US3576702A - Tufted carpet and a method for producing said carpet - Google Patents

Tufted carpet and a method for producing said carpet Download PDF

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Publication number
US3576702A
US3576702A US626613A US3576702DA US3576702A US 3576702 A US3576702 A US 3576702A US 626613 A US626613 A US 626613A US 3576702D A US3576702D A US 3576702DA US 3576702 A US3576702 A US 3576702A
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United States
Prior art keywords
filament
carpet
composite
component
filaments
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Expired - Lifetime
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US626613A
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English (en)
Inventor
Masao Matsui
Keizo Ueda
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.)
SNIA Viscosa SpA
Kanegafuchi Spinning Co Ltd
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SNIA Viscosa SpA
Kanegafuchi Spinning Co Ltd
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Publication of US3576702A publication Critical patent/US3576702A/en
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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • Y10T428/23964—U-, V-, or W-shaped or continuous strand, filamentary material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • a tufted carpet having a double surfaced structure and a unique appearance the pile of which is composed of multifilament consisting of a composite filament composed of two thermoplastic synthetic linear polymers and having a latent crimpability and one-component filament composed of a thermoplastic synthetic linear polymer, said composite filament being adhered tightly and distributed uniformly on the surface of a base cloth for the carpet in crimped state and said one-component filament forming loop on the surface of the pile.
  • the method for producing said tufted carpet comprising tufting substantially not crimped multifilament consisting of the composite filament and the one-component filament on the base cloth for the carpet to form carpet pile and then subjecting the resulting carpet to a heat or swelling treatment to develop fully crimps of the composite filament, said composite filament being produced by melting two thermoplastic synthetic linear polymers having ditferent shrinkabilities separately and extruding said melted polymers through a common orifice to form unitary filament, in which said two polymers are bonded eccentrically in sideby-side or sheath and core relation along the total length of said unitary filament and taking up on a bobbin into a bundle.
  • the present invention relates to a tufted carpet having a unique structure in which a multifilament composed of composite filaments having latent crimpability which consists of two different components and conventional onecomponent filaments is subjected to tufting and then to after-treatment with heat, water, solvent, etc., and a method for producing said carpet.
  • non-crimpable filament has a poor covering property, it is not suitable for raw yarn for carpet, so that spun yarn or crimped yarn having a high covering property hitherto has been generally used.
  • crimped yarn is liable to form uneven pile shape, because tension is ununiform in tufting step, and it is difiicult to obtain a carpet having a uniform surface state. Therefore, the above mentioned drawbacks have been solved by subjecting composite filament having latent crimpability to tufting and then to after-treatment such as swelling and shrinking to develop crimpability.
  • the covering property is proportional to the curliness, and the greater the curliness of yarn, the higher its covering property.
  • the tendency for forming felt increases extremely, and the surface of carpet is not always satisfactory.
  • yarn having a poor curliness forms a surface having loops on the surface of pile, but is insufficient in the covering property.
  • the object of the present invention is to solve the above mentioned drawbacks and to provide a particular tufted carpet having a unique surface and an improved covering property based on the difference of crimpabilities of filaments constituting the carpet.
  • the above mentioned object can be attained by tufting a non-twisted or lowly twisted multifilament which consists of composite filaments having latent crimpability,
  • nontwisted multifilament or lowly twisted multifilament of less than 100 t.p.m., preferably less than 50 t.p.m., which is composed of two-component composite filaments having latent crimpability and usual one-component filaments.
  • the number of twists is larger, not only crimp developability is disturbed, but also loops of the non-crimpable filament are not formed, so that it is not suitable for the present invention.
  • the two-component composite filament having latent crimpability which constitutes the above mentioned multifilament can be obtained by melting separately two thermoplastic synthetic linear polymers having different crimpabilities when heat treated or treated with swelling agents and extruding them through a common orifice simultaneously to form a unitary filament in which said two polymers are bonded and extended eccentrically in side-by-side or in sheath and core relation along the axis of the filament.
  • the thermoplastic synthetic linear polymers to form these filaments can be selected suitably.
  • the multifilament to be used in the present invention can be produced by doubling the two-component composite filaments having latent crimpability with ordinary one-component filaments or spinning these filaments simultaneously through a special spinneret, and taking up on a bobbin the resulting filaments into a bundle. Furthermore, tufted carpets having variously different elegancies and characteristics can be obtained depending upon the desire by varying the mixing ratio of the composite filament to the one-component filaments or varying the constitution of denier of both filaments suitably, but the ratio of the composite filaments in the multifilaments given in the Formula A should be 30 to 90%, preferably 40 to 80%.
  • the composite filaments are governed by the one-component filaments, so that the composite filaments can not exhibit crimp developability and satisfactory covering property can not be obtained.
  • the value of the Formula A is too large, a sufficiently high covering property can be obtained, but a tendency for forming felt is increased, and moreover the effect of loops formed on the surface of pile by the one-component filaments is decreased, so that the characteristic of the present invention is lost.
  • the two-component composite filaments to be used in the present invention have latent crimpability, but said filaments need not necessarily maintain a completely uncrimped state, but a part of the latent crimpability may be developed to form few crimps.
  • all of the latent crimpability must be developed, but before tufting 3 to 50%, preferably 5 to 30% of the latent crimpability may also be developed.
  • crimp development before tufting must be preliminary and the amount of crimps to be developed must be less than 50%.
  • Such preliminary development of crimp gives such advantages that the main development of crimp, after tufting can be easily made and an excess solidification of the obtained carpet can be prevented.
  • filaments shrink strongly in the main development of crimps, so that the obtained carpet is liable to become hard, while if the filaments are crimped preliminarily, the shrinkage is low, so that the obtained carpet is very bulky and elastic.
  • the percentage of crimp of two-component composite filament can be obtained in the following way.
  • the twocomponent composite filament of 3,000 deniers in which crimp has not yet been developed is treated with hot water at 100 C. for minutes under no load and dried in air. Thereafter, the length of the crimped filament (L is measured under no load and then the crimped filament is subjected to a load of 1 kg. and after 1 minute the length of the filament (L is determined.
  • the percentage of saturated crimp is determined by the following formula.
  • the preliminar crimp can be developed by feeding non-crimped composite filament or multifilament composed of composite filament and one-component filament to heating zone at a constant speed to develop crimps partially on the filaments by dry heat, steam heat or wet heat, delivering the partially crimped filaments at a velocity less than the feed velocity and then taking up on a bobbin.
  • the heating temperature is set by the kinds of polymer constituting the filament, travelling velocity of the filament, heating time, etc.
  • the over feed ratio is set suitably depending upon the percentage of preliminary crimp.
  • the step for forming pile by tufting multifilament on base cloth is carried out in a conventional method by using a previously known machine.
  • the tufted carpet thus obtained is treated with heat, water and swelling agent until the main development of crimp of the twocomponent composite filament in the pile is fully made,
  • the figure is a cross-sectional view of the tufted carpet according to the present invention.
  • 1 shows composite filament having latent crimpability
  • 2 shows a one-component noncrimpable filament
  • 3 shows a base cloth for tufting.
  • the non-crimpable filament 2 appears in a loop shape on the surface of the pile to provide remarkably luxurious appearance and touch which have not been obtained in conventional carpets, while the filament 1 having latent crimpability is crimped with aftertreatment to provide a high covering property.
  • the filament having latent crimpability to be used in the tufted carpet according to the invention has a particu larly high crimpability, the amount of pile can be decreased, as the covering property increases, so that the manufacturing cost can be reduced.
  • Nylon-6 having an average polymerization degree of 162. was referred to as polymer A.
  • a copolymer consisting of parts of nylon-6 and 10 parts of polyhexamethylene isophthalamide and having an average polymerization degree of 194 was referred to as polymer B.
  • the polymers A and B were melted separately and fed to a common spinneret for conjugate spinning at the same weight and velocity through separate gear pumps.
  • the percentage of saturated crimp of the filament was 60.7%.
  • a drawn tri-lobal filament yarn of 1,500 deniers/ 100 filaments consisting only of nylon-6 was referred to as filament D.
  • Each one of filament C and filament D were doubled while applying 30 t.p.m. of twist to obtain filament E, with which a tufted carpet was produced.
  • the tufting was effected in gauge number (course) of 6/inch, stitch number of 7/inch and a pile length of 18 mm., and then the resulting carpet was dipped inot hot water at 60 C., without cutting loops, and then the temperature was raised gradually to 100 C. in 30 minutes, and said temperature was maintained for 30 minutes to develop crimps fully.
  • the carpet was cooled and dipped in a dyeing bath at 30 C., and the temperature was raised gradually to 70 C. in 60 minutes, after which the carpet was washed, dried and subjected to lining to obtain a carpet product F, which had a very complicated surface. That is, the crimped two-component filament was adhered tightly to the bottom and distributed, and the non-crimped one-component filament rose and fell in a loop state, so that the surface had a double structure and a luxurious appearance.
  • EXAMPLE 2 Filament C obtained in Example 1 was passed through a metal tube heated at C. and having a length of 80 cm. and an inner diameter of 4 mm., at a feed velocity of '60 m./min. and a delivery velocity of 40 m./min.
  • the filament G and the filament D as described in Example .1 were doubled to obtain multifilament having the same constitution and number of twist as those in Example 1. Then, the obtaining multifilament was subjected to tufting, crimp development, dyeing, drying and lining under the same condition as described above to obtain a carpet product H.
  • the obtained product H had a very soft touch and a high elasticity, and moreover the crimped two-component filament was adhered tightly and distributed over all the carpet, and was low in lustre due to its crimp.
  • the one-component filament rose and fell in a loop state on the surface of carpet having no crimp and gave an excellent lustre. Therefore the carpet had a unique, complicated and luxurious appearance.
  • EXAMPLE 3 Two-component composite filaments consisting of polymer A and polymer B as described in Example 1, and one-component filaments consisting only of polymer A were extruded through a common spinneret simultaneously, and taken up on a bobbin into a bundle.
  • the obtained undrawn filaments were drawn to 2.6 times their original length by a drawing and taking up machine and then taken up on the machine without twisting to obtain a substantially non-twisted multifilament J consisting of 120 of two-component filaments of 15 deniers and 80 of one-component filaments of 15 deniers.
  • the filament J was subjected to a preliminarily crimp developing treatment in the same manner as described in Example 2. In this case, the feed velocity was 50 m./min. and the delivery velocity was 35 m./min.
  • the two-component filament was taken out from the obtained multifilament and the percentage of preliminary development of the latent crimpability was determined to be 14.5%.
  • Said multifilament and the multifilament applied a twist of 50 t.p.m. were treated in the same manner as described in Example 1 to obtain two carpet products K and L respectively.
  • the product K was similar to the product obtained in Example 2, and the product L was similar to the product obtained in Example 1, and both of them had an improved elasticity and a complicated and luxurious appearance.
  • a method of producing a tufted carpet having a double surfaced structure which comprises tufting substantially non-twisted multi-filament consisting of a composite filament having a latent crimpability and composed of two thermoplastic synthetic linear polymers and a onecomponent filament on a base cloth for the carpet to form carpet pile, and then subjecting the resulting carpet to a treatment for developing the latent crimpability to develop fully crimps of said composite filament to obtain a product wherein crimped loops of said composite filament are adhered to and distributed on the surface of said base cloth and loops of said one-component filament are disposed generally on top of the loops of said composite filament.
  • said treatment for developing the latent crimpability is a heat treatment.
  • a method as claimed in claim 7, wherein said treatment for developing the latent crimpability is a swelling treatment.
  • said mul- X 100 (percent) tifilament is produced by spinning a composite filament composed of two thermoplastic synthetic linear polymers and having a latent crimpability and a one-component filament simultaneously through a common orifice, and then taking up on a bobbin into a bundle.
  • said composite filament and said one-component filament are composed of fibre-forming thermoplastic synthetic linear polymers selected from the group consisting of polyamides, polyesters, polyacrylonitriles, polyolefins, polyvinyl halides and polyvinylidenehalides.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
  • Multicomponent Fibers (AREA)
  • Spinning Methods And Devices For Manufacturing Artificial Fibers (AREA)
  • Yarns And Mechanical Finishing Of Yarns Or Ropes (AREA)
US626613A 1967-01-05 1967-03-28 Tufted carpet and a method for producing said carpet Expired - Lifetime US3576702A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP130567 1967-01-05

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US3576702A true US3576702A (en) 1971-04-27

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US (1) US3576702A (it)
BE (1) BE697121A (it)
DE (1) DE1654135A1 (it)
ES (1) ES339204A1 (it)
GB (1) GB1133688A (it)
NL (1) NL6707375A (it)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4452160A (en) * 1978-07-19 1984-06-05 Teijin Limited Method of manufacturing a cut pile carpet
US5445860A (en) * 1992-12-29 1995-08-29 Gff Holding Company Tufted product having an improved backing

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2141146A (en) * 1983-04-20 1984-12-12 Spectrum Carpets International Improvements in hand woven floor and wall coverings
DE4111455C1 (it) * 1991-04-09 1992-07-23 Norddeutsche Faserwerke Gmbh

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4452160A (en) * 1978-07-19 1984-06-05 Teijin Limited Method of manufacturing a cut pile carpet
US5445860A (en) * 1992-12-29 1995-08-29 Gff Holding Company Tufted product having an improved backing

Also Published As

Publication number Publication date
DE1654135A1 (de) 1972-02-10
BE697121A (it) 1967-10-02
ES339204A1 (es) 1968-05-16
NL6707375A (it) 1968-07-08
GB1133688A (en) 1968-11-13

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