ES2616298T3 - Carpet and procedure for the manufacture of a carpet - Google Patents

Abstract

Process for the manufacture of a carpet having a patchwork fabric appearance in which chain threads and at least one weft thread are used; comprising the following steps: - arranging the warp threads next to each other without overlapping each other, - inserting and interlacing said weft threads through said warp threads in such a way that said weft threads are positioned in consecutive lines and essentially perpendicular to said warp threads; the weft threads are inserted in the same line in a repetitive manner and according to a previously defined insertion pattern, characterized in that said insertion pattern is interrupted at least once so as to create, on one of the faces of the carpet, the minus one line of seams, said line of seams represents a border between two areas of the carpet that have different appearances and is defined by a plurality of warp yarn segments, said segments having a distance D that is longer than the distance d of a visible warp thread by the use of said insert model.

Description

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DESCRIPTION

Carpet and procedure for the manufacture of a carpet

The present invention relates to a process for the manufacture of a carpet that has the appearance of patchwork fabric, or "patchwork". The invention also relates to the carpet obtained by the use of the process of the invention.

Prior art

A carpet of scrap cloth is obtained by assembling different pieces of carpet, usually of different colors and / or designs. The assembly is done by hand sewing the different carpet pieces together (JP 2001 87116). This assembly by hand prolongs the time of manufacture of said carpet and increases the cost of manufacture of the carpets of scrap cloth.

The object of the invention is to provide a process for the manufacture of a carpet that has an appearance of retal fabric in an automated manner without having resorted to the hand assembly of the different parts that form the carpet of retal fabric.

Summary of the invention

In a first aspect, the present invention provides a process for the manufacture of a carpet that has a retinal fabric appearance in which warp threads and at least one weft thread are used; comprising the following steps: - arranging the warp threads in one plane next to each other without superimposing them, - inserting and interlacing said weft threads through said warp threads such that said weft threads are positioned in consecutive lines and essentially perpendicular to said warp threads; the weft threads are inserted in the same line repetitively and according to a previously defined insertion model. The procedure is characterized in that said insertion model is interrupted at least once so that at least one seam line is created on one of the faces of the carpet. Said seam line represents a boundary between two areas of the carpet that have different appearances and is defined by a plurality of warp thread segments, said segments having a distance D that is longer than the distance d of a visible warp thread by the use of said insertion model.

In another aspect, the present invention provides a carpet comprising weft threads inserted and interwoven with warp threads; said weft threads are positioned in lines essentially perpendicular to said warp threads; said weft threads are inserted in the same line repetitively and according to a previously defined insertion model. The carpet is characterized in that said insertion model is interrupted at least once so that it creates, on one of the faces of the carpet, at least one seam line, said seam line represents a border between two areas of the carpet which have different appearances and is defined by a plurality of warp thread segments, said segments having a distance D that is longer than the distance d of a warp thread visible by the use of said insertion model.

The present invention allows the manufacture and obtaining of a carpet that has the appearance of remnants fabric without needing the manual work that consists of sewing different pieces of the carpet forming the carpet of remnants. The production process according to one embodiment of the invention can be completely automated. This represents a considerable gain in costs and production times.

Brief description of the figures

Fig. 1 illustrates an example of insertion of the weft threads in relation to the warp threads according to an embodiment of the invention.

Fig. 2 illustrates another example of insertion of the weft threads in relation to the warp threads according to another embodiment of the invention.

Fig. 3 illustrates an example of carpet comprising seam lines.

Fig. 4 illustrates another example of carpet comprising seam lines.

Description of exemplary embodiments

The invention relates to a process for the manufacture of a carpet that has the appearance of remnants. The invention also relates to the carpet obtained by the use of the process of the invention. The carpet according to a preferred embodiment is provided with careful finishes.

The term "carpet that has a retinal cloth appearance" is used to designate the carpet that has a carpet-like appearance obtained by assembling several pieces of carpet sizes and / or

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different shapes and / or colors and / or motifs.

The term "union" is used to designate the interlocking of the weft threads with the warp threads to form a carpet.

In a first aspect, the present invention provides a process for the manufacture of a carpet that has a used appearance in which warp threads and at least one weft thread are used. The procedure comprises the following steps:

- arrange in a plane the warp threads next to each other without superimposing them between them, in other words parallel to each other, thus forming a support for the weft threads and therefore for the carpet. The warp threads are preferably laid between the loom cylinders known to the person skilled in the art. Said loom can have the rectangular or circular shape,

- inserting and interlocking said weft and threads through said warp threads such that said weft threads are positioned in consecutive lines and essentially perpendicular to said warp threads. In the same line, the weft threads are inserted repetitively and according to a previously defined insertion model. The lines of consecutive weft threads can be placed one above the other if the loom and the warp threads are arranged vertically in relation to a person. The lines of weft threads will be placed next to each other if the loom and the warp threads are arranged horizontally in relation to a person.

In a preferred embodiment, the warp threads are arranged in at least two planes parallel to each other. In each plane, the warp threads are arranged side by side without overlapping each other. The two planes form a support for the weft threads and therefore for the carpet.

In a preferred embodiment, the weft threads are inserted and interwoven through said warp threads by passing said warp threads above - or below - a first number of juxtaposed warp threads and then below - or by above - a second number of warp threads juxtaposed and arranged directly next to the first warp threads. The repetitive passage of the weft threads below and above the warp threads while keeping the first number and the second number of warp threads constant is thus a model of insertion. The insertion model is repeated several times at the level of a line of weft threads. Said first number of warp threads may be the same or different from the second number of warp threads. The first number of warp threads can be 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 threads. The second number of warp threads can be 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 threads.

The number of warp threads defines the width, length or diameter of the carpet. The first warp thread occupies the first position going from right to left or from left to right of the support formed by the warp threads. The weft threads are inserted and interwoven through the warp threads in lines such that a line begins at the level of the first warp thread and extends to the last warp thread, which is more distant from the first thread of warp. The insertion is made in one direction and / or in the other: from right to left and / or from left to right of the support formed by the warp threads.

The procedure is characterized in that said insertion model is interrupted at least once so that it creates, on one of the faces of the carpet, at least one seam line, said seam line represents a boundary between two areas of the carpet which have different appearances and is defined by a plurality of warp thread segments. Said segments have a distance D that is longer than the distance d of a warp thread visible by the use of said insertion model. The distance d of a visible warp thread designates the distance over which the warp thread extends when it is positioned above the weft thread within an insertion model.

In a preferred embodiment, the areas of the carpet that have different appearances are of different colors and / or comprise different drawings and / or different motifs and / or have different geometric shapes. Said geometric shapes can be rectangular, triangular, circular or any other geometric shape.

In a preferred embodiment, the warp yarn segments that have the distance D are visible on the surface of the carpet. The surface of the carpet designates the face of the carpet that is not in contact with the floor when the carpet is extended in a room or room for example. Since the warp threads are arranged next to each other without overlapping each other, the segments that have the distance D and visible on the surface of the carpet will be parallel to each other.

In a preferred embodiment, the distance D of the segments defining a seam line is variable such that the relationship between the longest distance D and the shortest distance D is at least 1, preferably 1.1, more preferably 1.2, even preferably 1.3, even more preferably 1.4. This relationship can be at least 1.5, 1.6, 1.7, 1.8, 1.9 or 2.

In a preferred embodiment, the distance D of the segments defining the seam line is variable such that the relationship between the longest distance D and the shortest distance D is at least 50, preferably at most 40, even more preferably at most 30, even more preferably at most 20. Said

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relationship can be at most 10, 9, 8, 7, 6, 5 or 4.

In a preferred embodiment, the ratio between the thickness of a weft thread in relation to a warp thread is at least 10, preferably at least 12, even preferably at least 14, even more preferably at least 15, 16 or 20. This relationship is at most 40, 35, 32, 30 or 25.

In a preferred embodiment, the insertion model is interrupted so that it creates at least two seam lines on the surface of the carpet. Said seam lines are separated by an area of the carpet in which the insertion model is applied. Given the difference in thickness between the warp threads, thinner, and the weft threads, thicker; there is a difference in height between the region that includes the seam lines and the region that separates them. Indeed, the region that separates the seam lines will be thicker than the one that comprises the seam lines thus creating a handmade appearance, that is, as if the carpet pieces have been joined together by seams. Hand made

In a preferred embodiment, the thickness of a warp thread is at least 1 mm, preferably at least 1.5 mm, even preferably at least 1.8 mm, even more preferably at least 2 mm. The thickness of a warp thread can also be at least 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm or 5 mm. In a preferred embodiment, the thickness of a warp thread is a maximum of 10 mm, preferably a maximum of 9 mm, even preferably a maximum of 8 mm, even more preferably a maximum of 7 mm.

In a preferred embodiment, the relationship between distance D and distance d is at least 1.1, preferably at least 1.5, even preferably at least 2. The relationship between the two distances can be at least 3 , 4, 5, 6, 7, 8, 9, 10 or any value between the indicated values.

In a preferred embodiment, the relationship between distance D and distance d is at most 50, preferably at most 45, even preferably at most 40. The relationship between the two distances can be at most 33, 30, 25 , 20, 15, 13, 12, 11 or any value between the indicated values.

In a preferred embodiment, the ratio between the density of the weft threads in relation to the warp threads is at least 2. The density ratio is between 3 and 20, preferably between 4 and 18, even of preference between 5 and 15. The density of the warp threads is a maximum of 10 warp threads per centimeter of carpet and a maximum of 40 warp threads per centimeter of carpet. For reference, said density is at least 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20 warp threads per centimeter of carpet and at most 39, 38, 37, 36, 35 or 34 threads of warp per centimeter of carpet.

In a preferred embodiment, the insertion model is interrupted so that the visible segments that have the distance D belong to juxtaposed warp threads.

In a preferred embodiment, the insertion model is interrupted so that the visible segments having the distance D belong to warp threads separated by at least 1, 2, 3, 4, 5, 6 or 7 warp threads.

Fig. 1 represents a top view of a joint that forms the surface of a carpet produced according to a preferred embodiment of the invention. The weft threads are inserted and intertwined in lines L with the warp threads arranged according to the C-C axis reproducing a MI insertion model. The lines L of weft threads are perpendicular to the warp threads. In the insertion model, a warp yarn C1 is visible on the surface of the carpet while the warp book juxtaposed to the visible warp yarn C1 is covered by the weft or threads and as a consequence is not visible on the surface of the carpet Thus in this example, the first constant number of warp threads is equal to 1 and the second constant number of warp threads is also equal to 1. At the level of the line L 'of fig. 1 no interruption of the MI insertion model has been introduced. Said insertion model makes the warp thread C1 visible over a distance d represented in fig. 1. The insertion model MI is interrupted at the level of the other weft lines - other than L '- so that segments of the same warp thread are visible. As depicted in fig. 1, the segments extend over different distances D between sf and greater than the distance d defined by the insertion model MI. At the level of the example illustrated by fig. 1, the insertion model MI is interrupted so that the warp thread segments visible over distances D belong to juxtaposed warp threads C ', C' ', C' '' and define two seam lines LC1 and LC2. As depicted in fig. 1, each seam line comprises segments of visible warp lines that have a distance D that is either constant or variable. The seam line LC1 comprises warp line segments whose distance D is the same for all visible segments while the seam line LC2 comprises warp line segments whose distance D ranges from one segment to another.

Fig. 2 represents a top view of a joint that forms the surface of a carpet produced according to another preferred embodiment of the invention. The weft threads are inserted and intertwined in lines L with the warp threads arranged according to the C-C axis reproducing a MI insertion model. The lines L of weft threads are perpendicular to the warp threads. The insertion model MI of this example is similar to that described for the example in fig. 1. Said insertion model makes the warp thread C1 visible over a distance d represented in fig. 2. The MI insertion model is interrupted at the frame line level so that

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leave visible segments of the same warp thread. As depicted in fig. 2, the segments extend over different distances and greater than the distance d defined by the insertion model MI. At the level of the example illustrated by fig. 2, the insertion model MI is interrupted so that the visible warp thread segments that have distances D belong to non-juxtaposed warp threads, but which are separated by at least one warp thread. This is illustrated by the warp threads Ca and Cb that are separated by 1 warp line Cc. At the level of this example, the insertion model MI is interrupted so that the warp thread segments visible over distances D define two seam lines LC3 and LC4. As depicted in fig. 2, each seam line comprises visible warp line segments that have a constant distance D.

In a preferred embodiment, the warp threads are made of linen or wool. Preferably said warp threads are made of cotton. Said threads can have any color and preferably have an ocher color that intensifies thus the worn appearance of the carpet.

In a preferred embodiment, the material of the weft threads is chosen from the following group: linen, wool, cotton and silk. The weft threads and the warp threads can be of different or identical material.

In a preferred embodiment, the weft threads comprise at least 2 colored threads. The number of weft threads is between 3 and 12, preferably between 4 and 10, preferably between 5 and 9, even preferably between 6 and 8 weft threads. Said weft threads are preferably of different colors and are different in color from the warp threads. The weft threads are inserted and interwoven through the warp threads in an overlapping manner. For example, with reference to fig. 1 and assuming that 3 weft threads are used in the same line, the weft thread T visible on the surface of the carpet is positioned above the other two weft threads that are thus not visible on the surface of the carpet . It is also possible to leave, at the level of the same weft line, more than one weft thread T visible on the surface of the carpet. The weft threads are inserted and interwoven with the warp threads by varying the weft threads that will be visible on the surface of the carpet. This allows to create drawings and / or motifs on the surface of the carpet.

In a second aspect, the present invention provides a carpet comprising weft threads inserted and interwoven with warp threads. The weft threads are positioned in lines essentially perpendicular to said warp threads. The weft threads are inserted in the same line repetitively and according to a previously defined insertion model. The carpet is characterized in that said insertion model is interrupted at least once so that it creates, on one of the faces of the carpet, at least one seam line. Said seam line represents a boundary between two areas of the carpet that have different appearances and is defined by a plurality of warp thread segments, said segments having a distance D that is longer than the distance d of a visible warp thread by the use of said insertion model.

In a preferred embodiment, the carpet comprises at least one seam line, which extends in a direction substantially parallel to the weft threads and / or a seam line that extends in a direction substantially parallel to the warp threads. .

Fig. 3 illustrates an example of carpet comprising seam lines. The warp threads are arranged according to the C-C axis and the weft threads are inserted and interwoven with the warp threads according to the T-T axis. The carpet comprises seam lines 10, 10 ', 11 and 11' defined by segments of warp threads visible on the surface of the carpet and having a distance D that is longer than the distance d of a warp thread visible by the use of the carpet insertion model of fig. 3. The seam line 10 is parallel and the seam line 10 'is substantially parallel to the axis of insertion of the T-T weft threads. The seam lines 11 and 11 'are parallel to the C-C axis according to which the warp threads are arranged. Seam lines 10, 10 ', 11 and 11' define four areas of carpet Z1, Z2, Z3 and Z4. These zones are different from each other because of their respective appearances. They can be of different colors and / or comprise different drawings and / or different motifs and / or be of different geometric shapes.

Fig. 4 illustrates an example of a carpet comprising seam lines. The warp threads are arranged according to the C-C axis and the weft threads are inserted and interwoven with the warp threads according to the T-T axis. The carpet comprises seam lines 12, 13 and 14 defined by segments of warp threads visible on the surface of the carpet and having a distance D that is longer than the distance d of a warp thread visible by the use of the model of insertion of the carpet of fig. 4. The seam line 14 is parallel and the seam line 12 is substantially parallel to the axis of insertion of the T-T weft threads. The seam line 13 is parallel to the C-C axis according to which the warp threads are arranged. Seam lines 12, 13, and 14 define three areas of carpet Z5, Z6 and Z7. These zones are different from each other because of their respective appearances. They can be of different colors and / or comprise different drawings and / or different motifs and / or be of different geometric shapes.

The embodiment described in the foregoing and illustrated in the attached figures is an example given below.

illustrative and the invention is in no way limited to this example. The framework of the invention is defined by the

claims.

Claims (14)

5 10 fifteen twenty 25 30 35 40 Four. Five 1. Procedure for the manufacture of a carpet that has the appearance of patchwork fabric in which chain threads and at least one weft thread are used; which comprises the following stages: - arrange the warp threads in one plane next to each other without overlapping each other, - inserting and interlacing said weft threads through said warp threads such that said weft threads are positioned in consecutive lines and essentially perpendicular to said warp threads; the weft threads are inserted in the same line repetitively and according to a previously defined insertion model, characterized by that said insertion model is interrupted at least once so that it creates, on one of the faces of the carpet, at least one seam line, said seam line represents a boundary between two areas of the carpet that have different appearances and this defined by a plurality of warp thread segments, said segments having a distance D that is longer than the distance d of a warp thread visible by the use of said insertion model. 2. The method according to claim 1, wherein the distance D of the segments defining the seam line is variable such that the ratio between the longest distance and the shortest distance is at least 1.1. 3. Method according to any one of claims 1-2 in which the distance D of the segments defining the seam line is variable such that the relationship between the longest distance and the shortest distance is at most 20. 4. The method according to any one of claims 1 - 3 wherein the insertion model is interrupted so that the visible segments having the distance D belong to juxtaposed warp threads and / or warp threads separated by at least one thread of warp. 5. The method according to any one of claims 1-4 wherein the ratio between the thickness of a weft thread in relation to a warp thread is at least 10. 6. Method according to any one of claims 1-5 wherein the thickness of a warp thread is at least 1 mm. 7. Method according to any one of claims 1-6 wherein the relationship between distance D and distance d is at least 1.1, and maximum 50. 8. Method according to any one of claims 1-7 wherein said weft threads comprise at least 2 colored threads. 9. Method according to any one of claims 1-8 wherein the ratio between the density of the weft threads relative to the chain threads is at least 2. 10. The method according to any one of claims 1-9 wherein the warp threads are arranged so that they have a maximum of 10 warp threads per centimeter of carpet. 11. Method according to any of claims 1-10 wherein the warp threads are arranged so that they have a maximum of 40 warp threads per centimeter of carpet. 12. Carpet comprising weft threads inserted and interwoven with warp threads; said weft threads are positioned in lines essentially perpendicular to said warp threads; said weft threads are inserted in the same line in a repetitive manner and according to a previously defined insertion model characterized in that said insertion model is interrupted at least once so that it creates, on one of the faces of the carpet, the minus a seam line, said seam line represents a boundary between two areas of the carpet that have different appearances and is defined by a plurality of warp yarn segments, said segments having a distance D that is longer than the distance d of a warp thread visible by the use of said insertion model. 13. Carpet according to claim 12, wherein the seam line extends in a direction substantially parallel to the weft threads. 14. Carpet according to claim 12, wherein the seam line extends in a direction substantially parallel to the warp threads.