JP6014873B2 - Carpet manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a carpet and a carpet, and more particularly, to a method for manufacturing a blurred tone carpet.

Conventionally, a space die method is known as a method for producing a carpet having a desired color pattern.
The space die method is a method of manufacturing a carpet by dyeing one pile yarn in advance in multiple colors at a predetermined interval by a space die device and tufting the dyed pile yarn (space die yarn) onto a base fabric.
However, in the space die method, the color pattern of the resulting carpet depends on the color pattern of the pile yarn that has been dyed in advance, so it is suitable for mass production of carpets of the same color pattern. Not suitable for manufacturing.
In recent years, carpets with various color patterns have been demanded in the market due to diversification of user requests. In order to cope with this, in the space die method, it is necessary to stock a large number of space die yarns according to the various color patterns or raw machines obtained by tufting them. Or, a storage place for live equipment is required. In particular, when manufacturing carpets of various color patterns in small amounts, the space die yarn must be exchanged according to the color patterns, and there is a problem that the manufacturing cost increases due to a decrease in work efficiency.

In Patent Document 1, as a method of manufacturing a space die carpet, a pile yarn having a patchy pattern portion and a background color portion, the pile yarn having the patchy pattern portion dyed with a metal complex dye, is tufted on a base fabric, It is disclosed that a raw machine (a base fabric on which pile yarn is tufted) is dipped in a dye bath to dye the ground color portion of the pile yarn.
According to the manufacturing method of Patent Document 1, a space die carpet in which the boundary between the spotted pattern portion and the ground color portion is not blurred and the pattern is clear can be obtained.

However, in the manufacturing method of Patent Document 1, a pile yarn whose spotted pattern portion is pre-stained with a metal complex dye is used. Therefore, in the manufacturing method of Patent Document 1, a carpet with a different color pattern is used as described above. Not suitable for manufacturing.
Specifically, for example, when the patchy dyed portion of the pile yarn is dyed red by a metal complex dye, after tufting the pile yarn, even if the ground color portion of the pile yarn is dyed in an arbitrary color, The color pattern of the resulting carpet always includes a red patchy dyed portion. Therefore, the pile yarn is suitable for manufacturing a carpet having a red pattern, but cannot be used for manufacturing a carpet having another pattern such as a blue pattern. For this reason, even in the method of Patent Document 1, a large number of pile yarns of various colors must be stocked according to the user's request.

  Further, in the manufacturing method of Patent Document 1, the boundary between the spotted pattern portion and the ground color portion is not blurred, and therefore, it is not possible to manufacture a gradation carpet with a blurred pattern.

No. 7-30713

The purpose of the present invention, even a few types of pile yarn advance stock is to provide a way capable of producing carpet blur Mokucho of different colors and patterns.

The carpet manufacturing method of the present invention is a pile yarn having an undyed region, and a preparation step of preparing a pile yarn in which a part of the undyed region has been subjected to a dye-proofing process; and the pile yarn a tuft step of tufted into backing, a pile yarn is tufted into the base fabric possess a dyeing step of dyeing with a dye, and in the dyeing process, the resist printing process is applied portion, by said dye It is dyed lightly as compared with the portion not subjected to the above-mentioned anti-dyeing treatment.

In a preferred method for producing a carpet according to the present invention, the portion subjected to the dyeing treatment is dyed to 20% to 80% of the degree of dyeing of the portion not subjected to the dyeing treatment.

In a preferred method for producing a carpet of the present invention, in the preparation step, a pile yarn subjected to the dyeing treatment is prepared by applying a dye-proofing agent to an undyed yarn using a space die device. For example, the anti-dyeing treatment is performed by adjusting the coating amount of the anti-staining agent. Preferably, the anti-dyeing agent is an aromatic sulfonic acid condensation polymer compound, an aromatic sulfonate, a polyhydric phenol condensation polymer compound, or glycols.
In the preferred carpet manufacturing method of the present invention, the dyeing step is performed by a continuous dyeing method.

According to the production method of the present invention, even if the number of pile yarns to be stocked in advance is small, it is possible to produce a blurry tone carpet having various color patterns. For this reason, according to the manufacturing method of the present invention, it is possible to manufacture a blurred tone carpet at a relatively low cost .

The front view which shows one Embodiment of the pile yarn in which the dyeing-proof process was performed partially. However, both sides of the pile yarn are omitted. FIG. 2 is an enlarged view of a circled part II in FIG. 1. III-III sectional view taken on the line of FIG. The front view which shows other embodiment of the pile yarn to which the dyeing-proof process was given partially. However, both sides of the pile yarn are omitted. The enlarged view of the circle enclosure V part of FIG.

The carpet manufacturing method of the present invention is a pile yarn having an undyed region, and a preparation step of preparing a pile yarn in which a part of the undyed region has been subjected to a dye-proofing process; and the pile yarn A tufting process for tufting to a base fabric, and a dyeing process for dyeing an undyed region including a dyed portion of the pile yarn tufted to the base fabric with a dye, if necessary And may have other steps. As the other steps, for example, a washing step for removing the dye attached to the dyed green machine, a backing step for performing backing processing with a resin such as PVC on the dyed base fabric, and a base fabric subjected to backing processing are predetermined. The cutting process etc. which cut into a shape and obtain a tile carpet are mentioned.
Hereinafter, the present invention will be specifically described.
In this specification, the notation “PPP to QQQ” means “PPP or more and QQQ or less”. In the present specification, “unstained” means a state that can be dyed with a dye but is not dyed.
It should be noted that the dimensions, scales, and shapes of each drawing are different from the actual ones.

[Pile yarn preparation process]
The pile yarn preparation step is a step of preparing a pile yarn in which a part of the undyed region has been subjected to a stain-proofing treatment.
The pile yarn may be composed of one undyed yarn, but is usually composed of a plurality of undyed yarns.
When the pile yarn is composed of a plurality of undyed yarns, the number is not particularly limited, but is, for example, 2 to 10. The thickness of the undyed yarn is not particularly limited, but is, for example, 1,000 dtex to 5,000 dtex, and preferably 2,500 dtex to 3,500 dtex.
A plurality of undyed yarns are aligned and entangled or twisted as necessary to form a pile yarn.

The plurality of undyed yarns may have the same dyeability, but preferably have different dyeability. A pile yarn having a plurality of undyed yarns having different dyeing properties is dyed in a color pattern corresponding to the number of undyed yarns, so that the color pattern of the carpet using the pile yarn can be diversified.
Undyed yarns having different dyeability mean undyed yarns that do not dye the same.
For example, examples of undyed yarns having different dyeability include the following cases.
(1) A case where one undyed yarn is dyed with a specific dye and the other undyed yarn cannot be dyed with the specific dye and is dyed with another different dye. That is, a plurality of undyed yarns that cannot be dyed with the same dye have different dyeability.
(2) One undyed yarn and another undyed yarn can be dyed with the same dye, but the dyeing densities are different from each other. That is, a plurality of undyed yarns having different dyeing densities have different dyeability.
(3) One undyed yarn and the other undyed yarn are dyed with different dyes and have different dyeing densities. That is, a plurality of undyed yarns that cannot be dyed with the same dye and have different dyeing densities have different dyeability.

  Examples of such an undyed yarn include an undyed yarn dyed with an acid dye, an undyed yarn dyed with a cationic dye, an undyed yarn dyed with a disperse dye, and an undyed yarn dyed with a metal complex dye. Examples include dyed yarn. The undyed yarn is dyed with the same dye, such as an undyed yarn dyed with an acid dye and dyed relatively darkly, an undyed yarn dyed with an acid dye and dyed relatively thinly, etc. Examples thereof include undyed yarns having different dyeing densities.

The material of the undyed yarn is not particularly limited, and examples thereof include synthetic fibers such as thermoplastic polymers such as polyamide, acrylic resin, polyester, and polypropylene; natural fibers such as wool. Polyamide-based fibers are preferably used because they can be satisfactorily dyed in various colors.
In general, polyamide-based undyed yarns can be dyed with acid dyes, cationic dyes, disperse dyes and metal complex dyes, and acrylic resin-based undyed yarns can be dyed with cationic dyes. Undyed yarn can be dyed with disperse dyes.

The undyed yarn may be composed of one undyed single yarn or a plurality of undyed single yarns.
Hereinafter, when referring to an undyed yarn composed of a plurality of undyed single yarns, it is referred to as “undyed multifilament” and is generally referred to as an undyed yarn and an undyed multifilament composed of a single undyed single yarn. "Undyed yarn".

  The thickness of the undyed single yarn is not particularly limited, but is, for example, 300 dtex to 2,000 dtex, and preferably 800 dtex to 1,500 dtex. If one undyed single yarn is too thick, there is a risk that a moderately soft carpet may not be obtained. On the other hand, if the undyed single yarn is too thin, the pile yarn will be relatively thin, so moderate elasticity. There is a possibility that a carpet having the property cannot be obtained.

In the undyed multifilament, the number of undyed single yarns is not particularly limited, but is, for example, 2 to 4.
A plurality of undyed single yarns are arranged and entangled or twisted as necessary to form an undyed multifilament.
The undyed yarn may be crimped.

  By applying a stain-proofing treatment to a part of the pile yarn, a pile yarn having a stain-proofing treatment applied to a part of the undyed region is obtained. Examples of the anti-dyeing treatment include covering an undyed region with an anti-dyeing agent. Hereinafter, a pile yarn in which a part of the undyed region has been subjected to a stain-proofing treatment may be referred to as a “powder-proofed pile yarn”.

In one embodiment, a pile yarn in which a part of the undyed region is subjected to a stain-proofing process is obtained by performing a stain-proofing process at a plurality of locations with a desired interval in the longitudinal direction of the pile yarn. It is done. Such a dyed pile yarn is subjected to an intermittent dyeing treatment in the longitudinal direction.
Such a dye-resistant pile yarn can be obtained by applying a heat-resisting agent to a pile yarn made of undyed yarn at a desired interval by a space die device or the like, and performing a heat treatment.
As shown in FIG. 1, the pile yarn 1A that has been subjected to the stain-proofing treatment has a longitudinal direction of a stain-proofing treatment portion 2A that has been subjected to the stain-proofing treatment and a non-dyeproofing treatment portion 3A that has not been subjected to the stain-proofing treatment. Alternately.
2 is an enlarged view of a round enclosure II portion of the dyed pile yarn 1A shown in FIG. 1, and FIG. 3 is a cross-sectional view taken along the line III-III in FIG. In FIG. 1 and FIG. 2, in order to make it easy to understand the part subjected to the dye-proofing process, it is expressed by light ink painting.
In addition, the part to which the stain-proofing process part and the stain-proofing process were performed is synonymous, and the part which is not subjected to the stain-proofing process part and the stain-proofing process is also synonymous.

The dyed pile yarn 1A shown in FIGS. 2 and 3 is formed by twisting three undyed yarns 41A, 42A, 43A, for example. However, the dyed pile yarn 1A is not limited to the case of being composed of three undyed yarns 41A, 42A, 43A, and is composed of two or four or more undyed yarns as described above. (Not shown). The undyed yarn of the pile yarn is not limited to the twisted yarn.
2 and 3, each of the first to third undyed yarns 41A, 42A, 43A is represented as one single yarn, but these are composed of undyed multifilaments. . The first to third undyed yarns 41A, 42A, and 43A may each be composed of an undyed single yarn.

By covering a plurality of locations spaced at desired intervals in the longitudinal direction of the pile yarn with a stainproofing agent, the stainproofed pile yarn 1A is provided with a plurality of stainproofing processing sections 2A. Between the plurality of stain-proofing treatment units 2A, there is a non-dyeproofing treatment unit 3A in which an undyed region is exposed.
When a plurality of the stain-proofing treatment parts 2A are formed in the longitudinal direction of the pile yarn, the length L1 in the longitudinal direction of each of the dye-proofing treatment parts 2A can be arbitrarily set according to the desired pattern of the carpet. The lengths L1 in the longitudinal direction of the respective antifouling treatment units 2A may all be the same or all may be different. Or the length L1 of the longitudinal direction of some anti-fouling process parts 2A among the some anti-fouling process parts 2A may be the same, and the length L1 of the longitudinal direction of the remaining anti-fouling process parts 2A may differ.
In addition, when a plurality of the stain-proofing treatment portions 2A are formed in the longitudinal direction of the pile yarn, the distance L2 between the adjacent stain-proofing treatment portions 2A and 2A can be arbitrarily set according to the desired carpet pattern. The intervals L2 between the adjacent antifouling treatment units 2A and 2A may all be the same or all may be different. Alternatively, some of the intervals L2 among the plurality of intervals L2 may be the same and the remaining intervals L2 may be different.

In another embodiment, at least one arbitrarily selected among the plurality of undyed yarns constituting the pile yarn (except for selecting all of the plurality of undyed yarns), By performing the anti-dyeing treatment, a pile yarn having a non-dyed region subjected to the anti-dyeing treatment is obtained.
In another embodiment of the present invention, the anti-dyeing pile yarn is subjected to anti-dyeing treatment on one or a plurality of undyed yarns or at a plurality of locations at desired intervals in the longitudinal direction of the undyed yarn. Applied, and the dyed undyed yarn and one or more undyed yarn not subjected to the dyeing treatment are aligned and entangled or twisted as necessary. .

For example, as shown in FIGS. 4 and 5, the dyed pile yarn 1 </ b> B according to another embodiment includes first to third undyed yarns 41 </ b> B, 42 </ b> B, 43 </ b> B that are twisted together. The undyed yarn 41B is subjected to a stain-proofing treatment, and the second and third undyed yarns 42B and 43B are not subjected to a stain-proofing treatment. In this case, the first undyed yarn 41B that has been subjected to the stain-proofing process corresponds to the stain-proofing process part 2B that is a part that has been subjected to the dye-proofing process, and the second and third that have not been subjected to the stain-proofing process. The undyed yarns 42B and 43B correspond to the non-dyeproofing treatment part 3B, which is a part not subjected to the dyeing-proofing treatment.
In FIG. 4 and FIG. 5, in order to make it easy to understand the portion subjected to the dye-proofing process, it is shown in light ink painting.

  The dyed pile yarn 1B shown in FIGS. 4 and 5 is formed by twisting three undyed yarns 41B, 42B, and 43B, but is not limited to this, and two or four or more yarns are used. It may be composed of undyed yarn (not shown). In addition, in the dyed pile yarn 1B shown in FIGS. 4 and 5, only one undyed yarn 41B has been dyed-treated, but at least one undyed yarn has not been dyed-treated. As a condition, a plurality of undyed yarns may be anti-dyed (not shown). Further, the dyed pile yarn 1B shown in FIG. 4 and FIG. 5 has been subjected to a stain resistant treatment over the entire longitudinal direction of the first undyed yarn 41B. May be subjected to a stain-proofing treatment (not shown). The undyed yarn of the pile yarn is not limited to the twisted yarn.

  The formation of the anti-dyeing treatment part can be appropriately set in consideration of the desired color pattern of the carpet. Since this dye-resisting part is not dyed or thinly dyed in the dyeing process described later, the more the proportion of the anti-dyeing part in the dye-treated pile yarn, the lighter the color. A patterned carpet is obtained.

  The dye-proofing agent used for the dye-proofing treatment is not particularly limited, and can be appropriately selected according to the kind of undyed yarn and the kind of dye that dyes it. The anti-dyeing agent is preferably colorless and transparent so that the anti-dyeing agent itself is not colored in the anti-dyeing part. But you may use the anti-dyeing agent (compound) which has few colors in the range which does not impair the effect of this invention.

The anti-staining agent does not contain a dye component and does not itself have a dyeing function, and substantially prevents dyeing of an unstained region with a dye, or is unstained with a dye. The region allows the region to be slightly stained (in other words, the region undyed with the dye is incompletely stained).
As the anti-dyeing treatment part is lightly dyed, a blurry tone carpet can be obtained. Therefore, as the anti-dyeing agent, an agent that allows the undyed area to be slightly dyed by the dye is used. Is preferred.
It is preferable to use a stain-proofing agent such that the stain-proofing treatment part can be dyed to 20% to 80% of the dyeing degree of the non-dyeproofing treatment part.
The fact that the anti-dyeing part is dyed to 20% to 80% of the dyeing degree of the non-anti-dyeing part is defined as 0% when the non-dyeing part is undyed and 100% when the limit dyeing is performed. In this case, it means that the anti-dyeing part is dyed to 20% to 80%.

Examples of the dye-proofing agent include aromatic sulfonic acid condensation polymer compounds, aromatic sulfonates, polyhydric phenol condensation polymer compounds, and glycols.
Specific examples of the condensed polymer compound of aromatic sulfonic acid include MESITOL NBS liquid (manufactured by Tanatex Chemicals Japan Co., Ltd.).
Specific examples of the aromatic sulfonate include EDOLAN Z-PAW liquid (manufactured by Tanatex Chemicals Japan Co., Ltd.).
Specific examples of the polyhydric phenol-based condensation polymer compound include nylon resist DO (manufactured by Meisei Chemical Industry Co., Ltd.).

The coating amount of the anti-dyeing agent on the undyed yarn is not particularly limited and can be appropriately selected. For example, even when a stain-proofing agent that is excellent in dye blocking effect is used, if the coating amount of the stain-proofing agent is relatively small, the stain-proofing part has a dyeing degree of 40%. % To 80%. On the other hand, even when a stain-proofing agent that is inferior in the blocking effect of the dye is used, if the coating amount of the stain-proofing agent is relatively large, the stain-proofing part has a dyeing degree of the non-stain-proofing part. % To 60%.
In this way, by appropriately designing the type and covering amount of the dye-proofing agent, the dye-proofing portion is lightly dyed in the later-described dyeing step, so that a carpet with a thin color pattern as a whole can be obtained.

The coating amount of the anti-dyeing agent is, for example, 10 mg to 100 mg, preferably 30 mg to 80 mg per 1 m of undyed yarn of 3,000 dtex.
Moreover, in one pile yarn, you may form several dyeing | staining-proof process parts using the same kind of different dyeing agent from which the several dyeing degree from which a dyeing degree differs, or the coating amount. Accordingly, a pile yarn having a plurality of portions having different dyeing degrees can be formed, and carpets with more various color patterns can be manufactured.

The anti-dyeing treatment can be performed using a known apparatus. For example, the anti-dyeing treatment can be performed by applying an anti-dyeing agent to the undyed yarn using a known space die apparatus.
For example, the procedure for obtaining a dyed pile yarn as shown in FIGS. 1 to 3 will be briefly described. A pile yarn made up of a plurality of undyed yarns is fed to a coating machine and desired in the longitudinal direction of the pile yarn. Apply an anti-stain agent at an interval of. Next, this pile yarn is preheated and further heated with steam while being pressurized. Thereafter, the pile yarn is washed with water and dried to obtain a pile yarn that has been subjected to the anti-dyeing treatment.
In addition, when apply | coating a dye-proofing agent, you may employ | adopt the various methods of dyeing | staining in cheese shape of the conventional space die method, dyeing | staining in a cake shape, or dyeing | knitting.

[Pile yarn tufting process]
The tufting step is a step of tufting the pile yarn including the pile yarn that has been subjected to the anti-dyeing treatment obtained in the preparation step onto the base fabric.
In the carpet manufacturing method of the present invention, the pile yarn used in the tufting process may include other pile yarns on the condition that the pile yarn includes a dye-proof treated pile yarn. Examples of the other pile yarn include a pile yarn made of an undyed yarn that has not been subjected to a stain-proofing treatment, and a pile yarn that has already been dyed. Moreover, the dyeing | stain-resistant pile yarn may be used individually by 1 type, or 2 or more types which are different.

  When the other pile yarn is included, the ratio of the dyed pile yarn to the other pile yarn is the dyed pile yarn: other pile yarn (weight ratio) = 99: 1 to 50:50. Is preferable, and 99: 1 to 60:40 is more preferable. If the other pile yarns are included too much, the effects of the present invention may not be sufficiently achieved.

  The base fabric for tufting the pile yarn is not particularly limited, and a known base fabric can be used. Examples of the base fabric include sheet-shaped fabrics such as woven fabric, nonwoven fabric, and knitted fabric. Examples of the fiber material constituting the base fabric include synthetic fibers such as polyester, polypropylene, polyethylene, and polyamide; natural fibers such as cellulose and wool; semi-synthetic fibers such as rayon. Among them, it is preferable to use a synthetic fiber because it is particularly excellent in thermal stability and hardly deforms during production.

Although the length of a base fabric is not specifically limited, In order to manufacture a carpet in large quantities mechanically, a long base fabric is used.
The long base fabric is, for example, a base fabric having a length of 10 m or more, and preferably a base fabric having a length of 100 m or more.
The width of the base fabric is not particularly limited, but in order to cut out a plurality of carpets in the width direction and mechanically produce a large amount of carpet, an integral multiple of the length of one side of the carpet (for example, 2 to It is preferable to use a base fabric having a width of 12 times.

A long base fabric is fed in the longitudinal direction, and each pile yarn is tufted on the downstream side using a known tufting machine. For example, if two different types of dyed pile yarns are tufted, the two dyed pile yarns may be alternately tufted in the gauge direction, or two dyed treatments with a desired number of tufts. Each pile yarn may be tufted.
By tufting the pile yarn on the base fabric, a living machine before dyeing is obtained, which is a structure in which the pile yarn including the anti-dyeing pile yarn is tufted on the base fabric.

[Dyeing process]
The dyeing process is a process of dyeing each pile yarn tufted on the base fabric in the tufting process.
The method for dyeing the pile yarn is not particularly limited, and a conventionally known method can be used.
Examples of the staining method include a continuous staining method and a Wins staining method.
Since the dyeing can be completed in a short time and the productivity is excellent, it is preferable to dye an undyed region of the pile yarn by a continuous dyeing method.

Dyeing by the continuous dyeing method can be performed by the following procedure, for example.
A long raw machine is fed in the longitudinal direction, and the dye is applied to the pile surface of the green machine in the middle. The dye is appropriately selected according to the kind of the undyed yarn.
For example, when the pile yarn is composed of an undyed yarn dyed with an acid dye and an undyed yarn dyed with a cationic dye, an acid dye and a cationic dye are used as the dye.

The method of applying the dye is not particularly limited, and examples thereof include a method of spraying the dye from the discharge nozzle onto the pile surface of the living machine, and a method of passing the living machine through the dyeing tank filled with the dye.
Normally, a plurality of discharge nozzles are provided at desired intervals in the width direction and longitudinal direction of the green machine in the middle of the line for sending the green machine, and the dye is applied to the pile surface of the green machine being conveyed downstream from the nozzles. .
When discharging the dye, a mixture of the acidic dye and the cationic dye may be discharged from each nozzle, or the acidic dye is ejected from a plurality of nozzles, and the cationic dye is discharged from another plurality of nozzles. You may squirt.

After applying the dye, the green machine is heat-treated to fix the dye to the pile yarn.
The heat treatment can be performed by, for example, warm air, steam, or the like.
Since heat is easily applied to the pile yarn substantially uniformly, it is preferable to perform heat treatment using steam.
By fixing the dyeing, a carpet having a desired color pattern can be obtained.

  In the non-dye-proofing part of the above-mentioned dye-proofed pile yarn (and other pile yarns), the undyed region of the undyed yarn is exposed without being covered with the anti-dyeing agent. The fixing of the dye is completed in the non-dye-proofing part, and the non-dye-proofing part is dyed in a predetermined color according to the dyeability of the undyed yarn.

On the other hand, in the anti-dyeing part of the dyed pile yarn, since the undyed yarn is coated with the anti-dyeing agent, the dyeing process does not substantially fix the dye in the anti-dyeing part, or A little dye is fixed.
Preferably, the anti-dyeing process part is dye | stained lightly compared with a non-dyeing process part. Specifically, it is preferable that the anti-dyeing part is dyed to 20 to 80% of the dyeing degree of the non-dyeing part, and more preferably 20 to 60% of the dyeing degree. It is particularly preferable that the dye is dyed to 30% to 50% of the dyeing degree.
As described above, the dyeing degree of the dye-proofing treatment part can be adjusted by selecting the kind of the dye-proofing agent and the dye and setting the coating amount of the dye-proofing agent.

According to the production method of the present invention, the pile yarn that has been partially subjected to the dyeing treatment is dyed after tufting, so that the part that has undergone the dyeing treatment is not dyed or slightly dyed, and A toned carpet can be obtained by completely dyeing the part which has not been dyed.
The dyeing processing unit is not preliminarily given a predetermined color. For this reason, in the dyeing | staining process, the dyeing | staining process part is not dye | stained substantially with the dye which dye | stains a non-dyeproof process part, or is dye | stained slightly with the said dye.
Therefore, the pile surface of the resulting carpet has a color pattern based on the color of the dye.

Specifically, when the anti-dyeing treatment part is not substantially dyed with the dye, the non-dyeing anti-dyeing part is dyed with the dye, and an achromatic anti-dyeing part (however, the color unique to the anti-dyeing agent composition). And a chromatic color non-resistant treated part that relies on the dye, a patchy tone carpet is obtained.
On the other hand, when the anti-dyeing part is slightly dyed with the dye, the thin chromatic anti-dyeing part depending on the dye and the chromatic non-anti-peeling part depending on the dye are patchy. In addition, a blurred tone carpet can be obtained.

  As described above, according to the manufacturing method of the present invention, since the color pattern of the entire pile surface is the same system as the color of the dye, pile yarns corresponding to various color patterns are stocked as in the conventional manufacturing method. The carpet can be manufactured relatively inexpensively. In the manufacturing method of the present invention, a plurality of carpets having different colors can be manufactured from one living machine.

[Washing process]
The washing step is a step of removing the dye attached to the dyed green machine after the dyeing step.
The dye remains in the raw machine after dyeing.
In order to remove the remaining dye, washing is preferably performed as necessary.
The washing liquid in the washing step is not particularly limited as long as it can remove the remaining dye, and examples thereof include water and low-concentration alcohol water.

The temperature of the cleaning liquid is usually about 5 ° C to 50 ° C.
The cleaning method is not particularly limited, and examples thereof include a method of spraying a cleaning liquid from a discharge nozzle onto a pile surface of a living machine, and a method of passing a living machine through a bath filled with the cleaning liquid.
The fresh machine after washing is dried.
The drying treatment may be natural drying, but forced drying using warm air or the like is preferable for shortening the time.

[Backing layer formation process]
The forming step of the backing layer is a step of forming a backing layer on the back surface of the green machine after dyeing.
The backing layer constitutes the back layer of the carpet, and a conventionally known backing layer can be employed.
For example, the backing layer has a backing layer, a reinforcing sheet, and a grounding layer. The backing layer is provided on the back surface of the living machine (the surface opposite to the pile surface), and a reinforcing sheet is provided on the back surface of the backing layer. The grounding layer is provided on the back surface of the reinforcing sheet and constitutes the backmost layer of the carpet.

The backing layer and the grounding layer are formed of a known synthetic resin. For example, as the synthetic resin for the backing layer and the grounding layer, PVC type such as vinyl chloride resin, EVA type such as vinyl chloride-vinyl acetate copolymer, APP type such as APP resin, PUR type such as polyurethane, etc. can be mentioned. It is done. From the viewpoint of processability, durability, and cost, it is preferable to use a PVC system such as polyvinyl chloride resin.
The reinforcing sheet is not particularly limited, and a known sheet can be used. For example, examples of the reinforcing sheet include woven or non-woven fabrics of inorganic fibers or synthetic fibers such as glass, polyester, and polyamide. In particular, since the dimensional stability effect is excellent, it is preferable to use a glass fiber nonwoven fabric or woven fabric as the reinforcing sheet.

[Cutting process]
The living machine having the backing layer obtained as described above is cut into a predetermined shape. For example, a tile carpet can be obtained by cutting the living machine into a rectangular shape of 500 mm × 500 mm.

In addition, a roll carpet can also be manufactured with the said manufacturing method of a carpet. When manufacturing a roll carpet, the fresh machine used for it is obtained by the above-mentioned preparation process, tufting process, dyeing process, and washing process. After the cleaning process, an adhesive layer such as styrene butadiene rubber (SBR) or acrylic latex is applied to the back surface of the living machine, and then a grounding layer such as jute or felt is attached. The obtained roll carpet is appropriately cut to a necessary length, and then wound or stored in a roll.
The carpet of the present invention (tile carpet, roll carpet) has a pile yarn and a base fabric on which the pile yarn is tufted, and the pile yarn is subjected to a dye-proofing treatment, The pile yarn is dyed including the dye-proof treatment part and the non-dye-proof treatment part. In particular, this dye-proofing part is lightly dyed compared with a non-dyeproofing part.
Such a carpet according to the present invention has an ambiguous color at the boundary between the dye-proof processing part and the non-dye-proofing part, and exhibits a preferable blurred tone appearance.

  EXAMPLES Hereinafter, an Example is shown and this invention is explained in full detail. However, the present invention is not limited to the following examples.

[Materials used]
Undyed yarn: trade name “427C” manufactured by INVISTA. This is an undyed yarn that is dyed relatively deeply with an acid dye, and is a multifilament in which 46 single yarns having a thickness of 20.1 dtex made of a polyamide fiber (nylon 6, 6) having a basic group are twisted together.
Dye-proofing agent: “MESITOL NBS liquid” commercial product made by Tanatex Chemicals Japan Co., Ltd.

[Example]
(Pile yarn preparation)
The anti-dyeing agent is partially applied to the original yarn produced by mixing the undyed yarn from the discharge nozzle provided in the space die apparatus with an interval of 20 cm to 50 cm, and about 10 by steam. Heat treated for minutes. In addition, the coating amount of the anti-dyeing agent was about 50 mg per 1 m of the raw yarn. Thereafter, the pile yarn was sufficiently rinsed with cold water, dried and wound up to obtain a pile yarn having been subjected to anti-dyeing treatment.

(Pile yarn tuft)
The dyeing-treated pile yarn was tufted in the longitudinal direction of a base fabric having a width of 420 cm (polyester spunbond nonwoven fabric; trade name “Marix” manufactured by Unitika Ltd.) to produce a living machine. The dyed pile yarn was tufted in a level loop with a basis weight of 700 g / m ² and a pile height of 4.0 mm using a 1/10 gauge tufting machine.

(Dyeing of live equipment)
While feeding the raw machine in the longitudinal direction of the continuous dyeing machine, acid dye (trade name “Tectilon” manufactured by HANTSMAN) is applied to the pile surface of the raw machine through a discharge nozzle arranged at a predetermined interval in the width direction. ). Thereafter, the raw machine was heat-treated with steam for about 4 minutes, and then sufficiently rinsed with cold water to remove the dye. Furthermore, dyeing of the living machine was completed by fixing the dye by applying a chemical solution and drying it sufficiently.

(Formation of backing layer)
Formed on the conveyor is a grounding layer made of a paste-like polyvinyl chloride resin with a thickness of about 1.5 mm, in which a polyester resin net (trade name “Kurenet” manufactured by Kurashiki Boseki Co., Ltd.) is embedded as the first reinforcing sheet. Further, a glass mat (weight per unit area: 40 g / m ² ) is laminated as a ^second reinforcing sheet on the ground layer, and a backing made of a polyvinyl chloride resin paste having a thickness of about 2.0 mm is formed on the glass mat. Layers were laminated.
After placing the dyed live machine on the backing layer, the whole was heated to cure the polyvinyl chloride resin.
The carpet thus obtained was cut into a 500 mm square in the tuft direction and the width direction by a cutting machine to produce a square tile carpet.

[Comparative example]
A carpet was manufactured according to an example disclosed in Patent Document 1 (Japanese Utility Model Publication No. 7-30713), and the carpet was cut into a 500 mm square to produce a tile carpet.

[Evaluation]
When visually comparing the tile carpets of the example and the comparative example, the carpet of the example has a tone-like appearance in which the shade of the dye color is blurred, whereas the carpet of the comparative example has a clear shade of the dye color. It appeared.
In addition, as an additional test, the living machines of Examples and Comparative Examples were dyed with a dye having a color different from the above dye. Even in that case, the carpets of the examples had a toned appearance with a shading (although different dye colors). On the other hand, since the color of the pile yarn before dyeing did not change, the carpet of the comparative example had a discomfort color pattern.

1A, 1B Dye-proofed pile yarn 2A, 2B Dye-proof processing part 3A, 3B Non-dye-proofing part 41A, 42A, 43A, 41B, 42B, 43B Undyed thread

Claims (6)

A pile yarn having an undyed region, a preparation step of preparing a pile yarn subjected to a stain-proofing treatment on a part of the undyed region,
A tufting process of tufting the pile yarn onto a base fabric;
A dyeing step of dyeing the pile yarn tufted on the base fabric with a dye,
The method for producing a carpet, wherein in the dyeing step, the portion subjected to the dyeing treatment is dyed lighter than the portion not subjected to the dyeing treatment with the dye . The carpet manufacturing method according to claim 1, wherein in the preparation step, the pile yarn subjected to the dyeing-proofing treatment is prepared by applying a dye-proofing agent to the undyed yarn using a space die device . The method for producing a carpet according to claim 2, wherein in the preparation step, a coating amount of the stain-proofing agent is adjusted to perform a stain-proofing treatment . The method for producing a carpet according to claim 2 or 3, wherein the antifouling agent is an aromatic sulfonic acid condensation polymer compound, an aromatic sulfonate, a polyhydric phenol condensation polymer compound, or glycols. .   The carpet according to any one of claims 1 to 4, wherein the portion subjected to the stain-proofing treatment is dyed to 20 to 80% of the dyeing degree of the portion not subjected to the stain-proofing treatment. Production method.   The method for producing a carpet according to any one of claims 1 to 5, wherein the dyeing step is performed by a continuous dyeing method.

Images