Please read the following questions and if you do not find your answer, please answer your question, we will answer you as soon as possible.
Transverse density or carpet comb: The number of roots or knots per square meter of carpet width is called comb. For example, a machine carpet with 700 combs means that 700 roots (knots) are woven in each cubic meter of carpet width. . Common piles in the carpet market are: 500 pile carpet, 700 pile carpet, 1000 pile carpet and 1200 pile carpet.
Longitudinal density of the carpet (density): The density is the same as the comb and is called the number of knots per square meter of the length of the machine carpet. For example, the carpet has a density of 2550 per square meter of the length of 2550 roots or knots.
Density of carpet: 600, 700, 800, 1000, 1700, 2000, density 2550, density 2700, density 3000, density 3600
Number of roots (nodes) per square meter: If the number of roots in the length (density) is equal to 2700 and the number of roots in the width (shoulder) is equal to 700, then the number of nodes per square meter is equal to: 2700*700=1890000
As a result, the more the comb of the carpet is, the finer the machine-made carpet is, and it is very similar to the hand-woven carpet, that’s why they are also called hand-woven carpets. It is clear that it is related to the density of the carpet and the higher the density of the carpet, the stiffer and heavier the carpet. If you are planning to buy a machine-made carpet, we suggest you to buy carpets with a high density and pile because these carpets are durable and They are more durable than other carpets.
Basically, the process of heat set and steaming is to increase the quality of the yarn and finally the machine carpet. Experience has proven that the use of heat set yarn in a carpet weaving unit has increased production efficiency between 7 and 10 percent, which will be a very high figure in a company’s financial period. As mentioned, this increase in efficiency is due to the removal of many yarn defects in the heat setting stage, and this is one of the reasons why carpet manufacturers welcome heat set yarn. Heatset is almost a requirement for today’s high-tech carpet weaving machines. Nowadays, the weaving speed is increasing, and especially in the high density of the carpet, the yarns must have a high tear resistance so that excessive tearing does not disturb the production. Among the most important properties of heat-set acrylic yarn, the following can be mentioned:
1- The fluffiness of the thread and bulk and as a result better coverage of the carpet
2- Reduction of lint
3- Thermal stabilization and torsion stabilization 4- Softer subordinate
5- Less tearing of thread in weaving
6- Identifying the clues in the woven carpet (carpet graining or Pin Point effect) In general, heat set machines use water vapor as a thermal medium for heat set without damaging the yarn in two types, specifically for acrylic yarn or all synthetic yarns. On average, 24 to 48 thread heads are fed to the machine in the heat set machine. Basically, the steaming process of acrylic yarns is an essential process for weaving high-quality machine-made carpets. Steaming creates high resistance against tearing, high dimensional strength, reduction of surface fluff and as a result fluffiness of the thread, ability to absorb a lot of color, bulking of the thread and creating a completely uniform surface with a soft underhand. Next to the feeding coil, there is also a reserve coil so that the production process does not stop when the first bobbin is finished. After passing through the pre-feeding unit, the yarns enter a system known as a coiler. In this section, the yarns are spread in continuous rings on each other and on a conveyor belt. In new models of heat set machines, the width of the conveyor belt that guides the threads has been increased to increase the production. Usually, the production of heat set machine varies between 3 and 12 tons per day depending on the type of yarn, quality of yarn, grade of yarn. Then the threads enter the steaming area from the conveyor belt. After leaving the steam heads, the threads enter the dryer and then the cooler. Since acrylic can absorb moisture, this step is necessary.
Then the leads enter the electronic control section and from there they are directed to the winding unit. Before this unit, there are yarn storage units (accumulators) which are used to prevent the line from stopping. The important thing is that in the heat set lines that have the ability to heat set all kinds of polyester-polypropylene-polyamide-acrylic-wool and mixed yarns for spun and BCF yarns, the length of the steam tunnel and the steaming time are longer in the TVP3 machine. The heat set operation is carried out in a closed tunnel and the temperature of water vapor can rise up to 140 degrees, while in the LV machine, and the acrylic yarn does not need a temperature higher than 100 degrees to become fluffy, the steam is applied in one atmosphere without pressure. Another point is that in the TVP3 machine, you can also obtain milled yarn from this line. In this way, before entering the yarn into steaming, the yarn can be passed through a freezing and cooling unit and then the yarn can be heat set.