Carpet and carpet manufacturing method

Abstract

To provide a carpet with excellent environmental characteristics, which has good biodegradability and suppresses generation of harmful substances when incinerated.SOLUTION: A carpet 1 includes a base fabric 11 formed stretching in a planar direction, and a pile material 12 provided on the base fabric 11 so as to cover a surface 11a side of the base fabric 11. The pile material 12 includes piles 121 made of pulp, and the piles 121 are planted at a density that limits the inflow of air into the pile material 12.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to a rug and a method for making a rug. [Background technology]

[0002] 2. Description of the Related Art Many of the floor coverings used indoors and outdoors, such as rugs, carpets, and artificial turf, are made of synthetic resins such as polyethylene and polypropylene. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Special Publication No. 2013-503273 Summary of the Invention [Problem to be solved by the invention]

[0004] Synthetic resin floor coverings are not biodegradable and produce harmful substances when incinerated, posing problems when they are disposed of.

[0005] In view of the above circumstances, the present invention aims to provide a carpet that has good biodegradability, reduces the generation of harmful substances when incinerated, and has excellent environmental characteristics, and a manufacturing method thereof. [Means for solving the problem]

[0006] The invention described in claim 1 is a rug comprising a base fabric stretched in a planar direction and a pile material provided on the base fabric covering the front side of the base fabric, the pile material including piles made of pulp, the piles being planted at a density that restricts the inflow of air into the pile material, and the pile material being planted at a density such that there are 10 or more piles per square inch of the base fabric in both the vertical and horizontal directions.

[0007] The invention described in claim 2 is characterized in that the pile material is planted at a density of 14.9 or more pile threads per square inch of the base fabric in the vertical direction and 10 or more pile threads per square inch in the horizontal direction, and the length of the pile threads protruding from the base fabric to the surface side is 10 mm.

[0008] The invention described in claim 3 is characterized in that the floor covering is an artificial turf installation to be laid on a ground or a rug to be used indoors.

[0009] The invention described in claim 4 is a method for manufacturing a rug, comprising the steps of: a pulp manufacturing process in which Manila hemp pulp or wood pulp is cooked to produce pulp; a papermaking process in which base paper for Japanese paper thread is manufactured by papermaking; a slitting process in which the base paper for Japanese paper thread is cut to widths of 1 mm to 4 mm to create tapes; a twisting process in which the cut tapes are twisted to produce Japanese paper thread; and a weaving process in which a paper rug having a base fabric with pile of the Japanese paper thread woven on the surface side is manufactured by machine weaving.

[0010] The invention described in claim 5 is characterized in that the base fabric is made of a nonwoven fabric made of synthetic resin, and further includes a backing process for applying a resin coating to the back side of the base fabric to prevent the pile from coming loose from the base fabric.

[0011] The invention described in claim 6 is characterized in that the Japanese paper thread is formed by twisting the tape having a width of 1 mm to 4 mm.

[0012] The invention described in claim 7 is characterized in that the pile is formed by twisting together two or four of the Japanese paper yarns.

[0013] The invention described in claim 8 is characterized in that in the weaving process, the pile is planted at a density such that the number of pile threads per square inch of the base fabric is 10 or more in both the warp and weft directions.

[0014] The invention described in claim 9 is characterized in that in the weaving process, the pile is planted at a density such that the number of pile threads per square inch of the base fabric is 14.9 or more in the vertical direction and 10 or more in the horizontal direction, and the length of the pile protruding from the base fabric to its surface side is 10 mm.

[0015] The invention described in claim 10 is characterized in that the floor covering is an artificial turf installation to be laid on a ground or a rug to be used indoors. Effect of the Invention

[0016] According to the invention described in claim 1, the pile that constitutes the pile material is formed from pulp (paper), which makes it highly biodegradable and reduces the generation of harmful substances through incineration, making it possible to provide a carpet with excellent environmental properties.

[0017] Furthermore, because the pile is planted at a density that limits the inflow of air into the pile material, it is possible to provide a carpet that has excellent fire resistance, even though it is made of pulp (paper).

[0018] Furthermore, according to the invention described in claim 1, the density at which the pile is planted is 10 or more threads per square inch of the base fabric in both the vertical and horizontal directions, which effectively restricts the inflow of air into the pile material, thereby enhancing flame retardancy and improving fire resistance.

[0019] According to the invention described in claim 2, the density of the piles is set to 14.9 or more threads in the vertical direction and 10 or more threads in the horizontal direction per square inch of the base fabric, which makes it possible to better restrict the inflow of air into the pile material and further improve the fire resistance.

[0020] According to the invention described in claim 3, it is possible to provide an artificial turf installation and rug that have excellent environmental properties and fire resistance.

[0021] According to the invention described in claim 4, since the pile embedded in the base fabric is made of washi yarn containing pulp, it is possible to manufacture and provide a carpet with excellent environmental characteristics.

[0022] Here, the base paper for the washi yarn produced by papermaking is cut to create tape, and the cut tape is then twisted to produce washi yarn, which ensures that the washi yarn has good processability for machine weaving and ensures the strength of the pile woven into the base fabric.

[0023] Furthermore, the use of Manila hemp pulp or wood pulp makes it possible to provide paper fabrics that are particularly excellent in terms of environmental performance.

[0024] According to the invention described in claim 5, a base fabric made of a nonwoven synthetic resin is used and a resin coating is applied to the back side of the base fabric, which makes it possible to easily plant pile into the base fabric while effectively preventing the planted pile from coming loose.

[0025] According to the invention described in claim 6, the width of the tape cut from the base paper of the washi yarn is set to 1mm to 4mm, which makes it possible to carry out the twisting process smoothly, gives the washi yarn after twisting an appropriate thickness and strength, and enables the pile to be planted on the base fabric at the required density.

[0026] According to the invention described in claim 7, by forming the pile by twisting together multiple (specifically, two or four) Japanese paper threads, it is possible to make the pile uniform and strong, providing a paper rug that can adequately withstand repeated use and washing.

[0027] According to the invention described in claim 8, the density of the pile is set to 10 or more threads per square inch of the base fabric in both the vertical and horizontal directions, which effectively restricts the inflow of air into the gaps between the pile threads in the paper fabric, thereby improving the flame retardancy and fire resistance.

[0028] According to the invention described in claim 9, the density of the piles is set to 14.9 or more threads in the vertical direction and 10 or more threads in the horizontal direction per square inch of the base fabric, which makes it possible to better restrict the inflow of air into the gaps between the piles and further improve the fire resistance.

[0029] According to the invention as defined in claim 10, it is possible to produce artificial turf installations and rugs that have excellent environmental properties and fire resistance. [Brief description of the drawings]

[0030] [Figure 1] 1 is a perspective view showing, in outline, the configuration of a covering (artificial turf installation) according to one embodiment of the present invention. [Diagram 2] FIG. 2 is an enlarged cross-sectional view taken along line AA shown in FIG. [Diagram 3] 2 is an enlarged cross-sectional view taken along line BB shown in FIG. [Figure 4] 1 is a flow chart showing the basic steps of a method for manufacturing a carpet according to one embodiment of the present invention. [Diagram 5] FIG. 2 is an explanatory diagram showing a schematic diagram of a slitting step and a twisting step of the above-mentioned manufacturing method. [Figure 6] FIG. 2 is an explanatory diagram showing a schematic diagram of a weaving process of the manufacturing method. [Figure 7] FIG. 1 is a schematic diagram showing equipment used for a surface temperature test. [Figure 8] FIG. 2 is a schematic diagram showing the positional relationship between the artificial turf sample and the lighting in the above test. [Figure 9] 4 is a graph showing a change in surface temperature as a result of the above test. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0032] As shown in Figure 1, a paper carpet (hereinafter simply referred to as "the carpet") 1 according to one embodiment of the present invention comprises a base fabric 11 and a pile material 12. Figure 1 shows the outline of the pile material 12 roughly by a two-dot chain line.

[0033] In this embodiment, the floor covering 1 is an artificial turf laid on a ground. By covering the entire or part of the ground with this floor covering 1, an artificial turf can be formed. The ground in question may be either an outdoor or indoor ground.

[0034] The base fabric 11 fixes pile 121 for forming the turf. The base fabric 11 is formed with predetermined vertical and horizontal dimensions so as to extend in the vertical and horizontal directions of the rug 1, that is, in a planar direction parallel to the ground or floor surface on which the rug 1 is placed. In FIG. 1, the vertical direction of the rug 1 is shown as the Y direction, and the horizontal direction is shown as the X direction. The Z direction is the vertical upward direction, that is, the upward direction. The base fabric 11 can be formed from an appropriate synthetic resin material such as polyester or polypropylene, and may be a nonwoven fabric or a woven fabric made by plain weaving synthetic resin yarns.

[0035] The pile material 12 is provided so as to cover the entire surface side of the base fabric 11. The pile material 12 includes a large number of piles 121 formed from pulp, and these large number of piles 121 are planted in the base fabric 11 at a density that limits the inflow of air into the interior of the pile material 12, in other words, into the gaps between the individual piles 121 or the Japanese paper threads 1211 that make up the pile material 12. Here, the pile material 12 means a collection of a plurality or large number of piles 121.

[0036] In this embodiment, each pile 121 is formed by twisting together a plurality of Japanese paper threads 1211. In other words, the pile 121 is in the form of twisted yarn. The Japanese paper threads 1211 constituting the pile 121 are also called spun yarns, and are sold by the applicant of the present application under the product name "OJO + " is commercially available under the Japanese Patent Application No. 2002-2003-13444. The washi thread 1211 is colored to resemble grass (e.g., green).

[0037] 2 and 3, which are enlarged cross-sectional views of the rug 1, the piles 121 are arranged in rows along the vertical direction (Y direction) (FIG. 3), and a number of similar rows are arranged at regular intervals in the horizontal direction (X direction) (FIG. 2). The roots 121a of each pile 121 penetrate the base 11 from the front side to the back side, and are fixed to the base 11 by a resin coating 13 applied and formed on the back side of the base 11.

[0038] As described above, each pile 121 is formed by twisting together multiple Japanese paper threads 1211, and in this embodiment, one pile 121 is formed by twisting together four Japanese paper threads 1211. Here, the pile 121 is released from the constraint caused by the twisting at the tip end opposite the root portion 121a fixed to the base fabric 11, and is in a state where it is unraveled into individual (i.e., four) Japanese paper threads 1211. Each of the Japanese paper threads 1211 simulates a lawn. The number of Japanese paper threads 1211 twisted together may be any number other than four, for example, two.

[0039] The density of the pile 121 is set so that the number of piles 121 per square inch of the base fabric 11 is 10 or more in both the vertical and horizontal directions, i.e., in this embodiment, 14.9 or more in the vertical Y direction and 10 or more in the horizontal X direction. Here, the number of piles 121 per unit square may be the same in the vertical and horizontal directions or may be different. The height dimension of the part of the pile 121 that protrudes upward from the base fabric 11, i.e., the length L, is set to 10 mm.

[0040] A method for manufacturing the floor covering 1 according to this embodiment will be described below.

[0041] In the flow chart shown in FIG. 4, in the pulp production step shown in S101, Manila hemp pulp or wood pulp is cooked to produce pulp.

[0042] In the papermaking process shown in S102, paper is made using the pulp produced in S101 to produce base paper P for Japanese paper thread. A dyeing process for coloring the base paper P is carried out in association with the papermaking process.

[0043] In the slitting process shown in S103, the base paper P produced in S102 is cut to a predetermined width W to create a Japanese paper tape TP. Specifically, as shown in Fig. 5(a), while the base paper P is moved in the transport direction shown by the arrow, a slit cutter C1 is applied to the base paper P and cut into a width W of 1 mm to 4 mm. In this way, a tape TP having a width W is created.

[0044] In the twisting process shown in S104, the tape TP produced in S103 is twisted to produce Japanese paper thread TH. A predetermined number of Japanese paper threads TH (four in this embodiment) are then twisted together to form a twisted Japanese paper thread, i.e., a pile 121. The pile 121 is stored in a wound state on a creel stand. Figure 5(b) shows the process of twisting the tape TP to produce Japanese paper thread TH, and Figure 5(c) shows the process of twisting four Japanese paper threads TH to form the pile 121.

[0045] In the weaving step shown in S105, the pile 121 produced in S104 is tufted by a tufting machine to produce a paper fabric 1 having the pile 121 woven on the front side of the base fabric 11.

[0046] Specifically, as shown in FIG. 6(a), the pile 121 is woven into the base fabric 11 conveyed in the direction indicated by the arrow (one-way arrow) in the same manner as weaving a carpet. The pile 121 is driven from the back surface 11b of the base fabric 11 to the front surface 11a by the needle N reciprocating in a direction perpendicular to the back surface 11b of the base fabric 11, and the pile 121 is fixed in the position after driving by the keeper K reciprocating in a direction parallel to the front surface 11a of the base fabric 11. After fixing by the keeper K, the needle N is pulled out and the keeper K is retreated to its original position. Then, as shown in FIG. 6(b), the loop portion 121b at the tip of the pile 121 is cut off by a cutter or hook knife C2, thereby releasing the tip of the pile 121 and unraveling the pile 121 into individual Japanese paper threads 1211. This completes the planting of the two piles 121.

[0047] In the backing process shown in S106, a backing treatment is performed on the back side of the base fabric 11. Specifically, a suitable synthetic resin material such as styrene-butadiene rubber (SBR) or nitrile rubber (NBR) is applied to the back side of the base fabric 11, and the resin material is dried in a dryer called a tenter to form a resin coating. This fixes the pile 121 to the base fabric 11 and prevents the pile 121 from coming off the base fabric 11.

[0048] Thus, according to this embodiment, the pile 121 that constitutes the pile material 12 is formed from pulp (paper), which makes it possible to provide a rug 1 that is highly biodegradable and reduces the generation of harmful substances due to incineration, thereby providing an environmentally friendly rug 1.

[0049] Specifically, the pile 121 or washi yarn 1211 of the woven fabric 1 according to this embodiment has eight heavy metals (antimony Sb, arsenic As, barium Ba, cadmium Cd, chromium Cr, lead Pb, mercury Hg, and selenium Se) whose detection values ​​are all below the detection limit obtained by testing as specified in the Japanese Industrial Standards JIS L 1030 (the detection limit for antimony Sb, arsenic As, barium Ba, cadmium Cd, chromium Cr, lead Pb, mercury Hg, and selenium Se is 5 mg / kg for Sb, As, Cd, Cr, and Hg, and 10 mg / kg for Ba, Pb, and Se), resulting in no detection, and also no detection of formaldehyde (the detection value for free formaldehyde according to the Harmful Substances Testing Method specified in the Ministry of Health, Labor, and Welfare Ordinance No. 34 is 20 μg or less per 1 g), making it possible to realize a rug 1 that is extremely low in harmfulness to humans and highly safe. Furthermore, the antibacterial activity value obtained by the bacterial liquid absorption method defined in JIS L 1902:2015 is 2.3, proving that it has antibacterial properties.

[0050] Furthermore, since the pile 121 is planted at a density that limits the inflow of air into the pile material 12, it is possible to provide a carpet with excellent fire resistance even though it uses pulp (paper).

[0051] Here, the density at which the piles 121 are planted is 10 or more threads in each of the vertical and horizontal directions per square inch of the base fabric 11, specifically, 14.9 or more threads in the vertical direction and 10 or more threads in the horizontal direction, thereby effectively restricting the inflow of air into the pile material 12, thereby enhancing flame retardancy and improving fire prevention performance.

[0052] The following rugs of Example 1, Comparative Example 1, and Comparative Example 2 were each subjected to a fireproofing performance test certified by the Japan Fire Retardant Association. Only Example 1 passed the test, while Comparative Examples 1 and 2 failed. Compared to Example 1, Comparative Example 1 differs in that the pile density is low and that no level cut is performed, leaving the pile with loop portions. On the other hand, Comparative Example 2 differs in that, although level cut is performed, the pile density is low and the pile weight per unit square (i.e., basis weight) is small.

[0053] (1) Example 1 Using a 1 / 10G tufting machine (tuft gauge), the pile was tufted at a density of 14.9 threads per square inch lengthwise and 10 threads per square inch widthwise, and the loop portions at the ends of the pile were removed using a level cut to produce a rug with a pile length of 10mm and a pile weight of 1,230g per square meter.

[0054] (2) Comparative Example 1 Using a 5 / 32G tufting machine, the pile was tufted at a density of 9.6 threads per square inch lengthwise and 6.4 threads per square inch widthwise to produce a high cut, low loop (1:1) rug with a pile length of 14mm or 5mm and a pile weight of 812g per square meter.

[0055] (3) Comparative Example 2 Using a 5 / 32G tufting machine, the pile was tufted at a density of 11 threads vertically and 6.4 threads horizontally per square inch, and the loops at the ends of the pile were removed using a level cut to produce a rug with a pile length of 10 mm and a pile weight of 1,100 g per square meter.

[0056] In addition to the above, according to this embodiment, the pile 121 is made of paper and the pile material 12 has good breathability, so it is less likely to become stuffy and the rise in surface temperature due to heating by sunlight is suppressed, making it possible to ensure comfort even when used outdoors in the summer.

[0057] Tests were conducted to measure the surface temperature using the testing device shown in Figure 7 for each of the floor covering 1 of this embodiment (hereinafter referred to as "paper artificial turf"), artificial turf with pile made of nylon (hereinafter referred to as "nylon artificial turf"), and artificial turf with pile made of polyester (hereinafter referred to as "polyester artificial turf").

[0058] Paper artificial turf SPL1, nylon artificial turf SPL2 and polyester artificial turf SPL3 were placed on a polystyrene foam sample stage 301 with their respective front surfaces facing up and their back surfaces facing down, and artificial sunlight was irradiated for a predetermined period of time onto the surfaces of the artificial turf samples from an artificial solar lighting lamp (artificial solar lighting lamp XC-500EFSS, manufactured by Ceric Corporation, hereafter referred to as "lighting lamp") 201 installed at a predetermined height H from the top surface of the sample stage 301. Height H is, for example, 50 cm.

[0059] After the illumination lamp started irradiating the artificial turf samples SPL1, SPL2, and SPL3, the surface temperatures were measured every hour using a thermo camera (InfReC R550, manufactured by Nippon Avionics Co., Ltd., with emissivity set to 1.0) 202. Irradiation was performed multiple times (four times in this embodiment), with the positions of the artificial turf samples SPL1, SPL2, and SPL3 being swapped each time. As shown in FIG. 8, the illumination range R of the artificial sunlight from the illumination lamp 201 was divided into four, with the upper left quadrant in the figure being the first region Rq1, and the quadrants arranged clockwise from the first region Rq1 being the second region Rq2, the third region Rq3, and the fourth region Rq4. In FIG. 8, the symbols SPLa, SPLb, SPLc, and SPLd indicate the artificial turf samples arranged in the four quadrants Rq1 to Rq4, respectively. The center C of the artificial turf samples SPLa, SPLb, SPLc, SPLd arranged in each of the quadrants Rq1 to Rq4 (ie, the intersection point C of the two axes dividing each quadrant) coincides with the center of the illuminating lamp 201.

[0060] In the first irradiation, nylon artificial turf SPL2 is placed in the first region Rq1, polyester artificial turf SPL3 is placed in the second region Rq2, and paper artificial turf SPL1 is placed in the third region Rq3. No artificial turf sample is placed in the remaining fourth region Rq4, and the upper surface of the sample stage 301 is exposed. In the second irradiation, nylon artificial turf SPL2 is placed in the second region Rq2, polyester artificial turf SPL3 is placed in the third region Rq3, and paper artificial turf SPL1 is placed in the fourth region Rq4. As described above, no artificial turf sample is placed in the remaining first region Rq4, and the upper surface of the sample stage 301 is exposed. In this way, the artificial turf samples SPL1, SPL2, and SPL3 placed in each region Rq1 to Rq4 are replaced with each other for each round, and the surface temperatures Tspl measured for each of the artificial turf samples SPL1, SPL2, and SPL3 in each round are averaged, and the average value is the test result.

[0061] Figure 9 shows the change over time in surface temperature Tspl obtained as a result of the test for each of the artificial turf samples SPL1, SPL2, and SPL3. The horizontal axis shows the time t elapsed since the start of irradiation, and the vertical axis shows the surface temperature Tspl of the artificial turf sample. The thick solid line shows the surface temperature Tspl1 of the paper artificial turf SPL1, the dashed line shows the surface temperature Tspl2 of the nylon artificial turf SPL2, and the dashed double-dashed line shows the surface temperature Tspl3 of the polyester artificial turf SPL3. The temperature in the test room was 20±2°C.

[0062] As shown in Figure 9, the surface temperature Tspl tends to increase over time t for each of the artificial turf samples SPL1, SPL2, and SPL3, and a significant difference in surface temperature Tspl occurs between the paper artificial turf SPL1 and the other artificial turf samples SPL2 and SPL3. This difference also tends to increase over time t. At time t1 (e.g., 30 minutes after the start of irradiation), the surface temperature Tspl1 of the paper artificial turf SPL1 was 55.7°C, the surface temperature Tspl2 of the nylon artificial turf SPL2 was 71.6°C, and the surface temperature Tspl3 of the polyester artificial turf SPL3 was 70.2°C.

[0063] Since the surface temperature of natural grass when exposed to sunlight is around 50°C, it was found that with the carpet 1 of this embodiment, the rise in surface temperature Tspl1 is significantly suppressed compared to the artificial turf samples SPL2 and SPL3 made from synthetic resin material, and it is possible to provide a usage environment similar to that of natural grass. In this case, as described above, the surface temperature Tspl2 of the nylon artificial turf SPL2 is 71.6°C, and the surface temperature Tspl3 of the polyester artificial turf SPL3 is 70.2°C. Therefore, at these surface temperatures, the temperature rise will be so great that a user will not be able to walk barefoot on the nylon artificial turf SPL2 or polyester artificial turf SPL3, and even if they are wearing shoes, there will be a significant temperature impact on the user's feet and a significant heat impact on the entire body due to heat reflection. In contrast, with the paper artificial turf SPL1 of this embodiment, even under the same environmental temperature conditions, the temperature rise is the same as with natural turf, so users can walk barefoot.It can also be seen that the effects of heat on the feet and the entire body when walking or running in shoes are significantly reduced compared to polyester artificial turf and nylon artificial turf.

[0064] In this embodiment, the case where the floor covering 1 is an artificial turf installation to be laid on the ground has been described. After the pile 121 is planted in the base cloth 11, the loop portion at the tip is cut off and the pile 121 is cut to an open end, making it possible to provide an artificial turf installation with good water absorption, drying and drainage properties and good breathability. The floor covering 1 is not limited to an artificial turf installation, but may also be a rug to be used indoors. In this case, it is possible to not only cut off the loop portion 121b at the tip of the pile 121 to form a cut pile, but also to leave the loop portion 121b uncut to form the pile material 12 as a loop pile. [Explanation of symbols]

[0065] 1...Paper mat (artificial turf installation) 11...Base fabric 11a…Surface of base fabric 11b…Back side of base fabric 12…Pile material 121...Pile (twisted yarn) 121a...Base part 121b...Loop section 1211…Japanese paper thread 13...Resin coating 201…Artificial solar lighting 202…Thermal camera 301...Sample stage P…Japanese paper thread base paper TP…Tape TH…Japanese paper thread N…Needle K...keeper C1…Slit cutter C2…Hook knife SPL…Artificial turf sample

Claims

1. A base fabric stretched in a planar direction; The base fabric is provided with a pile material covering the front surface side of the base fabric, The pile material includes pile formed from pulp, and the pile is planted at a density that limits the inflow of air into the pile material.

2. 2. The carpet of claim 1, wherein the pile material is arranged at a density of 10 or more pile threads per square inch of the base fabric in both the longitudinal and transverse directions.

3. 3. The carpet according to claim 2, wherein the pile material is planted at a density of 14.9 or more pile threads per square inch of the base fabric in the longitudinal direction and 10 or more pile threads per square inch in the transverse direction, and the length of the pile threads protruding from the base fabric to the surface side is 10 mm.

4. 4. The carpet according to claim 2 or 3, which is an artificial turf installation to be laid on a ground or a rug to be used indoors.

5. a pulp manufacturing process for producing pulp by cooking Manila pulp or wood pulp; A papermaking process for producing base paper for Japanese paper thread by papermaking; a slitting process in which the base paper of the washi thread is cut into a width of 1 mm to 4 mm to create a tape; a twisting step of twisting the cut tape to produce washi yarn; and a weaving step for producing a paper carpet having a base fabric with pile of the washi yarn woven on the surface side by machine weaving.

6. 6. The method for manufacturing a rug as described in claim 5, wherein the base fabric is made of a nonwoven fabric made of synthetic resin, and further comprises a backing step of applying a resin coating to the back side of the base fabric to prevent the pile from coming loose from the base fabric.

7. 7. A method for manufacturing a rug as claimed in claim 5 or 6, characterized in that the washi yarn is formed by twisting the tape having a width of 1 mm to 4 mm.

8. 8. A method for manufacturing a rug as claimed in any one of claims 5 to 7, characterized in that the pile is formed by twisting together two or four of the washi yarns.

9. 9. A method for manufacturing a carpet as claimed in any one of claims 5 to 8, characterized in that in the weaving step, the pile is planted at a density such that the number of pile threads per square inch of the base fabric is 10 or more in each of the warp and weft directions.

10. 10. The method for manufacturing a carpet as set forth in claim 9, wherein in the weaving step, the pile is planted at a density such that the number of pile threads per square inch of the base fabric is 14.9 or more in the vertical direction and 10 or more in the horizontal direction, and the length of the pile threads protruding from the base fabric to its surface side is 10 mm.

11. 11. The method for manufacturing a floor covering according to claim 9 or 10, characterized in that the floor covering is an artificial turf installation to be laid on a ground or a rug to be used indoors.

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