US2389657A - Method of making cemented pile carpet - Google Patents

Description

Nov. 27, 1945. P, FARls T L 2,389,657

METHOD OF MAKING CEMENTED FILE CARPET Original Filed Jan. 4, 1944 5 Sheets-Sheet 1 INVENTORS JHAROLD P FARIS ATTORNEYS JOHN ZJVHITE Nov. 27, 1945. H. P. FARIS ETAL 2,389,557

METHOD OF MAKING CEMENTED PILE CARPET Original Filed Jan. 4, 1944 5 Sheets-Sheet 2 INVENTORS HAROLD P. FARIS 2 BY JOHNE.WHITE ATTORNEYS Nov.- 27, 1945. H. P. FARIS ET AL 2,389,657

METHOD OF MAKING CEMENTED PILE CARPET I Original Filed Jan, 4, 1944 5 Sheets-Sheet 3 IN V EN TORs HAROLD P.FARIS BY JOHN gwnmz M M W ATTORN EYS Nov. 27, 1945. H. P. FARIS ETAL 2,389,657

METHOD OF MAKING CEMENTED PILE CARPET Original Filed Jan. 4, 1944 5 Sheets-Sheet 4 INVENTORS HAROLD PFARIS JOHN E.WHITE' ATTORNEYS H. P. FARIS ET AL 2,389,657

METHOD OF MAKINGCEMENTED FILE CARPET Original Filed Jan. 4, 1944 5 Sheets-Sheet 5 INVENTORS HAROLD PQFARIS JOHN E.WH|TE ATTORNEYS Patented Nov. 27, 1945 METHOD OF MAKING CEMENTED PILE CARPET Harold P. Faris, Philadelphia, Pa., and John E. White, Trenton, N. J., assignors to National Automotive Fibres, Ina, Detroit, Mich., a corporation of Delaware Original application July 20, 1942, Serial No.

451,626, now Patent No. 2,338,499, dated January 4, 1944. Divided and this application July 6, 1943, Serial No. 493,666

3 Claims. (Cl. 11733) This invention relates generally to the manufacture of rugs, carpets and the like and constitutes a division of our application filed July 20, 1942, bearing Serial No. 451,626, which issued January 4, 1944 as Patent 2,338,499.

More specifically, the present invention relates to the manufacture of cemented pile carpet wherein the pile surface thereof is composed of a multiplicity of individual upstanding fibers that simulate ordinary woven pile in appearance.

Preferably the carpet is made by depositing the individual fibers onto a cement or adhesive covered base while the latter is being vibrated, however in the present instance the invention is characterized by (1) successive deposits of different types or grades of fibers onto the adhesively covered base, (2) the uniform feeding and uniform deposition of the fibers, (3) the removal from the base of loose or excess fibers before successive deposits are made, (4) the uniformity in weight and length of the fibers initially deposited, (5) a more perfect initial formation of the fibers, (6) the use of a longer pile material than ordinarily employed, ('7) the positive breaking up and carding of the flock into individual fibers, (8) the controlled supply of fibers from the feed units, and (9) the improved or more equalized vibrating means for the base to obtain a more uniform and deeper penetration of the fibers into the adheslve or cement covering on the base.

Thus, one of the essential objects of the present invention is to provide an improved method of making cemented pile carpet whereby a carpet having a better pile surface is obtained.

Another object is to provide an efficient method which may be expeditiously employed for mak ing quickly and on a large scale or production basis cemented pile carpet and the like having improved characteristics.

Other objects, advantages and novel details of construction of this invention will be made more apparent as this description proceeds, especially when considered in connection with the accompanying drawings, wherein:

Figure 1 is a side elevational view of a machine embodying our invention for making the carpet, with parts broken away and in section;

Figure 2 is a vertical sectional view taken on line 2-2 of Figure 3;

Figure 2A is a sectional view taken on the line 2A2A of Figure 2;

Figure 3 is a rear end view of the assembly illustrated in Figure 2;

ure 4 is a sectional view taken substantially on the line 4-4 of Figure 3;

Figure 5 is a top plan view of the structure illustrated in Figure 2;

Figure 6 is an enlarged elevational view of the first feed unit, with parts broken away and in section;

Figure 7 is a fragmentary side elevation of the. rear end of the machine illustrated in Figure 1 and showing a slight modification;

Figure 8 is a side elevation of the first feed unit as illustrated in Figure 1 but showing a modified agitator assembly in combination therewith;

Figure 9 is a vertical sectional view through the material X before being flocked;

Figure 10 is a vertical sectional view through a carpet made in accordance with my invention.

Referring now to the drawings, A and B respectively, are feed rolls of calendered material to be flocked, C is a vertical series of tension rolls for said material, D is an adhesive doctor knife or cement spreader knife, E, F and G respectively, are vibrator or beater assemblies for the material, H is a roll for pulling material from the feed rolls A and B over the vibrator assemblies E, F and G'respectively, J, K and L respectively, are flock feed units, and M, N and 0 respectively, are suction nozzles for cleaning off or removing loose or excess fibers from the adhesive or cement upon said material.

As shown, the rolls A and B are spaced vertically apart and are carried by a suitable frame It at one end of the machine. Preferably the material on the lower roll A is used first and then the material on the upper roll B is used. If desired, the lead end of the material on the upper roll B may be spliced or otherwise secured to the tail end of the material on the lower roll A to provide a continuous operation. In each instance. the material X may be burlap I, woven cloth or a synthetic sheet or paper having the proper tensile strength, or a smooth sheet of any other suitable material calendered to uncured sponge rubber 8, or some other suitable substance having resilient qualities. Such material is drawn from the rolls A and B around the tension rolls C and over the vibrator or heater assemblies E, F and G respectively, by the puller roll H at the other end of the machine.

The tension rolls C may be any suitable construction and are arranged to keep the material X firm and unde tension as it passes through the machine. Suitable means (not shown) may be employed for driving the tension rolls C at approximately five (5) per cent slower speed than the puller roll H.

After leaving the tension rolls C the material having the rubber side thereof lowermost passes over idler rolls I and I2 respectively, onto the first agitator or beater assembly E. However, before it reaches the assembly E, the upper surface of the material is covered substantially with a layer 9 of suitable adhesive substance or cement which may be a rubber cement or some plastic substance that is impervious to gasoline and cleaning fluids. For this purpose the adhesive doctor blade or cement spreader knife D is mounted over the idler roll I I and may be provided with a suitable adjustment, as desired. Any suitable means (not shown) may be applied for supplying an adhesive or cement to the doctor blade.

The first agitator or beater assembly E has an endless conveyor l3, and a battery i4 of rotating beaters l5. Preferably the conveyor I 3 comprises an endless apron for supporting the material X over the beaters l5 and is driven at substantially the same speed as the puller roll H. The beaters l5 may be any suitable construction but are preferably six-sided bars that extend across and engage the underside of the top portion or flight of the endless conveyor 13 at spaced points longitudinally thereof. Any suitable means such as the motor driven belt l6 which engages pulley wheels I! at one end of the bars l5 may be used to rotate said bars, while any suitable means such as the crank l8, pitman l8a and lever l9, may be used to slide the rotating bars l5 back and forth lengthwise of the conveyor l3 to equalize as far as possible the vibration wave and obtain a better and more uniform penetration of the fibers in the adhesive substance or cement 9 upon the material X being agitated. In fact, the

posite directions. Moreover, the bars are journaled in bearings and 2| respectively, clamped upon rails 22 and 23 respectively, slidably engaging suitable guide blocks 24 and 25 respectively, carried by the supporting frame 26. One of these bearings 20 is rigid with the lever l9 so that the bars l5 will move back and forth in unison.

If desired, two heaters 21 and 28 respectively, of six-sided formation may be mounted for rotary movement only in front and in rear respectlvely the battery H of agitators and may be driven by the belt l6 constituting the drivin means for the beaters IS.

The second a itator assembly F is between the first assembly E and the puller roll H and preferably comprises a battery 29 of beaters 30 of sixsided formation that are mounted for rotary movement only and have agitating engagement with the underside of an endless conveyo 3| for the material X.

The third a itator assembly G is between the second assembly F and the puller roll H and preferably consists of two spaced electric vibrators or electromagnetic settling plates 32 and 33 respectively, which engage directly and form vibrating supports for the underside of the material X after it leaves the conveyor 3| for the puller roll 1!.

The puller roll H may be any suitable construction and may be driven by any suitable means. Preferably the periphery of said roll is provided with teeth 34 or'other suitatble means for positively engaging the material to pull it forward through the machine as desired.

The first flock feed unit J is spaced above t e first agitator assembly E and handles only selected flock. In fact, the flock used at this point I is substantially uniform in weight and length so as to be well balanced and, therefore, may be considered to have only grade A type fibers. Preferably flock of this type in bulk form is dumped into a suitable storage bin 35' from which it is conducted by a screw conveyor (not shown) within a suitable duct 36 to the unit J where it is positively broken up and carded into individual fibers before being discharged onto the adhesive or cement covered material advancing over the agitator assembly E.

In the present instance, the positiv breaking up and carding action is performed by a group of co-operating rolls 31, 38, 39, 40, 4| and 42 respectively, that have at their peripheries suitable carding wires 43 for engagement with the flock. A feed roll 44 at the discharge end of the duct 36 controls the supply of the flock from the duct to the carding rolls. while a fancy roll 45 at the other side of the group of carding rolls controls the discharge of individual fibers from said group onto the adhesive or cement covered material X. Any suitable means (not shown) may be employed for rotating the rolls mentioned. In fact, the feed and quantity of flock transferred from the duct 36 to the carding rolls is controlled by the speed of rotation of the feed roll 44. The carding rolls 3! to 42 inclusive rotate in predetermined directions as indicated by the respective arrows thereon and at predetermined speeds to accomplish the positive breaking up and carding of the flock into individual fibers and to advance such fibers in straightened condition to the fancy roll 45. As shown, the fancy roll 45 is provided with longer carding wires 46 and rotates at a faster speed so that it can throw the individual fibers downwardly in substantially a uniform stream to the cement or adhesive covered material X where most of them are imbedded endwise in the cement or adhesive substance thereon as the material is vibrated.

Thus, the discharge of the fibers from the feed unit J and-the deposition thereof on the cement or adhesive covered material X is controlled and substantially uniform and tends toprovide a better and more uniform initial formation thereof in the adhesive substance or cement on the material X as it is agitated. The positive breaking up and carding action precludes the fibers falling in gobs, balls or other substantially solid formations onto the cement or adhesive covered material X and permits longer fibers to be used to make a deeper pile on such material. Moreover, it is unnecessary, due to this positive breaking up and carding action, to initially sift or dryclean the flock as heretofore, as it is not now necessary to have the fibers bone dry before being used. Instead, it will suflice if the flock is merely subjected to an ordinary inexpensive scouring to remove traces of grease and dirt.

Preferably therolls aforesaid of the feed unit J are within a metal hood or casing 41 that has an inlet opening 48 at the discharge end of the duct 36 and is provided at the fancy roll 46 with an outlet-opening 49 from opposite sides of which suitable sheet metal panels 50 'and 5| incline downwardly in the form of an'inverted V toward the a itator assembly E. Electric vibrators 52 and 53, respectively, of conventional design are mounted upon the back of these panels 50 and SI to agitate the same and thereby prevent the fibers discharged from the fancy roll 46 sticking or adhering to the opposed faces of said panels.

assacsv The second flock feed unit K is spaced above the second agitator assembly F and is preferably identical to the first feed unit J. However, a somewhat inferior grade of flock is preferably used in this feed unit. Such flock is selected as a secondary fill for the initial formation on the adhesive or cement covered material X to help build up a, solid pile on said material.

The third flock feed unit L is also spaced above the second agitatorassembly F and preferably comprises a vertical chute provided at its lower discharging end with suitable carding rolls 6!! and Bi respectively. The same grade of flock used in the second feed unit K or a more inferior grade of flock may be used in the third unit to make the final fill for the pile previously formed on the material X.

The suction nozzles M, N and respectively are preferably located at spaced points of the machine to clean off or remove loose or excess fibers from the adhesiv or cement covered material X after the fibers have been deposited thereon from the feed units J, K and L respectively. As shown, the first nozzle M is between the first and second feed units J and K for cleaning up the material X after the initial deposit is made thereon and before the deposit from the second feed unit K is made; the second nozzle N is between the secand and third feed units K and L for cleaning up the material X after the second deposit and before the deposit from the third feed unit is made; and the third suction nozzle 0 is at the rear of the third feed unit L for making a final clean-up. Such nozzles M, N and 0 may be connected by suitable ducts to the storage bins from ich the fiock for the respective feed units is obtained. Preferably the first nozzle M is connected to a duct 62 that leads to th storage bin 35 for the first feed unit J and contains a suitable suction fan or blower 63 for drawing off-the material X and returning to the first bin 35 any loose fibers that did not become imbedded in the cement or adhesive substance on said material after being discharged from the first feed unit J. In this connection, the duct 62 has a branch 6Q that extends from the bottom of a trough 65 located below the first agitator assembly E for receiving any fibers overflowing the sides of the endless conveyor it. Thus, the fibers that are discharged from the first feed unit J and fail to be imbedded in the cement or adhesive substance on the material X are returned to the storage bin 35 for the first feed unit J to be used again.

Likewise, the second suction nozzle N is connected to a duct 66 that leads to a second storage bin (not shown) for the second feed unit K and contains a suction fan or blower 61 for drawing off the material X and returning to the second bin mentioned any loose fibers that did not become imbedded in the cement or adhesive substance on the material X after being discharged from the second feed unit K.

The third suction nozzle 0 is connected to a duct 68 that leads to the third feed unit L and that contains a suction fan or blower 69 for drawing off the material X and returning to the third feed unit L any loose fibers that did not become imbedded in the cement or adhesive substance on the material X after being discharged from the third feed unit L. However, in this instance, there is a branch duct that leads from the duct 68 to the second bin mentioned, and there is also a supply duct II that leads from the second bin mentioned to the duct 68 on the intake side .of

the blower 69. A suitable directional damper I2 may be provided at the juncture of the ducts S8 and III to control the flow therethrough of fibers from the blower 69.

Thus, with this arrangement, it will be apparent that provision has been made in the first instance for depositing one type of flock onto the material X, then cleaning the material X, then depositing another type of flock onto said material, then again cleaning the material X, finally depositing the same type of flock again onto the material X, and finally again cleaning the material X before completing the process. Hence, the surface of the adhesive substance or cement on the material X is clean in each instance before the flock is deposited thereon. Actually, each successive deposit of fibers may be accomplished without interference on the material X with loose fibers that would form obstacles that would prevent the deposited fibers from becoming imbedded in the adhesive substance or cement on such material. As a result more of the fibers deposited will become imbedded in the adhesive substance or cement to provide a denser pile formation. Moreover, it will be apparent that the three a tator assemblies E, F and G respectively are located at such points relative to the feedunits J, K and L respectively, that the fibers imbedded in the adhesive substance or cement on the material X will sink farther and farther into such adhesive substance or cement as the material advances over and is agitated by the respective assemblies E, F and G. In fact, by the time the fibers pass over the third and final agitator assembly G they will sink to a point near the bottom of the cement or adhesive substance on the material X, hence such'fibers will not only be dense as aforesaid but will also be anchored firmly and solidly as desired. As a result, a solid, wellanchored pile is provided on the material X.

If desired, some other means such as the cooperating rolls 8!! and 8| respectively may be employed instead of the electric vibrators 32 and 33 after the pile has been formed as aforesaid on the material X to push the fibers of the pile down farther into the cement or adhesive substance on said material for better anchorage purposes. As shown, the lower roll M is an idler roll and engages the underside of the material X, while the upper roll is a pressure roll and has suitable adjusting means 82. Preferably the periphery of at least the upper roll 80 is covered with sponge rubber 83 or the like for engagement with the pile formed on the material X.

After the pile mentioned is formed, the material X provided with such pile is advanced through an oven or other heating chamber (not shown) where the sponge rubber 8 on the underside of the material X is cured and where the adhesive substance or cement 9 in which the pile is anchored is dried or cured to provide the finished product.

In Figure 8 I have illustrated a slight modification wherein electro-static equipment R is provided instead of the agitator assembly E beneath the first feed unit J. As shown, an electrically charged reciprocating screen of conventional design is supported between the fancy roll 45 and the endless conveyor i3 in position to receive the fibers discharged from the unit J, while an electrically charged electrode 9| is located immediately below the top flight portion of the endless conveyor as an agitator for the material X. Thus, the electrically charged screen 90 causes the fibers to dance up and down and fall in a straightened condition into the adhesive substance or cement 9 on the material X, while the charged electrode 9| will vibrate the material X so that such fibers will be imbedded endwise in the cement or adhesive substance mentioned. Otherwise the construction and operation of the parts illustrated in Figure 8 are the same as in Figure 1.

In use, the material X from thefeed rolls A and B will be covered by the doctor blade D with a suitable layer 9 of adhesive substance or cement which will receive successively three deposits of fibers from the feed units J K and L respectively as the material is advanced over and vibrated successively by the three agitator assemblies E, F and G respectively. The initial deposit from the feed unit J consists of selected, well-balanced fibers of substantially uniform length and weight to provide a better and more uniform initial formation on the material X, while the second and third deposits may be of an inferior grade of fibers. The suction nozzles M, N and respectively will effectively remove loose fibers from the adhesive substance or cement 9 on said material to insure a clean surface for each successive deposit of fibers. Hence, a denser formation of the fibers on the material X may be obtained. The arrangement of the agitators E, F and G for the material X insures the proper anchorage of the fibers in the adhesive substance or cement 9 because successive vibrations cause such fibers to sink farther and farther into such adhesive substance or cement. Thus, the pile formed by the fibers on the material X will be denser and anchored better than heretofore.

What we claim as our invention is:

l. The method of making a cemented pile carpet, comprising the steps of covering advancing sheet material with an adhesive substance, projecting a batch of fibers onto the adhesive covering while vibrators are moved back and forth lengthwise of the underside of said material to cause a substantial proportion of said fibers to imbed themselves substantially uniformly in said adhesive covering and thereby produce a substantially uniform initial pile formation, withdrawing loose and excess fibers from said initial formation, again vibrating the advancing material to cause the fibers of the initial formation to be imbedded farther into the covering and simultaneously proprojecting a second batch of fibers onto the adhesive covering while the material is being vibrated again as aforesaid to cause a substantial proportion of the second batch of fibers to be imbedded in the covering to make the initial formation denser, withdrawing loose and excess fibers from the denser formation while the advancing material is vibrated again as aforesaid, continuing'the vibration of the advancing material to cause the fibers of the denser formation to be imbedded farther into the covering and simultaneously projecting a third batch of fibers onto the adhesive covering while the vibration of the material is continued to cause a substantial proportion of the third batch of fibers to be imbedded in the covering to complete the pile formation, withdrawing loose and excess fibers from the complete formation, and again vibrating the advancing material to cause the fibers of the complete formation to be imbedded farther into the adhesive covering.

2. The method of making a cemented pile carpet, comprising the steps of advancing a base material beneath an adhesive spreader and over three spaced groups of agitators so that such advancing base material will in turn be covered by adhesive from said spreader and thereafter successively vibrated by said agitators, depositing carded fibers onto said adhesive covering as the base material passes over the first group of agitators to produce an initial pile formation and simultaneously moving the agitators of the first group back and forth lengthwise of said advancing material to substantially equalize the vibration of said material to thereby obtain a substantially uniform penetration of the fibers in the adhesive covering, sucking loose and excess fibers from said initial pile formation as said base material advances from the first group to the second group of agitators, depositing more carded fibers onto the adhesive covering as the base material advances over and 'is vibrated by the second group of agitators to make the initial pile formation denser, sucking loose and excess fibers from said denser pile formation as said base material is being vibrated by the second group of agitators, depositing additional fibers onto the adhesive covering as the base material advances still farther over the second group of agitators to complete the pile of fibers, and sucking loose and excess fibers from the complete pile of fibers before the advancing base material reaches the third group of agitators to be vibrated thereby.

3. The method of making a cemented pile carpet, comprising the steps of advancing a base material beneath an adhesive spreader and over three spaced groups of agitators so that such advancing base material will in turn be covered by adhesive from said spreader and thereafter successively vibrated by said agitators, depositing fibers of substantially uniform weight and length onto said adhesive covering as the base material passes over the first group of agitators to produce an initial pile formation and simultaneously sliding the agitators of the first group back and forth lengthwise of said advancing material to substantially equalize the vibration of said material to thereby obtain a substantially uniform penetration of the fibers in the adhesive covering, sucking loose and excess fibers from said initial pile formation when said advancing base material is between the first group and the second group of agitators, depositing more carded fibers onto the adhesive covering as the base material advances over and is vibrated by the second group of agitators to make the initial pile formation denser, sucking loose and excess fibers from said denser pile formation as said base material is being vibrated by the second group of agitators, depositing additional fibers onto the adhesive covering as the base material advances still farther over the second group of agitators to complete the pile of fibers, and sucking loose and excess fibers from the complete pile of fibers before the advancing base material reaches the third group of agitators to be vibrated thereby.

HAROLD P. FARIS. JOHN E. WHITE.

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