There are different types of carpets. You can choose from synthetic materials like nylon and polypropylene, or you can also get natural materials like wool and cotton. Each material has its own advantages. For example, nylon is the most stain and fade resistant. It is also the leader in heat resistance. The durability and wearability of a carpet depend on its fibers and pile height.
Before the Industrial Revolution, the carpet industry was based in cottage industries. However, with the advent of more advanced technology, the manufacturing of carpets changed to become a commercial industry. This was driven by the purchasing needs of middle classes. Consequently, the industry moved quickly with the introduction of innovative manufacturing solutions. In the 1950s, the industry saw the introduction of a new fiber, polypropylene. Although this synthetic fiber is not as durable as nylon, it has a high degree of abrasion resistance.
Today, synthetic materials are the dominant fibers used in the carpet industry. Polyester and nylon are two of the most popular. They have good color clarity and are stain and fade resistant. But, the main determinant of quality is the density of the pile.
Aside from fibers, a number of other factors affect the quality of a carpet. These include the twist of the yarn, the face weight and the treatment of the pile. Higher density carpets are usually more durable, while lower density ones have shorter lifespans.
Quality is also affected by the type of backing the carpet has. Most carpets are made of either woven or non-woven fabric. When making carpets from woven fabric, the primary backing is a coating of latex that is applied to the fibers. If the backing is non-woven, a secondary coating of latex is typically applied to the backing.
Carpets can be either tufted or woven. Tufting is a process that uses large fixed needles to firmly attach fibres to a backing. This technique is similar to sewing. Tufting machines look like big sewing machines. During the process, the speed of the tufting machine controls the stitch rate. Typically, a stitch rate of at least a thousand penetrations per inch is considered a high-quality carpet.
Needle punched is another carpet-making method. With this technique, the fibers are not hooked onto a warp, but are stitched into a backing. This process can produce very fine carpets that have a sculptured appearance.
Another method is the yarn dyeing process. This is an excellent method of achieving a consistent colour and side-by-side color consistency. Unlike other dyeing processes, yarn dyeing provides uniformity and the opportunity to make large lot sizes.
Lastly, shearing is the final stage in carpet manufacture. After shearing, loose ends are removed and the tips of the yarn are defined. Some of the more common synthetic fibers used in the carpet industry are polyester, nylon and polypropylene. Polypropylene is widely used for loop-pile constructions. It is not as abrasion-resistant as nylon or polyester, but it is soft.
