A carpet is a textile floor covering consisting of an upper layer of "pile" attached to a backing. The pile is generally either made from wool or a manmade fibre such as polypropylene, and usually consists of twisted tufts which are often heat-treated to maintain their structure.
Etymology
The term "carpet" derives from Armenian "karpet" (կարպետ), "kar" meaning a "knot" or "stitch". Sometimes the term "carpet" is used interchangeably with the term "rug". The hand-knotted pile carpet probably originated in the Caucasus between the 3rd and 2nd millennium BC. Cilician Armenia which had intensive trade relations with Venice, brought carpets to all of Europe, where they were primarily hung on walls or used on tables. Only with the opening of trade routes in the 17th century were significant numbers of Persian rugs introduced to Western Europe. Historically the word was also used for table and wall coverings, as carpets were not commonly used on the floor in European interiors until the 18th century.
Carpet types
Woven
The carpet is produced on a loom similar to woven cloth and is usually a cut pile although looped pile carpets of woven construction are not unheard of. Normally many colored yarns are used and this process is capable of producing intricate patterns from pre-determined designs( although some limitations apply to certain weaving methods with regard to accuracy of pattern within the carpet). These carpets are normally the most expensive (although not always) due to the relatively slow speed of the manufacturing process.
Needlefelt
These carpets are more technologically advanced. Needle felts are produced by electrostatic attraction of individual synthetic fibers forming an extremely durable carpet. These carpets are normally found in the contract market such as hotels etc. where there is a lot of traffic.
Knotted
On a knotted pile carpet (formally, a supplementary weft cut-loop pile carpet), the structural weft threads alternate with a supplementary weft that rises at right angles to the surface of the weave. This supplementary weft is attached to the warp by one of three knot types (see below), such as shag which was popular in the 1970s, to form the pile or nap of the carpet. Knotting by hand is most prevalent in Oriental rugs and carpets.
Tufted
These are carpets that have their pile injected into a backing material, which is itself then bonded to a secondary backing comprising a woven hessian weave or a man made alternative to provide stability. This is the most common method of manufacturing of domestic carpets for floor covering purposes in the world.
Others
A flatweave carpet is created by interlocking warp (vertical) and weft (horizontal) threads. Types of oriental flatwoven carpet include kilim, soumak, plain weave, and tapestry weave. Types of European flatwoven carpets include Venetian, Dutch, damask, list, haircloth, and ingrain (aka double cloth, two-ply, triple cloth, or three-ply).
A hooked rug is a simple type of rug handmade by pulling strips of cloth such as wool or cotton through the meshes of a sturdy fabric such as burlap. This type of rug is now generally made as a handicraft.
Embroidery
Unlike woven carpets, embroidery carpets are not formed on a loom. Their pattern is established by the application of stitches to a cloth (often linen) base. The tent stitch and the cross stitch are two of the most common. Embroidered carpets were traditionally made by royal and aristocratic women in the home, but there has been some commercial manufacture since steel needles were introduced (earlier needles were made of bone) and linen weaving improved in the 16th century. Mary Stewart Queen of Scots is known to have been an avid embroiderer. 16th century designs usually involve scrolling vines and regional flowers (for example, the Bradford carpet). They often incorporate animal heraldry and the coat of arms of the maker. Production continued through the 19th century. Victorian embroidered carpet compositions include highly illusionistic, 3-dimensional flowers. Patterns for tiled carpets made of a number of squares, called Berlin wool work, were introduced in Germany in 1804, and became extremely popular in England in the 1830s. Embroidered carpets can also include other features such as a pattern of shapes, or they can even tell a story.
Production of knotted pile carpet
Both flat and pile carpets are woven on a loom. Both vertical and horizontal looms have been used in the production of European and Oriental carpets in some colors.
The warp threads are set up on the frame of the loom before weaving begins. A number of weavers may work together on the same carpet. A row of knots is completed and cut. The knots are secured with (usually 1 to 4) rows of weft.
There are several styles of knotting, but the two main types of knot are the symmetrical (also called Turkish or Ghiordes) and asymmetrical (also called Persian or Senna).
Contemporary centers of carpet production are: Armenia, Iran (Tabriz), Afghanistan, Azerbaijan, India, Turkey, Northern Africa, Pakistan, Nepal, Spain, Turkmenistan, and Tibet.
The importance of carpets in the culture of Turkmenistan is such that the national flag features a vertical red stripe near the hoist side, containing five carpet guls (designs used in producing rugs).
Child labour has often been used in Asia. The Rugmark labelling scheme used throughout Europe and North America assures that child labour has not been used: importers pay for the labels, and the revenue collected is used to monitor centres of production and educate previously exploited children.
Fibers and yarns used in carpet
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 and 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, with the most common blend being 80% wool to 20% synthetic fibre, giving rise to the term "80/20". Wool is relatively expensive.
Nylon : Up until recent times this was 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 : Also known as "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 : (Polytrimethylene terephthalate) polymer, also called Sorona or 3GT (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 st
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