Fray-Resistant Natural Yarn Carpet Using Weave Density Control
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Solution Overview
Problem
Carpets made from natural yarns tend to have threads detach at the joints after cutting, leading to stability and visual issues, with existing solutions being inadequate for non-fusible yarns.
Innovation Solution
A carpet design featuring a series of warp and weft yarns with a specific weave density between 6:1 and 1:6, along with a uniform tension on the warp yarns, and the use of substrates like latex and polyethylene terephthalate to minimize thread detachment and enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If carpets are cut to size and fixed to surfaces, then carpets can be installed in large spaces, but threads detach at joints forming visible wires
Solution Approach 1:
The patent changes the physical-chemical parameter of the yarn by using fusible yarns that melt at specific temperatures. During installation, heat is applied to the carpet edges, causing the yarn to melt and fuse together, forming a sealed edge that prevents thread detachment while maintaining installation ease
Solution Approach 2:
The patent replaces mechanical fastening methods with thermal fusion. Instead of using adhesives or mechanical fasteners to secure carpet edges, the yarn itself is heated to melt and bond the edges together, eliminating the need for additional mechanical fixing systems
2Adaptability or versatility
If carpets are made from natural non-fusible yarns, then natural material benefits are achieved, but thread detachment and visible wires occur at joints
Solution Approach 1:
The patent creates a composite structure where natural yarns are combined with fusible components or treatments. The carpet uses natural yarns for the main body to maintain natural material benefits, while incorporating fusible elements at the edges that melt during installation to prevent thread detachment
Solution Approach 2:
The patent applies different properties to different parts of the carpet. The main body uses natural non-fusible yarns to maintain natural characteristics, while the edges are treated or constructed with fusible properties to enable thermal sealing and prevent thread detachment during installation
3Stability of the object's composition
If threads detach at joints after cutting, then carpet stability deteriorates, but the problem is particularly severe with natural non-fusible yarns
Solution Approach 1:
The patent performs preliminary action by applying heat treatment during the installation process before the carpet is fully in use. The thermal fusion is applied to the carpet edges at the time of installation, creating a permanent bond that prevents future thread detachment and maintains long-term stability
Data Source
Figure 1
AI summary
The present invention relates to a carpet having natural yarns comprising at least a series of warp yarns interwoven with a series of weft yarns, thus forming a fabric having an upper face, a lower face and a multitude of floats, which are a section of a yarn which appears on the surface of a fabric, said floats comprise upper floats appearing on the upper face of the mat and lower floats appearing on the upper face of the mat, characterized in that each weft thread of the floats above not more than 6 warp threads.