Carpet manufacturing device, and carpet manufacturing method using the same

Abstract

To provide a carpet manufacturing device capable of manufacturing a carpet having an improved weave structure, high volume, thickness and density, and an improved texture, and a carpet manufacturing method using the same.SOLUTION: A carpet manufacturing device 1 in which pile yarns 8 are laid between a plurality of parallel warp yarns 7 and 70, and which performs a weft inserting 9, beating, and a doup yarn 90, comprises: a plurality of rising parts 2 arranged at intervals of one or more warp yarns 7 and 70 and engaging below the doup yarn 90; a plurality of falling parts 3 arranged at intervals of one or more warp yarns 7 and 70 and adjacent to the respective rising parts 2 and engaging above the doup yarn 90; an advancing / retracting mechanism 4 that drives the rising parts 2 and the falling parts 3 to advance and retreat between an engagement position 40 and a disengagement position 41; and an opening / closing mechanism 5 that raises each rising part 2 placed at the engagement position 40 beyond each falling part 3 and lowers each falling part 3 placed at the engagement position 40 beyond each rising part 2.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to carpet manufacturing technology, and more particularly to a carpet manufacturing apparatus for weaving a dantsu carpet and a carpet manufacturing method using the same. [Background technology]

[0002] Conventionally, carpet manufacturing machines have been known to weave carpets by repeating the process of placing pile yarns between multiple parallel back warp threads and face warp threads, inserting weft yarns, beating, and intertwining leno yarns. However, when the leno yarns are beaten, each back warp thread and each face warp thread are reverse-shed, and the next pile yarn is placed between the back warp threads and face warp threads, weft yarns are inserted, and beating is performed, it is difficult to obtain sufficient tightening force at the base of the pile yarns from the leno yarns, the holding power of the pile yarns is poor, it is difficult to increase the durability of the ground weave, and a sense of volume cannot be obtained between the back warp threads and face warp threads, making it difficult to obtain a thick and dense carpet.

[0003] For example, Patent Document 1 (Japanese Utility Model Publication No. 59-10142) shows a pile winding bar used in carpet manufacturing, in which pile yarns attached to parallel warp yarns are wound spirally by winding hooks attached to the outer periphery of the tip of the winding bar as the bar moves forward, and no hook step is formed between the tip face of the winding bar and the outer surface of the winding hook on the moving side. This eliminates the hook step that could cause the pile yarn to unnecessarily wind around the winding bar as the winding bar rotates and moves forward, and allows the pile yarn to be wound smoothly around the winding bar, contributing to labor savings.

[0004] Furthermore, Patent Document 2 (Patent Publication No. 3721374) describes a carpet manufacturing device in which pile yarns are attached to multiple parallel back warp threads, and the pile yarns between these back warp threads are wound spirally around a winding bar that moves forward while rotating, and in which weft insertion, beating, reverse shedding, and entanglement of leash yarns are performed; the base of the hook provided at the tip of the winding bar is made thicker than the thickness of the winding bar, and the boundary between the top of the hook and the base of the winding bar is made into an introduction section that is thicker than the thickness of the winding bar itself, rising and sloping in a curved line. The pile yarn wound spirally by the rotation of the winding bar is wound spirally at the initial introduction section to a size that is larger than the diameter of the winding bar, and this large wound yarn moves sequentially to the winding bar, so that the pile yarn is wound with a slack state around the winding bar, reducing the load on the entire winding drive device and improving work efficiency.The carpet manufacturing device is shown in which the tip surface of the hook is directly or indirectly flush with the tip surface of the winding bar, allowing the pile yarn to be freely wound onto the winding bar, and there is no risk of the pile yarn getting caught accidentally, allowing for smooth work. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Jikko No. 59-10142 [Patent Document 2] Patent No. 3721374 Summary of the Invention [Problem to be solved by the invention]

[0006] However, as in the above-mentioned Patent Document 1, carpet manufacturing equipment that eliminates the hook step in the shape of the winding rod, makes the pile yarn winding operation smoother, and saves labor, has been able to increase carpet manufacturing efficiency, but improvements to the winding rod alone have not been able to improve the texture of the carpet, such as its volume, thickness, density, and feel.

[0007] Furthermore, as in the aforementioned Patent Document 2, a carpet manufacturing device in which the thickness of the winding rod is partially changed to allow the pile yarn to be wound with a sufficient margin, thereby reducing the load on the entire winding drive device and increasing work efficiency, was able to increase carpet manufacturing efficiency, but it was not able to manufacture carpets that were more voluminous, thicker, denser, and had excellent texture such as feel.

[0008] In view of the above circumstances, the present invention aims to provide a carpet manufacturing apparatus and a carpet manufacturing method using the same, which improves the weaving structure and enables the manufacturing of carpets with a higher quality feel, with a greater sense of volume, thickness and density. [Means for solving the problem]

[0009] The present invention relates to a carpet manufacturing apparatus for installing pile yarns between a plurality of parallel back warp threads and face warp threads, inserting weft threads, beating, and intertwining leash threads, the carpet manufacturing apparatus comprising: a plurality of ascending sections arranged for every one or more intervals of the back warp threads and face warp threads and engaging below the leash threads; a plurality of descending sections arranged for every one or more intervals of the back warp threads and face warp threads, adjacent to each ascending section in pairs in the weft direction, and engaging above the leash threads; an advancing and retreating mechanism for driving each ascending section and each descending section to advance and retreat between an engagement position where they engage with the leash threads and a disengagement position where they disengage from the leash threads; and an opening and closing mechanism for raising each ascending section arranged at the engagement position above each descending section, and for descending each descending section arranged at the engagement position above each ascending section.

[0010] The ascending section is driven by the advancing / retreating mechanism to advance to the engaging position and engage under the leash, driven by the opening / closing mechanism to ascend the leash beyond the descending section, driven by the opening / closing mechanism to descend beyond the descending section, and driven by the advancing / retreating mechanism to retreat to the disengaging position.

[0011] The descending part is driven by the advancing / retreating mechanism to advance to the engaging position and engage with the leash, driven by the opening / closing mechanism to pass over the ascending part and lower the leash, driven by the opening / closing mechanism to rise over the ascending part, and driven by the advancing / retreating mechanism to retreat to the disengaging position.

[0012] The advancing / retracting mechanism drives each ascending section and each descending section to advance and retreat between an engagement position where they engage with the entangled yarn and a disengagement position where they disengage from the entangled yarn. When the advancing / retracting mechanism moves each ascending section and each descending section to the engagement position, the opening / closing mechanism operates. For example, the advancing / retracting mechanism moves each ascending section and each descending section simultaneously (simultaneously) to the engagement position or the disengagement position. For example, each ascending section and its adjacent (paired) descending section move sequentially in the weft direction to the engagement position or the disengagement position.

[0013] The engagement position is a position where the ascending and descending sections are advanced until they engage with the leash, and the disengagement position is a position where the ascending and descending sections are retracted until they are disengaged from the leash.

[0014] The opening / closing mechanism raises each ascending section disposed at the engagement position above the descending section, and lowers each descending section disposed at the engagement position above the ascending section. It also lowers each ascending section disposed at the engagement position above the descending section, and raises each descending section disposed at the engagement position above the ascending section. For example, the ascending sections and the descending sections are opened and closed simultaneously, and the leash threads are simultaneously arranged in a sinusoidal waveform when viewed from the front. For example, each ascending section and its adjacent (paired) descending section are opened and closed sequentially in the weft direction, and the leash threads are sequentially arranged in a sinusoidal waveform when viewed from the front in the weft direction. Each of the two adjacent ascending sections and the one descending section disposed therebetween moves in the warp direction to guide the leash threads into a shape equivalent to one wavelength of the sinusoidal waveform when viewed from the front.

[0015] The present invention relates to a carpet manufacturing apparatus in which the ascending section is an ascending needle having a conical tip, and the descending section is a descending needle having a conical tip.

[0016] The tip of the ascending part is a cone-shaped ascending needle, and when it is arranged in the engagement position, the leash thread does not get caught in the center of the tip, so that it can be inserted more reliably under the leash thread. Also, the tip of the descending part is a cone-shaped descending needle, and when it is arranged in the engagement position, the leash thread does not get caught in the center of the tip, so that it can be inserted more reliably over the leash thread.

[0017] The present invention relates to a carpet manufacturing device in which the opening and closing mechanism comprises a support shaft that supports the base of each of the ascending and descending sections so that it can rotate freely around a weft axis, levers that are bent and extended from the base ends of each of the ascending and descending sections, and an opening and closing shuttle that opens and closes each lever.

[0018] The support shaft supports the ascending section and the descending section so that they can be opened and closed. The support shaft, for example, pivotally supports the bases of the ascending section and the descending section so that they can rotate freely around a lateral axis. The levers enable the ascending section and the descending section to be opened and closed. The levers, for example, are bent and extended from the bases of the ascending section and the descending section. The opening and closing shuttle opens and closes the levers of the ascending section and the descending section. The opening and closing shuttle is, for example, an opening and closing movable body that opens and closes the levers in the process of moving in the lateral direction like a shuttle. The ascending section and the descending section have, for example, an opening and closing biasing means that elastically biases each other in an opening direction (in the ascending direction and the descending direction, respectively) when not subjected to a closing operation by the opening and closing shuttle.

[0019] The present invention relates to a carpet manufacturing method in which pile yarns are laid between a plurality of parallel back warp threads and face warp threads, weft yarns are inserted, the reed is beaten, and leash yarns are intertwined, and the advancing and retreating mechanism advances the ascending section and the descending section to an engagement position, and each ascending section is disposed below the leash yarns for every one or more alternate back warp threads and face warp threads, and each descending section is disposed above the leash yarns for every one or more alternate back warp threads and face warp threads at positions adjacent to each ascending section in the weft direction, and The carpet manufacturing method uses a carpet manufacturing device in which a closing mechanism section raises each ascending section above the adjacent descending section and lowers each descending section above the adjacent ascending section, arranging the leash threads in a sinusoidal waveform when viewed from the front, reverse-opening each back warp thread and each face warp thread, and clamping the leash threads in a sinusoidal waveform when viewed from the front, and the advancing / retreating mechanism section retracts the ascending section and the descending section to a release position, beats the leash threads clamped in the sinusoidal waveform when viewed from the front, thereby increasing the weave density of the leash threads.

[0020] The advancing / retracting mechanism advances the ascending section and the descending section to the engaging position. Each ascending section is arranged below the leash for every one or more intervals of the back warp and the front warp. Each descending section is arranged above the leash at a position adjacent to each ascending section in the weft direction for every one or more intervals of the back warp and the front warp. The opening / closing mechanism raises each ascending section above the adjacent descending section and lowers each descending section above the adjacent ascending section. The leash is arranged in a sinusoidal waveform when viewed from the front. Each back warp and each front warp are reverse-opened, and the leash is clamped in a sinusoidal waveform when viewed from the front. The advancing / retracting mechanism retracts the ascending section and the descending section. The leash clamped in a sinusoidal waveform when viewed from the front is beaten to increase the density of the leash. [Effects of the Invention]

[0021] The carpet manufacturing apparatus of the present invention can lengthen the twill yarns that are folded into the carpet during the manufacturing process, increasing the yarn density, enhancing the weight, feel, and texture of the carpet, while also improving durability, thereby achieving the excellent effect of providing a carpet of higher quality.

[0022] According to the carpet manufacturing device of the present invention, it is equipped with an advance / retreat mechanism and an opening / closing mechanism, and each ascending section and descending section is made up of an ascending needle and a descending needle, so that each ascending needle and descending needle do not interfere with the leash thread, and each ascending needle is always inserted below the leash thread and each descending needle is always inserted above the leash thread, thereby realizing more stable manufacturing.

[0023] According to the carpet manufacturing apparatus of the present invention, the opening and closing mechanism has a support shaft, a lever, and an opening and closing shuttle, and the opening and closing shuttle moves back and forth smoothly and quickly in the weft direction, thereby more efficiently arranging the twill yarns in a sinusoidal waveform.

[0024] According to the carpet manufacturing method using the carpet manufacturing apparatus of the present invention, the advancing / retreating mechanism and the opening / closing mechanism operate the ascending section and the descending section more efficiently, and after arranging the leash in a sinusoidal wave shape when viewed from the front, the back warp threads and the face warp threads are reverse-opened and the leash is clamped in a sinusoidal wave shape. Therefore, even after the ascending section and the descending section retreat to the release position, the sinusoidal wave shape of the leash is maintained, and further, the leash is beaten, which more reliably prevents unnecessary fraying of the leash. [Brief explanation of the drawings]

[0025] [Figure 1] FIG. 10 is a front view showing the entangled twine 90. [Figure 2] FIG. 10 is a front view showing the wavy-arranged braided yarn 90. [Figure 3] FIG. 10 is a front view showing the beaten twine yarn 90. [Figure 4] 1 is a front view showing the weave of a carpet manufactured by the carpet manufacturing apparatus 1. FIG. [Figure 5] (A) A side view showing the closed ascending section 2 and descending section 3. (B) A side view showing the open ascending section 2 and descending section 3. (C) A front view showing the opening / closing shuttle 6. DETAILED DESCRIPTION OF THE INVENTION

[0026] Hereinafter, the carpet manufacturing apparatus according to this embodiment and the carpet manufacturing method using the same will be specifically described with reference to FIGS. The carpet manufacturing apparatus 1 is a carpet manufacturing apparatus that installs pile yarns 8 between a plurality of parallel back warp yarns 7 and face warp yarns 70, inserts weft yarns 9, beats the yarns, and intertwines leno yarns 90. The carpet manufacturing apparatus 1 has, for example, a winding rod (not shown). The winding rod is positioned so that it intersects the back warp yarns 7 and face warp yarns 70 at right angles when viewed from the front, and moves in the weft direction (the direction of the axis of rotation) while rotating about its axis. A winding hook attached to the outer periphery of the tip of the winding rod winds the pile yarns 8 spirally around the winding rod, successively enveloping and intertwining the back warp yarns 7 and face warp yarns 70, thereby producing a loop pile carpet as shown in Figure 4. As shown in Figure 4, the loop pile can be partially or entirely trimmed to create a carpet with partially or entirely cut pile. The carpet manufacturing apparatus 1 creates a weave by, for example, alternately switching the front and back sides of the back warp yarns 7 and the face warp yarns 70 at each weft insertion.

[0027] As shown in Figures 1, 4 and 5(A) and (B), the carpet manufacturing apparatus 1 includes, for example, a plurality of ascending sections 2 arranged at intervals of one or more of the back warp threads 7 and the face warp threads 70 and engaging below the leash thread 90; a plurality of descending sections 3 arranged at intervals of one or more of the back warp threads 7 and the face warp threads 70 and adjacent to each ascending section 2 in pairs in the weft direction and engaging above the leash thread 90; an advancing and retreating mechanism 4 that drives each ascending section 2 and each descending section 3 to advance and retreat between an engagement position 40 at which they engage with the leash thread 90 and a disengagement position 41 at which they disengage from the leash thread 90; and an opening and closing mechanism 5 that raises each ascending section 2 arranged at the engagement position 40 above each descending section 3 and lowers each descending section 3 arranged at the engagement position 40 above each ascending section 2. The advancing / retreating mechanism 4 and the opening / closing mechanism 5 start operating after, for example, as shown in FIG. 1, the weft thread 9 is inserted, beaten, the back warp thread 7 and the front warp thread 70 are swapped, and the leash thread 90 is inserted or leash-wound.

[0028] 5(A) and 5(B), the advancing and retreating mechanism 4 has a forward and backward movement source (not shown), and for example, moves the ascending section 2, descending section 3, opening and closing mechanism 5, and opening and closing shuttle 6 forward and backward relative to the leash thread 90 (back warp thread 7 and front warp thread 70). The forward and backward movement width can be set to the distance between the engagement position 40 where the ascending section 2 and descending section 3 engage with the leash thread 90 and the separation position 41 where the leash thread 90 is separated. The ascending section 2 and descending section 3 at the separation position 41 do not interfere with any of the threads, such as the back warp thread 7 and the front warp thread 70, as well as the leash thread 90.

[0029] In the carpet manufacturing apparatus 1, for example, the tip of the ascending section 2 is a conical ascending needle 20, and the tip of the descending section is a conical descending needle 30.

[0030] In the carpet manufacturing apparatus 1, for example, the opening and closing mechanism section 5 has a support shaft 50 that supports the base of each of the ascending section 2 and the descending section 3 so that it can rotate freely around a weft axis, levers 51, 52 that are bent and extended from the base ends of each of the ascending section 2 and the descending section 3, and an opening and closing shuttle 6 that opens and closes each of the levers 51, 52.

[0031] In the opening / closing mechanism 5 of the ascending section 2 and the descending section 3, the levers 51 and 52 extend rearward from the support shaft 50. For example, as shown in FIG. 5(A), when the ascending section 2 and the descending section 3 are disposed at the engagement position 40, with the ascending section 2 positioned directly below the leash 90 and the descending section 3 positioned directly above the leash 90, the levers 51 and 52 are in an open position at approximately equal opening angles above and below the horizontal.

[0032] As shown in FIG. 5(C), the opening / closing shuttle 6 has, for example, an opening rail 60 and opening / closing guide sections 61, 62 disposed at the weft-direction ends of the opening rail 60. The opening rail 60 has a weft-direction length corresponding to a plurality of warp yarns 7, 70, and includes upper and lower rails 60a spaced apart vertically to allow the diameters of the levers 51, 52 to pass smoothly. The opening / closing guide sections 61, 62 are symmetrical with respect to a center line C, which is an imaginary warp line located halfway between the weft-direction ends of the opening rail 60. The ascending section 2 and the descending section 3 have an opening biasing means, located either between the ascending section 2 and the descending section 3 or between the levers 51, 52, for example, for elastically biasing each other in the opening direction when not subjected to a closing operation by the opening / closing shuttle 6.

[0033] The opening guide section 61 is composed of upper and lower opening plates 61a that open while tilting up and down toward the lateral direction of travel of the opening rail 60. As shown in Figures 5(A) and (C), the lateral tip ends of the upper and lower opposing walls of the upper and lower opening plates 61a contact the respective levers 51, 52 that are separated vertically (when the ascending section 2 and the descending section 3 are close to each other). As shown in Figures 5(B) and (C), as the opening plates 61a move lateral, the opposing walls on the lateral base ends of each contact the respective levers 51, 52, guiding the respective levers 51, 52 to approach each other. In the process, the ascending section 2 is raised above the descending section 3, and the descending section 3 is lowered above the ascending section 2.

[0034] Furthermore, as the opening / closing shuttle 6 moves forward in the weft direction, the levers 51, 52, which are guided to be disposed close to each other above and below, maintain the open position of the ascending section 2 and the descending section 3 while they are between the upper and lower rails 60a of the opening rail 60. At this time, as shown in Fig. 2, the braid 90 is subjected to the up and down movements of the ascending section 2 and the descending section 3 and is arranged to form a sine wave shape when viewed from the front.

[0035] For example, the ascending section 2, descending section 3, forward / backward mechanism section 4, opening / closing mechanism section 5 and opening / closing shuttle 6 shown in FIG. 5 are a wavy yarn arrangement machine 10 incorporated in the carpet manufacturing apparatus 1 of the present invention.

[0036] As described above, the closing guide section 62 has upper and lower closing plates 62a that are symmetrical (with respect to the center line C) to the opening guide section 61. As the opening / closing shuttle 6 moves in the weft direction, the levers 51, 52 are positioned between the upper and lower rails 60a of the opening rail 60 toward the base ends of the upper and lower closing plates 62a, and are further guided toward the tip ends, so that the ascending section 2 and the descending section 3 approach each other, as shown in Figures 5(A) and 5(C). Therefore, as shown in Figure 2, when the opening / closing shuttle 6 moves in the weft direction, the levers 51, 52 within the weft width range of the opening / closing shuttle 6 sequentially move the ascending section 2 and the descending section 3 up and down, respectively, and the entangled yarns 90 are arranged in a sinusoidal wave shape in the weft direction.

[0037] As shown in Figure 2, after the leash threads 90 are arranged in a sinusoidal shape, either before or immediately after the forward / backward mechanism 4 moves them from the engagement position 40 to the disengagement position 41, the back warp threads 7 and the front warp threads 70 are reversed (opened in reverse), and the leash threads 90 arranged in a sinusoidal shape are sandwiched between the back warp threads 7 and the front warp threads 70, thereby maintaining the sinusoidal shape of the leash threads 90.

[0038] The advancing / retreating mechanism 4 retracts the ascending section 2 and the descending section 3 to the detached position 41, and as shown in Fig. 3, the leash yarns 90 clamped in the sinusoidal waveform when viewed from the front are beaten to increase the density of the leash yarns 90. The above-mentioned process can be performed either in the process of folding in some of the leash yarns 90 or in the process of folding in all of the leash yarns 90 during the carpet weaving process. For example, some of the leash yarns 90 that are not deformed into a sinusoidal waveform when viewed from the front can be woven into the same weave as conventional. [Industrial Applicability]

[0039] The carpet manufacturing apparatus and carpet manufacturing method using the same of the present invention can be used to manufacture textiles of any fiber. [Explanation of symbols]

[0040] 1. Carpet manufacturing equipment 2. Ascending section 3 Descending part 4 Advancement / retraction mechanism section 40 Same engagement position 41 Same Departure Position 5 Opening and closing mechanism 50 Same support shaft 51 Lever of the ascending part 2 52 Lever of the descending part 3 6 Opening and closing shuttle 60 Same Open Rail 60a Same upper and lower rails 61 Open guide section 61a same open plate 62 Same closed induction part 62a Same Closed 7 Back warp 70 Front warp 8 pile yarn 9 Weft 90 Twisted Thread

Claims

1. A carpet manufacturing apparatus in which pile yarns are laid between a plurality of parallel back warp yarns and face warp yarns, weft yarns are inserted, beaten, and entangled with leash yarns, a plurality of ascending portions disposed at intervals of one or more of the back warp threads and the front warp threads, and engaging with the underside of the leash thread; a plurality of descending portions arranged at intervals of one or more of the back warp threads and the front warp threads, adjacent to each of the ascending portions in a weft direction in pairs, and engaging with the upper side of the leash threads; an advancing / retracting mechanism for driving each ascending section and each descending section to advance and retreat between an engagement position where they engage with the leash and a disengagement position where they disengage from the leash; an opening / closing mechanism that raises each ascending portion disposed at the engagement position beyond each descending portion and lowers each descending portion disposed at the engagement position beyond each ascending portion; A carpet manufacturing apparatus comprising:

2. The rising portion is a rising needle having a conical tip, The descending portion is a descending needle having a conical tip, 2. The carpet manufacturing apparatus according to claim 1.

3. The opening and closing mechanism is a support shaft that supports each base of the ascending portion and the descending portion so as to be rotatable about a latitudinal axis; a lever bent and extended from each base end of the ascending portion and the descending portion; An opening / closing shuttle that opens and closes each lever, 2. The carpet manufacturing apparatus of claim 1, comprising:

4. A carpet manufacturing method comprising: laying pile yarns between a plurality of parallel back warp yarns and face warp yarns; inserting weft yarns; beating; and intertwining the weft yarns; the advancing / retracting mechanism advances the ascending portion and the descending portion to the engagement position; Each rising portion is arranged under the leash of each of the back warp and the face warp, and Each descending portion is disposed on the leash at a position adjacent to each of the ascending portions in a weft direction and paired with each other for every one or more of the back warp and the face warp; the opening and closing mechanism raises each ascending section above the adjacent descending section and lowers each descending section above the adjacent ascending section; The tangled yarn is arranged in a sinusoidal waveform when viewed from the front, Each back warp thread and each front warp thread are reverse-shed, and the leash thread is sandwiched in a sinusoidal waveform when viewed from the front. The advancing / retreating mechanism retracts the ascending section and the descending section to a detached position, The woven yarns sandwiched in the sinusoidal waveform when viewed from the front are beaten with a reed to increase the weave density of the woven yarns. A carpet manufacturing method using the carpet manufacturing apparatus according to any one of claims 1 to 3.

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