Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04G—MAKING NETS BY KNOTTING OF FILAMENTARY MATERIAL; MAKING KNOTTED CARPETS OR TAPESTRIES; KNOTTING NOT OTHERWISE PROVIDED FOR
  • D04G3/00—Making knotted carpets or tapestries
  • D04G3/02—Making knotted carpets or tapestries by hand; Tools therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
  • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
  • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
  • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2503/00—Domestic or personal
  • D10B2503/04—Floor or wall coverings; Carpets
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2505/00—Industrial
  • D10B2505/08—Upholstery, mattresses

Definitions

• the present invention concerns the new use of a synthetic material, in particular for making carpets, as well as the carpets thus obtained.
• Furnishing fabrics made from synthetic material for example, Nylon, Polypropylene, Polyethylene, etc.... have been known for a long time and have become common in daily life use.
• the fabrics obtained with artificial fibres have the great advantage of being more resistant to mechanical wearing, typically represented by treading, to weather: rain, snow but also intense sunlight, as well as to chemical substances of various nature, or oily substances or dirt typically comprising mud or grass.
• carpets thus produced are generally considered of low value and of inferior quality; therefore, they are usually used to cover surfaces like terraces, balconies or, in any case, they are often placed in rooms like cellars or storage rooms, where they are less visible.
• the present invention therefore, has the purpose of proposing a carpet that on one hand has the advantages of carpets made from artificial materials, but does not have the aforementioned drawbacks.
• the present invention concerns a carpet made from synthetic material that has the touch characteristics and visual appearance like a carpet made from common natural fibres.
• knotted carpets possibly hand-knotted or rolled, hand-tufted, hand-woven “Kelim” (or “Kilim”), “Schumacks” (or “Soumak”), “Karamanie” and similar hand-woven fabrics.
• the carpet according to the present invention made from recycled polyethylene terephthalate (RPET) is completely similar to and it is also difficult to tell apart from a carpet woven in mercerised cotton or in silk.
• RPET recycled polyethylene terephthalate
• rPET has proven to be particularly suitable for the purposes of the present invention even with respect to non recycled (virgin) polyethylene terephthalate.
• the carpet of the present invention is obtained by plaiting threads of warp and threads of weft both made from recycled PET, with no other material being used for the manufacture thereof. If necessary, however, for making handloom or tufted carpets that require a fabric on the back arranged so as to support the carpet itself, a PET based glue can advantageously be used.
• PET and recycled PET are esters of terephthalic acid with ethylene glycol.
• polyethylene terephthalate is the material of choice for the production of containers intended for preserving food and, particularly, beverages.
• the material used for the production of carpets according to the present invention consists of post consumption recycled polyethylene terephthalate.
• bottles and containers made from polyethylene terephthalate are separated from other types of waste, like organic waste, metal, paper or plastics of different nature, are triturated and the material thus obtained in powder or granules are washed so as to eliminate possible foreign residue like paper or possible metallic parts.
• the powder or the granules are then melted and then the mass is extruded obtaining the yarn made from rPET.
• the yarn of recycled polyethylene terephthalate used for the purposes of the present invention has the characteristics shown in the Table 1.
• this is for example selected in the range of 1,2 and 3 denier.
• denier we mean the unit of measurement of the linear mass of the fibres and it is defined in grams of material per 9,000 metres.
• the fibre used moreover, preferably has a length comprised between 50-150 mm.
• a single or double fibre can be used, whereas the double fibre is obtained by intertwining single fibres.
• the man skilled in the art shall be able to select the type of fibre based upon the requirements.
• the carpet produced with the yarn made from recycled polyethylene terephthalate according to the present invention can be made in different sizes and thicknesses.
• carpets with fleece will be characterised by having an overall thickness of about 10-11 mm, in which the fleece has a height of about 6-7 mm.
• these will normally be characterised by having a smaller thickness, that is variable, for example, between 2 and 5 mm.
• a thicker carpet thanks to its particular strength, can be used to cover or protect outdoor surfaces or, more in general, should it need to, stand greater friction and wearing, like in places characterised by frequent treading; a thinner thickness will be preferred, on the other hand, for carpets or drapery for covering and protecting furniture like shelves, consoles, chests of drawers, etc.
• the yarn made from recycled polyethylene terephthalate of the present invention can undergo dyeing processes before it is weaved, by using natural or artificial dyes known in the field and according to the techniques known by the man skilled in the art. Thanks to the possibility of dyeing the fibres, the carpet made by weaving the yarn described according to the present invention can thus be characterised by geometrical, flower, tartan or striped patterns, according to the appropriate arrangement of the threads of warp and weft, according to methods known in the art.
• the dyeing of the yarn made from recycled polyethylene terephthalate surprisingly makes it possible to obtain the same chromatic effects that can be obtained with non recycled (virgin) polyethylene terephthalate.
• the colourfastness i.e. the capability of the yarn of rPET of not losing its colour when washed, even at a temperature of 60°C, and of not fading over time due to light exposure, contrarily to many other synthetic fibres that, on the other hand, have low colourfastness.
• the carpet made according to the present invention therefore, advantageously has all the desired characteristics of a carpet obtained with the commonly used natural yarn.
• the yarn made from polyethylene terephthalate surprisingly makes it possible to make drapery that is particularly soft to touch. Consequently, a carpet can be obtained that is characterised by having the same softness and same pleasant feel of those made from natural materials.
• the carpet of the present invention can surprisingly and advantageously be mistaken for a carpet made from a much more valuable natural yarn.
• the carpet of the present invention has proven to pass the tests carried out with results that were more than satisfactory, thus making it ideal for the aforementioned purposes.
• the main source of rPET is represented by mineral water bottles recovered thanks to the waste sorting.
• a drapery made according to the present invention not only comes from recycled material but there should be emphasised how it is also completely recyclable. Indeed, in order to produce it there is no need to use other non-recycled material. If it is foreseen for there to be a label for commercial purposes, at the moment in which the carpet is thrown away because it is too old or ruined, the label itself can be easily and quickly removed allowing the carpet to be placed in the containers suitable for recycling plastic. Disposal, therefore, is made much easier.
• the drapery of the present invention is extremely advantageous also with respect to the common "carpets" of the "wall to wall carpet” type.
• their structure comprises a lower layer (secondary backing), in contact with the surface they are resting on, generally made from polypropylene to which a layer called primary backing is joined through a glue made from a styrene based latex (styrene-butadiene, SBR) comprising calcium carbonate.
• SBR styrene-butadiene
• the gluing layer used is represented by material of the thermosetting type that, once used, cannot be melted or used again.
• the carpet made according to the present invention advantageously, has anti stain properties, since the material is sufficiently hydrophobic not to absorb or limitably absorb possible liquids like oil, sauces or ink stains with which it can become soiled. In any case, even if it is soiled it can be washed in the washing machine at 60°C, thus being easily cleaned. In this regard, see what mentioned above about the surprising results obtained in the tests carried out on the carpet of the present invention.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Carpets (AREA)

Priority Applications (1)

Applications Claiming Priority (1)

Publications (1)

Family

ID=43244910

Family Applications (1)

Country Status (1)

Cited By (1)

Citations (3)

• 2010
  • 2010-08-03 EP EP10425267A patent/EP2415373A1/fr not_active Withdrawn

Patent Citations (3)

Non-Patent Citations (5)

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