METHOD AND APPARATUS FOR THE MANUFACTURE OF CARPET

Abstract: A carpet includes a weft fill material (18c) which fills the loops formed in the pile of warp yarns (14a and 14b) so as to be partially visible and contribute to both the design and appearance of the resultant carpet and the durability by supporting the inside of the loops formed by the warp yarns (14a and 14b). The binding chains (17a and 17b), with the wefts (18a and 18b), bind the pile warp yarns (14a and 14b) to the carpet backing with the stuffer (16) being held securely between the wefts (18a and 18b). In alternative embodiments the binding chains (17a and 17b) can be partially or totally omitted with the warp yarns (14a and 14b) being fed over and under the stuffer (16). Apparatus for forming the carpet is described.

Description: METHOD AND APPARATUS FOR THE MANUFACTURE OF CARPET BACKGROUND OF THE INVENTION The present invention relates to improvements in and relating to a method and apparatus for the manufac¬ ture of carpet and to a carpet manufactured thereby. To the present time various types of carpet such as Wilton can be manufactured by various techniques in producing a commercially acceptable product. The term "carpet" is used throughout this specifi¬ cation to cover all types of woven surface covering. Presently available techniques for making woven carpet suffer from various disadvantages including the complexity of the looms. The Wilton wire loom requires for example a multiplicity of pile wires to be inserted and withdrawn leaving the pile as a hollow loop or is cut open by a bladed wire. These hollow loops also have the drawback of contributing to the flammability of the carpet in providing a source of oxygen for any flame within the pile. Existing production techniques may also tend to suffer from a certain lack of flexibility in allowing ease of change of carpet patterns. It is thus an object of the present invention to provide an improved method and/or apparatus for the manufacture of carpet and/or an improved carpet, over¬ coming or at least obviating the disadvantages in meth¬ ods, apparatus and/or carpets available to the present time or to at least provide the public with a useful choice. Further objects of the invention will become apparent from the following description. BRIEF SUMMARY OF THE INVENTION According to one aspect of the present invention there is provided a method for the production of carpet comprising weaving together warp and weft materials and including an additional weft material to be held by and to be partially visible through the pile warp material. According to a further aspect of the present invention there is provided an apparatus for producing carpet comprising means for feeding weft and warp material to a weaving means for their weaving together and wherein said feeding means includes means for feeding an additional weft material to be held by and to be partially visible through the pile warp material. According to a further aspect of the present inven¬ tion there is provided a method for the producing of carpet substantially as herein described with reference to any one of the embodiments of the invention. According to a still further aspect of the present invention there is provided an apparatus for producing carpet substantially as herein described with reference to any one of the embodiments of the invention. According to a still further aspect of the present invention there is provided a carpet produced by the method and/or apparatus of any of the four paragraphs immediately above. According to a still further aspect of the present invention there is provided a carpet comprising weft and warp material woven together with an additional weft material held by and partially visible through the pile warp material. According to a still further aspect of the present invention there is provided a carpet substantially as herein described with reference to any one of the embodiments of the invention. Further aspects of the present invention which should be considered in all its novel aspects will be¬ come apparent from the following description given by way of example of possible embodiments thereof and in which reference is made to the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figures IA, IB and 1C: Show very diagrammatically examples of "prior art" carpet manufacture; Figures 2A and 2B: Show very diagrammatically cross-sectional and perspective views of carpet according to one possible embodiment of the present invention; Figure 3; Shows very diagrammatically a side perspective view of a carpet loom according to one possible embodiment of the invention; Figure 4t Shows very diagrammatically a plan view of the loom of Figure 3; Figure 5; Shows very diagrammatically shedding detail of the loom of Figures 3 and 4; Figure 6: Shows an alternative shedding detail according to a further embodiment of the invention; Figure 7; Shows an alternative shedding detail according to a further embodiment of the invention. DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION In the understanding of the invention the following is a glossary of the terms which have been used with their intended meanings: Flammability - The extent to which a material is flammable. Rapier - A metal rod which carries weft material and inserts a length into the open sheds which is then cut. Dent - A space between two vertical wires in the reed, similar to a comb. Warp - Yarn material used for the backing or pile and running in a linear direction. Weft - Yarn material running in a transverse direc¬ tion. Shed - The intermittent space created between the yarn materials during the weaving cycle to allow insertion of the rapiers carrying weft yarns. Wire - A metal wire strip typically 0.200" high by 0.050" thick, used to form pile loops, which may remain hollow or may be cut open, in weaving Wilton pile products. Beat up arm - The mechanism carrying the reed which "beats" the materials together tightly. Weft fill - The additional weft material contributing to the pile and provided by the present invention. Heald wire - A wire with an eye approximately half way up its vertical length. Breast plate - A flat plate supporting the point of weave. Point of weave - The focus of all the warp and weft materials, the point where individual materials become the carpet. Yarn - One or more synthetic or natural filaments or fibres, including several twisted together. Pile - The generally vertical material above the backing. Backing - The structure providing stability and a base for the pile. Binding chain - Warp yarn woven in a chain like manner to link all components tightly together. Stuffer - Warp yarn laying straight in the backing, woven under heavy load and providing linear stability and strength. Weft presenter - The mechanism which presents the wefts for pick up by the rapiers. Shot - A single insertion of weft. Beam - Metal "bobbin" type holder for the backing material. Cheese - Material wound on a tube (a tube is a bobbin without flanges) . Dobby - A mechanism for activating warp yarn materials in groups to give simple designs and visual effects. Jacquard - A mechanism for activating individual warp yarn materials in any programmed sequence to give more complex designs and visual effects. Creel - A frame holding hundreds of "cheeses" of pile yarn material. Referring firstly to Figures IA, IB and IC, these show very diagrammatically examples of prior art carpet structures. The very diagrammatic cross-sectional view in Figure IA shows binding chains la and lb forming a chain of links which, with wefts 3, bind the pile warp yarn 4 to the backing. The stuffer 2 lies straight in the centre of the backing. The binding chains la and lb alternately connect with wefts 3, which in turn bind pile warp yarns 4a, 4b. In Figure IB, the binding chains la and lb and the wefts 3, bind the pile warp yarns 4a and 4b alternately to the backing. Once again the stuffer 2 lies straight in the centre of the backing. The carpet of Figure IB is a Wilton type carpet with the hollow loops of the pile warp yarns 4a and 4b being formed by pile wires which are sequentially inserted and withdrawn during the carpet manufacture. In Figure IC, the binding chains la and lb and the wefts 3, bind the pile warp yarn 4 to the backing. The stuffer 2 lies straight in the linear direction through the centre of the backing. The carpet of Figure IC is a Wilton type carpet with hollow loops of pile warp 4 being formed by pile wires which are sequentially inserted and withdrawn during the carpet manufacture. The term "Wilton" generally refers to a loop pile or cut pile carpet but due to the versatility of the Wilton loom, the term can be regarded as a generic term covering many styles of products such as those shown in Figures IA, IB and IC. In the Wilton wire loom, t * he backing materials are brought together to make the backing for the pile mate¬ rial, in the traditional weaving method of combining warp and weft materials. Concurrently with the production of the backing the pile is formed by inserting a succession of metal wires under the pile yarn material which is raised to a higher plane than the backing materials to accommodate the wires. As weaving proceeds, the first wire (the wire nearest the operator) from a set of say 30 such wires is withdrawn to leave a row of hollow loops above the backing of the carpet. These wires are withdrawn and inserted in a sequential manner providing a constant supply of wires. The cycle of all necessary actions in the formation of each row of loops across the width of the product requires two, and in some cases more, revolutions of the crankshaft central to the loom function. The complexity of the Wilton loom with its requirement to sequence the insertion and withdrawal of a multiplicity of long wires has inevitably resulted in a relatively slow process time. In contrast, the present invention does away with the use of such wires and permits a single cycle operation as opposed to a multi-cycle operation to further speed up the production rate and in doing so achieves a carpet which has inherent advantages over previous types of carpet produced such as by the Wilton loom. It is useful to refer in greater detail to the Wilton wire loom. This type of loom generally weaves a two shot construction. By its very nature, each shot must be inserted separately, the back shot simultaneously with the wire insertion and the second shot coinciding with the wires withdrawal, binding the pile yarn just used over the wire to the backing of the carpet. The shedding provides open sheds as appropriate to accept both the shots of weft and the wire but the two shots and the wire cannot be accommodated simultaneously. This situation results in a slow production rate, for example, a typical Wilton wire loom of 1.5 metres width would weave at a rate of about 70-75 picks or shots per minute. Each row of loops requires two shots, so that weaving a carpet of a linear density of 315 rows per metre, the Wilton loom will produce, at 100% efficiency 75 x 60 = 4500 picks % 630 = 7.14 lineal metres per hour. The present invention in one embodiment however in trials, weaving 1.5 metre width carpet, has run at 73 insertions/minute = 73 x 60 - 4380 picks. However, each insertion creates one row of loops so this total is only divided by 315 - 13.9 lineal metres per hour. It is anticipated that the increased production rate will apply in comparison to any width of loom. A loom according to one possible embodiment of the present invention can provide open sheds to accommodate all three weft components, the top shot, the bottom shot and the weft fill instead of the wire and hence the completion of each row every cycle rather than the need for two cycles as in the Wilton wire loom mentioned above. The 100% efficiency mentioned above is of course never achieved. A Wilton wire loom could normally be expected to run at approximately 65-70% efficiency. It is envisaged that because of the simplified design of a loom according to the present invention with its lesser number of parts and the lack of the complex wire insertion/withdrawal mechanism which can account for much of the total down time of the Wilton loom, an efficiency of perhaps 70-80% for the present invention is believed to be feasible. Referring to Figures 2A and 2B, a carpet according to one possible embodiment of the invention is referenced generally by arrow 10 and is shown very diagrammatically in cross-sectional and perspective views. Figures 2A or 2B show a group of warp yarns contained in one dent of which there may be typically 270-360 per metre across the width of the product although a wider range is possible typically from at least 120, with bulkier yarns to 480 or more with finer yarns. In Figures 2A and 2B, binding chains 17a and 17b form a chain of links which with wefts 18a and 18b bind the pile warp yarns 14a and 14b to the backing, the stuffer 16 being held securely between wefts 18a and 18b. It is seen however that an additional weft material 18c is provided to fill the loops formed in the pile of warp yarns 14a and 14b. This "weft fill" 18c will therefore be partially visible and so will contribute to the design and appearance of the resultant carpet. It has been found that just from two or three specified shades, several pile yarns 14a and 14b and weft fill 18c can be assembled, using solids and stipples, and these can be woven to give many permutations of different colour and effect combinations because of the contribution to the design and appearance by the weft fill 18c. Various other advantages may, the applicant believes, be achievable from the introduction of the weft fill 18c, including: i) An improved appearance retention; ii) A increased durability for the same weight and/or reduced weight for the same durability; iii) An improved resistance to flammability; iv) An improved resistance to fibre loss; v) Ease of cleaning; vi) Resistance to staining; vii) Less weight of carpet resulting in easier handling and installation; and viii)Reduced friction to devices moving over the carpet. On the flammability aspect, it will be appreciated that in a typical Wilton product as described previously in respect of Figures 1, the hollows provided within the pile loops are believed by the applicant to provide a source of oxygen which will sustain any flame present in or on the carpet. In contrast the weft fill 18c is taking up what otherwise would be an oxygen containing space and must therefore reduce the amount of oxygen available for feeding any flame. The weft fill 18c is also providing an intermediate layer to support and absorb pressures imposed on the warp yarns 14a and 14b so as, it is believed, to improve durability and appearance retention as mentioned above. Alternative embodiments of the invention may provide different carpet structures to that shown in Figures 2A and 2B. For example the pile yarn material 14a and 14b may be fed over and under the stuffer 16 in eliminating the use of the binding chains 17a and 17b relying on friction to hold the structure together and prior to a backing coating being applied. The production of such a structure is described hereinafter in respect of Figure 6. Any suitable materials could be used for the carpet of the present invention. For example the backing mate¬ rials may be polyester and glass fibre or polypropylene with the pile warp and weft fill being woollen yarns. Alternative materials and alternative techniques of weaving same will be readily apparent to those skilled in the carpet making art. Referring now to Figures 3 to 5, a loom according to one embodiment of the present invention is referenced generally by arrow 100 and shows very diagrammatically the woven product 101 being produced to be fed on to a roll 113. A platform 112 is shown provided for an op¬ erator of the machine. The loom 100 is shown having a breast plate 102 being fed by a reed 103 with the pile yarn 104, stuffer yarn 106 and binding chain yarn 107. The breast roller 130 pulls the warp material and the woven carpet through the loom at a preset rate relevant to the linear density of the carpet. Rapiers 108 act in feeding the weft material into the open sheds. The beat up arm 109 carries the reed 103 to beat the materials together tightly. 118 shows the heald drive operating the heald wires 105 (see Figure 4). In Figure 5 the sheds (spaces) are shown open so that the rapiers 108b and 108c carrying the weft and 108a carrying the weft fill can be inserted simultane¬ ously. The stuffer warp 106 remains stationary through¬ out the weaving cycle. During the weaving cycle, binding chain warps 107 exchange positions with each other at the same time as the pile yarns 104 exchange positions with each other. The binding chain warps 107 and the pile yarns 104 are driven up and down by the heald wires 105. Each of the heald wires 105 is shown provided with an eye 120 through which binding chain warp 107 and pile yarns 104 can pass. While four heald wires 105 are shown in Figure 5, it is envisaged that additional or less heald wires could be used in alternative embodiments. The heald wires 105 connect to a cam disc arrangement or Dobby to control the required patterning. Connecting the heald wires 105 to a Jacquard will allow for more detailed patterns to be produced. In use, beat up arm 109 carrying reed 103 is driven forward to a point just short of the leading edge of the breast plate 102 as shown in Figures 5 and 6. This is the point of weave where the warps 104 and 107 are approximately half way through their vertical movement and are more or less in a horizontal line together with warp 106 extended from the breast plate 102. The reed 103 beats up the three wefts previously inserted by the rapiers 108a, 108b and 108c into the carpet and the exchange of all the warp positions is then completed immediately following this in readiness for the next weaving cycle. Figures 3 and 4 show generally the positioning of the pile yarn cheeses 116, the stuffer beam 110, the binding chains beam 111 and the tension weights 119. The pile yarn cheeses 116 are shown provided on a creel frame 115, with respective creel weights 117. Returning to the enlarged diagrammatic view shown in Figure 5, it is seen that three rapiers 108 are used, rapiers 108b and 108c for carrying two wefts and top rapier 108a for carrying the weft fill (18c in Figures 2A and 2B) . In an alternative embodiment shown in Figure 6, it is seen that only one rapier 108a for the weft fill and one rapier 108b for the weft, are shown provided. Also, the binding chain warp yarn 107 is absent in this em¬ bodiment and instead the yarn pile 104 is being fed over and under the stuffer warp yarn 106 to combine with the weft fill and weft material. In yet a further embodiment shown in Figure 7, it is seen that two rapiers 108 and 108b are used to incorporate binding chains 107 either in the usual number of two per dent or any chosen reduction desirable to approximately the same extent as the pile warp thus providing for tighter binding of the weft fill. It will be appreciated that the rapiers 108 each comprise a pair of centre transferring rapier members working together to feed in, and to receive, the weft material respectively. Other types of weft insertion could however be used. It is thus seen that the method and apparatus of the present invention achieve the insertion of a weft fill pile yarn material which is tightly retained to form part of the pile thus avoiding the hollow loops remaining from the Wilton wires. This is therefore much simpler and faster than using a typical Wilton wire loom and, due to the lesser number of machine components, is notably quieter and easier to operate and maintain. The resultant product due to its use of a weft fill material also has inherent advantages as mentioned above. Where in the foregoing description reference has been made to specific components or integers of the invention having known equivalents then such equivalents are herein incorporated as if individually set forth. Although this invention has been described by way of example and with reference to possible embodiments thereof it is to be understood that modifications or improvements may be made thereto without departing from the scope of the invention as defined in the appended claims.

Claims: CLAIMS 1. A method for the production of carpets comprising weaving together warp and weft materials and including an additional weft material to be held by and to be partially visible through the pile warp material. 2. A method as claimed in claim 1 including the step of forming a pair of pile warp yarns into loops and positioning said additional weft material within said loops. 3. A method as claimed in claim 2 including the step of feeding said pile warp yarns over and under a stuffer warp yarn. 4. A method as claimed in claim 2 wherein binding chain warp yarns are provided and are fed over and under said weft materials and a stuffer warp yarn. 5. A method for the production of carpets substantially as herein described with reference to any one of the embodiments of the invention of the accompanying drawings. 6. Apparatus for producing carpets comprising means for feeding weft and warp material to a weaving means for their weaving together and wherein said feeding means includes means for feeding an additional weft material to be held by and to be partially visible through the pile warp material. 7. An apparatus as claimed in claim 6 wherein said feeding means for said weft material comprises a plurality of rapiers respectively carrying one of said weft materials and said additional weft material, said additional weft material being provided within loops formed by said warp material. 8. An apparatus as claimed in claim 7 wherein said warp material includes binding chains which are positioned over and under said weft materials and a stuffer warp material. 9. An apparatus as claimed in claim 6 wherein the feeding means for said weft material and said additional weft material each comprises a respective rapier, the warp material being fed over and under a stuffer warp material to combine with the weft material and the additional weft material, said additional weft material being provided within loops formed by said warp material. 10. An apparatus for producing carpets substantially as herein described with reference to Figures 3 to 5, Figure 6, or Figure 7 of the accompanying drawings. 11. A carpet comprising weft and warp material woven together with an additional weft material held by and partially visible through the pile warp material. 12. A carpet as claimed in claim 11 wherein the warp material includes pile warp yarns defining loops within which said additional weft mater-ial is positioned. 13. A carpet as claimed in claim 12 wherein said warp material includes a stuffer warp yarn and binding chains with said binding chains being positioned over and under said stuffer warp yarn. 14. A carpet as claimed in claim 12 wherein said warp material is provided over and under a stuffer warp yarn. 15. A carpet substantially as herein described with reference to Figure 2 and/or when made by the method of any one of claims 1 to 5 and/or when made by the apparatus of any one of claims 6 to 10.

Inventors: CARLSON BRIAN, CARLSON, BRIAN
Applicants: CARLSON BRIAN, DURALITE CARPET CORP LTD, CARLSON, BRIAN, DURALITE CARPET CORPORATION LIMITED
Application year: 1993
Main classification: D03D27
IPC codes: D03D27, D03D39