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Thursday, October 4, 2007

Carpet can be made from many single or blended natural and synthetic fibers. Fibers are chosen for durability, appearance, ease of manufacture, and cost. The most important yarn constructions are:
Wool & wool blended with synthetic fibers: Wool has excellent durability, can be dyed easily and is fairly abundant. When blended with synthetic fibers such as nylon the durability of wool is increased. Blended wool yarns are extensively used in production of modern carpet. Wool is relatively expensive.
Nylon: This is the most popular synthetic fiber used in carpet production. Nylon can be dyed topically or dyed in a molten state (solution dying). Nylon can be printed easily and has excellent wear characteristics. In carpets Nylon tends to stain easily because it possesses dye sites on the fiber. These dye sites need to be filled in order to give Nylon any type of stain resistance. As nylon is petroleum-based it varies in price with the price of oil.
Polypropylene: This polymer is used to produce carpet yarns because it is cheap, although it is difficult to dye and does not wear as well as wool or nylon. Large looped Berber carpets made from this fiber are usually only suited for light domestic use and tend to mat down quickly. Berber carpets with smaller loops tend to be more resilient and retain their new appearance longer than large looped Berber styles. Commercial grade level-loop carpets have very small loops, and commercial grade cut-pile styles are well constructed. When made with polypropylene (also called Olefin) these styles wear very well, clean easily and are suitable for areas with heavy foot traffic such as offices. Commercial grade carpets can be glued directly to the floor or installed over a 1/4" thick, 8-pound density padding. Outdoor grass carpets are usually made from polypropylene.
Polyester: Polyester Also known as "2GT" or "PET" is used in carpet manufacturing in both spun and filament constructions. After the price of raw materials for many types of carpet rose in the early 2000s, polyester became more competitive. Polyester has good physical properties and is inherently stain-resistant because it is hydrophobic, and, unlike nylon, does not have dye sites. Color is infused in a molten state (solution dyeing). Polyester has the disadvantage that it tends to crush or mat down easily. It is typically used in mid- to low-priced carpeting
PTT: PTT polymer, also called Sorona (Dupont)or Corterra (Shell), is a variant of Polyester. Lurgi Zimmer PTT was first patented in 1941, but it was not produced until the 1990s, when Shell Chemicals developed the low-cost method of producing high-quality 1,3 propanediol (PDO), the starting raw material for PTT Corterra Polymers. PTT is similar to Polyester, but its molecules have a "kink", similar to a spring, that makes the fiber more crush resistant, resilient, and easy to clean. PTT also does not have dye sites, and is inherently stain resistant because color is infused in a molten state. Carpets made with PTT dry quickly and are resistant to mold.
The binding in woven carpet is usually cotton. and the weft is jute.

Carpet binding
Carpet binding is a term used for any material being applied to the edge of a carpet to make a rug. Carpet binding is usually cotton or nylon, but also comes in many other materials, such as leather. Natural binding, in other words, binding not made from synthetic material is frequently used with bamboo, grass, and wool rugs, but is often used with carpet made from other materials.

Early carpets

The Pazyryk Carpet, among the oldest surviving carpets in the world.
The hand-knotted pile carpet probably originated in southern Central Asia between the 3rd and 2nd millennium BC.
The earliest surviving pile carpet in the world is called the "Pazyryk Carpet", dating from the 5th-4th century BCE. It was excavated by Sergei Ivanovich Rudenko in 1949 from a Siberian burial ground where it had been preserved in ice in the valley of Pazyryk. The origin of this carpet is attributed to either the Iranian Scythians or the Persian Achaemenids. This carpet is 200 x 183 cm (6'6" x 6'0") and has 360,000 knots/m².
The earliest group of surviving knotted pile carpets was produced under Seljuk rule in the first half of the 13th century on the Anatolian peninsula. The eighteen extant works are often referred to as the Konya Carpets. The central field of these large carpets is a repeated geometrical pattern. The borders are ornamented with a large-scale, stylized, angular calligraphy called Kufic, pseudo-Kufic, or Kufesque

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