Carpet with a Woven Microrelief and Method

Abstract

The present invention relates to a carpet with woven surface relief, comprising at least a series of tension warps (1), a series of binding warps (2), said warps (1, 2) being interwoven with a series of weft yarns (3), the ratio of the length of said binding warps (2) relative to the length of said tension warps (1) being greater than 1.20, preferably greater than 1.50.

1 . Carpet with woven surface relief, comprising at least a series of tension warps ( 1 ), a series of binding warps ( 2 ), said warps ( 1 ,  2 ) being interwoven with a series of weft yarns ( 3 ), wherein said carpet comprises an aspect side and a back side, and wherein a backing layer ( 6 ) is adhered to said back side, characterised in that the ratio of the length of said binding warps ( 2 ) to the length of said tension warps ( 1 ) is greater than 1.50. 
     
     
         2 . Carpet according to  claim 1 , further comprising a second series of tension warps and/or pile warp yarns. 
     
     
         3 . Carpet according to  claim 1 , wherein said carpet comprises at least one weft yarn ( 31 ) which weft yarn is an effect yarn ( 31 ), selected from the group comprising a polyester chenille yarn, acrylic chenille yarn and/or a fancy yarn, selected from the group comprising a woollen yarn, a cotton yarn, a polyamide yarn, a bouclé and/or a frisé yarn. 
     
     
         4 . Carpet according to  claim 1 , wherein said carpet comprises at least one weft yarn ( 32 ), which weft yarn is not an effect yarn, selected from the group comprising cotton and a jute yarn. 
     
     
         5 . Carpet according to  claim 1 , wherein the ratio of the length of said tension warps ( 1 ) to the length of said binding warps ( 2 ) is greater than 1.60 and preferably greater than 1.70. 
     
     
         6 . Carpet according to  claim 1 , wherein the ratio of the length of said tension warps ( 1 ) to the length of said binding warps ( 2 ) is less than 5.0 and preferably is less than 4.0. 
     
     
         7 . Carpet according to  claim 1 , wherein said series of weft yarns ( 3 ) have a greater length density than said series of binding warps ( 2 ). 
     
     
         8 . Carpet according to  claim 7 , wherein the ratio of the length density of said weft yarns ( 3 ) to the length density of said binding warps ( 2 ) is greater than 1.5, preferably greater than 2.0. 
     
     
         9 . Carpet according to  claim 1 , wherein said backing layer ( 6 ) is comprised of a nonwoven, a knit or a fabric. 
     
     
         10 . Carpet according to  claim 9 , wherein said backing layer ( 6 ) is comprised of a nonwoven made of PET, polyester or polypropylene. 
     
     
         11 . Carpet according to  claim 1 , comprising pile warp yarns ( 4 ,  5 ), wherein one or more pile warp yarns ( 4 ,  5 ) are provided with a spacedye pattern. 
     
     
         12 . Carpet according to  claim 1 , comprising pile warp yarns ( 4 ,  5 ), wherein the thickness of at least one pile warp yarn ( 4 ,  5 ) is at least 1.15 times and preferably at least 1.30 times greater than the thickness of at least one warp yarn ( 1 ,  2 ). 
     
     
         13 . Carpet according to  claim 1 , comprising pile warp yarns ( 4 ,  5 ), wherein at least one pile warp yarn ( 4 ,  5 ) is comprised of wool and at least one pile warp yarn ( 4 ,  5 ) is comprised of chenille. 
     
     
         14 . Carpet according to  claim 13 , wherein the ratio of the number of pile warp yarns ( 4 ,  5 ) made of wool to the number of pile warp yarns ( 4 ,  5 ) made of chenille is between 5:1 and 1:1. 
     
     
         15 . Carpet according to  claim 13 , wherein at least one woollen pile warp yarn ( 4 ,  5 ) and at least one chenille pile warp yarn ( 5 ) appear alternately on the surface. 
     
     
         16 . Carpet according to  claim 1 , comprising two or more pile warp yarns ( 4 ,  5 ) which are different from each other. 
     
     
         17 . Method for manufacturing a carpet with woven surface relief, comprising the steps of:
 providing at least a series of tension warps ( 1 ), a series of binding warps ( 2 ) in the warp direction of a weaving frame;   interweaving a series of weft yarns ( 3 ) with said warps ( 1 ,  2 ), thereby obtaining a carpet with an aspect side and a back side;   bonding a backing layer ( 6 ) to said back side;   characterised in that the preliminary tension on said tension ( 1 ) and binding warps ( 2 ) being adjusted so that the ratio of the length of said binding warps ( 2 ) to the length of said tension warps ( 1 ) in the manufactured carpet is greater than 1.50, preferably greater than 1.60.   
     
     
         18 . Method according to  claim 17 , wherein the ratio of the length density of said weft yarns ( 3 ) to the length density of said binding warps ( 2 ) is greater than 1.5, preferably greater than 2.0. 
     
     
         19 . Method according to  claim 17 , further comprising the step of applying a backing layer ( 6 ) comprised of a synthetic foam, a nonwoven, a knit or a fabric on a back side of said carpet. 
     
     
         20 . Method according to  claim 17 , wherein said warp yarns ( 1 ,  2 ) and/or pile warp yarns ( 4 ,  5 ) are arranged in a warp comb with a series of teeth and wherein at least two warp yarns ( 1 ,  2 ) and/or pile warp yarns ( 4 ,  5 ) are arranged between two teeth of said warp comb. 
     
     
         21 . Method according to  claim 20 , wherein one or more warp yarns ( 1 ,  2 ) and/or pile warp yarns ( 4 ,  5 ) are dyed in advance in a spacedye pattern.