The History and Science of Carpet

Okay, we admit it. Sometimes, people think carpet is boring. I know. It's shocking. But if you've read anything that we've ever written here at The Carpetology Blog, you know that we firmly and passionately disagree. We think carpet is fascinating, right down to its molecular structure. Which is what brings me here today. There's a whole science to Wear-Dated carpet that one just doesn't recognize when shopping in a typical flooring retail store. History helps put it into perspective.

In case you didn't realize, Solutia Inc. is Wear-Dated's parent company. Solutia, a spin-off of Monsanto (a name you probably recognize), is a performance materials and specialty chemicals company headquartered here in St. Louis. This is a fancy way of saying that the company uses science and technology to develop innovative solutions for customers. According to the company Web site, "Solutia creates performance materials that are used primarily in the automotive and architectural, transportation and industrial markets." One of these materials is Nylon 6,6.

Nylon? Like pantyhose, you ask? Actually, kind of.

Rayon, the first manmade fiber, was invented in the 1800s by Count Hilaire de Chardonnet, a French chemist who was trying to find a cheap substitute for silk. But the first truly synthetic fiber was patented by Dr. Wallace Hume Carothers, the “Father of Polymer Science,” in the early 1930s. He was part of an elite group of chemists hired by DuPont to explore the possibilities of polymer chemistry. This team also discovered polyester and neoprene, the first synthetic rubber.

In 1931 Carothers traveled to Washington DC to present a paper to the American Chemical Society. The paper was titled Fiber 6,6 – the first name of Nylon 6,6. Seven years later, the first commercial product made from Nylon 6,6 hit the market for consumers to buy - toothbrush bristles!

In 1939, nylon stockings were introduced at the World's Fair in New York (one of the largest of all time) and became a huge hit. They were far more affordable than silk, they conformed to the leg and they could be dyed unlimited colors. At this point in time, women actually fought over nylons, which they bought for $1 a pair. [Now, you'd have to fight me to make me wear a pair. Funny how times have changed, no?] Then during WWII, nylon became a luxury. It was rationed for military use and served as material for parachutes and artillery belts, a far cry from women's stockings. Talk about a multi-tasking material.

In 1953, after the war, Monsanto began manufacturing nylon as a way to diversify its business. Monsanto spun its chemical businesses off into Solutia in 1997, and Solutia still manufactures Nylon 6,6.

So that, in a nutshell, is the history of nylon. But the story doesn't end there...

There's an actual science to nylon that's especially important to us. You see, we specifically chose to manufacture Nylon 6,6 over other nylon chemistries for our carpet fiber which goes into residential as well as commercial carpet.

In terms of fiber manufacturing, Nylon begins at the oil well, where crude oil is used to make nylon intermediates. Out of nylon intermediates come hexamethylene diamine and adipic acid [also used as a food ingredient], two critical Nylon 6,6 building blocks that are transformed into nylon salt and then go into yarn manufacturing to emerge as either staple or bulked continued fiber [BCF] for carpet.

Our Pensacola plant makes primarily staple fibers, while our Greenwood, SC plan makes BCF fibers. [Check out our handy-dandy illustration for a more visual look at nylon manufacturing.]

Once manufactured, fiber goes to carpet mills to be spun into yarn, then tufted into carpet.

Did you know that the structure of the fiber itself is important to the final outcome of carpet made with Wear-Dated Nylon carpet fiber? And that Nylon 6,6 is better than nylon 6?

Here's why. Because its actual molecular structure is denser, Nylon 6,6 makes a harder and more resilient fiber, able to better withstand soil and dirt, prevent crushing, and offer more resistance and recovery. All reasons contributing to Nylon 6,6 being the carpet fiber most often specified by architects and designers for commercial installations. It's also why we refer to it as the durable fiber!

Below are a few terms to know when it comes to fiber technology...

Denier refers to the size of the fiber. There are two types - the size of the individual filament and the total size of a bundle of filaments (the fiber).

The Cross section is the shape of the individual filaments of the fiber (we're at a molecular level here). Many of our Wear-Dated and Ultron Nylon 6,6 carpet fibers feature a "mixed denier" cross section where we combine different cross sections to give our fiber the most natural-like luster in the marketplace, and get as close to wool as we can.

Our carpet fibers have a trilobal shape - a three-sided shape with a smooth surface and no grooves to attract soil. In fact, the trilobal shape itself actually aids in hiding soil [the first nylon fibers had a round cross-section and tended to draw attention to soil].

The luster of a fiber refers to the brightness of the fiber. Fiber manufacturers make a wide range of lusters ranging from bright (for residential applications), all the way to dull (for commercial applications).

Solutia manufactures Nylon 6,6 fiber in a variety of denier sizes. Carpet mills use denier as one of the tools to help them provide you, the consumer, with a wide array of color and styling options. This way, you can choose from carpet styles ranging from velvety soft cut pile to thick, nubby berbers.

Little did you know that when you're shopping for carpet, it's important to turn to science before you make a final decision.

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Nature Inspires Invision's Altered Elements Carpet Collection

Ann Hurley recently caught up with Laura Compton [pictured here on the right], Invision Carpet Systems Director of Design, to discuss Altered Elements, its newest commercial carpet collection. The collection consists of three carpet lines:

Image courtesy of J&J/Invision
+ Broken Slate
+ Tumbled Stone
+ Weathered Steel

All three are inspired by nature in a way that "captures the interplay between the elements and the wonder and drama Mother Nature creates on a daily basis" per the press release.

Ann asked Laura to talk more about the collection and its inspiration.

According to Laura, the intent for the collection was to create visual textures that still read at a distance. She wanted to emphasize the distinctions of nature -not only its variations but also its imperfections [e.g., the effects of time and pressure on slate, tumbled stones, and the natural patina of rain on steel...].

Image courtesy of J&J/Invision

To make this intent reality, she incorporated novelty yarns with specialty textures.

In many ways, she took an approach more similar to what is seen in fashion apparel than traditionally in floor covering. Not only did she work with novelty & specialty textures, but also with luster & dye levels that create subtle reflections & colorations.

Ann's take on this: by combining various luster and dye levels, Laura's team at Invision has produced this new collection, creating new colors with dimension, as well as reflections, taking commercial carpet to a new level!

Pretty exciting, if you ask me!

All three carpet lines are available in modular tile and broadloom in a rich palette of 20 colors ranging from vibrant to neutral.

We are particularly excited because the Altered Elements collection uses Ultron® nylon 6,6 carpet fiber, bringing together stunning aesthetics with cutting edge fiber technology.

All three lines work well together or alone for corporate, retail, or almost any environment.

Ann is much more involved on the commercial carpet side of the business than I am. However, several elements caught my attention when I first read Invision's press release titled "Invision Introduces Altered Elements. New Product Collection Proves - When Elements Collide, Something Beautiful Happens."

The notion of being inspired by 'colliding elements' and the effects of the weather on surfaces definitely intrigued me.

But, then, I was also impressed and curious about a product launch that seemed - from its very inception - to turn traditional processes upside down.

According to the release, the collection "represents ... a new level of collaboration between top product design and technical fiber development teams from Invision and industry-leading designers Shawn Littrell and Donna Stubbs, who have worked extensively over the past two years with Invision Director of Design Laura Compton to create Altered Elements. From the base fiber materials to the dye lab, everyone was inspired to create unusual yarn constructions that allow the yarn’s varying luster and dye levels to capture the richness and texture of the weather’s effects."

It seems, too, that design, manufacturing and marketing collaborated for the creation process. Very cool!

Before finalizing the three carpet lines, Compton and her team reviewed a multitude of images capturing visual representations of the effects on steel, stone and slate that weather has. In my mind's eye, I can envision [or invision?] textures and colors, closeups and groupings that have the brain reinterpreting everyday elements.

By the way, you may have caught sight of Broken Slate in A Foot's Perspective - Episode 9.

Although these carpet styles are geared more toward the commercial end of the marketplace, we are seeing more and more of these elegant looking styles in high tech residential media rooms.

Whether in a commercial or a residential setting, the Altered Elements collection definitely capture wonderful inspiration from nature, delivering a look and feel that combine contrasts in luster, dye levels, textures and yarns, and are guaranteed to both delight and soothe the soul while inspiring the mind.

Image courtesy of J&J/Invision

NOTE: While putting this article together, Laura put me in contact with Natalie Faulkner, Creative Marketing & Communications Manager for J&J / INVISION. Natalie shared with me the advertisement Invision is running for Weathered Steel [see right].

This ad pictured on the right - and the ones for Tumbled Stone and Broken Slate - are quite distinct with a definite 'Altered Elements' look to them.

Natalie says that "the people in the ads are real. They were painted and dressed to blend into the elements in the background. Their emotions and overall look give each element a unique feel."

Very cool!

Thank you, Laura and Natalie.

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Marianne Cone Discusses Surfaces, By The Foot and Wear-Dated Natural Nylon

During Surfaces 2008, Kemp Harr, publisher of Floor Focus Magazine and FloorDaily.net interviewed Wear-Dated's own Marianne Cone.

In the interview, Marianne, our director of marketing, describes Wear-Dated's presence at Surfaces 2008. [It took place from January 31 through February 1st, 2008 in Las Vegas.]

First, our overall theme: By The Foot, based on our award-winning marketing campaign.

By The Foot updates Wear-Dated's reputation for durability [our tagline is "You'll Wear Out Before Wear-Dated Does."] with fashion and beauty, making us more relevant particularly to women consumers.

By all accounts By The Foot continues to generate enthusiastic reactions, and - we're hopeful - spirited conversation around fashionable carpet options.

Next, Wear-Dated Natural Nylon.

First introduced during Surfaces 2007, Wear-Dated Natural Nylon has been successfully adopted. We now have a multitude of products from well-known carpet mills showcased in our booth. Many are already available or will shortly be available to consumers.

What is Wear-Dated Natural Nylon?

From a recent press release recapping Surfaces:
 
"Wear-Dated Natural Nylon combines the superior performance characteristics of Solutia type 6,6 nylon with a proprietary insert technology that binds individual fibers together. The result is a patented fiber structure with sharp pinpoint tip definition and a natural ‘wool-like-look’ in constructions previously limited to BCF fiber, all with superior appearance retention."


In other words, it creates carpet with the beauty, luster and hand of wool, in delicious pattern and loop styles, but with the durability of Nylon 6,6.

Creating Beauty. Comfort. Durability. Pretty exciting!

Finally, new carpet introductions made with Wear-Dated carpet fiber.

Marianne describes some of the carpet styles featured in our Surfaces 2008 booth. More specifically she talks about Marciano from Mohawk and SuperChic from Tuftex [both pictured here; SuperChic is the intensely thick area rug, atop Marciano].

We're pleased to share with you both the audio file of the interview with Marianne and the video version. [We heartily recommend the video version.]

We hope you enjoy the interview, and the glimpse it offers into the excitement of Surfaces 2008.
If you'd like to read more about our Surfaces 2008 experiences, you can do so with Surfaces 2008, The Elegance of Dupioni Silk and The Latest in Carpet Style Trends.

~ The Women of Wear-Dated

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"Feet Appreciate Beauty"

“Feet appreciate beauty in their own right. A little pedicure, foot rub and some nail polish and that once ho-hum foot is now ready for a night on the town. Throw a pair of strappy stilettos in the mix and your now sexy little left and right will be turning heads right and left. Like everything, feet like to be admired. No different than the carpet in your home.”

That excerpt is from the award winning Wear-Dated brochure, By The Foot – a foot’s perspective of beauty. Life. Carpet.

Some fourteen months ago we determined it was time to update the Wear-Dated marketing materials. Past brand marketing efforts had resulted in a very fine reputation for producing durable carpet fiber….nothing wrong with that! So why change? The challenge we presented to ourselves was to maintain our coveted reputation for durability while making the way in which we communicate our message more relevant to our audience, the female consumer. While a durable product is certainly relevant, we know beauty and comfort are important characteristics for her as well.

Now you may not know it, but the very best type of nylon fiber is nylon 6,6. That's the kind of nylon carpet fiber we make. Nylon 6,6 is actually the result of some pretty sophisticated organic chemistry, created by really intelligent chemical engineers. Our challenge? How to tell the female consumer that good chemistry means durability, beauty, and comfort in her home. We decided the very best way to tell the story of good chemistry would be to engage her with color and quirkiness, simplify the content into a more consumer friendly format that educates about the benefits of Wear-Dated carpet fiber, and then connect with her on an emotional level.

By The Foot of course is a take off on the way in which carpet is planned within a room, but it is something far more interesting than just measurement. If we picked just one part of the body that should have a legitimate say about the sensory experience of carpet – or any flooring material for that matter – feet should have the first and last word. Thus, we wanted to create a unique visual experience that would sell the benefits of our Wear-Dated carpet fiber from the perspective of……feet! The result is an interesting and unique story that connects in a casual, sassy kind of way. The graphic design, colors, illustrations, and copy all come together in a way that is her best friend explaining the ‘how & why’ rather than the stodgy salesman…..informative but with lots of feminine personality.

This was an adventurous concept for carpet industry literature, but we’ve heard it described as eccentric but fun…, informative and smart..., whimsical yet serious…, sometimes strong, sometimes beautiful… Just like a woman. Coincidence?

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