US20080095974A1 - Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method - Google Patents

Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method Download PDF

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Publication number
US20080095974A1
US20080095974A1 US11/923,381 US92338107A US2008095974A1 US 20080095974 A1 US20080095974 A1 US 20080095974A1 US 92338107 A US92338107 A US 92338107A US 2008095974 A1 US2008095974 A1 US 2008095974A1
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US
United States
Prior art keywords
carpet
loops
rug
pile threads
tuft substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/923,381
Inventor
Gerhard Hoffe
Mario Mittendorf
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MALTZAHN CARPETS GmbH
Original Assignee
MALTZAHN CARPETS GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DE200610050704 priority Critical patent/DE102006050704A1/en
Priority to DE102006050704.5 priority
Application filed by MALTZAHN CARPETS GmbH filed Critical MALTZAHN CARPETS GmbH
Assigned to MALTZAHN CARPETS GMBH reassignment MALTZAHN CARPETS GMBH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HOFFE, GERHARD, MITTENDORF, MARIO
Publication of US20080095974A1 publication Critical patent/US20080095974A1/en
Abandoned legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05CEMBROIDERING; TUFTING
    • D05C15/00Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04Tufting
    • D05C15/08Tufting machines
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • DTEXTILES; PAPER
    • D05SEWING; EMBROIDERING; TUFTING
    • D05DINDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
    • D05D2305/00Operations on the work before or after sewing
    • D05D2305/22Physico-chemical treatments
    • D05D2305/26Heating
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/23907Pile or nap type surface or component
    • Y10T428/23979Particular backing structure or composition

Abstract

A method of producing a carpet or rug pursuant to a tufting process, including tufting pile threads into a tuft substrate, and guiding the back side of the tuft substrate along while pressing the back side, together with the loops of the pile threads pierced through the tuft substrate, against a heated drum. At a predetermined temperature, the loops of the pierced-through pile threads begin to melt, and at a predetermined pressure are pressed flat against the tuft substrate.

Description

  • The instant application should be granted the priority date of 24 Oct. 2006, the filing date of the corresponding German patent application DE 10 2006 050 704.5.
  • BACKGROUND OF THE INVENTION
  • The present invention relates to a method of producing a carpet or rug pursuant to a tufting process, and also relates to a carpet or rug produced pursuant to such a method.
  • Carpets or rugs manufactured using the tufting process serve primarily as design goods for flooring, for floor coverings in vehicles, or for similar purposes. In order to hold the loops of the pile threads that are pierced through the tuft substrate securely in place during the tufting process, a liquid or plastic, synthetic or natural adhesive/binder or latex is applied to the underside of the tuft substrate.
  • The adhesive that is applied during the manufacture using the tufting process must be dried, for which purpose a large quantity of energy and time is required, and whereby, depending upon the type of adhesive, more or less noxious vapors are released. The loops of the pile threads leave a certain amount of pile material, as a function of the thickness of the threads or yarns, in the back side of the rug or carpet, as a result of which the ratio of the weight of pile used to the weight of the pile layer as visible pile material or usable layer is negatively influenced. A rough and relatively stiff back carpet side results since the adhesive covers not only all of the loop but also the tuft substrate, and after drying appropriately cures or hardens. This reduces the ability of the carpet or rug to deform or be worked, which is a drawback in particular when it is to be used as a floor covering in vehicles.
  • To avoid the aforementioned drawbacks, pursuant to a method known from EP 1 598 476 A1 the underside of the carpet is guided along a heated roller. In so doing, the loops of the pile threads that are pierced through the tuft substrate are heated and begin to melt, and are thereby anchored to one another and to the tuft substrate. The melting of the pile threads for anchoring in the tuft substrate is viewed as adequate; none the less, with the known method it is recommended—as is with the case with the previously mentioned state of the art—that an adhesive layer be applied to the underside of the tuft substrate. The applied adhesive layer also has the aforementioned drawbacks with regard to drying and evaporation of noxious vapors.
  • It is therefore an object of the present invention to provide a method of the aforementioned general type with which an anchoring of the pile threads in the tuft substrate is possible without using any type of adhesive layer.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • This object, and other objects and advantages of the present invention, will appear more clearly from the following specification in conjunction with the accompanying schematic drawings, in which:
  • FIG. 1 is a cross-sectional view through a carpet or rug pursuant to the state of the art;
  • FIG. 2 is a cross-sectional view through a carpet or rug pursuant to the present application; and
  • FIG. 3 shows a machine for producing the carpet or rug of FIG. 2.
  • SUMMARY OF THE INVENTION
  • The method of the present application for producing a carpet or rug pursuant to a tufting process includes the steps of tufting pile threads into a tuft substrate, and guiding a back side of the tuft substrate along while pressing the back side, together with loops of the pile threads pierced through the tuft substrate, against a heated drum to heat the loops, wherein at a predetermined temperature, the loops begin to melt, and are pressed flat against the tuft substrate at a predetermined pressure. The carpet or rug produced by this method includes pile threads tufted into the tuft substrate, wherein the loops of the pile threads that are pierced through the tuft substrate and are connected therewith are pressed flat, and wherein on an upper side opposite the back side the pile threads are oriented parallel to one another.
  • A satisfactory anchoring of the pile loops in the tuft substrate is achieved by the melting and pressing of the pile loops. The melted and pressed pile loops thus by themselves provide a satisfactory pile anchoring. Although a fusion of the pile loops with the tuft substrate is not necessary, it can, if desired, be achieved, for example in those cases where the pile and the tuft substrate are made of the same material. An adhesive layer for the pile binding can be entirely eliminated without limitation. An emission of noxious vapors is precluded. Furthermore, the quality of the carpet or rug is improved since the back side of the carpet or rug is smooth and has an increased flexibility. By pressing the loops of the pile threads that are pierced through the tuft substrate against the tuft substrate, it is possible, using the same length of threads, to achieve a higher pile layer than can be achieved with a carpet or rug that is provided with an adhesive layer, thus requiring less material for the manufacture of the carpet or rug.
  • Further specific features of the present application will be described in detail subsequently.
  • DESCRIPTION OF SPECIFIC EMBODIMENTS
  • Referring now to the drawings in detail, a carpet or rug manufactured using the tufting process is comprised of a woven base or spun fabric, a tuft support or substrate 1, into which are tufted pile threads or filaments 2 on a multiple needle machine. Above the tuft substrate 1, the pile threads 2 form a pile layer 3 having the height a in FIG. 1. The loops 4 of the pile threads 2 are pierced through the tuft substrate 1 and must be held securely in place.
  • Pursuant to the state of the art of FIG. 1, the pile binding is effected in that a layer 5 of a liquid adhesive is applied onto the underside of the tuft substrate 1, together with the pierced-through loops 4 of the pile threads 2; the layer 5 covers the tuft substrate 1 and encases the pierced-through loops 4 of the pile threads 2. To cure the adhesive, the coated carpet is heated, whereby the volatile material present in the adhesive evaporates. This thermal treatment involves an increased expenditure of energy and time, and is associated with an emission of more or less noxious vapors.
  • In order pursuant to the present application to entirely eliminate the adhesive layer, the pile binding is effected in the manner described subsequently. Pursuant to FIG. 3, a length of the carpet or rug produced using the tufting process is guided through a known calander. The calander has a heated drum 6. The back side of the length of the carpet, together with the loops 4 of the pile threads 2 pierced through the tuft substrate 1, faces the heated drum 6. The electrical heating system of the heated drum 6, or the heating system that contains an internal oil circulation, is in a position to variably adjust a temperature that is uniform over the periphery of the drum 6. Guide rollers 7 are disposed upstream and downstream of the heated drum 6. The height of the two guide rollers 7 that are adjacent to the drum 6 can be adjusted. In this way, the looping angle of the length of carpet about the drum 6 can be adjusted, as can the pressure that the drum 6 exerts upon the underside of the carpet.
  • Synthetic fibers, e.g. polyamide (PA), polyethylene (PES), polyacrylic or polyacrylate resins (PAC), polypropylene (PP), or mixtures of natural fibers and synthetic fibers are preferably used as material for the carpet or rug that is to be produced. The surface temperature of the heated drum 6 is adapted to the material of the pile threads 2 and of the tuft substrate 1. The temperature is set such that the loops 4 of the pile threads 2 that are guided through the tuft substrate 1 begin to melt while the carpet or rug is guided over the heated drum 6. By means of the adjustable guide rollers 7, a predetermined pressure is exerted upon the length of carpet, as a result of which pressure is exerted against the loops 4 of the pile threads 2 that are pierced through the tuft substrate 1, whereby the loops 4 are pressed flat. A connection or binding of the loops 4 of the pile threads 2 with the tuft substrate 1 can be variably adjusted as a function of the materials used, the temperatures selected, and the contact pressure. The pile threads 2, which now have a U-shape, are fixedly bound in the tuft substrate 1. The thus resulting rug or carpet has a flexible underside.
  • The carpet or rug produced using the method of the present application is schematically illustrated in FIG. 2. Here one can see that the loops 4 of the pile threads 2 rest flat against the tuft substrate 1. By the use of the predetermined pressure, the pile threads 2 are oriented perpendicular to the tuft substrate 1 and parallel to one another, and demonstrate a U-shaped profile. A pile layer 3 having a height b is provided that, at the same pile thread length, is greater than the height a of the pile layer 3 of the prior art of FIG. 1. Therefore, at a required height of the pile layer 3, a saving in material results, since the pile thread length can be reduced relative to that of the conventional process. Furthermore, the method of the present application has a positive effect upon homogeneity of the pile layer as well as upon the pile stability.
  • The specification incorporates by reference the disclosure of German priority document DE 10 2006 050 704.5 filed 24 Oct. 2006.
  • The present invention is, of course, in no way restricted to the specific disclosure of the specification and drawings, but also encompasses any modifications within the scope of the appended claims.

Claims (4)

1. A method of producing a carpet or rug pursuant to a tufting process, including the steps of:
tufting pile threads into a tuft substrate; and
guiding a back side of said tuft substrate along while pressing said back side, together with loops of said pile threads pierced through said tuft substrate, against a heated drum to heat said loops, wherein at a predetermined temperature, said loops begin to melt, and are pressed flat against said tuft substrate at a predetermined pressure.
2. A method according to claim 1, wherein said tuft substrate is caused to melt, and wherein the melted loops of said pile threads are connected with said tuft substrate.
3. A carpet or rug produced pursuant to the method of claim 2, wherein said pile threads are tufted into said tuft substrate, wherein said loops of said pile threads that are pierced through said tuft substrate and are connected therewith are pressed flat, and wherein on an upper side opposite said back side said pile threads are oriented parallel to one another.
4. A carpet or rug according to claim 3, wherein said loops of said pile threads are pressed flat in a U-shaped manner.
US11/923,381 2006-10-24 2007-10-24 Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method Abandoned US20080095974A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
DE200610050704 DE102006050704A1 (en) 2006-10-24 2006-10-24 A method of making a carpet and carpet made by the method
DE102006050704.5 2006-10-24

Publications (1)

Publication Number Publication Date
US20080095974A1 true US20080095974A1 (en) 2008-04-24

Family

ID=38895674

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/923,381 Abandoned US20080095974A1 (en) 2006-10-24 2007-10-24 Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method

Country Status (5)

Country Link
US (1) US20080095974A1 (en)
EP (1) EP1916330A1 (en)
CN (1) CN101168891A (en)
DE (1) DE102006050704A1 (en)
RU (1) RU2007135040A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2012110403A (en) * 2010-11-22 2012-06-14 Suminoe Textile Co Ltd Method of manufacturing tile carpet, and tile carpet manufactured by the method
CN102578894A (en) * 2012-03-15 2012-07-18 冯建兵 Patch embroidery tufting floor mat and production method thereof
US20120219751A1 (en) * 2009-11-09 2012-08-30 Kaneka Corporation Pile fabric and process for producing same
US20130240117A1 (en) * 2010-12-06 2013-09-19 Niaga Bv Method to Produce a Textile Product and a Textile Product Resulting from the Same

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL2003763C2 (en) * 2009-11-06 2011-05-10 Klieverik Heli Bv Decorative covering and method for manufacturing them.
CN104695159B (en) * 2009-11-09 2017-04-12 株式会社钟化 Processing device for pile textiles
DE202014010747U1 (en) * 2014-06-10 2016-07-04 Kiener Maschinenbau Gmbh Apparatus for processing a backside of a web material
AU2016349412A1 (en) * 2015-11-05 2018-05-10 Dsm Ip Assets B.V. A method to manufacture a textile product, a use thereof and a device for applying the method
DE102016120169A1 (en) 2016-10-24 2018-04-26 Kiener Maschinenbau Gmbh Method and device for producing a discharge on a web material

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US3616137A (en) * 1969-11-03 1971-10-26 Kessler Products Co Inc Pile weatherstripping with monofilament thermoplastic backing
US3778330A (en) * 1970-12-31 1973-12-11 S Shorrock Tufted carpet
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US4426415A (en) * 1981-12-11 1984-01-17 V&L Manufacturing Company, Inc. Tufted carpeting, especially artificial turf, with tufts stitched through multiple layers of pre-woven backing material of differing gauge
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US5532035A (en) * 1992-05-01 1996-07-02 Hoechst Celanese Corporation Recyclable tufted fabric
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US5556684A (en) * 1994-02-04 1996-09-17 Forero; Miguel Manufacturing process for synthetic fiber carpets fixed by fusion at regular intervals with crest or tufts, without using glues or using small amounts of glues, where threads do not loosen and thus obtaining the carpets
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US5660911A (en) * 1993-12-02 1997-08-26 Tesch; Guenter Tufted carpet and process for producing the same
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US20020039636A1 (en) * 1999-04-12 2002-04-04 Fink Wilbert E. Carpet and carpet making methods
US6475592B1 (en) * 1997-04-29 2002-11-05 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
US6932424B2 (en) * 2002-08-23 2005-08-23 Daimlerchrysler Corporation Articulated base with guide track for fold-in-floor vehicle seat
US20050189464A1 (en) * 2004-02-27 2005-09-01 Dipl.-Ing. Agr. Andreas Reichhardt Support for a rotatable commercial vehicle seating and operating unit
US6962384B2 (en) * 2002-08-23 2005-11-08 Daimlerchrysler Corporation Fold flat motor vehicle seat
US20050284558A1 (en) * 2004-05-21 2005-12-29 Johannes Boerrigter Method for manufacturing a carpet
US20070270064A1 (en) * 2006-05-22 2007-11-22 Aseere Lester M Carpet primary backing having enhanced tufting and tuft securing characteristics
US7364634B1 (en) * 2006-08-07 2008-04-29 Darwin Enterprises Carpet construction having secondary backing

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Publication number Priority date Publication date Assignee Title
US3285797A (en) * 1964-05-04 1966-11-15 Bigelow Sanford Inc Axminster carpet
US3616137A (en) * 1969-11-03 1971-10-26 Kessler Products Co Inc Pile weatherstripping with monofilament thermoplastic backing
US3778330A (en) * 1970-12-31 1973-12-11 S Shorrock Tufted carpet
US3904799A (en) * 1970-12-31 1975-09-09 Stanley Shorrock Tufted carpet
US4439476A (en) * 1979-11-29 1984-03-27 Don Brothers, Buist P.L.C. Tufted fabrics and method of making
US4426415A (en) * 1981-12-11 1984-01-17 V&L Manufacturing Company, Inc. Tufted carpeting, especially artificial turf, with tufts stitched through multiple layers of pre-woven backing material of differing gauge
US4668552A (en) * 1986-07-28 1987-05-26 Collins & Aikman Corporation Wrap yarns having low-melt binder strands and pile fabrics formed therefrom and attendant processes
US4705706A (en) * 1986-09-16 1987-11-10 Avco Synthetic Turf Production Distribution, Inc. Tufted carpeting having stitches thermally bonded to backing
US5532035A (en) * 1992-05-01 1996-07-02 Hoechst Celanese Corporation Recyclable tufted fabric
US5630896A (en) * 1992-05-01 1997-05-20 Hoechst Celanese Corporation Method of making recyclable tufted carpets
US5538776A (en) * 1992-12-28 1996-07-23 Hoechst Celanese Corporation Carpet containing a hot melt polyester layer
US5660911A (en) * 1993-12-02 1997-08-26 Tesch; Guenter Tufted carpet and process for producing the same
US5556684A (en) * 1994-02-04 1996-09-17 Forero; Miguel Manufacturing process for synthetic fiber carpets fixed by fusion at regular intervals with crest or tufts, without using glues or using small amounts of glues, where threads do not loosen and thus obtaining the carpets
US5536551A (en) * 1994-07-18 1996-07-16 Jps Automotive Method for binding tufts
US5618624A (en) * 1995-02-22 1997-04-08 Hoechst Trevira Gmbh & Co. Kg Formable, heat-stabilizable textile pile material
US5654067A (en) * 1995-02-22 1997-08-05 Hoechst Aktiengesellschaft Formable, heat-stabilizable textile loop pile material
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US6479125B1 (en) * 1997-04-29 2002-11-12 Darwin Enterprises, Inc. Backing for tufted carpet that imparts dimensional stability
US6475592B1 (en) * 1997-04-29 2002-11-05 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
US20020039636A1 (en) * 1999-04-12 2002-04-04 Fink Wilbert E. Carpet and carpet making methods
US6932424B2 (en) * 2002-08-23 2005-08-23 Daimlerchrysler Corporation Articulated base with guide track for fold-in-floor vehicle seat
US6962384B2 (en) * 2002-08-23 2005-11-08 Daimlerchrysler Corporation Fold flat motor vehicle seat
US20050189464A1 (en) * 2004-02-27 2005-09-01 Dipl.-Ing. Agr. Andreas Reichhardt Support for a rotatable commercial vehicle seating and operating unit
US20050284558A1 (en) * 2004-05-21 2005-12-29 Johannes Boerrigter Method for manufacturing a carpet
US20070270064A1 (en) * 2006-05-22 2007-11-22 Aseere Lester M Carpet primary backing having enhanced tufting and tuft securing characteristics
US7364634B1 (en) * 2006-08-07 2008-04-29 Darwin Enterprises Carpet construction having secondary backing

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120219751A1 (en) * 2009-11-09 2012-08-30 Kaneka Corporation Pile fabric and process for producing same
JP2012110403A (en) * 2010-11-22 2012-06-14 Suminoe Textile Co Ltd Method of manufacturing tile carpet, and tile carpet manufactured by the method
US20130240117A1 (en) * 2010-12-06 2013-09-19 Niaga Bv Method to Produce a Textile Product and a Textile Product Resulting from the Same
US9096047B2 (en) * 2010-12-06 2015-08-04 Again Ip B.V. Method to produce a textile product and a textile product resulting from the same
US10017899B2 (en) 2010-12-06 2018-07-10 Again Ip B.V. Method to produce a pile textile product and a textile product resulting from the same
US10422075B2 (en) 2010-12-06 2019-09-24 Again Ip B.V. Method to produce a pile textile product and a textile product resulting from the same
CN102578894A (en) * 2012-03-15 2012-07-18 冯建兵 Patch embroidery tufting floor mat and production method thereof

Also Published As

Publication number Publication date
RU2007135040A (en) 2009-03-27
DE102006050704A1 (en) 2008-04-30
EP1916330A1 (en) 2008-04-30
CN101168891A (en) 2008-04-30

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Legal Events

Date Code Title Description
AS Assignment

Owner name: MALTZAHN CARPETS GMBH, GERMANY

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:HOFFE, GERHARD;MITTENDORF, MARIO;REEL/FRAME:020008/0936

Effective date: 20070727

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION