EP1148171A1 - Method for producing textile products, especially tufted products, with geometric or non-geometric patterns and products obtained thereby - Google Patents

Abstract

To produce a material with a patterning of a geometric or non-geometric design, it incorporates at least two yarns in a uniform and repeated structure. A given pattern is laid of dye pastes in different colors with a particular affinity for each specific type of yarn. The fabric is produced on a tufting machine, using two bars or more with a relative longitudinal displacement between them. The tufted loops are of the same or different height levels, using the different yarn feeds. The tufted material is stabilized by a conventional coating, and is cut into tiles. The tiles are gathered by an index system at an assembly where dye pastes are applied in an accurate repeat color pattern, using an injection action to deliver the dyes of different colors into accurate locations on to the material surface and into its body mass.

Description

Subject of the invention

The present invention relates to a method of production for producing textile products, and more particularly tufted products, provided drawings which may or may not be geometric.

The invention also relates to the products obtained by such a process, preferably in the form of slabs with designs that are perfectly connectable.

Technological background of the invention

It is well known to make products of textile-based floor covering such as rugs, carpets or slabs by pattern printing techniques, printing being defined as coloring (dyeing) local, usually performed using cylinders or printing frames, fed with colored pastes which are locally deposited on a previously colored background or unbleached.

Other techniques are based on the use of threads of different colors which form a continuous structure at the start of the different thread according to a chosen motif.

Among these latter techniques, the technique tufting allows for colorful patterns in acting on the implantation of the wires, generally two in three different colors on the needle bar of the tufting machine.

By the very configuration of the bars to needles, the patterns are strictly geometric and extremely repetitive, but also very limited.

When the successive bars of a machine to tufter allows a relative translational movement of rows of needle bars in relation to the frame of the machine, effects of shifting the patterns in each row loops are possible, without modifying the repetitive geometric character of the patterns.

So we developed tufting machines more complex which are equipped with power control on each wire, which makes it possible to create heights of different loops. The wires used are also two to three different colors and their location on the needle bar, combined with the difference in height of loops, used to create designs.

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

The drawings being made on a tablecloth non-stable textile, it is however not possible to work on geometric designs which can then be cut into slabs, the connectability of such designs being impossible to guarantee. Therefore, all drawings existing are all-over for installation in the same direction or geometric but with obligatory installation indeed checkerboard, which limits the decorative possibilities.

In addition, on the high loops, this causes wear and above all preferential soiling.

Furthermore, the use of dyed yarn limits the adaptability of this process and in the case of modification of colors or designs, a minimum of production is necessary (1000 to 2000 m ² depending on the products), since each modification implies change the power supply and therefore replace a large number of spools of wires.

In addition, the mass density of matter is not not constant over the entire height, the most curls short locally reducing this density.

Finally, the type of achievable patterns of this way remains relatively weak and limits the creativity of producers, mainly due to mottled and the like.

The use of affinity yarns (substantivity) differential to dyes has already been also available for creating colorful effects, especially for dyes off the padding type, possibly combined with reserve effects. Also in this case, the type of colored patterns is very limit.

Aims of the invention

The invention aims to avoid the drawbacks state of the art. It aims in particular obtaining structured textile products with designs, economically attractive way, especially in the form of tiles with a great freedom of patterns but which however remain connectable.

Character-defining elements of the invention

According to the present invention, there is provided a process for the production of textile products provided with decoration in the form of geometric designs or not, preferably made by tufting machines in using at least two sons of different affinity to dyes to form uniform and regular structures and then deposit, according to a pre-established pattern, different pastes of different coloring and specific affinity for each type of wire.

The type of tufting machine used according to the invention can be relatively simple and can be limit to achieve, without creation of height of loops different, a uniform geometric pattern thanks to a displacement of the needle bars associated with a mounting of thread (either off-white with different affinities, or thread mass dyed but always with polymers of different affinities).

It is however also possible depending on the invention of using tufting machines described above acting on wire feed differences of the two bars to create a restful structure effect on different loop heights, but always uniform and localized.

Yarns obtained from polymers with differentiated dye affinities are well known.

We can cite for example the sons of acid polyamide and basic affinity polyamide respectively for basic and acid dyes.

The different types of wires used can be unbleached or can be dyed in the mass.

The use of twisted yarns of various natures is possible according to the invention.

Advantageously, textile products obtained in this way can be coated with classic stabilization and be cut into slabs, which are then taken individually from indexed way on the installation which allows said deposit different coloring pastes according to drawings perfectly connectable for different slabs.

The technique used is suitable particularly for coloring produced in the form of depositing of coloring pastes using a pasta depot, equipped with several injection heads individual coloring pastes on the surface and in the mass of the textile product.

Using such an installation for staining slabs, it is completely possible to create geometric designs or not, but perfectly connectable, since the operation is done on a completely stable finished product, the distribution of which geometrical of the different threads is perfectly known.

In this way, there are no restrictions to the installation, called "same direction", of these drawings.

This type of machine is generally equipped to deposit six different colors, it is possible to make up to twelve colors on the finished product when each paste contains two types of dyes.

From a stock of ecru slabs made in different tufting constructions giving different effect bases, so it's possible to carry out any type of design and color very flexible with this type of machine that can print very low minima of the order of a few square meters.

By this technique, we can create effects which are in no way comparable to printing because, each loop takes on the coloring corresponding to the affinity of his thread. This produces effects originals specific to this technique.

We can therefore consider that we train first a "latent" design in the basic material which is then "revealed" by the pasta.

The invention will be described in more detail in reference to the accompanying drawings relating to a form preferred embodiment of the invention.

Brief description of the drawings

Figure 1 shows a sectional view diagram of a tufted product provided with drawings according to the state of the art (1/10 gauge);

Figure 2 shows a sectional view similar diagram of a tufted product with drawings according to the invention (1/10 gauge);

Figure 3 shows a view of a slab tufted according to the invention before coloring;

Figure 4 is a partial view of the slab after coloring and;

Figure 5 illustrates the connection between the drawing of the tiles in Figure 4.

Description of a preferred embodiment of the invention

According to the known technique, illustrated in Figure 1, a drawing can be obtained using a advanced tufting facility. This machine allows for differential tufting from son 1 of a first coloring (black in the drawing) and 2 of a second color (white in the drawing).

Relative to the height of the loop made using wire 1, the loops made using of wire 2 are respectively high loops (2A) used for drawing and low loops (2B), not visible.

In the case of the form of execution according to the invention of Figure 2, it is not necessary (but not excluded) to use tufting machines capable of varying the height of the loops during tufting.

According to the invention, the tufting machine classic is supplied with basic wires 1 (colored in gray) with an affinity for acid dyes and in acidic threads 2 (colored in black) having an affinity for basic dyes.

After tufting the product, which is preferably a slab, may for example include the pattern shown in Figure 3.

Each type of thread having an affinity different to dyes will react specifically when depositing one or more coloring pastes with a printing technique adapted to the decorative effects that we wish to obtain.

Provided that this impression of so-called indexed manner, that is to say respecting the clean geometry of a slab, for example as was done according to Figure 4, it becomes possible to pose tiles joined together with a perfect connection, without limitation of the laying direction as illustrated in Figure 5.

Although a form of execution has been described specific to the invention, it should be understood that is only an illustrative example of the possibilities of the proposed technique.

The use of tufting machines creating Differential pitch loops, in exact match or not, and even random compared to the colored pattern that you want to create is possible, as is the use of more than two threads of different coloring. Shades in the same color are also possible, as well as any other additional decorative, colored, texture, structure, relief etc.

Claims (7)

Process for the production of textile products with decoration in the form of geometrical or non-geometric designs, characterized in that uniform and regular structures are produced from at least two threads and that different, then deposited, according to a pre-established pattern pastes of different coloring and specific affinity for each type of yarn. Method according to claim 1, characterized in that the textile structures are produced by tufting machines. Method according to claim 1 or 2, characterized in that the textile structures are produced by tufting machines with two or more bars, allowing relative longitudinal movement between them. Method according to claim 3, characterized in that the textile structures are produced by tufting machines, without creating different heights of loops. Method according to claim 3, characterized in that the textile structures are produced by tufting machines making it possible to create different heights of loops using feed equipment for each thread. Process according to any one of Claims 1 to 5, characterized in that the textile products undergo a conventional stabilization coating and are cut into slabs, which are then taken up individually in an indexed manner on an installation which allows said deposition of the different pastes of coloring according to perfectly connectable drawings. Method according to any one of claims 1 to 6, characterized in that the deposition of the coloring pastes is carried out using a pasta deposition machine equipped with several injection heads of individual coloring pastes on the surface and in the mass of the textile product.

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