn introduction hole portion 21. . Reference numeral 35 in the figure denotes a holding portion for restricting the return of the pile yarn P provided on the supply side of the pile yarn P of the length measuring holding portion 27, and the supplied pile yarn P is elastically moved by the spring member 36. It is provided to hold down.

  Reference numeral 37 in the figure denotes a valve unit, each of which controls air supply for introducing air into each selected yarn introduction hole 21 of the pile yarn selection / delivery unit 20 (not shown), Valves (not shown) are provided for controlling the air supply to the air cylinders 28 of the pile measuring unit 27 and the air cylinders 32 of the pressing means 30. These valves mainly consist of solenoid valves, and are configured to be controlled in accordance with the planting action of the pile yarn P for each yarn introduction hole 21 by a signal from the control unit. In the figure, 38 is an air passage from the valve unit 36 to each yarn introduction hole 21, and 39 is an air supply passage to each of the air cylinders 28 and 32. The air supply passage 39 is divided into two forks on the way and communicates with both air cylinders 28 and 32.

  Each valve in the valve unit 37 opens the valve of the air passage 38 to the yarn introduction hole 21 by a signal from the control unit, for example, when the pile yarn P of the selected yarn introduction hole 21 is sent out. By closing the valve of the air supply passage 39, air is introduced into the yarn introduction hole portion 21, and at the same time, the air supply to the air cylinder 28 of the length measuring holding portion 27 and the air cylinder 32 of the pressing means 30 is shut off. Thus, the pile yarn P is controlled so as to be sent by the air introduced into the yarn introduction hole 21. When the delivery of the pile yarn P having a predetermined length is completed, the air passage 38 to the yarn introduction hole 21 is completed. While the valve of the air supply passage 39 is opened, the air introduction to the yarn introduction hole portion 21 is shut off, and at the same time, the air cylinder 28 and the pressing means 30 of the length measuring holding portion 27 are closed. No Control is performed so as to supply air to the cylinder 32, and the sending of the pile yarn is stopped, and the pile yarn P is pulled out to the holding traveling portion 25b by the pulling roller 26 of the length measuring holding portion 27 and controlled. Is done.

  Normally, the valve unit 37 operates with a slight time difference so that the operation of the air cylinder 33 of the pressing means 30 is performed first by a signal from the control unit when the delivery of the pile yarn P having a predetermined length is detected. To be controlled.

  Further, a position for bending and bonding the pile yarn P by the press bonding means 50 described later is provided in front of the sending stop position of the pile yarn selecting and sending unit 20 (forward in the sending direction of the pile yarn P). A pile yarn holding portion 40 having a pair of openable and closable pinching members 41, 41 for pinching the pile yarn P fed from the selected yarn introduction hole 21 in the horizontal direction from both sides is provided at the center. Yes.

  The both clamping members 41, 41 are provided so as to open and close by the operation of the air cylinders 42, 42, whereby the pile yarn P fed between the both clamping members 41, 41 can be clamped. . Concave grooves 43a and 43a that form a guide space 43 for pressing in the pile yarn clamping state are formed in the center portion on the opposite surface side of the both clamping members 41 and 41, and when the pile yarn P is clamped, it will be described later. A circular guide space 43 (including an ellipse) can be formed between both the holding members 41, 41 when viewed from a plane through which the rod-like pressing member 51 of the pressing adhesive means 50 can pass downward. The guide space 43 does not necessarily have a circular shape, and can be implemented in various shapes as long as the pressing member 51 can pass therethrough. Note that the holding force of the pile yarn P by the both holding members 41 and 41 is set to such an extent that the pile yarn P can be extracted by the lowering of the pressing member 51.

  Reference numeral 44 denotes a support plate that supports the holding members 41 and 41 so as to be openable and closable and supports the air cylinders 42 and 42, and a pressing member of the pressing adhesive means 50 described later at a position corresponding to the guide space 43. A guide through hole 45 through which 51 can be inserted is provided so that the pile yarn P can be pressed through the through hole 45. 46 in the figure is a sensor for detecting the delivered pile yarn P. When the pile yarn P is detected by this sensor 36, the air cylinders 42, 42 of the clamping members 41, 41 are operated to perform the clamping operation. Further, the pile yarn feeding of the pile yarn selecting / sending unit 20 is set to be stopped by a signal from the control unit. The support plate 44 is connected to a fixed frame member and supported at a predetermined position (not shown).

  Between the pile yarn holding portion 40 and the pile yarn selecting and sending portion 20, the pile yarn P fed from the yarn introduction hole portion 21 and pinched by the pinching members 41 and 41 of the pile yarn holding portion 40 has a predetermined length. A cutter device 48 is provided for cutting. As the structure of the cutter device 48, various types of cutters such as a saddle type, a slide blade and a rotary blade type can be used. However, a vertical type cutter device is preferable in practice. Both are configured to immediately cut after the clamping operation by the clamping members 41, 41.

  A position corresponding to the guide space 43 between the two clamping members 41 of the pile yarn holding portion 40 and the through hole 45 of the support plate 44, that is, above the pressing position for bending and bonding, is for bending and bonding. The pressing adhesion means 50 is provided. The pressing adhesive means 50 includes a bar-shaped pressing member 51 extending downward that can be lowered through the guide space 43 and the through hole 45, and the pressing member 51 is appropriately connected to the pressing drive means 52. It is supported so that it can move up and down.

  The pressing drive means 52 is made of, for example, a rotary actuator, and a bar-shaped pressing member 51 that is connected to the rotary actuator and extends in the downward vertical direction is lowered by the operation of the rotary actuator. The lower end portion 51a engages with the pile yarn P held across the guide space 43, and the pile yarn P is extracted from between the both sandwiching members 41, 41 of the pile yarn holding portion 40, and below the pile yarn P. It is inserted into the through hole 45 of the support plate 44 and the through hole 14 for bonding guide of the guide board 11 and bent, and the bent portion P2 is placed on the base material 1 on the xy table 10, that is, on the support plate 15. It is provided so as to press and adhere to the adhesive layer 3 on the surface of the substrate 1.

  In particular, the pressing member 51 of the pressing adhesive means 50 is lowered in a non-rotating state by the operation of the pressing drive means 52 such as the rotary actuator, and when it is lowered, the lower end 51a is lowered from a predetermined position. Below the position where it engages with the pile yarn P, a desired angle, for example, a case of 1/4 rotation, is provided so that it can be appropriately selected. It is configured such that a required number, for example, one place, is alternately selected to perform the press bonding operation.

  Therefore, the lower end 51a of the pressing member 51 is inverted V-shaped so that it can be locked across the pile yarn P held horizontally by the holding members 41, 41 as shown in FIGS. 13 (a) and 13 (b). Alternatively, an arcuate groove 53 perpendicular to the axis is formed to form a downwardly bifurcated shape. Thereby, when the pressing member 51 is lowered, as shown by a chain line in FIG. 14, the bifurcated portion can be lowered with the pile thread P strung over the pile yarn P, and by the rotation of the pressing member 51 The pile yarn P can also be rotated along with it, so that the parallel direction of the pair of piles P1, P1 bent can be changed.

  In the case of the figure, both side surfaces in the groove direction of the concave groove 53 are notched in the lower part of the pressing member 51, and the two piles P1 and P1 which are bent are formed on both sides of the pressing member 51. This notch is held in the through hole 14 of the guide board 11 (FIGS. 15B and 15C).

  The pile measuring unit 27 including the length measuring holding unit 27, the pile yarn pressing unit 30, and the moving unit 22 in the supply path of the pile yarn P, the pile yarn holding unit 40, the cutter device 48, the pressing adhesive unit 50, etc. The planting mechanism constructed in combination can be carried out by providing only one set on one xy table 10. However, in practice, the planting mechanism having the above configuration is regarded as one unit and one xy table 10. It is preferable that a plurality of sets, for example, four sets of the planting mechanism as shown in FIG.

  In this case, as shown in the figure, the area of the guide board 11 corresponding to the base material 1 placed on the xy table 10 is divided into, for example, four areas, and one set of the planting mechanism for each section. Each planting mechanism is simultaneously and individually controlled in accordance with the movement of the xy table 10, and in each planting mechanism, the pile yarn P is selectively sent and the pile yarn is held by the pile yarn selection / sending unit 20. A series of planting operations of holding the pile yarn P by the portion 40, cutting by the cutter device 48, bending the pile yarn P by the pressing and adhering means 50, and bonding are performed at the same time. As a result, in the four sections, a predetermined position, for example, the planting position of the corner portion can be sequentially planted in any vertical and horizontal directions, and the planting efficiency can be improved.

  A method of manufacturing the pile structure material A according to the embodiment of the present invention using the manufacturing apparatus of the above-described embodiment will be described together with the operation state of the apparatus.

  As a preparatory work up to the start of production, a pile yarn of a desired number of yarn types and color types according to the pattern and color of the pile structure material A to be produced, for example, a 12-color pile yarn in the case of a 12-color pattern P is pulled out from the pile yarn supplying section through the length measuring holding section 27 in the supply path and the pile yarn pressing means 30 for sending regulation, and the respective yarn introduction hole portions of the pile yarn selecting and feeding section 20 corresponding to each. 21 so that it can be inserted and sent out. At this time, under the control of the valve unit 37, the valves of the air passages 38 to the respective yarn introduction holes 21 are closed, while all the valves of the air supply passage 39 are kept open, so Air is supplied to the air cylinder 32 of the air cylinder 28 and the pressing means 30, and the pile yarns P are pulled out to the holding traveling section 25 b by the pulling roller 26 of the length measuring holding section 27. The member 31 is pressed down (FIG. 10).

  Then, the manufacture of the pile structure material A is started, and the base material 1 such as a nonwoven fabric having an adhesive applied to the surface is supplied onto the support plate 15 that also serves as a hot plate on the xy table 10. Is positioned and placed at a predetermined position, and the adhesive layer 3 on the surface is held in a heat-softened state. At this time, it is preferable to preliminarily heat the adhesive layer 3 on the surface by placing the base material 1 in the preheated portion 16 in advance because the heating time can be shortened.

  Thereafter, by the movement control of the xy table 10, a predetermined position of the pile yarn P on the surface of the base material 1 on the xy table 10, that is, a planting set in parallel at predetermined intervals in the vertical and horizontal directions. Among the positions, the first planting position for planting start, for example, one through hole 14 of the guide board 11 corresponding to one planting position of the corner is bent and bonded by the pressing bonding means 50. It is located below the pressing position. At the same time, in accordance with a selection command from the control unit, the movement means 22 is controlled to move, along with the moving body 22a, each yarn introduction hole portion 21 of the pile yarn selection / delivery unit 20 connected thereto is moved to form a pattern on the pile surface. Accordingly, the yarn introduction hole 21 of a predetermined pile yarn P corresponding to the color of the pile at the planting position is selected, and the yarn introduction hole 21 is moved to the sending stop position and stopped.

  Next, the valve of the valve unit 37 is controlled by a command from the control unit, and the valve of the air passage 38 to the one yarn introduction hole 21 that is selected and stopped at the sending stop position is opened, and the yarn introduction Air is introduced into the hole 21, and the air supply path 39 to the air cylinder 28 of the length measuring holding part 27 and the air cylinder 32 of the pressing means 30 in the supply path of the pile yarn P reaching the yarn introduction hole 21 is provided. The valve is closed and the air supply to the air cylinders 28 and 32 is shut off. As a result, the drawing roller 26 of the length measuring holding unit 27 is advanced to a position where it does not act on the pile yarn P by the urging force of the spring means 28a, and at the same time, the pressing member 31 of the pressing means 30 is moved to the pile yarn P by the urging force of the spring means 32a. Release the pressing action against.

  Thus, the pile yarn P held in the yarn introduction hole 21 is sent out by the air introduced into the yarn introduction hole 21. In particular, the pile yarn P corresponding to the length drawn from the linear traveling portion 25a in the length measuring retaining portion 27 to the retaining traveling portion 25b is sent in the horizontal direction (FIG. 11).

  As described above, the delivered pile yarn P is formed by the pair of sandwiching members 41, 41 of the pile yarn holding portion 40 disposed around the bending position in front of the sending stop position and the pressing position for bonding. It extends through (FIG. 12 (b)). When the predetermined length of the pile yarn P is delivered, for example, when the tip of the pile yarn P is detected by the sensor 46, the air cylinders 42, 42 of the clamping members 41, 41 are immediately actuated with the signal as a signal. And the pile yarn P is clamped (FIG. 12C).

  At the same time, the valve of the valve unit 37 is controlled by a signal from the control unit so as to stop the delivery of the pile yarn P of the pile yarn selection / delivery unit 20. That is, while closing the valve of the air passage 38 to the yarn introduction hole portion 21 and opening the valve of the air supply passage 39, the introduction of air to the yarn introduction hole portion 21 is blocked and the length measurement is performed. Air is supplied to the air cylinder 28 of the holding portion 27 and the air cylinder 32 of the pressing means 30. In the pressing means 30, the pressing member 31 is advanced against the spring means 32 a by the air cylinder 32 to press the pile yarn P. To prevent sending. On the other hand, in the length measuring holding part 27, the pulling roller 26 is moved to the side against the spring means 28a by the operation of the air cylinder 28, and the pile yarn P is drawn out to the holding traveling part 25b (FIG. 10).

  Further, after the pinching action by the pinching members 41, 41 of the pile yarn holding portion 40, the cutter device 48 between the pile yarn holding portion 40 and the pile yarn selecting / feeding portion 20 is operated, so that the pile yarn P is predetermined. Cut to length. Usually, the center portion of the pile yarn P sandwiched between the sandwiching members 41, 41 is cut to a length located in the portion of the pressing guide space 43 between the sandwiching members 41, 41. Accordingly, the cut pile yarn P is held at the center portion across the guide space 43 (FIG. 12C).

  After the cutting action, the pressing drive means 52 of the pressing adhesive means 50 provided above the pile yarn holding portion 40, for example, a rotary actuator is operated to lower the rod-shaped pressing member 51. When the pressing member 51 is lowered, the lower end 51a of the pressing member 51 enters the guide space 43 of the clamping members 41 and 41 and descends (FIG. 15A). The bifurcated portion formed by the concave groove 53 engages with the pile yarn P held across the portion of the guide space 43, and the center portion of the pile yarn P is pushed down, so that the pile yarn P is held between the both clamping members 41. , 41, while being extracted from between 41, 41 is inserted into the adhesive guide through-hole 14 of the guide board 11 located below (FIG. 15 (b)). Thus, the pressed pile yarn P is bent so as to form two piles P1 and P1 along the inner peripheral surface of the through hole 14. At this time, since both side surfaces of the lower end portion 51a of the pressing member 51 are notched in a tapered shape, the bent portions of the two piles P1 and P1 are located between the inner peripheral surface of the through hole 14. It is held in the gap. Further, when pressed by the pressing member 51, the bent portion b <b> 2 of the pile yarn P that has passed through the through hole 14 is formed on the adhesive layer 3 on the surface of the base material 1 positioned below the guide board 11. It is pressed and adhered to the pressing action by the pressing member 51 (FIG. 15C). After the pressing and adhering action, the pressing member 51 is lifted by the operation of the pressing drive means 52 leaving the pile yarn P, and returns to the original position above the guide board 11 and the pile yarn holding portion 40. The glued pile yarn P remains held in the through hole 14 of the guide board 11.

  Thereafter, by the movement control of the xy table 10, the through hole 14 of the guide board 11 corresponding to the next planting position of the pile yarns P arranged in parallel in the vertical and horizontal directions, that is, the adjacent planting position is folded by the pressing and bonding means 50. The pattern is formed on the surface of the pile by moving the yarn introduction holes 21 of the pile yarn selection / delivery section 20 by the moving means 22 in the same manner as described above. Accordingly, the yarn introduction hole portion 21 of the predetermined pile yarn P corresponding to the color of the pile at the planting position is selected and stopped at the sending stop position, and the pile yarn P in the yarn introduction hole portion 21 is stopped. The pile yarn P is pinched by the pinching members 41 and 41 of the pile yarn holding portion 40 and cut by the cutter device 48. After cutting, the pressing member 51 of the pressing adhesive means 50 is lowered and cut. The center of the pile yarn P And bent into the through hole 14 of the guide board 11 to form two piles P1 and P1, and the bent portion P2 from which the through hole 14 of the guide board 11 is extracted is formed on the base 1 Adhere to the surface.

  In this way, for each planting position of each pile yarn P on the surface of the substrate 1, the pile yarn P corresponding to the pattern expressed on the surface of the pile is selected and sent from the pile yarn selection sending unit 20 in sequence. The pile yarn P that has been fed is cut into a predetermined length, and the folded pile portion P2 is formed as a base material while the cut pile yarn P is bent at the center so as to form a pair of piles P1, P1. Adhere to the surface of 1.

  In particular, in the case of the manufacturing apparatus of the present invention, when the cut pile yarns P are pressed by the pressing member 51 of the pressing adhesive means 50 to bend and bond, by the operation of the pressing drive means 52 such as a rotary actuator, When descending in a non-rotating state and when descending at a desired angle, for example 1/4 turn, from a predetermined position when descending, it can be selected as appropriate. Two piles P1 and P1 can be bent and planted in parallel in the direction of delivery of the pile yarn P. Further, when the lower end 51a is engaged with the pile yarn P when it is lowered, it rotates 1/4. In this case, the pile engaged with the lower end 51a as the pressing member 51 rotates while the bifurcated portion of the lower end 51a of the pressing member 51 is engaged across the pile yarn P. Thread P is the same as this Then, while being rotated and pushed into the adhesive guide through hole 14 of the guide board 11 and bent (chain line in FIG. 16), the parallel direction of the two piles P1 and P1 bent is Are implanted on the surface of the substrate 1 in a crossed arrangement.

  Therefore, the required number of planting positions of the pile yarns P arranged in parallel in the vertical and horizontal directions, for example, an arrangement in which the parallel direction of the two pairs of piles P1 and P1 that are bent are alternately crossed in the vertical and horizontal directions. (FIG. 16), the pile density in the vertical and horizontal directions is made uniform over the entire surface, and there is a risk that wrinkle-like streaks and stripes may occur on the surface of the pile, and cracks may occur. For example, a pile structure material as shown in FIG. 1 (FIG. 2) having a beautiful and beautiful pile surface can be provided.

  As described above, when the pile planting of one pile structure material is completed, the support plate 15 on the xy table 10 is lowered, and the piles P1 and P1 held in the through holes 14 of the guide board 11 are lowered. P1 is pulled out downward and taken out to the side. The pile structure material taken out is cured for the adhesive and then sent to a processing step such as shearing. On the support plate 15, the base material 1 is newly supplied, and the same pile planting as described above is performed.

  INDUSTRIAL APPLICABILITY The present invention can be used for various pile structure materials used for carpets, interior materials such as wall materials and ceiling materials, and decorative materials such as wall hangings.

  A ... Pile structure material, P ... Pile yarn, P1 ... Pile, P2 ... Bending part, 1 ... Base material, 3 ... Adhesive layer, 10 ... xy table, 11 ... Guide board, 12 ... Support leg, 14 ... Penetration Holes: 15 ... support plate, 16 ... preheating part, 17 ... frame-shaped member, 17a, 17b, 17c ... measuring member, 20 ... pile yarn selection sending part, 21 ... yarn introduction hole part, 21a ... sending side end 22, moving means, 22 a, moving body, 23, mounting plate member, 24, air introduction section, 25 a, linear traveling section, 25 b, traveling section for holding, 26, drawer roller, 27, length measuring retaining section, 28 ... Air cylinder, 28a ... Spring means, 30 ... Pile thread pressing means, 31 ... Holding member, 32 ... Air cylinder, 32a ... Spring means, 35 ... Holding part, 36 ... Spring member, 37 ... Valve unit, 38 ... Air Passage 39 ... Air supply path 40 ... Par Ile yarn holding part 41 ... clamping member 42 ... air cylinder 43 ... pressing part 43a ... recessed groove 44 ... support plate 45 ... guide through hole 46 ... sensor 48 ... cutter device 50 ... Press bonding means, 51... Pressing member, 51 a... Lower end, 52.

Claims (8)

On the surface of a plate-like or sheet-like base material, pile yarns cut into a predetermined length are bent at the center so as to form a pair of two piles, and the bent portions are arranged vertically and horizontally in parallel. It is a pile structure material that is bonded and planted,
Each pile yarn is vertically and horizontally alternated in the parallel direction of a set of two piles that are bent at each planting position in each of the vertical and horizontal rows of pile yarns arranged in parallel in the vertical and horizontal directions. A pile structure material characterized in that the pile density is uniform across the entire surface of the pile surface, with the direction being changed so as to form an array intersecting with each other . On the surface of a plate-like or sheet-like base material, pile yarns cut into a predetermined length are bent at the center so as to form a pair of two piles, and the bent portions are arranged vertically and horizontally in parallel. A method of manufacturing a pile structure material that is bonded and planted,
The pile yarn supplied above the base material is cut to a predetermined length, and the bent portion is bent at the center so as to form a pair of piles. When bonding to each other, in the vertical and horizontal rows of pile yarns arranged side by side in the vertical and horizontal directions, the parallel direction of the two piles of folded two piles alternately alternates vertically and horizontally for each planting position. adhered changes direction to form a crossed arrangement, method for producing a pile structure material, wherein Rukoto to uniform the pile density of the vertical and horizontal over the entire surface of the pile surface. The method for manufacturing a pile structure material according to claim 2, wherein the pile yarn to be supplied is a pile yarn selected and sent from a pile yarn selection / delivery section at each planting position in accordance with a pattern on the surface of the pile. An xy table capable of controlling movement vertically and horizontally, on which a plate-like or sheet-like substrate can be placed;
A plurality of adhesive guides are supported on the xy table so as to be movable together with the xy table at a required interval at which a base material can be placed, and are arranged in parallel in the vertical and horizontal directions at intervals corresponding to the pile pitching pitch. A guide board in which a through hole is formed;
Above the guide board, a plurality of yarn introduction holes for holding a plurality of types of pile yarns supplied from a pile yarn supply unit so as to be capable of being sent out in the horizontal direction are moved in parallel in one vertical and horizontal direction and in the parallel direction. A pile yarn selection / delivery part that is arranged in a possible manner and can select one yarn introduction hole and stop it at a predetermined delivery stop position;
In front of the sending stop position of the pile yarn selecting and sending unit, the pile yarn sent in the horizontal direction from the selected yarn introduction hole is opened at the center, and is openable and closable from both sides with a pressing guide space. A pile yarn holding portion having a pair of clamping members;
A cutter device that cuts the pile yarn that is fed from the selected yarn introduction hole and sandwiched between the both clamping members into a predetermined length between the pile yarn holding unit and the pile yarn selection and delivery unit;
A bar-shaped pressing member supported by a pressing drive means at a position corresponding to the upper side of the pressing guide space between the holding members of the pile yarn holding section is supported so that the lower end portion of the pressing member is lowered by the lowering of the pressing member. Engage with pile yarn held across the guide space, pull the pile yarn downward from the pile yarn holding section, and insert it into one adhesive guide through hole of the guide board to bend And a pressing adhesive means provided to press and bond the bent portion to the surface of the substrate on the xy table,
The pressing member of the pressing adhesive means is provided so as to be able to appropriately and selectively control the case where the pressing member is lowered in a non-rotating state and the case where the pressing member is rotated by a predetermined angle during the lowering. Pile structural material manufacturing equipment. 5. The pile structure material according to claim 4 , wherein the pressing drive unit is a rotary actuator that can selectively control when the pressing member is lowered in a non-rotating state and when the pressing member is rotated at a predetermined angle during the lowering. manufacturing device. The pile yarn supply path from the pile yarn supply unit to the pile yarn selection / delivery unit includes a drawing roller for drawing the pile yarn sending length sideways from the linear traveling unit and holding it. The pile structure material manufacturing apparatus according to claim 4 or 5 , wherein a length measurement holding part is provided. The pull-out roller of the pile yarn length measuring holding unit is connected to and supported by an air cylinder having spring means for pressing and urging in one direction, and the pile thread is linearly resisted by the spring means by the operation of the air cylinder. The pile structure material manufacturing apparatus according to claim 6 , wherein the pile structure material is provided so as to be drawn out from the traveling unit to the side holding traveling unit. The pile structure material manufacturing apparatus according to claim 6 or 7 , wherein pile yarn pressing means for restricting the delivery of the pile yarn is provided between the length measurement holding portion and the pile yarn selection and delivery portion.

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