GÜNDÜZ ALI (TR)
| WO2006035270A1 | 2006-04-06 | |||
| WO2000070137A1 | 2000-11-23 |
| DE20100378U1 | 2001-06-28 | |||
| CN209873295U | 2019-12-31 |
| CLAIMS 1- The invention is related to a seamed carpet base production mechanism which enables the carpet base to be produced as a single piece by seaming the base fabrics made of polypropylene (PP) material that are ultraviolet protected or that are not ultraviolet protected, to each other, without necessitating fibre reinforcement characterized by comprising; a feeding section (1) onto which rolls (3) that are wound with at least two base fabrics (2) made of polypropylene (PP) material that are ultraviolet protected or that are not ultraviolet protected are loaded, tension cylinders (13) that adjusts the tension in order to ensure that the surfaces of the base fabrics (2) received from at least two rolls (3) that have been loaded onto the feeding section (1) coincide with each other precisely without leading to air pockets or sagging; a seam section (4) onto which the base fabrics that have been received from the tension cylinders (13) that coincide with each other without having air pockets or sagging are transferred; a bottom and top yarn source (6,7) that is used for completing the fixation of at least two base fabrics (2) to each other by seaming, pre winding tension cylinders (8) onto which at least two base fabric (2) that have been fixed to each other and that are made of ultraviolet protected or non ultraviolet protected polypropylene (PP) material are transferred; a winding section (9) where the base fabrics (2) whose tensions have been adjusted and that have been fixed to each other are wound over the rolls and a control unit (11) which controls the entire machine. 2- A seamed carpet base production mechanism according to claim 1, characterized by comprising a sliding moveable sewing table (4.8) which automatically carries out the sewing process according to the pattern (10) that is desired to be woven onto the, at least two base fabrics (2) that are made of polypropylene (PP) material that are ultraviolet protected or that are not ultraviolet protected and that have been fixed to each other by seaming at the sewing section. 3- A seamed carpet base production mechanism according to any of the preceding claims, characterized by comprising a second fabric (2.3) that is formed like a mesh from polypropylene material, that provides extra resilience and that is provided at one of the rolls located at the feed section. 4- A seamed carpet base production mechanism according to any of the preceding claims, characterized in that a material formed of polyester strips instead of polypropylene material can be used as woven fabric. 5- A seamed carpet base production mechanism according to claim 2, characterized by having two or three bar sewing section that has needles thereon in order to provide multiple patterns. 6- A seamed carpet base production mechanism according to claim 1 and claim 2, characterized by having at least two, non concentric pre-sewing tension cylinders (13) that adjust the tensioning before sewing, which move left and right together with the bars and the sliding sewing table (4.8). 7- A seamed carpet base production mechanism according to claim 1, characterized by having pre-winding tension cylinders (8) that are formed of at least three cylinders, that are not concentric and that move up and down. 8 The invention is related to a seamed carpet base production method which enables the carpet base to be produced as a single piece by seaming the base fabrics made of polypropylene (PP) material that is ultraviolet protected or that are not ultraviolet protected, to each other characterized by comprising the steps of; at least two base fabrics made of ultraviolet protected or non -ultraviolet protected (PP) material are placed onto the rolls (3), after this the base fabrics are transferred from the rolls (3) towards the sewing section (4), the base fabrics (2) whose tensions have been adjusted and that have been transferred from the feeding rolls (3) towards the sewing section (4), are given the desired pattern and are fixed to each other the base fabrics (2) that have been fixed to each other are then transferred directly to the adjustable tension cylinders (8) and are wound around the winding cylinders located at the winding section, when the wound and fixed seamed base fabric reach the desired length, the fabric is cut and the packaging process is started. 9- A seamed carpet base production method according to claim 8, characterized by comprising the steps of; while the first set of yarns (6,7) are being threaded into the sewing needles, the other set of yams that are received from the bottom section of the sewing section are threaded into the sewing needle, after these yarns (4.6) and the base fabrics (2) are received at the sewing section (4), a sewing loop is established at the top section of the base fabrics (2) that are desired to be fixed to each other, following this a sewing loop is established, a separate yarn is received from the bottom section of the base fabric at the same time, and the locking process of the sewing loops is performed. 10- A seamed carpet base production method according to claim 8 and claim 9, characterized in that a material formed of polyester strips instead of polypropylene material can be used as woven fabric. 11- A seamed carpet base produced by means of the mechanism according to claim 1-7, characterized in that both of the base fabrics that have been fixed to each other are made of ultraviolet protected or non-ultraviolet protected (PP) material. 12- A seamed carpet base produced by means of the mechanism according to claim 1-7, characterized in that one of the base fabrics that have been fixed to each other is a base fabric (2.1) made of ultraviolet protected or non-ultraviolet protected (PP) material and the other is a second carpet base (fabric) (2.3) formed as a polypropylene mesh. 13- A seamed carpet base according to claim 11, characterized in that a third carpet base (fabric) (2.3) formed as a polypropylene mesh is placed over the two base fabrics (2.1, 2.2) that have been fixed to each other and that are made of ultraviolet protected or non ultraviolet protected (PP) material. 14- A seamed carpet base according to claim 11, claim 12 or claim 13, characterized in that; the material formed of polyester strips instead of propylene material can be used as woven fabric. |
Technical Field of the Invention:
The invention is related to a base fabric that is made into a single piece by seaming the base fabrics made of polypropylene (PP) material that is ultraviolet protected or that are not ultraviolet protected, to each other without necessitating fibre reinforcement.
Our invention is particularly related to providing a base fabric that is highly resilient, easy to produce, and low cost, that has been made into a single piece by seaming base fabrics to each other without disrupting the structural integrity of the base fabric, that do not necessitate reinforcement of fibre materials which are used in base fabrics that are suitable for all kinds of floors onto which artificial turf can be installed or floors such as football field carpets.
Prior Art and Technical Problems that are Faced:
In the prior art, highly resilient base fabrics are produced by means of reinforcing them with fibre type materials in order to increase the resilience of base fabrics that are used for floor covering for football field carpets and for base fabrics. The reason for preferring fibre reinforcement is that it enables the artificial grass that is woven onto the base fabric to be securely fixed.
The mechanism that is used in producing a carpet base fabric that is produced with fibre reinforcement, has sections such as mixing, carding and pinning and therefore it occupies wider spaces. The mechanism also requires more operators, higher energy usage and more time.
In order to provide fibre reinforcement for base fabrics that are made of ultraviolet protected or non-ultraviolet protected polypropylene (PP) material, during the production of a fibre reinforced carpet base fabric, a mixing section is available where the fibre mix is prepared in order to provide fibre reinforcement. In this section, the fibre type materials having various ratios for fibre reinforcement are delivered into the mixing section and are turned into a single material, following this they are carded in the carding section and are converted into muslin, after this, they are spread over an ultraviolet protected or non-ultraviolet protected (PP) material and the material is pinned in the pinning section in order for it to be fixed to the ultraviolet protected or non-ultraviolet protected (PP) material and following this the material is turned into a fibre reinforced base fabric by being subjected to a thermal process. The utility model document numbered TR 201001641 Y can be given as an example to the prior art.
If the ratios of the fibres that are mixed in the section where the fibre mix is prepared in the mechanism of the prior art, cannot be adjusted precisely, homogeneity problems are faced. Moreover, as fibre reinforcement can be carried out at different ratios on every area of the base fabric, quality problems also arise. Due to this mixing process, more time is consumed and workmanship costs increase and also extra costs are encountered due to the fibre that is used to increase resilience. Moreover, the dust that is produced during the mixing, carding and pinning processes also affects the health of the workers.
When the fibre reinforced base fabrics are being produced, pinning needs to be carried out continuously in order to fix the base fabric and therefore several needle holes occur on the surface of the base fabric. Due to this pinning process, disadvantageous changes are encountered regarding the permeability of air and water through the base fabric. As the material is pinned several times, the resilience of the material is reduced and it can be easily deformed depending on usage.
As reinforced fabric is used in the present system, and as the fibrous surface is not a smooth surface during application, latex absorption is severely increased. As the latex amount used is increased, this increases the cost of the base fabric and negatively affects its resilience.
The repair of the mechanism used for fibre reinforcement if any breakdowns occur is very time consuming and as production will be interrupted during such repairs, production loss is encountered. The repair and maintenance costs of such a system are also very high.
The Solution of the Technical Problems by means of the Invention and its Precedence to the Prior Art. In our invention a single piece base fabric is produced by seaming, using a seaming technique of seaming base fabrics made of ultraviolet protected or non-ultraviolet protected (PP) material, to each other, without necessitating any fibre reinforcement to base fabrics made of ultraviolet protected or non-ultraviolet protected (PP) material that is used in the production of base fabrics.
As in our inventions sections of the prior art, such as mixing, carding or thermal processing are not available in our invention, other elements that are required for the installation of these sections are not required. The production of base fabric can be carried out in a smaller area with higher quality.
As fibre reinforcement is not required, the costs of fibre material are also eliminated. The health issues that are experienced due to the dust produced during the preparation of fibre in the mixing and carding sections are also eliminated. Moreover, as fibre reinforcement that is prepared for reinforcement is not required, the loss of time is eliminated, and the production of base fabrics can be carried out in a much shorter period of time. The technical problems due to the fibre not being homogenous are prevented and therefore effort is not shown to solve this problem.
By means of our invention, there are fewer needle holes on our base fabric in comparison to the fibre reinforced base fabric of the prior art and therefore the base fabric is much more resilient.
When fibre is used, as the fibrous surface is not a smooth surface during application, latex absorption is severely increased. In our seamed produced where fibre is not used, as the surface is smooth, latex absorption is seriously reduced and this is beneficial as it directly affects the production cost of the client, buyer. The customers that purchase this product can obtain a cheaper carpet coating by using less lamination material.
Description of the Figures:
Figure- 1 Detailed perspective view of the 3 feed version of our machine that performs the seamed base fabric production subject to the invention
Figure-2: Section view of the seam section of our machine that performs the seamed base fabric production subject to the invention Figure-3: Detailed perspective top side view of the 3 feed version of our machine subject to the invention
Figure-4: Top perspective view of the 3 feed version of our machine subject to the invention
Figure-5: Detailed front view of the seam section of our machine that performs the seamed base fabric production subject to the invention
Figure-6: Detailed side view of the seam section of our machine that performs the seamed base fabric production subject to the invention
Figure-7: Detailed view of the two same fabrics, before the sewing and after the sewing process that is made of ultraviolet or non-ultraviolet protected polypropylene (PP) fabric and that is produced with the machine that performs the seamed base fabric production, subject to our invention
Figure-8: The detailed view of the carpet subject to our invention, before the sewing and after the sewing process, wherein one of the base fabrics that have been fixed to each other is a base fabric made of ultraviolet protected or non-ultraviolet protected (PP) material and the other is a second carpet base formed as a polypropylene mesh.
Figure-9: The detailed view of the two same fabrics, before the sewing and after the sewing process, that are made of ultraviolet or non-ultraviolet protected polypropylene (PP) fabric, and the third carpet base formed like a mesh on the top side, that are produced with the machine that performs the seamed base fabric production, subject to our invention
Reference Numbers:
1 - Feeding section
2- Base fabric
2.1 G st base fabric
2.2 2’nd base fabric
2.3 Mesh base fabric
3- Roll wound with the base fabric
4- Seam section
4.1 Needle driveshaft
4.2 Needle diving position
4.3 Fabric
4.4 Hook
4.5 Hook shaft 4.6 Sewing yam
4.7 Hook body
4.8 Sliding moveable table (Section that moves the needles)
5- Sewing table
6- Bottom yam source
7- Top yam source
8- Pre-winding tension cylinders
9- Winding section
10- Laminated base fabric
11- Computerized control system
12- Mesh type carpet base
13- Pre-sewing tension cylinders
Detailed Description of the Invention:
Our invention is related to a base fabric that is made into a single piece by seaming the base fabrics made of polypropylene (PP) material that are ultraviolet protected or that are not ultraviolet protected, to each other; a seamed carpet base production mechanism which enables to produce said base fabric and a method of producing said base fabric
Our mechanism which enables production of said seamed base fabric subject to the invention, comprises a feeding section (1) onto which rolls (3) that are wound with at least two base fabrics (2) are loaded, tension cylinders (13) that adjusts the tension in order to ensure that the surfaces of the base fabrics (2) received from at least two rolls (3) that have been loaded onto the feeding section (1) coincide with each other precisely without leading to air pockets or sagging; a seam section (4) onto which the base fabrics that have been received from the tension cylinders (13) that coincide with each other without having air pockets or sagging are transferred; a bottom and top yarn source (6,7) that is used for completing the fixation of at least two base fabrics (2) to each other by seaming, pre winding tension cylinders (8) onto which at least two base fabric (2) that has been fixed to each other, made of ultraviolet protected or non-ultraviolet protected polypropylene (PP) material are transferred; a winding section (9) where the base fabrics (2) whose tensions have been adjusted and that have been fixed to each other are wound over the rolls and a control unit (11) which controls the entire machine. In our mechanism subject to the invention, the winding process is carried out without experiencing problems such as folds, creases or overlapping sections by means of the adjustable tension cylinders (13) that are provided before the winding section. Moreover, the problems of non-coinciding sections or overlapping that may be experienced before the sewing process are eliminated by means of the tension cylinder (13) that is located between the feeding section and the sewing section.
The seamed base fabric subject to our invention is provided by seaming and fixing the base fabrics (2) having the same or different base weights that are wound over rolls (3) (Figure - 8). In our invention, after at least two base fabrics made of ultraviolet protected or non ultraviolet protected (PP) material that have been received from the feeding section (1), located on the rear section of our sewing mechanism, are placed onto the rolls (3), the base fabrics are then transferred from the rolls (3) towards the sewing section (4).
The sewing table at the sewing section (4) used in our mechanism, is a sliding moveable sewing table (4.8) which automatically carries out the sewing process according to the pattern (10) that is desired to be woven onto the base fabrics (2) that have been fixed to each other by seaming at the sewing section. By this means a seamed base fabric onto which the desired pattern (10) is woven is carried out. These seaming patterns are carried out by means of a control mechanism that is computer-controlled. The program related to the desired pattern is uploaded to the machine and the seaming patterns are completed according to this program.
While the yarns (6,7) that have been transferred from the feed rolls (3) to the sewing section (4) are being threaded into the sewing needles in order to sew the base fabrics (2) whose tensions have been adjusted and the other yams that are received from the bottom section of the sewing section are threaded into the sewing needle. After these yarns (4.6) and the base fabrics (2) are received at the sewing section (4), a sewing loop is established at the top section of the base fabrics (2) that are desired to be fixed to each other. After this sewing loop is established, a separate yarn is received from the bottom section of the base fabric at the same time, and the locking process of the sewing loops is performed. As a result, the base fabrics (2) that are received from at least two separate rolls (3) located at the feeding section (1) is fixed to each other. The base fabrics (2) that have been fixed to each other are transferred directly to the adjustable tension cylinders (8), and following this, the winding process is continued and the process is completed. When the seamed base fabric that has been produced is brought to the desired length, the roll is cut and packaging process is continued.
In the base fabric subject to our invention, a second carpet base (12) can also be used which is formed as mesh made of polypropylene material, instead of using two base fabrics that have the same properties. This second carpet base (12) formed as a mesh, provides extra resilience and provides the homogenous distribution of the latex that is to be spread over the surface of the seamed base fabric.
In our invention, the seamed base fabric subject to our invention, made of ultraviolet protected or non-ultraviolet protected (PP) material, are placed in order to be discharged as a roll, into the feeding section (1) that is located at the rear section of our sewing mechanism. In our mechanism which enables the production of the base fabric subject to our invention, at least two ultraviolet protected or non-ultraviolet protected (PP) material base fabrics (2) are seamed and fixed to each other.
In our seamed carpet base production mechanism subject to the invention, a material formed of polyester strips instead of polypropylene material can be used as woven fabric.
In our seamed carpet base production mechanism subject to the invention, a two or three bar sewing section is provided that has needles thereon in order to provide multiple patterns simultaneously.
In our seamed carpet base production mechanism subject to the invention, at least two, pre sewing tension cylinders (13) that move left and right together with the bars and the sliding mechanism, that are not concentric and that adjust the tensioning before sewing, have been provided.
In our seamed carpet base production mechanism subject to the invention, pre-winding tension cylinders (13) have been provided that is formed of at least three cylinders, that are not concentric and that move up and down.