EP1728911A1 - Bemusterter Teppich sowie Verfahren zu dessen Herstellung - Google Patents

Bemusterter Teppich sowie Verfahren zu dessen Herstellung Download PDF

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Publication number
EP1728911A1
EP1728911A1 EP06017400A EP06017400A EP1728911A1 EP 1728911 A1 EP1728911 A1 EP 1728911A1 EP 06017400 A EP06017400 A EP 06017400A EP 06017400 A EP06017400 A EP 06017400A EP 1728911 A1 EP1728911 A1 EP 1728911A1
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EP
European Patent Office
Prior art keywords
woven
carpet
design
substrate
pattern
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Withdrawn
Application number
EP06017400A
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English (en)
French (fr)
Inventor
designation of the inventor has not yet been filed The
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Milliken and Co
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Milliken and Co
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Filing date
Publication date
Priority claimed from US09/876,912 external-priority patent/US6884493B2/en
Application filed by Milliken and Co filed Critical Milliken and Co
Publication of EP1728911A1 publication Critical patent/EP1728911A1/de
Withdrawn legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
    • D06B11/0079—Local modifications of the ability of the textile material to receive the treating materials, (e.g. its dyeability)
    • D06B11/0089—Local modifications of the ability of the textile material to receive the treating materials, (e.g. its dyeability) the textile material being a surface
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06B—TREATING TEXTILE MATERIALS USING LIQUIDS, GASES OR VAPOURS
    • D06B11/00—Treatment of selected parts of textile materials, e.g. partial dyeing
    • D06B11/0056—Treatment of selected parts of textile materials, e.g. partial dyeing of fabrics

Definitions

  • the present invention is directed to applying color, pattern, design, and/or the like by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively transfer printing, silk screen printing and rotary printing, etc., to preferably a woven carpet, where the yam in the carpet is all white or a light shade or color (no dye applied) or where yam is treated chemically or where the yam is pre-dyed with a single or multiple colors.
  • the preferred woven carpet has a sisal-like look or appearance.
  • the woven carpet can be made with a conventional loom weaving process or hand weaving process, for example Wilton, Axminster, Spool, Spool Gripper and Chenille looms, hand gun tufted or any other conventional carpet weaving method or methods.
  • the problem is, there is an aspect ratio in the dots per inch. They are not square dots but rectangles, for example a 7 row by 7 ends is a square dot, but a 10 row by 7 ends is a rectangular dot. This causes problems when weaving for example, a rug.
  • the rug or design can only be woven in one direction. To turn the rug or design at 90° to maximize the use of the carpet web, would distort the design in either the length or width directions.
  • the only dot matrix that might work is the 7x7 square dot but then one would be tied into only one price point when weaving rugs.
  • the new method or carpet of the present invention eliminates or addresses all of the three-fold problems previously mentioned and takes advantage of the best of the old weaving methods, namely the superior carpet construction of a woven verses a tufted carpet.
  • the invention includes the following :
  • the white woven substrate may be formed of 2 ply yam (2/56 means 56 yards to the oz), 100% wool, 100% nylon or other post dyeable synthetic and/or natural yam or blend such as 80% nylon, 20% wool, or the like, and have a weave construction of 7X4.5, 7X5, 7X6, 7X7, 7X8, 7X9, 7X10, 7X12, etc., and may be woven from a white yam or a solid colored yam which can be dyed or printed (over dyed or over printed) to produce the final effect.
  • the background color of the rug is printed along with the design or pattern if that color is not white.
  • the yam is a dyed or colored yam (solution dyed, yam dyed, naturally colored, or the like) then the design or pattern is printed thereon, but the background color is already created by the yam itself. It is preferred to use white or a light off white color yam.
  • the carpet substrate is woven, the carpet substrate is cut into selected pieces, tiles, or the like, then each of the cut pieces is dyed or printed.
  • the carpet substrate is woven, then the substrate is jet dyed with particular colors, patterns, designs, and/or the like, then particular rugs, area rugs, runners, and the like are cut from the woven dyed carpet.
  • the carpet substrate is woven, the carpet is dyed with a, for example, solid background color, then it is dyed or printed with a pattern or design, and then it is cut into rugs.
  • the undyed woven substrate can have the pattern applied to it with dyes that have resist chemistry, then the background shade can be applied in line with an overflow applicator or the background shade can be applied as a separate step in a "Beck Dye" applicator.
  • the end product is, for example, an area rug
  • FIG. 4 of the drawings there is shown a 5X7 weave pattern and a 10X10 DPI print pattern which is independent of the weave pattern.
  • FIG. 5 of fhe drawings an unlimited variety of elements can be created on a single piece of woven carpet substrate or base, for example, the area rug designs or patterns 12, 14, 16 and 18 on the woven substrate 10. This maximizes the efficiency of the process, minimizes cost, and provides for mass customization where the manufacturer, designer, printer, or the like can provide orders for one a or more items from a multitude of different customers one right after the other without shutting down the machinery.
  • flooring 20 such as, a rug, carpet, area rug, or the like having a design 22 printed or dyed thereon.
  • flooring 30 such as, an area rug or runner having a design 32 and an edge or border 33 printed thereon.
  • pattern, design, or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively transfer printing, silk screen printing and rotary printing, etc., to a woven carpet, where the yam in the carpet is all white (no dye applied) or where yam is treated chemically or where the yam is pre-dyed with a single or multiple colors.
  • the woven carpet can be made with any conventional loom weaving process or hand weaving process, for example Wilton, Axminster, Spool, Spool Gripper and Chenille looms, hand gun tufted, or any other method or methods of weaving carpet.
  • an undyed (all white) woven carpet that has a Sisal-like look, (see FIGS.1, 2 and 16) and using a post-dye technique, pattern is applied (various design/motif elements) to it (FIGS. 8,9, and 17-21).
  • the method of achieving a patterned sisal product with conventional methods was to hand-paint a Sisal carpet or rug, or use a limited color creel on the loom which allows for very limited color in the Sisal weave
  • One concept of the present invention is to weave a sisal-like carpet on a loom of some kind, the sisal-like carpet is woven using any post-dyeable yarn or fiber type, it is woven with undyed (white) yam then pattern/design is applied using a jet-dye or other post dyeing pattern application process.
  • Another concept of the present invention is to put various design elements on a sisal-like woven product.
  • the present invention can maximize the economics and delivery achievable through mass production.
  • the present invention supports various weave constructions, yarns, fibers and dyes.
  • the carpet substrate is woven on a Wilton loom and dyed using a Millitron jet dye or printing machine.
  • machine or hand woven natural fiber mats or rugs are simulated.
  • natural fiber products that are simulated are jute fiber, palm fiber, peat, sisal, cotton, kapok, paper, coconut fiber, wood fiber, and the like.
  • the products of the present invention can provide a woven, thatched, textured, or the like design or pattern.
  • this woven carpet would start as white (undyed) carpet. It may have various yarns and fibers, i.e. nylon, wool or any other post dyeable fiber in various combinations. It may have various filler yarns, i.e. jute, cotton, polypropylene in various combinations. It may have various yams/fibers used in combination to create the surface weave, i.e. differential dyed yarns. These are yarns that are treated in different ways so that they will receive dyes differently from each other. This can create different looks when the same color dye is applied to the differential yarns (see FIGS. 24 and 25)..
  • the sisal-like carpet is then taken, in its undyed state and presented to a jet-dyeing, or any other kind of post-dyeing/post patterning application, including but not exclusively, inkjet printing, screen printing, rotary printing and heat transfer printing.
  • a jet-dyeing, or any other kind of post-dyeing/post patterning application including but not exclusively, inkjet printing, screen printing, rotary printing and heat transfer printing.
  • the carpet is transported through the process and pattern is applied to it in various colors and styles and motifs.
  • the motifs and styles might include but not exclusively, flowers, leaves, ornament, geometric designs (see FIGS. 8, 17-21).
  • One variation of this process may be:
  • Sisal-like weave equates to carpet that is woven on a mass producing loom where the weave of the carpet (i.e. the construction of the warp and weft) is arranged to create loops and rows of loops that resemble the various weaves of natural sisal, rafla, grass, and woven mats and rugs and broadloom (See FIGS. 8, 9, and 16).
  • the yam could be one of solution dyed yam, yam dyed, or the like and the carpet can be woven or graphics tufting.
  • the sisal-like white woven substrate may be formed of 2 ply yam (2/56 means 56 yards to the oz), 100% wool, 100% nylon or other post dyeable synthetic yam, 80% nylon, 20% wool, or the like, and have a weave construction of 7X4.5, 7X5, 7X6, 7X7, 7X8, 7X9, 7X10, 7X12, etc., and may be woven from a white yam or a solid colored yam which can be dyed or printed (over dyed or over printed) to produce the final effect.
  • the background color of the rug is printed along with the design or pattern if that color is not white.
  • the yam is a dyed or colored yam (solution dyed, yam dyed, naturally colored, or the like) then the design or pattern is printed thereon, but the background color is already created by the yam itself.
  • the sisal-like carpet substrate is woven, the carpet substrate is cut into selected pieces, tiles, or the like, then each of the cut pieces dyed or printed.
  • the sisal-like carpet substrate is woven, then the substrate is jet dyed with particular colors, patterns, designs, and/or the like, then particular rugs, area rugs, runners, and the like are cut from the woven dyed carpet.
  • the sisal-like carpet substrate is woven, the carpet is dyed with a, for example, solid background color, then it is dyed or printed with a pattern or design, and then it is cut into rugs.
  • the undyed woven substrate can have the pattern applied to it with dyes that have resist chemistry, then the background shade can be applied in line with an overflow applicator or the background shade could be applied as a separate step in a "Beck Dye" applicator.
  • the end product is, for example, an area rug
  • FIG. 4 of the drawings there is shown a 5X7 weave pattern and a 10X10 print pattern which is independent of the weave pattern.
  • FIG. 5 of the drawings an unlimited variety of elements can be created on a single piece of woven carpet substrate or base, for example, the area rug designs or patterns 12, 14, 16 and 18 on a sisal-like woven substrate 10. This maximizes the efficiency of the process, minimizes cost, and provides for mass customization where the manufacturer, designer, printer, or the like can provide orders for one a or more items from a multitude of different customers one right after the other without shutting down the machinery.
  • flooring 20 such as, a rug, carpet, area rug, or the like having a design 22 printed or dyed thereon.
  • flooring such as, an area rug or runner 30 having a design 32 and an edge or border 33 printed thereon.
  • edge or frame-like border 33 By printing an edge or frame-like border 33 on the rug 30, and making the border of sufficient width, the manufacturer can accommodate slight variations in the registration of the design and the cutting equipment so that a customer will not notice if the design is slightly off registration or if the cut is slightly off of its intended location.
  • pattern, design, or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively transfer printing, silk screen printing and rotary printing, etc., to a sisal-like woven carpet, where the yam in the carpet is all white (no dye applied) or where yam is treated chemically or where the yam is pre-dyed with a single or multiple colors.
  • the woven carpet can be made with any conventional loom weaving process or hand weaving process, for example Wilton, Axminster, Spool, Spool Gripper and Chenille looms, hand gun tufted, or any other method or methods of weaving carpet.
  • a woven-like carpet product may be produced by treating selected yarns or yarn areas with various chemical or physical treatments so that following the dyeing thereof, the resulting carpet product has subtle color variations which give it the appearance of a woven carpet.
  • an all-white carpet substrate woven, bonded, or tufted
  • a chemical which has a certain percent resistance to dye color so that following dyeing of the carpet substrate there is produced a color variation between different yarns or different areas in the carpet.
  • certain yarns may be bright fiber and a dull fiber blended or may have a higher twist than other yarns so as to provide a different dyed color than other yarns within the carpet substrate.
  • a carpet substrate is made with bright fiber yarns, dull fiber yarns, blended fiber yarns, low-twist yarns, and high-twist yarns to produce color variations in the dyed pattern or design.
  • a carpet substrate is chemically treated, physically treated, and/or constructed of bright fibers, dull fibers, bright fiber and dull fiber blends, twisted yarns, untwisted yarns, and the like to produce a dyed carpet product having subtle color variations which give it a woven-like appearance. Pattern or design may then be overlaid over the subtle color variation or background coloration.
  • FIG. 24 merely uses different shades or colors to represent the random-type pattern created by the different yarns, chemical treatments, or the like in a carpet substrate which is typically all white.
  • the variation in yarns or chemical treatments would usually only become visible after the post-dye application of pattern, design or color and then one would be able to visualize the subtle effect throughout the carpet.
  • the rugs, area rugs, mats or the like of the present invention have a washable, skid-resistant, non-slip, non-creep, and/or the like backing, base or lower surface.
  • a washable latex backing material may be spray-coated, roller-coated, knife-coated, or the like onto the back of the carpet.
  • a rubber backing may be applied by spraying, coating, or the like, or a sheet or layer of rubber may be applied using an adhesive or by vulcanizing the carpet to the rubber sheet.
  • carpet, broadloom carpet, rugs, mats, area rugs, or the like appear to have a woven base with a jet-dyed design, pattern, color, and/or the like thereon.
  • a woven face foam back floor covering may include a woven upper layer and a lower backing layer of resin, foam, adhesive, and a cover material.
  • the woven upper layer may be jet-dyed or patterned.
  • a stabilized cushion back carpet tile includes at least a primary carpet layer, an adhesive layer, a stabilizing layer, and a foam layer.
  • a woven or woven-like appearance, carpet or substrate is bonded to a stabilized foam backing layer by an adhesive such as a resilient hot melt adhesive to form a carpet tile substrate or composite as described in above U. S. Patent Nos. 4,522,857 , 5,540,968 , and 6,203,881 .
  • the woven or woven-like appearance carpet tile substrate or composite may be dyed before or after the carpet tile composite is cut into tiles.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Coloring (AREA)
  • Treatment Of Fiber Materials (AREA)
EP06017400A 2000-06-13 2001-06-12 Bemusterter Teppich sowie Verfahren zu dessen Herstellung Withdrawn EP1728911A1 (de)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US21129500P 2000-06-13 2000-06-13
US24117000P 2000-10-17 2000-10-17
US09/876,912 US6884493B2 (en) 2000-06-13 2001-06-08 Patterned carpet and method
EP01952151A EP1290258B1 (de) 2000-06-13 2001-06-12 Bemusterter teppich sowie verfahren zu dessen herstellung

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
EP01952151A Division EP1290258B1 (de) 2000-06-13 2001-06-12 Bemusterter teppich sowie verfahren zu dessen herstellung

Publications (1)

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EP1728911A1 true EP1728911A1 (de) 2006-12-06

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EP06017400A Withdrawn EP1728911A1 (de) 2000-06-13 2001-06-12 Bemusterter Teppich sowie Verfahren zu dessen Herstellung

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1985739A3 (de) * 2007-04-24 2008-12-17 Mohawk Industries, Inc. System und Verfahren zum Färben eines Teppichs

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2412030A1 (de) * 1974-03-13 1975-10-16 Artos Meier Windhorst Kg Verfahren zum bedrucken von teppichen o.dgl.
GB1448620A (en) * 1974-01-03 1976-09-08 Deering Milliken Res Corp Pattern dyeing of textile materials
DE2733697A1 (de) * 1976-09-13 1978-03-16 Champion Int Corp Verfahren zur herstellung eines gemusterten teppichmaterials
WO1980000145A1 (en) * 1978-06-28 1980-02-07 T Vidalis Rug stencil printing system
WO1981001161A1 (en) * 1979-10-18 1981-04-30 B Otting Jet pattern dyeing of material,particularly carpet
US4522857A (en) 1984-09-24 1985-06-11 Milliken Research Corporation Carpet tile with stabilizing material embedded in adhesive layer
GB2187419A (en) * 1986-03-06 1987-09-09 Dawson Ellis Ltd Application of liquid to web or is sheet metal
US5540968A (en) 1994-03-03 1996-07-30 Milliken Research Corporation Cushioned backed carpet tile with stabilized nonwoven backing
US6162748A (en) 1995-02-15 2000-12-19 Collins & Aikman Floorcoverings, Inc. Woven floor coverings

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1448620A (en) * 1974-01-03 1976-09-08 Deering Milliken Res Corp Pattern dyeing of textile materials
DE2412030A1 (de) * 1974-03-13 1975-10-16 Artos Meier Windhorst Kg Verfahren zum bedrucken von teppichen o.dgl.
DE2733697A1 (de) * 1976-09-13 1978-03-16 Champion Int Corp Verfahren zur herstellung eines gemusterten teppichmaterials
WO1980000145A1 (en) * 1978-06-28 1980-02-07 T Vidalis Rug stencil printing system
WO1981001161A1 (en) * 1979-10-18 1981-04-30 B Otting Jet pattern dyeing of material,particularly carpet
US4522857A (en) 1984-09-24 1985-06-11 Milliken Research Corporation Carpet tile with stabilizing material embedded in adhesive layer
GB2187419A (en) * 1986-03-06 1987-09-09 Dawson Ellis Ltd Application of liquid to web or is sheet metal
US5540968A (en) 1994-03-03 1996-07-30 Milliken Research Corporation Cushioned backed carpet tile with stabilized nonwoven backing
US6203881B1 (en) 1994-03-03 2001-03-20 Milliken & Company Cushion backed carpet
US6162748A (en) 1995-02-15 2000-12-19 Collins & Aikman Floorcoverings, Inc. Woven floor coverings

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1985739A3 (de) * 2007-04-24 2008-12-17 Mohawk Industries, Inc. System und Verfahren zum Färben eines Teppichs
EP2343407A3 (de) * 2007-04-24 2011-11-09 Mohawk Industries, Inc. System und Verfahren zum Färben eines Teppichs
US8082057B2 (en) 2007-04-24 2011-12-20 Mohawk Carpet Distribution, Inc. Carpet dyeing systems and methods

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