JP6761296B2 - Carpet continuous dyeing machine and carpet continuous dyeing method - Google Patents

Description

The present invention relates to a carpet continuous dyeing machine capable of expressing various color patterns and the like.

In general, the color pattern of carpet is expressed by post-dyeing of the pile yarn of the raw machine by a continuous dyeing machine, an inkjet printing machine or the like.
The continuous dyeing method of dyeing using a continuous dyeing machine is a method of dyeing a living machine while the living machine is being conveyed in the longitudinal direction. In the continuous dyeing method, a dye is discharged from a plurality of nozzles arranged in the width direction of the raw machine to the surface of the raw machine to be conveyed to dye the raw machine, so-called "shower curtain type", or the raw machine is immersed in a dyeing solution. The dyeing process is continuously performed using a so-called "dipping method" or the like. Such a conventional continuous dyeing machine can dye a large amount of livestock by using only a single type of dye or by using an acid dye and a cationic dye in combination, and is excellent in carpet productivity.
However, the continuous dyeing machine has a limit in the expression of color patterns, and even if the acid dye and the cationic dye are used in combination as described above, it is difficult to obtain carpets having various color patterns.

On the other hand, the inkjet method using an inkjet printing machine is a method of dyeing a raw machine by injecting a dye into a mist from a printer head, and can express a delicate color pattern (Patent Document 1).
However, the inkjet printing machine has a problem that the printing speed is relatively slow and the productivity of the carpet is poor. Further, since the dye is sprayed according to a predetermined pattern, only a predetermined color pattern can be expressed, and it is difficult to obtain a carpet having a natural blur-like feeling as if the dye had exuded.

Japanese Unexamined Patent Publication No. 6-25965

An object of the present invention is to provide a continuous dyeing machine and a continuous dyeing method for carpets, which can dye a living machine in various color patterns with a natural blur tone .

In the first continuous carpet dyeing machine of the present invention, a transport device for transporting a carpet raw machine and a raw machine transported by the transport device are provided with a resist dye and a treatment agent containing at least one of water. It has a pretreatment part to be applied and a dyeing part to apply a dyeing agent to a raw machine to which the treatment agent is applied by the pretreatment part, and the pretreatment part applies the treatment agent in the width direction of the raw machine and The coating is applied to a plurality of spot-like portions spaced apart in the longitudinal direction, and a portion to which the treatment agent is not attached and a portion to which the treatment agent is attached are formed on the living machine .

The preferred continuous carpet dyeing machine of the present invention has a roll in which the pretreatment section rotates in synchronization with the transportation of the raw machine and comes into contact with the surface of the raw machine to apply the treatment agent.
The preferred continuous carpet dyeing machine of the present invention has a spray in which the pretreatment section sprays the treatment agent on the surface of the raw machine.
In the second continuous dyeing machine for carpet of the present invention , a dyeing agent and a treatment agent containing at least one of water are added to the raw machine to convey the raw machine of the carpet and the raw machine conveyed by the transport device. It has a pretreatment part to be applied and a dyeing part to apply a dyeing agent to a raw machine to which the treatment agent is applied by the pretreatment part, and the pretreatment part applies the treatment agent in the width direction of the raw machine and It is configured to be applied to a plurality of spot-like portions spaced in the longitudinal direction, and the dyeing portion is arranged in the width direction of the raw machine transported by the transport device and a plurality of dyes are discharged. It has a discharge port and an induction plate which is arranged between the raw machine and a plurality of discharge ports and guides the dyeing agent discharged from the discharge port to the raw machine, and the discharge port discharges the first dyeing agent. The first discharge port and the second discharge port for discharging a second dyeing agent different from the first dyeing agent are included, and the first discharge port and the second discharge port are alternately arranged in the width direction. The guide plate is arranged so as to be inclined so as to be mixed in the width direction in the process of guiding the first dyeing agent and the second dyeing agent discharged from the first discharge port and the second discharge port to the living machine. ing.

According to another aspect of the present invention, there is provided a method for continuously dyeing a carpet.
The first continuous dyeing method of the present invention includes a transport step of transporting a raw material for carpet, a pretreatment step of applying a treatment agent containing at least one of a resist dye and water to the raw machine, and the treatment agent. It has a dyeing step of dyeing the applied raw machine with a dyeing agent, and in the pretreatment step, the treatment agent is applied to a plurality of spot-like portions spaced in the width direction and the longitudinal direction of the raw machine. By coating, a portion to which the treatment agent is not attached and a portion to which the treatment agent is attached are formed on the raw machine .
The second continuous dyeing method for carpets of the present invention includes a transport step of transporting a raw machine of the carpet, a pretreatment step of applying a treatment agent containing at least one of an anti-dyeing agent and water to the raw machine, and the treatment. It has a dyeing step of dyeing a raw machine coated with the agent with a dyeing agent, and in the pretreatment step, the treatment agent is applied to a plurality of spots spaced apart in the width direction and the longitudinal direction of the raw machine. It is applied to a portion, and in the dyeing step, different dyes, a first dyeing agent and a second dyeing agent, are discharged onto an induction plate from a plurality of discharge ports arranged in the width direction of the raw machine, and the first dyeing is performed. The agent and the second dyeing agent are guided to the raw machine while being mixed in the width direction in the process of flowing on the induction plate.

According to the continuous dyeing machine and the continuous dyeing method of the present invention , the treatment agent is applied to a plurality of spot-like portions spaced in the width direction and the longitudinal direction of the living machine, so that the living machine has a variety of natural blurring tones . Can be dyed in various color patterns .

Top view of the carpet. FIG. 2 is a cross-sectional view taken along the line II-II of FIG. The schematic diagram of the carpet continuous dyeing machine which concerns on one Embodiment. Top view of the pretreatment part and the dyeing part of the continuous dyeing machine as viewed from above. However, both sides of the raw machine are omitted (the same applies to FIGS. 5 to 12). The side view of the pretreatment part and the dyeing part of the continuous dyeing machine. The perspective view of the dyeing part of the continuous dyeing machine. The plan view of the dyeing part of the continuous dyeing machine. The side view of the dyeing part of the continuous dyeing machine. The plan view of the dyeing part of the continuous dyeing machine which concerns on a modification. The plan view which shows the pretreatment step and the dyeing step of a continuous dyeing method. The same side view. The plan view which shows the state which stopped the discharge of the dyeing agent from a part discharge port in a dyeing process. The plan view of the pretreatment part and the dyeing part of the continuous dyeing machine which concerns on another embodiment. The plan view which shows the pretreatment process and the dyeing process using the continuous dyeing machine. The same side view. The perspective view of the dyeing part of the continuous dyeing machine which concerns on another embodiment.

Hereinafter, the present invention will be described with reference to the drawings as appropriate.
In the present specification, the numerical range represented by "~" means a numerical range including the numerical values before and after "~" as the lower limit value and the upper limit value.

[Carpet overview]
FIG. 1 is a plan view of a carpet according to an embodiment of the present invention, and FIG. 2 is a cross-sectional view of the carpet.
As shown in FIG. 1, the carpet 1 is formed in a single-wafer shape such as a substantially square shape in a plan view. However, the plan view shape of the single-wafer-shaped carpet 1 is not limited to a substantially square shape, and is formed into, for example, a substantially rectangular shape, a substantially circular shape, a substantially elliptical shape, a substantially polygonal shape such as a substantially triangular shape or a substantially hexagonal shape, and the like. It may have been. In the present specification, "abbreviation" means a shape permitted in the technical field to which the present invention belongs. The "abbreviation" of a substantially polygonal shape such as a substantially square shape, a substantially rectangular shape, or a substantially triangular shape in a plan view is, for example, a shape in which corners are chamfered, a shape in which a part of a side is slightly bulged or recessed, or a side. Includes shapes that are slightly curved. Further, the "abbreviation" of the substantially circular shape and the substantially elliptical shape in the plan view includes, for example, a shape in which a part of the circumference is slightly bulged or dented, a shape in which a part of the circumference is slightly straight or diagonal, and the like. ..
The size of the carpet 1 having a substantially square shape in a plan view is not particularly limited, and examples thereof include 500 mm × 500 mm.

The carpet 1 may have a long strip shape. Here, in the present specification, the long strip shape means a substantially rectangular shape in a plan view in which the length in the longitudinal direction is sufficiently longer than that in the width direction. As the long strip, for example, the length in the width direction is 1000 mm to 4000 mm, the length in the longitudinal direction is 5 m or more, and the length in the longitudinal direction is preferably 10 m or more. The width direction is a direction orthogonal to the longitudinal direction.

As shown in FIG. 2, the carpet 1 has a dyed living machine 11 and a back surface layer 12 laminated on the back surface side of the living machine 11.
The dyed raw machine 11 has a base cloth 111 and a pile yarn 112 planted on the base cloth 111, and the pile yarn 112 is dyed in a desired color pattern by a continuous dyeing machine described later. ..
In the illustrated example, the back surface layer 12 is composed of an adhesive layer 121, a reinforcing material 122, and a backing layer 123 in this order from the front surface side. The back surface layer 12 is provided to join the living machine 11 and the reinforcing material 122. The reinforcing material 122 is provided for the dimensional stability of the carpet 1, and for example, a non-woven fabric or a woven cloth is used. The backing layer 123 is a layer that forms the weight of the carpet 1 and is grounded to the construction surface. The backing layer 123 is formed of a synthetic resin such as a vinyl chloride resin, rubber, or the like.
In the present invention, the layer structure of the raw machine 11 having the pile yarn 112 and the base cloth 111 and the back surface layer 12 is not limited to the illustrated example, and conventionally known ones can be appropriately adopted.

[Continuous dyeing machine for carpet]
As shown in FIGS. 3 to 8, the carpet continuous dyeing machine A of the present invention uses a transport device 3 for transporting the carpet raw machine B, a pretreatment unit 4 for pretreating the raw machine B, and a dyeing agent. It has a dyeing portion 5 to be applied to B.
The pretreatment section 4 is provided on the upstream side of the dyeing section 5. The pretreatment unit 4 applies a treatment agent containing at least one of a resist dye and water to the living machine B.
The dyeing unit 5 is arranged in the width direction of the raw machine B conveyed by the transfer device 3 and is arranged between the plurality of discharge ports 51 for discharging the dyeing agent, and between the raw machine B and the plurality of discharge ports 51. It has a guide plate 52 that guides the dyeing agent discharged from the discharge port 51 to the living machine B, and an adjusting unit 53 that adjusts the amount of the dyeing agent discharged from each of the discharge ports 51.

<Transport device>
The transport device 3 transports the long strip-shaped raw machine B in the longitudinal direction. The white arrows in each figure indicate the transport direction of the raw machine B. The transport device 3 has a conventionally known roller and a drive device (not shown). The raw machine B transported by the transport device 3 is an undyed raw machine. The undyed raw machine B has a long strip-shaped base cloth and an undyed pile yarn tufted on the base cloth.
The undyed raw machine B refers to a raw machine before dyeing the pile yarn with a dyeing agent in order to obtain the final design of the carpet. Therefore, as will be described later, the undyed raw machine B includes not only the case where the pile yarn is not dyed at all, but also the case where the pile yarn is dyed with some color.
In this specification, the side to which the livestock is sent is referred to as the "downstream side", and the opposite side is referred to as the "upstream side".

<Pretreatment unit>
The pretreatment unit 4 is a device for applying a treatment agent to the surface of the undyed raw machine B. The surface of the raw machine B is made of pile yarn.
The treatment agent contains at least one of a resist dye and water, and may contain other components if necessary. Examples of other components include viscosity regulators such as glues, pH regulators, dyes, leveling agents and the like. The details of the treatment agent will be described in detail in the column of continuous dyeing method.

The treatment agent is applied to the surface of the raw machine B using an appropriate pretreatment section 4.
The pretreatment unit 4 is not particularly limited as long as the treatment agent can be applied to the surface of the raw machine B transported by the transfer device 3. In the illustrated example, a roll 41 that rotates in synchronization with the transfer of the raw machine B is used as the pretreatment unit 4. The roll 41 may be one or a plurality of rolls 41 may be arranged side by side. In the illustrated example, two rolls 411 and 412 (first roll 411 and second roll 412) are arranged in parallel with each other in the transport direction of the raw machine B.
The axis of the roll 41 (first roll 411 and second roll 412) is arranged substantially parallel to the width direction of the raw machine B, and is rotatable around the axis. The roll 41 may be rotated by applying a driving force by a separate driving device (not shown). Alternatively, the roll 41 may be rotatably supported on a shaft in a state of being in contact with the surface of the living machine B, and may rotate in accordance with the transportation of the living machine B.

A coating portion (not shown) provided with a treatment agent is provided on the peripheral surface of the roll 41.
As the coating portion with the roll 41, for example, a printing method can be used.
Specifically, (1) using a roll having a convex portion formed on the peripheral surface, a treatment agent is adhered to the top surface of the convex portion from a separate treatment agent supply roll, and the peripheral surface is convex as the roll rotates. A method of applying a treatment agent to the living machine B by bringing the top surface of the portion into contact with the surface of the living machine B (using the letterpress printing method), (2) a separate treatment using a roll having recesses formed on the peripheral surface. A method of applying a treatment agent to a living machine B by filling the recesses with a treatment agent from a agent supply roll or the like and bringing the concave portions on the peripheral surface into contact with the surface of the living machine B as the roll rotates (intaglio printing method). ), (3) Using a roll in which innumerable micropores are formed on the peripheral surface, the treatment agent is supplied from the inside of the roll, and the peripheral surface is brought into contact with the surface of the raw machine B as the roll rotates to make the treatment agent fine. Examples thereof include a method of exuding from the holes and applying the mixture to the raw machine B (using the stencil printing method).
When the rolls 41 of (1) and (2) are used, the treatment agent has substantially the same shape as the plan view shape of the convex portion and the concave portion and is transferred to the raw machine B. When the roll 41 of (3) is used, the treatment agent is transferred to the raw machine B in a shape substantially the same as the aggregate shape of innumerable micropores.
Since the amount of coating per hour is large, it is preferable to use the roll 41 of (3) above. In particular, by applying the treatment agent containing a large amount of water using the roll 41 of the above (3) capable of applying a relatively large amount of the treatment agent, the dyeing agent in the dyeing portion 5 on the downstream side is sufficiently diluted. It is possible to express a color pattern with a good blur tone.

The coating shape of the treatment agent can be appropriately set according to the form of the coating portion of the roll 41.
For example, when a roll 41 having a spot-shaped coating portion provided on the peripheral surface is used, the treatment agent C is formed as a spot in a plan view on the surface of the living machine B at a predetermined interval in the longitudinal direction. It is applied to the shape. The spot-like shape is not particularly limited, and examples thereof include a substantially polygonal shape such as a substantially rectangular shape and a substantially triangular shape, a substantially circular shape, a substantially elliptical shape, a substantially star shape, and other arbitrary shapes. In this case, only one coating portion having a spot-like shape such as a substantially rectangular shape may be provided on the peripheral surface of the roll 41 in the circumferential direction, or a plurality of coating portions may be provided at predetermined intervals in the circumferential direction. You may be. Further, only one spot-shaped coating portion may be provided on the peripheral surface of the roll 41 in the axial direction thereof, or a plurality of coating portions may be provided in the axial direction at predetermined intervals. ..

Further, for example, when the roll 41 in which the peripheral surface of the roll 41 is provided with a coating portion having a continuous shape over the entire circumferential direction, the treatment agent C is flat on the surface of the living machine B in the longitudinal direction. It is applied in the shape of a visual band. Examples of the continuous shape include an annular shape extending over the entire circumferential direction of the peripheral surface. In this case, only one coating portion having a shape continuous in the circumferential direction may be provided on the peripheral surface of the roll 41 in the axial direction, or may be predetermined on the peripheral surface of the roll 41 in the axial direction. A plurality of them may be provided at intervals.
Further, the peripheral surface of the roll 41 may be provided with the spot-shaped coating portion and the continuous-shaped coating portion. In addition, the form of the coating portion provided on the roll 41 can be set in various ways.

As described above, when a plurality of rolls 41 are arranged side by side (for example, the first roll 411 and the second roll 412), the form of the coated portion of each roll 41 may be the same or different. From the significance of using a plurality of rolls 41, it is preferable to use a plurality of rolls 41 having different forms of coated portions.
For example, the first roll 411 is provided with a plurality of spot-shaped coating portions such as a substantially rectangular shape, and the second roll 412 is provided with a continuous coating portion.

<Dyeing part>
In FIGS. 3 to 5, a dyeing section 5 is provided on the downstream side of the pretreatment section 4.
The dyeing unit 5 is a device for applying a dyeing agent to the surface of the undyed raw machine B. The type of the dyeing agent application device is not particularly limited, and examples thereof include a shower curtain type and a dipping type. The shower curtain type is a device for dyeing by pouring an appropriate amount of dyeing agent onto the living machine B from above and applying the dyeing agent, and the dipping type is for submerging the living machine B in a dyeing tank in which the dyeing agent is stored. It is a device that dyes by. Since there is no risk of the treatment agent applied to the raw machine B flowing out in the pretreatment unit 4, the amount of dyeing can be controlled, and the dyeing homogenization and the dyeing speed are also excellent, a shower curtain type coating device is available. preferable.
In the illustrated example, the shower curtain type coating portion 5 is shown.
As shown in FIGS. 4 to 8, the dyeing unit 5 is arranged between the plurality of discharge ports 51 and the raw machine B and the plurality of discharge ports 51, and the dyeing agent discharged from the discharge ports 51 is used as the raw machine B. 52, and an adjusting unit 53 for adjusting the discharge amount of the dyeing agent from each of the discharge ports 51, preferably measuring the discharge amount of the dyeing agent flowing out from each of the discharge ports 51. Further has a flow meter 54 to be used.

A guide plate 52 is arranged in the middle of the transfer device 3 and immediately downstream of the pretreatment unit 4. The guide plate 52 is made of a plate-like body having a flat surface, and in the illustrated example, the guide plate 52 has a substantially rectangular shape in a plan view. The back surface of the guide plate 52 may be flat or may be formed in an uneven shape. The guide plate 52 is not limited to a flat plate, and a plate-shaped body having a bent portion or a plate-shaped body having a curved surface portion may be used. Further, as shown in FIGS. 5 and 8, the lower end 521 of the guide plate 52 is preferably sharp in the side view. Since the lower end 521 of the guide plate 52 is sharp in the side view, the dyeing agent is cut well, and the dyeing agent flowing on the front surface of the guide plate 52 is less likely to wrap around to the back surface side of the guide plate 52.
The material of the guide plate 52 is not particularly limited, and examples thereof include metal, synthetic resin, glass, pottery, and combinations thereof. Above all, the guide plate 52 is preferably made of stainless steel because it has excellent corrosion resistance and it is difficult for the dyeing agent to adhere to it.

The guide plate 52 is arranged on the surface of the raw machine B transported by the transport device 3. The guide plate 52 is arranged so that the lower end 521 of the guide plate 52 extends substantially parallel to the width direction of the living machine B so as to extend in the width direction of the living machine B.
As shown in FIG. 8, the guide plate 52 is fixed to the fixed side (not shown) with its lower end 521 separated from the surface of the living machine B. Further, a moving device (not shown) for moving the guide plate 52 up and down may be provided so that the lower end 521 of the guide plate 52 can be brought closer to or further away from the surface of the living machine B.
The lower end 521 of the guide plate 52 in the illustrated example is linear in a plan view. However, the lower end 521 of the guide plate 52 has a wavy line shape, a zigzag shape, an arc shape or a bending shape in which the central portion in the width direction is recessed inward, an arc shape or a bending shape in which the central portion in the width direction protrudes outward, and the like. You may.

When the lower end 521 of the guide plate 52 is separated from the living machine B, the linear length H1 between the lower end 521 of the guiding plate 52 and the surface of the living machine B is not particularly limited, but if it is too small, they come into contact with each other. If it is too large, the size of the device may be increased, and the dyeing agent flowing down from the lower end 521 of the guide plate 52 may bounce off the surface of the raw machine B. From this point of view, the guide plate 52 is preferably arranged so that the linear length H1 between the lower end 521 of the guide plate 52 and the surface of the living machine B is 5 mm to 100 mm, and is preferably 10 mm to 50 mm. It is more preferable that the guide plate 52 is arranged.
When the moving device for moving the guide plate 52 up and down is provided, the linear length H1 can be finely adjusted to an appropriate distance according to the manufacturing conditions, the environment, and the like.

As shown in FIGS. 4 and 7, the length of the guide plate 52 in the width direction is larger than the width of the raw machine B conveyed by the transfer device 3, and therefore, both ends of the guide plate 52 in the width direction are the raw machine B. It protrudes outward from both ends in the width direction of.
Further, as shown in FIG. 8, the length L1 of the guide plate 52 (the length of the guide plate 52 corresponding to the longitudinal direction of the living machine B) is not particularly limited, but if it is too small, the area through which the dyeing agent is transmitted becomes large. It may become too small. From this point of view, the length L1 of the guide plate 52 is preferably 100 mm or more, more preferably 200 mm or more. Further, if the length L1 of the guide plate 52 is too large, the size of the device is increased. Therefore, the length L1 of the guide plate 52 is preferably 500 mm or less.

As shown in FIG. 8 and the like, the guide plate 52 is arranged so that the lower end 521 of the guide plate 52 is lower than the upper end 522 in a side view and the surface thereof is non-parallel to the surface of the living machine B. There is. Preferably, the guide plate 52 is arranged so that the internal angle α formed by the surface of the guide plate 52 and the surface of the living machine B is more than 0 degrees and 90 degrees or less, and more preferably, the internal angle α is 10 degrees or more. The guide plate 52 is arranged so as to be 80 degrees, and more preferably, the guide plate 52 is arranged so that the internal angle α is 30 degrees to 70 degrees. By arranging the guide plate 52 at an acute angle with respect to the living machine B in this way, the dyeing agent flows satisfactorily from the surface of the guiding plate 52 to the surface of the living machine B.
However, when the guide plate 52 has a shape having a bent portion or a curved surface portion, the internal angle α formed by the surface of the guide plate 52 and the surface of the living machine B is an average angle.
Further, an angle adjusting device (not shown) may be provided on the guide plate 52 so that the internal angle α can be changed. If the internal angle α is made smaller, the dyeing agent is more easily mixed, and if the internal angle α is made larger, the dyeing agent is more difficult to be mixed. By providing an angle adjusting device and adjusting the internal angle α (tilt angle) of the guide plate 52, the degree of mixing due to differences in conditions such as the type and viscosity of the dyeing agent can be stabilized, or depending on the desired color pattern. You can adjust the width of the blur area.

Further, a vibrating device (not shown) for vibrating the guide plate 52 may be provided. The vibrating device vibrates the guide plate 52 in parallel with the width direction of the live machine, vibrates the guide plate 52 in parallel with the longitudinal direction of the live machine, and moves the guide plate 52 closer to or further away from the live machine. It has at least one motion selected from the motion of vibrating in the vertical direction. By vibrating the guide plate 52, it is possible to change the way the dyeing agent is mixed on the guide plate 52. If the vibration width of the guide plate 52 by the vibrating device is too small, there is substantially no effect of vibration, and if it is too large, the dyeing agent may leak significantly from the guide plate 52. From this point of view, the vibration width of the guide plate 52 is preferably about 0.3 mm to 10 mm.

A plurality of discharge ports 51 are arranged on the surface of the guide plate 52. The plurality of discharge ports 51 independently discharge the dyeing agent. Each discharge port 51 is an outlet for a dyeing agent supplied from a tank described later, and each discharge port 51 discharges the dyeing agent to the surface of the guide plate 52. Such a discharge port 51 is also generally called a nozzle, and a conventionally known discharge port 51 can be used as the discharge port 51.
The material of the discharge port 51 is not particularly limited, and examples thereof include metal and synthetic resin. Above all, the discharge port 51 is preferably made of stainless steel because it has excellent corrosion resistance and it is difficult for the dyeing agent to adhere to it. The diameter of the discharge port 51 is not particularly limited, and is, for example, about 3 mm to 40 mm.

As shown in FIGS. 6 and 7, the plurality of discharge ports 51 are arranged side by side on the surface of the guide plate 52 in the width direction of the raw machine B before dyeing to be conveyed to the transfer device 3. .. The discharge ports 51 are arranged side by side in a straight line in the width direction of the living machine B. In the illustrated example, the discharge ports 51 are arranged side by side in one row, but as shown in FIG. 9, each discharge port 51 may be arranged in two or more rows in the longitudinal direction of the living machine B. ..
The distance W1 between the adjacent discharge ports 51 is not particularly limited, and is, for example, 5 mm to 100 mm, preferably 10 mm to 60 mm. If the interval W1 is too large, it becomes difficult to express in detail, and if it is too small, the apparatus becomes complicated and it may become difficult to discharge the dyeing agent. The number of discharge ports 51 can be appropriately set according to the length of the raw machine B in the width direction and the distance between the discharge ports 51. Although the number of discharge ports 51 is 10 in the illustrated example, it should be noted that this number is schematically shown.

Each discharge port 51 is fixed to a fixed side (not shown) away from the surface of the guide plate 52. However, the discharge port 51 may be fixed so as to come into contact with the surface of the guide plate 52.
When each discharge port 51 is separated from the guide plate 52, the linear length H2 between each discharge port 51 and the surface of the guide plate 52 is not particularly limited, but if it is too small, they come into contact with each other and are too large. As a result, the size of the device is increased, and the dyeing agent discharged from the discharge port 51 may bounce off the surface of the guide plate 52. From this point of view, the linear length H2 (the linear length drawn from the discharge port 51 in the vertical direction with respect to the surface of the guide plate 52) between each discharge port 51 and the surface of the guide plate 52 exceeds 0 and is 60 mm or less. It is preferable that each discharge port 51 is arranged so as to be 10 mm to 40 mm, and more preferably each discharge port 51 is arranged so as to be 10 mm to 40 mm.

Each discharge port 51 is arranged correspondingly between the lower end 521 and the upper end 522 of the guide plate 52. The linear length L2 between each discharge port 51 and the lower end 521 of the guide plate 52 is not particularly limited, but when each discharge port 51 is too close to the lower end 521 of the guide plate 52, the dyeing agent is applied on the surface of the guide plate 52. The flowing distance becomes relatively small. From this point of view, it is preferable that each discharge port 51 is arranged so that the linear length L2 from each discharge port 51 to the lower end 521 of the guide plate 52 is 50 mm to 500 mm, and each discharge port 51 is 100 mm to 400 mm. It is more preferable that the discharge port 51 is arranged.
Further, each discharge port 51 is moved up and down so that each discharge port 51 can approach or move away from the surface of the guide plate 52 and / or each discharge port 51 can move closer to or farther from the lower end 521 of the guide plate 52. A moving device (not shown) for causing the movement may be provided. By providing such a moving device, it is possible to adjust the mixing condition of the dyeing agent.

A flow meter 54 is provided at each discharge port 51. The flow meter 54 measures the amount of dyeing agent discharged from each discharge port 51. The flow meter 54 is connected to a control device (not shown), and the discharge amount of the dyeing agent from each discharge port 51 measured by the flow meter 54 is sent to the control device and managed.

Further, each discharge port 51 is provided with an adjusting unit 53. The adjusting unit 53 discharges the dyeing agent from the discharge port 51, changes the discharging amount of the dyeing agent, and stops the discharging of the dyeing agent. As the adjusting unit 53, for example, a valve body can be typically used. The adjusting unit 53 of the valve body or the like may be manually operated, but it is preferable that the adjusting unit 53 is connected to the control device and can mechanically throttle the discharge (increase / decrease the discharge amount) and stop the discharge. Examples of such an adjusting unit 53 include an automatic valve. Further, since it is relatively simple, the adjusting unit 53 may have a function of only switching between discharging the dyeing agent and stopping the discharge. Examples of such an adjusting unit 53 include a solenoid valve. Discharge and stop of the dyeing agent by the adjusting unit 53 such as the automatic valve or the solenoid valve are controlled by, for example, the control device and can be automatically controlled. As shown in FIGS. 5 to 7, the adjusting unit 53 may be provided on the upstream side of the flow meter 54, or may be provided between the discharge port 51 and the flow meter 54.
When the discharge and stop of the dyeing agent are controlled by the control device, it is necessary to adjust the adjusting unit 53 based on the data measured by the flow meter 54, so that the adjusting unit 53 is located upstream of the flow meter 54. It will be provided.

Each discharge port 51 is connected to the tank 56 via a supply tube 551 and 552. In FIGS. 6, 7, and 9, the supply tubes 551 and 552 are represented by different lengths, but it is preferable that they all have the same length. By using the supply tubes of the same length, the pressure in each supply tube becomes substantially uniform, the dyeing agent can be supplied to the discharge port 51 at a uniform speed, and the flow rate of the dyeing agent can be controlled accurately. ..
The number of tanks 56 may be one, but a plurality of tanks 56 are provided in order to discharge two or more kinds of dyeing agents from independent discharge ports 51. In the illustrated example, two tanks 56 are illustrated for convenience. That is, in the illustrated example, two sets of dyeing agent supply units composed of one tank and members connected to the tank are set. Hereinafter, when distinguishing tanks, discharge ports, etc. included in these dyeing agent supply units, "first" and "second" may be added to the beginning of each term.
In the present invention, two or more sets of dyeing agent supply sections including at least a tank, a supply tube, an adjusting section and a discharge port may be provided, and three sets or four sets may be provided. Since the types of dyeing agents can be increased according to the number of sets of dyeing agent supply units, the number of colors of the color pattern displayed on the raw machine can be increased, but on the other hand, the dyeing machine becomes more complicated and large. To go. In consideration of these, the number of sets of the dyeing agent supply unit is set.

The first tank 561 is provided with a first pump 571. Further, on the downstream side of the first tank 561, a first manifold 591 is provided through a first supply pipe 581. A plurality of first supply tubes 551 are connected to the first manifold 591, and the first discharge port 511 of the plurality of discharge ports 51 is connected to each of the first supply tubes 551.
The first manifold 591 branches the dyeing agent supplied from the first tank 561 into each first supply tube 551. The dyeing agent is sent from the first tank 561 to the first manifold 591 through the first pump 571, and the dyeing agent is discharged from the first discharge port 511 after passing through each adjusting unit 53 and the flow meter 54. ..

The second tank 562 is provided with a second pump 572. A second manifold 592 is provided on the downstream side of the second tank 562 through the second supply pipe 582. A plurality of second supply tubes 552 are connected to the second manifold 592, and a second discharge port 512 of the plurality of discharge ports 51 is connected to each of the second supply tubes 552.
The second manifold 592 branches the dyeing agent supplied from the second tank 562 into each second supply tube 552. The dyeing agent is sent from the second tank 562 to the second manifold 592 through the second pump 572, and the dyeing agent is discharged from the second discharge port 512 after passing through each adjusting unit 53 and the flow meter 54. ..

The first discharge port 511 connected to the first tank 561 and the second discharge port 512 connected to the second tank 562 can be appropriately selected from the discharge ports 51 arranged in the width direction, but the striped pattern is blurred. Since the tonal design can be easily dyed, for example, the first discharge port 511 and the second discharge port 512 are alternately arranged one by one in the width direction. The arrangement is not limited to this, and for example, the first discharge port 511 and the second discharge port 512 may be arranged alternately by 2 to 5 in the width direction. Further, the alternate arrangement is not limited to the same number, and the number of discharge ports may be different, for example, one first discharge port and two second discharge ports are alternately arranged. Good.

Further, when there are three or more tanks 56, some discharge ports are connected to each tank, but some are connected to each tank in order to form a striped blur tone due to each dyeing agent. It is preferable that the discharge ports of the above are also arranged alternately. For example, when three tanks are provided, some first outlets connected to the first tank, some second outlets connected to the second tank, and some third outlets connected to the third tank. Can be arranged in various patterns such as being arranged one by one in the width direction, being arranged alternately by two to five in the width direction, or being arranged alternately instead of the same number. ..

The manifold may be omitted as appropriate.
Further, although each tank 56 is provided with a pump 57 mainly for sending the dyeing agent to the manifold, it is not always limited to the case where the dyeing agent is discharged by applying pressure from each discharge port 51 as described later. Therefore, the pump 57 may be omitted. When the pump 57 is omitted, for example, by installing each tank 56 at a position higher than each discharge port 51, the dyeing agent can be supplied from each tank 56 to the discharge port 51 by potential energy.

[Continuous dyeing method for carpet]
Next, the method for continuously dyeing the carpet of the present invention will be described.
The carpet continuous dyeing method of the present invention can be carried out as one step incorporated in the production of carpet.
For example, the carpet manufacturing method includes an undyed raw machine preparation step, a raw machine pretreatment step, a raw machine dyeing step, and a back surface layer forming step, and may have other steps as required. Good.
Each of these steps may be carried out in series on one production line, or one or more steps selected from the above steps may be carried out on one line, and the remaining steps may be carried out on the other one or more. You may go on two or more lines. In addition, one performer may perform all of the steps, or one performer may perform one or more steps selected from the steps, and the remaining steps may be performed by another. May be done by a person.

<Preparation of raw machine>
A long strip-shaped undyed raw machine B is produced. The undyed raw machine B is obtained by tufting a pile yarn on a long strip-shaped base cloth.
The pile yarn is not particularly limited as long as it can be dyed with a dyeing agent in the dyeing step described later, and may be the pile yarn itself or a pile yarn colored in a desired color.
As the pile yarn, conventionally known yarns can be used, and examples thereof include synthetic fibers made of thermoplastic resin and the like, natural fibers such as cotton and wool, and mixed fibers of synthetic fibers and natural fibers. The material of the synthetic fiber is not particularly limited, and examples thereof include polyamide, acrylic, polyester, polypropylene, polyvinyl alcohol, polyurethane, cellulose, and polyvinyl chloride. Since it can be dyed well in various colors, it is preferable to use a pile yarn containing a polyamide-based resin fiber or a pile yarn composed of only a polyamide-based resin fiber.
The pile yarn tufted on the base fabric may be a cut pile or a loop pile. The pile height is also not particularly limited, and is, for example, 1 mm to 20 mm, preferably 2 mm to 10 mm. Further, the pile height may be constant or different. By tufting the pile yarn with different pile heights, an uneven pattern due to the pile height can be formed on the surface of the raw machine.
After the pile yarn is tufted on the base fabric to form a raw machine, a sealing layer made of an adhesive or the like is formed on the back surface of the base fabric to prevent the pile yarn from unraveling, if necessary. May be good.

<Pretreatment process>
The transport device 3 of the continuous dyeing machine A is used to transport the long strip-shaped undyed raw machine B in the longitudinal direction thereof.
As shown in FIGS. 10 and 11, the treatment agent C is applied to the surface of the raw machine B from the pretreatment unit 4 arranged during the transfer.
As the treatment agent C, a liquid one having fluidity is used. The treatment agent C contains at least one of a resist dye and water, and may contain other components if necessary. Examples of other components include viscosity regulators such as glues, pH regulators, dyes, leveling agents and the like.

The anti-dyeing agent does not contain a dyeing component and does not have a dyeing function by itself, and substantially prevents dyeing of the undyed pile yarn, or is undyed by the dyeing agent. It allows the pile yarn of No. 1 to be slightly dyed (in other words, the dyeing of the pile yarn by a dyeing agent is incomplete). As the anti-dyeing agent, conventionally known ones can be used, and examples thereof include condensed polymer compounds of aromatic sulfonic acids, aromatic sulfonates, polyhydric phenol-based condensed polymer compounds, glycols and the like. ..
The water allows undyed pile yarns to be dyed with a dye, but is lighter in color.
The glue is added to the treatment agent C, if necessary, in order to fix the treatment agent C applied to the surface of the living machine B and to adjust the viscosity of the treatment agent C. As the adhesive, conventionally known adhesives can be used, and examples thereof include water-based adhesives such as polyvinyl alcohol-based adhesives.
The dye is added to the treatment agent C, if necessary, in order to impart a slight color to the treatment agent C.

In the first example, the treatment agent C is composed of water and a paste.
In the second example, the treatment agent C comprises water, a paste, a dye and a pH adjuster.
In the third example, the treatment agent C comprises water, a paste and a dye.
In the fourth example, the treatment agent C comprises a resist dye, water, a paste and a pH adjuster.
In the fifth example, the treatment agent C comprises a resist dye, water, a paste, a dye and a pH adjuster.
In the sixth example, the treatment agent C comprises a resist dye, water, a paste and a dye.
In the seventh example, the treatment agent C comprises a resist dye, water, and a paste.
In the eighth example, the treatment agent C comprises a resist dye, a paste, a dye and a pH adjuster.
In the ninth example, the treatment agent C comprises water, a dye and a pH adjuster.
In the tenth example, the treatment agent C comprises water and a dye.
In the eleventh example, the treatment agent C comprises a resist dye, water and a pH adjuster.
In the twelfth example, the treatment agent C comprises a resist dye, water, a dye and a pH adjuster.
In the thirteenth example, the treatment agent C comprises a resist dye and a pH adjuster.
In the 14th example, the treatment agent C comprises only a resist dye.
In the fifteenth example, the treatment agent C consists only of water.
In the present embodiment in which the treatment agent is applied by the roll 41, the treatment agent C preferably contains water and a paste, and is preferably selected from the above 1st to 7th examples, for example.

The viscosity of the treatment agent in the present embodiment is not particularly limited, but is preferably 50 mPa · s to 10000 mPa · s, and more preferably 100 mPa · s to 8000 mPa · s. By using the treatment agent C having such a viscosity, the treatment agent C can be satisfactorily applied to the living machine B using the roll 41, and the applied treatment agent C does not spread unnecessarily.
However, in the present specification, the viscosity of the treatment agent is measured at 23 ° C. using an E-type viscometer (model "VISCONIC E" manufactured by Tokyo Keiki Co., Ltd., rotation speed 25 to 100 RPM).

Further, when a plurality of rolls 41 (first roll 411 and second roll 412 in the illustrated example) are used as described above, the same treatment agent C may be applied to each roll 41, or different treatments may be applied. Agent C may be applied.
For example, in the first roll 411, one kind of treatment agent C (for example, the treatment agent C of the first example) is applied, and in the second roll 412, the same treatment agent C (for example, the treatment agent C of the first example) is applied. The treatment agent C) is applied. Alternatively, in the first roll 411, one kind of treatment agent C (for example, the treatment agent C of the first example) is applied, and in the second roll 412, a treatment agent C different from this (for example, the treatment agent C of the fourth example) is applied. The treatment agent C) is applied.

As described above, the treatment agent C is applied to the raw machine B at the coating portion of the roll 41. Hereinafter, the portion of the surface of the living machine B to which the treating agent C is applied is referred to as a “treatment agent adhering portion”.
For example, when a roll 41 provided with a spot-like coating portion is used, the treatment agent C is applied to the surface of the living machine B in a plan view shape substantially the same as the spot-like shape, and the flat surface thereof. Visually shaped processing agent adhering portions are formed at predetermined intervals in the longitudinal direction of the living machine B. That is, a plurality of spot-like processing agent adhering portions are formed on the surface of the living machine B in the longitudinal direction, and in this case, the treating agent adhering portions are discontinuous in the longitudinal direction.
On the other hand, for example, when a roll 41 provided with a continuously shaped coating portion is used, a plan-view strip-shaped processing agent adhering portion extending continuously in the longitudinal direction thereof is formed on the surface of the living machine B. To go.

When a plurality of rolls 41 (first roll 411 and second roll 412 in the illustrated example) are used, a part of the treatment agent adhering portion formed by the application of the treatment agent C on each roll 41 overlaps. It may be used, or none of them may overlap. A part of the treatment agent adhering portion overlaps, for example, a part of the treatment agent adhering portion formed by the application of the second roll 412 overlaps with the treatment agent adhering portion formed by the coating of the first roll 411. To say. The fact that none of the treatment agent adhering portions overlap means that, for example, the treatment agent adhering portion formed by the application of the first roll 411 does not overlap with the treatment agent adhering portion formed by the application of the second roll 412. Say.
From the significance of using a plurality of rolls 41, it is preferable that each roll 41 is configured to apply the treatment agent C so that the treatment agent adhesion portions formed by them do not overlap. When the treatment agent C is applied so that the treatment agent adhered portions overlap, the upstream roll 41 (first roll in the illustrated example) is applied to the coated portion of the downstream roll 41 (second roll 412 in the illustrated example). The treatment agent C from 411) may come into contact with the roll 41 on the downstream side and be contaminated with the treatment agent on the roll 41 on the upstream side.

In FIG. 10, in order to show the treatment agent adhering portion in an easy-to-understand manner, for convenience, the treatment agent adhering portion by the first roll 411 is shaded to the left and the treatment agent adhering portion by the second roll is shaded to the right. ing.
In FIG. 10, the treatment agent adhering portion based on the first roll 411 has a substantially rectangular shape in a plan view, and the treatment agent adhering portion based on the second roll 412 has a plan view band shape. The treatment agent adhering portion based on the first roll 411 and the treatment agent adhering portion based on the second roll 412 do not overlap each other and are separated from each other with a gap in the width direction of the living machine B.
The plan view shape of the portion to which the treatment agent is attached by each roll 41 is not limited to this, and the treatment agent C can be applied to various shapes by appropriately setting the shape of the coating portion of the roll 41. Further, by arranging the coating portion at an appropriate position on the peripheral surface of each roll 41 in the circumferential direction and / or the axial direction, the treatment agent adhering portion formed by each roll 41 as described above does not overlap. Can be. In this case, even if the coated portion of each roll 41 has the same shape and the same size (for example, a substantially rectangular shape of the same size), by shifting the arrangement of the coated portion in each roll 41, each roll as described above. It is possible to prevent the treatment agent adhering portions formed by 41 from overlapping.
After the pretreatment, the dyeing treatment is performed.

<Dyeing process>
Using the transport device 3 of the continuous dyeing machine A, the undyed raw machine B subjected to the pretreatment is transported in the longitudinal direction thereof. As shown in FIGS. 10 and 11, the dyeing agent is discharged from each discharge port 51 arranged in the middle of transportation, and the dyeing agent is applied to the surface of the raw machine B from the lower end thereof along the surface of the guide plate 52. ..
As described above, in the continuous dyeing machine A provided with a plurality of tanks 56, different dyeing agents are usually put into each tank 56. However, even in the continuous dyeing machine A provided with a plurality of tanks 56, the same dyeing agent may be put into at least two tanks selected from the plurality of tanks 56, or the same dyeing may be applied to all the tanks. You may add an agent.
The different dyes are (a) dyes with different colors for dyeing pile yarn, (b) dyes with the same color but different color depth, and (c) dyes with the same color but the dye itself. (D) Different types of dyeing agents as described later (for example, acidic dyes and cationic dyes are different types of dyeing agents), (e) selected from the above (a) to (d). There are at least two combinations, and the like.

For example, the first tank 561 contains a dyeing agent capable of dyeing the pile yarn in a desired color (for example, blue), and the second tank 562 is dyed with the pile yarn in a different color (for example, white). A dyeing agent that can be used is added. Further, for example, an acid dye having a desired color is placed in the first tank 561, and a cationic dye having a desired color is placed in the second tank 562. Hereinafter, these different dyeing agents may be referred to as a first dyeing agent and a second dyeing agent.
In the above, a dyeing machine having two sets of dyeing agent supply units including a tank, a supply tube, an adjusting unit and a discharge port is shown, but when three or more sets of dyeing agent supply units are provided, , It is preferable that different dyeing agents are discharged from each supply unit.
Further, the dyeing agent to be put in each tank may be a combination of various dyes, for example, a mixed dye in which an acid dye and a cationic dye are mixed, a dye in which a plurality of acid dyes are mixed and adjusted to a desired color, and the like. Good.

The type of dyeing agent can be appropriately set according to the pile yarn, and examples thereof include dyes and pigments, and dyes are preferably used. Examples of the types of dyes include acidic dyes, cationic dyes, metal-containing dyes, disperse dyes, direct dyes, reactive dyes, fluorescent dyes, sulfurized dyes, and combinations thereof.
As the dyeing agent, a liquid one having fluidity is used.
The viscosity of the dyeing agent is not particularly limited, but if the viscosity is too high, the dyeing agent does not flow well on the surface of the guide plate 52, and if the viscosity is too low, the dyeing agent flows along the surface of the guide plate 52 at an early stage. There is a risk of From this point of view, the viscosity of the dyeing agent is preferably 0.6 mPa · s to 100 mPa · s, more preferably 0.6 mPa · s to 10 mPa · s.
However, in the present specification, the viscosity of the dyeing agent is measured at 23 ° C. using an E-type viscometer (model "VISCONIC E" manufactured by Tokyo Keiki Co., Ltd., rotation speed 0.5 to 100 RPM).

The discharge rate of the dyeing agent from each discharge port 51 is not particularly limited, and is independently, for example, 0.2 to 10 L / min, preferably 0.5 to 5 L / min. By setting the discharge rate within the above range, it is possible to effectively prevent the dyeing agent from bouncing off on the guide plate 52.
The dyeing agent is discharged from each discharge port 51.
The discharge properties of the dyeing agent from each discharge port 51 are not particularly limited, and the dyeing agent may be discharged in the form of a mist, but the first dyeing agent and the second dyeing agent (different dyeing agents) are discharged on the guide plate 52. ) Are mixed well, as shown in FIG. 11, it is preferable to discharge each dyeing agent from the discharge port 51 in a substantially linear shape. The dyeing agent discharged from each discharge port 51 first falls on the guide plate 52 in a striped manner.

When the first dyeing agent D1 is discharged from the first discharge port 511 and the second dyeing agent D2 is discharged from the second discharge port 512 onto the guide plate 52, the first dyeing agent D1 and the second dyeing agent D2 are transferred to the guide plate 52. It flows up to the lower end 521 side of the guide plate 52. Then, the first dyeing agent D1 and the second dyeing agent D2 spread in the width direction toward the lower end 521 side of the guide plate 52, as if two rivers merge in the region near the lower end 521 of the guide plate 52. While both dyeing agents are mixed, they move from the lower end 521 of the guide plate 52 to the surface of the living machine B.
In FIG. 10, for the sake of clarity, the first dyeing agent is provided with innumerable dots and the second dyeing agent is shaded (the same applies to FIGS. 12 and 14).
By moving the first dyeing agent D1 and the second dyeing agent D2 previously mixed on the induction plate 52 to the living machine B in this way, the first dyeing agent D1 to the second dyeing agent D2 (or the second dyeing agent) The color change is continuous from D2 to the first dye D1). Therefore, both dyeing agents are mixedly applied and continuously colored between the region mainly coated with the first dyeing agent D1 and the region mainly coated with the second dyeing agent D2 and the two regions. The changed gradation region and is formed on the surface of the living machine B.

Further, based on the discharge amount of the dyeing agent from each discharge port 51 measured by the flow meter 54, the adjusting unit 53 of each discharge port 51 is operated to increase or decrease the discharge amount of the dyeing agent from an arbitrary discharge port 51. It can be stopped or stopped.
Further, the adjusting unit 53 can be operated to increase or decrease the amount of the dyeing agent discharged from the arbitrary discharge port 51, or to stop it, regardless of the amount of the dyeing agent discharged by the flow meter 54. Each adjusting unit 53 is independent, and the adjusting unit 53 can independently increase or decrease the amount of dyeing agent discharged from each discharging port 51 for each discharging port 51. Further, each discharge port 51 may be divided into a plurality of groups, and the increase / decrease and stop of the discharge amount of the dyeing agent from the discharge port 51 may be controlled independently for each group.

As described above, the operation of the adjusting unit 53 is controlled by, for example, a control device (not shown). In the control device, for example, when the value of the flow meter 54 is large, the discharge amount of the dyeing agent is reduced, and when the value is small, the discharge amount is increased, that is, automatic control such as feedback control is performed. By performing such control, the discharge amount can be stabilized regardless of physical properties such as the type and viscosity of the dyeing agent and changes in the environment. The administrator manually operates the adjusting unit 53 to change the dyeing conditions such as the dyeing density, the color mixing state, and the switching of the dyeing agent, and makes adjustments such as stabilizing the discharge amount while looking at the flow meter 54. You may do it. When an ON / OFF type such as a solenoid valve is used as the adjusting unit 53, the dyeing agent is discharged and stopped at each discharge port 51. By controlling the discharge and stop of the dyeing agent at each discharge port 51, it is possible to change the dyeing conditions such as the color mixing state and the switching or replacement of the dyeing agent.

For example, as shown in FIG. 12, the dyeing agent from one or more of the first discharge ports 511 out of the plurality of first discharge ports 511 is stopped by the adjusting unit 53. Alternatively, the adjusting unit 53 stops the dyeing agent from one or more of the second discharge ports 512 among the plurality of second discharge ports 512. Since the dyeing agent does not come out from the stopped discharge port 51, the dyeing agents from the discharge ports 51 on both sides of the discharge port 51 are mixed on the guide plate 52, and the surface of the living machine B is formed from the lower end 521 of the guide plate 52. Will move to.
In FIG. 12, the dyeing agents from the second discharge port 512 and the seventh first discharge port 511 from the upper side of the paper surface are stopped by the adjusting unit 53. In this case, the first dyeing agents from the first and third first discharge ports 511 from the upper side are mixed, but since the second discharge port 512, which is the second from the upper side, is stopped, the first dyeing to be mixed. The concentration of the agent becomes thin. Therefore, the raw machine B is also lightly dyed in this region, resulting in a blurred tone. The same applies to the second dyeing agent from the second discharge port 512, which is the sixth and eighth from the upper side.

Further, although not particularly shown, in another embodiment, the amount of the dyeing agent from one or more of the first discharge ports 511 among the plurality of first discharge ports 511 is reduced by the adjusting unit 53. Alternatively, the adjustment unit 53 reduces the amount of the dyeing agent from one or more of the second discharge ports 512 among the plurality of second discharge ports 512. Since the amount of dyeing agent discharged from the discharge port 51 squeezed by the adjusting unit 53 is reduced, the dyeing agent from the discharge port 51 is largely mixed with the dyeing agent from the discharge ports 51 on both sides thereof, and the guide plate 52 It comes to shift from the lower end 521 of the above to the surface of the living machine B.
Further, although not particularly shown, in another embodiment, the amount of the dyeing agent from one or more of the first discharge ports 511 out of the plurality of first discharge ports 511 is increased by the adjusting unit 53. Alternatively, the adjustment unit 53 increases the amount of the dyeing agent from one or more of the second discharge ports 512 among the plurality of second discharge ports 512.
Stopping, decreasing and increasing these dyeing agents can be arbitrarily selected from each discharge port 51.

<Post-treatment process>
As shown in FIG. 3, it is preferable that the dyeing agent is fixed on the pile surface of the raw machine B1 coated with the dyeing agent by passing steam through the steam chamber 91 as needed. By applying steam, the color of the raw machine B1 is less likely to fade.
Further, if necessary, it is preferable to pass the living machine B1 through the cleaning chamber 92 to clean the pile surface. By washing, the remaining dyeing agent and the like can be removed. The cleaning liquid is not particularly limited as long as it can remove residual components such as a dyeing agent and a treatment agent, and examples thereof include water and low-concentration alcoholic water. The temperature of the cleaning liquid is usually about 5 ° C to 50 ° C. The cleaning method is not particularly limited, and examples thereof include a method of spraying the cleaning liquid on the living machine B1 and a method of passing the living machine B1 through a bath filled with the cleaning liquid.
In addition, after washing, the raw machine B1 is dried. The drying method is not particularly limited, and examples thereof include natural drying and drying using warm air.

<Formation process of back surface layer>
A back surface layer is formed on the back surface of the dyed raw machine B1. The back surface layer can be formed by a conventionally known method.
By forming the back surface layer, a long strip-shaped carpet is obtained. The back surface layer may be formed before the dyeing step. In this case, the dyeing step is performed on the undyed raw machine B having the back surface layer formed on the back surface. When the back surface layer is composed of a plurality of layers, the back surface layer forming step may be divided into two or more, one may be performed before the dyeing step, and the rest may be performed after the dyeing step.
By cutting the long strip-shaped carpet thus obtained into a desired shape, a single-wafer-shaped carpet 1 as shown in FIG. 1 can be obtained. The long strip-shaped carpet may be stored and transported as it is.

The carpet continuous dyeing machine and the continuous dyeing method of the present invention can continuously dye a long strip-shaped raw machine B, and are excellent in carpet manufacturing efficiency.
Further, in the carpet continuous dyeing machine and the continuous dyeing method of the present invention, a pretreatment section 4 is provided on the upstream side of the dyeing section 5, and the pretreatment section 4 contains a resist dye and a treatment agent containing at least one of water. C is applied to the raw machine B. Therefore, when the dyeing agent is subsequently applied to the dyeing portion 5, the central portion of the treatment agent adhering portion is hardly dyed by the dyeing agent and becomes a light color, and gradually increases from the central portion toward the periphery of the treating agent adhering portion. It becomes darker and becomes the color of the dyeing agent on the outside of the part where the treatment agent is attached.
For the blur-like color pattern, adjust the viscosity of the treatment agent C, and when using the treatment agent C containing a resist dye, adjust the content ratio of the resist dye to adjust the strength of the blur. Can be controlled. For example, when the treatment agent C having a high viscosity is used, the blur tone becomes weak and the contour is clearly expressed, and conversely, when the treatment agent C having a low viscosity is used, the blur tone becomes strong. Further, when the treatment agent C having a high content ratio of the resist dye is used, the blur tone becomes strong, and when the treatment agent C having a low content ratio of the resist dye is used, the blur tone becomes weak.

As described above, according to the present invention, the raw machine B1 can be dyed in a blur-like color pattern having a natural feeling as if the dyeing agent has exuded around the portion to which the treating agent is attached, and the treating agent C is applied to a desired portion. By doing so, the raw machine B1 can be dyed in various blurred color patterns.
In particular, in dyeing using a continuous dyeing machine, it is conventionally difficult to express a pattern that is not continuous in the longitudinal direction. In this respect, according to the present invention, the treatment agent C can be applied in a spot manner in the longitudinal direction of the living machine B, and in this case, a discontinuous treatment agent adhering portion is formed in the longitudinal direction of the living machine B ( For example, (see FIG. 10 and the like), it is possible to express a color pattern that is not continuous in the longitudinal direction. As described above, according to the present invention, various color patterns can be expressed on the living machine.

Further, since the dyeing unit 5 is provided with the guide plates 52 below the plurality of discharge ports 51, the living machine B can be further dyed in a color pattern having a good blur tone.
Specifically, as described above, the first dyeing agent D1 and the second dyeing agent D2 from the first discharge port 511 and the second discharge port 512 (each discharge port 51) are mixed in advance on the guide plate 52. It shifts to the raw machine B while matching. Since the first dyeing agent D1 and the second dyeing agent D2 flowing on the induction plate 52 are mixed according to the fluidity of the dyeing agent itself, an unartificial and natural gradation is generated between the two dyeing agents. By shifting to the living machine B, on the surface of the living machine B, between the region stained with the first dyeing agent D1, the region dyed with the second dyeing agent D2, and the two color regions. It is possible to dye a color pattern having a good blur tone, which is a mixture of two dyeing agents and has a gradation region of natural color change. This gradation region continuously changes from the color of the first dyeing agent D1 to the color of the second dyeing agent D2 (from the color of the second dyeing agent D2 to the color of the first dyeing agent D1), and is a natural color. Carpets with a variable blur design can be provided. When the first dyeing agent and the second dyeing agent are dyeing agents of the same color, the gradation region has a blur tone in which the color depth is lightened with a single color.

The continuous dyeing machine A having the dyeing unit 5 in addition to the pretreatment unit 4 has a region dyed with the first dyeing agent D1 and a region dyed with the second dyeing agent D2, and a gradation of natural color change. At the portion where the region overlaps the portion to which the treatment agent is attached, a light color that is hardly dyed by the dyeing agent and a natural blur-like color pattern in which the dyeing agent has exuded are generated, respectively. Therefore, by combining the dyeing section with the pretreatment section, it is possible to express a natural-looking blurred color pattern in a more complicated and diverse manner.
In addition, the pretreatment unit 4 and the dyeing unit 5 can efficiently and mass-dye the entire living machine while expressing the color pattern in the continuous dyeing of the dyeing unit 5.

Further, since the discharge amount of each dyeing agent is measured by the flow meter 54, it is possible to discover a situation in which a large amount of dyeing agent is inadvertently discharged at each discharge port 51, and each of them is detected via the adjusting unit 53. The amount of dyeing agent at the discharge port 51 can be adjusted.
Further, since the adjusting unit 53 is provided in each discharge port 51, the discharge amount of the dyeing agent can be controlled independently for each discharge port 51, and the raw machine B1 can be dyed in various blurred color patterns.

[Other Embodiments]
The present invention is not limited to the above embodiment, and can be variously modified within the scope intended by the present invention. Hereinafter, other embodiments of the present invention will be described, but in the description thereof, configurations and effects different from those of the above-described embodiments will be mainly described, and for similar configurations, terms or symbols are used as they are, and the same. The description of the configuration may be omitted.

In the above embodiment, the roll 41 is used as the pretreatment unit 4, but for example, as shown in FIG. 13, a spray 42 may be used.
The spray 42 sprays the treatment agent C in the form of a mist. Although one spray 42 may be provided, it is preferable that a plurality of sprays 42 are provided in the width direction of the living machine B as shown in the illustrated example. The tube that supplies the treatment agent to the spray 42 is omitted in the middle.
Further, as shown in the drawing, the plurality of sprays 42 may be arranged side by side in one row in the width direction of the living machine B, or, although not particularly shown, two rows arranged in the width direction are arranged in the longitudinal direction. The above may be arranged side by side, or may be arranged alternately (staggered in a plan view) in the width direction and the longitudinal direction. Further, the spray 42 may be provided so as to be movable in the width direction and / or the vertical direction. For example, the spray 42 may be provided with a moving device (not shown). In this case, by applying the treatment agent while moving the spray 42 in the width direction, for example, a wavy treatment agent adhesion portion meandering in the longitudinal direction can be formed on the surface of the living machine B, and a color pattern rich in variation can be formed. Can be expressed.

The material of the spray 42 is not particularly limited, and examples thereof include metal and synthetic resin. Above all, the spray 42 is preferably made of stainless steel because it has excellent corrosion resistance and the dyeing agent does not easily adhere to it.

In the continuous dyeing machine in which the spray 42 is used as the pretreatment unit 4, the long strip-shaped undyed raw machine B is conveyed in the longitudinal direction by using the transfer device 3 in the same manner as described above, and FIGS. 14 and 15 show. As shown, the treatment agent C is applied to the surface of the living machine B from the spray 42 (pretreatment section 4). In FIG. 14, the treatment agent is shaded for convenience in order to clearly show the portion to which the treatment agent is applied.
The treatment agent C is not particularly limited. In the present embodiment in which the treatment agent is applied by spray 42, the treatment agent C does not necessarily have to contain a glue. For example, in the present embodiment, various agents such as the first to fifteenth examples illustrated above can be used as the treatment agent C, and it is preferable to select from the ninth to fifteenth examples.
The viscosity of the treatment agent in the present embodiment is not particularly limited, but is preferably 0.1 mPa · s to 5000 mPa · s, and more preferably 0.5 mPa · s to 3000 mPa · s. By using the treatment agent C having such a viscosity, the treatment agent C can be satisfactorily applied to the living machine B by using the spray 42.

The treatment agent C sprayed from each spray 42 may be the same or different for each spray 42. In the illustrated example, a state in which one type of treatment agent C is sprayed on the living machine B from some of the plurality of sprays 42 and a different treatment agent C is sprayed on the living machine B from the remaining spray 42 is shown. There is. In FIG. 14, one type of treatment agent is shaded downward to the left, and a different treatment agent C is shaded downward to the right.
Also in the pretreatment unit 4 using the spray 42, various treatment agents C containing at least one of the resist dyeing agent and water are applied to the desired portion in the pretreatment unit 4 as in the above embodiment. The raw machine B1 can be dyed in a blurred color pattern.
In particular, when the spray 42 is used, the treatment agent C having a relatively low viscosity can be applied, so that a more natural blur-like color pattern can be expressed.

Further, in the dyeing step of the above embodiment, different dyeing agents are applied to the living machine B from each discharge port 51, but for example, the same dyeing agent may be applied to the living machine B from all the discharge ports 51. In this case, the carpet raw machine B has one color in terms of color, but since the treatment agent C is applied, a natural-looking shade is generated at the portion where the treatment agent adheres, and the carpet with one color of blurring is produced. can get.

Further, in the dyeing unit 5 of the continuous dyeing machine of the above embodiment, the flow meter 54 and the adjusting unit 53 are independently provided in the plurality of discharge ports 51, but even if these are not provided in each discharge port 51. Good. Alternatively, each discharge port 51 may not be provided with these, and a flow meter and an adjusting unit may be provided between the tanks 561, 562 and the manifolds 591 and 592.
Further, the discharge port 513 of the dyeing unit 5 is not limited to a plurality of independent ones, and for example, as shown in FIG. 16, a discharge port 513 having a slit-shaped opening 513a extending in the width direction of the living machine B may be used. Good. The dyeing agent is supplied from the tank 563 to the discharge port 513 through the supply pipe 583, and the dyeing agent is discharged from the opening 513a onto the guide plate 52. The discharge port 513 of the illustrated example has an opening 513a formed to have substantially the same width as the living machine B so that the dyeing agent can be applied to the entire width direction of the living machine B. However, the slit-shaped opening is not limited to substantially the same as the width of the living machine B, and may be formed in, for example, half or one-third of the width of the living machine B (not shown). Further, although only one discharge port 513 in the illustrated example is provided for the living machine B, the present invention is not limited to this, and two or more discharge ports 513 may be provided.

Further, although the dyeing unit 5 has the guide plate 52, the dyeing agent may be applied directly to the surface of the raw machine B from the discharge port without providing the guide plate 52.
In addition, the continuous dyeing machine and the continuous dyeing method of the present invention are not limited to the above-described embodiments and modifications, and various designs can be changed within the range intended by the present invention.

A Continuous dyeing machine B Raw machine before dyeing B1 Raw machine after dyeing C Treatment agent D1, D2 Dyeing agent 1 Carpet 3 Transport device 4 Pretreatment part 41,411,412 Roll 42 Spray 5 Dyeing part 51,511,512,513 Vomiting Outlet 52 Induction plate 53 Adjusting part 54 Flow meter

Claims (6)

A transport device that transports live carpets and
A pretreatment section for applying a resist dye and a treatment agent containing at least one of water to the raw machine transported by the transfer device.
The raw machine to which the treatment agent has been applied by the pretreatment unit has a dyeing unit to which the dyeing agent is applied.
The pretreatment section applies the treatment agent to a plurality of spot-like portions spaced apart in the width direction and the longitudinal direction of the living machine, and the portion to which the treatment agent is not attached and the portion to which the treatment agent is attached A continuous dyeing machine for carpets, which is configured to form the raw machine. The continuous carpet dyeing machine according to claim 1, wherein the pretreatment unit rotates in synchronization with the transportation of the raw machine and has a roll that comes into contact with the surface of the raw machine to apply the treatment agent. The continuous carpet dyeing machine according to claim 1, wherein the pretreatment unit has a spray for spraying the treatment agent on the surface of the living machine. A transport device that transports live carpets and
A pretreatment section for applying a resist dye and a treatment agent containing at least one of water to the raw machine transported by the transfer device.
The raw machine to which the treatment agent has been applied by the pretreatment unit has a dyeing unit to which the dyeing agent is applied.
The pretreatment section is configured to apply the treatment agent to a plurality of spot-like portions spaced apart in the width direction and the longitudinal direction of the raw machine.
The dyeing unit is arranged in the width direction of the raw machine conveyed by the transfer device and is arranged between a plurality of discharge ports for discharging the dyeing agent, and between the raw machine and the plurality of discharge ports, and is discharged from the discharge port. It has a guide plate that guides the dyeing agent to the living machine.
The discharge port includes a first discharge port for discharging the first dyeing agent and a second discharge port for discharging a second dyeing agent different from the first dyeing agent, and the first discharge port and the second discharge port. Discharge ports are arranged alternately in the width direction,
The guide plate is inclined so as to be mixed in the width direction in the process of guiding the first dyeing agent and the second dyeing agent discharged from the first discharge port and the second discharge port to the living machine. , Carpet continuous dyeing machine. The transport process for transporting the carpet raw machine and
A pretreatment step of applying a resist dye and a treatment agent containing at least one of water to the raw machine, and
It has a dyeing step of dyeing a raw machine coated with the treatment agent with a dyeing agent.
In the pretreatment step, by applying the treatment agent to a plurality of spot-like portions spaced apart in the width direction and the longitudinal direction of the living machine, the portion to which the treatment agent is not adhered and the treatment agent adhere to the portion. A method for continuously dyeing a carpet, in which the portion is formed on the living machine . The transport process for transporting the carpet raw machine and
A pretreatment step of applying a resist dye and a treatment agent containing at least one of water to the raw machine, and
It has a dyeing step of dyeing a raw machine coated with the treatment agent with a dyeing agent.
In the pretreatment step, the treatment agent is applied to a plurality of spot-like portions spaced apart in the width direction and the longitudinal direction of the raw machine.
In the dyeing step, the first dyeing agent and the second dyeing agent, which are different dyeing agents, are discharged onto the guide plate from a plurality of discharge ports arranged in the width direction of the living machine, and the first dyeing agent and the second dyeing agent are dyed. A method for continuously dyeing a carpet, in which the agent is guided to the raw machine while being mixed in the width direction in the process of flowing on the guide plate.

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