카페트의 다양한 제직방법(기계종류)manufacturing methods
1)엑스민스터 직기
....................... (1) 그립퍼 타입
....................... (2) 스풀 타입
2)윌튼 직기
....................... (1) Woven
....................... (2) Face to Face
3)터프트 카페트
4) Flat 제직
5) 본딩 제직
6) 니들펠트 부직포
엑스민스터와 윌튼기계로 제직한 전통적인 직조카페트는 200여년간 생산되어왔다.
카페트를 제직하고 있는 기계는 해를 거듭하면서 상당히 변화했지만,파일사와 바닥사를 엮어서 제직하는 기본원리는 거의 변화가 없는 상태이다.
다음은 일반적으로 카페트산업에서 생산에 쓰고 있는 방법들이다. (외국자료)
1-1.Woven axminster (Gripper)
-In an axminster gripper weave, cut tufts of yarn are inserted at the point of weaving by means of grippers.
-For each tuft to be inserted along the width of the carpet, there is a corresponding metal gripper which rises from the bed of the loom to grip the appropriate coloured end of yarn from the vertical yarn carrier.
-A knife blade slices the tuft to the correct length, the gripper then returns to the bed of the loom and places the tuft in the appropriate position, the weft shots of the backing yarns then bind it into place.
-A beater bar pushes each row of tufts and weft shots tightly against one another to form the carpet.
-The “beatup” (rows) can vary from as low as 5 to 14 rows per inch, or even higher if required. Different coloured ends of yarn (according to design) can be selected from the yarn carrier, which is raised or lowered by means of a jacquard (punched card) mechanism.
-Many different colours can be used in this weaving method. More modern looms have electronic jacquards which enable them to produce very complicated designs with almost infinite pattern repeats.
1-2.Woven axminster (Spool)
-In a spool axminster weave, the coloured yarns for each weft-wise row are wound on separate spools according to the design.
-The spools are suspended above the loom in design sequence on a series of chain mechanisms.
-The yarns from each spool are threaded through tubes, which hang downwards with the yarn protruding.
-The rows of spools on the chains move one forward for each new row of carpet.
-The row of spools due to form the next row of tufts is lowered from the overhead chain into the loom so that the yarn falls between the warp chains.
-A dummy comb set underneath the loom moves upwards and turns the loose end of the yarn up into the “U” shape of the tuft.
-The tufts are severed from the yarn tubes and three weft backing yarns shots bind the tuft in place.
-The spool is then replaced in the design sequence on the chains and another one takes its place.
-The “beatup” or rows per inch of the spool axminster is similar to gripper axminster.
2-1.Woven wilton
-A traditional wilton weave carpet is one in which the pile threads run continuously into the carpet and are raised above the surface of the integral backing by means of wires or hooks.
-Wilton carpets are often cut or loop products and different yarn types can be used to produce different surface textures.
-Wilton weaving is not as versatile as axminster for the production of patterned carpets, due to continuous yarns that create waste yarn on the back of the carpet.
2.2 Typical face to face wilton weave
-Wilton carpets are woven on looms designed and built by our own engineers in our own factory.
-They differ from traditional wilton looms as they have no “dead” or wasted yarns in the back.
-These advanced design looms weave two carpets as a sandwich, know as \face to face\, which is then sliced into separate rolls.
-As with traditionally woven wilton carpet, Brintons face to face looms produce a durable woven product, which is hard wearing and dimensionally stable.
-The carpet does not suffer from the delamination and stability weakness often associated with tufted carpets.
-Wilton carpets are available from stock in a wide range of textures and plain colours.
-For many years, wilton woven carpets were considered to have better wear properties than axminster but, with modern looms, axminster carpets can be engineered to perform as well as, or better than, wilton products.
General characteristics of woven carpet
-A woven carpet cannot delaminate in use as the backing is an integral part of the whole carpet.
-The structure is 3 dimensional and as many as 12 backing yarns can support each individual tuft.
-A woven carpet will absorb considerable stresses and strains during use, which is a very important consideration for heavy wear areas.
-Generally high quality woven carpets use robust yarns which ensures the carpet\'s performance in use.
-Woven or slit selvedges are produced with a woven product allowing accurate pattern match and ease of installation.
-Pattern definition on woven carpets using pre-dyed yarns is also excellent.
3.Tufted
-A number of needles arranged across the width of the machine stitch yarns into a primary backing cloth, which is fed through the machine.
-Once the pile has been created, it is held in place by a latex backing.
-Secondary backings can be applied to add weight and handle to the product.
-Both cut and loop can be produced in the same carpet.
General characteristics of tufted carpet
-Although some tufting machines are capable of producing carpet using many different types of yarns, the most economic are those produced from yarns less likely to break during manufacture.
-It is for this reason that nylon, and in particular continuous filament nylon yarns, predominate the tufted market, although higher priced wool/nylon blends are also produced.
-Tufted carpet styles range from loop, cut pile and combinations of cut and loop, and with different pile heights across the carpet.
-A number of patterning techniques are available which are achieved by stepping or zig zagging individual needle bars.
-This style of patterned carpet is frequently referred to as graphics pattern.
-Generally, the pattern capability of any tufted is not as versatile as a woven axminster.
-Some tufteds are also subject to delamination of the secondary back from the primary backing.
-Delamination tends to occur with more highly patterned products due to inadequate adhesion of the secondary back to the uneven primary backing.
-Accurate pattern match across a tufted carpet is difficult to achieve since the process does not produce a woven or slit selvage such as that formed with most woven products.
-Pattern match from one carpet to another is less accurate than with woven carpets.
4.Flatweave
-This is a typical flatweave construction.
-It is a basket weave effect, the polypropylene and wool yarn wefts are either raised or lowered for the wool warp yarns to pass under or over them with each different shot.
5.Bonded
-Bonded carpet is produced by implanting loops or yarns directly onto an adhesive coated backing.
-This method of production differs from tufted carpet as the yarns are not stitched into the primary backing before the adhesive is applied.
6.Needlefelt
-A web laid either lengthwise, crossways or diagonally is mechanically consolidated on the needle machine and is simultaneously needled into a loosely woven jute backing.
-The resulting material is then anchored using a latex binder, compressed and levelled on a press or calender.
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