EP4335956A1 - Garne für fussbodenbeläge und verfahren zur herstellung von garnen - Google Patents

Garne für fussbodenbeläge und verfahren zur herstellung von garnen Download PDF

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Publication number
EP4335956A1
EP4335956A1 EP22194551.2A EP22194551A EP4335956A1 EP 4335956 A1 EP4335956 A1 EP 4335956A1 EP 22194551 A EP22194551 A EP 22194551A EP 4335956 A1 EP4335956 A1 EP 4335956A1
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EP
European Patent Office
Prior art keywords
yarn
yarns
air
entanglement
dtex
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.)
Pending
Application number
EP22194551.2A
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English (en)
French (fr)
Inventor
Michiel LEYS
Anthony SINNAEVE
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Beaulieu International Group NV
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Beaulieu International Group NV
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Beaulieu International Group NV filed Critical Beaulieu International Group NV
Priority to EP22194551.2A priority Critical patent/EP4335956A1/de
Priority to PCT/EP2023/074542 priority patent/WO2024052444A1/en
Publication of EP4335956A1 publication Critical patent/EP4335956A1/de
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/08—Interlacing constituent filaments without breakage thereof, e.g. by use of turbulent air streams
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D13/00—Complete machines for producing artificial threads
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/16—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics using jets or streams of turbulent gases, e.g. air, steam
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/20—Combinations of two or more of the above-mentioned operations or devices; After-treatments for fixing crimp or curl
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/34—Yarns or threads having slubs, knops, spirals, loops, tufts, or other irregular or decorative effects, i.e. effect yarns

Definitions

  • the present invention in general relates to yarns having variable properties along the length of the yarn, and methods and apparatuses for producing such yarns.
  • the yarns are typically polyamide yarns which are shaped and then implemented on tufting machines. It should be noted that compared to weaving, tufting involves the implementation of a support on which the yarns will be tufted.
  • a main objective in the carpet industry is to be able to obtain carpets with a design that is defined by variations in colours and thicknesses that result in a design that can be more or less sophisticated. It should be noted that there are two main types of carpet finishes:
  • the carpet industry is increasingly structured according to two segments:
  • the existing technologies are only suited to mass production with a limited level of design quality (residential market), but respond poorly to the contract market (e.g., public buildings, architectural projects, hotels), consisting of small and medium series with a specific level of design and high quality.
  • the present invention solves one or more of the aforementioned problems, by providing a yarn that has become "programmable".
  • the design of the carpet would be generated automatically by the simple tufting of the yarns.
  • these yarns would be shaped in a specific way to be able to generate the desired design as the tufting operation progresses.
  • Sophisticated design carpet manufacturing operations could be carried out from simple and inexpensive tufting machines, since the latter would no longer have to generate sophisticated designs made from several types of spools of yarn. This makes it possible to solve a large part of the problems encountered in obtaining contract products in small and medium series with a high design level.
  • the invention solves this problem by varying the colour contrast from 2 up to 6 yarn ends by entangling from 2 to 6 yarn ends alternatively before entering the Air-Twisting process following a random or fixed pattern.
  • the yarn may then be used in a standard level loop-pile carpet.
  • the sections of the yarn are produced in such a way that a defined yarn pattern of variation can be repeated and can be developed to match with a specific carpet design.
  • the invention may have one or more of the following advantages. It allows the possibility to produce floor coverings, such as carpets, rugs, and artificial turfs:
  • the present invention provides a yarn entanglement apparatus for producing a yarn with variable properties along the length of the yarn.
  • the yarn entanglement apparatus comprises one or more, preferably all of following features:
  • the apparatus further comprises M yarn guiding elements, preferably positioned between the M cutting elements and the air-entanglement and/or air-twisting unit.
  • the apparatus further comprises a venturi type yarn injector, preferably positioned before the air-entanglement and/or air-twisting unit, for example M venturi type yarn injector position between the M yarn guiding elements and the air-entanglement and/or air-twisting unit.
  • a venturi type yarn injector preferably positioned before the air-entanglement and/or air-twisting unit, for example M venturi type yarn injector position between the M yarn guiding elements and the air-entanglement and/or air-twisting unit.
  • the apparatus further comprises a yarn accumulator, preferably positioned after the air-entanglement and/or air-twisting unit.
  • the present invention provides a method for producing a yarn with variable properties along the length of the yarn.
  • the method preferably comprises the steps of:
  • the method preferably comprises N stages, each with a time duration ⁇ t_n.
  • Each stage n ranging from 1 to N preferably comprises one or more, preferably all, of the steps of:
  • the method according to the second aspect of the invention thereby obtains a yarn comprising multiple sections with variable properties along the length of the yarn.
  • At least 2 of the M yarns differ in at least one property parameter, preferably all of the M yarns differ in at least one property parameter.
  • at least 2 of the M yarns, preferably all of the M yarns differ in at least one of following property parameters: colour, thickness, material, number of filaments, shape of filaments.
  • at least 2 of the M yarns, preferably all of the M yarns differ in colour.
  • M is at least 3, preferably at least 4, for example at most 8, for example 6.
  • N is at least 10, for example at least 50.
  • the value of N may be fixed or randomized.
  • Each stage may be fixed or randomized.
  • the air-entanglement and/or air-twisting unit operates at a pressure in the range of at least 1 bar and at most 20 bar, more preferably at least 2 bar and at most 15 bar, and even more preferably at least 4 bar and at most 12 bar, most preferably at least 7 and at most 10 bar.
  • the time duration ⁇ t_n for each stage 1 to N is at least 1.0 s and at most 20.0 s.
  • the M yarns are Bulk Continuous Filament (BCF) and/ or Continuous Multifilament (CF) yarns.
  • the M yarns have a linear density of at least 150 dtex and at most 3000 dtex, for example at least 300 dtex and at most 1400 dtex, preferably at least 400 dtex and at most 1000 dtex, preferably at least 500 dtex and at most 800 dtex, preferably at least 600 dtex and at most 700 dtex, for example about 650 dtex.
  • the present invention provides a computer program or a computer-readable storage medium comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method according to the second aspect of the invention, or (preferred) embodiments thereof.
  • the present invention provides a yarn with variable properties along the length of the yarn, produced with an apparatus according to the first aspect of the invention, or (preferred) embodiments thereof, or produced by the method according to the second aspect of the invention, or (preferred) embodiments thereof.
  • the present invention provides a method for producing a floor covering, such as a carpet, a rug, or an artificial turf, with a variable design on the surface of a floor covering.
  • the method preferably comprises one or more, preferably all, of the steps of:
  • the method according to the fifth aspect of the invention thereby produces a floor covering, such as a carpet, rug, or artificial turf, with a variable design on the surface.
  • the present invention provides a floor covering, such as a carpet, a rug, or an artificial turf, with a variable design on the surface of the floor covering, produced by the method according to the fifth aspect of the invention, or (preferred) embodiments thereof.
  • a resin means one resin or more than one resin.
  • endpoints includes all integer numbers and, where appropriate, fractions subsumed within that range (e.g. 1 to 5 can include 1, 2, 3, 4 when referring to, for example, a number of elements, and can also include 1.5, 2, 2.75 and 3.80, when referring to, for example, measurements).
  • the recitation of end points also includes the end point values themselves (e.g. from 1.0 to 5.0 includes both 1.0 and 5.0). Any numerical range recited herein is intended to include all sub-ranges subsumed therein.
  • the present invention provides a yarn entanglement apparatus for producing a yarn with variable properties along the length of the yarn.
  • the yarn entanglement apparatus comprises one or more, preferably all of following features:
  • the apparatus preferably comprises M yarn feeders, preferably positive yarn feeders, configured for feeding M yarns, wherein M is at least 2.
  • the yarn feeders comprise 2 feeding rolls.
  • the yarn feeders are positive yarn feeders, i.e., they comprise a motor to rotate the feeding rolls, preferably a small electric motor.
  • Such a yarn feeder is an active feeder during the transition phase instead of being a merely passive feeder and provides controlled feeding length of the yarn.
  • the positive yarn feeder ensures that the tension is properly controlled and that the required yarn is in the proper position, for the synchronisation to be properly performed.
  • the yarn feeders may also be used as or may comprise clamping elements.
  • the apparatus preferably comprises M yarn cutting elements, configured for cutting each of the M yarns prior to feeding the M yarns to an air-entanglement and/or air-twisting unit.
  • Each yarn cutting element comprises a cutting element, configured to cut the yarn.
  • the cutting element may be positioned after the guiding element.
  • the yarn cutting open motion preferably allows the free yarn to be properly drawn by Venturi.
  • the yarn feeder start/stop may be delayed from the yarn cutting elements, to accumulate some free yarn within the yarn guide element ready to be sucked properly by Venturi.
  • the apparatus preferably comprises an air-entanglement and/or air-twisting unit, herein also referred to as entanglement jet or Air-Twist.
  • the yarns may be entangled or twisted, and both terms may be used interchangeably herein.
  • the air-entanglement and/or air-twisting unit may be operated continuously or in discrete bursts (e.g., only operational when there are 2 or more yarns present, but not operational if there is only 1 yarn present).
  • the air-entanglement and/or air-twisting unit is operated continuously.
  • the air-entanglement and/or air-twisting unit typically has an air-injection feed.
  • the air-entanglement and/or air-twisting unit allows for 2 or more yarns to be entangled and form a new yarn.
  • the apparatus further comprises M yarn guiding elements, preferably positioned between the M feeding elements and the air-entanglement and/or air-twisting unit; preferably positioned between the feeding elements and the cutting elements.
  • the yarn guiding elements may be tubes, for example metal or plastic tubes.
  • the yarn guiding elements keep the yarn stable from any environment conditions (air flow, etc..) and may be used to conserve space.
  • the yarn guiding elements may have a length from 5 cm to 100 cm, preferably from 20 cm to 50 cm.
  • the yarn guiding elements may have an inner diameter from 2.0 mm to 8.0 mm, preferably from 3.5 mm to 4.0 mm.
  • the yarn guiding elements ensure that the correct yarns are brought closely to the entrance of Venturi and/or the air-entanglement and/or air-twisting unit, are properly fed into the air-entanglement and/or air-twisting unit, and do not get entangled prior to entering the air-entanglement and/or air-twisting unit. They also allow the other elements of the apparatus, such as the cutting element and/or the yarn feeders, to be properly spaced apart, despite the relatively small entry to the air-entanglement and/or air-twisting unit. This allows for proper guiding and/or accumulation of yarn.
  • the apparatus further comprises a venturi type yarn injector, preferably positioned before the air-entanglement and/or air-twisting unit, for example M venturi type yarn injector position between the M yarn guiding elements and the air-entanglement and/or air-twisting unit.
  • a venturi type yarn injector preferably positioned before the air-entanglement and/or air-twisting unit, for example M venturi type yarn injector position between the M yarn guiding elements and the air-entanglement and/or air-twisting unit.
  • the apparatus further comprises a yarn accumulator, preferably positioned after the air-entanglement and/or air-twisting unit.
  • the apparatus further comprises one or more bobbins, herein also referred to as feed bobbins, preferably M bobbins, upon which the M yarns are wound prior to being fed to the apparatus.
  • bobbins herein also referred to as feed bobbins, preferably M bobbins, upon which the M yarns are wound prior to being fed to the apparatus.
  • the apparatus further comprises a yarn printer.
  • the yarn printer is located after the air-entanglement and/or air-twisting unit. This yarn printer may provide additional colour to the yarn exiting the air-entanglement and/or air-twisting unit and may be preferred when light-coloured yarns are used.
  • the present invention provides a method for producing a yarn with variable properties along the length of the yarn.
  • the method preferably comprises the steps of:
  • the method preferably comprises N stages, each with a time duration ⁇ t_n.
  • Each stage n ranging from 1 to N preferably comprises one or more, preferably all, of the steps of:
  • the method according to the second aspect of the invention thereby obtains a yarn comprising multiple sections with variable properties along the length of the yarn.
  • the method preferably comprises the step of providing M yarns, wherein M is at least 2.
  • the method comprises the step of providing M yarns on M bobbins.
  • the yarns may be monofilament yarns or multi-filament yarns. Each filament may be the same or different.
  • the yarns may be multi-coloured multi-filament yarns.
  • one or more of the M yarns are fed at a speed of at least 100 m/min to at most 1 000 m/min, preferably at least 200 m/min to at most 800 m/min, preferably at least 400 m/min to at most 600 m/min, for example about 500 m/min.
  • the method preferably comprises N stages, each with a time duration ⁇ t_n.
  • ⁇ t_n ⁇ t_n1 + ⁇ t_n2.
  • Each stage n ranging from 1 to N preferably comprises the step i. of feeding at least one yarn m1 of the M yarns into the air-entanglement and/or air-twisting unit, while clamping at least one other yarn m2 of the M yarns, during a time duration ⁇ t_n1.
  • This sub-stage allows for a section to be produced wherein the yarn comprises yarn m1 but does not comprise yarn m2.
  • step i. of some or all N stages comprises feeding exactly one yarn into the air-entanglement and/or air-twisting unit.
  • step i. of some or all N stages comprises feeding more than one yarn into the air-entanglement and/or air-twisting unit.
  • Each stage n ranging from 1 to N preferably comprises the step ii. of releasing the yarn m2 and feeding the yarn m2 simultaneous with the yarn m1 into the air-entanglement and/or air-twisting unit, during a time duration ⁇ t_n2.
  • This sub-stage allows for a section to be produced wherein the yarn comprises both yarn m1 as well as yarn m2. This section may also be called a change-over section.
  • step ii. of some or all N stages comprises feeding exactly two yarns into the air-entanglement and/or air-twisting unit.
  • step ii. of some or all N stages comprises feeding more than two yarns into the air-entanglement and/or air-twisting unit.
  • a sub-stage comprising only 1 colour of yarn is shorter than a sub-stage comprising multiple differently coloured yarns. This shorter section may be called a change-over section.
  • a sub-stage comprising multiple differently coloured yarns may be shorter than a sub-stage comprising only 1 colour of yarn. This shorter section may be called a change-over section.
  • Each stage n ranging from 1 to N preferably comprises the step of cutting at least one yarn selected from m1 or m2 before starting the next stage n+1. This action allows for a new section to be produced, without yarn m1 or m2. At least one of the yarns that is fed in step ii. is not cut but maintained in step i., such that the yarn continuous in the next section.
  • the method may be continuous or discrete, preferably the method is continuous.
  • At least 2 of the M yarns differ in at least one property parameter, preferably all of the M yarns differ in at least one property parameter.
  • at least 2 of the M yarns, preferably all of the M yarns differ in at least one of following property parameters: colour, thickness, material, number of filaments, shape of filaments.
  • at least 2 of the M yarns, preferably all of the M yarns differ in colour and/or colour shade. This allows for a yarn to be produced wherein sections have different colours.
  • some or all yarns differ in colour, and are for example mono- and/or multicolour, ecru, solution dyed (also referred to as dope dyed), and/or bobbin dyed.
  • some or all yarns differ in yarn count and/or thickness.
  • some or all yarns differ raw material.
  • some or all yarns differ in number of filaments and/or filament shape. The other property parameters of each yarn may also be the same or different.
  • two or more of the M yarns are identical, optionally all are identical. This still allows a yarn to be produced with different sections. For example, the thickness of each section will depend on the number of yarns present in each section.
  • the yarns may comprise polyamide (such as nylon), polypropylene, polyethylene, polyester, wool, and/or any other raw material.
  • M is at least 3, preferably at least 4, for example at most 8, for example 6. This number of yarns was found to be ideal
  • N is at least 10, for example at least 50, for example at least 100.
  • the length of at least one section, preferably of both sections, produced during each of the N stages is at least 2.0 m, preferably at least 5.0 m, preferably at least 10.0 m.
  • the length of the change-over section produced during each of the N stages is at least 0.05 m, preferably at least 0.10 m, preferably at least 0.20 m, for example about 0.50 m.
  • the value of N may be fixed or randomized. Each stage may be fixed or randomized.
  • each stage n ranging from 1 to N comprises the step of applying an Air Entanglement Parameter AE_n in the air-entanglement and/or air-twisting unit depending on the stage n or depending on the sub-stage; wherein at least one stage n differs in at least in one Air Entanglement Parameter AE_n from the Air Entanglement Parameter AE_n-1 from the previous stage n-1.
  • the Air Entanglement Parameter is defined as the pressure of the air-entanglement and/or air-twisting unit.
  • the air-entanglement and/or air-twisting unit operates at a pressure in the range of at least 1 bar and at most 20 bar, more preferably at least 2 bar and at most 15 bar, and even more preferably at least 4 bar and at most 12 bar, most preferably at least 7 and at most 10 bar.
  • the time duration ⁇ t_n for each stage 1 to N is at least 1.0 s and at most 20.0 s, for example at least 2.0 s and at most 15.0 s, for example at least 5.0 s and at most 10.0 s.
  • the time duration ⁇ t_n1 and/or ⁇ t_n2 for each sub-stage is at least 0.5 s and at most 18.0 s, for example at least 1.0 s and at most 15.0 s, for example at least 2.0 s and at most 10.0 s.
  • the method further comprises the step of unwinding the M yarns from one or more bobbins, preferably M bobbins, upon which the M yarns were wound prior to being fed to the apparatus.
  • the method further comprises the step of printing the yarn with a yarn printer, preferably after exiting the air-entanglement and/or air-twisting unit.
  • the M yarns are Bulk Continuous Filament (BCF) and/ or Continuous Multifilament (CF) yarns.
  • BCF Bulk Continuous Filament
  • CF Continuous Multifilament
  • the M yarns have a linear density of at least 150 dtex and at most 3000 dtex, for example at least 300 dtex and at most 1400 dtex, preferably at least 400 dtex and at most 1000 dtex, preferably at least 500 dtex and at most 800 dtex, preferably at least 600 dtex and at most 700 dtex, for example about 650 dtex.
  • M is lower, such as 2 or 3
  • the dtex of each of the yarns separately may be in the higher range.
  • M is higher such as 5 or 6, the dtex of each of the yarns separately may be in the lower range. This allows for a suitable yarn to be formed, that is still strong yet can still easily be tufted.
  • the present invention provides a computer program or a computer-readable storage medium comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method according to the second aspect of the invention, or (preferred) embodiments thereof.
  • the present invention also provides a data processing apparatus/device/system comprising means for carrying out the method according to the second aspect of the invention, or (preferred) embodiments thereof.
  • the apparatus as described herein comprises a computer.
  • the method as described herein is a computer-implemented method.
  • the present invention provides a yarn with variable properties along the length of the yarn, produced with an apparatus according to the first aspect of the invention, or (preferred) embodiments thereof, or produced by the method according to the second aspect of the invention, or (preferred) embodiments thereof.
  • the yarn has an average linear density of at least 1300 dtex and at most 10000 dtex, preferably at least 2000 dtex and at most 3200 dtex, wherein the average is calculated over the entire length of the yarn.
  • the yarn is a Type I yarn.
  • Type I yarn may be defined as yarn comprising A - AB - B sections (and variations thereof), wherein the yarn changes from yarn A to yarn B with a change-over AB.
  • the change-over section AB is preferably smaller than sections A and B, preferably at most 0.5 x the average size of sections A and B, preferably at most 0.2 x the average size of sections A and B, for example at most 0.1 x the average size of sections A and B.
  • the yarn is a Type II yarn.
  • Type II yarn may be defined as yarn comprising A - AB - A sections (and variations thereof), wherein the yarn changes comprise a constant A yarn, with sections whereby one or more additional B yarns are superimposed.
  • the constant yarn A may also be referred to as carrier yarn.
  • the AB section may be smaller than the A sections, preferably at most 0.5 x the average size of average size of the A sections, preferably at most 0.2 x, for example at most 0.1 x.
  • the AB section may be larger than the A sections, preferably at least 2 x the average size of the A sections, preferably at least 5 x the average size, for example at least 10 x the average size.
  • the yarn is a Type III yarn.
  • Type III yarn may be defined as yarn comprising A - AB - B sections (and variations thereof), wherein the yarn changes from yarn A to yarn B via AB.
  • the section AB is preferably larger than sections A and B, preferably at least 2 x the average size of sections A and B, preferably at least 5 x the average size of sections A and B, for example at least 10 x the average size of sections A and B.
  • the yarn is a combination of Type I and Type II yarn. In some embodiments, the yarn is a combination of Type I and Type III yarn. In some embodiments, the yarn is a combination of Type II and Type III yarn. In some embodiments, the yarn is a combination of Type I, Type II, and Type III yarn.
  • the present invention provides a method for producing a floor covering, such as a carpet, a rug, or an artificial turf, with a variable design on the surface of the carpet, rug, or artificial turf.
  • the method preferably comprises one or more, preferably all, of the steps of:
  • the method according to the fifth aspect of the invention thereby produces a floor covering, such as a carpet, rug, or artificial turf, with a variable design on the surface.
  • the present invention provides a floor covering, such as a carpet, a rug, or an artificial turf, with a variable design on the surface of the carpet, rug, or artificial turf, produced by the method according to the fifth aspect of the invention, or (preferred) embodiments thereof.
  • the present invention has the advantage that it allows floor covering manufacturers (such as carpet tufting companies) to create a special design on the floor covering (such as a carpet) while only using standard tufting machinery with the new yarn, instead of having to invest in a more complex and expensive technical tufting machinery.
  • the tufted floor covering may be a looped floor covering. In some embodiments, the tufted loops may be cut. In some embodiments, the tufted floor covering may be a cut loop floor covering.
  • the floor covering is a level floor covering, such as a level loop-pile carpet.
  • the yarn may be used in a standard level loop-pile carpet.
  • the sections of the yarn are produced in such a way that a defined yarn pattern of variation can be repeated and can be developed to match with a specific carpet design.
  • the present invention also relates to a computer-implemented method that translates the design of a floor covering, such as a carpet, rug, or artificial turf, to the design of the yarn.
  • the present invention also relates to a computer program or a computer-readable storage medium comprising instructions which, when the program is executed by a computer, cause the computer to carry out the method computer-implemented method that translates the design of a floor covering, such as a carpet, rug, or artificial turf, to the design of the yarn.
  • FIG. 1 illustrates an embodiment of an apparatus (100) and method according to the invention.
  • FIG. 1A illustrates the full apparatus (100) and method leading to the final yarn (1).
  • Six bobbins (12) comprising six yarns (10), labelled A to F, are unwound and fed to the apparatus (100) (only 4 bobbins (12) and yarns (10) A-D are explicitly shown).
  • Each yarn (10) A-F is connected to a positive yarn feeder (20) with a feeding speed of 500 m/min. Subsequently, each yarn (10) A-F is connected to a cutting element (30), configured for cutting each yarn (10).
  • the apparatus (100) also comprises a yarn guiding element (40) for each yarn (10) A-F, such that yarns (10) that are not cut and clamped, are fed into their respective yarn guiding elements (40).
  • the yarn guiding elements (40) guide the yarns (10) into the air-entanglement and/or air-twisting unit (60), which entangles the yarns (10).
  • a yarn (1) exits the air-entanglement and/or air-twisting unit (60) and may be stored in a yarn accumulator (70).
  • FIG. 1B illustrates a close-up of the entry of the yarns (10) to the air-entanglement and/or air-twisting unit (60) according to an embodiment of the invention.
  • Each of five yarns (10), herein labelled as A-E, may be fed to the air-entanglement and/or air-twisting unit (60), but details are only shown for yarn C.
  • Yarn C is connected to a positive yarn feeder (20), comprising two rolls (22) and a small electric motor (24), with a feeding speed of 500 m/min.
  • yarn C is connected to a cutting element (30), configured for cutting yarn C.
  • yarn C is fed to yarn guiding element (40), which guides yarn C into the air-entanglement and/or air-twisting unit (60, via a venturi type yarn injector (50).
  • FIG. 2 illustrates different types of yarn (1) that may be produced according to embodiments of the invention.
  • FIG. 2A illustrates the sections that are present in yarn (1) of Type I.
  • This type of yarn comprises A - AB - B sections (and variations thereof), wherein the yarn changes from yarn A to yarn B with a change-over AB.
  • the change-over sections are smaller than the sections comprising a single yarn.
  • the yarn comprises the following sections: A / AD (change-over) / D / DB (change-over) / B / BA (change-over) / A / AC (change-over) / C.
  • each of the yarns A, B, C, and D comprise a different colour (or darkness)
  • this will result in a yarn comprising sections with different colours.
  • A is blue
  • B is red
  • D is black
  • C is white
  • this sequence would result in following colour sections: blue / dark blue (small) / black / dark red (small) / red / purple (small) / blue / light blue (small).
  • change-over sections are much smaller than sections comprising a single yarn, such that they become negligible when tufting a floor covering such as a carpet, this would visually result in a yarn with following colour sections: blue / black / red / blue.
  • FIG. 2B illustrates the sections that are present in yarn (1) of Type II
  • This type of yarn comprises C - CD - C sections (and variations thereof), wherein the yarn changes comprise a constant C yarn, with sections whereby one or more additional D yarns are superimposed.
  • the CD sections are larger than the C sections.
  • the change-over occurs at the sections with only a single C yarn, and these sections are smaller than the sections comprising two different yarns.
  • the yarn comprises the following sections: C (change-over) / CD / C (change-over) / CB / C (change-over) / CA / C (change-over).
  • each of the yarns A, B, C, and D comprise a different colour (or darkness)
  • this will result in a yarn comprising sections with different colours.
  • A is blue
  • B is red
  • D is black
  • C is white
  • this sequence would result in following colour sections: white (small) / grey (light black) / white (small) / pink (light red) / white (small) / light blue / white (small).
  • FIG. 2C illustrates the sections that are present in yarn (1) of Type III.
  • This type of yarn comprises A - AB - B sections (and variations thereof), wherein the yarn changes from yarn A to yarn B with a change-over AB.
  • the change-over occurs at the sections with only a single yarn, and these sections are smaller than the sections comprising two different yarns.
  • the yarn comprises the following sections: A (change-over) / AD / D (change-over) / DB / B (change-over) / BA / A (change-over) / AC / C (change-over).
  • each of the yarns A, B, C, and D comprise a different colour (or darkness)
  • this will result in a yarn comprising sections with different colours.
  • A is blue
  • B red
  • D is black
  • C is white
  • this sequence would result in following colour sections: blue (small) / dark blue / black (small) / dark red / red (small) / purple / blue (small) / light blue.
  • change-over sections comprising a single yarn are much smaller than the sections comprising multiple yarns, such that they become negligible when tufting a floor covering such as a carpet, this would visually result in a yarn with following colour sections: dark blue / dark red / purple / light blue.
  • FIG. 3A illustrates level loop-pile carpets tufted with a yarn (1) according to an embodiment of the invention on the left-hand side, demonstrating the colour changes in the yarn (1) that become visible as colour changes in the carpet on the right-hand side.
  • FIG. 3B and FIG. 3C compare structure loop-pile carpets tufted with yarns according to the prior art on the left-hand side, to level loop-pile carpets tufted with a yarn (1) according to an embodiment of the invention on the right-hand side.
  • FIG. 4 illustrates a venturi type injector (50) suitable for an embodiment of the invention.
  • venturi type injector (50) comprises a vortex assembly (51) within an outer assembly (56).
  • the vortex assembly (51) comprises a fibre inlet (52) and a fibre exit (53), connected through a main hole (54).
  • the vortex assembly (51) also comprises one or more sub holes (55), positioned at an injector angle compared to the main hole (54).
  • the outer assembly (56) comprises a compressed air inlet (57), feeding an air reservoir (58).
  • the air reservoir (58) is connected to the main hole (54) through the sub hole(s) (55).
  • FIG. 5 illustrates simplified representation of an intermingling process taking place in an air-entanglement and/or air-twisting unit (60), more specifically an intermingling nozzle (60) according to an embodiment of the invention.
  • the intermingling nozzle (60 comprises a compressed air inlet (61). Textured yarn (15) may enter the intermingling nozzle (60) and may exit as intermingled yarn (16), comprising interlacing points (17).

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
EP22194551.2A 2022-09-08 2022-09-08 Garne für fussbodenbeläge und verfahren zur herstellung von garnen Pending EP4335956A1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP22194551.2A EP4335956A1 (de) 2022-09-08 2022-09-08 Garne für fussbodenbeläge und verfahren zur herstellung von garnen
PCT/EP2023/074542 WO2024052444A1 (en) 2022-09-08 2023-09-07 Yarns for floor coverings and methods for producing yarns

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP22194551.2A EP4335956A1 (de) 2022-09-08 2022-09-08 Garne für fussbodenbeläge und verfahren zur herstellung von garnen

Publications (1)

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EP4335956A1 true EP4335956A1 (de) 2024-03-13

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EP22194551.2A Pending EP4335956A1 (de) 2022-09-08 2022-09-08 Garne für fussbodenbeläge und verfahren zur herstellung von garnen

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EP (1) EP4335956A1 (de)
WO (1) WO2024052444A1 (de)

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150275400A1 (en) * 2008-08-22 2015-10-01 Invista North America S.A.R.L. Bulked Continuous Filaments with Trilobal Cross-Section and Round Central Void and Spinneret Plates Producing Filament
US20210388540A1 (en) * 2020-06-16 2021-12-16 Aladdin Manufacturing Corporation Systems and methods for producing a bundle of filaments and/or a yarn
US20210388539A1 (en) * 2020-06-16 2021-12-16 Aladdin Manufacturing Corporation Systems and methods to provide color enhanced yarns

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20150275400A1 (en) * 2008-08-22 2015-10-01 Invista North America S.A.R.L. Bulked Continuous Filaments with Trilobal Cross-Section and Round Central Void and Spinneret Plates Producing Filament
US20210388540A1 (en) * 2020-06-16 2021-12-16 Aladdin Manufacturing Corporation Systems and methods for producing a bundle of filaments and/or a yarn
US20210388539A1 (en) * 2020-06-16 2021-12-16 Aladdin Manufacturing Corporation Systems and methods to provide color enhanced yarns

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