DE20215361U1 - Wire foundation carpet, has warp threads made exclusively of wool - Google Patents

Abstract

A wire carpet has two thread systems at right angles to each other. The longitudinal thread system consists of a warp embedded within a woven foundation, a tie thread and a fundamental chain. The transverse thread system has weft threads. Together, the tie thread and fundamental chain form the woven foundation. The threads forming the warp (P) are made esp. exclusively of wool. The warp threads are yarn having a strength of 4.0 - 10.0 Nm (250 tex - 100 tex). The warp nap count is between 120,000 and 200,000/m2. The warp depth (H) is 2 mm or less. The warp (P) yarn is 600 - 1000 g/m2. The loop pile thread density is greater than 34/cm and there are at least 34 rows of loop pile threads/10 cm in the transverse array. The carpet is made using the shaft-wire weaving or jacquard shaft-wire weaving process.

Description

The invention relates to a rod carpet with two thread systems crossed at right angles, wherein the longitudinal thread system consists of a pile warp bound into a base fabric, a binding warp and a ground warp and the transverse thread system consists of the weft threads, wherein the threads of the ground and binding warp form the base fabric with the weft threads.

When weaving a rod carpet, two thread systems are crossed at right angles. The lengthwise threads are called the warp, while the crosswise threads are called the weft threads.

The longitudinal threads are called pile warp, binding warp and ground warp. The binding warp connects the transverse weft threads with the longitudinal pile and ground warp. The ground warp forms the foundation of the rod carpet.

The weft threads are alternately passed over the base warp as underweft and overweft. The weft threads, together with the threads of the binding and base warp, form the base fabric of the rod carpet. The weft threads consist primarily of jute, polypropylene, glass fiber, polyester, cotton and mixtures of the aforementioned fibers.

To produce the rod carpet, a simple compartment is formed from the threads of the base and binding warp, into which the weft thread is inserted by the shuttle.

At the same time, the pile threads that form the pile form a second compartment, into which a solid rod, the rod, is inserted parallel to the weft thread. If only a single compartment is formed during the next weft insertion and the pile thread is integrated into the base fabric, it forms a loop above the rod, which remains raised when

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After a few more shot and rod entries, the rods inserted first are pulled out again in the direction of the shot.

If these rods are not round and smooth, but have a cutting blade at their ends, the pile nubs formed by the loops are cut open when they are pulled out, creating a velour carpet. If a smooth-walled rod is used, the pile nubs remain. The result is a boucle carpet.

The applicant has been producing rod carpets for around 30 years using the process described above, the thread density of which in the direction of the longitudinal thread system is 28 - 34 pile threads per 10 cm, with 33 rows of pile tufts per 10 cm arranged in the direction of the transverse thread system. This results in a maximum number of pile tufts of 112,000 per m ² . The pile threads of the known rod carpet are made with carded or semi-worsted yarn made of polyamide fibers or from endless polyamide threads. The yarn thickness of the pile threads produced in this way is in the range of Nm 3 to 6 (Nm = metric number) »(333 tex - 167 tex). This known rod carpet achieves a suitability for object use, the classification of which results in the overall assessment "extreme" according to the test standard EN 1307, which is generally applicable to carpets made of polyamide fibers.

A disadvantage of the well-known rod carpet is the occurrence of pilling. Pilling refers to small knots that form in synthetic fabrics due to walking on them, rubbing, rubbing or incorrect cleaning.

Based on this state of the art, the invention is based on the task of creating a rod carpet of the type mentioned at the beginning, which according to the test standard EN 1307,

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The overall rating "extreme" is achieved and the pilling effect is avoided.

This task is solved in the rod carpet of the type mentioned above by

that the pile threads forming the pile warp consist exclusively of wool,
the pile threads have a yarn thickness of Nm 4.0 - 10.0 (250 tex - 100 tex)

the number of pile tufts is between 120,000 and 200,000 pile tufts per ^m2 of the rod carpet, the pile height is less than or equal to 2 mm and the yarn insert of the pile warp (P) is between 600 - 1000 grams per ^m2 of the rod carpet.

Because the pile-forming threads consist exclusively of wool, the undesirable pilling effect is effectively avoided.

The use of wool not only eliminates the pilling effect, but is also beneficial from an ecological point of view, as the wool used is a renewable natural textile raw material. Only robust and durable wool, such as New Zealand wool, is suitable for the production of rod carpets. The pile of the rod carpet according to the invention recovers extremely quickly even under extreme stress, so that a uniform appearance is always guaranteed. The use of wool also helps to balance the humidity in the room air. This effect is due to the wool's ability to absorb moisture. Finally, the carpet according to the invention is less flammable when suitable for a given object and is therefore safer than conventional carpets in this class.

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The object suitability is achieved by the pile threads of the pile warp having a yarn thickness of Nm 4 to 10 (250 tex - 100 tex), the number of pile tufts per m ² is increased compared to the known rod carpet to at least 120,000 tufts per m ² , but no more than 200,000 tufts, while at the same time the pile height is reduced from 2.2 mm to a pile height </= 2 mm. The pile height is the distance from the highest point of the cut or pulled pile tufts to the base fabric. Surprisingly, it has been shown that reducing the pile height not only results in a particularly good pile position, but also has a positive effect on the load-bearing capacity of the rod carpet. For the extreme loads of the rod carpet according to the invention, the yarn used in the pile warp is between 600 and 1000 g/m ² .

The increased number of pile tufts is preferably achieved by deviating from the previously usual reed setting by selecting a reed setting of more than 34 reeds/10 cm, preferably 40 reeds/10 cm. This reed setting results in a thread density in the direction of the longitudinal thread system that is greater than 34 pile threads per 10 cm, in particular 40 pile threads per 10 cm. In the direction of the transverse thread system, so many rows of pile tufts are to be arranged that the number of pile tufts required by the main claim of at least 120,000 is achieved.

Preferably, at least 34 rows of pile tufts per 10 cm should be arranged in the direction of the transverse thread system. If this lower limit is maintained, the thread density in the direction of the longitudinal thread system should be increased accordingly in order to achieve the required number of pile tufts.

The pile nubs can be designed in a conventional manner as drawn loops or as cut nubs. In addition, it is possible to add

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the combination of pulled loops and cut knobs to give a structure.

The rod carpet is preferably woven in a two-weft weave. However, a three-weft weave is also possible. In the first case, two weft insertions are required to form a pile tuft, in the second case, three.

A rod carpet woven using the shaft-rod weaving process is either single-colored or striped in the warp direction. To produce color-patterned goods, it is necessary that each individual thread of the pile warp can be raised and lowered individually and independently of one another to form the pattern. The requirement to control each thread individually by machine is met by producing the rod carpet using the Jacquard rod weaving process.

The invention is explained in more detail below using an embodiment.
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Figure 1 shows a section through a rod carpet 1 according to the invention with loops pulled into pile knobs 2 in a two-weft weave.

The carpet fabric consists of the binding warp designated B, which consists of longitudinal threads. The threads of the binding warp connect the transverse weft threads, which are designated in the figure as upper weft OS and lower weft US. The carpet fabric also comprises a pile-forming poly warp P, the individual threads of which, according to the invention, consist exclusively of wool. Together with the threads of the binding warp B and the base warp G, the weft threads OS, US form the base fabric of the rod carpet 1 according to the invention.

Figure 1 shows 6 rows 3 with pile tufts 2. In the direction of the longitudinal thread system, the thread thickness is

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density of the rod carpet according to the invention is at least 34 pile threads / 10 cm. The distance A between the weft insertions is chosen for the given thread density so that a pile number of at least 120,000 pile threads per m ² is achieved.

The rod insertion R is carried out in such a way that a pole height H of less than 2 mm results.

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List of reference symbols

1 Rod carpet 2 Polknopp 5 3 Row R rod P Polkette OS Surplus 10 US Deficit E. Binding chain G Basic chain E Pole height A Distance shot entries

Claims (8)

1. A rod carpet with two thread systems crossed at right angles, the longitudinal thread system consisting of a pile warp, a binding warp and a ground warp bound into a base fabric and the transverse thread system consisting of the weft threads, the threads of the base and binding warp forming the base fabric with the weft threads, characterized in that - that the pile threads forming the pile warp (P) consist exclusively of wool, - the pile threads have a yarn thickness of Nm 4.0-10.0 (250 tex -100 tex) - the number of tufts is between 120,000 and 200,000 tufts ( 2 ) per m ² of the rod carpet, - the pole height (H) is less than or equal to 2 mm and - the yarn usage of the pile warp (P) is between 600-1000 grams per m ² of the rod carpet. 2. Rod carpet according to claim 1, characterized in that the thread density in the direction of the longitudinal thread system is greater than 34 pile threads/10 cm. 3. A rod carpet according to claim 1, characterized in that at least 34 rows of pile knobs ( 2 )/10 cm are arranged in the direction of the transverse thread system. 4. Rod carpet according to one of claims 1 to 3, characterized in that the pile knobs ( 2 ) are designed as drawn loops and/or as cut pile knobs ( 2 ). 5. Rod carpet according to one of claims 1 to 4, characterized in that it is woven in two-weft weave. 6. Rod carpet according to one of claims 1 to 4, characterized in that it is woven in three-weft weave. 7. Rod carpet according to one of claims 1 to 6, characterized in that the rod carpet ( 1 ) is manufactured using the shaft-rod weaving process. 8. Rod carpet according to one of claims 1 to 7, characterized in that the rod carpet ( 1 ) is manufactured using the Jacquard rod weaving process.