Development of an innovative method for binding of pile yarns to the carpet structure instead of traditional carpet back-coating process

Carpet finishing process is the chemical binding process applied to the back of carpet after the carpet weaving process is completed. In the current technology, this process involves applying the prepared binding solution through rollers to the back of the carpet, and then passing the carpet through the hot rollers in the drying chambers. Thus, the applied binding solution penetrates into the carpet structure and the water in the solution is evaporated. This process significantly affects the carpet costs in terms of energy and machine investment. The aim of the present project is to develop an innovative and environmental friendly finishing method for acrylic woven fabrics. Composite weft yarn samples were produced by wrapping jute yarns with a mono-filament 0.2 mm diameter polymer with 1, 2 and 4 plies and 0.5 mm diameter monofilament polymer with 1 ply. Then, by using these weft yarn samples, a total of 24 carpet samples were produced at 3 different pile densities (55, 102 and 132 wefts / 10 cm) and two different weave structures (1/1 and 1/2). In addition, 6 different carpet samples were produced by applying standard latex finishing on the same pile density values and weave structures. The produced samples were applied pile withdrawal force and compression-recovery tests and their performance were analyzed. As a result, it was seen that both test values were superior to standard carpet samples.