ES2644350T3 - Carpet and procedure for manufacturing said carpet - Google Patents

Description

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DESCRIPTION

Carpet and procedure for the manufacture of said carpet

The present invention concerns a process for the manufacture of a carpet with an effect of old style or of used aspect. The invention also relates to the carpet obtained by using the method of the invention.

Prior art

A carpet with an old-style effect or a worn look is obtained by subjecting the newly produced carpet to physical and / or chemical treatments. These treatments are applied to erase and / or detach, at least partially, the color of the carpet. The treatments are generally applied to certain areas of the carpet, thus creating a worn or old-style look.

Said physical and / or chemical treatment of the carpets prolongs the manufacturing time of said carpet, makes the manufacturing more expensive and can also present health risks if chemical products are used for the creation of the aspect used.

Document DE 2228837 describes a base fabric for handwork and background fabric for handmade carpets. In a normal background fabric for handwork or carpet work, also, only in the direction of the warp, there are floating threads made of a thread other than that of the background fabric. These floating threads that pass over several crosses of the background fabric determine loops of different lengths and are offset from each other. The floating threads, which stand out from the warp at various sites of the background fabric, serve for the knotting of the strands of thread that constitute the work by hand or the carpet.

US 5343600 describes an oriental carpet weave comprising: a) a plurality of warp threads located vertically at two levels, one directly behind the other; b) a plurality of base weft threads located horizontally between the two levels of warp threads, in order to be used as a sturdy base for the carpet; and c) a plurality of decorative broach coating weft threads located horizontally with each loop successively on a group of two of said warp threads in the two levels, which produces a continuous warp structure, so that said weft yarn Decorative brooch coating alternates with the base weft threads, in order to determine a well-made delicate oriental rug.

The prior art does not provide any solution to the problem indicated above. It is the objective of the invention to provide a process for the manufacture of a carpet with a worn aspect, without having to resort to the use of physical and / or chemical treatments of the carpet.

The present invention provides a method according to claim 1 and a carpet according to claim 10.

In a preferred embodiment, the segments of warp yarns in sight and having the distance D cover between 1% and 99%, preferably between 5% and 95% of the surface of the carpet.

The present invention allows the manufacture and the obtaining of an old style carpet or with a worn aspect, without having to resort to the application of physical and / or chemical treatments in the carpet. This represents a considerable cost savings and a shortening of production time. The present invention also makes it possible to avoid the use of chemical products for the treatment of carpets, thus considerably reducing the risk of diseases among employees, and the spillage of chemical products into the environment.

Brief description of the figures

Figure 1 illustrates an example of insertion of the weft threads with respect to the warp threads according to an embodiment of the invention.

Figure 2 illustrates another example of insertion of the weft threads with respect to the warp threads according to another embodiment of the invention.

Figure 3 illustrates an example of carpet with an aspect used according to an embodiment of the invention. Description of exemplary forms of realization

The invention concerns a process for the manufacture of a carpet with an effect of old style or of used aspect. The invention also relates to the carpet obtained by using the method of the invention. The carpet according to a preferred embodiment is provided with careful finishes.

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

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The terms "zone" and "region" are used as synonyms and refer to a part of one of the two sides of the carpet.

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

- arrange the warp threads in one plane next to each other without overlapping each other, in other words, parallel to each other, thus determining a support for the weft threads and, therefore, for the carpet. The warp threads are preferably tensioned between the loops of a loom known to a person skilled in the art. Said loom can have a rectangular or circular shape.

- 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. In the same line, the weft threads are inserted repetitively and according to a predefined insertion pattern. The lines of consecutive weft threads can be placed one on top of the other if the loom and the warp threads are arranged vertically with respect to a person. The weft thread lines will be located next to each other if the loom and the warp threads are arranged horizontally with respect 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 determine 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 weft threads above - or below - a first number of juxtaposed warp threads and then below -or 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 constant the first number and the second number of warp threads, thus constitutes an insertion pattern. The insertion pattern is repeated several times in correspondence with 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 determined by the warp threads. The weft threads are inserted and interwoven through the warp threads in lines such that a line starts in correspondence with the first warp thread and runs to the last warp thread, the one that is farthest from the first warp thread. The insertion is carried out in one direction and / or in the other: from right to left and / or from left to right of the support determined by the warp threads.

The procedure is characterized in that the insertion pattern is interrupted at least once, in order to expose, on one of the faces of the carpet, at least two segments of at least one warp thread. Said segments have a distance D longer than the distance d of a warp thread in sight by using said insertion pattern. The distance d of a warp thread in sight designates the distance over which the warp thread extends when positioned above the weft thread within an insertion pattern. Said segments of warp yarns in sight and having the distance D are grouped in correspondence with at least one zone Z of the surface of the carpet and within the same zone Z, said sight segments extend in different distances between yes and greater than the distance d defined by the insertion pattern.

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

In a preferred embodiment, a zone Z covers between 1% and 40%, preferably between 2% and 38%, preferably between 3 and 35%, still preferably between 5 and 30% of the total area of the carpet. In a still preferred embodiment, a zone Z covers between 8% and 28%, preferably between 10% and 25%, preferably between 12 and 25%, still preferably between 15 and 20% of The total area of the carpet. The carpet comprises at least one Z zone, preferably two Z zones or more. The carpet comprises at least one Z zone, preferably two Z zones or more.

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According to the invention, a zone Z extends at least 1 cm, at least 2 cm, at least 3 cm, at least 4 cm, at least 5 cm, at least 6 cm, at least 7 cm, at least 8 cm, at least 9 cm, at least 10 cm in the direction of the warp threads. According to the invention, a zone Z extends at least 1 cm, at least 2 cm, at least 3 cm, at least 4 cm, at least 5 cm, at least 6 cm, at least 7 cm, at least 8 cm, at least 9 cm, at least 10 cm in the direction of the weft threads. In a preferred embodiment, a zone Z extends at a maximum of 50 cm, a maximum of 45 cm, a maximum of 35 cm, a maximum of 25 cm, a maximum of 20 cm, a maximum of 15 cm in the direction of the warp threads . In a preferred embodiment, a zone Z extends in a maximum of 50 cm, a maximum of 45 cm, a maximum of 35 cm, a maximum of 25 cm, a maximum of 20 cm, a maximum of 15 cm in the direction of the weft threads .

In a preferred embodiment, a zone Z may have any regular shape, such as rectangular, triangular, circular or any other known regular shape. The Z zone may also have an irregular shape.

In a preferred embodiment, the set of Z zones covers between 1% and 99%, preferably between 5% and 95%, preferably between 10 and 90%, still preferably between 15 and 80 % of the total area of the carpet. In a still preferred embodiment, the zone Z covers between 20 and 70%, preferably between 25 and 60%, still preferably between 30 and 50% of the total area of the carpet.

In a preferred embodiment, a zone Z comprises between 2 and 1000 segments of warp yarns in sight and having the distance D, preferably between 5 and 900, preferably between 10 and 850, still preferably between 15 and 800 segments of warp and sight threads and having the distance D. In a still preferred embodiment, a zone Z comprises between 20 and 750 segments of warp threads in sight and having the distance D, preferably between 25 and 700, preferably between 30 and 650, still preferably between 35 and 600 segments of warp threads in sight and having the distance D. In a still more preferred embodiment, a zone Z comprises between 40 and 550 segments of warp threads a the view and having the distance D, preferably between 45 and 500, preferably between 50 and 450, still preferably between 55 and 400 segments of warp threads in sight and having the distance D. The number of segmen Cough of warp threads in sight and having the distance D can also be comprised between any value indicated above. The segments of warp threads in sight and having the distance D are parallel to each other and extend in different distances from each other and greater than the distance d defined by the insertion pattern.

In a preferred embodiment, the insertion pattern is interrupted so that the segments in sight that have the distance D belong to warp threads separated by at least 1, 2, 3, 4, 5, 6 or 7 threads of warp.

Figure 1 represents a top view of a determinant tie of the surface of a carpet produced according to a preferred embodiment of the invention. The weft threads are inserted and interwoven in lines L with the warp threads arranged according to the axis C-C reproducing an insert pattern MI. The lines L of weft threads are perpendicular to the warp threads. In the insertion pattern, a warp yarn C1 is visible on the surface of the carpet, while the warp yarn juxtaposed to the warp warp yarn C1 is covered by the weft (s) and, consequently, It 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. In line L 'of Figure 1, no interruption of the pattern is introduced of insertion MI. Said insertion pattern exposes the warp thread C1 at a distance d represented in Figure 1. The insertion pattern MI is interrupted in correspondence with the other weft lines - different from L'-, in order to leave the view segments of the same warp thread. As shown in Figure 1, the segments extend in different distances from each other and greater than the distance d defined by the insertion pattern MI. With respect to the example illustrated by Figure 1, the insertion pattern MI is interrupted so that the segments of warp yarns in sight that have distances D belong to juxtaposed warp threads C ', C' ', C' '' .

Figure 2 represents a top view of a determinant tie of the surface of a carpet produced according to another preferred embodiment of the invention. The weft threads are inserted and interwoven in lines L with the warp threads arranged according to the axis C-C reproducing an insert pattern MI. The lines L of weft threads are perpendicular to the warp threads. The insertion pattern MI of this example is similar to that described for the example of Figure 1. Said insertion pattern exposes the warp thread C1 at a distance d represented in Figure 2. The insertion pattern MI is interrupted. in correspondence with the weft lines, in order to expose segments of the same warp thread. As shown in Figure 2, the segments extend in different distances from each other and greater than the distance d defined by the insertion pattern MI. With respect to the example illustrated by Figure 2, the insertion pattern MI is interrupted so that the segments of warp threads in sight that have distances D belong to non-juxtaposed warp threads that are separated by at least one warp thread . This is illustrated by the warp threads Ca and Cb that are separated by 3 warp lines Cc, Cd and Ce.

In a preferred embodiment, the ratio between distance D and distance d is at least 1.1,

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preferably, at least 1.5, still preferably, at least 2. The ratio 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 ratio between distance D and distance d is at most 50, preferably, at most 45, still preferably, at most 40. The ratio 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 with respect to the warp threads is at least 2. The ratio of densities is between 3 and 20, preferably between 4 and 18, still preferably between 5 and 15. The density of the warp threads is at least 10 warp threads per centimeter of carpet and, at most, 40 warp threads per centimeter of carpet. Preferably, 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 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, thus intensifying the used aspect of the carpet.

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

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, still preferably between 6 and 8 weft threads. Said weft threads are preferably of different colors and are different in color from the warp threads themselves. The weft threads are inserted and interwoven through the warp threads in an overlapping manner. For example, with reference to Figure 1 and assuming that in the same line 3 weft threads are used, the weft thread T in sight on the surface of the carpet is that positioned above the other two weft threads that Thus, they are not 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 obtained by the procedure described above. The carpet comprises 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 predefined insertion pattern characterized in that said insertion pattern is interrupted at least once in order to expose, on one of the faces of the carpet, at least two segments of at least one warp thread, said segments having a distance D that is longer than the distance d of a warp thread in sight when the weft threads are inserted and interwoven with the warp threads according to the insertion pattern Said segments of warp yarns in sight and having the distance D are grouped in correspondence with at least one zone Z of the surface of the carpet and within the same zone Z, said sight segments extend in different distances between yes and greater than the distance d defined by the insertion pattern.

Figure 3 illustrates an example of carpet that has a worn appearance. 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 zones Z1 and Z2 in which warp threads are visible on the surface of the carpet. These segments have distances D which, due to the use of the carpet insertion pattern of Figure 3, are longer than the distance d of a warp yarn in sight. These zones Z1 and Z2 give the carpet a worn or old-style look. The zone Z1 has a substantially circular shape, while the zone Z2 has a substantially rectangular shape.

In a preferred embodiment, the segments of warp yarns in sight and having the distance D cover between 1% and 99%, preferably between 5% and 95%, preferably between 10 and 90% , still preferably between 15 and 80% of the total area of the carpet. Said segments can also cover between 20 and 70%, preferably between 25 and 60%, still preferably between 30 and 50% of the total area of the carpet.

In a preferred embodiment, the warp yarn segments in sight and having the distance D are grouped in correspondence with at least one region of the carpet surface. Said region may have a rectangular, triangular, circular or other shape. Said region may extend, in the direction of the warp threads, preferably 1 cm, still preferably 1.5 cm, even more preferably 2 cm of the carpet. Said region may extend, in the direction of the warp threads, by a maximum of 20 cm, preferably 18 cm, still preferably 15 cm, even more preferably 12 cm from the carpet. Said region may extend, in the direction of the weft threads, preferably 1 cm, still preferably 1.5 cm, even more preferably 2 cm of the carpet. Said region may extend, in the direction of the weft threads, by a maximum of 20 cm, preferably 18 cm, still preferably 15 cm, even more preferably 12 cm from the carpet.

The embodiment described above and illustrated in the attached figures is an example given by way of illustration, and the invention is not limited in any way to this example. Any modification, any variant and any equivalent organization must be considered as included within the scope of the claims.

Claims (11)

5 10 fifteen twenty 25 30 35 40 Four. Five 1. Procedure for the manufacture of a carpet with a worn aspect in which warp threads and at least one weft thread are used, comprising the following steps: - 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 predefined insertion pattern, said insertion pattern is interrupted at least once in order to expose, on one of the faces of the carpet, at least two segments of warp threads, said segments having a distance D which is longer than the distance d of a warp thread in sight when the weft threads are inserted and intertwined with the warp threads according to the insertion pattern, said segments of warp threads in sight and having the distance D are grouped in correspondence with at least a zone Z of the surface of the carpet, said zone Z extends at least 1 cm in the direction of the warp threads and at least 1 cm in the direction of the weft threads, and said visible segments extend at different distances from each other and greater than the distance d defined by the insertion pattern. 2. The method according to claim 1, wherein the insertion pattern is interrupted so that the segments in sight that have the distance D belong to juxtaposed warp threads. 3. Method according to claim 1, wherein the insertion pattern is interrupted so that the segments in sight that have the distance D belong to warp threads separated by at least one warp thread. 4. The method according to any one of claims 1 to 3, wherein the ratio between distance D and distance d is at least 1.1, preferably, at least 1.5, still preferably, at least 2. 5. Method according to any one of claims 1 to 3, wherein the ratio between distance D and distance d is at most 50, preferably, at most 45, still preferably, at most 40. Method according to any one of claims 1 to 4, wherein said weft threads comprise at least 2 colored threads. 7. Method according to any one of claims 1 to 5, wherein the ratio between the density of the weft threads with respect to the warp threads is at least 2. Method according to any one of claims 1 to 6, in which the warp threads are arranged in order to have at least 10 warp threads per centimeter of carpet. 9. Method according to any one of claims 1 to 7, wherein the warp threads are arranged in order to have a maximum of 40 warp threads per centimeter of carpet. 10. 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 predefined insertion pattern, characterized in that said insertion pattern is interrupted at least once in order to leave it visible, on one of the faces of the carpet , at least two segments of warp threads, said segments having a distance D that is longer than the distance d of a warp thread in sight when the weft threads are inserted and interwoven with the warp threads according to the pattern of insertion, said segments of warp threads in sight and having the distance D are grouped in correspondence with at least one zone Z of the surface of the carpet, said zone Z extends at least 1 cm in the direction of the threads of warp and at least 1 cm in the direction of the weft threads, and said visible segments extend in different distances from each other and greater than the distance d defined by the insertion pattern. 11. Carpet according to claim 9, wherein the segments of warp yarns in sight and having the distance D cover between 1% and 99%, preferably between 5% and 95% of the surface of the carpet.