Carpet with a Woven Microrelief and Method

Abstract

The present invention relates to a carpet with woven surface relief, comprising at least a series of tension warps (1), a series of binding warps (2), said warps (1, 2) being interwoven with a series of weft yarns (3), the ratio of the length of said binding warps (2) relative to the length of said tension warps (1) being greater than 1.20, preferably greater than 1.50.

Description

TECHNICAL FIELD

The present invention relates to a carpet with woven surface relief and to a method for manufacturing said carpet. In particular, the invention relates to a carpet comprising tension and binding yarns which are clamped in such a way that the weft and/or pile warp yarns are emphatically located on the surface of the carpet.

BACKGROUND

Providing specific visual and technical aspects of carpets is an important challenge in order to be able to provide product diversification and thus be able to offer a unique product to a consumer. In addition, certain technical aspects of the carpet surface are intended to assist consumers in a technical way.

EP 2 851 459 provides a method for producing a carpet having a worn appearance; comprising the following steps: arranging in one plane the warp threads next to each other without overlapping them; and interlacing weft yarns through the warp yarns such that said weft threads are positioned in consecutive lines and substantially perpendicular to said warp threads; the weft threads are repeatedly inserted in the same line and in a predefined insertion pattern. Said insertion model is interrupted at least once so as to leave visible at least one segment of at least one warp thread.

EP 2 851 460 provides a method for producing a carpet having a patch-work appearance, comprising the steps of: arranging warp threads in a plane side by side without overlapping; inserting and interlacing weft yarns through said warp yarns such that said weft threads are positioned in consecutive lines and substantially perpendicular to said warp yarns; the weft threads are repeatedly inserted in the same line and in a predefined insertion pattern. The insertion model is interrupted at least once to create at least one line of seams on one of the surfaces of the carpet.

EP 3 199 678 relates to a carpet with glossy yarns, comprising a fabric with a series of weft threads, inserted substantially perpendicularly and interwoven with a series of mainly parallel warp yarns, wherein at least 0.1% of said weft threads are glossy with a gloss of at least 70 gloss units, measured at a 45° angle of incidence according to ASTM D2457, 10% to 40% of the weft yarns of glossy polymers and that 60% to 90% of said weft threads comprise one or more natural fibres.

U.S. Pat. No. 3,850,783 discloses a double pile tufted pile carpet with a backing material having a pre-printed chain with a repetitive colour pattern formed in a higher and lower tufted pile texture pattern with the last pattern correlated and combined with the repeat shade with colour pattern, and in which carpet the fibre stack can be either woven or tufted and wherein the patterns, or one of both, can be repeated transversally, longitudinally or both.

U.S. Pat. No. 4,045,848 shows a technology in which synthetic continuous filament yarn is woven with a sacrificial filling and thus formed into a prefab, selected portions of the prefabric are dyed, the prefabric is optionally crimped, either before or after dyeing, the prefabric is immersed in a dilute solution which, when concentrated will destroy the sacrificial filling, and the prefabric is then conducted through a heating and drying operation, boiling off the water and concentrating the solution, then substantially completely destroying the sacrificial filling and freeing the warp yarns as a free warp of intermittently coloured yarns.

EP 1 801 272 describes a woven carpet.

However, none of the above documents show how a refined microrelief can be applied to a carpet. The present invention seeks to provide a carpet with an accurate, microrelief on the surface of the carpet.

SUMMARY OF THE INVENTION

To this end the invention provides in a first aspect a carpet with woven surface relief, comprising at least a series of tension warps (1), a series of binding warps (2), said warps (1, 2) being interwoven with a series of weft yarns (3), wherein said carpet comprises an aspect side and a back side, and wherein a backing layer (6) is adhered to said back side; and wherein the ratio of the length of said binding warps (2) to the length of said tension warps (1) is greater than 1.20, preferably greater than 1.35 and more preferably greater than 1.50. By opting for a sufficiently high ratio of the length of said binding warps (2) to the length of said tension warps 2, the weft yarns comprised in the fabric are pressed more emphatically towards the surface of the carpet.

In a second aspect, the invention provides a method for manufacturing a carpet with a woven surface relief, more specifically a carpet according to the first aspect of the invention, comprising the steps of:

• • providing at least a series of tension warps (1), a series of binding warps (2) in the warp direction of a weaving frame;
  • interweaving a series of weft yarns (3) with said warps (1, 2), thereby obtaining a carpet with an aspect side and a back side;
  • bonding a backing layer (6) to said back side;

the preliminary tension on said tension (1) and binding warps (2) being adjusted so that the ratio of the length of said binding warps (2) to the length of said tension warps (1) in the manufactured carpet is greater than 1.20, preferably greater than 1.35 and more preferably greater than 1.50.

DESCRIPTION OF THE DRAWINGS

The explicit characteristics, advantages and objectives of the present invention will become further apparent to a person skilled in the art to which the invention pertains after reading the following detailed description of the embodiment of the invention and the attached figures herein. To this end, the figures serve to further illustrate the invention and are intended for illustration only, without thereby limiting the scope of the invention.

FIGS. 1 to 3 represent a simplified detailed representation of a carpet according to the present invention.

FIG. 1 is a schematic representation of a detailed view of a carpet with indication of warp yarn 1, 2, weft yarn 3 and pile warp yarns 4, wherein the binding yarn 2 is provided with a greater length compared to the tension yarn 1.

FIG. 2 is a schematic representation of a detailed view of a carpet with indication of warp yarn 1, 2, and weft yarn 3, wherein the binding yarn 2 is provided with a greater length compared to the tension yarn 1.

FIG. 3 shows a carpet according to the embodiment of FIG. 1, wherein one of the pile warp yarns 5 is provided as a chenille yarn (e.g. a polyester chenille or an acrylic chenille) and/or as a fancy yarn, such as for example a dyed woollen yarn, a cotton yarn, a polyamide yarn, a bouclé or a frisé yarn, etc.

DETAILED DESCRIPTION OF THE INVENTION

Unless otherwise defined, all terms used in the description of the invention, including technical and scientific terms, have the meaning as commonly understood by a person skilled in the art to which the invention pertains. For a better understanding of the description of the invention, the following terms are explained explicitly.

In this document, ‘a’ and ‘the’ refer to both the singular and the plural, unless the context presupposes otherwise. For example, ‘a segment’ means one or more segments.

When the term ‘around’ or ‘about’ is used in this document with a measurable quantity, a parameter, a duration or moment, and the like, then variations are meant of approx. 20% or less, preferably approx. 10% or less, more preferably approx. 5% or less, even more preferably approx. 1% or less, and even more preferably approx. 0.1% or less than and of the quoted value, insofar as such variations are applicable in the described invention. However, it must be understood that the value of a quantity used where the term ‘about’ or ‘around’ is used, is itself specifically disclosed.

The terms ‘comprise’, ‘comprising’, ‘consist of’, ‘consisting of’, ‘provided with’, ‘have’, ‘having’, ‘include’, ‘including’, ‘contain’, ‘containing’ are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.

Quoting numerical intervals by endpoints includes all integers, fractions and/or real numbers between the endpoints, these endpoints included.

The term ‘carpet’ in the context of the present invention specifically refers to a woven carpet, wherein the weft yarns are inserted and interwoven with a series of warp yarns. The repeated passing through of weft yarns below and above the warp yarns forms an insertion pattern. The insertion pattern can be repeated several times at the level of a weft row. Said first series of warp yarns can be the same or different from said second series of warp yarns. The first series of warp yarns can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 yarns. The second series of warp yarns can comprise 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 yarns. The number of warp yarns determines the width, length or diameter of the carpet. The weft yarns are inserted and interwoven over the warp yarns in rows so that one row starts at the level of the first warp yarn and extends to the last warp yarn. The warp yarns and the weft yarns are arranged in such a way that they are positioned mutually substantially perpendicularly to each other. The warp yarns and the weft yarns can be selected from the group comprising, but not limited to: linen, wool, cotton, silk. The weft yarns and the warp yarns can be of different or identical material. Preferably, said carpet has an area density between 500 gsm and 2500 gsm, preferably between 750 gsm and 2250 gsm, more preferably between 1000 gsm and 2000 gsm and most preferably with an area density of 1000 gsm, 1050 gsm, 1100 gsm, 1150 gsm, 1200 gsm, 1250 gsm, 1300 gsm, 1350 gsm, 1400 gsm, 1450 gsm, 1500 gsm, 1550 gsm, 1600 gsm, 1650 gsm, 1700 gsm, 1750 gsm, 1800 gsm, 1850 gsm, 1900 gsm or 1950 gsm, or any value in between.

The term ‘tension yarn’ is to be understood as a warp yarn and refers to a yarn provided in the warp direction of the carpet. The tension yarn is generally defined in relation to a binding yarn and is distinguished from it by a shorter length compared to the binding yarn. The tension yarn can be coloured so as to display a colour or a colour pattern on the surface of the carpet.

The term ‘binding yarn’ is to be understood as a warp yarn and refers to a yarn provided in the warp direction of the carpet. The binding yarn is generally defined in relation to a tension yarn and is distinguished from it by a larger length compared to the tension yarn. As a result, the binding yarn is usually clearly visible on the surface. The binding yarn is preferably not coloured because said binding yarns are not or only slightly visually perceptible and therefore do not contribute or contribute little to the visual result.

The term ‘weft yarn’ is to be understood as being transversely interwoven with the warp yarns and refers to a yarn provided in the weft direction of the carpet. The weft yarn is usually interwoven single or multiple between warp yarns. This means that one or more (for example two, three, four, five, six, seven, eight, etc.) weft yarns can be inserted in one stroke between the warps. A ‘stroke’ is to be understood as a single processing step in which one or more weft yarns are introduced between the series of transversely arranged warp yarns. After the ‘stroke’, the warp yarns are brought into a new, generally different position, and a new stroke is carried out. Consequently, the weft yarn is generally well visible on the surface. The weft yarn is preferably coloured so as to display a clearly discernible colour or colour pattern on the surface of the carpet. In the context of the present invention, the ‘length density’ of the weft yarn should be understood as the length density of the whole of the one or more weft yarns woven in in a single weft.

The term ‘pile yarn’ is to be understood as a synonym of the term ‘pile warp yarn’ and refers to a yarn provided in the warp direction of the carpet. The pile yarn generally has a larger diameter than the warp yarn and is therefore especially suited for appearing on the surface of the carpet. Consequently, the pile yarn is preferably coloured so as to display a colour or a colour pattern on the surface of the carpet. In a preferred embodiment, the present invention provides a carpet according to the first aspect, wherein said pile warp yarn is provided with a larger diameter than the warp yarn, expressed in Nm and/or expressed in dtex. Preferably, said pile warp yarn is provided with a thickness between 1.5 Nm and 6 Nm and between 1600 dtex and 6600 dtex.

The term ‘spacedye pattern’ is to be understood as a random pattern of two or more colours, which are alternately dominantly applied to a yarn. The present invention furthermore succeeds in simulating a spacedye pattern by using different warp and/or weft yarns, which appear on the surface of the carpet randomly alternately.

To this end the invention provides in a first aspect a carpet with woven surface relief, comprising at least a series of tension warps (1), a series of binding warps (2), said warps (1, 2) being interwoven with a series of weft yarns (3), wherein said carpet comprises an aspect side and a back side, and wherein a backing layer is adhered to said back side; and wherein the ratio of the length of said binding warps 2 to the length of said tension warps 1 is greater than 1.20, preferably greater than 1.35 and more preferably greater than 1.50. In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the ratio of the length of said tension warps (1) to the length of said binding warps (2) is greater than 1.60, greater than 1.70, greater than 1.80, greater than 1.90, and even greater than 2.0.

By opting for a sufficiently high ratio of the length of said binding warps (2) to the length of said tension warps (1), the weft yarns comprised in the fabric are pressed more emphatically towards the surface of the carpet. A microrelief is thus created on the surface as a result of the weaving process. By applying different warp yarns with a different visual aspect (e.g. colour), a unique relief and colour shade is observed, which simulates a spacedye pattern. By additionally applying a spacedye-type warp and/or weft yarn, a unique relief and colour shade are observed. A unique product can thus be created for a consumer.

This is shown schematically in FIG. 1. FIG. 1 is a schematic representation of a detailed view of a section of the carpet according to the invention perpendicular to the weft direction. FIG. 1 is a schematic representation of a detailed view of a carpet with indication of warp yarn 1, 2, weft yarn 3 and pile warp yarns 4, wherein the binding yarn 2 is provided with a greater length compared to the tension yarn 1. Thus, the weft yarns 3 are pushed to the surface, and a microrelief is created. A rougher surface is obtained by this microrelief.

FIG. 2 is a schematic representation of a detailed view of a carpet with indication of warp yarn 1, 2, and weft yarn 3, wherein the binding yarn 2 is provided with a greater length compared to the tension yarn 1. A microrelief is obtained by the carpet according to FIG. 2.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said carpet comprises at least one weft yarn which weft yarn is an effect yarn 31, such as, for example, a chenille yarn, (e.g. a polyester chenille or an acrylic chenille) and/or a fancy yarn, such as, for example, a dyed woollen yarn, a cotton yarn, a polyamide yarn, a bouclé and/or a frisé yarn, etc. The weft yarn 31 is provided in the carpet such that the weft yarn 31 (FIG. 1) appears on the surface of the carpet. Still preferably, the present invention provides a carpet according to the first aspect of the invention, wherein said carpet comprises at least one weft yarn which weft yarn is not an effect yarn, such as weft yarn 32, such as, for example, but not limited to, a cotton or jute yarn. The weft yarn 32 is provided in the carpet such that the weft yarn 32 (FIG. 1) does not appear on the surface of the carpet.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the ratio of the length of said tension warps (1) to the length of said binding warps (2) is greater than 2.00, greater than 2.25, greater than 2.50, greater than 2.75, greater than 3.00. A sufficiently large ratio ensures that the weft yarns are sufficiently pressed onto the surface of the carpet.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the ratio of the length of said tension warps (1) to the length of said binding warps (2) is smaller than 5.0, preferably smaller than 4.75, is smaller than 4.50, is smaller than 4.25, and even smaller than 3.75. By choosing the ratio equal to or less than 5, said weft yarns come to lie closer to each other on the surface.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said series of weft yarns (3) have a greater length density than said series of binding warps (2). By a sufficiently large thickness of the weft yarn, a rougher appearance of the surface of the carpet is obtained. In a more preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the ratio of the length density of said weft yarns (3) to the length density of said binding warps (2) is greater than 1.5, preferably greater than 2.0.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, further comprising a second series of tension warps. Such a second set of tension warps can be inserted to further refine the visual aspect of the carpet. Said second series of tension warps can be inserted with a length where the ratio of the length of said binding warps (2) to the length of said tension warps (1) is also greater than 1.20, preferably greater than 1.35 and more preferably greater than 1.50 and is even greater than 1.60, greater than 1.70, greater than 1.80, greater than 1.90, and even greater than 2.0.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said carpet comprises an aspect side and a back side, and wherein said back side is provided with a backing layer comprising a nonwoven, a knit or a fabric. Said backing layer is intended to provide a better dimensional stability of the carpet. Preferably, said backing layer is a nonwoven with a specific surface weight greater than 100 gsm, greater than 150 gsm, greater than 175 gsm, greater than 200 gsm, greater than 225 gsm or even greater than 250 gsm. More preferably, said backing layer is a nonwoven with a specific surface weight greater than 300 gsm, greater than 350 gsm, greater than 400 gsm, greater than 450 gsm, greater than 500 gsm, greater than 550 gsm, greater than 600 gsm, and even greater than 650 gsm. Preferably, said backing layer is a nonwoven with a specific surface weight of less than 1500 gsm and preferably less than 1200 gsm and even less than 800 gsm. Such a backing layer provides sufficient comfort, stability and sound insulation.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said backing layer (6), preferably said nonwoven, is bonded by means of an adhesive (7) and/or a latex (7), wherein said adhesive is preferably selected from e.g. polyvinyl acetate and ethylene vinyl acetate and wherein said latex is selected from e.g. carboxylated styrene-butadiene latex comprising calcium carbonate. Preferably, said adhesive and/or latex have an area density between 500 gsm and 2000 gsm, preferably between 750 gsm and 1750 gsm, more preferably between 800 gsm and 1600 gsm and most preferably with an area density of 800 gsm, 850 gsm, 900 gsm, 950 gsm, 1000 gsm, 1050 gsm, 1100 gsm, 1150 gsm, 1200 gsm, 1250 gsm, 1300 gsm, 1350 gsm, 1400 gsm, 1450 gsm, 1500 gsm, 1550 gsm or 1600 gsm, or any value in between.

In a more preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said backing layer is comprised of a nonwoven made of PET, polyester or polypropylene.

In a more preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein one or more of the aforementioned warp and/or weft yarns are provided with a spacedye pattern.

The spacedye pattern is a random pattern of two or more colours, which are alternately applied dominantly to a yarn, in the above-mentioned case to said warp and/or weft yarns. Thus, said warp and/or weft yarns are provided with a sequence of sections of arbitrary length, each section being characterised by a dominant colour. The pile warp yarn 4, 5 is hereby considered as a specific type of warp yarns, since pile warp yarns 4, 5 are provided in the warp direction of the woven carpet.

The detailed representation of FIG. 1 shows the warp yarns 1, 2, weft yarns 3 and pile warp yarns 4, said pile warp yarns 4 being provided with a spacedye pattern. This is made visible in FIG. 1 on the basis of the different, successive sections of the two pile warp yarns 4 shown, each section being provided with a different hatching type. Each hatching type corresponds to a specific colour, or rather, to a specific dominant colour. This means that the intensity of a colour can also vary within one colour section of a spacedye pattern. Also shown in FIG. 1 is the alternating pattern of pile warp yarn that appears at the top of the surface of the carpet. For example, the rough-hatched pile warp yarn is visible on the surface in the left of the figure, followed by a section in which the pile warp yarn with fine-hatched pile warp yarn is visible at the top of the surface. Another aspect of the invention which is expressed in the figure is the different length of the first 1 and the second 2 warp yarn. The second warp yarn is longer in length than the first warp yarn. This is due to the different tension on the respective warp yarns during the tensioning in the weaving frame. The result is that the weft yarns 3, which are shown across the width of the cross-section at the top of the figure, are pulled into the carpet. The weft yarns 3 thus partly ensure that the pile warp yarns 4 are revealed on the surface of the carpet. A further aspect illustrated by FIG. 1 is that the pile warp yarn 4 is wider in thickness than the warp yarn 1, 2. Partly as a result of this, the pile warp yarn 4 comes to lie better on the surface of the woven carpet. As a result, the colour shade is better expressed, since the colour shade is more visible on a relatively thick yarn than the same colour shade on a relatively thin yarn.

Because the warp yarns with colour shade are at least partially visible on the surface of the carpet, a unique colour shade is observed. A unique product can thus be created for a consumer. At the same time, a great diversity within a predetermined product category is achieved without increasing the required storage space. Moreover, the invention is advantageous with regard to the use of dyes. Dyes are relatively expensive components and their use in carpets should therefore be limited. By placing the spacedye pattern in separate sections of a single dye layer on the yarn as opposed to several dye layers in particular sections, the total consumption of dyes can be limited.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein one or more pile warp yarns are provided with a spacedye pattern. The colour shade becomes especially evident in the carpet obtained when the spacedye pattern is incorporated into the pile warp yarns. The pile warp yarns generally have a thicker cross-section than other warp yarns and are introduced into the carpet with a lower warp tension, whereby the length of the pile warp yarn in the carpet is greater than the length of an adjacent warp yarn.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the thickness of at least one pile warp yarn is at least 1.15 times and preferably at least 1.30 times greater than the thickness of at least one warp yarn.

The thickness of the pile warp yarn can be expressed on the basis of the dtex value, but preferably on the basis of the diameter of the cross-section of the yarn at rest. Pile warp yarns can be selected from the group comprising: chenille yarn such as cotton chenille 2.2 Nm; woollen yarn such as wool 6/2 Nm. Such yarns have the advantage that they are bulky and are well suited for maintaining the colour features after dyeing.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, comprising a plurality of pile warp yarns, wherein at least one pile warp yarn is comprised of wool and at least one pile warp yarn is comprised of chenille.

A chenille yarn is to be understood as a yarn comprising a central thread, also known as the ‘core’ of the yarn in technical jargon, which central thread preferably comprises 2, 3 or 4 threads. A multitude of lateral fabric particles are provided around the central thread, which ensure the large volume of the chenille yarn at low density. Because of this large volume at low density of the chenille yarn, the chenille yarn automatically comes to lie on the surface of the carpet during weaving. This makes the colour patterns in the chenille yarn clearly visible on the surface. Because a chenille yarn has a relatively low density, the total weight of the carpet is limited, which is advantageous during transport and installation.

Such an embodiment is shown schematically in FIG. 3. FIG. 3 is a schematic representation of a detailed view of a carpet according to the embodiment of FIG. 1, wherein one of the pile warp yarns is provided as a chenille yarn, 5 (e.g. a polyester chenille or an acrylic chenille) and/or as a fancy yarn, such as for example a dyed woollen yarn, a cotton yarn, a polyamide yarn, a bouclé or a frisé yarn, etc. This is illustrated by means of the cross hatching over the entire yarn. The varying thickness of the cross hatching indicates a varying colour, or rather, a varying dominant colour in a particular section of the chenille yarn, 5.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein the ratio of the number of pile warp yarns made of wool to the number of pile warp yarns made of chenille is 3:1.

This offers the advantage that an optimum of product features is achieved. Wool exhibits good wear resistance and durability as well as a relatively good natural elasticity and a good absorption capacity for dyes. At the same time, wool forms a good bulk or volume, which volume allows the woollen pile warp yarn to come to the surface, as described earlier. More than the woollen yarn, the chenille yarn is suitable for providing a relatively large volume and therefore also for displaying colours. Although any other ratio is possible, the inventors found an optimum ratio of woollen pile warp yarns to chenille pile warp yarns between 10:1 and 1:2 and more preferably between 5:1 and 1:1 and even more preferably at 4:1, 3:1 or 2:1, or any ratio in between.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein at least one woollen pile warp yarn and at least one chenille pile warp yarn appear alternately on the surface.

This offers the advantage that a greater variation in shade can be provided in the carpet. The alternation in the floating of woollen pile warp yarn and chenille pile warp yarn can be introduced by providing a woollen and a chenille pile warp yarn between two consecutive teeth of a weaving comb.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein said first series of warp yarns and said second series of warp yarns are provided with a different length.

This can be achieved by tensioning said first and said second series of warp yarns in the weaving frame with a different tension. As a result, a first series of warp yarns will be comprised in the carpet relatively linearly, such as, for example, warp yarns 1 in FIGS. 1 and 2. A second series of warp yarns, which are provided with a greater length and a lower tension in the woven carpet, will be pushed away from the centre of the carpet by the weft yarn, such as, for example, warp yarn 2 in FIGS. 1 and 2. The result is that the longer warp yarn, e.g. 2, will bring the weft yarns, e.g. 3, to the centre of the carpet in regular places. The weft yarns, e.g. 3, in turn push the pile warp yarns, e.g. 4, 5, to the centre of the carpet. As a result, the intermediate cut-offs of the pile warp yarn, e.g. 4, 5, are pushed out.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, wherein at least one pile warp yarn is longer than at least one warp yarn.

This can be achieved by weaving the pile warp yarn with a lower tension or even tension-free into the carpet. The result is that the warp yarn ensures that the weft yarns are pressed towards the centre of the carpet, whereby the pile warp yarns are brought through the weft yarns at regular places to the centre of the carpet, so as to press the intermediate sections of the pile warp yarn to the outside. This makes the colour shade in the pile warp yarn optimally visible on the surface of the carpet.

In a preferred embodiment, the present invention provides a carpet according to the first aspect of the invention, comprising two or more pile warp yarns which are different from each other. By opting for mutually different pile warp yarns, the features of the carpet can be further optimised, both with regard to the variation in the colour shade and features such as density, wear resistance, etc.

In a second aspect, the invention provides a method for manufacturing a carpet with a woven surface relief, more specifically a carpet according to the first aspect of the invention, comprising the steps of:

• • providing at least a series of tension warps (1), a series of binding warps (2) in the warp direction of a weaving frame;
  • interweaving a series of weft yarns (3) with said warps (1, 2), thereby obtaining a carpet with an aspect side and a back side;
  • bonding a backing layer to said back side;

the preliminary tension on said tension (1) and binding warps (2) being adjusted so that the ratio of the length of said binding warps (2) to the length of said tension warps (1) in the manufactured carpet is greater than 1.20, preferably greater than 1.35 and more preferably greater than 1.50. In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein the preliminary tension on said tension (1) and binding warps (2) is adjusted so that the ratio of the length of said tension warps (1) to the length of said binding warps (2) is greater than 1.60, greater than 1.70, greater than 1.80, greater than 1.90, and even greater than 2.00.

The method according to the second aspect of the invention is provided for manufacturing a carpet according to the first aspect of the invention, and the characteristics of the carpet according to the first aspect of the invention therefore apply to the method according to the second aspect of the invention.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein said series of weft yarns (3) are provided with a greater length density than said series of binding warps (2).

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein the ratio of the length density of said weft yarns (3) to the length density of said binding warps (2) is greater than 1.5, preferably greater than 2.0.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, further comprising the step of providing a second series of tension warps.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, further comprising the step of applying a backing layer comprising a synthetic foam layer, a nonwoven, a knit or a fabric on a back side of said carpet. In a more preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein said backing layer is comprised of nonwoven made of PET, polyester or polypropylene.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein one or more of said warp yarns are dyed in advance in a spacedye pattern. By applying said spacedye pattern to the aforementioned warp yarns, a colour shade becomes visible on the surface of the carpet. The spacedye pattern provided on the warp yarn provides a random alternation of colours on the visible surface of the carpet and thus results in a unique carpet. As a result, a great diversity within a certain product category is obtained without thereby increasing the required storage space.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein said warp yarns and/or pile warp yarns are arranged in a warp comb with a series of teeth and wherein at least two warp yarns and/or pile warp yarns are arranged between two teeth of said warp comb.

By introducing at least one warp yarn and/or pile warp yarn between two successive teeth of a weaving comb in a weaving frame, the at least two said warp and/or pile warp yarn can appear randomly alternately on the surface of the carpet during the weaving of the carpet. This offers the advantage that a greater variation in colour shade can be provided in the carpet, as well as a greater variation in texture of the surface of the carpet. For example, warp and/or pile warp yarn with different densities, roughness, gloss, etc. can be provided and thus lead to a variation in perception by the user.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein one or more of said warp yarns are dyed in advance in a spacedye pattern by means of spraying atomised dye at various locations of said warp yarns.

Atomising a dye on the warp yarns offers the advantage that the drying process for the coloured yarns is relatively limited in comparison with other colouring techniques. Various sections of said warp yarns can thus be provided with a colour, or rather, with a dominant colour. The adjacent sections can be provided with a different colour or can be provided without colour. The sections can also be coloured in different lengths. According to the prior art, a spacedye pattern is applied by first applying a first dye layer to the entire yarn; then a second dye layer on particular sections; and finally a third dye layer on particular parts of the second dye layer. Thus, some sections are provided with two or more dyes. According to the invention, predetermined sections are provided with a first dye; other sections with a second dye; etc. In this way, the yarn is provided with mainly only one dye layer, which entails a major limitation of dyes and therefore a considerable cost reduction.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention, wherein said first and second series of warp yarns are provided with different tension in said weaving frame.

By providing said first and second series of warp yarns with different tension, a first series of warp yarns with a higher tension compared to said second series of warp yarns, are included relatively linearly in the carpet, such as, for example, warp yarns 1 in FIGS. 1 and 2. A second series of warp yarns, which are brought with a greater length and a lower tension into the woven carpet, will be pushed away from the centre of the carpet by the weft yarn, such as, for example, warp yarn 2 in FIGS. 1 and 2. The result is that the longer warp yarn will bring the weft yarns to the centre of the carpet in regular places. The weft yarns in turn push the pile warp yarns to the centre of the carpet. As a result, the intermediate cut-offs of the pile warp yarn are pushed out, which provides a better visibility of the spacedye pattern on said pile warp yarns on the surface of the carpet.

Example 1

A fabric is formed by means of a binding warp, a tension warp and a weft yarn. The binding warp is provided in a 12/3Ne Co/PES 50/50 with a density of 7.4 threads per cm. The tension warp is provided in a 10/4Ne Co/PES 50/50 with a density of 3.7 threads per cm. The weft warp is provided in wool 2.2/3 Nm with a density of 5.5 wefts per cm. The fabric is provided with a surface weight of 1600 gsm.

The fabric is then provided with a latex precoat based on polyvinyl acetate and ethylene vinyl acetate with a dry substance content of 45-51% by weight and a pH between 4 and 7. The adhesive for laminating the backing layer is an aqueous dispersion based on carboxylated styrene-butadiene latex with calcium carbonate filler with a dry substance content of about 75-80% by weight. The backing layer is comprised of 100% PET nonwoven and is provided with a surface density of 675 gsm with a thickness of 4 mm. The surface weight of said adhesive with latex is 915 gsm.

Example 2

A fabric is formed by means of a binding warp, a tension warp, a pile warp yarn and a weft yarn. The binding warp is provided in a 12/3Ne Co/PES 50/50 with a density of 7.4 threads per cm. The tension warp is provided in a 10/4Ne Co/PES 50/50 with a density of 3.7 threads per cm. The pile warp yarn is provided in a 6/2 Nm wool. The weft yarn is provided in polyamide chenille 2.2 Nm with a density of 5.5 wefts per cm. The fabric is provided with a surface weight of 1070 gsm.

The fabric is then provided with a latex precoat based on polyvinyl acetate and ethylene vinyl acetate with a dry substance content of 45-51% by weight and a pH between 4 and 7. The adhesive for laminating the backing layer is an aqueous dispersion based on carboxylated styrene-butadiene latex with calcium carbonate filler with a dry substance content of about 75-80% by weight. The backing layer is comprised of 100% PET nonwoven and is provided with a surface density of 675 gsm with a thickness of 4 mm. The surface weight of said adhesive with latex is 1215 gsm.

Claims

1. Carpet with woven surface relief, comprising at least a series of tension warps (1), a series of binding warps (2), said warps (1, 2) being interwoven with a series of weft yarns (3), wherein said carpet comprises an aspect side and a back side, and wherein a backing layer (6) is adhered to said back side, characterised in that the ratio of the length of said binding warps (2) to the length of said tension warps (1) is greater than 1.50.

2. Carpet according to claim 1, further comprising a second series of tension warps and/or pile warp yarns.

3. Carpet according to claim 1, wherein said carpet comprises at least one weft yarn (31) which weft yarn is an effect yarn (31), selected from the group comprising a polyester chenille yarn, acrylic chenille yarn and/or a fancy yarn, selected from the group comprising a woollen yarn, a cotton yarn, a polyamide yarn, a bouclé and/or a frisé yarn.

4. Carpet according to claim 1, wherein said carpet comprises at least one weft yarn (32), which weft yarn is not an effect yarn, selected from the group comprising cotton and a jute yarn.

5. Carpet according to claim 1, wherein the ratio of the length of said tension warps (1) to the length of said binding warps (2) is greater than 1.60 and preferably greater than 1.70.

6. Carpet according to claim 1, wherein the ratio of the length of said tension warps (1) to the length of said binding warps (2) is less than 5.0 and preferably is less than 4.0.

7. Carpet according to claim 1, wherein said series of weft yarns (3) have a greater length density than said series of binding warps (2).

8. Carpet according to claim 7, wherein the ratio of the length density of said weft yarns (3) to the length density of said binding warps (2) is greater than 1.5, preferably greater than 2.0.

9. Carpet according to claim 1, wherein said backing layer (6) is comprised of a nonwoven, a knit or a fabric.

10. Carpet according to claim 9, wherein said backing layer (6) is comprised of a nonwoven made of PET, polyester or polypropylene.

11. Carpet according to claim 1, comprising pile warp yarns (4, 5), wherein one or more pile warp yarns (4, 5) are provided with a spacedye pattern.

12. Carpet according to claim 1, comprising pile warp yarns (4, 5), wherein the thickness of at least one pile warp yarn (4, 5) is at least 1.15 times and preferably at least 1.30 times greater than the thickness of at least one warp yarn (1, 2).

13. Carpet according to claim 1, comprising pile warp yarns (4, 5), wherein at least one pile warp yarn (4, 5) is comprised of wool and at least one pile warp yarn (4, 5) is comprised of chenille.

14. Carpet according to claim 13, wherein the ratio of the number of pile warp yarns (4, 5) made of wool to the number of pile warp yarns (4, 5) made of chenille is between 5:1 and 1:1.

15. Carpet according to claim 13, wherein at least one woollen pile warp yarn (4, 5) and at least one chenille pile warp yarn (5) appear alternately on the surface.

16. Carpet according to claim 1, comprising two or more pile warp yarns (4, 5) which are different from each other.

17. Method for manufacturing a carpet with woven surface relief, comprising the steps of:

providing at least a series of tension warps (1), a series of binding warps (2) in the warp direction of a weaving frame;

interweaving a series of weft yarns (3) with said warps (1, 2), thereby obtaining a carpet with an aspect side and a back side;

bonding a backing layer (6) to said back side;

characterised in that the preliminary tension on said tension (1) and binding warps (2) being adjusted so that the ratio of the length of said binding warps (2) to the length of said tension warps (1) in the manufactured carpet is greater than 1.50, preferably greater than 1.60.

18. Method according to claim 17, wherein the ratio of the length density of said weft yarns (3) to the length density of said binding warps (2) is greater than 1.5, preferably greater than 2.0.

19. Method according to claim 17, further comprising the step of applying a backing layer (6) comprised of a synthetic foam, a nonwoven, a knit or a fabric on a back side of said carpet.

20. Method according to claim 17, wherein said warp yarns (1, 2) and/or pile warp yarns (4, 5) are arranged in a warp comb with a series of teeth and wherein at least two warp yarns (1, 2) and/or pile warp yarns (4, 5) are arranged between two teeth of said warp comb.

21. Method according to claim 20, wherein one or more warp yarns (1, 2) and/or pile warp yarns (4, 5) are dyed in advance in a spacedye pattern.