By:- Hemant GhanGhor & Patanjal Kumar

carpet

Woven carpet Tufted carpet

Non woven carpet

Adhesive Bonded Carpet (I-tuft & U-tuft)

Needle Punched carpet

Electrostatically Flocked Carpet

Hand tufted •Cut pile•Loop pile

Machine tufted•Cut pile •Loop pile

HandWoven•Hand knotted •Tibbetan•Hand loom woven

Machine woven

Face to Face •Single rapier•Double rapier•Triple rapier

Axminster carpet•Spool Axminster•Spool Gripper•Chenille •Jacquard Gripper

Wire loom carpet

2--shot electronic jacquard (modern)

3-shot jacquard gripper(conventional)

Brussels weaving (for loop pile)

Wilton weaving (for cut pile)•Single frame•Multi frame

Introduction

• In this weaving of carpet the backing is woven at the same time as pile is inserted so that no major secondary backing process is required

• Originally produced in the English town Axminster

Advantages • Durable carpets • Good quality backing • Simplicity of mechanism• High proportion of effective pile• Unlimited possibilities of color and design• Modern m/c made carpets retained a hand made look• Pattern of texture as well as colors can be produced

with possibility of using pile yarns if different count and twist levels

Yarns used in Axminster carpets

Axminster carpet

Pile yarn•Traditionally wool fibre is used due to ease of cutting•100% wool •80% wool + 20% nylon

Chain warps• Chain warp and weft interlaced to form basic backing of the fabric

• PP• Nylon• PET etc.

Stuffer warp•Lies straight between the weft shots •To provide dimensional stability to carpet in warp direction•Fills the space between the pair of chain warps•Jute , Cotton , PP etc.

Shots (Weft)•Provide dimensional stability in cross direction•E.g Jute etc.

Identification of Axminster carpets

• The pile tufts are anchored by stiff weft shot across the width of carpet

• These shots creates an easily identifiable heavy ridged backing

• These stiff ridged allow the carpet to be rolled only in length wise direction

Types of Axminster carpet

Depending upon principle of loom three different techniques for weaving axminster carpets are :

1.Spool2.Spool Gripper 3.Gripper Jacquard

Spool literally means a cylindrical device on which threads can be wound.

Spool setting: Spools are prepared

The colored yarns are wound onto the spools in the order in which they are to appear in a row across the carpet.

•Firstly the yarn packages are kept on a table in the sequence in which they are to appear in a particular row of the carpet.

•The yarns pass through the reed, and a measured amount is wound onto a spools wound onto a spool

Spool axminster carpets

•The spools are attached to an endless chain.

•The spool required for a particular row of the carpet design is detached from the chain and taken to the wvg. position.

•And the carpet is woven.

Spool Axminster Carpet

weaving

Spool Axminster Loom

Chain wheels and detachable spools

Warp thread

shuttle

sley

Spool feeding tuft into weaving position

Finished Carpet

Knives

Comb folds tuft round shot (weft)

Spool Axminster CarpetProcess of Manufacture

• It is the development of spool axminster system.

• The spools are held by a fret (frame) which are suspended by a chain above the loom.

• The chain brings the frames of spools to the wvg position ready for selection by the grippers.

• The gripper comes ,withdraws the yarn end and move back to the wvg. Position.

• And the cycle continues.

Spool Gripper

Spool Gripper Process of

manufacture :(A) Spool setting

• Essential step which is carried out before the start of weaving process

• Involves the preparation of spools by winding a parallel assembly of pile yarns , with colors in the sequence required in a row of tufts of the carpet to be prepared

• Each individual spool is represented a different row in the design• Spools are fitted onto chain and are transported close to the wvg.

Position • Tuft length are drawn from them by the grippers

(B) Weaving

Ground weave

Pile formation

Same as jacquard gripper looms

Note :- Arc of travel of the grippers is much shorter than in traditional gripper looms , instead of 131 degree it is 64 degree (reducing the time of tuft insertion)

Spool Gripper

Gripper JacquardProcess of Manufacture:

A. Ground weave

Three heald frames (two for chain warp and one for stuffer warp)

Shedding: heald frames comes near the point if fabric formation from below at an angle , leaving space foe pile mechanism

Picking : weft is introduced to the shed by rigid rapier Selvedge formation: As rapier is withdrawn the selvedge is formed

Beat up : By sley , reed

Stuffer warp is moved by heald shaft above and below the rapier (lies straight between the weft shot)

Interlacing of chain and wefts

Creates the basic structure of backing

Gripper JacquardProcess of

Manufacture B. Pile Formation

Withdrawal of required length of pile yarns by the grippers

Cutting of piles of a multiple knife system

Rotation of gripper to point of fabric formation

Placing of tuft length vertically in the point of fabric formation

Insertion of double shot of weft

Movement of gripper in upper ward direction

Tipping of the second leg of pile around the weft shotFinally releasing its grip to form a U-tuft

Gripper Jacquard