EP0846796A1 - Process for producing a carpet and carpets obtained by making use of the process - Google Patents
Process for producing a carpet and carpets obtained by making use of the process Download PDFInfo
- Publication number
- EP0846796A1 EP0846796A1 EP97202967A EP97202967A EP0846796A1 EP 0846796 A1 EP0846796 A1 EP 0846796A1 EP 97202967 A EP97202967 A EP 97202967A EP 97202967 A EP97202967 A EP 97202967A EP 0846796 A1 EP0846796 A1 EP 0846796A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- yarns
- carpet
- pile
- denier
- polyester
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- D—TEXTILES; PAPER
- D03—WEAVING
- D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
- D03D27/00—Woven pile fabrics
- D03D27/02—Woven pile fabrics wherein the pile is formed by warp or weft
- D03D27/10—Fabrics woven face-to-face, e.g. double velvet
Definitions
- This invention relates to a process for producing a carpet of the face to face type, i.e. a carpet of which the pile yarns are knotted on the weft and to the carpets obtained according to said process.
- the object of the present invention is a method allowing the manufacture of carpets with mechanical means which reflect the outlook of hand made silk carpets, especially of the type known as Kerman " and Chinese " silk carpets.
- a remarkable step of the process according to the invention is characterised by the washing process consisting of the following steps:
- the carpet piles are treated with a product having oil and water-repellent, dry soil-repellent and pile stabilising properties.
- a product with such properties is commercialised by BAYER AG under the trademark BAYGARD " .
- the invention relates also to the carpets obtained by making use of the process according to this application.
- the pile of the carpets is made of 100 % polyester and/or polypropylene yarn.
- Polyester yarns as used according to the invention are characterised by new features such as strength, resistance to wear and tear, soft touch and twist retention: usually processed continuous artificial polyester fibres have never been used in the carpet industry.
- the polyester yarns are characterised by the following features:
- the pile is made of processed continuous polypropylene and/or polyester yarns on which a light twisting has been carried out in order not to affect the softness or thickness of the yarns which are then heat set.
- the basic yarn is 300 denier, the number of filaments is 72 and every three yarns have been twisted together until the figure requested is 900 denier and 72 filaments X 3 yarns, being 216 filaments.
- For the first time in the carpet industry use is made of twisted heat set processed continuous yarns with a thickness of 4.1666 denier per filament.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
- Woven Fabrics (AREA)
- Carpets (AREA)
Abstract
The invention relates to a process for producing a
carpet of the face to face type, i.e. a carpet of which
the pile yarns are knotted on the weft, characterised in
that use is made for said pile yarns of continuous
filaments processed yarns (C.F.) of the groups to which
polyester and/or polypropylene belong.
Description
This invention relates to a process for
producing a carpet of the face to face type, i.e. a
carpet of which the pile yarns are knotted on the weft
and to the carpets obtained according to said process.
Hand made silk carpets are well known
and their commercial value is very high due to his
accurate designs which need experienced and skilful
manufacturers capable of making knots in the required
accurate way.
Attempts to reproduce mechanically the
natural feeling and soft touch of silk carpet remained
up to now unsuccessful.
The object of the present invention is
a method allowing the manufacture of carpets with
mechanical means which reflect the outlook of hand made
silk carpets, especially of the type known as Kerman"
and Chinese" silk carpets.
To reach this object according to the
present invention use is made for said pile yarns of
continuous filaments processed yarns (C.F.) of the
groups to which polyester and/or polypropylene belong.
Still according to the invention use is
made of yarns with following features:
300 denier
72 filaments
every three yarns being twisted together resulting in a yarncount of 900 denier x 216 filament, i.e. 4.166 denier per filament.
300 denier
72 filaments
every three yarns being twisted together resulting in a yarncount of 900 denier x 216 filament, i.e. 4.166 denier per filament.
A remarkable step of the process
according to the invention is characterised by the
washing process consisting of the following steps:
After the washing process the carpet
piles are treated with a product having oil and water-repellent,
dry soil-repellent and pile stabilising
properties. A product with such properties is
commercialised by BAYER AG under the trademark
BAYGARD".
The invention relates also to the
carpets obtained by making use of the process according
to this application.
Other details of the invention will
appear from the following description of the process
for manufacturing mechanically carpets of the two face
type of which the natural feeling and look can be
compared with that of hand woven silk carpets.
After long researches and experiments
applicant did succeed in producing those carpets by
mechanical means.
According to the present invention the
pile of the carpets is made of 100 % polyester and/or
polypropylene yarn.
Processed continuous polypropylene
yarns have never been used before as a material in the
manufacture of carpets. The yarns used within the scope
of this invention are characterised by the following
features:
- Specific weight :
- 0.91
- Humidity restoration :
- 0
- Impenetrability :
- 4 grams/denier
- Elongation :
- 30 %
- Shrinkage :
- 4 %
- Self-folding :
- 2,5 %
- Melting point :
- 160°C
Polyester yarns as used according to
the invention are characterised by new features such as
strength, resistance to wear and tear, soft touch and
twist retention: usually processed continuous
artificial polyester fibres have never been used in the
carpet industry. The polyester yarns are characterised
by the following features:
- Cross-section :
- triangular
- Specific weight :
- 1.38
- Humidity restoration :
- 0.4 %
- Impenetrability :
- 4 grams/denier
- Melting point :
- 244-250°C
- Shrinkage :
- 4 %
To obtain a carpet with the features
set forth in the heading, especially carpets of the
Kerman silk type, not only use is made of a fibre
reflecting the natural effect and soft touch of silk
carpets but a strict choice concerning their denier,
the number of knots/m2 has to be observed. Therefore,
the pile is made of processed continuous polypropylene
and/or polyester yarns on which a light twisting has
been carried out in order not to affect the softness or
thickness of the yarns which are then heat set. The
basic yarn is 300 denier, the number of filaments is 72
and every three yarns have been twisted together until
the figure requested is 900 denier and 72 filaments X 3
yarns, being 216 filaments. For the first time in the
carpet industry use is made of twisted heat set
processed continuous yarns with a thickness of 4.1666
denier per filament. Features of the carpets
manufactured according to the present invention are as
follows:
- No.of yarns (PP) and (PE)
- :300/72/3 denier, 300/72/6 denier
300/72/7 denier, 300/72/8 denier
300/72/9
80 twists heatset - Weft yarns
- :100% Egyptian cotton
- Warp yarns
- :100% Egyptian cotton for narrow warp
- Weave structure
- :Double face cross weave with one shot
- Fringes
- :Fibres according to the invention
- Reed Density
- :500/m
- Pile Rows
- :15/cm
- No. of Knots
- :750,000/m2 (75 knots/cm2)
- No. of dots/points
- :1,500,000/m2
- Height of pile
- :5mm; (it is the first time to be able to reach the low height in the field of mechanical carpet manufacturing
- Calendering
- :The temperature of the polishing machine is 100°C on the front and 180°C on the back side, and the pressure is 230 air pressure unit.
- Pile yarn
- : - 1250 gm ± 5%
- Weft yarn
- : - 600 gm ± 5%
- Warp yarn
- : - 380 gm ± 5%
- Adhesive material (latex)
- : - 180 wet gm ± 5%
When weaving carpets of the "Shenwah" type
is contemplated, thin yarns are not used nor an accurate
weave structure. In this case use is made of continuous
polypropylene and/or polyester yarn 300 denier/72
filaments with 6 to 9 yarns twisted and heatset. In this
manner thick yarns are produced to maintain softness,
shine and weave structure.
Features of the carpets manufactured
according to this embodiment are as follows:
- No.of yarns (PP) and (PE)
- :300/72/2 denier heatset
- Weft yarns
- :100% Egyptian cotton 6/3 English number
- Warp yarns
- :Polyester/Viscose 65/35 % 20/3 metric number for narrow warp 20/3 metric number for soft warp
- Weave structure
- :Double face cross weave with two shots
- Fringes
- :100% Egyptian cotton extending from the background
- Ends
- :Same yarn used for the pile
- Reed Density
- :315/m
- Pile Rows
- :8/cm or 800/m
- No. of Knots
- :252,000/m2
- No. of points
- :504,000/m2
- Height of pile
- :1,5 mm ± 5%
- Calendering
- :The temperature of the polishing machine is 100°C on the piles.
- Pile yarn
- : - 2500 gm ± 10%
- Weft yarn
- : - 600 gm ± 10%
- Warp yarn
- : - 300 gm ± 10%
- Adhesive material (latex)
- : - 200 wet gm ± 10%
Claims (17)
- Process for producing a carpet of the face to face type, i.e. a carpet of which the pile yarns are knotted on the weft, characterised in that use is made for said pile yarns of continuous filaments processed yarns (C.F.) of the groups to which polyester and/or polypropylene belong.
- Process according to claim 1, characterised in that use is made, for obtaining a carpet of the so called Kerman" type, of yarns with following features:
300 denier
72 filaments
every three yarns being twisted together resulting in a yarn count of 900 denier x 216 filaments, i.e. 4.166 denier per filament. - Process according to claim 1, characterised in that use is made, for obtaining carpets of the so calleda) Bulky polypropylene yarns B.C.F. with 100 twist 300/72/7 resulting in Denier 2100 of 504 filaments;b) Bulky polyester yarns B.C.F. with 100 twist 300/60/8 resulting in Denier 2640 of 480 filaments.
- Process according to one of claims 1 - 3, characterised in that the carpet is pre-finished, i.e. subjected to a washing process comprising the following steps:a) steamingb) scouring with hot waterc) rinsing with cold waterd) extraction of watere) dryingf) polishing in a calendering machine at 100C frontside and 180°C backside.
- Process according to claim 4, characterised in that the carpet piles are treated after washing with a product having oil and water-repellent, dry soil-repellent and pile stabilising properties.
- Carpet of the face to face type characterised in that the pile yarns consist of continuous processed polyester or polypropylene yarns.
- Carpet according to claim 6, characterised in that the number of knots per square meter is of 750,000.
- Carpet according to one of claims 6 and 7, characterised in that the pile is made of processed continuous flat polyester and/or polypropylene yarn.
- Carpet according to claim 8, characterised in that the polyester and/or polypropylene yarn is 300 denier and the number of filaments is 72.
- Carpet according to claim 9, characterised in that the yarns are soft twisted heat set yarns.
- Carpet of the Kerman type according to one of the claims 6 - 10, characterised in that the polypropylene and polyester yarns used have the following characteristics:
300 denier x 72 filament x 3, i.e. 900 denier with 216 filament 80 twists and heat set. - Carpet of the
- Carpet of the Shanghai type according to one of the claims 6 - 10, characterised in that the polyester yarns have the following characteristics: bulky polyester yarns B.C.F. with 100 twist 300/60/8 resulting in Denier 2640 of 480 filaments.
- Carpet characterised by one of the following features:
No. Of polypropylen yarns 300 x 72 x 7
No. Of polyester pile yarns 300 x 60 x 8 - Carpet according to one of the claims 6 - 14, characterised by the following features:
- Weft yarns
- : 100% Egyptian cotton
- Warp yarns
- : 100% Egyptian cotton
- Weave structure
- : Double face cross weave with one shot
- Reed Density
- : 500/m
- Pile Rows
- : 15/cm
- Number of knots
- : 750.000/m2
- Number of points
- : 1.500.000/m2
- Height of pile
- : 5 mm
- Carpet according to one of the claims 6 - 14, characterised by the following features:
- Weft yarns
- : 100% Egyptian cotton
6/3 English number and/or - Warp yarns
- : Polyester/Viscose 65/35%
20/3 metric number for narrow warp
20/3 metric number for soft warp
: Double face cross weave with two shots
: 100% Egyptian cotton extending from the background - Ends
- : same yarn used for the pile
- Reed Density
- : 315/m
- Pile Rows
- : 8/cm or 800/m
- No. of knots
- : 252,000/m2
- No. of points
- : 504,000/m2
- Height of pile
- : 9,5 mm ± 5%
- Carpet according to one of the claims 11 to 15, wherein the materials used to produce one square meter have one of the following figures:
a) Pile yarns 1250 gm ± 5% Weft yarns 600 gm ± 5% Warp yarns 380 gm ± 5% Adhesive material (Latix) 180 wet gm ± 10% b) Pile yarns 1700 gm ± 10% Weft yarns 500 gm ± 10% Warp yarns 300 gm ± 10% Adhesive material (Latix) 200 wet gm ± 10%
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EG90296 | 1996-10-05 | ||
EG90296A EG23331A (en) | 1996-10-05 | 1996-10-05 | Carpet with new specification, method of manufacturing such mechanical woven carpets with processed file yarn similar to silk carpets and chinese carpets. |
BE9700369A BE1009885A6 (en) | 1996-10-05 | 1997-04-21 | Method for making a carpet and a carpet made this way |
BE9700369 | 1997-04-21 |
Publications (1)
Publication Number | Publication Date |
---|---|
EP0846796A1 true EP0846796A1 (en) | 1998-06-10 |
Family
ID=25663094
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP97202967A Withdrawn EP0846796A1 (en) | 1996-10-05 | 1997-09-26 | Process for producing a carpet and carpets obtained by making use of the process |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP0846796A1 (en) |
TR (1) | TR199701111A2 (en) |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1185793A (en) * | 1956-11-08 | 1959-08-05 | Montedison Spa | Improvements to pile fabrics |
FR1452359A (en) * | 1965-10-22 | 1966-02-25 | Schlegel Mfg Co | Pile fabric |
JPS62191566A (en) * | 1986-02-12 | 1987-08-21 | 東レ株式会社 | Method for finishing pile knitted fabric |
JPS63256748A (en) * | 1987-04-07 | 1988-10-24 | 東洋紡績株式会社 | Raised knitted fabric and its production |
JPH02160908A (en) * | 1988-12-08 | 1990-06-20 | Toray Ind Inc | Pile fiber and fabric for interior finish |
JPH06166926A (en) * | 1992-11-27 | 1994-06-14 | Unitika Ltd | Polyester pile fabric |
JPH07310258A (en) * | 1994-05-17 | 1995-11-28 | Asahi Chem Ind Co Ltd | Pile web and method for producing the same |
-
1997
- 1997-09-26 EP EP97202967A patent/EP0846796A1/en not_active Withdrawn
- 1997-10-03 TR TR97/01111A patent/TR199701111A2/en unknown
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR1185793A (en) * | 1956-11-08 | 1959-08-05 | Montedison Spa | Improvements to pile fabrics |
FR1452359A (en) * | 1965-10-22 | 1966-02-25 | Schlegel Mfg Co | Pile fabric |
JPS62191566A (en) * | 1986-02-12 | 1987-08-21 | 東レ株式会社 | Method for finishing pile knitted fabric |
JPS63256748A (en) * | 1987-04-07 | 1988-10-24 | 東洋紡績株式会社 | Raised knitted fabric and its production |
JPH02160908A (en) * | 1988-12-08 | 1990-06-20 | Toray Ind Inc | Pile fiber and fabric for interior finish |
JPH06166926A (en) * | 1992-11-27 | 1994-06-14 | Unitika Ltd | Polyester pile fabric |
JPH07310258A (en) * | 1994-05-17 | 1995-11-28 | Asahi Chem Ind Co Ltd | Pile web and method for producing the same |
Non-Patent Citations (5)
Title |
---|
DATABASE WPI Week 8739, Derwent World Patents Index; AN 87-274503, XP002050826 * |
DATABASE WPI Week 8848, Derwent World Patents Index; AN 88-343055, XP002050825 * |
DATABASE WPI Week 9605, Derwent World Patents Index; AN 96-045693, XP002050827 * |
PATENT ABSTRACTS OF JAPAN vol. 14, no. 423 (C - 0757) 12 September 1990 (1990-09-12) * |
PATENT ABSTRACTS OF JAPAN vol. 18, no. 501 (C - 1251) 20 September 1994 (1994-09-20) * |
Also Published As
Publication number | Publication date |
---|---|
TR199701111A2 (en) | 1998-04-21 |
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AKX | Designation fees paid | ||
RBV | Designated contracting states (corrected) | ||
STAA | Information on the status of an ep patent application or granted ep patent |
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18D | Application deemed to be withdrawn |
Effective date: 19981211 |