From polymer to carpet

• Synthetic yarn production

• Cross section

• Yarn count

• PA 6 versus PA 6.6

• Coloration techniques

• Carpet constructions

• Gauge

• Carpet tile construction

• Glas Polyver®, Polyscan® Computer

• Teflon®

• Cleaning and maintenance

• PVC versus bitumen

• Suitability of Desso carpet tiles on raised acces floors

Index

1

2

Synthetic yarn production

kleurstof /dye-stuf fs

A

E

A

B

C

koelen en verstrekken.gladde, continu-f i lamenten

cool ing and stretching smooth f i laments

bulken/texturenbulk ing/textur ing

volumineuze f i lamentenvoluminous f i lamentes

vezels/kaardprocesf ibres/carding process

kloscone

intermingling/verblazingsprocesIntermingl ing/a i rentangl ing process

één garen, het B.C.F.-garenf ina l yarn, B.C.F. yarn

(B.C.F.= Bulked Cont inuous F i lament)

lont tot garengesponnenspun yarn

F

A granulaatkorrels /polymer chips

B extruder /extruder

C schroef /mix ing dev ise

D spinplaat /spinneret

E kleurstof /dye-stuf f

F fi lament / f i lament

± 50 ºC

± 260 ºCD

AIR

AIR

A. Round: • Physical the strongest shape.• In nature the strongest constructions are round.• Stands much more pressure than for example a square construction.• Very tittle bulky -> you need a high mass for a luxurious looking poduct.• The round shape often gives a cheap plastic appearance to a product.• Soil will not be hidden. The round shape of the fibres works as a magnifying glass.

B.Trilobal: • Little weight already gives a high volume -> luxurious look. • Physically not the most strong shape.• Because of the relative big surface, soil can adhere rather easy to the sur face.• Therfore a trilobal cross section is a bit more sensitive for soiling than others are.

C. Delta: • Very good compromise between the strong round shape and the voluminous trilobal cross section.• Good volume / mass rating.• Good appearance retention.• No plastic look but a textile one.• Because of the relative small surface not sensitive for soiling.

D. Hollow:• Patented by dupont.• Very good soil hiding properties.

Cross sections

3 A B C D

Thickness (count) of a yarn is expressed in (D)tex

The count of a yarn is e.g. 3,000 Dtex which means:

10,000 m of this yarn has a weight of 3,000 gram.

Escomenda - yarn -> 2,700 DtexEscopallas - yarn -> 4,080 DtexEscomeral - yarn -> 5,400 Dtex

The higher the launt the thicker the yarn

BCF-yarn is built up out of a certain number of filaments.A filament is a very thin endless thread.

Menda yarn : 132 filaments > 2,700 / 132 = 20.5 dpf (Dtex per fil.)Pallas yarn : 135 filaments > 4,080 / 135 = 30.2 dpfMeral yarn : 168 filaments > 5,400 / 210 = 25.7 dpf

The coarser the filament, the stronger the filament.The finer the filament the softer the touch (textile touch).

Always a compromise between good physical properties and a luxurious textile touch.

Yarn Count

4

polyamide 6 polyamide 6.6polymerisationproduct polymerisationproduct1 monomer 2 monomerscaprolactam adepic acid + hexamethylene dia mine (contains 6 carbon atoms) (6 carbon + 6 carbon)

Tinsile strength40 mpa (=400 kg/cm2) 55 mpa (=550 kg/cm2)

Elongation at breaking point200 % 150 %

Water absorption at ambient conditions4.4 % 3.8 %

Dye propertiesvery good good

PA6 versus PA6.6

5

PA 6.6 has a higher tensile strength -> stronger than PA 6 ?

Not necessarily:

Elongation at breaking point is lower which makes pa 6.6 more brittle.

PA 6 has very good dye-properties which makes PA 6 the perfect PA for high differential dying and for printing.

When you want tone to tone colours PA 6.6 is your perfect partner.

Since PA 6.6 is less sensitive for dyestuff. It is automatically less sensitive for staining.

Is PA 6 is better than PA 6.6 ?

6

One cannot say PA 6.6 is better than PA 6

One cannot say PA 6 is better than PA 6.6

Solution dye • Very reliable; shade differences between batches are very little • Yarn supplier is able to give the yarn special properties such as: bleach resist, anti-microbial properties

• Very good fastness

• Low flexibility

Stock dye • Used for spun-yarn

• High flexibility

Space dye • Used for special effects in a carpet construction

Piece dye• Very flexible, almost every colour is possible

• Low stock

• Difficult production process

Coloration techniques

7

Needlefelt constructions:

Flat needlefelt (escoforto)

Hairy needlefelt (escolita)

Tuft constructions:Straight looppile (Menda-XL SC, Tempra, Fiori-N, Rima-XL SC, Sienna, Sinta, Escomeral-Plus, Pallas-XL)

Straight cutpile (Mila)

Sliding needlebar (Flavia, Palatino, Penta)

Cut/loop

Structured (Vitae)

Carpet constructions

8

9

Carding process

feedsheet

eed rol lers

feedrol lerstr ipper anglestr ipper

str ipper

worker

fancy

doffer

swift

doffer comb

l icker- in

fiber material

Needle punchingprocess

Fibre supply

10

Tufting process for a cut pile product

1 2 3 4

Tufting process for a loop pile product

1 2 3 4

Number of needles per Inch

Gauge = 1/10" = 10 needles per inch = 39.4 needles per dmGauge = 1/8" = 8 needles per inch = 31.5 needles per dm

Gauge = 5/64" = 64 needles per 5 inches = 50.4 ndls per dm

StitchrateNumber of stitches per dm

TuftdensityTuftdensity = gauge x stitchrate

Example

Escomenda-XL SC :

Gauge = 1/10" = 394 needles/mStitchrate = 44/dm = 440 stiches /mTuftdensity escomenda-xl sc = 394 x 440 =173,360 stitches/m2

Gauge

11

12

Desso carpet tile construction diagram

1. Pile Yarn

2. Polyester primary impregnated with latex key-coat which provides • fibre and tuft anchorage • rigidity • stability

3. Glass reinforcement giving perfect dimensional stability

4. Modified bitumen backing proving weight and good lay flat performance.

5. Non woven carrier.

A form of electrical charge created when two non-conductive materials are rubbed against each other.

AntistaticA carpet is antistatic when there is no electrostatic charge built up when a per-son walks over the carpet.

Still an antistatic carpet is not able to discharge a person who is charged with static electricity.

It may occur one has problems with static electricity although an antistatic car-pet is installed.

polyscan® computerDesso polyscan carpettiles are able to discharge a person who is charged with static electricity.

With Desso polyscan carpet tiles all problems with devices that are sensitive for static electricity are solved.

Static electricity

13

Polyscan Computer

14

Finish on the surface of a carpet which makes the surface of the carpet water- and oil repellent

Liquid (water) is the carrier for dirt.Teflon® helps a carpet to remain ‘new’ for a longer period of time.

Teflon® is applied during the production process. A cure-temperature of at least 100°c is necessary.

Teflon®

15

(Un)Treated fibres

16

Untreated fibres treated fibres

Untreated fibres treated fibres

Vacuum cleaner

17

Vacuum cleaner Brush vacuum cleaner

Vacuum cleaner Brush vacuum cleaner

Starts when buying a carpet.

Choose the construction that fits with the application.

Choose the colour that fits with the application.

Daily cleaning with a motor driven brush-vacuum-cleaner is necessary.

Comprehensive cleaning according to need not to time.

Comprehensive cleaning with a dry powder system.

Maintenance

18

Bitumen PVCHeavy part of mineral oil Polyvinylchloride

Black More colours possible

Writes Does not write

Aesthetically less beautiful then pvc Aesthetically more beautiful than bitumen

Protection-sheet is necessary No sheet necessary

For a good stability only little For a good stability only two reinforcement necessary glass-tissues necessary

Easy to cut during installation Because of glass-tissues difficult to cut

Flexible as it is Needs softening agent

Does not bleed Softener can bleed out

No toxic gas during combustion During combustion HCl and possibly dioxins come free for this reason not accepted in northern europe

Both are inert for climatic changes

PVC versus Bitumen

19

Raised acces floors

20

TopclothBacking

Raised floor panel Raised floor panel

J u s t a f t e r i n s t a l l a t i o n

ʺ 3mm

BackingTopcloth

Raised floor panel Raised floor panel

Months after insta l lat ion

The backing f lows horizontal ly to the gap and part ly f i l ls i t up