JPH0236711B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing carpets (including rugs and mats) having novel patterns.

[Conventional technology]

Conventionally, this type of carpet has been divided into carpets manufactured by hand and carpets manufactured by tufting machines.To manufacture carpets using a tufting machine, the machine's parallel needles are Tuft the base fabric by threading a single color or two-color tuft thread and activating all the needles at once, or tuft only the desired area of the base fabric by a fixed width over the entire length. If you want to set up a part that will not be performed, in advance,
A plurality of needles corresponding to the width portion are removed and tufting is performed using other needles.

[Problem to be solved by the invention]

In the case of the above-mentioned manual method, it is possible to make each pattern a different color while planting the piles in the desired pattern, but since it is done by hand, mass production is not possible. This is expensive and results in variations in the product.

On the other hand, when using a tufting machine, it is possible to mass-produce uniform products, but in general, tufting machines operate all needles at the same time to tuft pile onto the base fabric. Because it is a carpet that has piles all over it, it is only possible to manufacture carpets that are monotonous, lack variety, and have low commercial value.

In addition, if the desired number of needles are removed in advance, only a monotonous band-like part of a constant width without tufting can be formed on the base fabric, and even that can be formed over the entire length of the base fabric. It is possible to form patterns of animals, plants, etc. surrounded by a tufted part with a wide variety of variations, or to form different patterns such as shapes that are related to each other. Even if a strip of material with an appropriate color or pattern is later applied to the strip, it will be as unattractive as the above-mentioned carpet with pile tufted all over, and the commercial value will be reduced. It cannot be improved.

The purpose of the present invention is to solve these problems and provide a method for manufacturing carpets that have a beautiful pattern with rich elegance and variation, taking advantage of the advantages of a tufting machine and manual work. be.

[Means to solve the problem]

In order to achieve the above object, the carpet manufacturing method of the present invention uses a tufting machine in which a large number of needles arranged in parallel in the width direction of the base fabric perform tufting operations independently. A suitable pile fabric is tufted onto the base fabric while feeding the base fabric, and in the middle of the tufting, a plurality of parallel needle groups in a desired portion of the arrayed needles are rendered inactive, and the parallel needle groups are inactivated. By increasing or decreasing the number of stitches in response to changes in the width of the non-pile pattern pattern to be formed, a non-pile pattern pattern of an appropriate shape with exposed base fabric surface that is not tufted is formed at a desired location on the base fabric. After forming this non-pile pattern pattern, the pile fabric is tufted over the entire width of the base fabric by the operation of all the arrangement needles to produce a carpet main body. It is characterized in that the patterned portion is provided with a patterned area that is different in color or different from the pile fabric produced by the tufting machine.

[Effect]

Among the large number of needles arranged in a row in the tufting machine, a plurality of parallel needle groups in a desired part are set to be inactive, and the number of inactive stitches in the parallel needle group is determined by the width of the non-pile pattern pattern portion to be formed. By increasing or decreasing it in response to changes in the number of layers, it is possible to form a desired shape of a non-pile pattern part in which the surface of the base fabric is exposed in a desired part of the base fabric, and also to have different shapes and patterns that are related to each other. It is possible to easily form a plurality of non-pile pattern patterns, and by manually providing a pattern area with the same shape as the non-pile pattern pattern parts in a post-process, piles can be formed using a tufting machine. It is possible to obtain a beautiful carpet rich in color and elegance that cannot be obtained by using a tufting machine. can.

Also, among the parallel needles of the tufting machine, it is possible to operate either the odd-numbered needle or the even-numbered needle and leave the other inactive, so that all the parallel needles It is also possible to change the rough density and color of the pile fabric planted on the base fabric in conjunction with the operation.

〔Example〕

Embodiments of the present invention will be explained with reference to the drawings: 1
1 is the base fabric of the carpet, which is made of a plain woven fabric or plain woven fabric using appropriate flat threads such as synthetic resin tape yarn. A pattern pattern 2, 3 of piles 12, 13 made of ivy tufted yarn and a pattern part 5 made of the exposed base fabric surface where these piles 12, 13 are not tufted are formed, and the base fabric 1 of this pattern part 5 is formed. A ground pattern 15 made of a suitable sheet material and having a different color from the pile patterns 2 and 3 produced by the tufting machine is pasted on the surface.

To manufacture a carpet constructed in this way, first, a desired pattern 2, 3 is tufted by the piles 12, 13 using a tufting machine.

The tufting machine uses a large number of needles arranged in a row at small pitch intervals in the width direction of the base fabric 1.
ICN tufting machine (Indiividually Controlled Needle)
Tufting Machine).

It is also possible to tuft pile onto the base fabric 1 by inserting threads of the same color and quality through all the needles of this tufting machine, but the odd-numbered needles a,
For example, a white tufted thread is inserted through a...a, while a tufted thread of a different color, for example, black than the odd-numbered needle a is inserted into the even-numbered needles b, b...b to form the base fabric 1. It is also possible to form a pattern by tufting the piles 12, 13.

In this case, when forming an appropriate pattern 4 such as a background pattern of white and black, the pile is formed by operating odd-numbered needles a and even-numbered needles b corresponding to the pattern 4. When forming a white pattern 2 by densely tufting the pile 12, only the odd-numbered needle a of the plurality of needles corresponding to the pattern 2 is operated to tuft the pile 12. Similarly, when forming a black pattern 3, only the even-numbered needles b among the plurality of needles corresponding to the pattern 3 are operated to tuft the pile 13 onto the base fabric 1.

In this way, a row of piles can be created on the base fabric 1 by a part that operates all the needles a and b at the same time among the needle groups arranged in a row, and a part that operates only one needle a or b. At the same time, the next row of piles is tufted by changing the operating number of needles a and b in the part according to the width of the pattern. Section 4 will be formed.

That is, for example, when the width of the white pattern 2 to be formed increases, the number of needles corresponding to the width increases, so only the odd-numbered needle a of the needle group is operated, and the following steps are performed. The number of actuated needles a and b is made to correspond to the patterns 2, 3, and 4 to be formed.

Furthermore, while forming such patterns 2, 3, and 4 while tufting the pile on the base fabric 1, at a desired location on the base fabric 1, a plurality of needles corresponding to the location from among the needle groups arranged in one row are placed. By bringing the book needles a and b into a stopped state, a non-pile pattern pattern part 5 is provided on the base fabric 1 with the base fabric surface exposed. When forming this non-pile pattern pattern part 5, the width changes with respect to the feeding direction of the base fabric 1 depending on the shape of the pattern pattern part 5, but when forming the patterns 2, 3, 4, alike,
By sequentially increasing or decreasing the number of needles a and b that do not operate in accordance with the width and tufting the pile, patterns 2, 3, and 4 are formed while forming the non-pile pattern pattern portion 5.
will be established.

In order to form such pile pattern pattern parts 2, 3 and pattern part 4 on the base fabric 1 and the non-pile pattern pattern part 5 by activation and deactivation of each needle of the needle group of the tufting machine, it is necessary to , in the part of the base fabric 1 where these patterns 2 to 5 are to be provided, the pile patterns 2 to 5 are
The computer stores in memory that the needles a and b corresponding to 4 and the non-pile pattern 5 are activated and deactivated as described above, and each needle is moved as described above according to instructions from the computer during carpet manufacturing. It is something that allows people to do this.

Of course, if the odd-numbered needles a and the even-numbered needles b of the tufting machine are operated at the same time, it is possible to tuft the pile extremely densely on the base fabric 1. For example, even if a plurality of odd-numbered needles a corresponding to an appropriate width portion of the base fabric a are all operated at the same time, a pile with 1/2 of the tuft density of the pile by the needles a and b is tufted. , without damaging the appearance of the carpet.

However, if the pile is tufted with a pitch larger than this, the commercial value of the carpet will decrease. It is difficult to tuft the pile with different types of tufted yarn.

Note that tuft yarns of different colors, such as black to blue, are used in the tufting for at least one of the odd-numbered needles a and the even-numbered needles b, so that the base fabric 1 is made of two-color tufted yarns. It is possible to form a pattern continuously.

After the carpet main body A having the pile patterns 2 to 4 and the non-pile pattern pattern 5 is woven by the tufting machine, the non-pile pattern pattern portion 5 of the carpet main body A is woven by hand. Pile pattern pattern 2 by tufting machine,
A patterned area 15 of a color different from 3 is provided.

As such a patterned fabric 15, an appropriate fabric,
Alternatively, fabrics such as knitted fabrics or non-woven fabrics, or sheet materials such as fur and leather may be coated with the non-pile pattern 5.
This pattern fabric 15 is fitted to match the non-pile pattern 5, and the back side is attached to the base fabric surface using an appropriate adhesive or sewing. .

The entire surface of the patterned area 15 may be of a single color, or may have a pattern of two or more colors, or a pattern 19 of an appropriate shape made by cutting fabric may be pasted on the surface of the patterned area 15. It may be something that has been done.

Further, in the above embodiment, the piles 12 and 13 are tufted on the base fabric 1 by passing white and black tuft threads through the odd-numbered needles a and the even-numbered needles b, respectively. Of course, it is possible to use other different colored tufted yarns without having to be Piles may also be planted using thread.

Further, FIGS. 6 and 7 show another embodiment of the present invention, and in the above embodiment, odd-numbered needles a and even-numbered needles b of the tufting machine are each provided with a different color or different quality. The pattern patterns 2 and 3 made of piles 12 and 13 were created on the base fabric 1 by inserting the tufted yarn. A pile fabric 16 and a non-pile pattern pattern part 1 in this pile fabric
7 was formed.

That is, a pile fabric 16 of the same color and quality is tufted onto the base fabric 1 using tuft threads of the same color and quality inserted through all the needles a and b of the tufting machine, and a plurality of pile fabrics 16 of the same color and quality are tufted at desired locations on the base fabric during the tufting. A carpet main body is manufactured with a non-pile pattern pattern part 17 of an appropriate shape exposing the base fabric surface which is not tufted due to the non-operation of book needle groups.

Thereafter, the pile fabric 16 is manually applied to the carpet-based non-pile patterned portion 17 using the tufting machine in the same manner as in the above embodiment.
This is made by pasting a pattern 15 of a different color or quality by gluing or sewing.

The carpet obtained in this way has little color change compared to the above example, but since the pile fabric 16 is formed by operating all the needles a and b at the same time, it is extremely dense. Can be planted.

It goes without saying that in the present invention, the carpet includes not only what is generally called a carpet, but also rugs and mats.

Furthermore, the pattern 15 may be applied before or after lining the back side of the carpet base fabric 1 with the lining 20.

〔Effect of the invention〕

As described above, according to the carpet manufacturing method of the present invention, a tufting machine in which a large number of needles arranged in parallel in the width direction of the base fabric perform tufting operations independently is used to feed the base fabric in the length direction. While tufting an appropriate pile fabric onto the base fabric, in the middle of the tufting, a plurality of parallel needle groups in a desired portion of the arranged needles are rendered inactive, and the number of inactive stitches in the parallel needle groups is is increased or decreased in accordance with the change in the width of the non-pile pattern pattern to be formed, thereby forming a non-pile pattern pattern of an appropriate shape in which the surface of the base fabric that is not tufted is exposed at a desired location on the base fabric;
After the non-pile pattern pattern is formed, the pile fabric is tufted over the entire width of the base fabric by the operation of all the array needles, so that the desired area of the base fabric is surrounded by the pile fabric. It is possible to form non-pile patterns in various shapes such as animals, plants, etc. with the exposed base fabric surface, and in addition, the shapes and patterns are different.
Moreover, even a plurality of mutually related non-pile pattern parts can be easily formed in the pile ground.

Furthermore, after manufacturing the carpet having such a non-pile pattern pattern, a pattern different in color or different from the pile fabric produced by the tufting machine is provided on the non-pile pattern pattern, so that the user's wishes and desires can be determined. In addition to being able to form a pattern that corresponds to the pile pattern created by the tufting machine, the pattern provided in the pattern has a varied appearance with respect to the pile pattern created by the tufting machine. It is possible to obtain beautiful carpets rich in color patterns and elegance that cannot be obtained elsewhere.

Also, among the parallel needles of the tufting machine, it is possible to operate either the odd-numbered needle or the even-numbered needle and leave the other inactive, so that all the parallel needles The coarse density of the pile fabric planted on the base fabric can be changed in conjunction with the operation, and the color of the pile fabric can be arbitrarily changed by changing the colored threads inserted into each of the needles. It is.

[Brief explanation of drawings]

The drawings show an embodiment of the present invention, and FIG. 1 is a partially cutaway simplified plan view thereof, and FIG.
Figure 3 is a simplified sectional view along the line, Figure 3 is a simplified front view of the state in which the tufting machine is being manufactured, Figure 4 is
5 and 5 are enlarged front views of a portion thereof, and FIGS. 6 and 7 are simplified plan views for explaining another manufacturing method of the present invention. 1...Base fabric, 2,3,4...Pattern pattern part, 5,1
7...Non-pile pattern pattern part, 12, 13...Pile, 15...Patterned area, a, b...Needle.

Claims (1)

[Claims] 1 Using a tufting machine in which multiple needles arranged in parallel in the width direction of the base fabric individually perform tufting operations, appropriate pile fabric is tufted onto the base fabric while feeding the base fabric in the length direction. At the same time, in the middle of the tufting, a plurality of parallel needle groups in a desired part of the arranged needles are made inactive, and the number of inactive stitches in the parallel needle groups is changed by changing the width of the non-pile pattern pattern portion to be formed. By increasing or decreasing the amount in accordance with A carpet main body is produced by tufting a pile fabric over the entire width of the base fabric by the action of a needle, and then, the non-pile pattern pattern part of this carpet main body is tufted with a different color or different from the pile fabric by the tufting machine. A method for manufacturing a carpet characterized by providing a patterned area.