SOFTbank E-Book Center Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir Woodhead Publishing in Textiles: Number 87 Advances in carpet manufacture Edited by K. K. Goswami © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir Published by Woodhead Publishing Limited in association with The Textile Institute Woodhead Publishing Limited, Abington Hall, Granta Park, Geat Abington Cambridge CB21 6AH, UK www.woodheadpublishing.com Woodhead Publishing India Private Limited, G-2, Vardaan House, 7/28 Ansari Road, Daryaganj, New Delhi ± 110002, India Published in North America by CRC Press LLC, 6000 Broken Sound Parkway, NW, Suite 300, Boca Raton, FL 33487, USA First published 2009, Woodhead Publishing Limited and CRC Press LLC ß Woodhead Publishing Limited, 2009 The authors have asserted their moral rights. This book contains information obtained from authentic and highly regarded sources. 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Trademark notice: product or corporate names may be trademarks or registered trademarks, and are used only for identification and explanation, without intent to infringe. British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging in Publication Data A catalog record for this book is available from the Library of Congress Woodhead Publishing Limited ISBN 978-1-84569-333-6 (book) Woodhead Publishing Limited ISBN 978-1-84569-585-9 (e-book) CRC Press ISBN 978-1-4200-9491-6 CRC Press order number: N9491 The publishers' policy is to use permanent paper from mills that operate a sustainable forestry policy, and which has been manufactured from pulp which is processed using acid-free and elemental chlorine-free practices. Furthermore, the publishers ensure that the text paper and cover board used have met acceptable environmental accreditation standards. Typeset by Godiva Publishing Services Ltd, Coventry, West Midlands, UK Printed by TJ International Limited, Padstow, Cornwall, UK © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir Contents Contributor contact details ix Woodhead Publishing in Textiles xi 1 Carpet types and requirements 1 DWHITEFOOT, CText, FTI, UK 1.1 The role of textiles in floor coverings 1 1.2 Types of textile used as floor coverings 5 1.3 Methods of carpet construction 11 1.4 Future trends 17 1.5 Sources of further information and advice 18 2 Structure and properties of carpet fibres and yarns 19 SKCHAUDHURI and S B ANDYOPADHYAY, Australian Wool Innovation, India 2.1 Introduction 19 2.2 Structure and properties of carpet fibres 20 2.3 Carpet yarn manufacturing 27 2.4 Carpet yarn engineering 33 2.5 Yarn finishing 38 2.6 Carpet yarn testing and quality control 42 2.7 Future trends 43 2.8 Sources of further information and advice 43 2.9 References 43 3 Advances in carpet weaving 44 SDEMEY, N V Michel Van de Wiele, Belgium 3.1 Introduction 44 3.2 Face-to-face carpet weaving 45 3.3 Axminster weaving 58 © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir vi Contents 3.4 Wire Wilton and loop pile weaving 61 3.5 Automation in carpet-weaving mills 64 3.6 Management of carpet-weaving factory 68 3.7 Conclusions 75 4 Developments in wool carpet manufacture 77 EJW OOD , AgResearch Ltd, New Zealand 4.1 Introduction 77 4.2 Wool supply and early stage processing 79 4.3 Processing routes for wool 82 4.4 Technologies for wool carpet yarns 83 4.5 Manufacturing techniques for wool carpets 87 4.6 Technologies for tufting wool carpets 87 4.7 Wool carpet performance 93 4.8 Selecting the most appropriate wool carpet 96 4.9 Future trends 96 4.10 Sources of further information and advice 99 4.11 References 100 5 Developments in textile sports surfaces 102 GS CHOUKENS , Ghent University, Belgium 5.1 Introduction 102 5.2 Key requirements of sports surfaces 104 5.3 Types of textiles used in relation to the sports surfaces 104 5.4 Role of textiles in meeting performance requirements 106 5.5 Sliding and temperature, related to the used textiles 119 5.6 Future trends 128 5.7 Applications and examples of artificial turf fields 130 5.8 Acknowledgements 135 5.9 References 135 6 Developments in handmade carpets: introduction 138 KKG OSWAMI , Indian Institute of Carpet Technology, India 6.1 Introduction 138 6.2 The history of handmade carpets 139 6.3 Modern handmade carpet production 143 6.4 Carpet production in India 144 6.5 Carpet production in Iran 148 6.6 Carpet production in China 150 6.7 Carpet production in Pakistan 151 6.8 Carpet production in Nepal 152 6.9 Carpet production in Turkey 152 © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir Contents vii 6.10 Carpet production in Europe 154 6.11 The international trade in carpets 156 6.12 Terminology in carpet production 165 6.13 The role of handmade carpets in modern carpet production 165 6.14 Choosing and maintaining a handmade carpet 169 6.15 Acknowledgements 171 6.16 References 172 Appendix: terminology relating to handmade carpets 173 7 Developments in handmade carpets: design and manufacture 182 KKG OSWAMI , Indian Institute of Carpet Technology, India 7.1 Introduction: key issues in design 182 7.2 Traditional carpet designs 183 7.3 Key stages in design 198 7.4 Carpet materials 200 7.5 Sheep wool 200 7.6 Silk 206 7.7 Cotton 208 7.8 Other natural fibres 208 7.9 Synthetic fibres 210 7.10 Backing materials 211 7.11 Manufacturing techniques 212 7.12 Key terms in manufacturing 229 7.13 Weaving of handmade carpets 230 7.14 Carpet knots 237 7.15 Dyeing 240 7.16 Dyeing of wool 240 7.17 Chemical processing and dyeing of silk 252 7.18 Natural colours for wool and silk carpets 255 7.19 Eco-friendly and organic carpet manufacture 259 7.20 Colour matching 260 7.21 Quality issues 261 7.22 Customer attitudes to quality 264 7.23 Acknowledgements 267 7.24 References 268 8 Reducing static electricity in carpets 269 JS MALLWOOD , Electrostatic Solutions Ltd, UK 8.1 Introduction 269 8.2 Principles of static electricity in carpeted environments 270 8.3 Methods of reducing static electricity in carpet materials 280 8.4 Test methods and standards 281 © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir viii Contents 8.5 Applications 286 8.6 Future trends 288 8.7 Sources of further information and advice 288 8.8 Acknowledgement 289 8.9 References and further reading 289 9 Developments in the thermal processing of carpets 291 WC ARR and H D ONG , Georgia Institute of Technology, USA and H S L EE , Cerro Flow Products, Inc., USA 9.1 Introduction 291 9.2 Carpet yarn twist setting 293 9.3 Carpet dyeing and finishing 297 9.4 Carpet drying after dyeing and finishing 301 9.5 Latex curing 305 9.6 Energy consumption and management 307 9.7 Future trends 309 9.8 References 309 © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir Contributor contact details (* = main contact) Chapter 3 Stefaan Demey N.V. Michel Van de Wiele Chapter 1 Vandewielestraat 7 D. Whitefoot B-8510 Marke C Text, FTI Belgium Liveridge Farm E-mail: [email protected] Ribbesford Bewdley DY12 2UA Chapter 4 UK Dr E. J. Wood E-mail: [email protected] AgResearch Ltd Private Bag 4749 Chapter 2 Christchurch 8140 Dr S. K. Chaudhuri New Zealand Global Head ± Interior Textiles E-mail: [email protected] Australian Wool Innovation 310 Elegance Tower Chapter 5 Jasola District Centre Prof.dr.ir. Gustaaf Schoukens Jasola Ghent University New Delhi ± 110025 Faculty of Engineering Sciences India Department of Textiles E-mail: [email protected] Technologiepark 907 B-9052 Zwijnaarde (Gent) Mr Subhasis Bandyopadhyay Belgium Interior Textiles E-mail: [email protected] Australian Wool Innovation 310 Elegance Tower Jasola District Centre Jasola New Delhi ± 110025 India © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use. www.ebookcenter.ir x Contributor contact details Chapters 6 and7 Chapter 9 Professor K. K. Goswami Dr Wallace Carr and Dr Hongming Indian Institute of Carpet Technology Dong Chauri Road School of Polymer SRN Badohi ± 221 401 Textile and Fiber Engineering Uttar Pradesh Georgia Institute of Technology India USA E-mail: E-mail: [email protected] [email protected] S. Lee Chapter 8 Cerro Flow Products, Inc. Dr Jeremy Smallwood USA Electrostatic Solutions Ltd Southampton UK E-mail: [email protected] © SOFTbank2009 Woodhead E-Book Publishing Center Limited Tehran, Phone: 66403879,66493070 For Educational Use.