Method for manufacturing a carpet
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Solution Overview
Problem
Existing methods for producing carpets with varying pile heights and qualities are complex, time-consuming, and expensive, and machine-tufted carpets result in additional waste when attempting to create different pile heights.
Innovation Solution
A method involving cutting and gluing carpet pieces with different qualities and pile heights, applying adhesive layers, and shearing the edges to create a seamless and stable carpet with a folded edge and backing, using ethylene-vinyl acetate (EVA) for adhesion and sheep shearing machines for precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hand-tufting is used to create carpets with varying pile heights and qualities, then high-quality individualized carpets can be produced, but the process becomes complex, time-consuming, and costly
Solution Approach 1:
The carpet is divided into multiple separate carpet pieces that can be manufactured independently using machine-tufting, then assembled together. This allows each piece to have uniform quality while the overall carpet achieves variety through combining different pieces, resolving the contradiction between quality variation and process complexity.
Solution Approach 2:
Carpet pieces with different qualities and pile heights are pre-manufactured using machine-tufting before assembly. This preliminary production of standardized pieces simplifies the final assembly process while maintaining the ability to create varied, high-quality carpets through careful selection and arrangement of pre-made pieces.
2Productivity
If machine-tufting is used to produce carpets, then production efficiency is improved, but the carpet quality becomes uniform and additional waste is generated when creating different pile heights
Solution Approach 1:
The carpet is segmented into multiple pieces manufactured by machine-tufting, each piece maintaining uniform quality. Different pile heights are achieved by selecting and arranging pieces with inherently different characteristics rather than shearing, eliminating waste while preserving productivity benefits.
Solution Approach 2:
Different regions of the final carpet are created using pieces with locally optimized qualities. Each piece maintains its uniform machine-tufted quality, but the overall carpet achieves variety through combining pieces with different pile heights and characteristics, avoiding the need for wasteful shearing operations.
3Ease of manufacture
If machine-tufting is used with uniform settings, then production cost is reduced, but the ability to create different pile heights is limited and requires additional shearing that generates waste
Solution Approach 1:
The carpet is divided into multiple pieces manufactured with uniform machine-tufting settings, maintaining manufacturing simplicity and low cost. Different pile heights are achieved by assembling pieces with inherently different characteristics rather than shearing, eliminating waste while preserving ease of manufacture.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the production of high-quality carpets with varying qualities efficiently and cost-effectively, ensuring a flat and seamless finish without gaps or unevenness.
Implementation Method 1
an adhesive strip is applied, preferably using a hot glue gun, to the long sides of the edges along the formed butt line, and the carpet pieces are glued together at their edges
Implementation Method 2
an adhesive strip is applied, preferably using a hot glue gun
Implementation Method 3
an adhesive strip is applied, preferably using a hot glue gun
Implementation Method 4
the carpet pile of the turned-up edge is sheared on the back of the front carpet so that the remaining pile is approximately 3 mm long
Implementation Method 5
A third adhesive layer is applied to a volume fleece approximately 5 mm thick, with the third adhesive layer being applied to the short side of the volume fleece to form an adhesive side
Data Source
Figure 1a~1b
Figure 2
AI summary
The invention relates to a method for manufacturing a carpet (1) from different carpet pieces (2), comprising the steps: a) cutting the carpet pieces (2), b) removing protruding carpet fringes, c) arranging the carpet pieces (2) side by side, d) applying an adhesive strip (5a) to the long sides of the edges (3), and gluing the carpet pieces (2) together to form a pre-carpet (6), e) applying a first adhesive layer (5b) to the outer edges (7) of the back of the pre-carpet (6), f) folding the outer edge (7) inwards to form a folded edge (8), g) pressing the folded edge (8) to join the outer edges (7), h) shearing the carpet pile (9) of the folded edge (8) on the back of the pre-carpet (6), i) applying a second adhesive layer (5c) to the back of the pre-carpet (6), and applying a third adhesive layer (5d) to a volume fleece (9).j) Gradually applying the adhesive side (10) of the volume fleece (9) to the back of the pre-carpet (6) and smoothing the applied volume fleece (9).