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Water resistant carpet and method of manufacture the sameRelated Patent Categories: Stock Material Or Miscellaneous Articles, Pile Or Nap Type Surface Or Component, Composition Of Pile Or AdhesiveWater resistant carpet and method of manufacture the same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070048491, Water resistant carpet and method of manufacture the same. Brief Patent Description - Full Patent Description - Patent Application Claims
FIELD OF THE INVENTION [0001] The invention relates to the field of carpets and carpet manufacturing, and more specifically to carpets intended for both indoor and outdoor use and the manufacturing of the same. BACKGROUND OF THE INVENTION [0002] The present invention relates to a water resistant carpet that is suitable for use both indoors and outdoors. The present invention also relates to the manufacturing of such a carpet. [0003] The term "carpet" is used throughout this specification to cover all types of woven surface coverings. [0004] Carpets are typically woven from yarn. The yarn may include synthetic or natural filaments or fibers. Additionally, the yarn may consist of several filaments or fibers twisted together. A particular type of fiber of importance in carpet weaving is the staple fiber. The staple fiber is generally short fibers, usually ranging in lengths from 1 inch to 8 inches long. A group of these staple fibers are twisted together to form a yarn. These yarns are then used for different aspects of the carpet, such as the pile, weft and binding chain, as described below in further detail. [0005] The pile is the generally vertical material (when the carpet is placed on a horizontal surface) above the backing. The pile is the part of the carpet that protrudes upwards above the backing. The backing is the structure that provides stability for the pile. The backing may consist of numerous different materials, such as weft, binding chains and stuffer. [0006] Warp yarn refers to that yarn that may be used for the backing, piles and binding chains. The warp generally runs in a linear direction. The length of the warp controls the carpet's length. The weft is the yarn that runs in a transverse direction to the warp. The length of the weft controls the carpet's width. [0007] The binding chains are the warp yarn that is woven in a chain-like manner. This chain-like weaving is used to hold all the components of the carpet together, including the pile, weft and backing. [0008] The stuffer is additional warp yarn that lays flat in the backing, it is usually woven under a heavy load, and its purpose is to provide linear stability, strength, and additional weight to the carpet. [0009] In a typical weaving process, pile and warp yarn move in a linear direction at a steady rate. There may be more than one strand of each type of yarn (pile and warp) involved in the weaving of the carpet. The warp yarn may be used for different parts of the carpet, such as the binding chains or the stuffer. The pile and warp yarn are pulled through the eyes of heald wires. A heald wire is a wire with its eye (a small opening allowing the yarn to run through it, like the eye of a needle) approximately half way up its vertical length. Each strand of yarn may have its own heald wire that it travels through. Since the yarn travels through the eye of the heald wire, the yarn can be moved by driving the heald wire up or down. This will change the vertical position of the particular strand of yarn running through the moving heald wire. [0010] By driving the heald wires up and down, openings can be created in between the various different yarns. This intermittent space is called a shed. It is through these sheds that the weft material is inserted. The weft can be inserted through the shed with a shuttle. A shuttle is the part of the weaving loom that carries fill yarn back and forth across the fabric width. [0011] A particular weaving loom of importance in carpet weaving is the rapier loom. The rapier loom does not have any shuttles. Instead, one or more rapiers (small metal rods) are used to carry the weft material through the sheds across the width of the carpet. After the rapier has carried the weft yarn across the width of the carpet, the weft is cut. A single insertion of the weft is called a shot. [0012] A reed is then used to "beat" the material tightly together. A beat up arm controls the reed. The beaten material travels through the point of weave which is the focus of all the warp and weft material, and the point where the individual materials becomes a carpet. [0013] A Jacquard is a mechanism that moves individual warp yarn material in any programmed sequence. This allows for preprogrammed designs that are complex in design and visual effects. [0014] The selvage is the edge of the carpet finished in such a manner that it will not unravel and it does not require any additional binding or hemming. [0015] Face-to-face weaving is a useful weaving technique that allows two carpets with identical pile design to be woven at the same time, these two carpets being interlaced by the pile warp ends. The produced "double" carpet can be cut in the center, cutting the pile in between the two carpets, producing a top carpet and a bottom carpet. [0016] Presently, available carpets suffer from their incompatibility with certain environments. Some carpets are suitable for an indoor setting, being soft and luxurious among other characteristics. These carpets, however, do not withstand a more stressful outdoor environment. If these carpets were placed in an outdoor environment they may trap dirt, absorb water, become faded due to UV exposure, and the pile may become trampled down. [0017] Other carpets are suitable for an outdoor environment, being durable and rugged among other characteristics. These carpets, however, are not appropriate for an indoor environment. Outdoor carpets are generally made from more durable material that is not as soft as materials used for indoor carpets. If placed indoors, an outdoor carpet would be uncomfortable to walk on without shoes. Additionally, such a carpet would not give the appearance of a luxurious carpet, a typical aesthetic requirement for indoor carpet. [0018] Some presently available carpets are intended for both indoor and outdoor use. These carpets, although they may be softer and more luxurious than the typical outdoor carpet, and may be more durable and rugged than a typical indoor carpet, never achieve both indoor and outdoor characteristics to the same degree as achieved by exclusively indoor and outdoor carpet. In such a carpet there is a trade-off between indoor carpet and outdoor carpet qualities. [0019] There is thus a need for a carpet that is suitable for both indoor and outdoor environments, yet does not suffer from the trade-off between indoor and outdoor qualities. Such a carpet should be as soft and luxurious as an exclusively indoor carpet and as durable and rugged as an exclusively outdoor carpet. SUMMARY OF THE INVENTION [0020] The present invention provides for a carpet that is suitable for both indoor and outdoor use. This carpet will provide all the benefits of an indoor carpet, such as a soft luxurious finish, while remaining adaptable to the stressful outdoor environment. This carpet will include features not typically found in indoor carpets, such as water resistance, and features not found in indoor carpets, such as durability. [0021] According to one aspect of the present invention, there is provided a carpet having pile made of polypropylene extruded yarn. The pile yarn may optionally be made from a dyed polypropylene solution. The pile yarn may optionally include added UV stabilizers. Continue reading about Water resistant carpet and method of manufacture the same... 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