Tufted carpet accounts for about 90 percent of all
the carpet produced in the United States. Dalton Georgia is
considered the tufted carpet capital of the world. Due to limited
design possibilities, this type of carpet is usually plain or made up of
two interwoven colors or a series of dots or crude shapes. Designs can,
however, be printed on the surface.
In tufted carpet the pile material is stitched into an existing backing
material, usually a synthetic product, and held in place with a latex
adhesive, before a second layer of backing material is fixed to the
latex for greater structural strength. The backing can be either a
natural product, which will require a felt, or rubber, padding (also
called underlay) which can be fitted directly over the floor. Although
tufted carpet is not as strong as traditional types of carpet, the construction of tufted
carpet is effective and inexpensive to produce.
Tufted Carpet Features:
- Tufted carpet is the most prevalent method for carpet
fabric production (more than 90%)
- A textural flexibility
that is achieved with
varying colors, surface textures, using various type of yarns, etc.
- Tufted carpet allows for custom tufting
and is available for specially
designed carpet orders
- Tufted carpet comes in various
cut and loop
Tufted Carpet Process
This is the process of creating
textiles, especially carpet, using specialized multi-needle sewing
machines. The machines push yams through a primary backing fabric and hold
them in place to form clusters, or tufts, as the needles are withdrawn.
pile - After the needle is withdrawn from the primary backing, the
looper rocks back and leaves a loop.
- After the needle is withdrawn, the hook holds several loops while the
knife cuts another loop against the sharpened edge of the hook.
loop - A cut and loop effect can be achieved by having separate
cutting and looping systems under the machine. Precision cut/uncut and
Velva loop carpets are examples. Another method uses a cut/loop machine
with a spring-loaded hook.
This is the material into which carpet
yam is tufted. The function of primary backing is to hold tufts in place
- Woven backing - A fabric made
from interlacing yams. Most primary backing used with Shaw carpets is
woven. Yam that runs in the machine direction (see diagram) is called
the warp; and yam running across the machine direction is called the
pick, fill, or weft. When we refer to a backing as 24x 1 3, we mean 24
warp ends per inch and 13 pick ends per inch. The number of tufted
stitches per inch dictates which pick backing is used.
- Nonwoven backing - An assembly of
textile fibers held together by chemical, thermal, or mechanical
bonding. Nonwovens have an advantage over wovens in that they do not
bow and skew easily. However, because they are so rigid, they tend to
Tufted Carpet Guide
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