DE19705986A1 - Woven carpet production - Google Patents

Abstract

The woven carpet is composed of pile yarns and other yarns for the fabric structure to give a loop and/or pile surface and structured edges along the longitudinal sides. The carpet is woven with the raw white pile yarns in the weaving design, independently of subsequent dyeing operations. The woven carpet is tensed, and a dyestuff is applied at the same time continuously over the fabric width along the fabric length. After weaving and dyeing, the reverse side of the carpet is covered with a latex backing. The carpet is woven as a rush or Wilton carpet, in a width of 4-5 m or more. The structural yarns are mostly of synthetic fibre materials. The raw white pile yarns are mainly of polyamide, of all types, or they can be yarn-dyed polyamide pile yarns. The polyamide pile yarns have different dye affinities, to give multicolour effects. The pile yarns can also include other yarn types, and mixtures. The edges of the carpet are woven without the pile yarns, or a leno edge can be formed or other weaving actions to give a firm edge. The weaving density is set to prevent any sliding shift movements between the warps and wefts. All the required dye affinities are set at all points on the upper surface of the woven carpet. The dyeing action is specific to the yarn content of the carpet, to be applied while the carpet is taut without bunching or creasing.

Description

The invention relates to a woven carpet which can be used both as a floor and wall covering Can be found. Carpets are made from man-made fibers, wool, hair yarn, silk and cotton tufted, woven, knitted, knotted and needled. Weaving is related to the factory presented carpet area as the third strongest production technology after tufts and needles especially important for the upper market segment, mostly wool, but also Chemical fibers and in particular polyamide filament yarns and spun yarns for Come into play. The factory-made woven carpet, which is both as floor and as Wall covering can be used, in addition to comfort offers significant advantages among others also with regard to insulation and thereby favors the heat balance in buildings.

The woven carpet constructions that are common today consist mainly of several yarns: The pile or pile yarn, the binding warp threads, the filling warp threads and the weft threads. For these components use different materials. As pile or pile yarn wool or polyamide or mixtures thereof are mostly used. The other so-called mentioned auxiliary threads mostly consist of jute, cotton, viscose, polyamide, polypropylene threads, polyester threads or mixtures. On the back is the web construction a finish or latexing to solidify the different yarn systems the and thus applied to achieve dimensional stability.

The production of woven carpets (in the classic sense with pile material) is currently taking place so that pre-dyed pile yarns are woven together with other auxiliary threads and then be latexed on the back.  

Unfortunately, there are only a few companies that still manufacture woven carpets. Since the 50s Years of tufting technology, carpet weaving mills were able to No longer hold price pressure because weaving is much more expensive than tufting. Weaving machines working approx. 12 to 13 times slower than tufting systems, which is extremely important for the Goods price affects.

With appropriately equipped weaving machines, for example with jacquard equipment (cf. The modern carpet lexicon by Kurt Reichelt, RS Textil-Verlags-Kolleg GmbH, Duden hofen, 2nd extended edition 1989, page 66), on the other hand, can be considerably more complete More patterns than tufting can be achieved. When weaving - especially when manufacturing the provision of jacquard-patterned qualities - such as three-color pattern, three times as many pile yarns are added as with tufting, they must attached to the creel and checked during weaving; additionally the auxiliary or construction threads are added. An elaborate, sw res thread system that can not be compared with clothing fabrics or the like.

It is known and has been industrially common for approx. 25-30 years, tufted carpets initially from raw white yarns to make them as semi-finished products depending on the desired color or color combination.

With tufted carpets, pile yarns become a dimensionally stable tear sewn in germ material. This so-called tufted raw material is relatively soft and flexible. she can therefore be easily carried out in or through a dye bath. Only after dyeing Exercise is made by backing one or two latex layers and a pad (e.g. double weave, fleeces...) the sewn-in pile yarn solidifies. As a result, the ge desired and required dimensional stability, strength and rigidity of the tufting tep reached pichboden.

To the above anyway the slow operation of the weaving machines add up high set-up costs because every time a different color or color combination is woven the weaving machine has to be converted to put on other yarns with different colors bring. The weaving machine cannot produce during this time. As a result, the benefit fect worse and the web price continues to rise.

The weaving mill today creates very high-quality products, especially flake or strand have colored wool as pile material; jute and Cotton yarn used. Some companies that weave polyamide dye it in the flake, which is then spun into yarn and then woven.

The implementation of the piece color tufting system on woven carpets is according to the description perhaps close to this connection. But still, it was previously considered impossible see a webware - especially if it is four or even five meters wide points - to dye in one piece.

In addition to the ones described above, there are other reasons why piece dyeing Make tufting processes seem unsuitable for woven carpets: The weaving industry produ mainly adorns very classically designed carpets, mostly made of multicolored patterned wool. Piece coloring can only create two colors; these in different shades, but not anymore. The far greater obstacle is that the woven carpet the first is very stiff and firm and the second is inherently unstable. This means that the me Chanian burden of dyeing the pure yarn construction, which is a woven product in Ge contrast to tufting goods, would lead to the goods shifting within themselves severely warped in both the longitudinal and transverse directions, making it unusable.  

The trend and tendency of the market clearly point in one direction today, although less looking for a lot of colored carpet after color and design was "on the top" in the 80s, but rather turns to surface structures and patterns, which in detail do not colored, but are much more individual in their design. Through webtech Such surfaces and patterns can be designed that will be of importance in the future could be. Especially in a carpet market like Germany or Europe, in Contrary to the US market due to today's high level of individuality in the Interior furnishing ever larger range (color) palettes but smaller menus at the same time gene units used.

The claimed invention is based on the problem that it has not hitherto been technically possible It was possible to do the same with tufting for the manufacture of woven carpets. Therefore was the woven carpets - especially constructions using the rod or Wilton technique - previously considered unsuitable for piece dyeing.

Accordingly, the object of the invention is to create a woven carpet, whose construction and manufacturing process is designed to be economically advantageous and can be flexibly colored in small quantities.

To solve this problem, a woven carpet and / or a method for producing egg nes woven carpet, which at first glance looks at a well-known product has construction, but is advantageously characterized in that it predominantly from raw white yarns, but with the formation of a special fabric edge that will later be used is described in more detail, woven and then as a semi-finished or so-called raw material allows to be stretched and in this state by a continuous, Coloring solution applied simultaneously across the entire width of the fabric and finally getting latexed on the back.

Preferred embodiments of the invention and others achievable with the invention Advantages result from the following description. In the subclaims claimed such advantageous embodiments of the invention.

Contrary to the prevailing opinion and criticism from experts both from Konstruk tion and chemistry side has in the production following the intellectual invention try confirmed that the production of woven carpet from raw white yarns is possible and this association can be colored very safely if the material used, the Construction and the procedure carried out with regard to the required characteristics and Properties of the goods is selected and in turn the construction of the goods so trained Det is that existing production facilities can safely process the goods. Much more woven carpets produced according to the invention even have product-specific advantages in the way that the goods are compacted and thus the later ones Improve the product's durability, wearing and cleaning properties.

In this context, the utility model 74 36 681 from Girmes / Grefrath mentioned, which describes the production of a special clothing pile fabric, according to raw white weaving is dyed. It is pointed out to different coloring options sen, including the possibility of continuous dyeing.  

This document suggests a similar procedure for woven carpets not to be removed. This clearly shows how removed the piece dyeing from woven carpets even stands for companies that produce both woven fabrics and carpets and all Have production possibilities themselves.

Polyamide in one or more is used as the pile material for the woven carpet according to the invention Ren affinities proposed, mainly from spider made of polyamide fibers that are spun secondarily or from polyamides that are in one or more stages process have been extruded into an endless yarn, drawn, textured (BCF yarns bulk continuos filament) and / or fixed again.

One or more of these raw white yarn types become synthetic with the help of others Basic and auxiliary threads preferably a specially constructed raw white carpet woven fabric Made using the Wilton technique, on so-called rod looms.

The invention provides important details in the construction of the goods here:

• a.) A firm, inlaid, very wide selvedge, which the needling of the guide bands of the Continuous dyeing makes it possible and the goods are so evenly and controlled by dyeing and drying can be performed.
• b.) A pile thread construction z. B. according to the well-known Wilton weaving technique, which ideally has dyeable threads of every type of dye used at every point of the raw fabric. The poured-on dye solution can be bound regardless of the design.

If, however, this raw material were available in "pure white" after weaving, it would have been Patterns cannot be checked for errors during web production, resulting in would have suffered the consequence that the defects would only have been recognized after dyeing. We Considerable to the feasibility of the invention has therefore also contributed to the idea at ge to have a yarn type signed for the desired two-tone color of the end product. This means that after the raw white yarn production, the yarn which is the effect thread usually only has the smaller proportion, which is provided with a dye that later becomes easy can wash out. In this way, the sample image can be seen on the weaving machine and is therefore open ne accuracy can be made controllable. Web errors that may occur can occur immediately be recognized and eliminated.

But a differently designed visualization of the different yarns can also be used Execution come such. B. the marking of the spinning mass or the later over-coloring already slightly dyed yarn.

By forming the particularly firm, wide fabric edge on both long sides of the Raw white weave is the needling on the needle bands of the continuous dyeing and La texturing system enables. An inlaid edge from the already is particularly suitable existing synthetic basic and auxiliary threads, but without woven-in pile material, which limits the sides of the raw white goods. Likewise, a leno edge or another comparable web system form the wide, firm edge. So the goods - also in large width - with defined strong tension, which however does not stress one point too much and at the same time, the woven thread system is tensioned, safely guided through both production processes will. Especially the hot temperatures of the dye fixation are well tolerated and after dye fixation, the goods are even more stable than before.  

The dyeing of the raw white woven fabric is carried out on a so-called continuous system (cf. The modern carpet lexicon, op. cit., p. 73). So far, such Systems only for fast and uniform dyeing of very large batches of tufted goods turns. The advantages of this type of dyeing are that the goods are guided through the system is uniform and the goods always remain under tension and therefore do not warp or folded in an uncontrolled manner, compressed or uncontrolled loads (such as uneven Tensioning and pulling). The taut, raw white surface of the goods becomes quasi pulled under a dye solution "waterfall" (or passed through a dye bath) and then fixed, washed and dried.

After dyeing, the dyed raw material is washed with a high quality, suitable webwa ren-latex on the back, as is usually done with woven carpets. Everything However, with a fully synthetic construction, special attention must be paid to latex tion can be used. You must in order quantity, latex content, viscosity, mechanical Application to be precisely matched to the synthetic thread construction. The latex tion must be set so that the goods are firm and the pile threads are solidified, but with the later laying can still be braced (see also described later in Example 2, "smooth" threads in the lower and possibly upper structure).

Technical product improvements and economic aspects of the invention conventional production according to the state of the art:

The invention enables a lot - by favoring the Wilton or rod weaving technique most extensive possibilities of surface design such as velor, loop or combinations from both that are not possible with tufting. Combined with that by the invention possible flexible colors result from the most comprehensive pattern design and Conceptual options.

You can even create strong geometric patterns four or five meters wide the. Dimensions beyond this are also conceivable.

By dyeing only after the yarn is woven in because of the contact of the pile yarn with Water and heat a desired yarn shrinkage instead, which relax the pile yarn, shrink fen and thereby puffed up and thus provides an additional solidification. The pole over the weaving becomes evenly denser and more compact.

A first dyed and then woven comparable polyamide material (e.g. solution dye Yarn) cannot have this advantage. So the production is also special low and firm carpets possible without being denser only in the longitudinal direction becomes. During the loop carpet production over a width of four meters in the Wilton-Rutenwebtech With older weaving machines, only higher metal rods can often be entered. The The consequence is a pole that is higher than 4 mm. But by the one taking place during the coloring Shrinkage takes place an additional compression, that ultimately a lower pole - after coloring approx. 2.5 to 3 mm - results and here too compact, low and firm Goods can be achieved.  

In addition, there is increased production reliability, since an error occurs during weaving dyed yarn can easily result in a dyed yarn of the same batch no longer is available, thus the entire production or parts of it, "get lost". Same This also applies if the amount of yarn is insufficient for any reason. Go here Times for the new procurement irretrievably lost. In contrast, it is due to the Er possible piece coloring without problems, since a correction of a possible error easy and with little effort, especially because of the stock of raw goods, even at short notice, can be done.

By producing raw white woven goods, it is no longer necessary for each new one Color of a design of the same structure, a completely new weaving must be started.

So it is now possible, regardless of color-specific orders for raw goods to produce one or more defined designs and store them until a corresponding one Order of the respective design is available. Then the desired quantity in the ordered Coloring can be dyed and latexed and is therefore available at short notice - similar to tuft goods - ready for delivery.

This results in improved competitiveness. Is the web raw material worn out? appropriate pre-planning, can - for order production as well as for special color requests - can be delivered at very short notice. The webware can therefore be compared to the often very fast delivery times of tufted goods and needle felt can be made competitive.

Production costs are also significantly lower. The raw white production of one (or several patterns) can now take place in ideal configuration. That means one ideal or the largest possible amount with a thread attachment, for example in a design is produced. The result is maximum cost-effectiveness in the weaving process, because of the long set-up times on the machine and often lengthy pattern settings causes high costs. Thanks to the optimized production, the weaving machine itself better utilized and less frequent.

The invention gives an estimated cost advantage of about 20 to 30% compared to the conventional method when color batches of 400 to 800 m ^{2 are used as the} basis. Often there is certainly also the possibility of achieving even better effectiveness by improving the gate construction (accommodating larger coils).

Finally, the invention also serves to protect the environment, since it means less waste already finished, i.e. dyed, yarn. Ensuring every affinity for everyone Spot, at every point of the woven fabric, no dye is left unbound even during dyeing run off, which would give sewage problems.

Another advantage of the invention lies in the fact that the method can now be implemented Wool qualities mainly on weaving machines and with construction threads from nature fibers such as jute, cotton, etc. are made.

But if wool is now woven with synthetic construction and auxiliary threads, one is Raw white wool production and later dyeing are conceivable. The objection that wool in the Coloring felt, can be countered with the coloring on the continuous system. Here takes place in Compared to the usual stain dyeing a much lower and harmless mechanical Stress instead.  

Wool can be dyed with the same class of dyes as the polyamide-acid affinity Type. Wool can also be chemically treated in the undyed raw state so that it is possible It is possible to achieve light and dark shades of the same color in a dye bath. So can a carpet made of 100% wool can be made in two shades. It should also be particularly emphasized that it is possible to make a contrast with the wool obtain color when wool is used in the background and the effect is polyamide basic Affinity type as a suitable spun yarn construction.

In addition to polyamide and wool, other fibers and filaments are of course also conceivable, such as Cotton, silk and all other fibers, which are also otherwise due to chemical accumulation defined by dyes to be colored.

Example 1 - Patterning technique

Using the example of the possibilities of a Wilton weaving machine with jacquard equipment The application of the invention for a two-color product is explained below:

Thread feeding on the weaving machine

In order to produce 2-choir patterns in 2 colors, the weaving machine is fed into each feed both raw white yarn (e) A (for later color A - fund acid affinity) as well as raw white Yarn (s) B (for later color B - basic affinity) brought.

Weaving / production

Now a desired pattern is woven. The weaving machine works so that - depending on the Mu The stipulation for each defined point of the goods - always the raw white yarn pimple A or B partially brought to the top of the goods.

Theoretically, the existing indentation can now be used at short notice. H. with the same Another slip pattern can also be set.

Different yarn options

In addition to polyamide with all of its affinities known in tufting and use there specialties such as the use of so-called space yarns or solution dye Yarns, also as fancy yarns, can begin with a wide variety of yarn constructions from Saxony yarns from BCF, spun yarns of every conceivable construction to open Intermingled yarns can be used.

After the complex Wilton-Rutenstuhl technique, the raw white dyeing process allowed, it is also possible that the process is based on the Axminster weaving technology Double carpet weaving technology or also mechanically produced relatively stiff and rigid Transfer carpets. This also includes all variants of rustled carpets including in particular the double technology and the new loop carpet knitting process the Malimo machine factory (here unused pile threads are used in the upper or View loop).

The prerequisite is that the necessary parameters and materials are used here too.  

Example 2: Appropriate construction and process execution

A Wilton weave construction is made according to the following - known - weave construction. Particular attention must be paid to a broad, firm and, if possible, inserted selvedge.

in which
Pile / pile yarn: DU PONT PA 6.6 ANTRON 1350 dtex × 2,200 T / m,
(2 yarns per feed)
Fond yarn: regular affinity (yarn A)
Fancy yarn: basic affinity (yarn B)
approx. 900 g / m ²
Binding chain: polyester / viscose yarn (70% / 30%), Nm 8/3; approx. 125 g / m ²
Filling chain: Fibrillated polypropylene yarn, 2500 denier Nm 3.6 / 1; approx. 350 g / m ²
Weft: Fibrillated polypropylene yarn, heat set, 2500 denier; approx. 115 g / m ²
Graduation: 30 reeds, ie 30 indentations per 10 cm
Shots: 68 shots per 10 cm, ie 34 rows of pole loops per 10 cm
Feeder: Two pile yarns per feeder.

The edges were made as follows: approx. 4 to 5 cm wide, only formed from the existing ones Construction and auxiliary threads, without pile material, inserted.

It doesn't matter whether the velor or loop version is used. Here is based on the more difficult to weave loop technology explains the principle. Other variants, such as Examples of woven or semi-woven variants are the same as flat-woven ones Wilton constructions possible. If a pattern is desired, depending on the number of colors and pattern request, both a shaft device or a jacquard machine for production be used. One to three yarns can also be used per feed.  

Latexing

Latex: Synthomer VL 10505 and Syn thomer VL 10429
Applicator roller: counter-rotating
Order quantity: approx. 330 Ts / m ²

= 330 g / m ²

Achieved, characteristic test values of the new woven carpet construction

Chair leg test (DIN 54 324): grade 3.5
Chair role test (DIN 52 316): grade 2.8 *
Classification hard wearing (DIN 66 095 T2): extreme
Comfort value rating (DIN 66 095 T2): good
Estameter charge test: 0.55 kV
(Target <2 kV)
Radiant panel test: ∅ = 0.78 W / cm ²

(DIN 4102/14 target <0.45 W / cm ²

): B1
Volume resistance (DIN 66 095): 2.2 × 10 ⁸

Ω
Surface resistance (DIN 66 095): 3 × 10 ⁹

Ω

* z. Cf. A conventionally produced, comparable product only got the grade 2.4!

Claims (14)

1. woven carpet and / or method for producing a woven carpet, characterized in that it consists of a pile material and other construction threads, the weave construction has a loop and / or velor surface and has specially formed edges in the longitudinal direction and - regardless of the later Coloring - initially woven only from raw white pile yarns, depending on the design, and then dyed continuously, ie lengthways, in a stretched state using a dye liquor applied across the entire width of the fabric. 2. woven carpet and / or method for producing a woven carpet according to claim 1, there characterized in that after weaving and coloring a back latexing is brought. 3. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that it before is preferably produced by the rod or Wilton weaving technique. 4. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that it is a Can have a width of up to four or five meters or more. 5. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that as Construction threads predominantly synthetic yarns are used. 6. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that as Raw white pile yarns are mainly polyamide yarns of all types and types, So in addition to pure white also those polyamide yarns that are already colored by pretreatment are. 7. Woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that as Pole material preferably polyamide types of different affinities to achieve a later multicolor come into question. 8. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that in addition to Polyamide material also used other dyeable textile materials as pile material as well as different material mixtures. 9. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that the Weave a firm, particularly wide, possibly inlaid edge without woven-in Pole material that limits the sides of the raw white goods, or a leno edge or a ver similar web system forms the solid edge.   10. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that the Density of the weave a sufficient resistance to displacement of the warp and weft ge lasts. 11. Woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that each all necessary affinities for dye absorption are available at the location of the top of the goods stand. 12. Woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that the Coloring defines yarn-specific happens. 13. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that the The dyeing process does not compress or wrinkle the woven raw material, but in a taut state leads. 14. woven carpet and / or method for producing a woven carpet, in particular according to one or more of the preceding claims, characterized in that it is a Wall or flooring is used.