JPS63235584A - Production of multistage dyed carving mat - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] (Industrial Application Field) The present invention relates to a method for producing a multi-stage dyed curling mat, and more specifically, after the tip and root portions of the cut curls of the mat are dyed separately. This invention relates to a method for producing a multi-stage dyed carving mat, in which a backing layer is formed on the stitched surface of the base fabric, and then a pattern t'' pile surface is formed by cutting off at least the tip of the tongile.

(Prior art and its problems) Conventionally, in order to prevent dust attached to the soles of shoes from being brought indoors, dust collection machines have been installed at the entrances of offices, stores, residences, etc. , are installed and used at entrances, etc. Some of these types of mats have designs on their surfaces, such as letters, pictures, marks, etc., which are separated by color from the puck ground area. While this patterned Shimat is used while being repeatedly washed and regenerated, the pile threads of the pack ground part and the pile threads of the pattern part become entangled with each other in the boundary area between the pack ground part and the pattern part. Since the colors of the two threads are different, the color of the boundary area is an intermediate color, and as a result, the design gradually becomes blurred.

There is also a method in which the twill yarn in the pack ground part and the pile yarn in the pattern part are made the same color, and only the outline part is made a different color from the pack ground part to form the pattern. In this method, the outline part is tufted with tsquil yarn of a different color from the twill yarn of the pack ground part, or the pile yarn of the outline part is dyed a different color, and the outline part is further colored with a different color. The contours are formed by electrostatic flocking of fiber flocks. However, even if the contours are formed using this method, there is a drawback that the contours become unclear and the design gradually becomes blurred while the mat is in use.

The purpose of putting a pattern on a dusting mat is to give an impression of the store where the mat is installed to people who pass by the dusting mat, to promote the store, and to attract attention. When the pattern becomes blurred, the significance of the pattern is lost, and although the mat still has sufficient dusting performance, it loses its commercial value and shortens the life of the mat.

(Object of the Invention) An object of the present invention is to provide a method that can easily produce multi-stage dyed carving mats (for example, dusting mats) having patterns (designs) of various colors and tones. .

Another object of the present invention is to display patterns of various colors and tones clearly even when used under extremely harsh conditions such as repeated rentals, washing and regeneration, and to maintain this state in a stable manner forever. To provide a manufacturing method that can easily manufacture a multi-stage dyed carving mat with a pattern input that can be maintained.

(Structure of the Invention) The present invention includes a step of selectively dyeing the tips of cut piles tufted on a base fabric by spraying a dye solution, and a step of spraying a dye solution onto the base of the cut/four piles from the base fabric side. ], selectively dyeing the tip in a color different from that of the tip, applying a synthetic resin or synthetic rubber-containing liquid composition to the dyed mat base fabric and backing. A step of forming a layer, and cutting the cut pile of the dyed and backed mat with at least the tip dyed part and the root dyed part and/l or the intermediate part between the tip dyed part and the root dyed part to form a pattern f14. This is a method for producing a multi-stage dyed carving mat, which consists of a step of forming a carving mat.

(Preferred embodiment of the invention) The invention will now be described with reference to the accompanying drawings.

FIG. 1 is a sectional view schematically showing a partial cross section of a matte material in which pile is tufted on the base fabric used as the material in the manufacturing method of the present invention, and FIG. , is a cross-sectional view of the mat material shown in FIG. 1 with the tips and bases of the mat material dyed, and FIG. 3 is a cross-sectional view of the mat material shown in FIG. Fig. 4 and Fig. 5 are cross-sectional views of mats with layers formed, and Figs. FIG. 2 is a cross-sectional view of an example of carping pine.

The matrix materials used in the first dyeing process of the present invention are applied to the base fabric 1 as shown in FIG. The coil 2 is tufted, and the tip of the arm coil 2 is trimmed to form a flat surface to form a matte surface.

As the base fabric l, a woven fabric or non-woven fabric made of any synthetic fiber such as polyester is used, while i'L? As the fiber 2, synthetic fibers such as wrapped nylon fibers, vinylon fibers, acrylic fibers, natural fibers such as cotton fibers, or blended fibers of two or more of these fibers are used. The pile length and area weight may be within the range of mats conventionally used for the purpose of dust control (dust prevention, dust removal), and are generally 3 to 4.
0. /4 il length and 300 to 4000 gAn2. For pile 2, the stitch number of the nodile of 2,54 cm/temeter is 8, the gauge number of /4 ile of 2,54 cm is G, and the fineness of the pile is expressed in denier as D. When, S.G.D.
The pile density, which is the value expressed as the product of s, is from ooo to i, 280,000, especially from 20,000 to 300.
It is preferable that the tufting be performed in a range of 000. If the /4 density is smaller than the above range, the pattern created by forming the grooves in the subsequent process tends to be unclear, and if the density is larger than the above range, it tends to be difficult to form the grooves.

The pile 2 may be left in the white color of the used fibers without being particularly dyed, or may be dyed in any color (preferably light or light colors).

In the first dyeing step of the present invention, by spraying a dye solution onto the matte surface of the matte material, the tip end 2t of the pile 2 is selectively dyed, as shown in FIG.

The color for dyeing the pile tip 2t can be arbitrarily selected as desired.

It is preferable to dye the pile so that the average length Lt of the tip 2t of the pile is 20 to 80 inches of the length L of the armpit pile 2 from the base fabric surface. As the dyeing method, a dye solution suitable for the material of the pile 2 is used, and a method known per se, for example, a jet spray method can be appropriately adopted.

In the second dyeing step of the present invention, by supplying the dye solution from the base fabric side of the mat material, the pile 2 is dyed in a different color from the base 2bt to the tip 2t, as shown in FIG. do. The color of the root portion 2b can also be arbitrarily selected. Even if the dye solution is supplied from the side of the base fabric 1, since the base fabric 1 is a woven fabric or non-woven fabric as described above, the dye solution passes through the gap in the base fabric and dyes the root part 2bt of the base fabric. can do. Average length Lb of the root portion 2b of the pile
is preferably 20 to 80% of the length L of the pile 2 from the base fabric surface. The dyeing method for the root portion 2b uses a dye solution suitable for the material of the pile 2, and a method known per se, such as a jet spray method,
A single-type roll coater or the like can be appropriately employed. As shown in Fig. 2, dyeing of Nogil 2 is divided into three zones: a tip 2t, a base 2b, and an intermediate area 2t which is not dyed in the first and second dyeing steps. Alternatively, the intermediate portion 2m may be eliminated and two bands, a tip portion 2t and a root portion 2b, may be formed. The average length of the intermediate portion 2m is 0 to 60 inches of the length L from the base fabric surface of the pile 2.
It is preferable to dye the t and the root portion 2b.

In the third backing layer forming step of the present invention, a synthetic resin or synthetic rubber-containing liquid composition 1 is applied to the stitched surface of the dyed matte material base fabric 1 obtained in the above step, and then dried as necessary. A backing layer 3 is formed by vulcanization to produce a mat having a backing layer as shown in FIG.

Examples of the synthetic resin used for the backing include soft resins mainly composed of thermoplastic resins such as polyvinyl chloride, polyethylene, polypropylene, polybutene, and nylon, and if necessary, a weighting agent. These resins are applied in the form of latex to the stitched surface of the base fabric 1 and dried to form a backing layer. Further, a backing layer can also be formed by welding to the stitched surface of these resin-based base fabrics 1.

Rubbers used for the backing include acrylonitrile-butadiene copolymer rubber (NBR), styrene-butadiene copolymer rubber (SBR), chloroprene rubber, tutadiene rubber, and ethylene-propylene copolymer rubber.
rubber, ethylene-propylene-diene copolymer rubber, Inglene rubber, isobutylene rubber, polyurethane, and the like. These rubbers are applied in the form of latex to the entire back surface of the base fabric 1, dried, and then vulcanized to form a rubber backing layer.

Furthermore, depending on necessity, on the above rubber backing layer,
An unvulcanized rubber sheet formed by blending known vulcanizing agents, vulcanization accelerators, pigments, reinforcing agents, extenders, etc. with the rubber as exemplified above is attached and cured by vulcanization, or Alternatively, a rubber sheet obtained by vulcanizing and hardening the above-mentioned unvulcanized rubber sheet alone can be adhered.

In the fourth pile carping step of the present invention, at least the tip dyed portion 2t of the dyed and packed mat cut pile 2 obtained in the third step is trimmed, and/or the pile 2 is The root part 2b and/or the middle part 2m of the mat are made visible from the mat surface side, and the root part 2b and/or the middle part 2m of
b and/or a pattern by the intermediate portion 2m is formed on the pile surface.

When trimming the pile 2 in the fourth step of the present invention, as shown in FIG. Alternatively, the groove 5 having a substantially V-shaped cross section is formed by deep pruning until the root portion 2b is cut. On the same mat,
The grooves 4 and 5 may be formed individually, or may be formed in combination. By forming the groove 4t, the color of the middle part 2m appears on the pile surface, and the groove 51
! By forming i-, the color of the intermediate portion 2m and the color of the root portion 2b appear on the pile surface.

The cross-sectional shape of the groove 4 is such that the maximum depth Drn of the groove 4 is
The length of the tip part 2t is longer and the total length of the tip part 2t and the middle part 2m is shorter,
The opening angle α4 of the groove 4 is preferably 45 to 120 degrees, particularly preferably 60 to 90 degrees, so that it is approximately V-shaped. In addition, the cross-sectional shape of the groove 5 is such that the maximum depth Db of the groove 5 is greater than or equal to the total length of the tip portion 2t and the intermediate portion 2m of the pile, and less than or equal to the length L from the base fabric surface of the pile 2. The groove 5 has a substantially V-shape in which the opening angle α5 is the same as the opening angle α4 described above. The sloped portions of the cross-sectional shapes of the grooves 4 and 5 may be linear, but are not necessarily limited to a linear shape, and may be arcuate or wavy curves.

Further, the bottoms of the grooves 4 and 5 may be pointed or rounded, and the cross-sectional shape of the grooves 4 and 5 may be approximately U-shaped. When the cross-sectional shape of the grooves 4 and 5 is not V-shaped, the angle formed by the two straight lines connecting the bottom center point of the groove 4 or 5 and the open end of the groove 4 or 5 perpendicularly above the bottom center point is defined as the groove. The opening angle is α4 or α5. Also, if the opening angle α of the groove is smaller than 45 degrees, the outline will be unclear, and if the angle α is larger than 120 degrees,
If the outline part is too thick, the integrity of the pack ground part and the pattern part will be impaired, and it will tend to be unsightly.

As a method for forming the groove 4 or 5t, for example, the following method can be adopted.

That is, the pile is cut using a carping machine, the main part of which is shown in Figures 6 and 7, and grooves 4 or 4 of the desired shape are formed so as to match the outline of the desired design and form a mother turn. 5t-form.

FIG. 6 is a front view of a pile cutting portion of an example of a carping machine, and FIG. 7 is a side view of the same portion.

In FIGS. 6 and 7, the cutting machine stand 51 includes a fixed blade stand 52. Fixed blade base 52 is fixed by a bolt 53.
Two fixed blades 54 and 54' are fixed so that the blade edges are aligned to form a V-shape and the blade surfaces are in the same direction. Above the fixed blades 54 and 54' are movable blades 55 and 55'.
are each rotatably attached to the fixed blade stand 52 by bolts 56° and 56'. What about the movable blades 55 and 55'? A presser foot 57 made of an elastic plate is rotatably attached to the fixed blade stand 52 by a seat 56 and 56', and is fixed to the movable blades 55 and 55' at the end opposite to the cutting edge of the movable blades 55 and 55';57', it is pressed against the fixed blades 54, 54'. The fixed blade 54 and the movable blade 55, and the fixed blade 54' and the movable blade 55' are combined to form scissors. The movable blades 55, 55' together with the presser feet 57, 57' at the opposite end of the cutting edge are ? Ruto 58,
58' is rotatably attached to one end of the opening and doors 59 and 59'. The opposite end of the rod 59°59' is connected to the rod 61 by gel) 60, 60'.
, 61' are rotatably attached to one end. The opposite end of the mouth, Doro 1, 61' is
2 and 62', the rotary plates 63 and 63' are rotatably attached to eccentric positions. rotating plate 63,
63' is a seven-tar (
(not shown), the movable blade 55 rotates at a constant speed or at variable speed.
, 55', mouth, do 59, 59' and 61, 61
' is mounted in the above structure, so that the movable blades 55, 55 rotate as the rotary plates 63 and 63' rotate.
'The cutting edge makes a reciprocating motion.

The cutting machine stand 51 is attached to a carping machine main body (not shown), and the cutting machine stand 51 can be freely moved vertically and horizontally by operating the carping machine main body. The tips of the fixed blades 54 and 54' are buried in the mat surface of the mat, and the movable blades 55 and 55'
By moving the cutting machine stand 51 while sliding it, the pile on the mat surface is cut, and as a result, a groove having a V-shaped cross section can be formed. By adjusting the amount of embedding of the tips of the fixed blades 54, 54' into the mat surface, the maximum depth of the groove can be adjusted.
Further, by using a fixed blade stand 52 in which the fixed blade 54 and fixed blade 54' of the fixed blade stand 52 have different mounting portion angles, the opening angle α of the groove can be adjusted.

Furthermore, by incorporating a computer having a graphic storage device into the carping machine body, it is possible to automatically form the grooves 4 or 5 that match any desired pattern. Even if the groove 4 or 5 has a part where the width and depth of the open end of the groove 4 or 5 change depending on the design, the content can be stored in the computer in advance so that the position can be slightly shifted. The pile yarn was cut,
The embedding of the cutting edge can be changed and automatically formed as desired. Of course, it can also be operated manually.

Further, in another embodiment of the present invention, the fourth aspect of the present invention
In the process, as shown in FIG.
By cutting the tip part 2t and the middle part 2m,
By forming a groove 6 whose bottom surface is a plane substantially parallel to the base fabric 1, or by pruning deeply until the root portion 2b is cut, the bottom surface is a plane substantially parallel to the base fabric 1. It is also possible to form the groove 7 as shown in FIG.

By forming the groove 6, the color of the intermediate portion 2m appears on the pie file surface, and by forming the groove 7, the color of the root portion 2b appears on the pie file surface, possibly with a little color of the intermediate portion 2m. . The widths of the grooves 6 and 7 can be arbitrarily selected.

In FIG. 5, the cross sections of the grooves 6 and 7 are shown to be approximately rectangular, but they may also be square or inverted trapezoidal with an upward opening. Grooves 6 and 7 can be easily formed by using clipper cutting elements instead of the carping machine cutting elements as shown in FIGS. 6 and 7, or by using a combination of the two. can be formed.

In the present invention, grooves 6 shown in FIG.
Alternatively, the grooves 7 may be formed individually or in combination. Furthermore, the groove 4 shown in FIG.
One or more of the grooves 6 and 7 shown in FIG. 5 can be combined as appropriate, and further combinations can be made by changing their sizes, shapes, etc.

The pile of the multi-stage dyed carving mat produced according to the present invention has the effect of adsorbing and holding dust and quills adhering to the sole of the shoe through rubbing against the sole of the shoe. ! Dust adsorption/retention effect by mother oil? In order to further enhance
The pile can be coated or impregnated with a dust-absorbing liquid. Examples of such dust-absorbing liquids include liquid paraffin, spindle oil, alkylbenzene oil, diester oil, mineral oil such as castor oil, synthetic oil acid, vegetable oil-based oils, and Japanese Patent Publication No. 53-10194. and 5
The aqueous dust adsorbent described in Japanese Patent No. 3-37471 can be mentioned.

(Effects of the Invention) In the multi-stage dyed carving mat manufactured by the present invention, the Z4 tile is dyed in two or three colors, and grooves are formed by trimming at least the dyed tip of the z4 tile. One or two different colored layers at the tip of the pile are made to appear in these grooves, and a pattern is formed by combining these colored layers with the grooves. The above mat has a clear pattern.
Even during normal use, and even under extremely harsh usage conditions such as repeated rentals, cleaning, and regeneration, the pattern can remain clear and stable forever.

Furthermore, in the above mat, the pattern is made up of /4
With the above configuration, a pattern is formed by revealing the color of the part that is different from the tip of the multi-stage dyed mother tile, so the difference in color and the contrast with the groove are The residual effect makes the pattern even more stable.

Therefore, can the above mats be rented, washed and recycled? The pattern does not become blurred or disappear even after repeated use many times, so it does not have the disadvantages of conventional mats, where the pattern becomes meaningless due to dilution or disappearance, and the product life is shortened. This has the effect that the product life of the patterned mat can be stably maintained to the limit of the physical life of the mat.

Furthermore, according to the present invention, the color of the cut pile of the mat material used as the raw material, the hue and length of the dyed part at the tip of the pile, the hue and length of the dyed part at the root of the pile, the shape and size of the groove. By combining various types of
This has the remarkable effect of making it possible to easily manufacture mats having a wide variety of patterns, from simple patterns to complex patterns with subtle changes.

Furthermore, according to the present invention, pile can be easily dyed in multiple stages, and excellent mats as described above can be easily produced.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view schematically showing a partial cross section of an embodiment of a mat material in which pile is tufted on a base fabric used as a material in the manufacturing method of the present invention, and FIG. , is a cross-sectional view of the mat material shown in FIG. 1, with the tip and base of the /4 tile dyed, and FIG. 3 is a cross-sectional view of the mat material shown in FIG. FIG. 4 and FIG. 5 are cross-sectional views of a multi-stage dyed carving mat in which at least the dyed end portion of the pile of the mat shown in FIG. 3 is trimmed. 6 and 7 are drawings showing a pile cutting portion of an example of a carping machine used for forming grooves in the present invention, FIG. 6 is a front view thereof, and FIG. 7 is a side view thereof. It is a diagram. 1 is the base fabric, 2 is the pile, 2t is the tip of the tile, 2m
2b is the root of the pile, 3 is the backing layer, and 4, 5.6, and 7 are the grooves. 51 is the cutter @ machine base, 52 is the fixed blade base, 54 and 54' are the fixed blades, 55 and 55' are the movable blades, 57 and 57' are the presser feet, and 59.59' and 61.61' are the mouth and door. , 63°63
′ is a rotating plate. Figure 5 Figure 6

Claims (1)

[Claims] (1) A process of selectively dyeing the tips of the cut piles tufted to the base fabric by spraying a dye solution; selectively dyeing the root parts of the cut piles by supplying the dye solution from the base fabric side; A step of dyeing the mat in a color different from that of the tip, a step of applying a liquid composition containing synthetic resin or synthetic rubber to the stitched surface of the base fabric of the dyed mat to form a backing layer, and a step of dyeing the dyed and backing layer. A method for producing a multi-stage dyed carving mat comprising the step of trimming at least the tip dyed part of the cut pile of the mat to form a pattern on the pile surface by the root dyed part and/or the intermediate part between the tip dyed part and the root dyed part.