Carpet Weaving with Controlled Float Lengths for Vintage Appearance
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Solution Overview
Problem
Existing methods for creating a vintage appearance on rugs through physical and chemical treatments are time-consuming, costly, and potentially hazardous, and the production of rugs with visible warp yarn floats is complex.
Innovation Solution
A carpet manufacturing method involving the interlacing of warp and weft yarns with specific insertion patterns to create regular wide and narrow floats, reducing production time and costs while achieving a vintage appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If physical and/or chemical treatments are applied to create a vintage appearance, then the vintage appearance is achieved, but the manufacturing time is extended and costs increase
Solution Approach 1:
The invention creates vintage appearance directly during the weaving process by controlling the float lengths of warp yarns, rather than applying treatments after the rug is manufactured. The weaving machine is configured with specific insertion patterns that automatically produce the desired vintage effect as the rug is being made, eliminating the need for subsequent time-consuming treatment processes.
2Manufacturing precision
If physical and/or chemical treatments are applied to create a vintage appearance, then the vintage appearance is achieved, but the manufacturing cost increases
Solution Approach 1:
The vintage appearance is integrated into the base manufacturing process through predetermined insertion patterns in the weaving machine. This eliminates the need for separate, costly chemical treatment steps that would otherwise be required to achieve the same aesthetic effect, thereby reducing overall manufacturing costs.
3Manufacturing precision
If physical and/or chemical treatments are applied to create a vintage appearance, then the vintage appearance is achieved, but health risks are presented due to chemical use
Solution Approach 1:
The invention replaces chemical treatment processes with a mechanical solution - specifically, controlling the weaving pattern and float lengths through the mechanical insertion pattern of the loom. This mechanical approach achieves the vintage appearance without introducing harmful chemicals into the manufacturing process, thereby eliminating associated health risks for workers.
4Manufacturing precision
If irregular length warp yarn floats are used to create vintage appearance, then the vintage appearance is achieved, but the production process becomes complicated
Solution Approach 1:
The invention specifies precise parameter ranges for float lengths (wide floats: 4-6mm, narrow floats: 1.5-2.5mm) that can be consistently achieved through regular insertion patterns. By defining these specific parameter ranges, the invention simplifies the production process while maintaining the vintage appearance quality, making the manufacturing more predictable and easier to control.
Data Source
Figure 1
AI summary
The present invention relates to a carpet having a vintage appearance comprising a fabric having at least a series of weft yarns, inserted in a mainly perpendicular manner and interwoven with a series of mainly parallel warp yarns, the fabric comprising a first face and a second face opposite this first face, characterized in that said fabric comprises wide floats and narrow floats such that the length of the wide floats is between 4 and 6 mm and the length of the narrow floats is between 1.5 and 2.5 mm.