Carpet Yarn Denier Differential Improvements
20210131002 ยท 2021-05-06
Inventors
Cpc classification
D06N7/0005
TEXTILES; PAPER
International classification
Abstract
Different combining techniques are employed for directing multiple denier yarns to be tufted adjacently in a carpet by a tufting machine. Different aesthetic appearances be achieved which provide for many new design opportunities in the marketplace.
Claims
1. A method of manufacturing carpet comprising: directing first and second distinct yarns to be adjacently tufted beside one another on a tufting machine as directed from a common beam; and tufting carpet; wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn.
2. The method of claim 1 wherein the first yarn has a denier at least 100 higher than the second yarn, and the directing step further comprises directing the first and second distinct yarns to a single eye of a needle to then perform the tufting carpet step.
3. The method of claim 1 wherein the first yarn has a denier at least 150 higher than the second yarn.
4. The method of claim 1 wherein the first yarn has a denier at least 200 higher than the second yarn.
5. The method of claim 1 wherein the first yarn has a denier at least 250 higher than the second yarn.
6. The method of claim 1 wherein the first yarn has a denier at least 300 higher than the second yarn.
7. The method of claim 1 wherein the first denier is above 1000 and the second denier is below 1000.
8. The method of claim 2 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.
9. The method of claim 8 wherein the third yarn has a different denier than the first and second yarns.
10. A method of manufacturing carpet comprising: directing first and second distinct yarns to single eye of a needle of a tufting machine; and tufting carpet using the single needle; wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn.
11. The method of claim 10 wherein the first yarn has a denier at least 125% of the second yarn, and the directing step further comprises directing the first and second distinct yarns from a common beam.
12. The method of claim 10 wherein the first yarn has a denier at least 133% of the second yarn.
13. The method of claim 10 wherein the first yarn has a denier at least 150% of the second yarn.
14. The method of claim 10 wherein the first denier is above 1000 and the second denier is below 1000.
15. The method of claim 10 wherein the first denier is above 1000 and the second denier is below 1000.
16. The method of claim 10 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.
17. A method of manufacturing carpet comprising: directing first and second distinct yarns to single eye of a needle of a tufting machine from a common beam; and tufting carpet using the single needle; wherein the first distinct yarn has a denier less than 1000 and the second distinct yarn has a denier over 1000.
18. The method of claim 17 wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 50 higher than the second yarn.
19. The method of claim 17 wherein the first and second distinct yarns have a denier differential with the first yarn having a denier at least 120% of the second yarn.
20. The method of claim 17 wherein the step of directing the first and second distinct yarns further comprises directing a third yarn from the common beam to the single eye of the needle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings in which:
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0050]
[0051] While tufting with tufting machine 10, first and second yarns 14,16 can be tufted in a single location with a single needle 12 as shown in
[0052] First yarn 14 is shown as a high denier yarn as having a denier of at least 1000 in one embodiment of component filaments 38. Second yarn 16 is shown as a low denier yarn as one having less than 1000. Third yarn 18 could have high, low (and/or higher or lower denier). Fourth yarn 15, etc., could have high, low (and/or higher or lower) denier. Other embodiments may have other denier differentials. Furthermore, for at least some embodiments, first yarn 14 has a higher denier than second yarn 16 such as at least about by , or more than the second yarn 16 if not a fixed amount such as 50 more. For some embodiments, this could mean first yarn 14 could have a denier of 1300 and the second yarn 16 could have a denier of 1250. In other embodiments the first yarn 14 could have a denier of 2000 and the second yarn 16 could have a denier of 1250. Denier could range from less than 10 to roughly 7000 for various yarns. Additionally, second yarn 16 (or any of the other yarns 14,18) may not be heat set for some embodiments. For at least some embodiments, it is desirable for no-twist yarns to not be heat set. On the other hand, high twist yarns could be heat set. A combination of higher denier yarns combined with lower denier yarns has been found to provide better performing carpet than would be expected, while still being effective. Wear testing, such as performed under ASTM D 5252, ASTM D 5417, D 6119 Foot Traffic or other testing is believed to exhibit better performing carpets than would be expected.
[0053] When utilizing multiple yarns 14-18 through a single needle 12, one may do this in multiple fashions whether it be parallel feeding, piggy backing, twisting, cabling, core-cabling such as shown in co-pending application Ser. No. 14/160,123, incorporated herein by reference, or other technologies whereby multiple yarns would be simultaneously fed through a single eye 20 of a needle 12. All these type configurations of the present construction are believed to provide an aesthetic look which differs from prior art configurations. Specifically, the present embodiments preferably use pre-dyed yarns such as solution dyed yarns as first and second yarns 16,18.
[0054] It may be possible that one of the first, second and third yarns 14,16,18 has a higher denier than the other two or that when tufting two or more yarns such as 14,18 a first yarn 14 may have a higher denier than second yarn 16, etc.
[0055] The applicant has found that a denier differential of at least about 50, 100, 150, 250, 300, if not more, may give rise to a perceivable aesthetic and/or functional difference. Another way to describe the denier differential for some embodiments is that the first yarn 14 denier is 120%, 125%, 150% or even 200% or more of the denier of the second yarn 16.
[0056] Additionally, the applicant has discovered that a high denier product such as of about 1000 or more can be relatively easily distinguished from a lower denier such as one of less than 1000. In such a case, the denier differential may be as low as 50 or less than 20% for at least some embodiments, but still give rise to a difference than not only aesthetics but also into the performance of the tufted carpet as shown on the figures.
[0057] It should also be noted that the first and second yarns 14,16 could be selected as having the same or similar density with a different denier and still provide a twist differential.
[0058] Accordingly, applicant believes that denier differential is desirable in many embodiments.
[0059] In a similar manner,
[0060] While two yarns have been routinely directed through a single needle, whether twisted or joined through the process of the Creel patents of U.S. Pat. Nos. 5,531,392 and 5,613,613, adding the third 18, fourth 15 or fifth yarns 17 is not a normal procedure to proceed through a single eye 20 of a needle 12. For a tenth gauge machine total denier may be to about 7000 of all of the yarns 14,16,18,15,17 without changing needles and/or gauge for many embodiments. Usually the total denier may be less than 3500 for at least some embodiments.
[0061] The applicant has discovered that first and second yarns 14,16 can be twisted, cabled, or otherwise joined meaning fed or combined together, whether as a twisted pair with one of a predetermined twist rate along the entire length, a changing twist rate, and/or a random twist rate, or as joined yarns as could be combined in a similar or dissimilar manner as the Creel type patents of U.S. Pat. Nos. 5,531,392 and 5,613,613. In applicant's preferred embodiments, the yarns 14,16,18,15,17 are not secured to one another before proceeding through the eye 20 of the needle 12. Instead, it may be that first and second yarns 14,16 are twisted, cabled, and/or otherwise run together and then joined with third yarn 18, but are preferably directed from a common beam to an eye of the needle Not only can colors of the various yarns 14,16,18,15,17 be different, but the deniers 14,16,18,15,17 utilized may assist to provide aesthetic and/or other features not present in the marketplace to date.
[0062] Twisters can be utilized to provide the yarns directed to the group of yarns 14,16,18 and possibly including either of 15,17 as they are then could be wound about cones, beams or other structures for feeding to the eye 20 of a needle 12. Twisters traditionally are being used by the applicant and rated at about 75 yards per minute. Cabling techniques could also be utilized as could warpers, creels, beams and/or other supplies employed to direct the various yarns 14,16,18,15,17 as desired to a single eye 20 of a needle 12 to create various effects with at least two different deniers when tufted to become carpet as understood by those in the art.
[0063] Twisters can be utilized to twist the yarns and/or other methods of providing the twisted yarn could also be provided, such as warpers, creels, beams, cabling methodology and/or other techniques.
[0064] Additionally, when twisting or otherwise joining yarns, which is shown in a schematic in
[0065]
[0066] Additionally, in the context of combining yarns together with twist, what is known with a prior application of the applicant is to run a second yarn supply 204 through a first yarn supply 202 (as explained by the applicant in a copending patent application). However, no one has ever rotated the first yarn supply 202 at the first yarn supply while running a second yarn supply 208 through the first yarn supply 202 such as by using at least one of first and second gears 210,212, the first gear being run by a motor 214 or otherwise so that the twist rate of twisted yarns such as at location 216 is greater than it otherwise would have been without the use of the rotation of the first yarn supply 206. There are certainly other ways that also could be employed to provide a desired rate of twist between at least two if not more than two yarns as well as about one more yarns.
[0067] While warper 300 is being shown as the instrument of choice, this could certainly be done with a twister or other cabling or joining equipment. Furthermore, although one fan 306 is shown, it would also be understood that more than one fan 306 and others could be utilized. Furthermore, selectively changing the speed of the fan or the direction of air flow against the yarns 308,310 during the joining process.
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[0069] The yarns proceeding through needle 412, which is shown beside needle 418, could be one of a set of needles as driven by a tufting machine 420 as understood by those of ordinary skill in the art to manufacture carpet 410. The needle 412 is provided with first, second and third yarns 422,424,426 which are solution dyed yarns as opposed to skein, space or piece dyed yarns. Accordingly, these yarns are manufactured to a specific color. The applicant is unaware of any other party utilizing a combination of solution dyed yarns 422,424,426 in a multiple manner through a single needle 12 when manufacturing carpet 10.
[0070] When tufting, tufting machines operate by directing backing 416 in a linear direction such as direction 428 shown in
[0071] There are various ways to loosely twist yarn in the marketplace. Applicant has copending application Ser. No. 14/160,123 filed Jan. 21, 2014 incorporated herein by reference in its entirety. Twisting can intentionally reverse direction over a length of yarn using various techniques. Furthermore, randomization may also result in an appearance of reversing direction of twist over a length. Randomization may include re-orienting which occurs in yarn bundles 74 having at least three yarns A,B,C with at least one of the yarns changing relative positions relative to the others over a length. See also 62/217,251 filed Sep. 11, 2015, 62/168,001 filed May 29, 2015, and Ser. No. 14/617,054 filed Feb. 9, 2015, and/or 62/217,232 filed Sep. 11, 2015, all of which are incorporated by reference herein in their entirety.
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[0073] For some embodiments, the yarns 422-426 could be twisted, cabled, warped, or otherwise joined together such as up to one twist for every inch which would be tight for many applications but more likely one twist for every 12 inches or one twist for every 24 inches or even looser twists as could occur through the various twisting or randomization methods. One half twist over every 12 inches or 24 or even 48 inches, particularly if random in nature over that distance could still create a striated look. It is further anticipated that random twists or even reverse twisting such as twisting to the right, which is one twist for every 24 inches, or twisting left, which is one twist for every 24 inches, preferably without pre-knotting, in between changing twist directions could be accomplished through various methodologies. It is anticipated that a first twist direction could occur for up to 20 feet or more if not once every ten feet for those embodiments (and then switch). Random twists can be imparted from various techniques as well as predetermined changes in twists for various embodiments.
[0074] Although twist is certainly discussed as a means to quantify how the yarns are bundled relative to one another, randomization relates to the relative change in position and for many embodiments, the relative position of the yarns is likely to change over a predetermined length, such as one foot, it is likely that at least one of the yarns will have moved at least 30 degrees relative to the other (like the approximately 60 degrees yarn A is shown moved from
[0075] More likely, warpers may be used to warp multiple yarns together onto a single cone while blowing a fan onto the yarns so that as the yarns are fed onto the cone, the relative positions change, and then tend to reverse, so that over a 100 foot length there may be relatively no net twist, but in any individual segment of 10 feet, there is likely to be some variation as to the relative orientation of the yarns relative to one another.
[0076] Furthermore, for re-orientation, which could occur with more than two yarns A,B,C, it is anticipated that the relative placement of the yarns A,B,C, may change over a set length for at least some embodiments, such as, on average, within a length of 50 or 100 feet, or even within 1000 feet. This means that there is not necessarily a twist, but the relative placement of the yarns relative to one another changes (see the difference between
[0077] For more quantification for at least some embodiments, the angular relationship of at least one yarn can change over a length relative to another. For instance, yarn A moves at least 30 degrees between
[0078] The lengths as expressed herein could relate to either the yarns bundle 474 as it is fed to the needle 412 and/or the length of any particular row, such as first row 30, as expressed quantitatively for claiming purposes.
[0079] As can be seen with reference to
[0080] In addition to first and second yarns 422,424 as shown in
[0081] As one can see with reference to
[0082] Accordingly, one may see in many embodiments a twist pattern could be random of the first, second and/or third yarns 422,424,426 as well as other combinations of any other yarns shown herein. Furthermore, although three yarns 422-425 are shown twisted, there certainly could be two yarns provided together from needle 412 and more than three yarns as would be understood by those of ordinary skill in the art as directed through each of the various needles 412,418. Differing deniers can add to this effect.
[0083] The carpet of
[0084] In addition to the linear striation along a single height as is possibly shown in
[0085] One can anticipate that the relative twisting of yarns could be relative loosely which is defined as less than one complete twist per six inches and in many embodiments less than one twist per twelve inches or one twist for 24 inches and that the twist rate will change over length, preferably constantly changing for many embodiments as described above and herein.
[0086] In addition to manufacturing carpet 410 according to the present preferred embodiment of the present invention, one can also manufacture carpet tile by cutting the carpet 410 into predetermined shapes which are normally rectangularly (i.e., square) after tufting. By having the striated look as is shown in
[0087] It may be possible to provide extruded yarn calculated to be striated as it is provided from the spinnerets as a single yarn. When manufacturing these yarns, it may be that different filaments may be combined together so that the individual yarn strands provides the appearance of being striated along its length. However, these techniques would relate to a single yarn and not multiple yarns as directed through a single needle.
[0088]
[0089] Numerous alterations of the structure herein disclosed will suggest themselves to those skilled in the art. However, it is to be understood that the present disclosure relates to the preferred embodiment of the invention which is for purposes of illustration only and not to be construed as a limitation of the invention. All such modifications which do not depart from the spirit of the invention are intended to be included within the scope of the appended claims.