Method for manufacturing pile carpet
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Solution Overview
Problem
Existing methods for manufacturing cut-pile carpet, such as tufting and weaving, face issues like yarn damage, limited patterning options, high energy consumption, and difficulty in recycling due to the need for multiple layers and materials, as well as challenges in arranging V-pile yarns without damaging them.
Innovation Solution
A single-step process using a pile thread holder with guide channels on both sides, allowing V-pile yarns to be inserted without passing through the backing initially, which reduces yarn damage and enables easier patterning and recycling, using a gripping station to push the yarns through the guide channels and into the backing, and anchoring them under high pressure for a stable and flexible carpet tile production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If V-pile yarns are inserted through the backing in classical tufting, then the pile threads are anchored to the carrier, but the yarn is damaged and pulled out easily
Solution Approach 1:
The patent introduces a tufting needle as an intermediary tool that passes through the backing without the yarn passing through it. The needle creates a channel and deposits the yarn in a J-shape configuration, allowing the yarn to be anchored without direct friction and tension damage from passing through the backing material.
Solution Approach 2:
Instead of passing the yarn through the backing and anchoring it from the front, the invention inverts the process by inserting the yarn from the front in a J-shape and anchoring it from the back using the needle, thereby protecting the yarn from damage during insertion.
2Reliability
If multiple operations are used after tufting to anchor pile yarns and improve comfort, then the carpet quality is enhanced, but the production complexity and time increase
Solution Approach 1:
The patent combines multiple operations into a single tufting needle action: inserting the yarn, forming the J-shape, anchoring it through the backing, and creating the pile loop all in one continuous motion. This eliminates the need for separate anchoring and finishing operations, reducing production complexity while maintaining quality.
Solution Approach 2:
The tufting needle is designed as a multi-functional tool that performs insertion, shaping, anchoring, and loop formation simultaneously. This universal tool replaces multiple specialized operations, simplifying the production process while achieving the same quality outcomes.
3Reliability
If adhesive is used to anchor pile threads to the rear side of the carrier, then the pile threads are secured, but additional materials and energy-consuming drying ovens are required
Solution Approach 1:
The patent replaces the chemical adhesive system with a mechanical anchoring system. The tufting needle physically secures the yarn in a J-shape through the backing, eliminating the need for adhesive application and subsequent thermal drying processes, thereby significantly reducing energy consumption.
4Ease of operation
If secondary backing is added to increase comfort, then the carpet comfort is improved, but the number of layers and materials increases making recycling difficult
Solution Approach 1:
The patent extracts the secondary backing layer from the carpet structure, relying solely on the primary carrier and the mechanically anchored J-shape pile threads. This simplification maintains comfort through proper anchoring while eliminating material layers that complicate recycling processes.
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
This method increases pile density, reduces yarn loss, allows for flexible and washable carpet tiles with invisible seams, and enables the creation of three-dimensional patterns, using fewer raw materials and energy, while making the carpet tiles fully recyclable and easier to produce and lay without specialist fitters.
Implementation Method 1
a gripping station which pushes the pile threads through the pile thread guide channels from above (or pulls them from below)
Implementation Method 2
anchoring them under high pressure for a stable and flexible carpet tile production
Data Source
AI summary
The invention relates to a method for manufacturing pile carpet or pile carpet tiles, wherein a pile yarn (8) is connected via a pile thread holder (1) to at least a primary backing (7), wherein the pile thread holder (1) comprises a plurality of pile thread guide channels (2) which perforate the pile thread holder (1) through two opposite sides, wherein the pile thread holder (1) is provided between a pile thread gripping station (14) on a first perforated side (5) and a primary backing (7) on a second perforated side (6) such that the pile yarn (8) is arranged via the first perforated side (5) through a pile thread guide channel (2) to the second perforated side (6) onto, into or through the backing (7).