Classifications

• • 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
  • D05C17/026—Tufted products characterised by the tufted pile surface

Definitions

• the present invention refers, in general, to a process for manufacturing tufted carpets or rugs which are used, for instance, in decorating homes.
• Tufted carpeting can also be made in large-scale production machines without individual needle command, the carpeting being produced in rolls at a reduced cost, but with the limitation that it is not possible to produce carpets having a large variety of colors and patterns along the length of each roll.
• the present invention provides an intermediate solution for the production of carpets or rugs, so as to take advantage of both the high degree of mechanization and the low cost provided by the production of carpets in rolls, and also the quality of semi-manual production associated with hand-operated carpet tufting machines.
• a process for producing tufted carpets or rugs having a base web and tufts, the bottom side of the base having been subjected to under-finishing and optionally other finishing steps comprises the following steps:
• the step of applying other tufts may be carried out by using a hand-operated tufting machine.
• the region mentioned above comprises the outer border of the piece of carpeting, so that the other tufts will define the border pattern. There may be more than one region from which tufts are removed and substituted by other tufts.
• tufts of a different nature means tufts of any color, type, material, texture or other characteristic which differentiates them from the original tufts of the carpet or rug.
• the step of applying a stitch line delimiting said region is included, prior to the step of removing the first mentioned tufts.
• Said stitch line preferably in zigzag, serves to prevent tufts from being removed outside the chosen area, besides reducing the risk of these tufts loosening during the later steps.
• the removal of the tufts is carried out by pulling them from the region delimited by the seam line.
• the present invention further refers to a carpet or rug produced in accordance with the above-defined process.
• a carpet or rug having a base web and tufts comprises a piece of carpeting produced on an automatic tufting machine, surrounded by a border tufted by a hand-operated tufting machine. ln one embodiment, the carpet or rug may have an inner region away from the border, tufted by a hand-operated tufting machine.
• the process described above enables one to obtain a rug of any size from a piece of carpeting, with the option of varying colors, shapes, textures and patterns, at a cost and production capacity that are between those of large-scale production and semi-manual production, by virtue of the fact that advantage is taken off a piece of already tufted carpeting produced on a large scale.
• Another important improvement introduced is the fact that the new tufts are applied immediately after the stitch line, which ensures a natural continuation of the existing tufting, without the occurrence of any division or crack in the tufting.
• a layer of latex foam may be applied to the bottom surface of the rug to provide an anti-skid effect.
• Figure 1 is a perspective view of a roll of unfinished carpeting
• Figure 2 is a detailed view of the tufts of the roll of carpeting of Figure 1 ;
• Figure 3 is a front view of a piece of carpeting cut out of the roll of Figure 1 , showing stitch lines;
• Figure 4 is a front view of the piece of carpeting showing the regions from which tufts have been removed;
• Figure 5 is a detailed view of Figure 4, showing the tufted region and the un- tufted region with the base web being visible;
• Figure 6 is a front view of the carpet with tufts of a different nature, tufted in the region in which the base web was visible, as shown in Figure 4.
• Figure 1 shows a roll of carpeting 1 , produced by the conventional process in a large-scale production tufting machine.
• Carpeting 1 may be of any type.
• the illustrated example is formed from a polypropylene base 2 with tufts in "loop" (or in "boucle") 3, as shown in greater detail in Figure 2.
• the present invention deals with a new technique of effectively transforming a piece of carpeting 6 into a semi-artisanal carpet or rug.
• the roll of carpeting 1 is cut out along lines 4 and 5, precisely in accordance with the dimensions of the carpet or rug to be manufactured.
• the process of manufacturing the carpet or rug from a piece of carpeting 6 cut out of the roll comprises a first step of defining the region or regions of the piece that should be subjected to the semi-artisanal process. This is done by the zigzag stitching of lines 7 and 8, which mark the region or regions to be worked. As can be seen from Figure 3, the stitch line 7 delimits the outer border region of piece 6, where the border of the rug will be made. Similarly, stitch line 8 delimits a central triangular region where a decoration may be applied in the center of the rug, if desired.
• the tufts 3 in the delimited border and center region are pulled out, either by hand or by any adequate means, stitch lines 7 and 8 serving to prevent the tufts from being removed outside these regions and to reduce the risk of the tufts on the other side of these lines falling out later.
• the base web 2 remains visible in said regions, as shown in Figure 4 and in greater detail in Figure 5, where the stitch line 7 surrounding the tufted region 3 is also visible.
• under-finishing is carried out for the definitivey gluing or fixing of tufts 3 and 9 to the base web 2.
• This base may be any layer which imparts more resistance to the product, and/or may include, for instance, a layer of synthetic or natural foam to provide the rug with anti-skid characteristics.
• Another embodiment of the present invention consists in that the tufts 3 are "cut", in which case the formation of stitch lines 7 and 8 can be substituted by the simple marking of the base web 2 by means of a pen or pencil, by virtue of the fact that the tufts are substantially loose in the base web 2 prior to the under-finishing (for example, latexing) step, for which reason pulling out the tufts by hand and delimiting the regions to be worked on become simpler.
• under-finishing for example, latexing
• the present invention is not limited to the embodiments described in detail with reference to the drawings, but rather solely to the scope of the claims.
• the invention also relates to the production of carpets or rugs adorned only with outer borders of a single color or texture, rugs with border designs, rugs with inner regions of different colors or textures, rugs with inner regions carrying designs and the like, provided that one does not depart from the principal concept of the invention, namely the combination of large scale production techniques used for manufacturing car- peting with the semi-manual techniques used in the production of carpets or rugs.

Priority Applications (2)

Applications Claiming Priority (2)

Publications (1)

Family

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Family Applications (1)

Country Status (7)

Cited By (3)

Citations (4)

• 1997
  • 1997-12-15 BR BR9705644-8A patent/BR9705644A/pt not_active IP Right Cessation
• 1998
  • 1998-12-11 CA CA002315204A patent/CA2315204A1/en not_active Abandoned
  • 1998-12-11 AU AU16550/99A patent/AU1655099A/en not_active Abandoned
  • 1998-12-11 WO PCT/BR1998/000101 patent/WO1999031310A1/en active Application Filing
  • 1998-12-14 UY UY25301A patent/UY25301A1/es not_active Application Discontinuation
  • 1998-12-15 CO CO98074438A patent/CO5040187A1/es unknown
  • 1998-12-15 AR ARP980106372A patent/AR017431A1/es unknown

Patent Citations (4)

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