Yarn Carpet Striated Patterns via Differential Twist

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Solution Overview

Problem

Current methods for creating striated patterns in solution dyed yarn carpets are impractical and susceptible to stains and discoloration, while traditional piece or skein dyed yarns face challenges in achieving desired color variations and durability.

Innovation Solution

The method involves twisting yarns with differential twists and lusters, using a combination of high and low twist yarns, and solution dyed yarns, along with unbalanced tension and random twist rates, to create unique striated patterns and increased durability, while maintaining resistance to stains and bleaching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If piece or skein dyed yarns are used to create striated patterns, then design flexibility is improved, but susceptibility to stains and discoloration increases

Engineering Contradiction:

Improvedesign flexibilityVSAvoidsusceptibility to stains and discoloration

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The yarn is dyed with solution dyeing technology before tufting into carpet, so the color is permanently integrated into the yarn fibers. This preliminary dyeing action eliminates the need for post-tufting dyeing operations and provides inherent resistance to stains and discoloration while maintaining design flexibility through the ability to select from various pre-dyed yarn colors and patterns.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If traditional twisters operating at 75 yards per minute are used, then yarn twisting is achieved, but productivity is limited

Engineering Contradiction:

Improveyarn twisting speedVSAvoidtwist rate control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The twister system incorporates variable speed drives and dynamic tension control mechanisms that allow the twist rate to be adjusted in real-time during operation. This dynamic control enables the system to maintain precise twist rates even when operating at higher speeds, resolving the contradiction between productivity and manufacturing precision.

Inventive Principle:

Principle #15Dynamics

3Strength

If high twist yarns are used, then durability is improved, but aesthetic appeal and design variety are reduced

Engineering Contradiction:

Improvecarpet durabilityVSAvoidaesthetic appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The carpet construction uses a combination of high twist yarns in the tufted rows for durability and low twist or untwisted yarns in the filler rows for aesthetic appeal. This local differentiation of yarn twist characteristics allows each region of the carpet to fulfill its specific function while contributing to the overall quality and appearance of the finished product.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10443172B1Combined yarn carpet improvements

Publication Date: 2019.10.15 WEINER ROBERT S

AI summary

Different combining techniques are employed for directing multiple yarns through a single needle of a tufting machine. Different aesthetic appearances be achieved which provide for many new design opportunities in the marketplace.