IE53443B1 - Method and apparatus for making adhesive-bonded pile fabrics - Google Patents

Abstract

A fusion bonded, pile fabric is made by positioning a pile-forming yarn in pile forming fashion adjacent to one side of a liquid permeable base layer, applying a hot melt adhesive heated to at least its softening point to the base layer on the opposite side of the base layer from the side adjacent to the pile-forming yarn, forcing the hot melt adhesive through the base layer into bond-forming contact with the pile-forming yarn, and allowing the adhesive to cool to a temperature below its softening temperature to thereby bond the pile-forming yarn to the base layer. Apparatus for use in this process is also provided and various configurations of pile fabric are described.

Description

The present invention relates to a method of manufacturing hot-melt adhesive-bonded pile fabrics, and to apparatus which may be used for carrying out the method.

Pile fabrics such as carpeting may be manufactured in several ways such as weaving, tufting, needling or bonding. In each method, the pile must be secured to a base or support layer in one way or another. The present invention is particularly concerned in one aspect with a XO method of manufacture wherein the pile is bonded by means of a hot-melt adhesive to a base layer. Such fabrics will herein be referred to variously as hot-melt adhesive-bonded pile fabrics or hot-melt adhesive-bonded carpets.

X5 A number of techniques are known for the manufacture of bonded pile fabrics, which involve coating a preformed base layer with a layer of an adhesive and then pressing pile-forming lengths of a yarn into the adhesive, to bond pile-forming lengths to the base layer.

Known commercial techniques for making bonded fabrics have relied very extensively on the use of PVC plastisol formulations because of the processing disadvantages thought to be associated with the use of other adhesive formulations such as hot-melt systems.

According to such techniques, a polyvinyl chloride plastisol was applied to a base layer, the pile-forminq — .. yarn was positioned in contact with the base layer and the plastisol was fused or cured, typically by heating. When attempts were made to substitute other adhesives, such as hot-melt adhesives, for the PVC plastisol in this process, difficulties were encountered. Thus, for instance, with regard to hot-melt adhesives, it has generally been thought that the apparatus employed 3 -ί _ 3 for positioning the yarn may become coated with the adhesive requiring frequent shut downs of the apparatus for cleaning which is, of course, commercially unattractive.

Thus, while PVC plastisol has been the bonding agent of choice in the preparation of pile fabrics it is quite expensive, and it may tend to give off noxious gases when the product is subjected to combustion conditions. Also, while polyvinyl chloride (PVC) plastisol compositions generally may provide good tuft lock characteristics, that is its use results in a firm bond of the pile-forming yarn to the base layer, PVC plastisols generally may not penetrate to the desired extent into the yarn bundles to effect complete adhesion of all pile yarn fabrics of the pile yarn bundle to the pile fabric structure, which may result in fuzzing of the end product, especially in carpeting end uses.

Another disadvantage typically associated with the prior art techniques for making non-tufted pile fabrics, that is fabrics where the pile yarn is not tufted through the backing but simply adhered to the backing, is that the adhesive is normally applied to the base layer on the side of the base layer facing the pile yarns, and the base layer is normally of a construction such that the adhesive will not flow through it but will substantially remain on that surface with perhaps some penetration into the base layer. Then, if it is desired to apply a backing layer, e.g. a hard back, to the back side of the pile fabric as may be desired in the making of carpet tiles the backing layer must be either adhered directly to the backing layer or an additional process step of applying adhesive to the back side of the support layer may be necessary. In either event, there is created numerous distinct layers in the finished product, namely pile layer, adhesive layer, base layer, another adhesive layer and a hard back layer. Such constructions may inherently have processing disadvantages and be costly to construct. These layers may also be subject to undesired separation during use.

According to the present invention, a method for making a hot-melt adhesive-bonded pile fabric comprises positioning a pile-forming yarn in pile-forming fashion adjacent to one side of a liquid-permeable base layer; applying a hot-melt adhesive heated to at least its softening point to the base layer on the opposite side of the base layer from the side adjacent to the pile-forming yarn; forcing the hot-melt adhesive through the support layer into bond-forming contact with the pile-forming yarn; and allowing the adhesive to cool to a temperature below its softening temperature to thereby bond the pile-forming yarn to the base layer.

Products of this method may be referred to herein as pile fabrics of the present invention.

For use in such a method, apparatus according to the invention comprises means for positioning pile-forming yarn in pile-forming fashion adjacent to at least one side of a liquid-permeable base layer; means for applying a hot-melt adhesive heated to at least its softening point to the base layer on the opposite side of the base layer from the side adjacent to the pile-forming yarn; means for forcing the hot-melt adhesive through the base layer into contact with the pile-forming yarn; and means for cooling the hot-melt adhesive to a temperature below its softening temperature, thereby bonding the pile-forming yarn to the base layer.

A preferred method according to the invention, for making a hot-melt adhesive-bonded fabric, comprises positioning two continuous, liquid-permeable base layers in a passage, so that the layers lie substantially parallel and at a predetermined spacing; driving at least one continuous pile-forming yarn by folder blades alternately against the opposing surfaces of the base layers when they are at or near the entrance to the said passage, in such a way as to position the pile-forming yarn relative to the base layers and to fold it zig-zag; thereafter applying a hot-melt adhesive heated to at least its sotening point to the back surfaces of the base layers; forcing the hot-melt adhesive through the base layers, so that the hot-melt adhesive contacts the pile-forming yarn; and cooling the hot-melt adhesive to a temperature below its softening point, thereby bonding the pile-forming yarn to the base layers.

This preferred method preferably comprises the further step of separating the bonded product, to form two continuous hot-melt adhesive-bonded products.

Apparatus suitable for use in this preferred method comprises means for positioning two continuous, liquid-permeable base layers in a passage, so that the layers lie substantially parallel and at a predetermined spacing; folder blades for driving at least one continuous pile-forming yarn alternately against the opposing surfaces of the base layers when they are at or near the entrance to the said passage, in such a way as to position the pile-forming yarn relative to the base layers and to fold it ziz-zag; means for applying a hot-melt adhesive heated to at least its softening poibnt to the back surfaces of the base layers; means for forcing the adhesive through the base layers into contact with the pile-forming yarn; and means for cooling the hot-melt adhesive to a temperature below its softening point, thereby bonding the pile-forming yarn to the base layers. Preferably, such apparatus further includes 5 means for separating the bonded product, to form two continuous hot-melt adhesive-bonded products.

The invention involves the bonding of a pile-forming yarn to a base layer, using a hot-melt adhesive which is a relatively inexpensive and hence commercially attractive adhesive system, and which can, advantageously, flow into the individual yarn bundles to effect good adhesion of all the fibres of the pile-forming yarn to the pile fabric product. The novel methods and apparatus provide that the hot-melt adhesive 15 is applied to the base layer conveniently and in a manner which does not interfere with the machinery employed for positioning the pile yarn. This step in the method may accomplish an additional function, namely that of bonding the individual pile-forming yarns to themselves, typically at or near the portion of the yarns nearest the base layer, thereby providing improved performance . characteristics to the pile fabric product. In addition, a one-step adhesive layer application may both provide means, not only for bonding the pile yarn to the base layer but also for fixing a backing layer integrally to the base layer. The resulting product may be less complicated and costly to manufacture and may have fewer separate and distinct layers in the final product where undesired separation may occur, than comparable known products.

The pile fabrics of the present invention comprise a liquid-permeable base layer and a pile-forming yarn in pile-forming, preferably folded, fashion. Pile-forming 35 configurations include, for example, the so-called I-tuft configuration, e.g. a non-folded configuration, U-tuft bo. configurations, and loop-pile configurations. The phrase folded, pile-forming fashion, which refers to a preferred embodiment, should be understood as referring to a configuration of the pile yarns where the yarns are provided with at least one fold at the portion of the yarn generally most nearly adjacent to the base layer, e.g. a cut-pile configuration. Another folded configuration which is contemplated is a loop-pile configuration where the pile yarns remain uncut, in the form of substantially continuous folded yarns in the final product. A variety of pile configurations, both non-folded and folded, are illustrated in the accompanying drawings. According to the most preferred embodiment, the pile yarns are cut to form a folded, cut-pile product.

In the method of the invention, application of the hot-melt adhesive and the forcing of the adhesive thrcuch the base layer may be simultaneous or consecutive. Subsequently, the adhesive is allowed to cool, either passively or actively.

The preferred method of the invention may accomplish the function of bonding the individual pile-forming yarns to themselves, typically at or near the portion of the yarns nearest the base layers, thereby giving the pile fabric product good performance characteristics.

Separation of the product may be achieved by means of a stationary or moving knife blade positioned between the base layers, which cuts the pile yarns along the entire width of the joined base layers to provide the hot melt adhesive bonded products.

The yarn used in forming the pile may be made of any type of fibre known to be useful for fusion bonded fabrics such as carpets, for example nylon, acrylics, polyester, wool, cotton and rayon.

The hot melt adhesive compositions which may be employed according to the present invention include a wide range of hot melt adhesives which have been available for many years. Typically such compositions may have a melt viscosity of less than about 200,000 cps, preferably less than about 100,000 cps at 300°F. Examples include, for instance, blends of ethylene/vinyl ester copolymer, petroleum wax and a thermoplastic resin as disclosed in U.S. Patent Number 3,551,231 (incorporated by reference). Other suitable hot melt adhesives of the ethylene/vinyl ester type which may be used are disclosed in U.S. Patent Nos. 3,583,936, 3,676, 280, 3,684,600, 3,745,054, 3,723,371., 3,911,185, 3,914,489 and 4,012,547 (all incorporated by reference). Other hot melt adhesive formulations which may be employed include those of the atactic polypropylene type. In general such compositions may contain a predominant amount, e.g. from about 10 parts to about 100 parts or more, preferably from about 60 parts to 100 parts, by weight atactic polypropylene; from 0 to about 70 parts of another compatible thermoplastic material such as hydrocarbon resins, waxes, polyethylene, especially linear, low density polyethylene; isotactic polypropy30 lene, polyisobutylene and polybutene-1. Fillers in widely varying amounts may be added to such compositions as will be readily apparent to those skilled in the art.

Other compatible thermoplastic materials which may be employed in the adhesive formulation include ethylene/ . ethyl acrylate, polyacetals, polyesters, polystyrene, polyacrylonitrile, polyacrylic ester, polymethacrylic ester, polyvinyl chloride, polyvinylidene chloride, polyvinyl acetate, polyvinyl acetal, polyvinyl ether, polytetrafluoroethylene, polyamide, coumarone/indene resins, natural resins, hydrocarbon resin, bitumen and others.

The amount of hot melt adhesive applied may vary widely, based upon the particular pile yarn employed, base layer and properties desired in the pile fabric product.. In general, the amount employed may be from about 2 to about 200 ounces, preferably about 4 to about 80 ounces per square yard. Tuft binds for carpet yarns that may be achieved according to the invention may be from about 2 to about 20 pounds.

Suitable liquid-permeable base layers which may be employed in the product and process of the invention include woven fabrics, knitted fabrics, non-woven scrims, felted materials, or even flexible, foraminous materials.

Where it is desired to provide the hot melt adhesive bonded pile fabrics of the present invention as floor covering products, especially carpet tiles, it may be desirable to apply any of a wide variety of suitable, resilient backing layers to the fabric. Such carpet tiles are also considered to be within the scope of the present invention. The backing layer may be formed, for example, from a suitable thermoplastic material such as blends containing ethylene/vinyl acetate copolymers, atactic polypropylene, bitumen, hydrocarbon resins, waxes, synthetic and natural rubbers.

The backing may be bonded to the base layer by means of the same adhesive applied to the base layer to bond the pile fibres. Thus, the resulting product may have fewer separate layers subject to separation than known carpet tiles. This is, rather than having pile layer, adhesive layer, base layer, another adhesive layer and backing layer, the present carpet tile may typically have a pile layer; a single, integral, hot melt adhesive layer into which the base layer may be disposed or suspended, and a backing layer bonded to the composite by means of the hot melt adhesive. The backing layer may be provided with at least one stiffening and stabilising membrane, such as woven or non-woven glass fibres. After the backing has been applied the consolidated material may then be severed by suitable cutting means into a carpet tile by any of a variety of techniques which are well known to those skilled in the art.

The resulting carpet tile product is suitable for use as a floor covering in home and/or commerical use in an office environment where substantial high stress conditions (e.g. wheeled traffic) are applied across the tiles. The tiles typically have a dense pile and may not require adhesives for installation. The individual modules may be replaced or rotated as necessary or desired. The carpet tiles may also have excellent dimensional stability with substantially no curling, slipping, buckling, stretching or shrinking. In addition the.carpet tiles may have low smoke emission and low fuz2ing characteristics.

The invention may be further understood by reference to the drawings and accompanying description thereof. It is to be understood, however, that various changes may be made without departing from the .scope of spirit of the invention which is to be limited only by the scope of·the appended claims. Referring now to the drawings: Figure 1 is an elevation view of the apparatus; and Figures 2 through 4 illustrate various embodiments for forcing the adhesive through the base layer.

Figures 5 through 8 illustrate various pileforming configurations which may be employed in the hot melt adhesive bonded pile fabrics of the present invention.

Figures 9 and 10 illustrate conventional tufted pile 5344 fabric configurations showing the pile yarns tufted through a base layer. Figure 11 illustrates a conventional I-tuft bonded fabric configuration showing a relatively impermeable base layer.

Referring now to Figure 1, carpet yarn 10 is supplied from a yarn source (not shown) over and around guide rolls 12 and 14 and down to the vertical guides 16. Base layer 17 is supplied from rolls 18 into position between the guides 16. As the yarn 10 enters between the vertical guides 16 the folding blades 20 and 22 alternately displace the yarn in a zig-zag fashion into one or the Other of the base layer sheets 17 as the carpet backing is being drawn downwardly. Pivotally mounted bladelets 24 and 26 may assist in the folding of the yarn. Folding blades 20 and 22 are mounted, respectively, to connecting rods 28 and 30. Connecting rod 28 is pivotally connected to pivot shafts 32 and 34 and connecting rod 30 is pivotally connected to pivot shafts 36 and 38 through suitable links (not shown). The shafts 32 and 38 are oscillated by an oscillating crank arm mechanism (not shown).

It should be noted that the blade 20 is out of phase with, the blade 22 so that when the blade 22 is being pivoted inwardly as shown in Figure 1 the blade 20 is being pivoted outwardly and vice versa to provide a zigzag configuration of the yarn between the carpet base layers 17 which are liquid-permeable, that is permeable to the adhesive to be applied.

After the yarn has been positioned in zig-zag configuration between the carpet base layers 17, hot melt adhesive 80 maintained in troughs 82 is applied to applicator rolls 84 by passing through gaps 86 between the side walls 88 of the troughs 82 and the applicator rolls 84. The hot melt adhesive may be maintained in the liquid phase by heating means not shown. The amount of adhesive applied to the applicator rolls may be adjusted as desired by moving troughs 82 upwardly or downwardly as indicated. Applicator rolls 84 are caused to move preferably in the directions indicated by drive means not shown whereby adhesive is applied to the carpet base layers 17 and simultaneously forced through the base layers into contact with yarn 10. The rolls may also be forced to move in the opposite direction to the directions indicated if so desired.

After the hot melt adhesive has been applied to the carpet base layer and forced through it into contact with the carpet yarn, it may be converted into the solid phase by cooling means 90 to form a bond between the carpet yarn 10 and the carpet base layers 17. Cooling means 90 may be supplied with air blowers 92, cooling coils 94 over which air is forced and thereby cooled prior to exiting the cooling means through exit ducts 96 into contact with the carpet base layers to thereby cool the hot melt adhesive causing it to revert to the solid phase. The yarn 10 may then be severed, generally in the middle of the base layers 17 by cutting blade 98 to provide, simultaneously, two sheets of carpet.

Figure 2 is an enlarged view of the hot melt adhesive applicator means embodiment 78 shown in Figure 1. Numbers in Figure 2 corresponding to numbers used in preceding drawings refer to corresponding parts of the apparatus. The gaps 86 by means of which the amount of hot melt adhesive to be applied may be adjusted as desired are more clearly illustrated. Also shown in Figure 2 are pre-heated plates 101 which may be provided to pre-heat the base layers prior to application of hot melt adhesive and to facilitate such application.

Figure 3 illustrates an alternative embodiment . wherein the hot melt adhesive is maintained in a reservoir sided on one side by base layers 17 and on the other side by doctor blades 104, The adhesive 80 is allowed to contact the carpet backings and is forced therethrough by the tips 106 of doctor blades 104.

Figure 4 illustrates yet another embodiment of the invention where the hot melt adhesive is maintained in tanks 108. Application of the adhesive to the base layers 17 is accomplished by drawing the adhesive out of the tanks 80 through pumps 110 into manifolds 112. The adhesive is then forced from the opensing 114 in manifolds 112 under sifficient pressure to force the adhesive through the carpet base layers 17 into contact with, carpet yarn 10.

Figure 5 illustrates an embodiment of the present invention showing an l-tuft configuration of the pile yarns, base layer 17 in the form of a relatively openweave, adhesive permeable fabric. Hot melt adhesive 80 is shown as a continuous layer into which the base layer 17 has become embedded at the base thereof. A backing layer 150 made of a thermoplastic material is shown as having been bonded to the pile fabric by means of the same hot melt adhesive 80 used to bond the pile-forming yarns. Figures 6, 7 and 8 illustrate some folded configurations of the pile-forming yarns which may be preferred. Identifying numbers refer to the same structural components as in Figure 5. Figure 6 shows a folded, cut pile configuration. Figure 7 shows a loop pile configuration. Figure 8 shows another folded pile configuration where the folded portion of the yarn is on the surface giving the appearance of a loop pile, although the loops are not joined to one another at their base. This configuration provides in essence a loop pile product while simultaneously offering the advantages of, for instance, yarn savings of the socalled I-tuft configuration.

Figure 9 illustrates a conventional cut pile tufted carpet tile having pile yarn 10 tufted through a conventional, polypropylene backing 152, adhesive layer 153, and backing layer 154. Figure 11 differs from Figure 10 only in the illustration of a loop-pile tufted configuration rather than a cut pile configuration.

Figure 11 illustrates a conventional, multi-layered I-tuft bonded product showing the configuration of pile yarns 10, adhesive layer 155, adhesive impermeable base layer 156 in the form of tightly woven jute, another 10 adhesive layer 157 by means of which backing layer 158 may be adhered to the base layer.

The following Examples illustrate the invention. EXAMPLE 1 Using a machine similar to that shown in Figure 1, a 15 nylon carpet yarn was folded between layers of a woven rayon fabric. By means of an electrically-heated plate mounted on one side only, directly below the vertical guide 16, the yarn loops in contact with the fabric at this side only were lightly fused to the fabric. A loop 2θ pile fabric was produced on removal of the non-adhering rayon fabric.

A hot-melt adhesive composition was formulated using atactic polypropylene, hydrocarbon resin and wax, and a molten film of this adhesive was cast on a hot-plate at about 175 C (350°F). A portion of the loop pile fabric made as described above was contacted with a piece of non-woven glass scrim. This assembly was then placed with the glass in contact with the hot-melt adhesive, rolled to force the adhesive through the glass and into 3° the loop pile yarns, and cooled. Then the glass side of the sandwich was laminated under heat and pressure to a 1.5 mm (60 mil) thick sheet of Keldex ( a trade mark of DuPont for a filled hot melt composition based on a copolymer of ethylene and vinyl acetate). A blade was then used to cut the yarn sandwich between the rayon 63443 fabric and the glass, thus producing two cut-pile carpets.

Single yarns were then pulled from the carpet bonded by the hot-melt adhesive to the glass. The average force required was found to be 2.1 kg (4.6 lb).

EXAMPLE 2 The procedure of Figure 1 was followed, with a rayon fabric on the same side as the heater plate, an open leno-woven glass scrim fabric on the non-heated side, and a nylon carpet yarn folded into the gap. The glass side of the sandwich was contacted with a heated applicator (identified as 84 in Figure 1), above which was mounted a trough 88 containing the following formulated hot-melt adhesive at about 150 C (300°F): Elvax 350 (DuPont ethylene/vinyl 30 parts acetate copolymer melt index - 19) Shellmex 400 (shell micro 45 parts crystalline wax, melting point 81 C) Piccopale 100 (Hercules hydrocarbon 25 parts resin, softening point 100 C) By varying the speed of the application roll relative to the yarn sandwich, and the gap between the trough and the applicator roll, various levels of adhesive were applied to the yarn loops through the woven glass scrim. After cooling, and cutting the yarns to make two cut-pile carpets, the tuft bind was measured on the glass backed carpet portion. Values varied from 8.8 kg (4 lb) tuft 2 2 bind, when using 510 g/m (15 oz/yd , adhesive, to 13.2 2 2 kg (6 lb) when using 1700 g/m (50 oz/yd ) adhesive.

EXAMPLE 3 A hot-melt adhesive was formulated as follows: Elvax 350 30 parts UE 653-04 (U.S. Industries 10 parts ethylene/vinyl acetate copolymer, melt index; 375) Shellmax 500 (Shell micro 35 parts crystalline wax, melting point 77 C) Piccopale 100 25 parts Using the procedure of Example 2, this adhesive was applied to the glass side of the yarn sandwich, giving tuft bind ranging from 15.4 to 22 kg (7 to 10 lb) with an 2 2 adhesive pick-up of 1085 to 1625 g/m (32 to 48 oz/yd ). EXAMPLE 4 A hot-melt adhesive was formulated as follows: parts Elvax 260 (DuPont ethylene/vinyl acetate copolymer, melt index; 6) Shellmax 400 Piccopale 100 parts 25 parts Using the procedure of Example 2, a tuft-bind of 11 to 19.8 kg (5 to 91b) was obtained at levels of 270 to 1220 g/m^ (8 to 36 oz/yd^).

EXAMPLE 5 The same procedure as for Example 2 was used except that the heated applicator roll/trough to apply the hotmelt adhesive was replaced by a doctor blade applicator on the glass side, as depicted in Figure 3. The adhesive was; Elvax 660 (DuPont ethylene/vinyl 20 parts acetate copolymer, melt index 2.5) D-82 (Hercules experimental hot-melt 80 parts adhesive) With an adhesive pick-up in the range of 170 to 680 g/m 2 (5 to 20 oz/yd ) following from the relatively high viscosity of this adhesive, the tuft-bind averaged 8.8 kg (4 lb) .

EXAMPLE 6 The method of Example 5 was used but with a lower viscosity adhesive prepared from Atactic polypropylene 83 parts Dowlex (Dow linear low density 17 parts polyethylene, melt index: 20) A 6.6 kg (3 lb) tuft-bind was obtained with adhesive 5 pick-ups in the range of 475 to 1020 g/m^ (14 to 30 oz/yd^).

Claims (8)

1. A method of making a hot-melt adhesive-bonded pile fabric, which comprises positioning a pile-forming yarn in pile-forming fashion adjacent to one side of a 5 liquid-permeable base layer; applying a hot-melt adhesive heated to at least its softening point to the base layer on the opposite side of the base layer from the side adjacent to the pile-forming yarn; forcing the hot-melt adhesive through the support layer into bond-forming 10 contact with the pile-forming yarn; and allowing the adhesive to cool to a temperature below its softening temperature, thereby bonding the pile-forming yarn to the base layer.

2. A method for making a hot-melt adhesive-bonded 15 fabric, which comprises positioning two continuous, liquid-permeable base layers in a passage, so that the layers lie substantially parallel and at a predetermined spacing; driving at least one continuous pile-forming yarn by folder blades alternately against the opposing 20 surfaces of the base layers when they are at or near the entrance to the said passage, in such a way as to position the pile-forming yarn relative to the base layers and to fold it zig-zag; thereafter applying a hot-melt adhesive heated to at least its softening point 25 to the back surfaces of the base layers; forcing the hot-melt adhesive through the base layers, so that the hot-melt adhesive contacts the pile-forming yarn; and cooling the hot-melt adhesive to a temperature below its softening point, thereby bonding the pile-forming yarn to 30 the base layers.

3. A method according to claim 2, which comprises the further step of separating the bonded product, to form two continuous hot-melt adhesive-bonded products.

4. A method according to claim 1 or claim 2, 35 substantially as described in any of the Examples.

5. Apparatus suitable for use in a method according to claim 1, which comprises means for positioning pile-forming yarn in pile-forming fashion adjacent to at least one side of a liquid-permeable base layer; means for applying a hot-melt adhesive heated to at least its softening point to the base layer on the opposite side of the base layer from the side adjacent to the pile-forming yarn; means for forcing the hot-melt adhesive through the base layer into contact with the pile-forming yarn; and means for cooling the hot-melt adhesive to a temperature below its softening temperature, thereby bonding the pile-forming yarn to the base layer.

6. Apparatus suitable for use in a method according to claim 2, which comprises means for positioning two continuous, liquid-permeable base layers in a passage, so that the layers lie substantially parallel and at a predetermined spacing; folder blades for driving at least one continous pile-forming yarn alternately against the opposing surfaces of the base layers when they are at or near the entrance to the said passage, in such a way as to position the pile-forming yarn relative to the base layers and to fold it zig-zag; means for applying a hot-melt adhesive heated to at least its softening point to the back surfaces of the base layers; means for forcing the adhesive through the base layers into contact with the pile-forming yarn; and means for cooling the hot-melt adhesive to a temperature below its softening point, thereby bonding the pile-forming yarn to the base layers.

7. Apparatus according to claim 6, which further includes means for separating the bonded product, to form two continuous hot-melt adhesive-bonded products.

8. Apparatus according to claim 5, substantially as herein described with reference to Figure 1 of the accompanying drawings.