JPH0464253B2 - - 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]

Traditionally, this type of carpet includes carpets manufactured by hand and carpets manufactured by tufting machines. To manufacture carpets using a tufting machine, the machine's parallel needles are The pile is tufted into the base fabric by threading single-color or bi-color tuft threads and activating all the needles in unison.

[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 causes 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.

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 alternately inserts tufted yarns of different colors or different types into the parallel needles of a tufting machine, and passes these needles all at once or tufted yarns of the same color or different types. By activating only the inserted needles, a pile pattern is tufted onto the base fabric, and by deactivating a desired number of needle groups during the tufting, the base fabric surface is created at the appropriate location on the base fabric. A carpet main body having an exposed non-pile pattern pattern is woven, and then a pile different in color or different from the pile pattern produced by the tufting machine is manually planted in the non-pile pattern pattern of the carpet main body. It is characterized by this.

[Effect]

By not operating a plurality of needle groups at desired locations among the many needles arranged in a line on a tufting machine, it is possible to create a pile-free pattern of any shape with the base fabric surface exposed at a desired portion of the base fabric. A pattern can be easily formed, and a desired pile can be manually planted in this non-pile pattern pattern in a subsequent process to produce a carpet with variations.

Furthermore, by alternately inserting tuft yarns of different colors or different types into the parallel needles of the tufting machine and operating these needles all at once, it is possible to tuft piles of two colors or different types. It is, of course, possible to tuft a single color or homogeneous pile densely throughout by operating only the odd number of needles or only the even number of needles, and therefore by operating these needle groups accordingly. By this, a two-color or different pattern can be arbitrarily formed on the base fabric.

In addition, by manually planting piles of a different color or quality from the pile pattern produced by the tufting machine into the non-pile pattern pattern of the woven carpet, a more varied and beautiful carpet can be created. That's what you get.

〔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 woven fabric or non-woven fabric plain woven with suitable flat threads such as synthetic resin tape yarn. A pattern pattern 2, 3 of piles 12, 13 made of thread and a pattern part 5 made of the exposed base fabric surface where these piles 12, 13 are not tufted are formed, and one side of the base fabric of this pattern part 5 is A pile 15 is planted by hand using pile threads of a different color from the pile patterns 2 and 3 produced by the tufting machine.

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 (Individually Controlled Needle)
Tufting Machine).

Odd numbered needles a, a of this tufting machine
...If, for example, a white tuft thread is inserted into a, the even numbered needles b, b...b are inserted into the odd numbered needle a.
The piles 12 and 13 are tufted onto the base fabric 1 by inserting a tuft thread of a different color, for example, black.

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 a 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 portion 5, the width changes with respect to the feed direction of the base fabric 1 depending on the shape of the pattern portion 5, but when forming the patterns 2, 3, and 4, the width changes depending on the shape of the pattern portion 5. 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, pattern part 4, and non-pile pattern pattern part 5 on the base fabric 1 by activation and deactivation of each needle of the needle group of the tufting machine, it is necessary to prepare the following steps in advance. , 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 so that the needles a and b for the 4 and non-pile pattern 5 are activated and deactivated as described above, and the movements of each needle as described above are performed according to commands from the computer during carpet manufacturing. It is something that can be done.

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 onto the base fabric 1 very densely. Even if one of the needle groups, for example, 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, the tuft density of the pile created by both needles a and b is 1/ The second pile is tufted so that the appearance of the carpet is not impaired.

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 weaving the carpet main body A having the pile patterns 2 to 4 and the non-pile pattern pattern 5 using the tufting machine, the tufting is manually applied to the non-pile pattern pattern part 5 of the carpet main body A. Pile pattern pattern 2 using a sewing machine
A pattern 6 is provided by planting piles 15 of a different color from 3. Such manual formation of the pile 15 can be performed using a hand-type foot lug making machine or a tuft repair machine.

At this time, a single-color pattern 6 may be formed by tufting all the pile threads of the same color in the non-pile pattern pattern part 5, or a pattern 6 of a single color may be formed by using pile threads of two or more colors. A pattern 6 having a pattern 6 may be formed.

In addition, in the above embodiment, the odd numbered needle a
The piles 12 and 13 were tufted on the base fabric 1 by inserting white and black tuft threads through the even-numbered needles B, but the piles 12 and 13 were not limited to these colors, but other different color tuft threads could be used. Of course, it is also good,
Furthermore, instead of using different colors for such tufted yarns or manual pile yarns, piles may be planted using different tufted yarns or pile yarns of different counts or materials.

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.

〔Effect of the invention〕

As described above, according to the carpet manufacturing method of the present invention, yarns of different colors or different types are alternately inserted into parallel needles of a tufting machine, and yarns of the same color or quality are inserted through these needles all at once. A pile pattern is tufted onto the base fabric by activating only the needles that are in operation, and at the same time, by inactivating a desired number of needle groups during the tufting, the surface of the base fabric is exposed at appropriate locations on the base fabric. Since the carpet mainly has a non-pile pattern, tuft yarns of different colors or different types are alternately inserted into the parallel needles of the tufting machine. Not only can piles of two colors or different materials be tufted by using the needles, but also piles of a single color or the same material can be tufted entirely densely by operating only odd-numbered needles or only even-numbered needles. Therefore, by appropriately operating these needle groups, it is possible to arbitrarily form a two-color or different pattern on the base fabric.

Moreover, according to the manufacturing method of the present invention, in the tuft,
By stopping a plurality of needle groups in the parallel needles, it is possible to form a non-piled patterned area in which the base fabric surface is exposed at a desired location on the base fabric, and this patterned area and the pile formed by the tufting machine can be formed at a desired location on the base fabric. Various designs and patterns can be formed by using the tufted pattern part, and the non-pile pattern part can be provided in the part where the design or pattern is to be emphasized.

Since piles of a different color or a different color from the pile pattern pattern produced by the tufting machine are manually tufted onto the non-pile pattern pattern of the woven carpet, the tuft threads forming the hand-stitched pattern are By using one or more arbitrary colors as a material, it is possible to create a new pattern that accentuates the area and harmonizes with the pattern created by the tufting machine, creating a beautiful and varied pattern. This makes it possible to efficiently manufacture carpets.

[Brief explanation of the drawing]

The drawings show an embodiment of the present invention, and FIG. 1 is a partially cutaway simplified plan view of a carpet obtained by the method of the present invention, FIG. 2 is a simplified cross-sectional view taken along the line of FIG. 1, and FIG. The figure is a simplified front view of the state in which it is manufactured by a tufting machine, Figures 4 and 5.
The figure is an enlarged front view of a portion thereof. 1... Base fabric, 2, 3, 4... Pattern pattern part, 5... Non-pile pattern pattern part, 12, 13, 15... Pile, a, b
…needle.

Claims (1)

[Claims] 1 A pile pattern is created on the base fabric by alternately inserting tufted threads of different colors or different qualities into the parallel needles of a tufting machine and operating these needles all at once or only the needles through which tufted threads of the same color or quality are inserted. By tufting the pattern and inactivating a desired number of needle groups in the tuft, a carpet main body having a non-pile pattern pattern portion with the base fabric surface exposed at a proper location on the base fabric is woven. . A method for manufacturing a carpet, which comprises manually planting piles of a different color or quality from the pile pattern produced by the tufting machine in the non-pile pattern pattern portion of the carpet.