JP5688174B1 - Light and shade carpet - Google Patents

Abstract

An object of the present invention is to draw a design pattern by a visual difference in shade on a pile surface of a tufted pile fabric having a pile length H of 5 mm or more. A carpet pile surface 15 composed of thermoplastic pile fibers 11 is heated by irradiating a laser beam, the tip of the pile fibers 11 is melted by heat, and the melted lump of the pile fibers 11 is fixed to the surface. A concave portion 17 is formed, and the length L of the concave portion 17 is inclined at an inclination angle θ of 20 degrees or less with respect to the base cloth 19 and continues in the inclined direction S from the inclined vertex 26 to the inclined bottom point 27. A slope 23 having a thickness of 15 mm or more is formed, and a light and shade visual sensitivity is imparted to the pile surface due to a change in the degree of light reflection at the concave portion 17 that changes in accordance with the inclination angle θ of the slope 23 formed. [Selection] Figure 2

Description

  TECHNICAL FIELD The present invention relates to a carpet having a tufted pile fabric used as a surface material, which is used to capture dust adhering to a shoe of a pedestrian that is placed at an indoor / outdoor doorway and passes through the doorway. .

  The appearance of a plain pile fabric with no pattern on the pile surface is considered to be the same when viewed from any direction around it, but the pile is slightly inclined in any direction, depending on the direction of viewing. The color tone changes slightly. Since the pile surface has a visual direction as described above, it is known to display the direction on the back surface of the tile carpet in order to facilitate the installation according to the inclination direction of the pile (for example, Patent Document 1). , 2).

  In addition, the pile inclination direction should be constant. Sometimes, in some areas of the pile surface, the pile is inclined in a direction different from the inclination direction of the piles in other surrounding areas. There may be a difference in color tone between some areas of the surface and other surrounding areas. In this way, a phenomenon in which a visual difference in density occurs between a part of the pile surface where the entire surface should be a solid color and the other surrounding areas is “pond”, “cloud” or “shedding” It is called “shadow” (see, for example, Patent Documents 3 and 4). Such a visual phenomenon caused by the inclination of the pile is used as a “spotting technique” for drawing a pattern on the pile surface (see, for example, Patent Documents 5 and 6).

  It is well known that a pile fiber is heated and melted by irradiating a laser beam to draw a pattern on the pile surface. An oscillator that oscillates the laser beam and an irradiation lens that collects the laser beam emitted from the oscillator and strikes it on the surface of the fabric A reflector for guiding the laser beam emitted from the oscillator to the irradiation lens, a spot moving means for moving the beam spot irradiated on the surface of the fabric, and an optical path for calculating the distance of the optical path of the laser beam from the oscillator to the beam spot The laser beam irradiation device is configured by the calculation means, the beam diameter adjustment means for adjusting the beam diameter of the laser beam, and the focus adjustment means for adjusting the focus of the irradiation lens according to the optical path, and the distance from the irradiation lens to the surface of the fabric changes. Even in order to keep the beam spot diameter constant, the beam diameter of the laser beam and the focus of the irradiation lens Adjusting means for adjusting also known (e.g., see Patent Document 7).

  In order to display Braille signs for guiding visually impaired persons, a bar code displayed by embossing the surface of the vinyl chloride resin layer laminated on the pile surface is covered with a transparent resin (for example, see Patent Document 8), or In addition, it is known to screw a braille rod into a through hole formed in a pile fabric (see, for example, Patent Document 9).

Japanese Utility Model Publication No. 61-95377 (No. 01-39502) JP 2005-127113 A (Patent No. 4554188) Japanese Patent Publication No.49-24840 Japanese Patent Publication No. 60-10723 Japanese Utility Model Publication No. 58-19188 Japanese Patent Laid-Open No. 06-330456 JP 2007-222902 A JP-A-10-102442 Japanese Patent Laid-Open No. 11-303030 (Japanese Patent No. 3830275)

The design pattern by the spatula technique is drawn by partially changing the woven structure of the base fabric that locks the base of the pile and partially changing the inclination angle of the pile locked to the base fabric.
However, in a pile fabric in which long piles of 5 mm or more protruding from the base fabric are densely planted, such as tufted pile fabric, all pile yarns are bent into a U shape and inserted into the base fabric. In addition, it is impossible to partially change the shape of the base of the pile bent into the U-shape, and it is not possible to partially change the inclination angle of the pile by pushing down some of the piles that are densely planted. The required pattern cannot be drawn on the pile surface by the spatula technique.

  Accordingly, an object of the present invention is to draw a design pattern based on a visual shading difference on a pile surface of a tufted pile fabric having a pile length H of 5 mm or more, as well as a design using a wetting technique.

The carpet according to the present invention has (1) a pile fabric formed by inserting pile yarns composed of pile fibers 11 which are thermoplastic synthetic fibers into a base fabric 19 to form a pile, and (2) a pile surface 15 thereof. Further, the tip of the pile fiber is heated and melted by the laser beam to form a recess 17 with the melted mass fixed to the surface. (3) In the recess, 20 degrees or less with respect to the base fabric. A slope 23 having a length L of 15 mm or more extending in the slope direction S from the top 26 of the slope to the bottom 27 of the slope is formed in the slope direction θ ( see FIGS. 1 to 5). ).

In the process in which the thermoplastic synthetic fiber (11) is heated and melted to form a molten lump, the molten lump is rounded and swollen by the surface tension acting on the hot-melt fiber polymer. The tip of the pile fiber 11 is shortened and a dent is generated.
The shape of the molten mass is different from the tip of the unheated pile fiber that is not heated by the laser beam on the pile surface, and the thick and rounded molten mass is shiny and melted compared to the tip of the unheated pile fiber. At least a visual shading due to a difference in gloss occurs between the concave portion 17 to which the mass is fixed and the convex portion 18 around the concave portion that remains unheated by the laser beam and is raised relative to the concave portion.

  The amount of shrinkage of the tip of the pile fiber and the mass of the molten mass are different at the top and bottom of the slope, and the pile fiber at the deeply depressed bottom point is greatly shrunk according to the depth of the recess, so that it is deeply recessed While the mass of the molten mass intervening at the bottom point 27 increases, the shrinkage of the pile fiber at the shallow apex of the dent is small, and the mass of the molten mass intervening at the apex 26 where the shrinkage is small is relatively small. A difference in gloss that gently changes according to the distribution amount of the molten mass occurs between the top and the bottom.

  A hard molten mass is pushed up by the pile layer in the recess, the shoe sole is rubbed by the hard molten mass, and the dust adhering to the shoe sole is scraped by the hard molten mass, so a high dust trapping function is required. A carpet suitable for a dust control mat is obtained.

It is a section side view of the carpet concerning the present invention. It is a section perspective view of the carpet concerning the present invention. It is a section perspective view of the carpet concerning the present invention. It is a section perspective view of the carpet concerning the present invention. It is a top view of the carpet based on this invention.

  In the present invention, the inclination angle θ of the slope 23 is 20 degrees or less, that is, the bottom face from the vertex 26 to the bottom point 27 at the slope length L from the slope 26 to the bottom point 27 of the bottom face 28 in the slope direction S. When the tangent function tanθ of the inclination angle θ shown by dividing the depth K of 28 is less than 0.3639702 (= tan20 °), it is depicted by a V-shaped cut groove cut into the pile layer with an inclination angle of 45 degrees or more. The so-called “carving” is meant not to bring about the expected effect of the present invention, and is outside the scope of the present invention.

  In order to smooth the gloss change and the light and shade change between the top part 26 and the bottom part 27 of the slope, the inclination angle θ is 10 degrees or less, that is, tan θ = 0.176 (= tan 10 °) or less, more preferably It is desirable that the inclination angle θ is 5 degrees or less, that is, tan θ = 0.0875 (= tan 5 °) or less.

  In this way, the concave portion with a small inclination angle θ is shallow, the particle size of the molten mass distributed on the inclined surface is fine, the distribution amount is small, and the difference in density between the concave portion 17 and the convex portion 18 is observed from directly above the pile surface. Even if it is taken, the contrast between the concave portion 17 and the convex portion 18 is not observed as far as the distance between the line of sight and the pile surface is 30 degrees or less, and the pedestrian passes through the concave portion 17. In the process, the degree of the appearance and hiding of the pattern drawn on the pile surface by the concave portion 17 is increased, and the appearance of the carpet is enhanced.

Highly visible and hidden designs can give a pedestrian's attention and provide a carpet with a high dust trapping function that is suitable for dust control mats.
Therefore, it is desirable that the inclination angle θ of the inclined surface 23 be extremely small, that is, 5 degrees (tan 5 ° = 0.0875) or less so that the step (K) between the concave portion 17 and the convex portion 18 is not felt.
In order not to obstruct the movement of the wheelchair or the carrier car, it is desirable that the step (K) between the concave portion 17 and the convex portion 18 be 5 mm or less (see FIG. 1).
The melted lump formed by the original pile fiber also changes the content of the original pigment according to its mass, so that a gentle shade difference in hue occurs between the top 26 and the bottom 27 of the slope.
And the reflection angle of light also changes according to the inclination angle θ of the slope 23.

In this way, the slopes 23a, 23b, 23c, 23d, 23e,... With different gloss and shade and different degrees of change are scattered, and the concave portions 17 and the convex portions 18 where the slopes 23 are formed. Not only the gloss but also the color tone has a difference in shade, and the gloss and shade difference between them renders a visual design similar to the spatula design and enhances the aesthetics of the carpet (see FIGS. 1 to 5).
Since the light reflection direction changes at the entrance corner 24 and the exit corner 25 inside the recess, and at the downhill 30 and the uphill 29, the aesthetic appearance of the pile surface that the pedestrian sees in the process of passing over the recess 17 changes every moment. (See FIG. 2).

  Therefore, in the first preferred embodiment of the present invention, the pile surface 15 is formed with a plurality of types of recesses 17 in which any of a plurality of types of slopes 23a, 23b, 23c, and 23d having different inclination directions S are formed. It is to be. The plurality of types of recesses may be recesses in which a plurality of types of slopes having different slope directions S are interposed together. For example, a slope of one recess faces left, a slope of another recess faces right, and another The inclined surface of the recess may be a plurality of recessed portions in which a plurality of types of inclined surfaces having different inclination directions S are individually interposed (see FIG. 2).

  A preferred second embodiment of the present invention is to form, on the pile surface 15, a plurality of types of recesses 17 in which any of a plurality of types of slopes 23a and 23e having different inclination angles θ are formed. The plurality of types of recesses may be recesses in which a plurality of types of slopes having different inclination angles θ are interposed together, as well as a plurality of types of slopes having different inclination angles θ. A plurality of recesses in which the slopes are individually interposed (see FIGS. 1 and 2).

  A preferred third embodiment of the present invention is to form a recess in the pile surface 15 in which a bottom surface 28 parallel to the base fabric 19 is interposed. The width of the bottom surface 28 inside the recess 17 may be such that a circle having a diameter R of 5 to 70 mm is inscribed in the bottom surface 28 (see FIG. 1).

A hill 32 raised from the bottom surface 28 can be provided inside the recess 17 (see FIGS. 1, 2, and 4). A plane in which the depth K from the pile surface changes stepwise, such as a river terrace or terraced rice field, can be formed inside the recess 17.
5 is divided into four sections (33a, 33b, 33c, 33d) by a cross-shaped bottom surface 28 parallel to the base fabric 19, and the inclination directions S are reversed by the protruding corners 25 that cross each section 33 diagonally. A carpet in which rectangular concave portions 17 divided into two triangular slopes 23a and 23b which face each other are arranged in a lattice shape is illustrated.
In order to enrich the expression of the pattern on the pile surface 15, the edge of the handle by carving with an inclination angle of 40 degrees or more, and the slopes 23 a, 23 b, 23 c, 23 d and the bottom surface 28 with different inclination directions surrounding the periphery The bottom surface has no slope (step) such as a step between the four corners of the cross-shaped bottom surface 28 (see FIG. 3) and a step (see FIG. 5) between the pile surface (convex portion 18) surrounding the recess 17 (see FIG. 5). It is possible to provide an enclosed recess or an inclined surface with an inclination angle θ exceeding 20 degrees. In this way, by changing the shape of the concave portions, the visual shading appears vividly, and a hidden and visible pattern can be expressed on the pile surface.

  The concave portions 17 having various contours with different lengths L, inclination angles θ, and inclination directions S of the slope 23 pass the pile fabric through a laser beam irradiation device, instantaneously heat the pile surface with the laser beam, and heat the tip of the pile fiber. It is melted and dented, and the molten mass is fixed and formed. In the process, the irradiation light quantity of the laser beam is changed, the length L of the slope is set to 15 mm or more according to the change of the light quantity, and the inclination angle θ with respect to the base fabric 19 is set. The inclination direction S is changed to 20 degrees or less.

  The molten mass generated on the pile surface is harder than the pile fiber, and is pushed up elastically by the pile layer and intervened in the pile surface. When doing so, it exhibits a dust trapping function that scrapes off dust adhering to the shoe back of the pedestrian.

In the laser beam irradiation apparatus, a laser beam is scanned in the width direction of the long material to be conveyed, and the irradiated portion of the laser beam remains on the surface of the long material as a scanning trace. The scanning trace of the laser beam generated on the pile surface in which the pile having a pile length (H) of 5 mm or more is densely implanted appears as a thin line having a width of 0.3 to 2.5 mm following the scanning direction of the laser beam. A portion where the fine lines are densely arranged in the pile fabric conveyance direction becomes the concave portion 17 and appears on the pile surface.

  A backing adhesive for fixing the pile fiber 11 to the base fabric 19 is appropriately applied to the back surface of the pile fabric 14.

(Pile fabric)
A polyester fiber non-woven fabric with a basis weight of 120 g / m ² is used as a base fabric, an original nylon fiber multifilament yarn having a single fiber fineness of 10 dtex and a total fineness of 1370 dtex is used as a pile yarn, and a gauge between needles of 25.4 mm (1/8 inch gauge) The tufted machine for cut piles was tufted with a pile planting density (stitch gauge) of 9 stitches / 25.4 mm to obtain a tufted pile fabric having a pile length of 10 mm and a pile weight of 900 g / m ² .

(Finish processing)
A nitrile butadiene latex compound is applied as a precoat on the back side of the pile fabric and dried, and then the pile surface is sprayed with a pretreatment agent aqueous solution having a solid content concentration of 5 mass% mainly composed of borax, sodium bicarbonate and sodium alginate. 300 g / m ² applied and dried, carbon dioxide laser beam irradiation device manufactured by Italy Hightech Co., Ltd. having an average output of 800 W, a laser beam wavelength of 10.6 μm, a laser beam moving speed of 4000 mm / min, and a mark line thickness of 0.4 mm The pile fiber on the surface of the pile is heated to form a molten lump on the surface of the pile, and then washed with water to remove the pretreatment agent and pass through a dryer. Finished.

(Finished state)
The cut pile after spray drying of the aqueous pretreatment solution has a tip that is solidified into a dry coating film of the pretreatment agent, and only the tip is heated by a laser beam to generate a molten mass. It was set to a pointed shape by the molten mass, washed with water, the solid content of the pretreatment agent was dissolved and removed, the cut pile recovered its bulge and exhibited a pencil point shape.
In the concave portion where the output of the laser beam was changed when the laser beam was irradiated, a slope was formed due to a change in the degree of thermal contraction of the pile fiber at the tip of the cut pile.

  The pile fabric obtained by the present invention is used for rugs such as car mats (vehicle foot mats), dust control mats, carpets and tile carpets.

11: Pile fiber 15: Pile surface 17: Concave portion 18: Convex portion 19: Base fabric 23: Slope 24: Entrance corner 25: Out corner 26: Top 27: Bottom point 28: Bottom 29: Uphill 30: Downhill 32: Hill 33 : Section H: Pile length K: Depth L: Inclination length R: Inscribed circle diameter S: Inclination direction θ: Inclination angle

Claims (5)

(1) A carpet having, as a surface material, a pile fabric formed by inserting a pile yarn composed of a pile fiber (11), which is a thermoplastic synthetic fiber, into a base fabric (19), and (2)
The pile fiber (11) is heated by being irradiated with a laser beam, the tip of the pile fiber (11) is melted and depressed, and a concave portion (17) in which a molten mass of the pile fiber (11) is fixed to the surface is formed on the pile surface (15). (3) Inclined at an inclination angle (θ) of 20 degrees or less with respect to the base fabric (19), and continues in the inclination direction (S) from the apex (26) of the inclination to the base (27) of the inclination. A gray-scale light-sensitive carpet in which a concave portion (17) in which a slope (23) having a thickness (L) of 15 mm or more is formed is present in a pile surface (15).   The light / dark sensitivity according to claim 1, wherein the pile surface (15) has a concave portion (17) in which any one of a plurality of types of slopes (23a, 23b, 23c, 23d) having different inclination directions (S) is formed. carpet.   3. The grayscale according to claim 1, wherein a concave portion (17) in which any one of a plurality of slopes (23 a, 23 e) having different inclination angles (θ) is formed is present in the pile surface (15). Sensitive carpet.   The light-sensitive carpet according to any one of claims 1, 2 and 3, wherein the pile surface (15) has a recess (17) in which a bottom surface (28) parallel to the base fabric (19) is formed.   The light-sensitive carpet according to any one of claims 1, 2, 3, and 4, wherein the pile fiber (11) is an original thermoplastic synthetic fiber spun by kneading a pigment into a fiber polymer.

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