9 - Pile carpets

Abstract

Textile pile structures in the areas of apparel, home textiles and carpets comprise too large a group to be considered effectively in a single chapter. Pile carpets have been selected as a particularly interesting case where the composition and range of structures affect the design scope, facets of the performance in use, and positive effects on the environment. Typically, they have three layers, presenting a special challenge for recycling. Tufting remains by far the most important method of carpet manufacture, although recent technical developments have mostly been in the area of weaving. The position of nylon as the leading pile fibre is being challenged by polypropylene, which is based on a cheaper monomer and provides better cover in the carpet because of its low specific gravity. Polyester fibres are becoming more important for two reasons: PET fibre is being manufactured from recycled drinks bottles; and PTT fibre has been shown to provide superior carpet properties compared with PET. Wool remains important in the higher qualities of carpets. Polymer pigmentation has become the most important coloration technique and, associated with the improved flexibility of the technique, BCF yarn production is increasingly being carried out by carpet manufacturing companies. The weak market position of soft floor coverings has prompted extensive R&D efforts to make carpet manufacture more environmentally friendly and to provide information about the positive effects of carpets on the interior environment.