1. Mechanical technology of nonwovens
TUFTING
Mechanical technology of nonwovens

2. Tufting the tufting process was invented in the early 1950s
Tufting is type of textile technology in which a thread is inserted on a primary backing

3. Application Carpets (90% of production
– residential and automotive application)
Blankets und plushes (upholstery)
Artificial turf

4. Tufting process:
Yarn and primary backing come together in the machine. Yarn comes from cones on creel racks (or from big spools called beams).
Yarn is fed through needles on a needlebar of a tufting machine. Needles repeatedly penetrate or tuft into the primary backing.
Fixation/stabilization of yarn by combing (blankets, plushes) or latex coating (carpets)
Dyeing or printing, brushing, shearing, finishing – fireproofing, antisoil, antistatic, antibacterial...
Completing - overcasting, sewing fringe on...

5. Tufting plant

6. Pile types
Cut pile - after the needle is withdrawn, the hook holds several loops while the knife cuts another loop against the sharpened edge of the hook.
Loop pile - after the needle is withdrawn from the primary backing, the looper rocks back and leaves a loop.

7. Design/patterning I Sliding Needlebar Techniques
– straight, staggered and double needlebars

8. Design/patterning II 2. Yarn Tensioning Systems 2.1 Eccentric Roll
The simplest system for varying pile height involves a series of grooved eccentric rollers mounted on a driven shaft, one disc for each yarn end. As the eccentrics turn, the tension of the yarn running in the groove changes, creating differences in pile height.

9. Design/patterning III
2.2 Scroll Patterning
In scroll patterning systems, the normal feed rollers are replaced by a series of rollers positioned across the top of the machine, each of which has a two-speed or three-speed drive operated by electromagnetic clutches
(similar to jacquard-patterning technology)

10. Design/patterning IV 2.3 Cut/Loop Tufting
The cut/loop mechanism is controlled by any one of the patterning attachments and works on the principle of yarn tensioning. The designs consist of areas of high cut pile and low loop pile.

11. Used materials
primary backing/base cloth - woven fabric or nonwoven (spun bond)
carpets - jute, polypropylene
blankets - polyester,viscose, cotton
turf – polypropylene
yarn - staple or bulk continuous filament
carpets - polypropylene, polyamide, wool
blankets - polyacrylonitrile
turf – polyethylene, polypropylene, polyamide

12. Carpets
How well a carpet will “perform” (e.g., stand up to regular wear and tear, including daily traffic, spills and pets) is determined primarily by:
Fiber - the material used to make yarn (and how it is treated to fight stains);
Construction – how the carpet is made (twist, gauge rate - number of needles per inch used to “tuft” the carpet, density, etc.);
Backing – the material through which the yarn is sewn;
Pad – the padding installed under a new carpet, which can make a big difference in the look, feel and wear of your carpet.

13. Carpet types I
Cut pile Carpet: Loops are cut, leaving individual yarn tufts. One of today's most popular constructions.
Saxony Carpet: This dense, cut pile carpet is made with the yarn tufts packed closely together to form a smooth surface. This is a more versatile carpet, and is used in less formal settings. Saxony styles will show footprints.
Plush Carpet:This cut pile carpet is made from straight, untwisted yarn. The cut ends blend together to form a smooth, level surface. This luxurious carpet is suited for formal settings, because it shows all footprints and vacuum marks.
Frieze Carpet: This cut pile carpet is suitable for high traffic areas. The highly twisted yarn tufts curl at the surface, hiding footprints.

14. Samples I

15. Carpet types II
Loop pile Carpet: Loops are the same height, creating an informal look. This makes the carpet easier to clean because soil doesn’t penetrate deep into the carpet. Loops are typically short and densely situated, making the carpet crush resistant. Consequently, level loop carpets are popular for high traffic areas in the home, such as family rooms, stairways or hallways.
Many of today’s popular Berber styles are level loop styles.
Cut and loop pile Carpet: Combination of cut and looped yarns. Provides variety of surface textures, including sculptured effects of squares, chevrons, swirls, etc.

16. Samples II

17. Tufted blankets and plushes (Larisa)
The base cloth of blankets has both mechanical and physical properties for the tufting of medium fibres.
In the manufacture of the surface fibres, the medium fibres are combed out from the centre of the material.

18. Artificial turf
Artificial turf is a surfacing material used to imitate grass.
It is generally used in areas where grass cannot grow, or in areas where grass maintenance is impossible or undesired.
Artificial turf is used mainly in sports stadiums and arenas, but can also be found on playgrounds and in other spaces.
The newest synthetic turf products have been chemically treated to be resistant to ultraviolet rays, and the materials have been improved to be more wear-resistant, less abrasive, and, for some applications, more similar to natural grass.

19. The fibers that make up the blades of "grass" are made of nylon, polypropylene and polyethylene.
The nylon blades can be produced in thin sheets that are cut into strips or extruded through molds to produce fibers with a round or oval cross-section (the extruded product results in blades that feel and act more like biological grass).