Innovative fiber systems make innovative carpets
2017-04-06 From: AGAPPARQUETBrowsing times:1582
As a mature industry, the tufted carpet business requires differentiated
product to drive sales. Because most carpet manufacturers are
vertically integrated back to fiber extrusion, developing unique fiber
systems is a first step in creating innovative carpet.
Nylon and polyester each have a place in today’s carpet market,
according to Brad Christensen, vice president, soft surface category
management at Shaw Floors. “If we can achieve a better product, it
doesn't matter if it’s PET or nylon. Consumers are becoming fiber
agnostics. They just want a beautiful carpet.”
Innovation for Shaw carpet goes all the way back to fiber extrusion,
where the company is experimenting with both nylon and PET with
different cross sections produced with new spinnerets, Christensen
reported.
Shaw’s newest fiber system, ClearTouch Platinum PET, is used for the
polyester styles in the TruAccents collection. “The ClearTouch Platinum
PET yields better durability and resiliency,” Christensen explained,
adding, “It will perform close to nylon.”
Mohawk’s EverStrand carpets are made with the Continuum PET process for products that “start clean and stay clean.”
Engineered Floors’ solution dyed PureColor yarn systems give its carpets
a cost advantage as well as performance features. Mike Sanderson, vice
president product marketing at Engineered Floors, said, “It’s the
manufacturing process that makes the difference. Whether it’s polyester
or nylon, it’s always PureColor. Our state of the art manufacturing
facilities allow us to manage the entire production process, from fiber
extrusion to quality assurance and distribution. This streamlined
manufacturing process allows us to be price competitive in the market.”
And solution dyed PureColor also offers superior colorfastness when
subjected to direct sunlight and can withstand cleaning with a bleach
solution, according to the company.
Beaulieu has engineered SoftSense Polyester and Nyluxe (nylon) fiber
systems to enhance the design and performance characteristics of its
soft floorcovering products, said Dallas Chapman, executive vice
president at Beaulieu America. “SoftSense and Nyluxe provide the
ultimate in design flexibility with numerous style options in both
solution dye and piece dye methods. We have developed products like
Urban Chic that blend SoftSense and Nyluxe together in a dense, tight,
tailored construction giving the product stylish yet durable
characteristics,” Chapman explained.
Beaulieu has also enhanced the appearance of traditional carpet using a
new technology called D.I. Design, which takes white Nyluxe patterned
substrates and creates added depth and dimension through an exclusive
dyeing process, Chapman said.
Phenix introduced its Opulence HD solution dyed polyester fiber this
past January at The International Surface Event, said Susan Curtis,
senior vice president, product development.
“We developed this new fiber from the ground up working with our
extrusion division to develop a yarn that provides great bulk, with a
soft, very luxurious hand. This fiber is a finer denier yarn that
aesthetically is low luster, with well-defined tips that delivers a
beautiful suede-like finish,” Curtis noted. “Because this fiber is
manufactured from solution dyed polyester it is inherently stain
resistant. Opulence HD is available in our Cleaner Home collection of
fine carpets that also feature Microban, an antimicrobial and SureFresh
odor capture.”
Flourish from the Phenix Cleaner Home Collection is made of Opulence HD solution-dyed polyester.
Shape matters
Continuous filament fiber is made by being extruded through a spinneret
(showerhead-like device). The filament can be extruded in different
cross-section shapes — round, trilobal, pentagonal, octagonal, etc. —
which can produce different visual effects and performance attributes in
the finished carpet.
