EP1386992A1 - Method for producing tufted textile products such as tufted textile tiles - Google Patents

Abstract

The procedure consists of implanting a base layer (14) with multiple threads (12) to create a tufted surface (16) with at least one decorative motif, guide lines (18) parallel to the direction of the tufted surface's manufacture, and cutting marks (20) in predetermined positions relative to the motifs. The guide lines are implanted along the edges of the material, and the cutting marks are made adjacent to them, using tufts of contrasting colors.

Description

Introduction

The present invention relates to a method for manufacturing textile products tufted such as for example tufted textile tiles.

State of the art

Tufting is the most common technique for production today carpets. Tufted carpets are made by stitching a multiplicity of threads through a base layer to form loops, left intact or cut, which then constitutes the velvet of the carpet.

The tufting technique makes it possible to produce colored patterns by acting on the implantation of the threads by the needle bars of the tufting machine, which extend over the entire width of the base layer. The achievable patterns with conventional machines are however extremely repetitive and very limits.

In more advanced tufting machines, each thread has a feed control, allowing you to create different loop heights. The wires used are of different colors and their location on the bar needles, combined with the difference in height of the loops, creates drawings.

These drawings are less systematically repetitive because some curls, presenting a different coloring from their neighbors, can sometimes appear in a drawing if they have the same height as their neighbors, or disappear if they have a lower loop height, being covered in this case by their neighbors.

A disadvantage of the tufting technique is dimensional instability of the base layer, which is particularly problematic in the manufacture of tufted textile tiles. The tiles are generally made by making a large tufted tablecloth, which is then cut to the format of the tiles. As the base layer is not stable at dimensional level, the tufted sheet tends to stretch, especially in the longitudinal direction (manufacturing direction). This is problematic for the production of slabs because it is then difficult to guarantee that after cutting, the slabs can be properly connected together. This is why the most tufted carpet tiles have so-called "all-over" patterns for laying in the "same direction" or with patterns including geometric designs with mandatory checkerboard installation, which limits the decorative possibilities.

Document EP 1 148 171 A1 describes a process for manufacturing products tufted textiles with decorations in the form of geometric designs or not, in which at least two wires are produced from structures uniform and regular and then deposit, according to a pre-established pattern, different pastes of different colors and specific affinity for each wire type. For the production of tiles, the tufted sheet is first cut in the format of the tiles, then the coloring pastes are applied to the slabs. This process therefore makes it possible to manufacture slabs which can be connected to drawings. geometric, since the coloring operation is done directly on the slab after cutting. However, such a process is relatively complex, since it involves treating each slab individually, and involves a step additional coloring.

Subject of the invention

The object of the present invention is to provide an improved method of manufacture of tufted textile products, which allows in particular the manufacture of Tufted textile tiles with geometric designs that can be connected. This objective is achieved by a method according to claim 1.

Statement of the invention

In accordance with the invention, a method of manufacturing products is proposed. tufted textiles, in which a multiplicity of threads are implanted in a base layer by a tufting technique. The implantation of the wires is produced so as to form a tufted sheet comprising at least one pattern decorative, a guide line parallel to the manufacturing direction of the tufted tablecloth, as well as cutting marks placed at predetermined positions of the tufted tablecloth. Then cut the tufted tablecloth on base of guide line position and cut marks to form tufted textile products, such as for example tufted textile tiles.

It will be appreciated that, in the present process, the cutting marks and the guide line are implanted in the base layer at the same time as decorative patterns. The tufts forming the guide line, respectively the cutting marks, therefore constitute a system for indexing the web tufted which is an integral part of the tufting carried out. In the technique of tufting, the implantation of the threads is typically done by needle bars which extend over the entire width of the base layer. The base layer is advanced under the needle bars (in the manufacturing direction) and installation is done row after row (transversely to the manufacturing direction). In setting out the guide line and the cutting marks at the same time as the or decorative patterns, so it is possible to position them with great precision in relation to these decorative patterns. So, despite the distortions that may undergo the tufted web due to lack of dimensional stability of the base layer, the cut marks are always positioned from the same way compared to decorative patterns. The tufted tablecloth can then be cut with great precision in relation to the patterns, which allows to guarantee the quality of the connection between slabs.

In addition, by marking the tufted web during its manufacture in accordance with the invention, any subsequent marking step is eliminated to the manufacture of the tufted tablecloth, which would be less precise and would lengthen the manufacturing process.

As pointed out e.g. in EP 1 148 171 A1, the production of slabs textiles with geometric patterns requires precise cutting to guarantee connection between slabs. In this known method, the problem of the connection is overcome slabs by making the geometric patterns using colored pastes, once the tiles have been cut. It will be appreciated that the method according to the present invention makes it possible to produce a tufted tablecloth with geometric patterns, which based on the indexing system formed by the guide line and the marks cutting, can be precisely cut into slabs. The present process therefore allows the production of tufted textile tiles with geometric patterns which can be correctly connected.

It will be understood that the guide line and the cutting marks are of preferably placed in areas of the tufted tablecloth that will be part of cutting scraps. In a preferred variant, the guide line is located on the edge of the tufted sheet. The cutting marks can be arranged adjacent to the guide line, at predetermined intervals. We can thus obtain, at the edge of the tufted sheet, an indication of the axis longitudinal of the sheet tufted by the guide line, as well as an indexing in the transverse direction of the sheet tufted by the cutting marks. For easier identification, we can also provide a second line of guidance on the opposite edge of the tufted web, as well as a series of marks cutting.

The cut of the tufted web is preferably done in a press cutting equipped with optical detection means for automated guidance of the tufted tablecloth. For this purpose, the guide line, respectively the cut marks, are advantageously formed by tufts of colors contrasting, which facilitates their detection. We will use for example white or yellow for the guide line and the cut marks when the tufts neighbors are black, gray or blue.

Preferably, the tufted sheet is first cut into transverse strips according to the cutting marks; then we cut each cross strip in tufted textile products based on the guide line.

In order to protect the back of tufted textile products, the tufted tablecloth with a conventional latex-based coating before the cut. It is thus possible to form a lower stabilizing layer for a use in flooring.

The present process is particularly interesting for the manufacture of tufted textile tiles, as it guarantees the connection of the tiles produced. According to the tufting technique used for the implantation of yarn, you can make slabs of cut pile or plain loop pile and Simple. It is also possible to tuft a geometric design (technologies graphics or hydrashift) or to form a design by a difference of velvet height (scroll and cutloop technologies).

Detailed description of an advantageous embodiment of the invention

Fig.1:

une vue schématique d'une nappe touffetée dans une machine à touffeter ; et

Fig.2:

une vue partielle de la bordure d'une nappe touffetée avant découpe.

Other features and characteristics of the invention will emerge from the detailed description of an advantageous embodiment presented below, by way of illustration, with reference to the accompanying drawings. These show:

Fig.1:

a schematic view of a tufted web in a tufting machine; and

Fig.2:

a partial view of the edge of a tufted sheet before cutting.

Fig. 1 is used to describe in more detail, by way of illustration of the present invention, the progress of a process for manufacturing textile tiles tufted. We can see schematically a tufting machine 10 powered by a multiplicity of wires 12. These wires 12 are implanted in a layer of base 14 by means of a series of needles, placed on one or more bars needles (not shown) extending over the entire width of the base layer 14, to form a tufted ply 16. This series of needles, each of which is preferably powered by a separate wire spool, pricks wires 12 to through the base layer 14. The wires 12 are then held for a few instants by hooks in order to form loops, or tufts, which will constitute the velvet of the tiles.

Each time the needle series retracts, a new row of velvet curls is formed. This is how you get a loop pile. To obtain a cut pile, a knife is placed next to each hook in order to cut the loops thus formed.

It will therefore be understood that during the implantation, the base layer 14 gradually scrolls from left to right (compared to Fig. 1) in the tufting machine 10, with a step corresponding to the width of a row tufts, which are planted row after row across the width of the layer base 14, that is to say transversely. This direction in which the base layer 14, respectively the tufted layer 16, progresses in the tufting machine 10 is called "manufacturing direction". In general, we manufactures large tufted tablecloths and the manufacturing direction is then also the longitudinal direction of the tufted sheet.

It will be appreciated that, according to the present method, the implantation of the wires 12 in the base layer 14 is made so that the tufted ply 16 includes a decorative pattern, a guide line parallel to the direction of manufacture of the tufted tablecloth and preferably on the edge thereof, thus as cutting marks. In the present variant, the decorative pattern is made on the base layer in transverse bands, which have dimensions corresponding to two rows of four slabs indicated 17. These bands are spaced apart in the manufacturing direction, which leaves margins to compensate for the possible elongation of the base layer and for facilitate cutting. On the two longitudinal edges of the base layer 14, guide lines 18 and cutting marks 20 are located at the same time decorative patterns. These guide lines 18 and these reference marks section 20 are therefore placed row after row, in the same way as the decorative patterns, and serve to index the tufted tablecloth 16 for its subsequent cutting.

As can be seen, the guide lines 18 are preferably located at the edge of the tufted ply 16. The cutting marks 20 are located adjacent to the guide lines 18, and extend perpendicularly to these in order to give the transverse cutting directions. Indeed, the cutting marks are placed before, respectively after, a strip cross to cut into slabs. Generally speaking, the guide lines 18 are preferably located so as to indicate the longitudinal direction of the tufted ply 16. The cutting marks 20 are located at predetermined positions in relation to the decorative patterns and in relation to the format of the tiles 17.

These cut marks and the guide line therefore constitute a system for indexing the tufted ply 16 for its subsequent cutting. As the guide line and the cut marks are established at the same time as the or decorative patterns, it is possible to position them with great precision with respect to decorative patterns. This can be seen in Fig. 2 which shows the edge of a tufted tablecloth at a cut mark 120 adjacent to a guide line 118. Thus, despite the deformations that may undergo the tufted web due to the lack of dimensional stability of the base layer, the cut marks are always positioned the same way relative to the patterns, and therefore provide reliable benchmarks allowing to cut the tufted tablecloth with great precision. In the case of Fig.2, it is clear that even if the tufted ply 16 undergoes a stretch in the longitudinal direction, the cutting mark 120 will always be opposite the tip of the triangle of the pattern drawn. The present method is therefore particularly advantageous for producing tiles with geometric patterns, because it guarantees a precise cut, which is necessary for the connection between slabs.

In practice, such a tufted sheet comprising on its edges longitudinal indexing system with guide lines and benchmarks cutting is carried out by providing in the tufting machine a series needles for setting up the indexing system. In Fig. 2, the mark 120 and line 118 are obtained by playing on the loop heights during the layout in order to bring out the clear curls in relation to the dark colored curls. Line 118 is obtained by highlighting, at the same transverse position, light colored loops, while doing take out neighboring dark curls. For the realization of cutting marks, it is only at certain predetermined intervals that one makes bring out more clear curls in the same row.

Once the tufted sheet 16 is finished, it is then cut from a cutting press (not shown) in the format of slabs 17. The cutting is advantageously provided with optical detection means for automated guiding of the tufted ply 16 in the press, with a view to precise cutting of the tiles.

In the present variant, the tufted ply 16 is first cut into transverse bands, i.e. perpendicular to the manufacturing direction, in based on the position of the cutting marks 20. Then, each transverse strip is cut in the direction of manufacture based on the position of the guide lines 18.

The marks 20 and guide lines are advantageously arranged by relative to the decorative patterns of the tiles in tufted areas of the tablecloth 16 which will form the scraps of cut.

Remain to note that before the cutting of the tufted ply 16, its reverse side, opposite to the tufting, is preferably subjected to a coating, to form a stabilizing bottom layer.

Claims (8)

Method for manufacturing tufted textile products, in which a multiplicity of wires is implanted in a base layer, the implantation of the wires being carried out so as to form a tufted sheet comprising: at least one decorative motif, a guide line parallel to the manufacturing direction of the tufted ply, and cut marks placed at predetermined positions relative to the decorative pattern; then the tufted web is cut based on the position of the guide line and the cutting marks to form tufted textile products. The method of claim 1, wherein the guide line is located on the edge of the tufted sheet. The method of claim 2, comprising a second line of guidance parallel to the direction of manufacture of the tufted ply implanted at the edge of the tufted tablecloth opposite that of the first guide line. Method according to any one of the preceding claims, in which the cutting marks are arranged adjacent to the guide line. Method according to any one of the preceding claims, in which is carried out to cut the tufted web in a press cutting equipped with optical detection means for guiding the tufted tablecloth. Method according to any one of the preceding claims, in which the guide line, respectively the cut marks, are formed with tufts of contrasting color. A method according to any one of the preceding claims, in which first cutting the tufted web into transverse strips according to the cutting marks; then each transverse strip is then cut into tufted textile products based on the position of the guide line. Method according to any one of the preceding claims, in which one subjects the tufted tablecloth to a coating before cutting it.

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