EP0760875B1 - Paillasson ameliore et procede de fabrication - Google Patents

Paillasson ameliore et procede de fabrication Download PDF

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Publication number
EP0760875B1
EP0760875B1 EP94916596A EP94916596A EP0760875B1 EP 0760875 B1 EP0760875 B1 EP 0760875B1 EP 94916596 A EP94916596 A EP 94916596A EP 94916596 A EP94916596 A EP 94916596A EP 0760875 B1 EP0760875 B1 EP 0760875B1
Authority
EP
European Patent Office
Prior art keywords
tufts
mat
yarn
track control
substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP94916596A
Other languages
German (de)
English (en)
Other versions
EP0760875A4 (fr
EP0760875A1 (fr
Inventor
John S. Combs
Michael Mchargue
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KLEENTEX INDUSTRIES Inc
Original Assignee
KLEENTEX INDUSTRIES Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by KLEENTEX INDUSTRIES Inc filed Critical KLEENTEX INDUSTRIES Inc
Priority to DK94916596T priority Critical patent/DK0760875T3/da
Publication of EP0760875A4 publication Critical patent/EP0760875A4/fr
Publication of EP0760875A1 publication Critical patent/EP0760875A1/fr
Application granted granted Critical
Publication of EP0760875B1 publication Critical patent/EP0760875B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/026—Tufted products characterised by the tufted pile surface
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/44—Yarns or threads characterised by the purpose for which they are designed
    • D02G3/445—Yarns or threads for use in floor fabrics

Definitions

  • the present invention relates generally to carpet, and more particularly relates to an improved carpet with coarse and fine fibers, and a process for making the same.
  • the carpet when used as a mat, removes large and small dirt particles from footwear due to improved grit and particulate gripping and moisture absorbing capabilities.
  • carpets are manufactured generally by feeding yam from spools through needles into a substrate. This process is known in the art as "tufting.” The type of yarn, length of needle, the needle spacing, and whether the yarn is looped or cut are just a few factors that relate to the final carpet product-and-its-intended-use.
  • This invention relates to carpet that is manufactured for use in making mats, such as welcome mats or "track control" mats as they are known in the industry.
  • track control mats are placed at or near an entrance of a house or other building to remove dirt, moisture or other matter from the bottom of the shoes, and conveyances (such as grocery carts and dollies) used by persons entering the building.
  • conveyances such as grocery carts and dollies
  • the wiping action should occur as the result of normal walking of one or two steps on the mat before the persons walk through the interior of the building.
  • the mats To prevent dirt and moisture from being tracked from outside throughout the interior of the building, the mats must not only have the ability to remove moisture and-dirt from footwear, but also to store the dirt and moisture within the body of the mat. If a mat does not effectively store the dirt and moisture within the mat, and leaves the dirt and moisture on the surface of the mat, the dirt and moisture will re-attach or stick to the bottom of footwear of other persons who subsequently walk on the mat. Dirt and moisture which re-attaches or sticks in this manner will then be tracked throughout the building, a condition known in the art as "re-tracking".
  • Some types of track control mats are made of a combination of coarse and fine fibers or filaments (hereinafter collectively referred to as "fibers"). These mats have been widely used in the past for the purpose of removing soil, moisture and other matter from a person's shoes or outer footwear.
  • the coarse fibers help to remove large particles of dirt and the fine fibers help to remove the fine particulate and moisture. There should be sufficient space between fibers to temporarily hold dirt and moisture to prevent re-tracking.
  • the intended use of a mat relates to the manner in which the mat is constructed. For example, if a mat will be exposed to significant moisture, the mat may be designed to contain a greater number of fine fibers to absorb and hold the moisture within its recesses. On the other hand, a mat that may be exposed to a significant amount of large particles of dirt may need to have a greater number of coarse fibers.
  • the degree of coarseness or fineness of a fiber is measured by its denier.
  • the term "denier” refers to the weight in grams for a 9,000-meter fiber.
  • a coarse fiber or filament for use in track control mats typically ranges in denier from 100 to 2,000 denier per filament ("dpf"); and fine fibers for the same application typically range from 15 to 100 dpf.
  • Most track control mats are made with a backing that holds the tufts in place relative to the substrate.
  • the backing is typically a plastic or rubber material that is melted or vulcanized and applied to the substrate. In this state, the backing bonds the tufts to the substrate.
  • US-A-3 940 522 discloses using latex cured in an oven which is applied to the underside of the fabric to secure the pile fibers to the backing.
  • mats should be manufactured in a manner that will withstand continued exposure to washing and drying.
  • the materials used to make the mat should be able to withstand elevated temperatures in both the washing and drying processes.
  • mats should be constructed so that the tufts do not separate from the backing during the cleaning process. Adhesion of the tufts to the carpet backing is known as "tuft lock.”
  • tuft lock Adhesion of the tufts to the carpet backing is known as "tuft lock.”
  • Many commercially available track control mats at present exhibit poor tuft lock and, as a result, are ineffective for reuse after washing.
  • the concentrated areas of stiff fibers exhibits poor tuft lock and become dislodged from the track control mat during use as well as during washing and drying. Moreover, the concentrated areas of stiff fibers, described in Breens et al ., tend to lie down against the backing. Conversely, if the mat were manufactured to provide sufficient stability for the coarse fibers, the fine fibers would have to be so densely tufted to support the coarse fibers inserted therein that the mat would be completely ineffective in retaining dirt or moisture.
  • the '566 and '333 patents teach that the coarse fibers should be separated from the fine fibers, typically to form a striped or checkerboard arrangement between the two types of fibers. While this type of track control mat may be effective at removing and storing dirt and other particles from the bottoms of shoes, the coarse fibers tend to become dislodged during use or washing of the mat because they are not adequately secured to the mat backing.
  • the tuft lock for these fibers is poor because when the coarse fibers are bonded to the backing at separate locations from the fine fibers, the coarse fibers do not bond well by themselves to the backing. Thus, when the mat is used and washed, many of the coarse fibers become dislodged from the backing. This renders the mat less effective in dirt and moisture removal and storage after a short period of time.
  • the '566 patent also describes a mat made with at least some crimped coarse fibers.
  • Mats manufactured in accordance with the '566 patent are extremely difficult to manufacture because the crimped fibers kink up as they are fed through the tufting needles which causes the fibers to eventually break. This requires the entire process to be shut down, the needles rethreaded and the process restarted.
  • the continuous kinking and ultimate breakage of the crimped coarse fibers results in a poor quality mat having many broken coarse fibers and many unattractive knots where the crimped fibers had to be reknotted or spliced to continue the tufting process.
  • the frequent breakage of the crimped coarse fibers results in a significant decrease in productivity.
  • mats using crimped fibers are also more expensive to manufacture due to the added process cost of crimping the fiber.
  • the '333 patent describes a mat made with at least one looped, uncrimped, coarse fiber. While mats made in accordance with the '333 patent do not have some of the above-identified problems associated with crimped fibers, it has been found that looped pile mats are less effective in dirt removal.
  • the term "pile" refers to the surface appearance of the carpet or mat. Carpet pile is either cut or looped. Mats having looped pile are difficult to clean and remove the dirt held therein. Thus, after a period of time, the mats having looped pile become less effective at dirt removal and storage.
  • the present invention overcomes these and other disadvantages associated with prior art track control mats.
  • the present invention provides a washable track control mat comprising tufts with at least one tuft being made of a yarn that is made of at least one fine denier fiber and at least one coarse denier fiber.
  • the yarn is made by twisting together the coarse denier fiber with the fine denier fiber.
  • the mat includes a substrate for receiving the tufts. The tufts in the substrate are bonded to a backing.
  • the present invention also is directed to a method for manufacturing a washable track control mat.
  • the method includes twisting together at least one coarse denier fiber with at least one fine denier fiber to create a yarn.
  • the method also includes tufting the yarn through a substrate and bonding the tufts to the substrate.
  • Fig. 1 shows a side view of a portion of a track control mat 10.
  • the mat 10 is made of a plurality of tufts 12.
  • the tufts 12 each include a yarn 14 made of a plurality of fine fibers 16 and one coarse fiber 18.
  • the coarse fiber 18 is preferably made of nylon or polyester.
  • the tufts 12 are secured to a substrate 20 by means of a backing 22.
  • the backing 22 bonds the tufted yams 14 to the substrate 20.
  • the backing 22 is preferably vulcanized rubber.
  • the mat 10 is made by first manufacturing the yarn 14 used in the tufting process.
  • the yarn 14, as shown in Fig. 2 is made of a plurality of fine fibers 16 twisted with one or more coarse fibers 18.
  • the denier range for the fine fibers 16 is preferably between 20 and 24, and the denier range for the coarse fibers 18 is 300-600. It is preferable that one coarse fiber 18 is used with a plurality of fine fibers 16 in each yarn 14.
  • the preferred weight ratio of fine fibers 16 to coarse fibers 18 is 20-24% to 76-80%, respectively.
  • the fine fibers 16 are twisted with the coarse fiber 18 to form a single-ply yarn 14.
  • the twist of the fine fibers 16 enables the fine fibers to stand up better when they are tufted into the substrate 20.
  • the twist of the fine fibers 16 help to support the coarse fiber 18 within the body of the yarn 14 so that the coarse fiber does not lie down when the mat 10 is finished. It is preferred that the yarn 14 be twisted 5 to 6 turns per 2.54cm (per inch).
  • the yarn 14 may be heat treated to set the twist in the fine fibers 16.
  • Some of the preferred fine fibers 16 used in the yarn 14 are made of non-heatset materials and do not need to be heat treated. Thus, the heat treatment of the yarn 14 after twisting is optional.
  • a plurality of yarns 14 or "plies" may be used in the manufacture of the mat 10 of the present invention.
  • Fig.2 shows two single-ply yarns 14 being twisted together to form a double or two-ply yarn 24.
  • the number of plies affects the resultant mat product 10, along with other factors discussed in detail below.
  • the yarn 14 is twisted and heat treated, if desired, and twisted with another yarn, if desired, the yarn is wound on spools and fed into tufting needles of a tufting machine where the tufts 12 of the mat 10 are formed into the substrate 20, shown in Fig 1.
  • the tufting machine cuts the tufts at the desired length.
  • the tuft length or pile height preferably ranges from 6.35 to 19.05mm (1/4 to 3 ⁇ 4 inches).
  • the needles in the tufting machine may be arranged to alter the density of the mat 10.
  • the distance between needles or "gauge” should preferably range from 3.97 to 4.76mm (5/32 to 3/16 inches).
  • the number of stitches each needle make per 2.54cm (inch) impacts the final product of the mat 10. It is preferred that the needles make between 5 to 7 stitches per 2.54cm (inch) for a 3.97mm (5/32 inch) gauge and between 5 to 8 stitches per 2.54cm (inch) for a 4.76mm (3/16) gauge.
  • the particular dimensions specified herein provides a mat 10 with sufficient numbers of voids 26 between the tufts 12 to receive and store dirt and moisture in sufficient volumes required of an effective track control mat.
  • the resultant mat 10 will vary in weight for a fixed length of carpet as a result of the different variables discussed above. It is preferred that the resultant mat 10 weigh between 542.5 to 813.75g/m 2 (16 to 24 ounces per square yard) prior to the application of any backing 22.
  • the mat 10 is moved from the tufting machines to an area where the backing 22 is applied to bond the tufts 12 to the substrate 20.
  • the backing 22 holds the individual tufts 12 to the substrate 20 and is machine washable. This feature enables the mat 10 to be subjected to commercial washing without degradation of the tufts 12.
  • a backing 22 made of rubber is also skid resistant and prevents the mat 10 from moving around once it is placed on the floor.
  • the first test involved washing a first mat made in accordance with the present invention and a second mat made pursuant to the disclosure in the '566 and '333 patents. Both mats were washed twenty (20) times. A visual comparison was made of the two mats.
  • the mat made in accordance with the teachings of the present invention showed no significant loss of coarse or fine fiber.
  • the mat made in accordance with the '566 and '333 patents showed significant loss of coarse fiber. This test demonstrates the capability of the present invention to achieve effective tuft-lock and maintain such tuft-lock after many washings.
  • the second test was related to analytically determining the effectiveness of the tuft-lock of the present invention.
  • Applicant compared the fiber loss of mat samples made in accordance with the present invention (set 1) with those made in accordance with the '566 and '333 patents (set 2). Both sets of examples were bone dried and weighed, then soaked with water, hung and allowed to drip dry for five (5) minutes. Both sets were then abraded for 2,500 cycles on a U.S. Testing Abrasion Tester. After being abraded, both sets were bone dried and weighed again. Set 1 showed a loss of 0.555 grams. Set 2 showed a loss of 2.094 grams.
  • the significant fiber loss of the mats made in accordance with the' 566 and '333 patents further demonstrates the effectiveness of the tuft lock achieved with the mats made pursuant to the present invention.
  • nylon or polyester may be the preferred materials for use as the coarse fiber
  • natural fibers such as jute may be used.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Carpets (AREA)

Claims (11)

  1. Procédé de fabrication d'un paillasson anti-traces lavable en machine, comportant les étapes consistant à torsader ensemble au moins une fibre de denier grossier avec au moins une fibre de denier fin pour créer un fil et mettre en touffe le fil à travers un substrat pour former une pluralité de touffes dans le substrat, caractérisé par les étapes consistant à :
    fixer les touffes sur le substrat à l'aide de caoutchouc vulcanisé de telle sorte que le paillasson puisse être lavé à la machine sans dégradation importante des touffes, les étapes consistant à mettre en touffe et à fixer étant effectuées d'une manière telle que les touffes sont structurées et agencées dans le substrat de telle sorte que les touffes enlèvent et stockent la poussière et l'humidité dans des vides existant entre les touffes pour maítriser les traces au sol de poussière et d'humidité.
  2. Procédé selon la revendication 1, dans lequel il existe une pluralité de fibres de denier fin.
  3. Procédé selon la revendication 1 ou 2, dans lequel le fil est mis en touffe à travers le substrat avec un taux de 3 à 10 boucles par pouce (par 2,54 cm).
  4. Procédé selon l'une quelconque des revendications précédentes, dans lequel le fil est torsadé sur 5 à 6 spires par pouce (par 2,54 cm).
  5. Procédé selon l'une quelconque des revendications précédentes, comportant de plus l'étape consistant à traiter thermiquement le fil après que le fil a été torsadé.
  6. Paillasson anti-traces lavable en machine, comportant une pluralité de touffes et un substrat pour recevoir les touffes, chacune de la pluralité de touffes comportant un fil constitué d'au moins une fibre de denier fin torsadée avec au moins une fibre de denier grossier, caractérisé par :
    une couche dorsale de caoutchouc vulcanisé qui fixe les touffes sur le substrat de telle sorte que le paillasson est lavable à la machine sans dégradation importante des touffes et les touffes sont structurées et agencées dans le substrat de sorte que les touffes enlèvent et stockent la poussière et l'humidité dans des vides existant entre les touffes pour maítriser les traces au sol de poussière et d'humidité.
  7. Paillasson anti-traces lavable en machine selon la revendication 6, dans lequel le fil est traité thermiquement.
  8. Paillasson anti-traces lavable en machine selon la revendication 6 ou 7, dans lequel le fil est reçu dans le substrat avec un taux de 3 à 10 boucles par pouce (par 2,54 cm).
  9. Paillasson anti-traces lavable en machine selon la revendication 6, 7 ou 8, dans lequel le fil est torsadé à raison de 5 à 6 spires par pouce (par 2,54 cm).
  10. Paillasson anti-traces lavable en machine selon l'une quelconque des revendications 6 à 9, dans lequel le paillasson pèse entre 16 et 24 onces par yard carré (54,25 × 10-2 kg/m2 ou 81,37 × 10-2 kg/m2) sans le caoutchouc vulcanisé.
  11. Paillasson anti-traces lavable en machine selon l'une quelconque des revendications 6 à 10, dans lequel la plage de rapport en poids de fibre de denier fin sur fibre de denier grossier est entre 20 à 24 % et 76 à 80 % respectivement.
EP94916596A 1994-04-29 1994-04-29 Paillasson ameliore et procede de fabrication Expired - Lifetime EP0760875B1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DK94916596T DK0760875T3 (da) 1994-04-29 1994-04-29 Forbedret rensemåtte og fremgangsmåde til dennes fremstilling

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US1994/004687 WO1995030040A1 (fr) 1994-04-29 1994-04-29 Paillasson ameliore et procede de fabrication

Publications (3)

Publication Number Publication Date
EP0760875A4 EP0760875A4 (fr) 1997-01-16
EP0760875A1 EP0760875A1 (fr) 1997-03-12
EP0760875B1 true EP0760875B1 (fr) 2004-06-23

Family

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP94916596A Expired - Lifetime EP0760875B1 (fr) 1994-04-29 1994-04-29 Paillasson ameliore et procede de fabrication

Country Status (4)

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EP (1) EP0760875B1 (fr)
AU (1) AU6820794A (fr)
DE (1) DE69433864T2 (fr)
WO (1) WO1995030040A1 (fr)

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GB2320934A (en) * 1997-01-06 1998-07-08 Palencia Ltd Yarn for use in tufted fabrics
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US6296919B1 (en) 1999-08-13 2001-10-02 Milliken & Company Cushioned carpeted floor mat with at least one cushioning integrated rubber protrusion
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US6726975B2 (en) * 2000-06-27 2004-04-27 Milliken & Company Multiple fiber floor mat and method
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US6420015B1 (en) 2000-09-27 2002-07-16 Milliken & Company Cushioned rubber floor mat and process
US6589631B1 (en) 2000-10-04 2003-07-08 Milliken & Company Flashless rubber floor mat and method
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US20200190718A1 (en) * 2017-06-07 2020-06-18 Invista North America S.A.R.L. Carpet with self-twisted loop pile and methods for making the same

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Also Published As

Publication number Publication date
EP0760875A4 (fr) 1997-01-16
DE69433864D1 (de) 2004-07-29
DE69433864T2 (de) 2005-06-30
WO1995030040A1 (fr) 1995-11-09
AU6820794A (en) 1995-11-29
EP0760875A1 (fr) 1997-03-12

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