Method for producing a textile product

Abstract

A method for producing a textile product (I), (II), comprising at least two synthetic pile threads (P1), (P2) having a different pile height, so that a predetermined design is formed, in which the synthetic pile yarns (P1), (P2) are manufactured by extrusion from the same raw material, according to production processes which only differ from each other by a different setting of one or several process parameters of their respective extrusion processes, so that they have a different shrinking capability, and in which the textile product (I), (II) is subjected to a heat treatment which causes the pile yarns (P1), (P2) to shrink differently. Also such a method for producing synthetic textile yarns (P1), (P2) having a different shrinking capability.

Claims

1. Method for producing a textile product comprising first and second pile threads made from a synthetic material and having a mutually different pile height so that the pile threads form a predetermined design or a predetermined pattern due to their different pile height, comprising: manufacturing first and second synthetic textile yarns by extrusion from the same raw material in the same texturing unit, using the same extrusion line comprising the same process components, and using the first and second synthetic textile yarns for pile forming, wherein the manufacturing of the first and second synthetic textile yarns by extrusion comprises using extrusion processes for each of the first and second synthetic textile yarns which only differ from each other by a different setting of one or several process parameters of their respective extrusion processes, so that the first and the second textile yarns have a different shrinking capability, wherein using the first and second textile yarns to form pile is done in order to produce in the shrunk state the desired pile height at the desired locations in accordance with the predetermined design or pattern, and further comprising subjecting the textile product to a heat treatment which causes the first and second textile yarns to shrink differently.

2. Method for producing a textile product according to claim 1, further comprising manufacturing a third synthetic textile yarn by extrusion from the same raw material in the same texturing unit, using the same extrusion line comprising the same process components, and using the third synthetic textile yarn for pile forming, and wherein extrusion of the third synthetic textile yarn comprises an extrusion process which only differs from the extrusion processes for the first and second synthetic textile yarns by a different setting of one or several process parameters, so that the first, second and third synthetic textile yarns have a mutually different shrinking capability, and wherein the first, second and third synthetic textile yarns are used to form pile so that, in the shrunk state, they produce the desired pile height in accordance with the predetermined design or pattern at the desired locations, and wherein subjecting the textile product to a heat treatment causes the different textile yarns to shrink differently so that at least three different pile heights are produced.

3. Method for producing a textile product according to claim 1, characterized in that the textile yarns are manufactured in the same texturing unit, in which at least one pair of draw rolls is provided before the texturing unit, and in which a winder is provided for winding up the extruded yarns, and in that said extrusion processes differ from each other by a modified setting of: one or several process parameters of the texturing unit, and/or the temperature of at least one pair of draw rolls, and/or the speed of at least one pair of draw rolls, and/or the speed of the winder.

4. Method for producing a textile product according to claim 1, characterized in that the synthetic textile yarns are manufactured from polypropylene, polyester or polyamide.

5. Method for producing a textile product according to claim 1, characterized in that the synthetic textile yarns have a different colour as well as a different shrinking capability.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The method according to some embodiments of the invention is illustrated in the attached figures, in which:

(2) FIG. 1 is a diagrammatic cross section of a portion of a double-face carpet while it is being woven on a double-face weaving machine; and

(3) FIG. 2 shows a diagrammatic cross section of a portion of one of the carpets from FIG. 1, after cutting of the pile warp threads, and after application of a heat treatment which makes the textile yarns used as pile yarn shrink differently.

DETAILED DESCRIPTION

(4) With double-face weaving, two base fabrics (I), (II) are simultaneously woven one above the other (see FIG. 1) using weft threads and warp threads of successive warp thread systems. In the figures, the warp threads of one warp thread system are shown.

(5) Using weft threads (1), binding warp threads (3, 4) and tension warp threads (7), an upper base fabric (I) is woven. Using weft threads (2), binding warp threads (5, 6) and tension warp threads (8), a lower base fabric (II) is woven.

(6) Each warp thread system also comprises two pile warp threads (P1), (P2) made of textile yarn with a different shrinking capability, which—in accordance with a desired design achieved by pile height differences—is either allowed to form pile by alternately interlacing it over a weft thread (1) of the upper fabric (I) and a weft thread (2) of the lower fabric (II) or not allowed to form pile and interlaces in one of the base fabrics (I), (II) while running along in an extended way with the tensioning warp thread (7), (8).

(7) In every weft insertion cycle, the pile warp threads (P1), (P2) are to this end positioned with respect to the two levels at which a weft thread (1), (2) is simultaneously inserted.

(8) By cutting the pile warp threads (P1), (P2) running between the base fabrics, the two fabrics are separated from each other and two separate pile fabrics (I), (II) are obtained. At that moment, there is no pile height difference in these pile fabrics. The pile legs produced using the different pile warp yarns (P1), (P2) are still identical.

(9) It is only after the pile fabrics (I), (II) have undergone a heat treatment that the pile legs made using the different textile yarns (P1), (P2) have a different length and thus form a respective zone having a different pile height, as can be seen in FIG. 2.