Method and apparatus for manufacturing carpets with an antique appearance using an automated carpet loom
A method and apparatus for manufacturing carpets with an antique appearance using an automated weaving machine. The system integrates advanced control of warp tension, specialized pile yarn, and a unique reed and lancet assembly to replicate the randomized wear patterns, variable pile heights, and textural intricacies characteristic of aged carpets. A blend of synthetic and natural fibers undergoes a proprietary crimping, spinning, and two-stage dyeing process, producing multicolored yarn with pseudo-random shrinkage properties. Warp threads are precisely positioned using weighted beams and tiered lancets, enabling the creation of areas with zero and non-zero pile heights, separated by gradual transition zones. The resulting carpets exhibit high aesthetic authenticity and structural durability. A chi-squared statistical process ensures the randomness of worn patterns, optimizing the antique effect. The invention provides a scalable and efficient solution for producing affordable carpets that closely mimic the look and feel of genuine antiques.
1 . A system for manufacturing carpets having an antique appearance, with an automated weaving machine configured to produce a pair of carpets simultaneously, comprising:
a warp beam stand producing a controlled tension, on a set of warp threads of the pair of carpets, operatively connected to the automated weaving machine;
a reed assembly, for packing of a set of weft threads against a pile yarn of the pair of carpets;
a first cutting table and a second cutting table adjacent the reed assembly;
a moving knife, adjacent the first cutting table and the second cutting table;
a set of draw-down lancets, positioned in the reed assembly with a first clearance above the first cutting table and a second clearance below the second cutting table; and
a set of pile yarn having a composition that exhibits a controlled variation in a breaking load parameter, a tenacity parameter, and an elongation parameter and having a multi-color yarn cross-section.
2 . The system of claim 1 , wherein the set of pile yarn further comprises about 90% of a mixed synthetic fiber and about 10% of a natural wool fiber.
3 . The system of claim 2 , wherein the mixed synthetic fiber further comprises about 90% polypropylene and about 10% ethylene terephthalate.
4 . The system of claim 1 , wherein a draw-down lancet of the set of draw-down lancets has a lower flat surface opposite an upper tiered surface.
5 . The system of claim 4 , wherein the upper tiered surface further comprises:
a set of flat tiers separated by a set of inclined portions and a lancet tip positioned adjacent the first cutting table and the second cutting table.
6 . The system of claim 5 , wherein the lancet tip has a height of about 3 mm.
7 . The system of claim 1 , wherein the multi-color yarn cross-section further comprises a darker core and a lighter exterior.
8 . The system of claim 7 , wherein the multi-color yarn cross-section is dyed with one of a group of cochineal, indigo and turmeric, in a two-step dyeing process.
9 . The system of claim 1 , wherein the set of warp threads further comprises:
a set of slack threads with a denier of about 800 to about 1500 and a set of tight threads with a denier of about 1000 to about 2000.
10 . The system of claim 1 , wherein the reed assembly has a density of about 320 dents per meter.
11 . The system of claim 1 , wherein a first carpet of the pair of carpets is a mirror image of a second carpet of the pair of carpets.
12 . The system of claim 11 , wherein the first carpet has a worn area and an unworn area separated by a transition zone.
13 . The system of claim 12 , wherein the worn area has about a first pile height of about 0 mm and the unworn area has a second pile height of about 3 mm.
14 . The system of claim 13 , wherein the transition zone has a width of between about 3 cm and about 5 cm.
15 . The system of claim 11 , wherein the first carpet has a plurality of worn areas and a plurality of unworn areas.
16 . The system of claim 15 , wherein a total area of the plurality of worn areas is between about 20% and about 60% of a total carpet area of the first carpet of the pair of carpets.
17 . The system of claim 1 , wherein the first clearance is between about 6 mm and about 8 mm and the second clearance is between about 6 mm and about 8 mm.
18 . The system of claim 1 , wherein the automated weaving machine operates with a pick density of about 40 weft threads per centimeter.
19 . The system of claim 1 , wherein the set of pile yarn is crimped.
20 . The system of claim 1 , wherein the automated weaving machine has a beam width of about 4 meters.
21 . The system of claim 1 , wherein each carpet of the pair of carpets meets a chi-squared test wherein a P-value is less than 0.5, and a significance level is 0.5.
22 . The system of claim 1 , wherein the set of warp threads is under a tension of between about 2 kg and about 5 kg.
23 . The system of claim 1 , wherein the pile yarn is under a tension of between about 1.5 kg and about 3 kg.
24 . The system of claim 1 , wherein the breaking load parameter has a coefficient of variation of about 6.8%.
25 . The system of claim 1 , wherein the tenacity parameter has a coefficient of variation of about 6.6%.
26 . The system of claim 1 , wherein the elongation parameter has a coefficient of variation of about 5.8%.
27 . A method for manufacturing carpets having an antique appearance, with an automated weaving machine, configured to produce a pair of carpets simultaneously, comprising the steps of:
providing a warp beam stand, producing a controlled tension on a set of warp threads of the pair of carpets, operatively connected to the automated weaving machine;
providing a reed assembly, for packing a set of weft threads against a pile yarn of the pair of carpets;
providing a first cutting table and a second cutting table adjacent to the reed assembly;
providing a moving knife adjacent the first cutting table and the second cutting table;
providing a set of one-sided draw-down lancets, positioned in the reed assembly with a first clearance above the first cutting table, and a second clearance below the second cutting table; and
providing a set of pile yarn with a composition that exhibits a controlled variation in a breaking load parameter, a tenacity parameter and an elongation parameter and having a multi-color yarn cross-section.
28 . The method of claim 27 , wherein the step of providing the set of pile yarn further comprises:
preparing a mixture of polypropylene pellets and polyethylene terephthalate pellets;
extruding the mixture into synthetic fibers with a denier between about 8 and about 9;
crimping the synthetic fibers to resemble wool fibers;
cutting the synthetic fibers to an average length of about 120 mm;
blending the synthetic fibers with a set of wool fibers to produce a set of raw fiber locks;
opening, cleaning and carding the set of raw fiber locks to create a set of carded fibers;
drawing the set of carded fibers to a diameter of between about 0.3 dtex and 1.0 dtex to create a set of drawn fibers;
spinning the set of drawn fibers to produce a twist of about 5.5 to 6.5 reps per inch in a Z-direction in the set of pile yarn;
dying the set of pile yarn using a two stage dyeing process to create a multicolored effect across a cross-section of the set of pile yarn; and
finishing the set of pile yarn by washing, softening and drying at a temperature of about 90° C.
29 . The method of claim 28 , wherein in the mixture comprises about 90% polypropylene pellets and about 10% polyethylene terephthalate pellets.
30 . The method of claim 28 , wherein the step of crimping the synthetic fibers is performed using a mechanical crimping tool with a series of rollers.
31 . The method of claim 28 , wherein the set of wool fibers includes New Zealand wool fibers with an average diameter of about 37 μm.
32 . The method of claim 28 , wherein the step of blending the synthetic fibers produces a fiber composition of about 90% synthetic fibers and about 10% wool fibers.
33 . The method of claim 28 , wherein the step of spinning the set of drawn fibers produces yarn with a denier of about 1.125/1.
34 . The method of claim 28 , wherein the two stage dyeing process further comprises:
using a stage 1 dye bath containing a first set of selected dyes; and
using a stage 2 dye bath containing a second set of selected dyes;
wherein the second set of selected dyes has a differing set of concentration from the first set of selected dyes.
35 . The method of claim 34 , wherein the stage 1 dye bath is maintained at about 98° C. for about 20 to 40 minutes.
36 . The method of claim 34 , wherein the set of pile yarn is dyed in the stage 2 dye bath for an additional 20 to 40 minutes at about 98° C.
37 . The method of claim 34 , wherein the stage 1 dye bath and the stage 2 dye bath are combinations of natural and synthetic dye elements.
38 . The method of claim 28 , when the step of finishing includes adjusting a pH of a washing bath to between about 5 and 6 using acetic acid.
39 . The method of claim 34 , wherein the first set of selected dyes is more concentrated than the second set of selected dyes.
40 . The method of claim 28 , wherein the step of drying is performed at about 90° C. for about one hour to set a permanent twist in the set of pile yarn.
41 . The method of claim 28 , wherein the set of pile yarn produced has a breaking load of about 4.2 kgf with a coefficient of variation of about 6.8%.
42 . The method of claim 28 , wherein the set of pile yarn has a tenacity of about 10.5 grams/tex with a coefficient of variation of about 6.6%.
43 . The method of claim 28 , the multicolored effect further comprises:
a lighter outer diameter and a darker inner diameter.
44 . The method of claim 28 , wherein the elongation parameter is about 22.25% with a coefficient of variation of about 5.8%.
45 . The method of claim 28 , wherein the set of pile yarn is capable of achieving a pile height ranging from about 0 mm to about 5 mm when woven into one carpet of the pair of carpets.
46 . The method of claim 27 , wherein the set of pile yarn exhibits sufficient variability in a set of properties to produce the pair of carpets with a randomized wear pattern that mimics an appearance of antique carpets.