Water resistant carpet and method of manufacture the same

Abstract

A carpet and method for making a carpet suitable for both indoor and outdoor use that has a soft and luxurious finish as well as adaptable to stressful outdoor environments. The carpet includes binding chains with both tight warp yarn and slack warp yarn, the slack warp yarn including synthetic fibers and the tight warp yarn including synthetic fibers and natural fibers. Weft is cut from polypropylene film and the pile is formed of polypropylene extruded yarn. The carpet is formed using a rapier loom with a double rapier head system.

1 . A carpet comprising: 
 weft formed from filling yarn;    pile formed from pile yarn; and    binding chains including: 
 tight warp yarn comprising a first synthetic fiber and a natural fiber, and  
 slack warp yarn including of a second synthetic fiber.  
   
   
   
       2 . The carpet of  claim 1 , wherein the first synthetic fiber and the second synthetic fiber include polyester staple fibers.  
   
   
       3 . The carpet of  claim 1 , wherein the natural fiber includes cotton.  
   
   
       4 . The carpet of  claim 2 , wherein the natural fiber includes cotton.  
   
   
       5 . The carpet of  claim 4 , wherein the tight warp yarn includes approximately 80% polyester staple fibers and 20% cotton fibers.  
   
   
       6 . The carpet of  claim 1 , wherein the pile yarn comprises polypropylene extruded yarn.  
   
   
       7 . The carpet of  claim 6 , wherein the polypropylene is dyed.  
   
   
       8 . The carpet of  claim 6 , wherein the pile yarn includes UV stabilizers.  
   
   
       9 . The carpet of  claim 1 , wherein the filling yarn includes polypropylene film.  
   
   
       10 . The carpet of  claim 9 , wherein the filling yarn is twisted at a high twist rate.  
   
   
       11 . The carpet of  claim 10 , wherein the filling yarn is twisted at 40 twists per meter.  
   
   
       12 . The carpet of  claim 11 , wherein the filling yarn is pre-shrunk.  
   
   
       13 . A method of making a carpet using a rapier loom with a double rapier head system comprising: 
 forming sheds within pile yarn and binding chains, the binding chains comprising tight warp yarn comprising synthetic fibers and natural fibers and slack warp yarn comprising synthetic fibers.    inserting weft in the sheds using an insert rapier head and receiving the weft using a receiving rapier head.    
   
   
       14 . The method of  claim 13  further including a step of adjusting a ratio of the tight warp yarn to the slack warp yarn.  
   
   
       15 . The method of  claim 14  wherein the adjusting step comprises the step of increasing the tight warp yarn to result in at least one of added stability, lowered elongation and lowered temperature variation sensitivity.  
   
   
       16 . The method of  claim 13  wherein the weft is cut from polypropylene film and the pile yarn comprises polypropylene extruded yarn.  
   
   
       17 . The method of  claim 13  wherein two carpets are formed simultaneously using a face-to-face weaving system.  
   
   
       18 . The method of  claim 13  wherein the pattern of the carpet is formed using a Jacquard system.  
   
   
       19 . The method of  claim 13  wherein the insert rapier head is made of hard metal and the receiving rapier head is micro ribbed.  
   
   
       20 . The method of  claim 19  wherein the rapier heads are plasma coated.  
   
   
       21 . The method of  claim 13  wherein the insertion head is operated at an advanced position in a cycle and the receiving head is operated at a delayed position in the cycle.  
   
   
       22 . The method of  claim 13  further comprising the step of cutting the weft with scissors, wherein the cutting step is performed at an advanced position in the cycle.