U.S. patent application number 10/338819 was filed with the patent office on 2004-07-08 for method for weaving floor coverings.
Invention is credited to Carvalho, John, Samel, Hiram, Voiers, Leslie, Wylde, Seddon.
Application Number | 20040129333 10/338819 |
Document ID | / |
Family ID | 32681513 |
Filed Date | 2004-07-08 |
United States Patent
Application |
20040129333 |
Kind Code |
A1 |
Samel, Hiram ; et
al. |
July 8, 2004 |
Method for weaving floor coverings
Abstract
A method of producing a floor covering including the steps of
providing two sets of yarns and machine weaving the sets of yarns
such that the second set of yarns is in the weft direction and
forms at least a substantial portion of the visible part of the
floor covering. A floor covering includes a set of suitable warp
yarns and a set of suitable weft yarns woven in a direction
perpendicular to the warp yarns, where the weft yarns form at least
a substantial portion of the visible part of the floor covering. A
method of producing a floor covering including the steps of cutting
selvage edges of first and second floor covering segments to form
corresponding sets of upper and lower selvedge portions, removing
the respective lower portions, and joining the corresponding upper
selvedge portions by hand stitching.
Inventors: |
Samel, Hiram; (Boston,
MA) ; Carvalho, John; (Fall River, MA) ;
Voiers, Leslie; (Harrisville, NH) ; Wylde,
Seddon; (Cambridge, MA) |
Correspondence
Address: |
LOWRIE, LANDO & ANASTASI
RIVERFRONT OFFICE
ONE MAIN STREET, ELEVENTH FLOOR
CAMBRIDGE
MA
02142
US
|
Family ID: |
32681513 |
Appl. No.: |
10/338819 |
Filed: |
January 7, 2003 |
Current U.S.
Class: |
139/383R |
Current CPC
Class: |
D03D 1/00 20130101; D03D
23/00 20130101; D10B 2503/04 20130101 |
Class at
Publication: |
139/383.00R |
International
Class: |
D03D 025/00; D03D
023/00 |
Claims
What is claimed is:
1. A method of producing a floor covering, comprising: providing a
first set of yarns; providing a second set of yarns; and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering.
2. The method of claim 1, wherein the second set of yarns forms
more of the visible part of the floor covering than is formed by
the first set of yarns.
3. The method of claim 1, wherein the second set of yarns forms
substantially more of the visible part of the floor covering than
is formed by the first set of yarns.
4. The method of claim 3, wherein the second set of yarns forms at
least about seventy-five percent of the visible part of the floor
covering.
5. The method of claim 1, wherein the second set of yarns forms
substantially all of the visible part of the floor covering.
6. The method of claim 5, wherein the second set of yarns forms at
least about ninety-five percent of the visible part of the floor
covering.
7. The method of claim 1, wherein the yarns of the second set have
a weight of between about 288 and about 1,760 yards per pound.
8. The method of claim 7, wherein the yarns of the second set have
a weight of between about 576 and about 832 yards per pound.
9. The method of claim 1, wherein the second set of yarns makes up
between about 85 percent and about 95 percent of the total weight
of the floor covering.
10. The method of claim 10, wherein the second set of yarns makes
up about 92 percent of the total weight of the floor covering.
11. The method of claim 1, wherein the first and second sets of
yarns are woven at a density of between about 75 and about 100 ends
per inch.
12. The method of claim 11, wherein the number of ends per inch is
about 85.
13. The method of claim 1, wherein the first and second sets of
yarns are woven at a density of between about 25 and about 65 picks
per inch.
14. The method of claim 13, wherein the number of picks per inch is
between about 40 and about 50.
15. The method of claim 1, wherein the first and second sets of
yarns are woven at a rate of between about 75 and about 250 picks
per minute.
16. The method of claim 1, wherein the floor covering has a weight
of between about 1.65 pounds per square yard and about 3.0 pounds
per square yard.
17. The method of claim 16, wherein the floor covering has a weight
of about 2.25 pounds per square yard.
18. The method of claim 1, wherein the yarns of the first set have
a cotton count between 20/2 and 80/2.
19. The method of claim 18, wherein the yarns of the first set have
a cotton count of 40/2.
20. The method of claim 1, wherein the floor covering has at least
one edge and further comprising the step of applying a border to
the at least one edge.
21. The method of claim 1, wherein the floor covering has at least
one face and further comprising the step of applying a backing to
the at least one face.
22. A floor covering, comprising: a set of warp yarns suitable for
use in a floor covering; and a set of weft yarns suitable for use
in a floor covering, the weft yarns woven in a direction
perpendicular to the warp yarns, wherein the weft yarns form at
least a substantial portion of the visible part of the floor
covering.
23. The floor covering of claim 22, wherein the weft yarns form
more of the visible part of the floor covering than is formed by
the warp yarns.
24. The floor covering of claim 22, wherein the weft yarns have a
weight of between about 288 and about 1,760 yards per pound.
25. The floor covering of claim 22, wherein the warp yarns have a
cotton count between 20/2 and 80/2.
26. The floor covering of claim 22, wherein the yarns are woven at
a density of between about 75 and about 100 ends per inch.
27. The floor covering of claim 22, wherein the floor covering has
a weight of between about 1.65 pounds per square yard and about 3
pounds per square yard.
28. The floor covering of claim 22, wherein the floor covering has
at least one edge and further comprising a border positioned
adjacent the at least one edge.
29. The floor covering of claim 22, wherein the floor covering has
at least one face and further comprising a backing positioned
adjacent the at least one face.
30. A method of producing a floor covering, comprising: providing a
first segment of a floor covering including a set of warp yarns
woven with a set of weft yarns, the first segment having a first
selvage edge; providing a second segment of a floor covering
including a set of warp yarns woven with a set of weft yarns, the
second segment having a second selvage edge; cutting the first
selvage edge to form a first top half and a first bottom half;
cutting the second selvage edge to form a second top half and a
second bottom half; removing the bottom halves of the respective
segments; and joining the top halves by hand stitching.
31. A method of producing floor coverings, comprising: providing a
set of warp yarns; providing a first set of weft yarns; machine
weaving the warp yarns and the first set of weft yarns to form a
first floor covering or floor covering segment; replacing at least
one of the weft yarns to form a second set of weft yarns; and
machine weaving the warp yarns and the second set of weft yarns to
form a second floor covering or floor covering segment.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to methods for weaving floor
coverings.
BACKGROUND OF THE INVENTION
[0002] Conventional woven floor coverings, such as rugs and
carpets, are manufactured on looms in which the yarns that give the
floor covering its color or form its pattern are supplied from the
warp direction. The warp yarns, which may number in the thousands,
or even tens of thousands, are woven with generally uniform weft
yarns to form the rug or carpet. One of the principal drawbacks of
this method is that it is very difficult and time consuming to
change the colors or pattern of the floor covering because changing
the warp yarns may mean changing, usually by hand, thousands and
thousands of creels. For this reason, it can be quite expensive to
produce rugs of differing colors and patterns. In cases in which
the quantity desired of a particular color or pattern is small, the
cost of configuring the warp yarns may be so high as to render
production of the pattern financially impractical.
SUMMARY OF THE INVENTION
[0003] One aspect of the invention provides a method of producing a
floor covering that includes the steps of providing a first set of
yarns, providing a second set of yarns, and machine weaving the
first set of yarns in a warp direction with the second set of yarns
in a weft direction, wherein the second set of yarns forms at least
a substantial portion of the visible part of the floor
covering.
[0004] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms more of the visible part of the floor covering than is formed
by the first set of yarns.
[0005] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms substantially more of the visible part of the floor covering
than is formed by the first set of yarns.
[0006] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms substantially all of the visible part of the floor
covering.
[0007] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the yarns of the second set have a
weight of between about 288 and about 1,760 yards per pound or,
more narrowly, between about 576 and about 832 yards per pound.
[0008] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the second set of yarns makes up
between about 85 percent and about 95 percent of the total weight
of the floor covering or, more narrowly, about 92 percent of the
total weight of the floor covering.
[0009] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the first and second sets of yarns are
woven at a density of between about 75 and about 100 ends per inch
or, more narrowly, at a density of about 85 ends per inch.
[0010] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the first and second sets of yarns are
woven at a density of between about 25 and about 65 picks per inch
or, more narrowly, at a density of between about 40 and about 50
picks per inch.
[0011] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the first and second sets of yarns are
woven at a rate of between about 75 and about 250 picks per
minute.
[0012] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the floor covering has a weight of
between about 1.65 pounds per square yard and about 3.0 pounds per
square yard or, more narrowly, about 2.25 pounds per square
yard.
[0013] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, and machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering, and wherein the yarns of the first set have a
cotton count between 20/2 and 80/2 or, more narrowly, where the
cotton count is 40/2.
[0014] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, and applying a border to at least
one edge of the floor covering, wherein the second set of yarns
forms at least a substantial portion of the visible part of the
floor covering.
[0015] Another aspect of the invention provides a method of
producing a floor covering that includes the steps of providing a
first set of yarns, providing a second set of yarns, machine
weaving the first set of yarns in a warp direction with the second
set of yarns in a weft direction, and applying a backing to at
least one face of the floor covering, wherein the second set of
yarns forms at least a substantial portion of the visible part of
the floor covering.
[0016] Yet another aspect of the invention provides a method of
producing floor coverings that includes the steps of providing a
set of warp yarns, providing a first set of weft yarns, machine
weaving the warp yarns and the first set of weft yarns to form a
first floor covering or floor covering segment, replacing at least
one of the weft yarns to form a second set of weft yarns, and
machine weaving the warp yarns and the second set of weft yarns to
form a second floor covering or floor covering segment.
[0017] Another aspect of the invention provides a method for
producing a floor covering. The method includes the steps of
providing two segments of floor covering, each including a set of
warp yarns woven with a set of weft yarns and each having a selvage
edge. The respective selvedge edges are cut to form respective top
halves and bottom halves. The respective bottom halves are then
removed and the respective top halves are joined by hand
stitching.
[0018] A further aspect of the invention provides a floor covering.
The floor covering comprises a set of warp yarns suitable for use
in a floor covering and a set of weft yarns suitable for use in a
floor covering, where the weft yarns are woven in a direction
perpendicular to the warp yarns and form at least a substantial
portion of the visible part of the floor covering.
[0019] These and other aspects of the present invention will be
apparent from the following detailed description and the appended
claims.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The accompanying drawings are not intended to be drawn to
scale. For purposes of clarity, not every component may be labeled
in every drawing. In the drawings:
[0021] FIG. 1 is a flowchart illustrating one embodiment of a
method of producing a floor covering in accordance with an aspect
of the present invention;
[0022] FIG. 2 is a cross-sectional view of a portion of one
embodiment of a floor covering manufactured in accordance with an
aspect of the present invention;
[0023] FIG. 3 is a perspective view of a portion of the floor
covering of FIG. 2;
[0024] FIG. 4 is a cross-sectional view of a portion of a second
embodiment of a floor covering manufactured in accordance with an
aspect of the present invention;
[0025] FIG. 5 is a perspective view of a portion of the floor
covering of FIG. 4;
[0026] FIG. 6 is a cross-sectional view of a portion of a third
embodiment of a floor covering manufactured in accordance with an
aspect of the present invention;
[0027] FIG. 7 is a perspective view of a portion of the floor
covering of FIG. 6;
[0028] FIG. 8 is a cross-sectional view of a portion of a fourth
embodiment of a floor covering manufactured in accordance with an
aspect of the present invention;
[0029] FIG. 9 is a perspective view of a portion of the floor
covering of FIG. 8; and
[0030] FIG. 10 is a flowchart illustrating another embodiment of a
method of producing a floor covering in accordance with an aspect
of the present invention.
DETAILED DESCRIPTION
[0031] This invention is not limited in its application to the
details of construction and the arrangement of components set forth
in the following description or illustrated in the drawings. The
invention is capable of other embodiments and of being practiced or
carried out in various ways. Also, the phraseology and terminology
used herein is for the purpose of description only and should not
be regarded as limiting. The use of "including," "comprising,"
"having," "containing," "involving," and variations thereof is
meant to encompass the items listed thereafter and equivalents, as
well as additional items.
[0032] The present invention relates to improved methods for
weaving colored or patterned floor coverings. In one embodiment of
the invention, the yarns that form the color or pattern of the
floor covering are woven in the weft direction. Such a method is
opposite the traditional method of machine weaving, in which the
yarns that make up the color or pattern are woven from the warp
direction. Among the advantages of weaving a floor covering with
the color or pattern yarns on the weft is that the colors and/or
pattern may be changed much more easily than in methods where the
yarns that make up the pattern run in the warp direction. The fact
that the colors may be changed easily and inexpensively as compared
to conventional methods may allow a manufacturer to make available
a wider range of floor coverings than has been feasible in the
past. Among the other advantages of such embodiments is that, by
facilitating quick and efficient production of large and small
batches of floor coverings with different colors or patterns, they
may also reduce the need to stock large quantities of floor
coverings and may therefore result in substantial savings in the
form of reduced inventory costs.
[0033] The present invention also relates to methods for joining
segments of colored or patterned floor coverings.
[0034] One embodiment of the invention provides a method for
weaving a colored or patterned floor covering. This method 50,
illustrated in steps 52-56 of FIG. 1, comprises weaving a first set
of yarns in a warp direction with a second set of yarns in a
substantially perpendicular weft direction, such that the weft
yarns form at least a substantial portion of the color or pattern
of the floor covering. As can be seen in steps 52-60 of FIG. 1,
this embodiment allows the colors or pattern to be changed by
simply changing one or more of the relatively small number of yarns
that make up the weft. The warp yarns do not need to be
reconfigured.
[0035] In various embodiments of the invention, the weft yarns may
form more of the visible part of the floor covering than is formed
by the warp yarns, may form substantially more of the visible part
of the floor covering than is formed by the warp yarns, or may form
substantially all of the visible part of the floor covering.
"Visible part" means that portion of the floor covering that can be
seen when the floor covering is placed on a floor or other flat
surface, uncovered by furniture or any other objects, as if for
normal use. Ordinarily, the visible part will be the floor
covering's top face, exclusive of portions covered by edging or the
like. In various embodiments, the weft yarns may make up at least
about 15%, 25%, 50%, 75%, or 95% of the visible part the floor
covering, such percentages to be measured by selecting a fixed area
of the visible part and determining, by visual, optical,
mechanical, digital, or other means, the percentage of the fixed
area that is occupied by weft yarns. It has been found that
increasing the proportion of the visible part that is comprised of
weft yarns allows the appearance of the floor covering to be
changed more easily.
[0036] The set of weft yarns may be one or more colors and, as
described above, may comprise varying portions of the color or
pattern of the floor covering. The weft yarns may include yarns
that form the color or pattern of the floor covering, as well as
yarns that have a principal purpose of tying other yarns or
portions of the floor covering together.
[0037] The set of warp yarns may comprise binder yarns, which may
operate to tie the various yarns and layers together, and stuffer
yarns, which may provide thickness, durability, and weight. The
binder yarns, at least a portion of which may be visible in the
finished product, may in some embodiments be of a color that is
neutral in value, such as an off-white or a light brown. In other
embodiments, the binder yarns may not be neural in value. As noted,
while the color of the binder yarns may contribute to the overall
appearance of the floor covering, their contribution is generally
less than that of the weft yarns. The color of the stuffer yarns
may be less important because they are generally not visible in the
finished product.
[0038] The composition of the warp and weft yarns is not critical
to the invention, and any of the below described embodiments may be
constructed of any suitable type of yarn, including, for example,
natural fibers such as woolens and cottons, synthetic materials
such as rayon, nylon, acrylic, and polyester, and/or any other
suitable material or combination of materials. The yarns may have
any suitable or desired colors, textures, or other aesthetic
characteristics or combination of characteristics.
[0039] Floor coverings according to the invention may be woven on
industrial fabric looms, such as those manufactured by Lindauer
Domier GmbH of Lindau, Germany. The invention is not limited to any
particular brand, type, or model of loom, however, and any suitable
loom may be used, as would be appreciated by one of skill in the
art.
[0040] One reason that materials are conventionally woven with the
color on the warp is that the colored yarns are generally thicker
than the other yarns, in part because they are intended to provide
the material with its appearance. The colored yarns would be
expected to cause problems if machine woven in the weft direction
in a conventional manner because their thickness would create a
large amount of tension on the warp and/or weft yarns as a result
of the beat up. In some cases, the amount of tension could be
sufficient to prevent the warp yarns from being fully hidden and/or
could cause failure of one or more warp yarns.
[0041] It has been found that one solution to the problem of
increased tension is to lower the speed at which the inventive
floor covering is woven. For example, while the looms on which the
inventive floor covering may be woven may conventionally be run at
a rate of about 400 picks per minute with the color on the warp,
floor coverings of some embodiments of the present invention may be
woven on these same looms, but with the color on the weft, at a
rate of between about 75 and about 250 picks per minute. Although
lowering the speed of the loom may mean that manufacture takes
longer than for than conventional materials woven on these looms,
the advantages described above, namely the flexibility in changing
the colors and/or pattern, can outweigh any additional
manufacturing time.
[0042] In one embodiment of the invention, the floor covering is
woven such that relatively thin binder and stuffer warp yarns are
woven with weft yarns that are thicker than a traditional weft
material. The binder yarns that are visible on the face of the
material are generally uniform in color. The result is a floor
covering that has the appearance of being composed of a grid of
small squares or rectangles, not unlike a traditional "needlepoint"
material. The stuffer yarns may be of varying thickness and
densities, so as to provide the appropriate thickness, durability,
and/or weight to the floor covering.
[0043] FIG. 2 shows a portion of a cross-section of an illustrative
"needlepoint"-type floor covering according to the invention. The
cross-section of FIG. 2 is taken in the weft direction and shows
the weft yarns in profile and the warp yarns in cross-section. FIG.
2 depicts the main body 102 of the floor covering, including top
face 104 and bottom face 106, as well as the seam selvedge area
108.
[0044] The floor covering of FIG. 2 employs three types of warp
yarns, primary binders 170a-c, secondary binders 180a-c, and
stuffers 190, and six weft, or "pick," yarns. In the particular
section shown in FIG. 1, picks 110 and 140 lie principally on the
top face 104 of the floor covering, and picks 120 and 150 lie
principally on the bottom face 106 of the floor covering. The
remaining picks 130 and 160 are binder wefts that operate, as
shown, to tie the warp yarns together. The weft yarns may be each
be a different color, allowing the floor covering of this
embodiment to have as many as six different colors on the weft. The
warp yarns, while commonly neutral, may also be colored. As noted,
by providing the color on the weft, as opposed to on the warp, some
or all of the colors of the pattern may easily be changed, as may
the pattern itself.
[0045] FIG. 3 is a perspective view of a portion of the top face of
the floor covering of FIG. 2 in which the spacing between the yarns
has been enlarged for purposes of clarity. From this view, it can
be seen that primary binders 170a-c lie largely on the top face of
the floor covering and, in combination with secondary binders
180a-c, impart a needlepoint-like appearance to the material. It
should be noted that, in this and the other illustrated
embodiments, primary and secondary binders 170, 180 may be fed from
a different beam than the stuffers 190.
[0046] FIG. 3 also illustrates variable interlacement, such as may
be used to impart a particular pattern or design to the floor
covering. In this embodiment, a first warpwise portion defined by
picks 10a-160a has picks 10a and 140a that lie entirely on the face
of the floor covering except where they pass under primary binders
170a-c, and picks 120a and 150a that lie entirely under the face of
the floor covering, except where they pass over secondary binders
180a-b. In a second warpwise portion defined by picks 110b-160b,
however, picks 110b and 140b lie entirely under the face of the
floor covering, except where they pass over secondary binders 180a
or 180b, while picks 120b and 150b lie on the face of the floor
covering, except where they pass under primary binders 170a-c. This
variable interlacement pattern is merely illustrative, however, and
it should be understood that the invention contemplates any number
of other patterns, variable or constant, as would be appreciated by
one of skill in the art.
[0047] FIG. 4 illustrates a portion of another "needlepoint"
embodiment that uses eight weft yarns in conjunction with primary
binders 270a-c, secondary binders 280a-c, and stuffers 290. The
floor covering of this embodiment may thus have as many as eight
colors on the weft. In the particular section shown in FIG. 4,
picks 210 and 240 lie principally on the top face 104 of the floor
covering, and picks 220 and 250, as well as picks 264 and 268, lie
principally on the bottom face 106 of the floor covering. The
remaining picks 230 and 260 are binder wefts that operate to tie
the neutral warp yarns together.
[0048] FIG. 5 is a perspective view of a portion of the face of the
floor covering of FIG. 4 in which the spacing between the yarns has
been enlarged for clarity. From this view it can be seen that,
similar to the floor covering of FIG. 2, primary binders 270a-c lie
largely on the face of the fabric and, in combination with
secondary binders 280a-c, impart a needlepoint-like appearance to
the floor covering. FIG. 5 also illustrates a variable
interlacement pattern. In first a warpwise portion defined by picks
210a-260a, picks 210a and 240a lie entirely on the face of the
floor covering except where they pass under primary binders 270a-c,
while picks 220a, 264a, 250a, and 268a lie entirely under the face
of the floor covering, except where they pass over secondary
binders 280a-c. In a second warpwise portion defined by picks
210b-268b, however, picks 210b and 240b lie entirely under the face
of the floor covering, except where they pass over secondary
binders 280a-b, while picks 220b and 250b lie on the face of the
floor covering, except where they pass under primary binders
270a-c. This variable interlacement pattern is also only
illustrative, however, as the invention includes any number of
other variable or non-variable patterns.
[0049] The floor covering of FIG. 6 is a third exemplar
"needlepoint" construction that employs ten weft yarns in
conjunction with primary binders 370a-c, secondary binders 380a-c,
and stuffers 390. The floor covering of this embodiment may thus
have as many as ten colors on the weft. In the particular section
shown in FIG. 6, picks 310 and 340 lie principally on the top face
104 of the floor covering, and picks 320, 364, 366, 350, 368, and
367 lie-principally on the bottom face 106 of the floor covering.
The remaining picks 330 and 360 are binder wefts that operate to
tie the neutral warp yarns together.
[0050] FIG. 7 is a perspective view of a portion of the face of the
floor covering of FIG. 6 in which the spacing between the yarns has
been enlarged for clarity. From this view it can be seen that,
similar to the floor covering of FIGS. 2 and 4, primary binders
370a-c lie largely on the face of the fabric and, in combination
with secondary binders 380a-c, impart a needlepoint-like appearance
to the floor covering. FIG. 7, like FIGS. 3 and 5, also shows an
exemplar variable interlacement pattern. In first a warpwise
portion defined by picks 310a-360a, picks 310a and 340a lie
entirely on the face of the floor covering except where they pass
under primary binders 370a-c, while the remaining picks lie
entirely under the face of the floor covering, except where they
pass over primary binders 370a-c, in the case of picks 330 and 360,
or over secondary binders 380a-c, in the case of the remaining
picks. In a second warpwise portion defined by picks 310b-360b,
however, pick 310a lies principally on the face of the floor
covering between primary binders 370a and 370c, and pick 340b lies
principally on the face between primary binders 370a and 370b, but
both are largely buried otherwise.
[0051] While the above-described figures show a maximum of ten
different weftwise colors, known currently available commercial
looms allow for up to twelve different colors on the weft. The
invention is not limited to even this amount, however, as it
contemplates any number of colors being provided from the weft
direction.
[0052] The weft yarns of the "needlepoint" embodiment may be one or
more colors and may have any desired uniform or non-uniform size,
weight, texture or appearance. In one embodiment, for example, weft
yarns of varying thicknesses may be used to achieve different
aesthetic effects. Some embodiments of the "needlepoint"
construction may use weft yarns with a Philadelphia or Bradford
count in the range of 3/18 to 1/110 (worsted 3/1.54 to 1/3.1;
approximately 288 to 1,760 yards per pound), or 4/32 to 2/65
(worsted 4/3.6 to 2/3.71; approximately 512 to 1,040 yards per
pound), or 3/36 to 2/55 (worsted 3/3.09 to 2/3.14; approximately
576 to 832 yards per pound). In one preferred embodiment, the
Philadelphia or Bradford count is 3/42 (worsted 3/3.6;
approximately 672 yard per pound). In other preferred embodiments,
the weft yarns may be Nm700 (worsted 1/0.62; 348 yards per pound),
Tex 2000 (worsted 1/44; approximately 249 yards per pound), and/or
4/4 cc (worsted 4/6.0; approximately 840 yards per pound). Yams in
these ranges and/or of these types are generally thick enough to
impart the desired aesthetic effects, while at the same time being
sufficiently thin to be machine woven from the weft direction
without causing excessive tension in the loom.
[0053] The warp yarns of the "needlepoint" embodiment also may have
any suitable uniform or non-uniform texture or appearance, although
it is preferred to employ warp yarns that are generally uniform in
color, such that they provide the appearance of a uniform grid.
Unlike conventional warp yarns, which are generally thicker than
the weft yarns so as to provide the fabric its color and texture,
the face warp yarns of the inventive floor covering may be thin, so
as to be seen as little as possible and/or to provide the
appearance of a uniform grid. In particular, some needlepoint
embodiments may use warp yarns with a cotton count in the range of
20/2 to 80/2 (approximately 8,400 to 33,600 yards per pound), or,
more narrowly, 30/2 to 60/2 (approximately 12,600 to 25,200 yards
per pound). In one preferred needlepoint embodiment, the warp yarns
may have a cotton count of 40/2, or approximately 16,800 yards per
pound. The number of warp ends per inch in the finished needlepoint
floor covering may be in the range of about 65 to about 110, or,
more narrowly, in the range of about 75 to about 100 ends per inch.
In one preferred embodiment, the floor covering is woven at about
85 ends per inch.
[0054] In another embodiment of the invention, the floor covering
is woven such that relatively thin binder warp yarns are combined
with thicker stuffer warp yarns and woven with relatively thick
weft yarns in such a way as to result in a "grosse pointe"
construction, characterized by pronounced warpwise rows or
ridges.
[0055] FIG. 8 depicts a portion of an embodiment of a "grosse
pointe" floor covering according to another embodiment of the
invention. The floor covering of FIG. 8 employs six weft yarns and
thus may have as many as six colors on the weft. This embodiment
includes three types of warps, including face yarns 470a-c,
backbinder yarns 480a-c, and stuffer yarns 490. Although this floor
covering has the same number of colored weft yarns as the floor
covering of FIG. 2, it has a very different appearance. The binder
wefts 430 and 460 both pass over adjacent face yarns (e.g., 470a,
470b) and under an intervening backbinder (e.g., 480a), creating
pockets (e.g., 485a) that, when filled with stuffer yarns 490,
create pronounced ridges running in the warp direction. The size of
the ridges may be controlled by the use of lighter or heavier
stuffer yarns 490. Light colored face warps 470 may be used in some
embodiments to provide a contrast with darker face weft yarns and
enhance the visual effect of the rows.
[0056] A portion of the floor covering of FIG. 8 can be seen in
perspective in FIG. 9, which also shows that the face of this
exemplar embodiment is dominated by the weft yarns 410a and 440a in
a lower portion defined by weft yarns 410a-460a, while a different
pattern of interlacing brings yarns 420b and 450b to the face in a
second portion defined by weft yarns 410b through 460b. In
different embodiments, face warp yarns of different colors may be
used to provide different effects.
[0057] As with the needlepoint construction, the warps yarns of the
"grosse pointe" embodiment may be of varying sizes, textures,
appearances, and/or colors, and warp yarns of varying
characteristics and/or appearances may be used to achieve different
aesthetic or physical effects. Some embodiments of the "grosse
pointe" construction may use weft yarns with a Philadelphia or
Bradford count in the range of 3/18 to 1/110 (worsted 3/1.54 to
1/3.1; approximately 288 to 1,760 yards per pound), or 4/32 to 2/65
(worsted 4/3.6 to 2/3.71; approximately 512 to 1,040 yards per
pound), or 3/36 to 2/55 (worsted 3/3.09 to 2/3.14; approximately
576 to 832 yards per pound). In one preferred embodiment, the
Philadelphia or Bradford count is 3/42 (worsted 3/3.6;
approximately 672 yard per pound). In other preferred embodiments,
the weft yarns may be Nm700 (worsted 1/0.62; 348 yards per pound),
Tex 2000 (worsted 1/44; approximately 249 yards per pound), and/or
4/4 cc (worsted 4/6.0; approximately 840 yards per pound). Yarns of
these types and/or in these ranges are generally thick enough to
impart the desired aesthetic effects, while and the same time being
sufficiently thin to be machine woven from the weft direction
without causing excessive tension in the loom.
[0058] Like the warp yarns of the needlepoint arrangement, the face
warp yarns employed in the grosse point construction may be thin,
so as to be seen as little as possible. The warp yarns may have a
cotton count in the range of 4/4 to 10/2 (approximately 840 to
4,200 yards per pound), or, more narrowly, 3/2 to 8/2
(approximately 1,260 to 3,360 yards per pound). In one preferred
"grosse pointe" embodiment, the warp yarns may have a cotton count
of 8/4, or approximately 1,680 yards per pound. The finished
"grosse pointe" floor covering may have in the range of about 20 to
about 40 ends per inch and, in one particular embodiment, may be
have about 28 ends per inch.
[0059] The heavy weft yarns of some embodiments may result in a
floor covering that has fewer weft picks per inch than in
conventional materials woven on the same loom. The needlepoint and
grosse point embodiments, for example, may be woven at between
about 25 and about 65 picks per inch, and preferably between about
40 and about 50 picks per inch.
[0060] As a result of weaving with heavier yarns on the weft, floor
coverings according to the invention are also heavier that other
materials woven on the same type of looms. In one embodiment, for
example, a floor covering woven according to the present invention
weighs between about 2 and about 3 pounds per square yard and, in
one particular embodiment, the floor covering weighs about 2.4
pounds per square yard. In contrast, the types of materials
typically woven on these types of looms generally weigh in the
range of less than 2 pounds per square yard. In addition, because
the weft is heavier than is conventional, floor coverings produced
according to the invention also have a larger proportion of their
total weight made up of yarns from the weft. In one embodiment, for
example, the weft makes up between about 85 and about 95 percent of
the total weight of the material and, in one preferred embodiment,
the weft makes up about 92 percent of the total weight of the
material.
[0061] In another aspect of the invention, a backing may be
positioned adjacent at least one side of the floor covering.
Advantages of a backing include extra strength and durability
conferred to the floor covering, especially where it is intended
for an application in which it will be subjected to many mechanical
stresses. In various embodiments, the backing may be comprised of
any suitable natural or synthetic material. In one embodiment, the
backing may be a type of plastic. The backing may be applied in any
conventional manner, as would readily be appreciated by one of
skill in the art.
[0062] The inventive floor covering, with or without a backing, may
also be cut to any desired dimension or shape. In some embodiments,
the floor covering may be woven on a wide loom, allowing the
production of a wide, continuous sheet of a fabric. The sheet of
material produced by the loom may be cut into any number of desired
shapes having any desired dimensions. The use of such a process may
speed up production of floor coverings and/or may facilitate the
production of a large number of orders for floor coverings of the
same pattern but different sizes.
[0063] In some embodiments, a border may be positioned along all or
a portion of one or more edges of the floor covering to further
strengthen the edges and reduce the possibility of fraying. Such a
border, which may be adhered to the floor covering by stitching,
adhesive, or any other suitable means, may cover the ends of some
or all of the warp and/or weft yarns to prevent fraying and may
comprise any suitable material or materials, including cloth,
paper, plastic, or leather, among others. If the floor covering is
circular, the border can be applied along the circumference.
[0064] Another aspect of the present invention provides a method
for joining segments of a woven floor covering. Such segments would
be employed, for example, where it is desired to produce a floor
covering wider than the operative width of the loom, such as in the
case of a wall-to-wall carpeting.
[0065] In one embodiment of such a joinery method, illustrated
generally as steps 550 through 560 of method 500 in FIG. 10, at
least two segments of floor covering material are provided, each
comprising a first set of yarns that are woven in a warp direction,
and a second set of yarns that are woven in a weft direction. Each
segment of floor covering will have a selvedge edge running along
at least one warpwise side as a by-product of the weaving process.
The two segments are aligned such that their warp yarns are
parallel and the respective selvedge edges of the sides to be
joined are adjacent to each other. The adjacent selvedge edges are
sliced along their outside edges, resulting in an upper selvedge
portion 109a and lower selvedge portion 109b, such as can be seen
in, for example, FIG. 2. The respective lower selvedge portions
109b are then either folded back under the main bodies 104 of the
floor covering segments or simply cut away, and the upper selvedge
portions 109a are then stitched together in a conventional manner
to join the two segments.
[0066] As a result of this joinery method, the inventive floor
coverings may be used in situations that call for floor coverings
that are larger than the operative width of the loom, and the
advantages associated with the inventive method of weaving with the
color on the weft, as discussed above, can be extended to a wider
variety of applications, such as wall-to-wall carpeting. The
combination of weaving with the color on the weft and the
above-described joinery method may therefore allow a wide variety
of large colored and patterned floor coverings, such as
wall-to-wall carpets, to be produced and sold without the expense
associated with changing thousands of creels and without the
expense of maintaining a large inventory.
[0067] Having thus described several aspects of at least one
embodiment of this invention, it is to be appreciated various
alterations, modifications, and improvements will readily occur to
those skilled in the art. Such alterations, modifications, and
improvements are intended to be part of this disclosure, and are
intended to be within the spirit and scope of the invention.
Accordingly, the foregoing description and drawings are by way of
example only.
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