What Are The Methods Of Carpet Construction?

What are the methods of carpet construction? Carpet is constructed through tufting equipment in the United States. The majority of the carpet in the U.S. is tufted rather than woven. Woven carpets can be...

The majority of the carpet in the U.S. is tufted rather than woven. Woven carpets can be handmade or machine-made and tend to be high end or more expensive. All carpet used to be hand woven. America's huge advantage in the carpet industry was the invention of tufting equipment in the 1930s. Tufting equipment is versatile and efficient and allows for a whole range of styling and design effects in an extremely cost effective manner. A tufting machine looks a lot like a sewing machine with hundreds of needles across the width that tuft the yarn into a substrate. The tufting machine punches the yarn into this grid of fabric that's called the primary backing. You get something that looks like a blanket and is known as "greige goods".

The greige goods are then dyed to the desired color. A secondary backing (the woven material seen on the back of most carpets) is then attached to the dyed carpet by using a latex coating between the dyed carpet and the secondary backing. This carpet is passed through an oven to cure the latex. This operation adds dimensional stability and also locks in the tufts. The carpet has a fuzzy surface at this point so the carpet must go through a finishing operation which is composed of shearing off the fuzz and trimming the carpet to the proper finished width. You now have carpet which can be shipped to the retailer.

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