MACHINE - MADE CARPET WITH SUNKEN BACKGROUND AND ALSO ITS PRODUCTION METHOD USING SHRINKAGE OF FIBER CUT IN THE FINISHING AND COMPLETING SYSTEM

TECHNICAL FIELD:

The present invention is related to the field of textile and also machine- made carpet industry and also weaving and spinning system in particular such as worsted yarn spinning system and also system of finishing and completing machine- made carpets. Broadly speaking, this invention is related to the machine- made carpet with high relief (embossing)

BACKGROUND OF THE INVENTION:

The weaving industry of carpet machine- made floorings dates back to Kidderminster city in England. ( Kidderminster is a large town and civil parish in the Wyre Forest district of Worcestershire, England .)

Given the above issue, threads in the machine- made carpet were manifestation of a kind of pile flooring between warp and weft using reciprocating motion. Later, ex-minister carpet industry turned common as a type of flooring with the pile thread. It should be noted that weaving machine- made carpet was developed and presented as double- sided basis by Van de Wide Company, so that many changes were created in the past years in the raw materials used, weaving equipment and machinery and also finishing and completion stage of final product as well. Hereunder are regarded as salient inventions presented in this field: In patent NO. US4629858A dated as Dec. 12, 1983 which has been registered by” Joseph H. Kyle” in USPTO, with title of” Method for engraving carpet and carpet so engraved” that are Methods for engraving carpet with beams of radiant energy. A beam of radiant energy, such as a laser beam, is intermittently directed at the surface of carpet to engrave the surface, and, if desired, to cause certain color changes. During the intermittent operation of the beam, the carpet is indexed to allow the beam to engrave designs. Alternatively, the beam may be indexed in relation to stationary carpet by means of lenses or mirrors to engrave designs. The method allows inexpensive and accurate engraving of carpet surfaces by which intricate designs may be formed on those surfaces in a minimum amount of time. Given the weaving process of machine- made carpets, Continue Filament (CF) is used which had high percentage of certain shrinkage. After the initial stages of completion and finishing, the length of these threads are corrected using shrink machinery, so that a uniform surface is created from juxtaposition of these yarns. Therefore, the surface of the product woven in weaving machine has distortion and heterogeneity due to the uniformity of Cyril stretch. Since available stretch in each of the yarns can change the degree of final shrinkage, juxtaposition of two threads with the different stretch or tension can be seen in the form of high or sunken relief in the long run of the carpet woven.

In different types of machine- made carpet, which occurs between two layers of upper and lower carpet reciprocally, the degree of stretch and non- uniformity of shrinkage of fibers and also threads can be considered as one of the greatest problems in the field of controlling the length of the thread.

With due observance to the said issue, two methods can be created in the long of thread, so that threads with different length create sunken motifs at carpet along with each other typically. In the first method, increased friction between thread and also tool for creation of tension device will cause more stretchiness at the time of weaving the desired motif. In this method, creation of limited motifs and also potential multicolor heterogeneity are kept away from direct view of spectator, so that comparing the motifs obtained is impossible. Therefore, the carpet woven, which is introduced as high- relief carpet, can be observed with the sunken flower pattern on the side of carpet, because, probable reliefs are cut and removed at the time of shrinking by blade of shrink machinery and only, sunken patterns can be observed on the carpet. In another method, machine- made carpet is woven using one or more colorful threads which have more shrinkage, so that these threads are used for weaving the underlying and background flowers.

Now, at the finishing and completion stage, carpet is woven with the inhalation of warm air into the surface of carpet after latex operation and shrinkage machinery while the said carpet moves on the roller as width as carpet with very low diameter. Change of direction (180 degree) in the course of movement of carpet will cause necessary aeration to the stem of carpet thread. However, total length of thread can hit its nominal shrinkage. Considering the mutual difference between shrinkage of different threads, the motifs have turned into necessary sunken motif, so that creation of sunken motif is created at the position of the mentioned thread.

EXISTING PROBLEMS:

Considering the partial difference of shrinkage of threads of carpet, the woven carpet can be turned into the waste carpet in case of weaving carpets that have used threads with high shrinkage after completion and aeration operation or creation of temperature using hot steam and/or immersion in fluid. Despite relief of motifs instead of immersion, existence of the mentioned defects will make production of underlying sunken carpet impossible. THE DESCRIPTION OF THE INVENTION:

The present invention is a type of machine- made flooring from the family of machine- made carpets. Moreover, the present invention discloses the method of production of this flooring as well. In this invention, thread or yarn is first produced using the fiber with the uniform shrinkage.

In this process, for reducing the effect of shrinkage in CF threads, packages of thread can be separated from each other with cutting the ordinary yarns and also packaging these threads. Of course, using de- packaging machine will pave the suitable way for creating a uniform mix of the fibers cut.

Given the above issue, disperse of fibers enjoys very low and very high shrinkage in the mentioned mix which has been distributed equally.

In another method of this invention, tops produced from this continuous fiber can be turned into the cut fibers. Homogenous mix obtained from mix of fibers is being aligned after entering the carding machine using pinpoint level of worker and cylinder in order to reach more uniformity. After producing web obtained from the carding machine and homogenization of several tops obtained from this web in the passage machine, completely homogenous wicks (tops) can be reached in terms of shrinkage of fibers. Now, yarns can be produced with the efficiency of homogenous and uniform shrinkage using ring weaving and using completely same weight pawls.

With twisting several strands of the mentioned yarns to one another, high- quality yarn can be provided for weaving carpet, so that the sample obtained from each part of production enjoys equal and identical efficiency of shrinkage.

Now, with twisting bobbins with length, eight and scale, exerting uniform and homogenous stretch as required in behind shelf of carpet weaving machine and also placing the mentioned yarns on the jacquard bars and also filling others parts with the colors as well as filling other parts with the colors, you can embark on weaving machine- made carpet with the underlying yarns made of cut fiber.

In the course of weaving process, underlying and background yarn are always equal to each other. On the other hand, the mentioned bobbins are placed with the complete bobbins if diameter of bobbins reaches to one third of ending bobbin for controlling tension obtained from weight of bobbin. On the other hand, considering the different consumption of background (themed) yarns in the width of carpet, some threads or yarns may end rapidly while some other may be reduced by process of time gradually.

Also, small twisting of diameter of bobbins can help uniformity and homogeneousness of tension of the background threads. Lack of long stop of carpet weaving machine in the middle of weaving process of a carpet is the notable point in the process of weaving as well.

After the end of weaving process, the mentioned carpet is completed and finished at the completion stage by the shrink machine, so that a completely uniform surface is created. Then, fibers of yarns can be forced to be shrunk in the vicinity of blowing warm air and/or hot steam and/or immersion in warm fluid such as hot water.

Since uniformity of disperse of fibers is very high, therefore, if the mentioned principles are taken into consideration such as homogeneity of tension and also weight of bobbins carrying thread, yarn, reciprocal traverse, it can expect that the background of carpet will shrink itself, so that motifs and patterns of carpet will remain longer.

BRIEF DESCRIPTION OF FIGURES:

Figure number one displays a view of the side of the carpet threads

1- Carpet threads with long length

2- Carpet threads after using shrinkage

3- Carpet background warp and weft threads