Advances in Carpet Manufacture

Cover Page
......Page 1
Advances in Carpet Manufacture......Page 2
Contents......Page 4
Contributor contact details......Page 8
Woodhead Publishing in Textiles......Page 10
1.1.1 Residential use......Page 14
1.1.2 Commercial use......Page 15
Thermal insulation......Page 16
Acoustic insulation......Page 17
Wool......Page 18
Polyamide......Page 19
Polyester......Page 21
Polyacrylate......Page 22
Polypropylene......Page 23
Wilton......Page 24
Gripper jacquard......Page 25
Spool-gripper......Page 26
Tufted carpets......Page 27
Other methods......Page 29
1.4.3 Influences......Page 30
Textbook......Page 31
2.1 Introduction......Page 32
2.2.1 Wool fibre......Page 33
2.2.2 Silk fibre......Page 35
2.2.4 Jute fibre......Page 36
2.2.5 Acrylic fibre......Page 37
2.2.6 Nylon fibre......Page 38
2.2.7 Polypropylene fibre......Page 39
2.3 Carpet yarn manufacturing......Page 40
2.3.2 BCF polypropylene......Page 41
2.3.6 Woollen system......Page 42
2.3.8 Comparison of woollen and semi-worsted yarn properties......Page 44
2.3.9 Worsted system......Page 45
2.4 Carpet yarn engineering......Page 46
Fibre diameter......Page 47
Medullation......Page 48
Coloration......Page 49
Blending......Page 50
2.5.1 Scouring......Page 51
2.5.2 Milling - batch process......Page 52
2.5.6 Static control......Page 53
2.5.8 Anti soil/anti stain......Page 54
2.6 Carpet yarn testing and quality control......Page 55
2.9 References......Page 56
3.1 Introduction......Page 57
Applications......Page 58
Weaving technique......Page 59
Weaving machine......Page 61
Applications......Page 62
Weaving technique......Page 63
Weaving machine......Page 64
Applications......Page 65
Weaving technique......Page 66
Weaving machine......Page 67
Weaving machine......Page 68
Applications......Page 69
Weaving technique......Page 71
Applications......Page 74
Weaving machine......Page 75
Applications......Page 76
3.5.1 Introduction......Page 77
3.5.3 Networking and process control......Page 78
3.5.4 Automated creel......Page 80
3.6.1 Complete carpet-weaving process......Page 81
3.6.2 Design possibilities......Page 82
3.6.3 Maintenance of machines......Page 83
3.6.5 Calculation of production and unit cost......Page 84
3.7 Conclusions......Page 88
4.1.1 A brief history......Page 90
4.1.2 Properties of wool......Page 91
4.2.1 Carpet wool production......Page 92
4.2.2 Wool scouring......Page 93
4.3.1 Woollen spinning......Page 95
4.4.1 TwistsetTM (formerly known as Chemset5)......Page 96
4.4.4 Felted yarn......Page 98
4.4.5 Insect-resist treatments......Page 99
4.6.1 Tufting needles......Page 100
4.6.2 Yarn supply to tufting......Page 102
Anti-photobleaching treatment......Page 103
Agents for rapid wool dyeing......Page 104
Prevention of pile reversal......Page 105
4.7.1 Performance testing......Page 106
Durability......Page 107
Tuft bind......Page 108
4.9 Future trends......Page 109
4.9.1 Marketing and promotional needs......Page 111
4.10.1 Wools of New Zealand Carpet Technical Information Bulletins......Page 112
4.11 References......Page 113
5.1 Introduction......Page 115
5.3 Types of textiles used in relation to the sports surfaces......Page 117
5.4.1 Choice of polymers for artificial turf fibres or yarns......Page 119
5.4.2 Role of the resilience of the fibres and yarns......Page 125
5.4.3 Materials and methods for resilience measurements......Page 127
5.5.1 Problem and objective......Page 132
5.5.2 Design of the test setup......Page 133
5.5.3 Measurements: temperature and sliding distance......Page 134
5.5.4 Influence of the height of strewing of infillmaterial on the sliding......Page 135
5.5.5 Calculation of the temperature increase at the surface of the skin......Page 138
5.6 Future trends......Page 141
5.7.1 Existing artificial turfs......Page 143
5.7.2 Costing of turfs......Page 144
5.7.3 Advantages of artificial turf fields......Page 145
Rubber infill......Page 146
5.7.5 Conclusions concerning existing artificial turf fields......Page 147
5.9 References......Page 148
6.1 Introduction......Page 151
6.2 The history of handmade carpets......Page 152
6.3 Modern handmade carpet production......Page 156
6.4 Carpet production in India......Page 157
6.5 Carpet production in Iran......Page 161
6.6 Carpet production in China......Page 163
6.7 Carpet production in Pakistan......Page 164
6.9 Carpet production in Turkey......Page 165
6.10.2 French carpets......Page 167
6.10.3 English carpets......Page 168
6.11.1 Handmade carpet export, import and the market share as at 2001......Page 169
6.11.6 Value and volume......Page 170
6.13 The role of handmade carpets in modern carpet production......Page 178
6.14 Choosing and maintaining a handmade carpet......Page 182
6.15 Acknowledgements......Page 184
6.16 References......Page 185
Appendix: terminology relating to handmade carpets......Page 186
7.1 Introduction: key issues in design......Page 195
7.2.1 Afshar carpets......Page 196
7.2.3 Bakhtiari carpets......Page 197
7.2.5 Bidjar carpets......Page 198
7.2.6 Gabbeh carpets......Page 199
7.2.8 Heriz carpets......Page 200
7.2.9 Isfahan carpets......Page 201
7.2.11 Kashmir carpets......Page 202
7.2.12 Kerman carpets......Page 203
7.2.14 Nain carpets......Page 204
7.2.15 Nepalese carpets......Page 205
7.2.16 Oriental carpets......Page 206
7.2.18 Sarough carpets......Page 207
7.2.19 Tabriz carpets......Page 208
7.2.21 Turkish carpets......Page 209
7.2.22 Indian carpets......Page 210
7.3 Key stages in design......Page 211
7.3.3 Repeats......Page 212
7.5 Sheep wool......Page 213
7.5.1 Requirements for wool in carpets......Page 215
7.5.2 Wool production......Page 217
7.5.3 Wool processing......Page 218
7.6 Silk......Page 219
7.8 Other natural fibres......Page 221
7.9 Synthetic fibres......Page 223
7.10 Backing materials......Page 224
7.11 Manufacturing techniques......Page 225
7.11.1 Handmade carpet production......Page 227
Tibetan technique......Page 235
Flowchart of hand-tufted carpet manufacturing......Page 236
Chain stitch rugs......Page 238
Carpet backing for hand-tufted/hand-loom carpet......Page 240
7.12 Key terms in manufacturing......Page 242
7.13 Weaving of handmade carpets......Page 243
7.13.1 Developments in loom design......Page 245
7.13.2 Carpet washing and finishing......Page 246
7.14.2 Turkish knot......Page 250
7.14.4 India knot4±6......Page 251
7.14.5 Knot density......Page 252
7.16 Dyeing of wool......Page 253
7.16.2 Mordant dyes......Page 254
7.16.3 Acid dyes......Page 256
7.16.5 1:1Metal complex dyes......Page 258
7.16.6 1:2Metal complex dyes......Page 262
7.17 Chemical processing and dyeing of silk......Page 265
7.17.1 Dyeing methods for silk (Fig. 7.64)......Page 267
7.18 Natural colours for wool and silk carpets......Page 268
7.19 Eco-friendly and organic carpet manufacture......Page 272
7.20 Colour matching......Page 273
7.21 Quality issues......Page 274
7.22 Customer attitudes to quality......Page 277
7.23 Acknowledgements......Page 280
7.24 References......Page 281
8.1 Introduction......Page 282
8.2.1 Some basic principles and terminology......Page 283
8.2.2 A simple electronic model of electrostatic charging......Page 285
8.2.3 The role of materials in charge generation......Page 286
8.2.4 The effect of atmospheric humidity......Page 287
8.2.5 Static charge build-up on walking personnel......Page 288
Resistance-to-ground......Page 290
Vertical resistance......Page 291
Human body voltage (walking test)......Page 292
Conductive fibres......Page 293
8.4.1 Standard organizations......Page 294
8.4.2 Comparison of methods for measuring resistance......Page 295
8.4.4 Performance requirements for floor coverings......Page 297
8.5.1 Electronics industry......Page 299
8.5.3 Offices, retail and domestic environments......Page 300
8.7 Sources of further information and advice......Page 301
8.9 References and further reading......Page 302
9.1 Introduction......Page 304
9.2.2 Autoclave......Page 306
9.2.4 Suessen......Page 309
9.3.1 Batch dyeing ^ atmospheric dye beck......Page 310
9.3.2 Continuous dyeing......Page 311
9.3.3 Carpet finishing......Page 313
9.4.1 Fundamentals of drying mechanisms......Page 314
9.4.2 Drying model......Page 316
9.5 Latex curing......Page 318
9.6.2 Control measures and energy management......Page 320
9.6.3 Low wet pickup dyeing......Page 321
9.8 References......Page 322