Carpet Materials
Last time, I discussed various methods of carpet construction. In this post, I’ll be discussing what sorts of materials are used in carpet construction. Carpets can be made from many single or blended natural or synthetic fibers. These fibers are chosen for their various properties such as durability, appearance, ease of manufacture and cost. Nylon and polypropylene comprise 90% of the commercial carpet market.
Nylon is the most common type of fiber used in carpet construction. It can be dyed topically or while it is in a molten state. It can also be printed easily and has excellent wear characteristics. Nylon possess many dye sites on the fiber which must be filled to try to avoid stains, which is why many nylon rugs are treated with stain-guards. Because nylon is a petroleum-based product, its price tends to vary with the price of oil.
Polypropylene is used often because it is quite inexpensive. However, it is difficult to dye and does not wear as well as nylon or wool. Polypropylene is often used to construct Berber carpets, and is then referred to as olefin. Large looped olefin Berber carpets are usually only suitable for light domestic use and tend to mat down quickly. Smaller looped Berbers wear much better than larger looped ones. Commercial grade carpets of this type have very small loops and are well-suited for offices. This type of carpet generally has good stain resistance, but not against oil based products. If a stain is allowed to set, it can become very difficult to treat. Outdoor faux grass carpets are usually made from polypropylene.
Polyester (PET, or polyethylene terephthalate) became more competitive in the early 2000s as a carpet material. It has good physical properties and is inherently stain-resistant because it is hydrophobic and does not have dye sites like nylon does. It is dyed in a molten state. The biggest disadvantage of polyester is that it tends to crush and mat down easily and is typically used in mid-to-low-priced carpets.
Acrylic is also used in carpet production. It is a synthetic material first invented by DuPont in 1941, but it has gone through many changes since then. Acrylics have been developed that minimize the original problems of pilling and developing fuzz easily, which happens when the fibers degrade over time and short strands break away with contact or friction. Acrylic is fairly difficult to dye but is colorfast, washable and has the feel and appearance of wool, making it a desirable rug fabric.
As for natural fibers, wool has excellent durability, can be dyed easily, is fairly abundant and is a renewable resource. When wool is blended with nylon, its durability is increased. Blended wool yarns, typically made up of 80% wool and 20% synthetic fibers (an “80/20” blend), are used extensively in the production of modern carpet. However, because wool is relatively expensive, it comprises a small portion of the global rug market.
Some rugs are made of silk. These are rare, and very expensive. True silk rugs are made with fibers that come from the cocoon of the silkworm. Often, rugs made of artificial silk (typically mercerized cotton or rayon, both made of almost pure cellulose) are passed off as real silk by unscrupulous dealers. Mercerized cotton is stretched, swollen and treated cotton that allows it to take on the same sheen and luster of silk. Like mercerized cotton, rayon is made of almost pure cellulose, but it is produced by dissolving wood pulp or cotton to produce a thick liquid called viscose, which is then extruded into long filaments which can be spun into thread and yarn.
Cotton is a natural, soft fiber sometimes used as thread for the base of a rug. It is easy to clean and maintain. Sisal stems from the agave plant and is a highly sustainable product. It does not attract dust and is static free.
Jute is a shiny, vegetable-based fiber that is one of the most affordable fibers on the market. It is second only to cotton as the most produced vegetable fiber. It is durable, has low thermal conduction and anti-static properties, all of which make it a popular choice with consumers.
Stayed tuned for more carpet information!
