Tufted Carpet Research Articles

A Computer Vision System for Detecting Tufted Carpet Defects.(Dept.T)

This work presents an approach to extract, analyze and select image attributes necessary for building a vision computer system that is able to detect and classify tufted carper defects. Four different tufted carpets and four different defects were considered; missing pile, higher pile, lower pile, slobs and knots. Carpet digital images were statistically analyzed to calculate Mean, Variance, Skewness, Kurtosis, and Entropy, known as tonal features. Texture features were extracted from co-occurrence matrices describing the relationships between intensities of two pixels at a certain distance and angle from each other and evaluated using SGLDM and GLDM statistics. Graphical presentation and visual assessment were made to choose the most significant features. For classification. artificial neural networks were built and trained using perceptron and back propagation algorithms. The recognition was successful in detecting common tufted carpet defects.

The Design of a Double X-axis Gantry Bayonet Tufted Carpet Weaving Machine

In order to achieve high-quality and high-efficiency production of hand tufted carpets, a gun-punched tufted carpet weaving machine is designed in this paper. The carpet weaving machine is based on the development of Advantech industrial computer and Googoltech GTS-800-PG. The designed double X-axis gantry frame ensures continuous production speed of up to 1500 clusters per minute. The precise frame transmission mechanism realizes smooth curves, sharp Angle and small stitch angle movement under high density. This article mainly introduces composition of the control system and the design of overall mechanical structure of the carpet weaving machine, and looks forward to the development trend of the machine.

Investigation of electromagnetic shielding properties of metal composite tufted carpets

In this research, it is aimed to develop tufted carpets with electromagnetic shielding (EMSE) effectiveness. For this purpose, stainless steel, copper, silver wires, and metalized silver PA filaments were commingled with textured polyester yarn to produce composite yarn. Composite yarns were used in tufted carpet backing fabric with different densities and directions. The EMSE of carpet samples was measured in the frequency range of 0.8–5.2 GHz by free space technique. The effects of metal type, composite yarn density, and placement direction on the EMSE were statistically analyzed in 0.8–3.0 and 3.0–5.2 GHz frequency ranges separately. Stainless steel and silver wires provided better EMSE in the range of 0.8–3.0 GHz. Stainless steel showed better EMSE in lower frequencies than 3 GHz. The metallized silver was more effective above 3 GHz. The increase in metal density significantly increased EMSE for all metal types. Carpets containing metal in two directions provided multidirectional shielding and maximum EMSE reached up to 44 dB level. As a result of the study, tufted carpets which can provide multi-axial protection were produced successfully.

Vibration Reduction of the Nonlinearly Tufted Carpet Yarn by a Modified Sliding Mode Control Method

The yarn vibration causes the yarn tension value to fluctuate, causing a change in the amount of yarn feed, thus causing a deviation of the carpet pile height from the predetermined value. To solve this problem, the sliding mode control algorithm is used to design the sliding mode function and the sliding mode control law. And four variables in the yarn vibration system are controlled by the MATLAB software. For solving the chattering problem of the control law, the sliding mode control law is improved. The fuzzy sliding mode control algorithm based on the quasisliding mode is adopted. The results show that the sliding mode control algorithm is effective, but the sliding mode control force needs to be switched at high frequency and there is severe chattering. The fuzzy sliding mode control algorithm based on quasisliding mode is adopted to achieve better control effect with a smaller force. In addition, the control force does not have high‐frequency switching, and the change is relatively stable, which reduces the chattering phenomenon of sliding mode control.

Impact of carpet construction on fluid penetration: The case of blood

Bloodstains and bloodstain patterns are often observed at crime scenes and their analysis through bloodstain pattern analysis (BPA) can assist in reconstructing crime scenes. However, most published work related to BPA only deals with hard, non-porous surfaces and none of the studies have carefully characterized carpets. Soft and porous carpets are often encountered at crime scenes since they are common in American homes accounting for 51% of total U.S. flooring market; this has motivated the research described herein. To assess fluid penetration into tufted carpers, a new method for determining porosity and pore size distribution in tufted carpets has been developed for bloodstains on carpet. In this study, three kinds of nylon carpet were used: a low, a medium and a high face-weight carpet. Each carpet had an antistain treatment, which was removed from half of each carpet by steam-cleaning with a pH 12 NaOH solution. This resulted in six carpet samples. Yarn twist, carpet weight, pile height, water contact angles on carpets, water contact angles on individual fibers, and fiber cross-sectional shapes were characterized. Porosity and pore size distribution were analyzed using confocal laser scanning microscopy (CLSM). Porcine blood was used as a human blood substitute at three liquid volumes (30μL, 10μL, and 2μL). Analysis showed that porous carpet construction and antistain finishing both affected penetration. The depth of blood penetration decreased with the increase of carpet face-weight but increased with increased drop height. The removal of antistain treatment increased blood penetration into the carpets and changed the pore size distribution. Effects of antistain treatment, porosity and pore size distribution of tufted carpet, and blood wicking behaviors on carpets were found to strongly affect blood penetration into the carpets.

The Development of Antibacterial-Fire Retardant Bamboo Pulp/Cotton Tufted Carpets

In order to develop good antibacterial-fire retardant bamboo pulp/cotton tufted carpet, the paper selects the antibacterial agent and flame retardant, the antibacterial finishing agent adopts FK732 and FK822, the flame retardant adopts DM-07, the flame retardant finishing and antibacterial finishing process is optimized, the optimization of the finishing process is determined. Antibacterial performance and flame retardant performance of tufted carpet are tested by the authoritative organization, bacteriostatic rate is greater than 99.9%, tufted carpets have good anti-mite effect and good flame retardant performance.

Advanced tufted carpet patterning technology

After a review of the tufting industry’s development, and a brief introduction to available systems for producing patterned tufted carpets, the principle of ICN (Individually Controlled Needle) and the related advanced tufting technology Colortec are presented. Finally, Colortec machine, Axminster weaving machine, and Wilton loom are compared. It is believed that the Cobble Colortec machine is a significant jump forward in the tufted carpets industry as it now allows access to all major carpet markets in a competitive fashion.

Stress Relaxation of Tufted Carpets and Carpet Components: Analysis of the Tufted Carpet Structure

Dimensional stability of tufted carpets has been a continuing problem in the carpet industry for years. When a tufted carpet is installed by the stretch-in method, it experiences stress relaxation over time which can cause the carpet to buckle, wrinkle and become loose with the only option being a costly re-stretching of the carpet. Analysis of the various components of the tufted carpet composite structure was performed to identify the role each component plays in the phenomenon of stress relaxation. A biaxial loading system was used to test various samples of the primary backing alone, primary backing after tufting (with tufts), secondary backing alone, and the finished carpet after attaching the backings with various binder weights per area. The four variables under consideration included primary and secondary backing constructions, tufting density, and latex weight. A rheological model that includes representations of each component in the carpet structure was developed and will be presented in a following paper.

Improving Carpet Through-Air Drying by Means of Increased Air Permeability 1

Air permeability is an important parameter in through-air drying of unbacked tufted carpet. The primary backing of tufted carpet is the dominant parameter determining carpet air permeability. Carpets of identical construction are tufted using woven and nonwoven primary backings, and the effects of primary backing type on air permeability and drying are studied. The carpet tufted with the nonwoven backing has significantly higher air permeability and significantly lower drying time for a constant pressure drop drying process.

Market Research for the Turkish Tufted Carpet Sector

Tufted carpet production in Turkey started in the 1980s and has since gradually increased. Today, one-fifth of the textile floorcoverings used are tufted carpets. Despite the rapid growth of the sector, there is no information about the structure of this very important market, from which possible investors as well as academics may benefit. To fill this gap, the market research reported in this paper was carried out such that private interviews were held with six producers, importers, wholesalers, and representatives of the tufting machine manufacturers in order to collect data such as capacity, current machinery lay-out, consumption, the technical specifications of the carpets preferred most in the market, etc. Furthermore, the factors affecting tufted carpet consumption were also studied and the main driver of the sector was found to be the construction industry. Accordingly, a statistical survey for this very sector was also done so that it could be possible to make projections for consumption, covering the next five years.

Recycling Carpet Waste by Injection and Compression Molding

Studies have been carried out to convert carpet waste into valued products. Two common processes, injection and compression molding, can be used to recycle carpet waste. Three types of carpet waste have been recycled: (1) edge trim from carpet manufacturing, (2) polypropylene shear lint from cutting tufted carpet loops, and (3) separated polypropylene from postconsumer carpet waste. For injection molding, shredded carpet waste was debulked, ground, dried, and molded. For compression molding, the recycled carpet waste was combined with glass mat reinforcement. The compression-molding process consists of debulking, stacking with glass mats, and consolidation. The mechanical testing results are encouraging. The injection-molded samples showed properties acceptable for many applications. The glass-mat-reinforced carpet waste made by compression molding had properties comparable to commercial virgin thermoplastics reinforced with glass mat.

Effect of Pile Parameters on the Noise Absorption Capacity of Tufted Carpets

This paper examines the effect of pile characteristics on the noise absorption capacity of tufted carpets in the audible frequency range (125 < f < 4000 Hz.) The parameters considered are fiber content and fiber denier, pile density, and average pile height. The noise absorption coefficients of sample carpets differing from each other in only one pile parameter were measured using the impedance tube technique. Results of the experiments are displayed and evaluated in terms of a heuristic physical picture based on the theory of sound transfer through porous media. One of the interesting results is that when there is an air gap behind tufted carpet used as a wall covering, noise absorption capacity increases significantly in the low and medium frequency range, 250 < f < 1000 Hz.

Microwave Drying of Nylon Tufted Carpets II. Electrical Characterization of a Modified TE10nResonant Cavity

AbstractA rectangular resonant cavity operating in the TE10n mode is described, which is designed to be the basic unit of a tufted carpet dryer. The cavity is suitably modified to minimize arcing of the stenter pins which carry the carpet through the dryer. Coupling of the microwave energy into the resonant cavity was experimentally investigated by measuring the influence of the moisture content of the tufted carpets on the cavity matching and tuning range. The performance of the cavity as part of a twin cavity dryer is discussed in terms of the Q-factor and its variation with moisture content.