IDCEC Course # 102822, Subject Code 5.8, Basic AIA Course #000202, Provider #G391 2013 The Carpet and Rug Institute IDCEC Approval 12/18/13 2/1/16
Registered Provider G391 The Carpet and Rug Institute is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non- AIA members are available on request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing or deal in any material or product. Questions related to specific materials, methods and services will be addressed at the conclusion c o of this presentation. This CEU is registered with the Interior Design Continuing Education Council (IDCEC) for continuing education credits. This credit will be accepted by the American Society of Interior Designers (ASID), International Interior Designers Association (IIDA) and Interior Designers of Canada (IDC). The content included is not deemed or construed to be an approval or endorsement by IDCEC of any material or construction or any method or manner of handling, using, distributing or dealing in any material or product. Questions related to specific materials, methods and services should be directed to the instructor or provider. This program is registered edfor.1 CEU (continuing education credit).
Course Objectives At the end of this course, the participant will be able to: Describe the fiber manufacturing gprocess List the benefits of various fibers Explain how yarns are processed. State the characteristics of fibers and yarns Distinguish between various fibers and yarns Summarize reasons to specify for performance
Carpet and Rug Fiber Market Share Wool and Other 1% Triexta 11% Polyester 25% Nylon 48% Polypropylene 15%
Natural Fibers Wool Natural fiber Staple fiber Durable Resilient Slf Self-extinguishing i when burned 1% of market
Synthetic Fibers Extrusion Every synthetic fiber is extruded: Nylon (Type 6 and Type 6,6) Polypropylene Polyester (PET) Triexta (PTT)
Synthetic Fibers Extrusion Extrusion Process Diagram 1. Blended polymers and colored pigments 2. Spinnerettes 3. Cooling tower 4. Yarn take-up And, once extruded, a fiber becomes a continuous filament.
Synthetic Nylon Features and Benefits Features Two types: 6 and 6,6 BCF or staple fibers White dyeable or solution dyedd Wide array of deniers, lusters and cross sections Virgin fiber and recycled fiber Approx. 50% of market Predominant fiber used in commercial market Significant fiber used in residential market Benefits Excellent wearability Resilient Resistant to abrasion Easily cleaned Permanent and inherent stain resistance and colorfastness (solution dyed)
Synthetic Polypropylene Solution dyed fiber only Mostly BCF (or staple for needlepunched carpet) Colorfast/resists fading Generates low levels of static electricity Resistant to acid-based stains and to water-based stains Resistant to moisture Primary fiber for indoor/outdoor carpet Approximately 15% of market
Synthetic Polyester Features Virgin and recycled PET BCF or staple Solution dyed d or white dyeable Inherent and permanent stain resistance Used in residential market Approximately 25% of market Benefits Resistant to acid-based stains Easily cleaned Color clarity Colorfastness (solution dyed)
Synthetic - Triexta Features BCF fiber Inherent and permanent stain resistance Solution dyed or white dyeable Entry ypoint is residentially focused. Approximately 11% of market Benefits Excellent colorfastness and bright colors Durability Resistance to fading (solution dyed) Cleanability Texture retention Luxurious hand
Synthetic Yarn Production BCF Fiber Bulked Continuous Filament Long strands of fiber form yarn bundles Then require one or more processes: 1. Plying 2. Air entangling 3. Twisting 4. Heat-setting Staple Fiber Simulates short fibers found naturally in wool Requires four steps to form yarn bundle: 1. Blending 2. Carding 3. Drafting 4. Spinning Twisting and heatsetting Not as predominant as BCF fiber
Synthetic Yarn Production
Synthetic Fiber Characteristics Each fiber manufacturer creates a fiber with certain specific characteristics: Polymer type Cross section Luster Denier Therefore, every fiber has its own ID.
Cross Section Fine Denier BCF Fiber Human Hair Conventional BCF Fiber Cross section is the shape of the individual filaments of yarn Cross section is determined by the hl holes in the spinneret during extrusion. Magnified 200x - the fiber size is smaller than a Magnified 200x - the fiber size is smaller than a human hair Each manufacturer of fiber has its own specific shape.
Shape affects these carpet properties: Luster Bulkiness Texture retention Silhidi Soil-hiding abilities Synthetic Fiber Production Fiber Cross Sections
Denier and Cotton Count Denier is used to measure BCF (Bulked Continuous Filament) Denier describes the filament size of the yarn. Multiple filaments make up a yarn bundle. The larger the denier, the larger the yarn The smaller the denier, the softer the yarn Less than 900 denier (small) to more than 3000 denier (large) Yarn bundle: individual filaments bundled together to create a single yarn strand.
Denier and Cotton Count Cotton Count is used to measure Spun/Staple p Yarns Cotton count is an indirect yarn count system The smaller the cotton count, the larger the yarn in staple/spun. 400( 4.00 (small) to 225(l 2.25 (large)
Yarn Processing Prior to tufting or weaving, yarn may be processed in one or more of the following ways: Air Entangling Air Twisting Ply Twisting Twisting and heat setting
Yarn Processing: Air Entangling
Yarn Twisting Air Twist Process Provides excellent color separation Allows for twisting 2-ply to 6-ply yarns in one step for added styling flexibility High speed operation Excellent performance characteristics in loop pile carpet
Yarn Processing: Ply Twisting Several colors ply twisted together Singles yarn Ply twisted yarn
Cut Pile Yarn Twist Yarn twist affects appearance retention and aesthetics for all carpet constructions Measured din TPI Turns per Inch High twist: 6 or greater TPI Medium twist Low twist: 3 TPI or less
Heat-setting Heat-setting is a continuous process to stabilize the yarn twist. Suessen Used mainly for spun yarn Uses dry heat Superba Used mainly for BCF yarn Uses steam
Anti-Static Properties Added to Fibers Static Inhibitors Specific fiber blends Specially engineered fibers (with carbon filaments) End Uses Important to maintain a proper balance of relative humidity General commercial, 3.5 kv is acceptable maximum value Critical commercial environments (data processing) kv is accepted upper limit
How Should Specifications Be Used To achieve desired performance and aesthetic objectives: Abyproduct by-product of the performance criteria A by-product of the aesthetic needs Abyproduct by-product of the flooring budget To obtain optimal flooring results for all of the diverse needs of the marketplace.
Construction and Performance Specifications They are Totally Interrelated Performance is overriding factor Performance must be blended with Color/Pattern/Design Performance is achieved by the right combination of elements
Elements of a Manufacturing Specification Yarn Construction Carpet Construction Dyeing Method Treatments Backing System
How Does Construction Affect Performance? Affect Performance? Construction largely determines performance. Construction consists of many facets, each playing a role: Fiber Yarn Dye Method Carpet Manufacturing Processes Backing System
Performance Features Specifier specifies certain performance features based on end use requirements: Stain Resistance Stain Resistance Soil Resistance Static Dissipation Anti-microbial Protection Lightfastness t Moisture Resistance Lightfastness Static Resistance Soil Resistance Warranties may support these performance features.
Carpet Specification: Pattern and Color Solid Heather Random Pattern Hides Least Hides Most
Preventive Measures for All Fibers Outside Mats/Tiles: Scrape debris off Use coarse texture mats Can hold soil Inside Mats/Tiles: Purpose: 1. Removes dirt and moisture 2. Dries wet soil for vacuuming 3. Confines soil to one area for easy removal At entrances and any high-soil area Clean inside and outside mats/tiles frequently.
Summary and Q&A Topics Discussed Fiber manufacturing process Benefits of various fibers Characteristics of fibers and yarns Performance specifications The Carpet and Rug Institute 100 S. Hamilton Street, t Dalton, GA 30720 706.428.2123 carpet-rug.org
Bibliography CRI: The Carpet Primer. The Carpet and Rug Institute, 2002 CRI: Model Specification for Commercial Carpet, 2012 Carpet and Rug Institute. (multiple pages about fiber selection, how to specify and buy carpet, installation and maintenance of commercial carpet. www.carpet-rug.org, 2013 Carpet Basics. The Carpet Site: An Online Consumers Guide to Carpet and Other Flooring Products. http://www.thecarpetsite.com, 2008 Fiber and Yarn Basics. Contract Sales Training. Shaw Learning Academy, Center for Sales Excellence, 2012. Floor Covering Weekly: The Industry s Business News & Information Resource, Carpet Industry Statistics, 2013 Floor Focus Magazine. Floor Daily. http://www.floordaily.net/floorfocus, 2009 How Carpet Is Made. Mohawk University, Mohawk Industries, training video 2001 Invista. http://www.invista.com, 2011 J&J Flooring Group, Images, 2013 Mohawk Industries. http://www.mohawkind.com, 2013 Quinstreet, Inc. The Carpet Buyers Handbook. Forest City, CA 2013 Solutia Inc. http://solutia.com, 2012 Wools of New Zealand, USA. Wool Research, Inc., Industry Website, http://www.woolsnz-partner.com/industry Yarn and Carpet Manufacture. Floor Tech: Understanding the Flooring Industry. Shaw Learning Academy, Center for Retail Excellence, 2011 The Carpet and Rug Institute CEU Workgroup members meet every six weeks to discuss and edit content for all CRI CEU courses. The CEU Workgroup is composed of technical and marketing managers from companies such as Shaw, Mohawk, Beaulieu, Bentley, Interface FLOR, J&J/Flooring Group, Tandus Centiva, Milliken, Atlas, Dow, Solutia, Invista, Shell and others.