US2707158A - Method of making pile fabric - Google Patents

Method of making pile fabric Download PDF

Info

Publication number
US2707158A
US2707158A US299615A US29961552A US2707158A US 2707158 A US2707158 A US 2707158A US 299615 A US299615 A US 299615A US 29961552 A US29961552 A US 29961552A US 2707158 A US2707158 A US 2707158A
Authority
US
United States
Prior art keywords
pile
slab
medium
backing
slabs
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US299615A
Other languages
English (en)
Inventor
Johaunes Bernhard Hans V Issum
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.)
Fabric Dev Co Ltd
Original Assignee
Fabric Dev Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fabric Dev Co Ltd filed Critical Fabric Dev Co Ltd
Application granted granted Critical
Publication of US2707158A publication Critical patent/US2707158A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/007—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by mechanical or physical treatments
    • D06N3/0079—Suction, vacuum treatment
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/244—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of halogenated hydrocarbons

Definitions

  • the invention relates to a method of and means for treating fibres, tufts or yarn pile of an unwoven pile material such as plush, velvet, imitation fur, carpets, rugs, mats and so forth, and while particularly applicable to the treatment of the pile of fabrics manufactured by methods such as described in specifications Nos. 2,516,559; 2,480,984 and 2,491,258, it may also be applied to a woven pile fabric.
  • a carpet for example, the pile of which is composed of high grade fibrous substance, is pleasantly sprmgy or resilient to walk on, and when relieved of the weight of the walker, quickly recovers its form. It also offers a high resistance to wear.
  • a material which is to simulate fur should be either soft or hard to the touch, according to the skin it is to imitate.
  • the above desired characteristics of a pile material or fabric are obtained by supporting the pile in a slab or the like of a solidifying medium or gel such as alginate with the ends of the pile exposed at opposite surfaces of the slab and protruding at one surface, and treating the pile with a reinforcing substance such as synthetic resin, which is applied to the surface of the support at which the pile ends protrude and sucked into intimate contact with the fibres or filaments of the pile by connecting the opposite surface of the support and the pile ends exposed at that surface to suction.
  • a solidifying medium or gel such as alginate
  • the nature, i. e. pH value, viscosity and so forth, of the treating medium and the degree and duration of the suction may be varied to suit the nature and length of the pile whether spun or unspun, so that the characteristics required are achieved according to the use for which the pile material is intended.
  • the treating medium With a yarn pile, or one com posed of spaced layers of fibrous substance the treating medium may be sucked down and through the pile, and even in a very fine state right through the pile.
  • a primary plastic coat is then applied.
  • a wedge like protuberance is drawn into the fibrous substance.
  • This protuberance may make the fibrous substance resilient or flexible as desired.
  • the preparatory treatment with weak solvent may be omitted. Depressions may be formed in the alginate support adjacent to the pile ends and be filled with treating medium, which after drying, affords considerable and effective locking or keying of the pile.
  • the pile after treatment and while still in its support or slab is preferably passed through a drying or curing chamber, and, in a method of manufacture as described in the specifications referred to, a final plastic backing may be then applied to the primary coating or film of treating medium on the surface of the slab.
  • the alginate ,supporting or consolidating medium is removed from the pile.
  • Apparatus for carrying out the above treatment may comprise a foraminous band, for carrying slabs or so.- lidified supports containing the piles to be treated, which travel over suction troughs or chambers which may be connected with any convenient suction producing means, suitable devices being provided to otherwise apply the treating medium.
  • the treating medium is sucked down into the yarn ends into intimate contact with the consolidated surface and with the yarn pile.
  • the suction and pH value of the treating medium may cause depressions to be formed in the surface adjacent to the ends of the pile, the depressions being completely filled with the treating medium.
  • the medium is drawn into and thus penetrates, or infiltrates the yarn pile, and under continuation of suction some medium in a very fine state may pass right down and through the pile.
  • the synthetic resin with which the pile has been treated is then cured, for instance, the treated slabs of pile are passed through a curing chamber, after which the final coating or backing of plastic is applied to any desired thickness.
  • spaced layers of fibrous substance are assembled in an alginate support as described in U. S. Patent No. 2,491,258. These are treated in a similar manner to that above described.
  • the degree of penetration of the treating medium depends to some extent on the pH value of the treating medium, which may be above or below 7.0.
  • a Woven pile carpet is supported by consolidating it in an alignate slab and treating it in a similar manner.
  • non-absorbent filamentous substance for a pile
  • the individual filaments of. nylon, rayon, or the like cannot be penetrated by the treating medium but it may be drawn down them so that the filaments are partly coated or sheathed at the base, leaving the tips untouched.
  • Air in the drier may be drawn through the pile before the primary coating or" treating medium is applied, soils to remove moisture present, thus facilitating the adherence and penetration of the coating medium.
  • Figure l is a side elevation of the apparatus.
  • Figure 2 is a side view of a portionof slab supporting a pile composed of spun fibrous substance.
  • Figures 3 and 4 are respectively a side view and plan of the portion of slab after the primary coating has been applied.
  • Figure 5 is a side view of the portion of slab after the second coating has been applied to form a final backing
  • Figure 6 is a side view showing the backing with the treated pile, after the gel or supporting medium has been removed.
  • Figures 7 to ll are corresponding views to Figures 2 to 6 illustrating corresponding stages in the treatment of a pile composed of spaced layers of unspnn fibrous sub stance or sliver.
  • Figure 12 is a side view of a portion of slab with the pile of a woven carpet embedded in the supporting medium
  • Figure 13 is a side view of the portion of slab after application of the primary coating.
  • Figure 14 is a side view of the portion of carpet after the supporting medium has been removed.
  • the apparatus comprises an endless conveyor which for convenience is in six sections, 1, 2, 3, 4, 5 and 6. It is composed of foraminous material.
  • the section 1 receives the slabs 4' of consolidating medium in which the pile to be treated is supported and conveys them under rotary brushes 7, 7, preferably having metallic bristles or pin rollers, which remove some of the gel or other consolidating medium from the upper surfaces of the slabs so that the ends of the pile protrude from the upper surfaces.
  • the consolidating medium may comprise gel, wax which is melted by heating and allowed to cool, a metal alloy of low melting point such as Woods metal, starch or gelatine solutions, rosin or animal or vegetable glue. The particles of medium removed are taken away by a suction trough 8.
  • a vacuum trough 38 may be provided below the conveyor section 1 to initiate removal of moisture and also to ensure that the slabs 4 will be held securely against the conveyor while passing under the brushes 7, 7. lt will be understood that the ends of the pile are exposed at the upper and. lower surfaces of the slabs.
  • the slabs are then conveyed through a drying chamber 9 in which air heated to about 210 F. is suitably distributed over the slabs to dry the protruding ends of the pile and upper surfaces of the slabs, vacuum troughs 10 being provided below the conveyor section 2 to remove moisture laden air.
  • the slabs delivered from the drying chamber 9 are conveyed by the conveyor section 3 over vacuum troughs 11 and under doctors 12 and 14.
  • the doctor 12 is supplied with the reinforcing substance for instance a solution or emulsion of synthetic resin and applies it to the slabs passing under it to form a primary coating 15, the emulsion flowing down the protruding pile ends on to the upper surfaces of the slabs.
  • the coated slabs pass over the suction troughs 11 so that the emulsion is sucked into intimate contact with the pile and the upper surfaces of the slab, penetrating the pile.
  • the slabs pass successively under the doctors 14 and over the vacuum troughs 11.
  • the doctors 14 are supplied with air which is blown by them on to the coating so as to maintain synthetic resin in a condition for continued sucking into the pile as the slabs pass over the suction troughs 11.
  • the number of these air doctors and their corresponding vacuum troughs may be varied to suit the character of pile to be treated, as some pile is more absorbent than others.
  • the slabs so far treated are then passed on to the conveyor section 4 and conveyed by it through a curing oven 17 in which air at an adequate temperature to cure the coating of synthetic resin is distributed over them and withdrawn by vacuum troughs 13.
  • a curing oven 17 in which air at an adequate temperature to cure the coating of synthetic resin is distributed over them and withdrawn by vacuum troughs 13.
  • several ovens may bearranged in series supplied with air at increasing temperatures so that the heat isgradually increased for example from 195 to 600 F. v
  • the slabs issuing from the curing oven 17 are conveyed under a doctor 20 which applies the substance to form with the primary coating 15 a backing 21 for the pile the protruding ends of which are to be embedded and fixed in the backing. Plastic or synthetic resin is preferred for this purpose.
  • the backing is then cured for instance by conveying the slabs on the conveyor section 6 through a curing oven 37 in which air at an adequate temperature is distributed over the slabs while passing over vacuum troughs 38.
  • the backing is cured the gel or other consolidating medium is removed from the pile which can be washed and brushed as explained in the U. S. patents before referred to.
  • Figures 2-6 illustrate the application of the invention to slabs supporting yarn pile as described in U. S. Patent No. 2,516,559.
  • Figure 2 shows a portion of a slab 4 after passing under the brushes or pin rollers 7, Figure l, the yarn pile 22 having protruding ends 23. The opposite ends of the pile are exposed at the lower surface of the slab but do not protrude.
  • Figure 3 shows a portion of the slab after passing under the doctors 12, and 14 and over the corresponding vacuum troughs 11.
  • the primary coating 15 is shown in intimate contact with the upper surface of the slab 4' and having protuberances 24.
  • the protuberances partly surround the pile as at 24 and penetrate into it as at 25. The extent of penetration varies according to the nature or quality of the pile some yarn being more loosely spun and more absorbent than others. Some of the emulsion may actually be drawn right down the pile.
  • the effect of suction may cause the formation of slight depressions in the upper surface of the slab surrounding the pile, the depressions being filled in with the emulsion and forming the parts 24 of the protuberances.
  • Figure 5 shows a portion of the slab 4 after it has passed under the doctor or extruder 20 and has been coated with a coating 21. of plastic which is united with the primary coating 15 and constitutes the final backing with the protruding yarn ends firmly fixed in it.
  • FIGS. 7 to 11 are corresponding views to Figures 5 to 6 illustrating corresponding stages in the treatment of a pile composed of spaced layers 26 of unspun fibrous substance, such as sliver as described in U. S. Patent No. 2,491,258.
  • the pile is indicated by 26, the protruding ends by 27, the slab by 4.
  • the protuberances 28 from the primary coating 15 are in the form of ridges partly extending along the sides of the layers 26 and partly extending in wedge form into the layers.
  • the slabs are arranged in close contact so that when provided with a backing by the doctor 20 they are united to form a continuous length.
  • a woven pile fabric such as a carpet having a woven or porous backing it is supported in a slab 4' of consolidating medium for instance a gel of alginate with the pile 29 embedded in the slab and the woven backing 3t) exposed as indicated in Figure 12.
  • a slab 4' of consolidating medium for instance a gel of alginate with the pile 29 embedded in the slab and the woven backing 3t
  • Figure 13 shows a portion of slab and carpet'after a primary coating 15 has been applied to the upper surface of the slab and after passing over the vacuum troughs so that protuberances 31 have been drawn from the coating 15 into the pile 29.
  • Figure 14 shows the carpet or woven pile fabric after removal of the gel.
  • the cured coating 15 not only provides the protuber ances for the pile but reinforces the woven backing. If a non-porous backing is required it can be applied subsequently to the woven backing and to the primary coating.
  • pile fabric is intended to include fabrics such as carpets, rugs, mats, plushcs and similar articles.
  • reinforcing medium, as used 111 the speck.
  • fication and claims is intended to define a medium which sets or is cured to a usually permanent, more or less resilient support embedded in or around at least the base portions of the fibers to maintain a springy pile; examples being synthetic resin, plastics or other suitable substances.
  • a method of treating a pile composed of fibres, tufts or yarn for use in a pile fabric which consists in supporting the pile in determined spaced relation in a slab of consolidating medium with the pile exposed at the two opposite surfaces of the slab, the pile at one surface protruding beyond that surface, applying a primary coating of a liquid containing synthetic resin to that surface and subjecting the opposite surface of the slab to suction for the purpose of sucking the coating into intimate contact with the pile, subsequently curing the primary coating of synthetic resin, applying a final backing of synthetic resin to said primary coating and curing said final backing, and removing the consolidating medium from the pile.
  • a method of treating the pile of a woven pile fabric including a backing supporting said pile, which consists in supporting said fabric with its pile embedded in a slab composed of consolidating medium and with the pile exposed at one of the surfaces of the slab and the woven backing exposed above the other of said surfaces, passing the slab through a drying chamber, applying a liquid reinforcing medium containing synthetic resin to the surface of the slab at which the woven backing is exposed, subjecting the opposite surface of the slab to suction for the purpose of sucking the said liquid reinforcing medium into the pile, subsequently curing the said liquid reinforcing medium and finally removing only the consolidating medium from the pile.
  • a plastic backing is applied to the pile projecting from the upper surface of the slab, said plastic backing is cured and the gel is subsequently removed from the pile, the additional step of reinforcing the pile prior to the application of the plastic backing by applying a solidifiable liquid reinforcing medium containing plastic to the upper surface of the slab and subjecting the lower surface of the slab to suetion for the purpose of drawing said medium into the pile while the pile is maintained in spaced relation by the gel and solidifying said medium before the application of said plastic backing.
  • a method of treating a pile composed of fibres, tufts or yarn for use in a pile fabric which consists in supporting the pile to be treated in a slab of consolidating medium with the pile exposed at two opposite surfaces of the slab, the pile at one of said surfaces also protruding therefrom, applying in a liquid state a solidifiable reinforcing medium to said protruding pile and the corresponding surface of the slab, subjecting the other of said surfaces to suction for the purposes of withdrawing moisture and sucking said reinforcing medium into said pile and along a portion of the length of said pile while the consolidating medium maintains the spaced relation of the pile, solidifying said reinforcing medium within and around said pile, and subsequently removing said consolidating medium from the pile, whereby said solidified reinforcing medium renders the pile more resilient and improves the resistance thereof to wear.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Woven Fabrics (AREA)
  • Knitting Of Fabric (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
US299615A 1951-07-24 1952-07-18 Method of making pile fabric Expired - Lifetime US2707158A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB17523/51A GB719465A (en) 1951-07-24 1951-07-24 Improvements in the manufacture and treatment of pile fabrics

Publications (1)

Publication Number Publication Date
US2707158A true US2707158A (en) 1955-04-26

Family

ID=10096675

Family Applications (1)

Application Number Title Priority Date Filing Date
US299615A Expired - Lifetime US2707158A (en) 1951-07-24 1952-07-18 Method of making pile fabric

Country Status (8)

Country Link
US (1) US2707158A (pt)
BE (1) BE513042A (pt)
CH (1) CH305399A (pt)
DE (1) DE947547C (pt)
FR (1) FR1064741A (pt)
GB (1) GB719465A (pt)
LU (1) LU31596A1 (pt)
NL (1) NL85937C (pt)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3179550A (en) * 1958-07-09 1965-04-20 Friedman Abraham Pile surfaced product and method of forming same
US3206343A (en) * 1958-12-23 1965-09-14 Celanese Corp Method of pile construction
US3207640A (en) * 1958-02-18 1965-09-21 Avco Corp Method of making reinforced material
US3333278A (en) * 1963-05-31 1967-07-25 Sperry Rand Corp Method of making frequency responsive device
US3635759A (en) * 1969-04-04 1972-01-18 Gulton Ind Inc Method of eliminating voids in ceramic bodies
US4045598A (en) * 1976-05-06 1977-08-30 Milliken Research Corporation Coating method and apparatus
US4118526A (en) * 1975-06-06 1978-10-03 United Merchants And Manufacturers, Inc. Method for treating fabrics
US4208173A (en) * 1975-06-06 1980-06-17 United Merchants And Manufacturers, Inc. Method for treating fabrics
US4334877A (en) * 1978-07-27 1982-06-15 United Merchants & Manufacturers Inc. Fabric treatment compositions

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1728471A (en) * 1924-04-02 1929-09-17 Bratring Kurt Method of and apparatus for treating foils of cellulose or derivatives thereof by means of suitable fluids
US2290741A (en) * 1938-03-03 1942-07-21 Celotex Corp Impregnated fiberboard
US2480984A (en) * 1945-11-06 1949-09-06 Fabric Dev Company Ltd Manufacture of pile fabrics
US2491258A (en) * 1946-02-28 1949-12-13 Fuhrhop Wilhelm Friedrich Manufacture of pile fabrics
US2516559A (en) * 1945-03-01 1950-07-25 Fuhrhop Wilhelm Friedrich Method of making pile fabrics
US2548872A (en) * 1948-08-10 1951-04-17 Minnesota Mining & Mfg Method of fixing particles to sheet material

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR715377A (fr) * 1930-08-12 1931-12-02 Procédé d'imprégnation locale ou non d'un tissu par un liquide d'impression, de teinture, d'apprêt ou analogue

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1728471A (en) * 1924-04-02 1929-09-17 Bratring Kurt Method of and apparatus for treating foils of cellulose or derivatives thereof by means of suitable fluids
US2290741A (en) * 1938-03-03 1942-07-21 Celotex Corp Impregnated fiberboard
US2516559A (en) * 1945-03-01 1950-07-25 Fuhrhop Wilhelm Friedrich Method of making pile fabrics
US2480984A (en) * 1945-11-06 1949-09-06 Fabric Dev Company Ltd Manufacture of pile fabrics
US2491258A (en) * 1946-02-28 1949-12-13 Fuhrhop Wilhelm Friedrich Manufacture of pile fabrics
US2548872A (en) * 1948-08-10 1951-04-17 Minnesota Mining & Mfg Method of fixing particles to sheet material

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3207640A (en) * 1958-02-18 1965-09-21 Avco Corp Method of making reinforced material
US3179550A (en) * 1958-07-09 1965-04-20 Friedman Abraham Pile surfaced product and method of forming same
US3206343A (en) * 1958-12-23 1965-09-14 Celanese Corp Method of pile construction
US3333278A (en) * 1963-05-31 1967-07-25 Sperry Rand Corp Method of making frequency responsive device
US3635759A (en) * 1969-04-04 1972-01-18 Gulton Ind Inc Method of eliminating voids in ceramic bodies
US4118526A (en) * 1975-06-06 1978-10-03 United Merchants And Manufacturers, Inc. Method for treating fabrics
US4208173A (en) * 1975-06-06 1980-06-17 United Merchants And Manufacturers, Inc. Method for treating fabrics
US4045598A (en) * 1976-05-06 1977-08-30 Milliken Research Corporation Coating method and apparatus
US4334877A (en) * 1978-07-27 1982-06-15 United Merchants & Manufacturers Inc. Fabric treatment compositions

Also Published As

Publication number Publication date
FR1064741A (fr) 1954-05-17
NL85937C (pt)
DE947547C (de) 1956-08-16
CH305399A (de) 1955-02-28
GB719465A (en) 1954-12-01
BE513042A (pt)
LU31596A1 (pt)

Similar Documents

Publication Publication Date Title
US3979538A (en) Flocked web and method of producing same
US4230650A (en) Process for the manufacture of a plurality of filaments
US2707158A (en) Method of making pile fabric
US3765974A (en) Spot-bonded mats and process for their manufacture
JPS5891859A (ja) 不織布の製造方法
US4018862A (en) Method for producing non-woven fabric
US3034927A (en) Manufacture of synthetic leather
US3585099A (en) Plastic sheet material having textured surface
TWI634245B (zh) 牛巴戈調皮革樣片及其製造方法
US3022813A (en) Method of making bonded non-woven fabric from textile fibers
DE2649860A1 (de) Schaumstoff aus nichtgeliertem latex
US2590713A (en) Method of coating and treating a pile fabric to set the fibers in the upstanding position
US3597307A (en) Supple sheet material and method of producing same
US2349153A (en) Method of producing flocked sheet material
US3906131A (en) Chamois leather-like material having improved water absorbency and abrasion resistance
US3695962A (en) Method of making pile fabrics
DE1635699C3 (de) Verfahren zur Herstellung eines für die Kunstlederherstellung geeigneten Faserverbundstoffes
US2114618A (en) Process for coating fabrics
US2271458A (en) Rubber impregnated and coated web
CA1191057A (en) Method for the manufacture of a cushioning material
US2289151A (en) Method of making perforate latex rubber films with or without textile fabric backings
US2111933A (en) Method for treating fibrous materials
US2704725A (en) Method of making pile-surfaced sheet material
US3010865A (en) Method of making elastomeric webs
US4431687A (en) Method for the manufacture of a fabric-type artificial leather