JP4348482B2 - Hook tile carpet by hook drag manufacturing method and manufacturing method thereof - Google Patents

Description

  The present invention relates to a hook tile carpet woven by a hook drag manufacturing method and a method for manufacturing the same.

  Conventionally, hook drag carpets laid on the floors of homes and offices have been manufactured from weaving to finishing on the basis of a single weave with a maximum width of 970 cm and a maximum length of 2500 cm for bespoke products other than fixed-size products. Buildings such as buildings and buildings have progressed, and due to restrictions on the maximum loading dimensions of the carry-in elevator and restrictions on the carry-in route such as indoor corridors, etc. And after carrying in the room, the cut part is jointed again. When carrying in, too much manpower is required, and advanced technology is also required for connecting cut products.

  In addition, small square tile carpets such as 50 cm × 50 cm that are easy to carry and easy to construct compared to the above long hook drag carpets are mainly used in offices and hotels. . Since tile carpets are mass-produced with the same design uniformly, there is a problem that it is originally a single woven product and is not suitable for mass production with hook drag by hand sword manufacturing method. Did not exist in the market.

  The present invention has been made in view of the above-described conventional circumstances, and a method for manufacturing a hook tile carpet in which the cutting size of a single-woven product by the hook drag manufacturing method is subdivided into predetermined tile dimensions, and its An object of the present invention is to provide a hook tile carpet manufactured by the manufacturing method.

  As a means for solving the above-mentioned problems, a method for manufacturing a hook tile carpet according to claim 1 of the present invention includes a weaving hook process in which a pile yarn is stabbed into a woven base fabric from the back surface by a hook machine, and weaving in the weaving process. The woven base fabric is fixed to a quadrilateral frame of a predetermined size with fixing nails, and the woven base fabric is dried and shrunk after being poured with hot water, and latex is applied to the back surface of the woven base fabric shrunk in the shrinking step. After the glass fiber is sprayed at a high pressure, the glass fiber is applied to the latex coated surface, and the latex is applied to the outer surface of the glass fiber applied to the back surface of the woven base fabric in the glass fiber applying step. A non-woven fabric pasting process in which the non-woven fabric is laminated on the latex coated surface, and the latex is coated on the outer surface of the non-woven fabric pasted in the non-woven fabric pasting step, and the latex coated surface is the same as the woven base fabric. A back base cloth pasting process in which a high-quality back base cloth is laminated and pasted, and a cutting process in which a carpet made by attaching the back base cloth in the back base cloth pasting process is divided into predetermined tile dimensions and cut. It is characterized by that.

In the method for producing a hook tile carpet of the present invention, in the glass fiber sticking step, the latex is sufficiently penetrated into the woven base fabric and the pile by cutting the latex onto the back surface of the woven base fabric shrunk in the shrinking step at a high pressure. When cut in the process, there is an effect that the pile yarn and the woven base fabric can be prevented from peeling from the cut surface.
Also, after spraying latex with high pressure on the back side of the woven base fabric in the glass fiber pasting step, the glass fiber is laminated on the latex coated surface and pasted together, and further on the back side of the woven base fabric in the nonwoven fabric pasting step By applying latex to the outer surface of the fabric and overlaying and bonding the nonwoven fabric on the latex coated surface, the warpage, width, and length of the glass fiber due to the synergistic effect of heat resistance, dimensional stability and tensile strength of the nonwoven fabric There is an effect that it is possible to prevent the shrinkage of the film.
Also, by bonding the back base fabric with the same material as the woven base fabric in the back base fabric affixing step, the shrinkage of the surface side woven base fabric and the back base fabric will be the same, preventing warpage There is an effect that can be done.

In the cutting process of the tile carpet manufacturing method according to claim 2, a cutting line for dividing the tile into a predetermined tile size is drawn on the outer surface of the carpet back base cloth made by the back base cloth attaching process. It is a work process that presses the blade of the electric cutter from above and cuts it, placing a guide rail on the carpet to move the electric cutter along the cutting line, and pin it into the pin hole provided on the guide rail And is temporarily fixed at a cutting position on the carpet, and the blade of the electric cutter is cut accurately at the cutting line at the time of cutting.
According to the cutting process of the present invention, the blade of the electric cutter does not deviate from the cutting line at the time of cutting, and there is an effect that the tile carpet can be cut accurately according to the cutting line.

The hook tile carpet according to claim 3 is a hook tile carpet manufactured by the manufacturing method according to claim 1 or 2, wherein a pile yarn is woven into a woven base fabric by a hook drag manufacturing method, and the woven base fabric is obtained. Apply the latex to the back side of the glass and bond the glass fiber, apply the latex to the outer surface side of the glass fiber and bond the nonwoven fabric, apply the latex to the outer surface side of the nonwoven fabric and make the same material as the woven base fabric. A hook carpet having a multi-layer structure in which a backing base fabric is bonded, and is divided and cut into predetermined tile dimensions.
Since the hook tile carpet of the present invention has such a multilayer structure, it is possible to prevent the pile yarn and the woven base fabric from being peeled off from the cut surface of the tile. However, there is an effect that deformation such as warpage and contraction can be prevented.

The hook tile carpet according to claim 4 is the hook tile carpet according to claim 3, a series of row numbers as an arrangement code indicating the original position before cutting on the back surface of each tile that has been divided and cut, It is characterized by a series of column numbers and tile up-down direction symbols.
The hook tile carpet of the present invention is inherently monolithic by attaching an arrangement code consisting of a series of row numbers, a series of column numbers, and a symbol indicating a specific side of the tile to the back of each tile. There is an effect that a certain hook carpet can be laid and constructed so as to accurately restore the original monowoven.

In the manufacturing method of the hook tile carpet of the present invention, by taking the above-mentioned means, in the manufacturing process, the pile yarn and the woven base fabric can be prevented from being peeled from the cut surface, and deformation such as warpage and shrinkage can be prevented. it can. Further, at the time of tile cutting, the tile carpet can be cut accurately according to the cutting line, and the dimensions of each tile can be made uniform.
In addition, the hook tile carpet of the present invention has a multi-layer structure, so that it is possible to prevent deformation such as warping and shrinkage both as a finished tile carpet product and after laying.
The single-size hook drag carpet that has been difficult to lay in high-rise condominiums and offices has been standardized as a tile carpet, making it easier to pack cases, improving productability and transportability, and building Carrying and laying construction into condominiums, hotels, offices, etc. with the construction of high-rise buildings has become extremely easy.
As described above, the present invention pioneers new uses of hook drag carpets as interior materials for high-rise buildings such as condominiums, hotels, and offices, and contributes to increasing demand.

Embodiments of the present invention will be described with reference to the drawings based on typical examples. FIG. 1 is a system diagram (block diagram) showing a manufacturing process of a hook tile carpet of the present invention. 1 shows that a woven base fabric is finished through a weaving process, a shrinking process, a glass fiber application process, a nonwoven fabric application process, and a back base fabric application process, and then a tile carpet divided into tile shapes is completed through a cutting process. Each manufacturing process is shown. Hereinafter, the manufacturing method of the hook tile carpet of this invention is demonstrated later on for every manufacturing process.
First, in the weaving process, the pile yarn 12 is pierced from the back surface of the woven base fabric 11 made of 100% cotton and woven using a hook machine. The weaving method involves applying tension to a four-sided frame-shaped weaving frame (loom) so that the back surface of the woven base fabric 11 becomes the weaving surface, and fixing with a nail pin, and the back surface of the woven base fabric 11 (weaving surface). The design original is enlarged and written to a specified size, and the pile yarn 12 is stabbed and woven with a hook machine from above the design line. (Since this weaving method is a conventional hook drag method, description thereof is omitted.)
The conventional hook drag carpet is a single-woven carpet woven by this weaving method, and is coated with an SBR / NBR mixed latex on the back surface and pasted with a coarse cloth to prevent pile yarn slippage. Is normal. Even if such a single-weave hook drag carpet is divided and cut into tile dimensions as it is, it is difficult to cut into tile dimensions accurately, and when laid and used as a tile carpet, problems such as warping and shrinkage occur. In the hook tile carpet of this invention, this problem is solved by adding each manufacturing process of the shrinkage | contraction process demonstrated below, a glass fiber sticking process, a nonwoven fabric sticking process, a back base cloth sticking process, and a cutting process.

  In the shrinking process, the woven base fabric 11 is carried into a drying chamber, and the back surface of the woven base fabric 11 is placed on the upper surface, and the four-side frame-shaped fixing frame 21 is tensioned and fixed with the frame nails 22. After applying hot water of about 50 ° C. to the surface, steam heat is applied from below the floor, and the woven base fabric 11 is dried at the surface temperature of 50 ° C. (first drying) to shrink the woven base fabric 11 by about 3%. In this shrinking step, the woven base fabric is sufficiently shrunk by firmly fastening the pile yarn 12 woven on the woven base fabric 11 and adjusting the woven portion 11a of the woven base fabric to a predetermined dimension, and This is to maintain the dimensional accuracy in each subsequent work process and prevent shrinkage after the product is finished as a tile carpet. FIG. 2 is a plan view of the back surface of the woven base fabric 11 fixed on the fixed frame 21 as viewed from above. The nail 22 is fixed inside the four frames of the fixed frame 21 so that the weaving portion 11a of the woven base fabric 11 is located. In this state, the woven base fabric 11 is poured with hot water and then the woven base fabric from under the floor. The surface of 11 is dried by applying steam heat to shrink the woven base fabric.

In the next glass fiber affixing step, an SBR 100% latex (first latex 13), which is a highly permeable adhesive from the four directions of the top, bottom, left and right in the weaving portion 11a on the back surface of the woven base fabric 11 which is contracted and tensioned. ) Is sprayed at a high pressure of 80 kgf / cm ² so as to uniformly penetrate the weaving part 11a. Then, after an equal latex coated surface is formed on the woven portion 11a on the back surface of the woven base fabric 11, the glass fiber 14 is overlapped with the woven portion 11a on the back surface of the woven base fabric 11 from above the first latex 13 coated surface. Paste. FIG. 3 is a plan view of the back surface of the woven base fabric 11 to which the glass fibers 14 are attached as viewed from above. In FIG. 3, the lower side of the glass fiber 14 is the first latex 13 application surface, as shown in FIG.

  In the next non-woven fabric sticking step, the SBR 100% latex (second latex 15) is evenly applied to the outer surface of the glass fiber 14 stuck in the glass fiber sticking step using a wooden spatula, and the latex coated surface becomes flat. Carefully flatten the surface using a sponge roller. And after making the flat 2nd latex 15 application | coating surface on the outer surface of the glass fiber 14, the nonwoven fabric 16 of 100% of ester is piled up on the application | coating surface of the 2nd latex 15, and the outer surface side ( Press the entire surface evenly with a plastic roller for weighting from the top. By pressing with a plastic roller for weighting, the bonding state of the glass fiber 14 and the nonwoven fabric 16 to the woven base fabric 11 becomes strong, and the entire surface is uniformly bonded. FIG. 4 is a plan view of the back surface of the woven base fabric 11 to which the nonwoven fabric 16 is attached as viewed from above. In FIG. 4, the lower side of the non-woven fabric 16 is the application surface of the second latex 15 as shown by breaking a part of the non-woven fabric 16 with a wavy line. Moreover, the glass fiber 14 is the lower side of the 2nd latex 15 application surface, as a part of 2nd latex 15 application surface was fractured | ruptured and shown with the wavy line. After this step, steam heat is applied to dry the woven base fabric 11 at a surface temperature of 50 ° C. (second drying), adhesion between the woven base fabric 11 and the glass fiber 14, and the glass fiber 14 and the nonwoven fabric 16. Promotes adhesion at the same time.

In the next backing fabric application step, the SBR / NBR mixed latex (third latex 17) is evenly applied to the outer surface of the nonwoven fabric 16 applied in the nonwoven fabric application step, and a sponge roller is applied so that the latex application surface becomes flat. Carefully flatten the surface, and apply the third latex 17 coating surface on the back base fabric 18 made of the same material (100% cotton) as the woven base fabric 11 and paste it on the outer surface side of the back base fabric 18 Press from the top surface with another sponge for weighting to make the adhesive state uniform and strong on the entire surface. FIG. 5 is a plan view of the back side of the woven base fabric 11 to which the back base fabric 18 is attached as viewed from above. In FIG. 5, the lower side of the back base fabric 18 is the third latex 17 application surface, as shown in FIG. Further, as shown by a part of the third latex 17 application surface broken by a broken line, the lower side of the third latex 17 application surface is the nonwoven fabric 16. After this step, drying (third drying) is performed at a surface temperature of 50 ° C. by applying steam heat from under the floor.
Then, after drying, the surface (pile side) of the woven base fabric 11 that has been the lower surface is placed again so as to be the upper surface, and the pile surface is sheared so as to be aligned with a predetermined pile length by a shearing machine. The hook carpet for the tile carpet is completed through the above steps. 6A is a plan view (A) showing a multilayer structure of a hook carpet for a tile carpet completed through each of the steps so far, and a portion on the A ′ side of the portion indicated by the line AA ′ in FIG. 6A It is an expanded sectional view (B).

In the next cutting process, a cutting line 31 for dividing the tile into predetermined tile dimensions is drawn on the outer surface of the back base cloth 18 of the hook carpet made in the back base cloth applying process, and the electric cutter 32 is placed on the cutting line 31. In the work process of pressing the blade and cutting, a guide rail 33 for linearly moving the electric cutter 32 along the cutting line 31 is placed on the carpet, and a pin is provided in a pin hole 34 provided in the guide rail 33. 35 is inserted and temporarily fixed at the cutting position on the carpet, and the blade of the electric cutter 32 accurately cuts at the position of the cutting line 31 at the time of cutting. FIG. 7 is a plan view showing the cutting line 31 written on the back surface of the hook carpet. As shown in FIG. 7, on the outer surface of the back base fabric 18 on the back surface of the hook carpet, a cutting line 31 for dividing the tile size into a grid pattern is written, and a guide is formed on the carpet along the cutting line 31. The rail 33 is fixed, and the electric cutter 32 is placed on the guide rail 33. The guide rail 33 is provided with a plurality of pin holes 34, and pins 35 are inserted into the pin holes 34. When the cutting at one place is completed, the guide rail 33 is moved to the adjacent cutting position and fixed, and the cutting is repeated with the electric cutter 32.
In this cutting process, by fixing the guide rail 33 at the cutting position of the carpet, the blade of the electric cutter does not deviate from the cutting line at the time of cutting, and the carpet is accurately cut according to the cutting line and divided into tiles 10a. be able to.

  The hook tile carpet manufactured through the manufacturing processes described above, the weaving process, the shrinking process, the glass fiber application process, the nonwoven fabric application process, the back base fabric application process, and the cutting process is woven with pile yarn by the hook drag manufacturing method. A woven base fabric, a glass fiber coated with latex on the back side of the woven base fabric, a nonwoven fabric coated with latex on the outer surface side of the glass fiber, and an outer surface side of the nonwoven fabric It has a multilayer structure composed of a back base fabric made of the same material as the woven base fabric, which is coated with latex and bonded. FIG. 8 is a cross-sectional view showing a multilayer structure of the hook tile carpet of the present invention. As shown in FIG. 8, the hook tile carpet 10 has a pile yarn 12, a woven base fabric 11, a first latex 13, a glass fiber 14, a second latex 15, a non-woven fabric 16, a third latex 17, and a back base from the surface side. A multilayer structure in which the cloths 18 overlap is formed.

The hook tile carpet of the present invention is obtained by dividing and cutting a single-woven product into a predetermined tile size. If the size of the single-woven product is not enough to lay on a wide floor surface, the single-woven product is Use in combination. Therefore, it is basically necessary to lay and construct each tile so as to reproduce the original surface pattern in units of a hook tile carpet of a single woven product. Therefore, at the time of cutting, an arrangement code composed of a series of row numbers, a series of column numbers, and a vertical direction symbol indicating the vertical direction of the tile is entered on the back surface of each tile.
FIG. 9 is an arrangement diagram showing arrangement numbers on the back surface of each tile 10a after the hook tile carpet 10 is cut. This layout diagram is a layout diagram of each tile at the time of laying construction. In each tile, a series of 1 to 8 row numbers indicating rows, and A to P column numbers indicating columns are sequentially described, and an upward arrow symbol (↑) indicating the upper side of the tile is further described. . In order to sell this hook tile carpet as a product and carry it to the construction site, for example, the hook tile carpet is arranged for each line number and stored in a packing case. At the time of packing, the arrangement number of tiles is written on the lid surface of the packing case, and they are shipped in the same row / column number. At the time of laying construction, according to the layout diagram of FIG. 9, the surface pattern of the original monowoven carpet is reproduced by laying the tiles in the order of row numbers and column numbers and by aligning the vertical positions of the tiles with arrow symbols. be able to.

FIG. 10 shows the test results of the hook tile carpet of the present invention. This test result was tested and certified by an authorized test operator “Kansai Laboratory Nara Lab (certified test operator identification number: 000137JP)” according to Article 57 of the Industrial Standardization Act.
According to the test results, “pile yarn pull-out strength = 64.65N”, “peeling strength of backing material (vertical direction) = 55.1N”, “peeling strength of backing material (weft direction) ) = 48.6N ”,“ warp under standard conditions = 0.8 mm ”,“ rate of change of dimensions due to heat and water (width) = − 0.25% ”,“ of dimensions due to heat and water ” The rate of change (length) = − 0.15% ”, which proves excellent performance as a tile carpet.

System diagram showing the manufacturing process of hook tile carpet Plan view of the back side of the woven base fabric fixed on the fixed frame in the shrinking process Plan view of the back side of the woven fabric with glass fiber applied in the glass fiber application process Plan view of the back side of the woven base fabric to which the nonwoven fabric has been applied in the nonwoven fabric application process Top view of the back side of the woven base fabric with the back base fabric applied in the back base fabric application process (A) Top view showing multilayer structure of hook carpet for tile carpet (B) A-A 'partial enlarged sectional view Top view showing the cutting line written on the back of the hook carpet Sectional view showing the multilayer structure of hook tile carpet Layout showing the layout number of each tile after cutting exam result

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Hook tile carpet 10a Tile 11 Woven base fabric 11a Weaving part 12 Pile yarn 13 1st latex 14 Glass fiber 15 2nd latex 16 Non-woven fabric 17 3rd latex 18 Back base fabric 21 Fixed frame 22 Frame nail 31 Cutting line 32 Electric cutter 33 Guide rail 34 pin hole 35 pin

Claims (4)

A weaving process in which a pile yarn is stabbed into the woven base fabric from the back by a hook machine,
A shrinking step of fixing the woven base fabric woven in the weaving step to a four-sided frame-shaped weaving frame (loom) of a predetermined size with a nail pin, applying hot water to the woven base fabric, and then drying and shrinking;
After spraying latex with high pressure on the back side of the woven base fabric shrunk in the shrinking step, a glass fiber pasting step of laminating and laminating glass fibers on the latex coating surface,
Applying latex to the outer surface of the glass fiber pasted on the back side of the woven base fabric in the glass fiber pasting step, and pasting the nonwoven fabric on the latex coated surface,
Applying a latex to the outer surface of the nonwoven fabric pasted in the nonwoven fabric pasting step, and overlaying and pasting the back base fabric of the same material as the woven base fabric on the latex coated surface;
A cutting process in which the carpet formed by attaching the back base fabric in the back base fabric application process is divided into predetermined tile dimensions and cut;
A method for manufacturing a hook tile carpet, comprising:   In the cutting step, a cutting line for dividing the tile into predetermined tile dimensions is drawn on the outer surface of the carpet back base fabric made in the back base cloth applying step, and the blade of the electric cutter is pressed onto the cutting line and cut. A guide rail for linearly moving the electric cutter along the cutting line is placed on the carpet, and a pin is inserted into the pin hole provided on the guide rail to temporarily place the cutting position on the carpet. The method for manufacturing a hook tile carpet according to claim 1, wherein the blade of the electric cutter is cut so that the blade of the electric cutter does not deviate from the position of the cutting line at the time of cutting.   Weaving pile yarn on the woven base fabric by the hook drag manufacturing method, applying latex to the back side of the woven base fabric and bonding glass fibers, applying latex to the outer surface side of the glass fibers and bonding nonwoven fabrics, A hook carpet having a multilayer structure in which latex is applied to the outer surface of the nonwoven fabric and a back base fabric made of the same material as that of the woven base fabric is bonded to the outer surface of the nonwoven fabric. The hook tile is divided and cut into predetermined tile dimensions. carpet.   The rear surface of each tile that has been divided and cut is provided with a series of row numbers, a series of column numbers, and a vertical direction symbol of the tile as an arrangement code indicating the original position before cutting. Item 4. The hook tile carpet according to Item 3.

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