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.

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.