JP2005507694A - Elongated pile subassembly, guide device and manufacturing pile subassembly article - Google Patents

Abstract

An elongated pile subassembly having a support beam for coupling to a plurality of yarn bundles. Each yarn bundle coupled to the beam has a pile end and a root end for securing the elongated pile subassembly. The root tip can also entangle the loose fibers for additional secure support of the elongated pile subassembly. The guide assembly is used to form a rooted tuftstring article such as a brush or a flooring article therefrom. Elongated pile subassemblies can be used alone to produce brushes or piles or bristle surface structures such as flooring, walls or automobile parts, such as when used to build pile or bristle surface structures. It may be used or placed with other elongated pile articles and bonded to a backing substrate. The brush or pile surface structure may be manufactured from the elongated pile subassembly alone or from the pile subassembly together with the brush body member or backing substrate.

Description

【Technical field】
[0001]
The present invention relates to a guide device that is useful for the purpose of manufacturing elongated pile subassemblies, pile subassembly articles, brushes, or piles or bristle surface structures such as flooring, walls or automotive parts. And about. More specifically, the present invention relates to an elongated pile subassembly having a “root” end for stably securing the elongated pile subassembly onto or through the substrate.
[0002]
Cross-reference of related applications
This application claims priority from US Provisional Application No. 60 / 336,226, filed Oct. 29, 2001.
[Background]
[0003]
The following disclosure relates to various aspects of the present invention and can be summarized briefly as follows.
[0004]
Conventional tuftstrings made from yarn are usually in a “U” shape when bonded or tufted into a backing substrate. A “U” shape is formed when a yarn segment is joined to an elongated strand near the midpoint of the yarn segment. This “U” shape is similar to that of a needle tufted thread that similarly forms two separate identifiable tufts from one thread segment. This “U” -shaped tuftstring has been disclosed in prior art such as US Pat. No. 6,069,096 to Veenema et al. ing.
[0005]
“U” shaped tuftstrings for wall or flooring are usually first bonded to a backing structure to form a pile fabric or carpet. The joining point for the “U” shaped tuftstring is at the bottom of the “U” shape, where the yarn and support beam are also joined together. This joining area is generally a solid mass of fibers fused together, providing only a small surface area for contacting and joining to the support substrate. Bonds between “U” shaped tuftstrings can be formed using thermal or solvent fusion methods, adhesives, or mechanical interlock methods. This small contact area generally produces a low “tuft-lock” value (eg, a force that breaks the joint). Furthermore, the round bottom of the “U” is subject to rotation that can result in undesirable visible defects (see FIGS. 1B and 1C). FIG. 1C shows an example of the effect of such rotation on a “U” shaped tuftstring. The bottom of “U” tilts or tilts to one side when aligned with the ridge 105a on the surface of the substrate 105 with embedded reinforcing fibers. This form of rotation results in density variations in the final product. Another example of “U” shaped tuftstring rotation is during the insertion / joining process that rotates the tuftstring sideways when the tuft on one side of the “U” has a higher frictional resistance than the opposite tuft. It is an undesirable visible defect that occurs (see FIG. 1B). When this happens, one row of tufts is effectively longer while the other row is effectively shortened by the same incremental length. These linear variations or visible defects are referred to as “rowiness”.
[0006]
Further, if an adhesive is used to bond the “U” shape to the substrate, the top surface of the adhesive is generally above the reference plane 300 of FIG. 5B, thus changing unwanted performance (eg, pile pile). Decrease in softness) Adsorption of adhesive into the tuft may occur.
[0007]
Another disadvantage of the “U” shaped tuftstring is that the two yarn ends of the “U” shaped tuftstring have a fairly large gap between them when manufactured. This gap is reduced due to compression or interference from other tuft strings to other tufts when the tuft strings are placed in close proximity to other tuft strings. However, since some of the pile filaments may be separated such that they are not all in vertical alignment, this compression or interference may be a further source of density variation. Some filaments are guided towards and bonded to the substrate or otherwise entangled so that they are not part of the desired pile density.
[0008]
U.S. Pat. No. 6,057,049 to Mokhtar et al. Describes a pile "tuftstring" in which each tuftstring is manufactured by winding a thread around a mandrel on which a support strand moves. Is described. As the support strand moves, it carries the yarn “wrap” to the ultrasonic welder, which connects the yarn wrap to the support strand. The joined wrap is further conveyed to a slitter station, which cuts the wrap, thereby forming a tuftstring. The tuftstring includes two rows of upstanding legs or tufts that are joined to the support strand at their base. The Moktar et al. Yarn is a multifilament crimped bulky yarn preferably made from a thermoplastic polymer such as nylon or polypropylene. The support strand is also preferably a thermoplastic polymer so that when passed under an ultrasonic welder, the yarn and the support strand melt and form a bond therebetween.
[0009]
It would be desirable to have an elongated pile subassembly with high “tuft-lock” values, controlled wicking and vertical alignment. A low-cost, elongate pile subassembly that includes a bundle of fibers arranged to provide high density, can be manufactured by a simple, inexpensive method, and packaged or brushed Alternatively, there is also a need for a pile subassembly that is designed to be used directly as a feed for the manufacture of pile / bristle surface structures. There is also a need for a strong and reproducible elongated pile subassembly that can be packaged and handled in the manufacturing process. It is also desirable to have a guide device for joining the elongated pile subassembly to the substrate.
[0010]
[Patent Document 1]
International Publication No. 99/29949 Pamphlet
[Patent Document 2]
US Pat. No. 5,472,762
[Patent Document 3]
US Pat. No. 5,470,629
[Patent Document 4]
US Pat. No. 5,547,732
[Patent Document 5]
US Pat. No. 5,498,459
[Patent Document 6]
US Pat. No. 5,012,636
DISCLOSURE OF THE INVENTION
[Means for Solving the Problems]
[0011]
The elongated pile subassembly of the present invention comprises a continuous length support beam having a longitudinal axis, a uniform or substantially uniform cross-sectional size and shape, an outer peripheral surface, and a location on the surface of the support beam. A reference plane that touches or coincides with the location and a plurality of bundles of filaments secured to the support beam. The filament bundle has a long bundle segment on the opposite side of the short bundle segment end. Filaments on at least one bundle end (eg, long bundle segment end) define a pile forming tuft. Each bundle has a region where the filaments are closely packed together and generally joined together, and the bundle is preferably secured to the support beam at the location of the closely packed region.
[0012]
Briefly, according to one aspect of the invention, an elongated beam having a longitudinal axis, a substantially uniform cross-sectional size and shape, an outer peripheral surface, and a filament secured to the outer peripheral surface of the beam. At least one bundle, wherein the at least one bundle is on the beam at a location along the length of the bundle that divides the length into longer and shorter bundle segments on either side of the longitudinal axis. An elongated pile subassembly is provided that is fixed and wherein the longer bundle segments define a pile forming tuft.
[0013]
In accordance with another aspect of the present invention, there is a brush that includes a first brush body member and at least one elongate pile subassembly secured to the first brush body member.
[0014]
In accordance with another aspect of the invention, there is a pile or bristle surface structure that includes a substrate and an elongated pile subassembly secured to the substrate.
[0015]
20. At least one elongate pile subassembly according to any one of the preceding claims having at least one short bundle segment end extending outwardly from the same side as the guide groove according to another form of the invention. A guide used to join at least one elongate pile subassembly to the substrate, and a means for joining at least one shorter bundle segment end to the substrate. is there.
[0016]
In accordance with another aspect of the present invention, a method of using a guide to join an elongated pile subassembly to a substrate with a groove with a shorter bundle segment extending beyond the groove in the guide to the outer surface. Guiding the elongate pile subassembly, applying a joining means to at least one of the substrate and the shorter bundle segment, bringing the substrate and the shorter bundle segment into contact contact with each other, and over the groove Securing the extending shorter bundle segment to the substrate.
[0017]
The invention will be more fully understood from the following detailed description when considered in conjunction with the accompanying drawings in which:
BEST MODE FOR CARRYING OUT THE INVENTION
[0018]
(Definition of terms)
The following definitions are provided as a reference consistent with how they are used in connection with the specification and the appended claims.
1. Beam or base string: A strand, string or cord made of one or more materials and having one or more distinct structural components each having its unique defined and identifiable shape. The beam or base string provides connectivity and support to the tuft attached thereto.
2. Bristle: A natural or man-made short and stiff fiber segment commonly referred to as having a diameter measured in several thousandths of an inch.
3. BCF or BCF yarn: a bulky continuous filament yarn; a textured continuous filament yarn commonly used in either carpet pile yarn or upholstery pile yarn.
4). Tuftstring: At least one of one or more filament yarns having a diameter, each reported in somewhat greater than a few thousandths of an inch (several mils) in denier, bonded to it beam.
5. Rooted tuftstring or elongated pile subassembly: A tuftstring in which a beam or base string divides a long bundle segment from a short bundle segment. Short bundle segments, also referred to as “roots,” are unbonded yarn fibers that bind the tuftstring to a substrate (ie, another article or support material). The long bundle segments are unbonded yarn fibers that form tuftstring piles or bristle ends.
6). Denier: 9000 meter gram mass of fiber, filament, or yarn.
7). Fiber: Textile raw material generally characterized by a high ratio of flexibility, fineness and length to thickness.
8). Filament: An infinite length of fiber.
9. Filament yarn: Usually a continuous filament. A yarn consisting of one or more filaments measured in deniers that essentially span the entire length of the yarn.
10. Yarn: A product of considerable length and relatively small cross-section consisting of twisted or untwisted fibers and / or filaments.
[0019]
The rooted tuftstring of the present invention may be understood from a general description of how it is manufactured. The method includes the steps of feeding a bundle of continuous filaments under tension along the center of rotation of an eccentric guide and rotating the guide to wrap the bundle of filaments around a support having a plurality of elongated ridges. Forming a series of wraps or flights of continuous length bundles of filaments wrapping the support, and a bundle of filaments formed by the support and wrapping process along at least one of the ridges on the support. Providing a beam by supplying a continuous strand of material between the flights, joining the filaments in the bundle together, fixing the bundle of filaments to the beam, and cutting the flight of the bundle of filaments Forming an elongated pile subassembly and advancing the elongated pile subassembly for further processing. As examples of the above method of forming a “U” shaped tuftstring, reference is made to (Patent Document 4), (Patent Document 1) and (Patent Document 5), the contents of which are incorporated herein by reference. . However, in the present invention, the above prior art references are distinguished from the present invention in the cutting process to produce a rooted tuftstring. A characteristic difference in the present invention is the position of the rotating slitter knife relative to the spliced beam (eg base string). In the above-referenced patent, the slitter is arranged to form two tufts of substantially equal length from one continuous yarn segment. In the present invention, a slitter, or beam joining location, or both, can be used with a first bundle of filament segments for use as a pile surface, a cloth or other such that the first segment is generally longer than the second segment. The position is changed to produce a tuftstring having a second bundle of filament segments for use in securing the tuftstring to the support structure (see FIGS. 9A and 9B). The above references are examples of mechanical methods that can produce tuftstrings with an improved cutting process, but are not exhaustive. There are various mechanical methods that can be applied to the production of the rooted tuftstring of the present invention.
[0020]
In a “U” shaped tuftstring (see FIG. 1A), the bundle of filaments is cut such that the base string 101 is substantially equidistant from the cut end of each bundle segment of the tuftstring 108. In FIG. 1A, the “U” shaped tuftstring 108 has equal bundle segment lengths 109 a and 109 b on either side of the base string 101. The tuftstring 108 is joined to the adhesive backing 107 at the 6 o'clock position 101a. A disadvantage of the “U” shaped tuftstring method is that the bundle segment lengths 109a and 109b may appear to be irregular when assembled with other “U” shaped tuftstrings (see 1B and 1C). See This can happen in various ways. For example, the base of a “U” shaped tuftstring may roll or rotate when it is guided and secured to the backing. More friction on the bundle segment 109b than on the bundle segment 109a will, for example, generate torque and cause the “U” shaped tuftstring to rotate counterclockwise as indicated by arrow 103a (see FIG. 1B). ) Another cause can be attributed to a substrate surface that is not flat, as in the case where reinforcing fibers are present and create a crease 105a on the surface. Referring to FIG. 1C, if the first side 109a of the “U” shaped tuftstring contacts the substrate surface before the second side 109b, the torque force is re-established, at which time the speed or motion is relative to the plane of the substrate. It makes a right angle and the tuftstring can be rotated or tilted. The tilt effect shown in FIG. 1C creates a space 132 between the tufts that creates undesirable spacing defects or at least results in density variations in the final pile.
[0021]
The present invention (see FIGS. 2A, 2B, 3A, and 4) allows tuftstrings and multiple tuftstrings to be brought together (e.g., as in carpets), particularly when adhesives are used as bonding agents. Utilizes an improved tuftstring that improves the bond strength between the substrates used to bond. Thus, the present invention (eg, the long bundle side 126 of fiber segments and the short bundle side 127, 128, 129 of fiber segments) eliminates the need to fold the yarn tuft into a conventional “U” formation. The long bundle segments 126 are arranged together as a continuous row of long bundle segments in an orientation appropriate for the functional value, while the short bundle segments 127, 128, or 129 are similar to adhesives or ultrasonic or solvent bonds. Other means are used to secure the elongated pile subassembly 125 to the backing substrate.
[0022]
In the present invention, the yarn used in the elongated pile subassembly 125 (see FIG. 2A) is a multifilament in which the filaments are typically “connected” to each other. The filaments are “connected” in that they are twisted at a level of at least about 1 revolution / inch to provide filament interlaces that enhance bonding (especially ultrasonic bonding), or the filaments are woven or knitted to provide crossing May be. The yarn may also include two or more strands of multifilaments that are twisted together. The twist may be a “true” S or Z strand and twist, or a reverse twist with alternating S and Z strands and twist, with joints in the twist and strand twist reversals. Preferably, the reverse twist yarn has a bond in the twisted yarn before reversing the twist, as described in US Pat. One such yarn is preferably made from crimped bulky heat treated filaments and is generally used as carpet yarn. The filaments of the yarn may have various cross sections that may be hollow, and may contain antistatic agents and the like. The yarn may have an applied finish that aids in ultrasonic bonding. In certain preferred embodiments, the yarn may be a multifilament, crimped, bulky, twisted yarn that has been heat set to maintain the twist.
[0023]
In other applications where a velor surface is preferred, such as in automotive floor finishes and paint rollers, another type of yarn is preferred. Such yarns include those in which multifilaments of BCF yarns are loosely entangled and not heat treated. For automotive or other transportation applications, a rooted tuftstring (ie, an elongated pile subassembly) is twisted to form individual long bundle segments as described in US Pat. Preferably made from unspun, untwisted or otherwise entangled BCF single yarn.
[0024]
When forming a rooted tuftstring using an ultrasonic bonding method, the yarn (preferably made from a thermoplastic polymer having the same composition as the beam) achieves a high bond strength to the beam of yarn bundles. . In some ultrasonic bonding applications, the yarn and beam can be of different compositions and still achieve sufficient bonding between the two. One such example is nylon yarn bonded to a polypropylene beam. It is further noted that using the same composition for the beam and yarn in bonding methods other than ultrasonic bonding provides high bonding strength and avoids the need for adhesives. However, full bonding with bonding methods other than ultrasound of different compositions for yarns and beams is also reasonable.
[0025]
When bonding yarns to a beam using an adhesive method, the yarn and beam composition is selected depending on the range of suitable materials that the adhesive can bond, or the selection of the yarn and beam composition. The adhesive is selected according to the above. It is important that the bond between the yarn and the beam is sufficient to deliver the yarn to the support structure without loss of the yarn segment or individual fibers from the yarn segment. Once the short segment fibers are bonded to the substrate, the bond strength between the beam and the yarn bundle becomes less important.
[0026]
In the present invention, the yarn typically includes a mixture of two or more thereof, a polyolefin such as polyamide, polyethylene or polypropylene, a polyester, a fluoropolymer, a polyurethane, a polyvinyl chloride, a polyvinylidene chloride, or a styrenic polymer. Alternatively, a thermoplastic polymer such as a copolymer. Polypropylene or polyamide such as nylon 6, nylon 11, nylon 6,6, nylon 6,10, nylon 10,10, nylon 6,12 is preferred. Alternatively, the yarn may be a poly (aryl ether ketone) or polyaramid or meta-aramid that can be joined by solvent, ultrasound, or heat.
[0027]
Beams useful in elongate pile subassemblies may have various cross-sectional shapes such as square, rectangular, elliptical, oval, circular, triangular, multi-lobed, flat ribbon-like. The beam must be bondable to the yarn and has sufficient stretch stability that the bond is not exposed to excessive stress due to excessive beam stretching or its tensile strength. The beam must provide sufficient stability to the pile subassembly so that it can be handled for its intended use, such as the manufacture of brushes or flooring articles such as carpets or rugs. . The beam may be a monofilament, a composite structure, a sheath / core structure, a reinforcing structure, or a twisted multifilament structure. The beam is preferably made from a thermoplastic polymer so that the yarn beam can be joined without the use of an adhesive. The beam is more preferably a polymer having a molecular structure oriented in the stretched direction and having a low dimensional change in the orientation direction due to an increase or decrease in moisture or a modest temperature change. One material for use as a support beam is a monofilament nylon polymer, such as Tynex® manufactured by the present applicant. Other materials for use as support beams include polypropylene and polyethylene. In some applications, one or more of the polymers named above can be combined, such as by coextrusion, to form a bicomponent beam.
[0028]
Filament manufacturing may be accomplished through the use of an extruder, and numerous variations of extruders such as twin screw extruders are available from manufacturers such as Werner and Pfleiderer . The polymer in the form of granules is fed into the extruder from the feeder either by volume or by weight. The slip agent is fed from a separate feeder through the side arm port into the extruder and blended with the polymer in the extruder at a temperature of 150-285 ° C. Alternatively, the slip agent can be pre-blended or pre-blended with the polymer so that a separate delivery system is not required. The polymer and slip agent are mixed as a melt in an extruder and the resulting composition is then metered into a spin pack having a die plate. The composition is filtered and filaments of various shapes and sizes are produced by extrusion through the holes in the die plate.
[0029]
Similar to the support beam discussed above, the filaments from which the filament bundles are prepared have various cross-sectional shapes, for example, as determined by the shape of the die plate orifice when manufacturing is by extrusion. May be. Shapes include, but are not limited to, circular, oval, rectangular, triangular, or any regular polygon, or the filament or beam (discussed above) may be an irregular non-circular shape. . Furthermore, the filament or beam may be hollow, hollow or contain multiple longitudinal voids in its cross section. Each run of the extruder can produce any combination of cross-sectional shapes by using die plates with various shapes of holes. By changing the size of the hole in the die plate, one or more diameter filaments or beams may be manufactured simultaneously. Alternatively, the filaments and / or beams used in the present invention may be produced by solution spinning.
[0030]
Another form of the invention involves the use of filaments and / or beams having a sheath / core structure. The sheath surrounds the core in a coaxial or concentric configuration. The polymer used for the core and sheath may be the same or different. If dissimilar polymers are used, the properties of the polymers must be such that they can be coextruded, stretched to scale and wound onto a spool. Nylon 6 and 6 are preferred as the sheath material. Sheath / core filaments or beams are typically manufactured by coextrusion using two extruders that share a common spin pack. The polymer used to make the core is sent from the first extruder to the center of the spinning plate hole, and the composition used to make the sheath is sent from the second extruder to the outside of the spinning plate hole.
[0031]
Yarn sheath / core filaments, or filament shaped beams, made from two or more sources of flowable polymer or polymer composition as described above are made from a single source of flowable polymer composition. It may be distinguished from the filament to be made. Such single source filaments may be referred to as single composition monofilaments. For the beam, the filament used in the present invention may be either a multicomponent monofilament or a single component monofilament, with a single component monofilament being preferred.
[0032]
Filaments for use in filament bundles in the present invention are about 1 mil or more, preferably about 2 mils or more, most preferably about 2.5 mils or more, as determined by the diameter of the smallest circle circumscribing it. Still further, it has a diameter or maximum cross-sectional dimension of about 15 mils or less, preferably 10 mils or less, more preferably about 5 mils or less. (The mill is 0.025 mm.)
[0033]
A filament or beam for use in the present invention contains a filler, colorant, stabilizer, plasticizer or antioxidant, or a polymer composition as described above containing a mixture of two or more thereof Or may be prepared with a surface coating.
[0034]
Reference is now made to FIGS. 2A-4 which show different end views and an encapsulated embodiment of the elongate pile subassembly of the present invention, or the “root” end of a rooted tuftstring 125. FIG. 2 shows an end elevation view of the elongated pile subassembly with the short filament bundle segment 127 penetrating the adhesive 117 and the backing substrate 115. FIG. 3A shows an end elevation view of an elongated pile subassembly in which the short filament bundle segment 127 has a flare penetration 128 of adhesive 117 and backing substrate 115. FIG. 4 shows an end elevation view of an elongated pile subassembly in which the short filament bundle segment 127 has surface flaring 129 in the adhesive 117. In FIGS. 2A-4, the short filament bundle fibers are fully encapsulated for strong anchoring of the elongated pile subassembly 125. Another variation not shown is that all the roots 127 in FIG. 2 are horizontally located on one side.
[0035]
Continuing with reference to FIGS. 2A-4, the ultimate location of the tuftstring root depends primarily on the properties of the substrate and the stiffness of the root filament. A non-woven nonwoven substrate will readily allow the root to penetrate the fabric structure without much deflection of the root as shown in FIG. 2A. A tightly woven fabric provides more resistance and deflects more of the roots as it enters the fabric as depicted in FIGS. 3A and 3B. Highly dense nonwovens such as Tyvek® or non-hollow sheets such as extruded thermoplastic structures prevent penetration by the filament roots into the substrate structure, FIG. Will result in complete deflection 129 of the short segment fibers 127 as shown in FIG.
[0036]
Still referring to FIG. 5A, FIG. 5A shows a plurality of bundles 154 of filaments as a thread secured to the support beam 119 at a position 73 on its outer peripheral surface. The longer bundle segment 126 of the elongated pile subassembly 125 defines a pile forming tuft. The shorter bundle segment 127 of the elongated pile subassembly 125 defines a rooting tuft.
[0037]
Still referring to FIG. 2A, FIG. 2A shows an elongated pile subassembly 125. Filament bundles 154 are joined to beam 119 to form an elongated pile subassembly. Filament bundle 154 has a tightly packed region 162 along its length, where the filaments are generally joined together and where the bundle is secured to support beam 119.
[0038]
Referring again to FIG. 5A, the support beam 119 has a uniform or substantially uniform cross-sectional size and shape, and an outer peripheral surface 133. A closely packed region 162 (FIGS. 2A-4) along the length of the elongated pile subassembly 154 where the filaments are joined together is secured to the outer peripheral surface 133 of the support beam 119 which is parallel and adjacent thereto. The bundle of filaments 154 is fixed to the outer peripheral surface 133 (perpendicular to the reference plane 71) of the beam from all ends of the close-packed region 162, or from a substantial portion to the end. Filaments that are substantially straight and thus have opposite ends 202 and 204 are contained within a bundle 154 of filaments. The opposite end of the filament defines the bundle length. The bundle 154 is positioned along the length of the bundle 119 at a position along the length of the bundle that divides the length into a longer bundle segment 126 having a longer length and a shorter bundle segment 127 having a shorter length. Fixed to the beam on either side of the axis 140.
[0039]
The longer bundle segment 126 contains longer filament segments, and the longer bundle segment length is contained in the longer bundle segment from the position that splits the filament bundle 154 into longer and shorter bundle segments. Measured to the end 202 of the longer filament segment. The longer bundle segment 126 is pile forming at the cut end 202 of the longer filament segment. The shorter bundle segment 127 contains shorter filament segments, the shorter bundle segment length from the position dividing the filament bundle into longer and shorter bundle segments. Measured up to. The usable portion of the longer bundle segment 126 and shorter bundle segment 127 is on the opposite side of the dense bundle region 125 of the filament bundle. Shorter filament segments are substantial in that they secure the tuft, particularly when the pile subassembly is used to manufacture brushes, pile surface structures or other articles as described herein. Define “roots” with usefulness.
[0040]
The length of the shorter bundle segment 127 (FIG. 2A) is preferably no more than about 90 percent of the length of the longer bundle segment 126. However, in other embodiments, the length of the shorter bundle segment is less than about 75 percent, less than about 50 percent, less than about 25 percent, less than about 10 percent, or less than the length of the longer bundle segment, if desired. It may be about 5 percent or less. The shorter bundle segment length is preferably greater than about 10 percent of the beam width. For example, if the beam width is 200 mils, the roots need to be longer than 20 mils. (It is further noted that the longer the short bundle segment 127 when bonded to the substrate, the more secure the elongate pile subassembly 125 is secured). The width of the beam is the following quantity: (i) of the cross-sectional area of the beam, measured parallel to the reference plane 71, perpendicular to and through the longitudinal axis of the beam, for example as shown in FIG. 5A. End-to-end distance 74, (ii) diameter of the smallest circle completely circumscribing the cross-sectional area of the beam, or (iii) longer of the two dimensions of the rectangle in the case of a cross-section of the beam that is a regular rectangle Defined as the smallest of the two. However, in further embodiments, the length of the shorter bundle segment may exceed about 55%, about 60%, about 75%, or about 100% of the beam width, if desired.
[0041]
Six test samples of rooted tuft strings were tested for bond strength using an Instron (Model # 1125). The rooted tuftstring sample was 1.00 inches long with a short segment length of 0.090 inches and a long segment length of 0.265 inches. Two test cells that were used repeatedly were made with the following cavity dimensions (length 1.00 inch x width 0.185 inch and depth 0.25 inch) to contain the adhesive. Etch. A. A hot melt adhesive of Profax polypropylene PF611CT sold by the Hanna Company was used. The test cell was heated and filled with Profax polypropylene PF611CT adhesive. The rooted tuftstring sample was placed in the test cell so that only short segment fibers were below the surface of the adhesive melt. The rooted tuftstring, adhesive and cell were then allowed to cool to room temperature before testing for bond strength. An Instron clamp device was securely fastened to the test cell and the other to the long segment fiber of the rooted tuftstring. An Instron test instrument was used to detect the peak force applied to the clamp at the moment of root breakage. The goal of these tests was for the rooted tuftstring to have a bond strength greater than 15 pounds. In tests following the test, there was no bond breakage observed between the short segment fibers in the test cell and the solid adhesive resin. The type of failure observed is 1) between the adhesive that is the most common failure and the test cell wall, and 2) the remaining failure is the yarn fiber that is broken near the bond between the yarn fiber and the beam. Met. All failure of the adhesive-test cell and of the yarn fibers occurred at tensions in excess of 45 pounds. These results far exceeded the minimum desired goal of 15 pounds.
[0042]
It is important to understand that the “root” of each yarn bundle is in three-dimensional space when fixed in the substrate. For example, FIG. 4 shows a root extending left or right of the bundle vertical center in this end view. Although this orientation 129 of the short bundle segment 127 can occur, they more likely extend 360 degrees from the vertical center of the bundle 125 in a plane parallel to and below the reference plane 71 of FIG. 5A. In FIGS. 2B and 3A, the roots extend in a conical shape below the reference plane 71 (FIG. 5A), each having a central vertical axis that generally contacts or coincides with the vertical bundle outer peripheral surface of the beam. . 2B is a narrow cone, while FIG. 3A is more hemispherical.
[0043]
In an embodiment of the invention, FIG. 5A shows an elongated pile subassembly in which a bundle of filaments is secured to a support beam 119, which is accomplished by ultrasonic bonding or other methods. The filaments of the short bundle segment 127 are used as anchoring points for the elongated pile subassembly 125. In comparison, the prior art “U” shaped tuftstring utilizes the dense portion 101a of the filament bundle (see FIG. 1a) and the bond line formed between the support strand and the yarn bundle as the anchoring surface. . This zone has the properties of a solid mass, and as such, the only surface available for adhesive bonding is the outer peripheral surface of the yarn / strand mass. This is a limiting characteristic of the prior “U” shape technology. In contrast, the short bundle segment 127 (FIG. 2B) of the present invention has a substantial surface area due to the “root” (eg, the fibers of the short bundle segment), which results in anchoring the filament bundle in the adhesive medium 117. . In the present invention, the root is a filament segment extending in the opposite direction of the segment that is connected to the pile forming filament segment. The short filament segment or the proximal end of the root is bonded to the beam and is thus fixed in place and has a limited surface area in that regard. However, the remaining length of the short filament segment root can and provides a considerable surface area. In the simplest case where the filament cross-section is circular, the surface area is simply the surface area of a cylinder.
[0044]
A comparison by example of the surface area of the “U” shaped tuftstring versus the surface area of the rooted tuftstring of the present invention clearly shows the benefits of the present invention. For example, if both a “U” shaped tuftstring and a rooted tuftstring are formed using a 28 mil beam and a 1500 denier twin yarn joined to the beam, the adhesive joint surface area of the “U” shaped tuftstring is: For rooted tuftstrings having 0.060 square inches per inch of tuftstring but 0.063 inch long short segment fibers and 11 tufts per inch, the surface area is per inch of tuftstring It can be seen that it is 0.864 square inches. This is a 1.340 percent increase in the surface area available for the adhesive to join.
[0045]
Furthermore, these unconstrained distal filament ends of the short segment fibers interact with the (fibrous) structure of the substrate for additional bond strength, as shown in FIG. 3B, and 121 can be entangled. The fibrous “root” of the present invention is encapsulated in an adhesive medium and mechanically locked when it solidifies. This mechanical bonding replaces the need for strong chemical or thermal bonding to secure the tuftstring to the support substrate, and as a result greatly expands the opportunity to use lower cost, environmentally friendly adhesives. .
[0046]
Referring to FIGS. 2B-4, the filaments of the short bundle segment 127 act as a core and draw the adhesive into the void space between the filaments, creating a matrix structure as seen in resin composite structures. The dense portion 162 of the filament limits the movement of adhesive that migrates up into the long bundle segment 126 by forming a barrier zone. In this embodiment, the opposite ends 202, 204 of the filaments define the bundle length. This bundle includes longer and shorter bundle segments, characteristics associated with the length of longer and shorter bundle segments, and shorter filament segments when bonded to a support substrate, as described above. And various orientations 128 and 129.
[0047]
If yarns with strong interconnections between the filaments are used, the roots should be such that the short segment fibers can be better dispersed into the adhesive and support substrate with minimal filament-filament entanglement. It may be preferable to “put a comb” into a short segment of a tufted string with a mark.
[0048]
Additional features of the bundle of filaments utilized in the elongated pile subassembly of the present invention include: (1) at least one bundle (a) on one side of the location having a first stiffness where the bundle is secured to the beam; It is divided into a first segment including a first filament segment and (b) a second segment including a second filament segment on the other side of the location having a second stiffness. The change in filament stiffness is proportional to the fourth power of the effective cross-sectional area and the third power of the length. Thus, for a given diameter, the relative stiffness will decrease by 87.5% when the unrestricted length is doubled, assuming no interaction with adjacent filaments. As a result, the stiffness of short segment bundles can be slightly higher or orders of magnitude stiffer than longer segment bundles, depending solely on the length ratio.
[0049]
Depending on the product to be manufactured from the rooted tuftstring, the length of the short segment is selected based on these properties such as stiffness and bond strength to the substrate. Longer short segment fibers have a reduced stiffness, and are therefore more “matte” as shown in FIG. Shorter short segment fibers will be stiffer and will have a greater chance of drilling holes in the surface of the support substrate as shown in FIG. As mentioned earlier, fiber filament denier also affects the extent to which the fiber punctures and penetrates into the substrate. Longer short segment fibers may entangle with adjacent rooted tuftstrings and thus share joint force with adjacent tuftstrings (see FIG. 3B). However, the desired length of short segment fibers is limited. At a certain length, as determined by composition, cross-section, shape, etc., the bond strength of the root can exceed the break strength of the fibers in the dense part of the rooted tuftstring. Therefore, unless the goal is to strengthen the substrate material, there is no value in increasing the root length. Cost is also a consideration here. As the short segment fiber length increases, the raw material costs increase as well. The optimum length can be selected based on the selected material and a test that ensures sufficient bond strength in the desired cost range.
[0050]
Since the feed yarn is wrapped around the mandrel, the beam is placed in a preferred position between the feed yarn and the mandrel (as described in US Pat. However, in an alternative embodiment, the beam can be secured to the yarn wrap or flight so that the wrap is positioned between the beam 119 and the mandrel. The properties of the close-packed junction region remain the same as described with respect to FIG. 2A.
[0051]
The unique geometry of the pile subassembly is described below and is shown "normalized" by expressing dimensional features as a ratio to free yarn bundle diameter. The yarn bundle diameter is a parameter related to the ability of the yarn to cover the surface in an efficient manner in the manufactured article. For measurement reproducibility, the yarn bundle diameter is 1 inch long of longer bundle segments far away from the cut end to avoid ambiguity that may cause flaring of the cut end when making measurements. The unstretched average diameter of the straightened portion. The yarn bundle diameter can be measured with good reproducibility using an optical comparator such as a “Qualifier 30” manufactured by a microscope with a grid line or an Opticom. FIG. 6 shows a diagram of the yarn in the qualifier 30. The top surface of a flat block 181 in which a 1 inch piece of straight thread without cut flare (which may be straightened with very low tension that does not compress the thread somewhat) is placed in the optical path of the comparator. Placed in. At 20 × magnification, the sample 182 is aligned with a horizontal line 184 on the comparator screen that passes through the peaks and valleys along the sample edge to define the average edge position. The line is moved to the opposite average edge of the yarn at position 186 and the distance moved 188 is recorded as the average “diameter” of the 1 inch long sample. This may be repeated with several samples of the feed yarn to further average the “diameter”. If there are bundles of different diameters along the beam, the bundle diameter will be the average diameter of all the bundle diameters along the representative length where the pattern of different diameters repeats. The yarn bundle diameter may be about 0.114 inches, preferably 0.020 inches to 0.150 inches.
[0052]
As mentioned earlier, the present invention is applicable to both single yarns and twisted / twisted yarns. A single yarn is an untwisted or highly entangled bundle of fibers. There is a “leveling” of loosely entangled filaments of single yarn by an ultrasonic horn in the joining process, which tends to average and redistribute the filaments. The relationship between bundles along the support beam is defined by the pitch, which is the distance between the bundles along the support beam, for the yarn, by the width of the support beam, and by the bundle diameter. Single yarns do not have a distinguishable P / D ratio.
[0053]
The bundle pitch / bundle diameter ratio (P / D ratio) represents the distance (pitch) between adjacent bundles of yarns placed along the length of the support beam compared to the yarn bundle diameter. The unique method of the present invention gives the product a much tighter bundle distribution along the beam than other elongate pile articles taught in the art. When the yarn is wound on the support beam, at least three ways to achieve a high density of bundles on the beam: 1) the pitch is reduced when the narrowed yarn is placed adjacent to each other along the beam There is a method of applying sufficient tension to the yarn bundle to reduce the diameter so that it is smaller than the free non-stretched bundle diameter, 2) a method of winding a multilayer of yarn bundles on the beam, and 3) the first two combinations. .
[0054]
In contrast to prior art “U” shaped tuftstrings, the P / D ratio for rooted tuftstrings is generally twice that of “U” shaped tuftstrings to achieve the same pile density ( 2x). Since the second shorter segment of the fiber bundle is used to bond the rooted tuftstring to the support substrate, it is a pile for the exposed surface as when using a “U” shaped tuftstring. Not available as. Doubling the pitch to achieve the desired density provides roots with a density that is commensurate with ensuring high bond strength in the rooted tuftstring.
[0055]
The P / D ratio can be better understood with reference to FIGS. The yarn bundle is joined to the opposite side of the beam 119 shown as simplified tufts 205a, 206a, and 208a. The simplified tuft is joined to the beam at the tightly packed region 162. Simplified rooted ends 205b, 206b, and 208b are shown extending past the beam. The bundle pitch “P” along the beam 119 is best understood with reference to FIG. 7 and seeing the tangent center-to-center spacing, ie, the pitch 210 between the tight junctions of adjacent bundles. Since the tuft end is somewhat free to move around, it is preferable to measure the pitch here instead of the tuft end. The bundle diameter “D” is represented by the end-to-end distance of the unstretched bundle, ie the diameter 75. Since some local variation should be expected, the pitch may have to be averaged along an inch length to obtain a representative number.
[0056]
FIG. 8 shows how the pitch is measured when there are multiple layers of bundles along beam 119 and how the simplified root portions of the bundle joint may overlap each other. Show. Bundle tufts, such as 205a, 206a, 214a, and 215a, are shown above the beam 119, and overlapping dense roots of bundle junctions for these bundles, such as 205b, 206b, 214b, and 215b, respectively. The marked end portion is shown below the beam 119. Pitch “P” is the distance between adjacent dense portions 162 of a bundle placed continuously along the beam at pitch 210. Again, the number of bundle joints along the 1 inch portion may need to be averaged to obtain a representative number of “P”. If there are different diameter bundles along the beam, possibly changing the pitch significantly, the pitch will be an average represented by the reciprocal of the number of bundles per representative length with different diameter patterns repeated. The bundle pitch may be about 0.033 inches, preferably about 0.015 to 0.150 inches. The P / D ratio may be about 0.30, preferably about 0.1 to 7.5.
[0057]
The width of the support beam is for the following reasons: 1) It must have an outer perimeter that is large enough to allow the use of a rooted tuftstring guide assembly (FIGS. 16 and 17) And 2) because it is too wide it causes the spacing between adjacent pile subassemblies to be excessive so that a dense arrangement of yarn tufts in the manufactured article cannot be achieved. These are important parameters in the present invention. Although other cross-sectional shapes may also be useful, rectangular beams have several advantages and are preferred. The vertical sides to which the yarn filaments are joined have a surface that is larger than, for example, the intersection of the yarn and the tangent surface of the circular or oval beam. The flat top and bottom surfaces are useful in vertically aligning the pile segments. The flat top surface of the beam, pressed against the slightly larger flat surface of the guide assembly, works in harmony with the slot used to pass the long filament segment and is rooted when it is processed with the backing substrate. Prevents the tuftstring from rotating. The horizontal flat bottom side of the beam provides a stable surface as opposed to a curved surface such as a curved surface of a circular or oval beam. The beam width is preferably between 0.010 and 0.70 inches.
[0058]
Important in certain embodiments, there are structural features related to the manner in which the bundle of filaments, or yarns, is joined to the beam 119 in the tightly packed region 162. A continuous filament inside each of the yarn bundles fixed to the beam and further fixed to the substrate ensures a high probability of capture and high bond strength for each individual fiber. However, it was found that when an appropriate adhesive was selected, the higher strength was for the adhesive and not for the beam. The rooted tuftstrings of the present invention minimize fuzz (eg, loose fibers released from the pile article due to breakage) for the reasons described above.
[0059]
Although the present invention has been described above as being performed on an automated device, alternative embodiments of the present invention can be performed by manual methods or any other suitable method. Still referring to FIGS. 9A and 9B, the supply yarn 20 is wrapped around a thin rectangular mandrel 282, for example, with a support beam 119 taped or otherwise held in place along the grooves 288 and 290. Can be wrapped by hand. After the supply yarn 20 is in place, the ultrasonic horn 292 can be passed along the yarn wrapped around the grooves 288 and 290 to join the yarn to the beam 119. The yarn can then be cut by a cutter or slitter 294 at a predetermined location on either side of the mandrel, near the beam 119. For greater efficiency and speed, the slitter is placed above the beam in groove 288 and below beam 119 in groove 290 (see FIG. 9B) or vice versa as shown in FIG. 9A. May be. In this way, the two elongated pile subassemblies are easily manufactured. In the first elongated pile subassembly, a short bundle segment associated with groove 288 is cut by slitter 294 at the upper end of beam 119. The long bundle segment of the rooted tuftstring would be the portion that extends from the beam 119 in the groove 288 to the slitter 293 located below the beam 119 in the groove 290 of FIG. 9B. The remaining slit yarn separated from the first elongate pile subassembly forms a second elongate pile subassembly. If only one rooted tuftstring assembly is desired, the second beam and slitter are removed along the glance. The mandrel can have a length 296 that is the same width as the carpet or article for which the rooted tuftstring is to be used.
[0060]
To assist in wrapping the yarn, the mandrel may be mounted in a rotatable chuck and the yarn moved along the rotating mandrel. A moving crosshead lathe may be used effectively to place the yarn on the mandrel. In the most general sense, the product can also be produced by placing a pre-cut bundle on one side of the mandrel beam and groove at a time and joining the bundle so that no lapping process is required.
[0061]
One method of manufacturing the elongated pile subassembly of the present invention includes contacting the elongated support beam with a plurality of bundles of filaments at locations along the outer periphery of the beam, and bringing both filaments together (the filaments are joined together). Forming a dense portion in the bundle) and joining the beam at a location along the beam. In the present invention, one method of joining the feed yarn to the beam is to use an ultrasonic drive device such as a Dukane Model 40A351 power supply capable of 350 Watts at 40 KHz coupled to a Dukane 41C28 transducer. Accompanied by. A Dukane booster may also be used. Bonding methods other than ultrasonic bonding may also be used to form dense portions of the bundle by securing the filaments to each other and to the beam. Such means may be solvent bonding or heat bonding with, for example, a hot rod, or a combination of solvent bonding, conductive bonding, and ultrasonic bonding. Alternatively, an adhesive may be introduced where the bundle is secured to the beam to form an adhesive bond between the bundle and the beam.
[0062]
The elongated pile subassembly of the present invention produces secondary processed articles such as floor coverings, pile surface structures such as paint brush rollers, or brush surface structures such as toothbrushes, buffing wheels, etc. May be used to The brush may be manufactured in various structures with or without a handle. The elongated pile subassembly of the present invention may be used to form a pile brush finish. A pile brush finish is a portion of a brush that may be used, for example, to apply or remove liquid material, or to change the surface by applying or removing liquid material. The pile brush finish on the brush may generally be flat in shape, or it may take other shapes, such as a generally cylindrical shape.
[0063]
Roller brushes used for activities such as paint application are typically examples of brushes having a cylindrical pile brush finish. A roller brush case may be illustrated as in FIGS. 10 and 11 showing a roller brush 310 having a pile cover 312 such as a brushed surface mounted on a hollow core 314, for example. The hollow core 314 can have any suitable shape, such as cylindrical or oval, depending on the application. The pile cover 312 is manufactured from at least one elongated pile subassembly 125 (FIG. 2A) having a support beam 119. The elongated pile subassembly 125 has at least one bundle of threads secured to the support beam 119, where a longer bundle segment 126 defines a pile forming tuft, as shown in FIG. 2A. The roller brush core is typically rotatable about a handle member not shown.
[0064]
With continued reference to FIGS. 10 and 11, the pile cover 312 is formed by securing one or more pile subassemblies to the outer surface of the core 314. In a preferred embodiment, one or more pile subassemblies are continuously wrapped in a spiral around the outer surface of the core 314. However, alternatively, the elongated pile subassembly is an array in which the elongated pile subassemblies are longitudinal, i.e., parallel to the core centerline axis, or it circles about the longitudinal axis along the circumference of the core. It may be mounted on the core 314 in a drawing arrangement or in some other variation of such an arrangement as described. The elongated pile subassemblies may be secured to the core in a parallel arrangement with one another.
[0065]
The elongated pile subassembly 125 (see FIG. 4) includes an adhesive binder that is applied to the outer surface of the core 314 just prior to wrapping or otherwise attaching the pile subassembly to the core. It is secured to the core 314 by any suitable joining means. Chemical or thermal bonding methods may also be used, however, in addition to other mechanical binders, such as anchors disposed at opposite ends of the core 314, or hook and loop lock systems. If a thermal bonding method is used, it is preferred that the core and / or elongated pile subassembly, or both, be prepared from a polymeric material. Part of the core and / or part of the elongated pile subassembly, or part of both, may then be softened by inducing their temperature above the melting or glass transition temperature of the polymer material. . At temperatures above the melting or glass transition temperature, the softened polymeric material will flow to create a zone of polymer flow. The elevated temperature that results in polymer flow may be by radiant or conductive heating means, but may preferably be achieved by ultrasonic energy. The polymer material from which the core is manufactured then flows and contacts the elongated pile subassembly, or the polymer material from which the elongated pile subassembly is manufactured flows and contacts the core, or both The flowing polymeric materials become welded and fixed at the point of contact after they cool and regain their solid state. As an alternative to elevated temperatures, the zone of polymer flow may be created by application of a suitable solvent to any component that has been fabricated from the polymer material.
[0066]
The core 314 may be prepared from a polymeric material as described above, or may be prepared from paper and resin coated with an adhesive. The core 314 can also include a spiral roll of resin impregnated paper to which an adhesive and fabric have been applied to form a continuous profile.
[0067]
In one embodiment, the pile-coated fabric is prepared at least in part from a material having a surface with pores, perforations or openings, such as a screen, mesh or mesh-like material. In such an embodiment, the shorter bundle segment 127 of the elongated pile subassembly may be secured to the fabric mesh, which is accomplished by positioning the filament segments in the shorter bundle segment to penetrate the mesh-like material. be able to. The pile-coated fabric is then bonded to the core. However, in other embodiments, the shorter bundle segment of the elongated pile subassembly may be secured to the surface of the core, or the elongated pile subassembly may be a bond between the core and the support beam, or the core And a shorter bundle segment and a support beam may be secured to the core by a joint. In these embodiments, the shorter filament segment becomes the point of contact for the application of adhesive between the substrate and the elongated pile subassembly and adheres between the substrate and the shorter filament segment. The bond may form or the shorter filament segment may be at or in contact with the zone of polymer flow. The shorter filament segments act as roots in these embodiments, ensuring a solid bond between the elongated pile subassembly and the substrate.
[0068]
Referring to FIG. 12, the elongated pile subassemblies 424, 426, 428, 430 are secured to the backing tape 440 by hot melt adhesive at the interface of the tape and shorter bundle segments and / or the support beam of each elongated pile subassembly. Another embodiment of the present invention is shown. When the elongated pile subassembly is spirally wrapped around the core 442 (FIG. 14) as described in US Pat. No. 6,057,049, the tape 440 has a tangent or adjacent wrap on the wrap. The elongated pile subassemblies from opposite sides of the tape are adjacent to each other, ie, after one flight or wrap of the tape, the elongated pile subassembly 424 is adjacent to the elongated pile subassembly 430 (( See Patent Document 4)). FIG. 13 shows the joining of short segment fibers to a support fabric without the action of an adhesive, such as when ultrasonic energy is used.
[0069]
Another use of the elongated pile subassembly in accordance with the present invention is to produce pile surface structures. Pile / brush surface structures are further secondary processed into various articles such as door panels, headliners, floor mats or trunk mats, or wall or flooring such as upholstery, or airplane parts or automotive parts for automobiles. Useful for. FIG. 15 shows a method of manufacturing a pile surface structure such as a carpet using the pile subassembly of the present invention. The drum 78 is assembled for rotation with the backing material 80 attached, for example, by pressing the backing ends 82 and 84 into the slot 86 of the drum. The outwardly facing backing surface 87 is coated with an adhesive coating such as a thermoplastic adhesive. The assembly 88 moves parallel to the axis of rotation of the drum and carries the elongated pile subassembly guide 90 and the hot glue applicator nozzle 92 in place, immediately before or simultaneously with contact with the elongated pile subassembly. , Set to meter the thermoplastic resin or thermosetting resin adhesive on its centerline. Other methods of heating may include hot air jets, radiant heaters, or frames. The elongated pile subassembly 45 could be fed directly from the reel 94 or from the mandrel.
[0070]
With continued reference to FIG. 15, as the drum 80 rotates clockwise, the elongated pile subassembly is pulled by the guide 90 and pressed against the applied adhesive on the fabric surface 87 of the backing 80. The elongated pile subassembly is in contact with the hot glue and joined to the backing. The assembly 88 operates at the same speed and moves along the drum surface and is placed in a spiral arrangement in the immediate vicinity of the elongated pile subassembly just pasted and previously pasted. The backing surface is laid with a helical array of elongated pile subassemblies with adjacent spaced runs of the spirals so as to define a pile surface structure. After the elongate pile subassembly has moved the axial length of the drum, wrapping is stopped and the elongate pile subassembly and backing assembly is aligned with the drum axis, such as at line 96 where the two backing ends meet at slot 86. Cut along. In the illustrated embodiment, only the elongated pile subassembly needs to be cut at 96 and the backing end needs to be removed to remove the pile structure assembly. The pile structure assembly can then be removed from the drum and placed horizontally to form a pile surface structure or carpet.
[0071]
The carpet product produced by the method has the feature that adjacent rows of elongated pile subassemblies are derived from different elongated portions of the same elongated pile subassembly, which eliminates yarn lot variation within the carpet. For example, about 3.3 ounces / ft ² Carpets having a length of 30 laps / inch and a 5/8 inch tuft length of 2350 denier joined along the beam, two strands of twisted yarn first produce an elongated pile subassembly, then 5 It can be manufactured by mounting pile subassemblies on a backing with a pitch of pile subassemblies / inch.
[0072]
In the variations of the method shown above and the products resulting from the method, the substrate backing may be selected from woven or non-woven materials. Sontara (registered trademark) by the applicant of the present patent application, Reemay (registered trademark) by Reemay Incorporated and Cerex from Cerex Advanced Fabrics (Cerex) Fabrics such as (R) are manufactured from polymeric materials and are provided in various weights and densities and can be used in various ways to bond rooted tuftstrings to them The selection of is particularly useful. Natural fiber fabrics can be used, but they are limited to the use of adhesives to join the rooted tuftstrings to them. The elongated pile subassembly may be secured to the backing substrate by selecting one of an adhesive, thermal bond or solvent bond to produce a pile surface structure. The elongated pile subassembly is secured to the backing substrate by using a support beam and / or shorter bundle segments on or below the surface of the backing substrate in the same manner used for brush construction. May be. Although the use of adhesive, thermal or solvent bonding methods may be preferred, the elongated pile subassembly may alternatively be secured to the backing substrate by conventional stitch welding and / or hook and loop bonding systems.
[0073]
Alternatively, rooted tuftstrings bind to relatively “hard” surface polymer sheets, such as sheets made from epoxy resins, thermosets, thermoplastics, wood, and flat metals. can do. (Some of these bonding methods require the use of adhesives.) As described above with respect to brushes, an alternative to helically wrapping an elongated pile subassembly as shown in FIG. One or more elongate pile subassemblies are, for example, producing a pile surface structure by creating an array that is in parallel alignment with each other and in contact with the bonding surface of the backing substrate.
[0074]
Another method of securing two or more elongated pile subassemblies to a backing substrate is illustrated by the guide assembly of FIGS. Unlike the rotating drum method described above, these guide assemblies are capable of continuous operation and do not need to be stopped to remove the “carpet” of the elongated pile article. FIG. 16 shows a schematic representation of a guide for an elongated pile subassembly 125 for producing a pile fabric or article. This flat guide assembly 90 is more suitable for relatively stiff substrates that will resist bending or otherwise incorporate the bend from the bent guide 91 of FIG.
[0075]
In FIG. 16, a long flat bottom surface is placed between the substrate (not shown) and the guide assembly 90 with a suitable gap parallel to them. The gap 310 is determined by one or more variables including the length of the short filament segment 127, the vertical dimension 315 of the beam, the depth 320 of the beam guide groove and the depth of the adhesive. The beam size 315 should not be able to pass the spacing 325. Spacing 325 loosely restricts the portion of the long bundle segment proximate to beam 119 along with gap 328 that accurately places the short and long fibers in a normal position relative to the substrate. Generally speaking, the spacing 325 is greater than 20% of the beam width 322, more preferably 20% to 50% of the beam width. A typical assembly consists of a beam bottom surface and substrate for substantially spreading the short segment filament 127 without causing its binding when the elongated pile subassembly 125 passes through the slot 97 of the guide assembly 90. The guide 90 would be positioned with the elongated pile subassembly 125 threaded through the guide 90 above the flat substrate with the smallest gap therebetween.
[0076]
Rooted tuftstring pile articles are fed continuously from one or more rooted tuftstring machines or from spool inventory. The elongated pile subassembly is guided into a guide groove by a roll and guide pins (not shown) with a short bundle end extending outwardly therefrom. The guide mechanism guides a plurality of individual short bundle segments of the elongated pile subassembly into contact with a backing substrate that is preferably fed continuously. An adhesive material such as a thermosetting resin or a thermoplastic resin adhesive is applied to the surface of the substrate just prior to passing under the guide assembly. Ideally, the linear speed of the process and the heat capacity of the adhesive are sufficient to achieve good wetting and short filament segment encapsulation prior to bonding to the substrate. The adhesive is cooled as it passes under the guide assembly so that the rooted tuftstring at the exit of the guide cannot move to another location.
[0077]
Another process embodiment of the present invention relating to the flat guide of FIG. 16 uses a thermoplastic polymer melt delivery system and a die assembly to expose a guide assembly 90 having an exposed portion of an elongated pile subassembly extending therefrom. Cast or mold the substrate onto the surface. In this case, the guide is turned upside down so that a short fiber bundle extends vertically upward from the guide. The polymer melt delivery system drops a polymer melt curtain onto the top surface of the guide. If the polymer melt has a tendency to adhere to the metal, such as Kapton ™ or Teflon ™ as a barrier to protect the otherwise exposed metal surface from the polymer melt Strips or strips of new material may be used. The guide surface is cold enough to cause rapid solidification of the polymer melt with short segment fibers encapsulated therein. The elongated pile article helps transport the melt from the plate and helps cool the thermoplastic polymer. Since the elongated pile article is strong enough and is not overheated, the polymer sheet will be well supported by the elongated pile article after continuing to cool off the guide.
[0078]
Another process embodiment of the present invention is schematically illustrated in FIG. When the elongated pile subassembly is fed through the guide 91, the short segment fibers 127 of the elongated pile subassembly 125 are directed toward the joining element (eg, adhesive applicator 95). The short bundle segment of the elongate pile subassembly preferably wipes the adhesive from the end of the applicator and the elongate pile subassembly continuously wipes the guide surface as it is fed through the guide to remove the adhesive in the guide. Avoid large growth. The cloth backing 99 is fed simultaneously with the tuftstring to join with one or more adhesive applicators 95 to form a pile-coated cloth 199. Although two applicators are shown in this embodiment, one may be sufficient. If one adhesive applicator 95 is used, the adhesive can be applied to the short bundle segment 127 just before it contacts the substrate 99, or alternatively directly to the cloth backing or substrate 99. The number of applicators used may also be increased to 3 or more in this embodiment if necessary.
[0079]
This process embodiment is suitable for substrates that are flexible enough to accommodate the curvature of the roll 91. Due to the low thermal conductivity of most substrates, hot melt adhesives are applied directly to substrates having good heat retention and high flow properties in contact with the short bundle segments of the rooted elongated pile article. For some substrates, some heating of the roll 93 may be required to maintain the fluidity of the adhesive until the time for the desired bond. This heating of the roll 93 may be particularly needed when the substrate is very thin.
[0080]
As with the guide assembly of FIG. 16, the guide device of FIG. 17 must be properly assembled for optimum performance. The curvature of the guide assembly 91 is designed to be concentric with the roll surface over the entire arc length. Again, the distance between the roll 93 rotating in the direction of arrow 98 and the guide 91 will penetrate properly into the substrate as shown in FIGS. 2A-4 when the short segment fibers are spread and / or pressed. Established to ensure that
[0081]
In both FIGS. 16 and 17, the guide assembly can be mounted on a mechanism that allows adjustment of the guide vertically and if necessary horizontally. This is advantageous because the guide can be removed for cleaning, threading or other preparation / maintenance activities. Small incremental adjustments in placement can be achieved while operating the process.
[0082]
18A and 18B illustrate ultrasonic bonding of a rooted tuftstring 125 to a substrate 115 in the present invention. The ultrasonic horns 340 and 345 vibrate in the directions indicated by arrows 342 and 343, respectively, with the anvils 350 and 355 providing a fixed support for the ultrasonic horn. While vibration energy is delivered from the energized horn, forces 346, 347 press the substrate 115 and the short segment fibers into contact with each other. The vibrational energy generates frictional heat generation at the interface, causing surface melting of at least one of the short segment fibers 129, the beam 119, and the substrate 115 and joining the elongated pile subassembly to the substrate. Produce. 18A and 18B show anvils 350, 355 and horns 340, 345, respectively, that function as elongated pile subassembly guides, respectively.
[0083]
Thus, an elongated pile subassembly having a “root” and a product made from the guide device and the elongated pile subassembly, which fully meet the goals and advantages described hereinabove, are provided according to the present method. It is clear that it has been. Although the present invention has been described in connection with specific embodiments thereof, it is evident that alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.
[Brief description of the drawings]
[0084]
FIG. 1A shows the prior art of a conventional “U” shaped tuftstring.
FIG. 1B is an elevational end view of the prior art showing visible defects resulting from “U” shaped tuftstring rotation.
1C is a prior art elevational end view showing a visible defect resulting from a “U” shaped tuftstring rotation. FIG.
2A is an elevational end view of an elongated pile subassembly of the present invention showing different “root” end penetrations. FIG.
FIG. 2B shows a rooted tuftstring of the present invention.
3A is an elevational end view of an elongate pile subassembly of the present invention showing different “root” end penetrations. FIG.
3B is an elevational end view of the multiple rooted tuftstring shown in FIG. 3A with rooted filament entanglement.
FIG. 4 is an elevational end view of the elongate pile subassembly of the present invention showing different “root” end penetrations.
FIG. 5A is a perspective view of an elongated pile subassembly of the present invention.
FIG. 5B is a prior art perspective view of an elongated “U” shaped tuftstring.
FIG. 6 is a schematic diagram illustrating one method for measuring the diameter of a pile yarn.
FIG. 7 is a simplified view of a portion along the center of an elongated pile subassembly support beam showing a tuft joined to the beam in a single layer with a “root” extending downward.
FIG. 8 is a simplified view of a portion along the center of a rooted tuftstring support beam showing bundles joined to the beam in an overlapping relationship.
9A is a diagram of a simple method for manufacturing an elongated pile article of the present invention. FIG.
9B is an end view of FIG. 9A showing a second slitter.
FIG. 10 is a side view of a paint roller pile assembly using the present invention.
11 is an end view of the paint roller of FIG.
FIG. 12 is an end elevation view of an embodiment of a plurality of elongated pile subassemblies.
FIG. 13 is an end elevation view of an embodiment of an elongated pile subassembly joined using ultrasonic welding.
FIG. 14 is an end elevation view of a plurality of elongate pile subassemblies of the present invention coupled to a core by an adhesive pile tape.
FIG. 15 is a diagram of a method of manufacturing a pile or bristle surface structure from an elongated pile subassembly of the present invention.
FIG. 16 is a schematic illustration of a guide used to bond or bond the elongated pile subassembly of the present invention to a backing substrate or bonding material.
FIG. 17 is a schematic representation of an elongate pile subassembly guide for joining with a flexible material.
18A shows an elevation view of two embodiments of an ultrasonic horn used for bonding in the present invention. FIG.
FIG. 18B shows an elevation view of two embodiments of an ultrasonic horn used for bonding in the present invention.

Claims (9)

An elongate beam having a longitudinal axis, a substantially uniform cross-sectional size and shape, and an outer peripheral surface; and at least one bundle of filaments secured to the outer peripheral surface of the beam;
At least one bundle is secured to the beam at a location along the length of the bundle that divides the length into longer and shorter bundle segments on either side of the longitudinal axis, the longer An elongate pile subassembly wherein a bundle segment defines a pile forming tuft and the shorter bundle segment defines an anchoring segment. The elongate pile subassembly of claim 1, wherein the shorter bundle segments secure the elongate pile subassembly to the substrate. A first brush body member;
A brush comprising: at least one elongate pile subassembly according to claim 1 secured to a first brush body member. The brush according to claim 3, wherein the first brush body member is substantially cylindrical. The brush according to claim 3, wherein the first brush body member is substantially flat. 4. The brush of claim 3, wherein at least one shorter bundle segment of the elongated pile subassembly is secured to the first brush body member. A substrate;
A pile or bristle surface structure comprising: at least one elongated pile subassembly according to claim 1 fixed to a substrate. A guide,
At least one groove for selectively guiding at least one elongate pile subassembly according to claim 1 having at least one short bundle segment end extending outwardly from the same side of the guide;
Means for bonding at least one shorter bundle segment end to the substrate;
A guide used to join at least one elongated pile subassembly to the substrate. A method of joining an elongated pile subassembly to a substrate using a guide, comprising:
Guiding the elongated pile subassembly of claim 1 by a groove with a shorter bundle segment extending beyond the groove of the guide;
Applying a joining means to at least one of the substrate and the shorter bundle segment;
Fixing a shorter bundle segment extending beyond the groove to the substrate.

Images