EP0846796A1

EP0846796A1 - Process for producing a carpet and carpets obtained by making use of the process

Info

Publication number: EP0846796A1
Application number: EP97202967A
Authority: EP
Inventors: Hassan Abuel Makarem
Original assignee: Middle East Carpet Co Associated - Sae
Current assignee: Middle East Carpet Co Associated - Sae
Priority date: 1996-10-05
Filing date: 1997-09-26
Publication date: 1998-06-10
Also published as: TR199701111A2

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.

A remarkable step of the process according to the invention is characterised by the washing process consisting of the following steps:

a) steaming

b) scouring with hot water

c) rinsing with cold water

d) extraction of water

e) drying

f) polishing in a calendering machine at 100°C frontside and 180°C backside.

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.

Materials used to produce one square meter:

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.

Materials used to produce one square meter:

Pile yarn: : - 2500 gm ± 10%
Weft yarn: : - 600 gm ± 10%
Warp yarn: : - 300 gm ± 10%
Adhesive material (latex): : - 200 wet gm ± 10%

Claims

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 called Shangai" type (Chinese silk) of yarns according to one of the following structures:

a) 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) steaming

b) scouring with hot water

c) rinsing with cold water

d) extraction of water

e) drying

f) 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 Shangai" type (Chinese silk) according to one of the claims 6 - 10, characterised in that the polypropylene yarns used have the following characteristics: bulky polypropylene yarns B.C.F. with 100 twist 300/72/7 resulting in Denier 2100 of 504 filaments.
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%