US2786508A - Manufacture of pile rugs, carpets, and mats - Google Patents

Manufacture of pile rugs, carpets, and mats Download PDF

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Publication number
US2786508A
US2786508A US428090A US42809054A US2786508A US 2786508 A US2786508 A US 2786508A US 428090 A US428090 A US 428090A US 42809054 A US42809054 A US 42809054A US 2786508 A US2786508 A US 2786508A
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United States
Prior art keywords
core
yarn
coil
coils
backing
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Expired - Lifetime
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US428090A
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English (en)
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Waage Jacob
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Individual
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Individual
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    • 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
    • D04H11/04—Non-woven pile fabrics formed by zig-zag folding of a fleece or layer of staple fibres, filaments, or yarns, strengthened or consolidated at the folds
    • 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
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1089—Methods of surface bonding and/or assembly therefor of discrete laminae to single face of additional lamina
    • Y—GENERAL 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
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/12—Surface bonding means and/or assembly means with cutting, punching, piercing, severing or tearing
    • Y10T156/1317—Means feeding plural workpieces to be joined
    • Y10T156/1322—Severing before bonding or assembling of parts
    • Y10T156/133—Delivering cut part to indefinite or running length web

Definitions

  • This invention relates to a method for manufacturing pile carpets, rugs, mats and the like, and has for its object to provide a method whereby such rugs, carpets and the like can be produced inexpensively as well from high class materials giving a high quality product, as from cheap or even waste material.
  • a method of making pile carpets, rugs, mats and the like comprises the steps of twisting or wrapping continuous lengths of material in closely packed or partial overlapping windings around a core, so that a helical coil of material enclosing said core is obtained, forming a sheet consisting of parallel rows of a plurality of said coils in a single layer, locking or anchoring the material in the coils facing one side in said sheet together by means of rubber latex or other adhesive, slitting the material in said coils at another location of the windings, and finally removing the cores through such slits.
  • said looking or anchoring is obtained by bonding to a sheet of hessian, canvas or similar material.
  • Fig. 1 is a section of the rug during its manufacture, drawn on an enlarged scale, the'left side showing aside elevation of a coil, the right side illustrating a section of the coil,
  • Fig. 2 is a section on the line IIII in Fig. 1,
  • Fig. 3 is a section similar to Fig. 2 illustrating some other preferred embodiments with respect to the core to be used,
  • Fig. 4 is an illustration substantially in diagrammatic form of apparatus and method used in a practical method of assembling a number of coils to a single layer row of coils and anchoring one side of the coils together,
  • Fig. 5 is a similar section as shown in Figs. 2 and 3, disclosing some further embodiments of cores for use in a special embodiment of apparatus and method,
  • Fig. 6 is a section on the linejVIVI of Figs. 5 and 7 on one end of coil while in said apparatus,
  • Fig. 7 is a plan view on a small scale of an apparatus 2,786,508 Patented Mar. 26,. 1957 6 along a coil, respectively, are shown, in order to illustrate the basic feature of the invention.
  • a yarn 10 is wrapped or twisted around a core 11 to form closely packed windings of a helical coil enclosing the central core 11.
  • the adhesive being applied in such quantities that a substantially continuous layer 12 is formed, each winding may be bonded along a longitudinal line to the other windings in the coil.
  • a web 13 may constitute the continuous layer.
  • a plurality of coils are laid closely packed in a single layer of parallel rows of coils and bonded together as well longitudinally as transversally on one side of said layer, as disclosed in Figs. 2 and 3, by means of adhesive and a suitable web.
  • each coil may be slit lengthwise, and the core removed.
  • vertical strands 15 are formed.
  • Such strands form the pile or nap of the finished carpet, and may eventually be further trimmed by cutting or clipping in the direction of the arrow 16. 5
  • the backing forming web 13 consists of an intermediate linen 17 impregnated with the rubber latex or other suitable adhesive 12, and a sheet of canvas, hessian or the like 18, as shown in Figs. 2 and 3.
  • yarn 10 as the coil forming material is disclosed and shown upon the drawings, but it should be understood that the yarn may be substituted by strips, ribbons, waste cuttings of for example textile cloth in continuous lengths and the like. In that case such lengths may be wrapped around the core with a partial overlap between adjacent windings.
  • the core 19 has an elongated cross section in the two first cores of that figure.
  • Said core is adapted to be produced in continuous lengths of a pliable material by extrusion in a suitablethermoplastic extrusion machine by using a suitable nozzle.
  • the cross section of the core 19 is as mentionedelom gated, having longitudinal sides-20 and a lower preferably rounder transversal lower side 21, and a groove 22 in its opposite upper side. It is readily apparent that when applying a cutting action in the direction of the arrow 23, the cutting tool may enter into the groove 22 and cut the strands of the yarn 10 completely through. It is thus in no danger of damaging the core during the cutting action, so that the core after removal from the coil may be used in a subsequent operation.
  • metal rails having a cross section as shown to the right in Fig. 3 may be used in such cases wherein a high degree of stillness. and eventually a self supporting ability is desired.
  • Such metal cores may consist of channel formed rails 24' having an openinginto the interior of the rail. The ends of the channellegs are bent inwardly at 26 in order to avoid any damagebr shearing action from such ends.
  • the metal rails 24' may be produced in continuous lengths from, plate metal in a suitable machine.
  • the pile usually is sufiiciently smooth after cutting, when using this embodiment of core section, the
  • surface may betrimmed in the finishing operation by applying a cutting action, for instance by rneans'of-a band knife, in the direction of the arrow 27.
  • any desired height of'pile may be obtained in the finished rug after cutting and removal of the core.
  • Such height may be regulated by means of the length of the longitudinal sides of the cores 19 and 24, respectively.
  • the density of the pile depends, among other factors, upon the dimensions of the yarn in relation to thethickness of the core. Among such factors governing the stiifness or density of the pile the twist of yarn should be mentioned. Obviously, the more twisted types of yarn contain a higher degree of filaments at a given cross sectional dimension, and should consequently be able to give a stiffer or denser pile in the carpet or rug.
  • highly twisted yarns should not be preferable in that they are apt to prevent penetration of the adhesive into the yarn for bonding each lament in the yarn to the carrier.
  • a good bond between backing and yarn is desired to prevent subsequent loosening of fibre bundles in the finished rug or carpet.
  • Such lowered penetrating ability may also be caused by selecting improper adhesive and/or using incorrect properties and proportions thereof.
  • a suitable selection of the different materials a wide range of pile types may be obtained. It has been shown in practice that it is possible to produce a pile rug or carpet having the desired degree of density by using loosely twisted yarns and by means of cores having thicknesses of several millimeters, and further that it is even possible to produce rugs according to the invention which are too stiff and not easily launderable in that an expressive number of strands are present in the pile.
  • coils consisting of yarn 1G and cores 11 as in Figs. 1, 2 or 3 travel from a roll 31 in the direction indicated by the arrow 310.
  • a reed 32 is used for distributing the coils for the formation of the single layer row of coils upon a beam 33, upon Which a sheet of canvas, hessian or similar strong material serving as a backing in the finished rug, has been laid as the lowermost layer.
  • Said sheet, indicated at 34 travels from a roll or beam 35 and together with an intermediate linen 36 and the ends of the coils 30 being secured to the beam 33 at 37.
  • the intermediate linen 36 is used as carrier for the adhesive and travels from a beam 38 over a roll 39 into a bath 40 over another roll 41, in the direction of the arrow 41a unto the beam 33. It is generally preferred to use rubber latex as the adhesive material in the bath 40.
  • cores having an elongated cross-section as shown in Fig. 3 preferably extruded from a thermoplastic pliable material into the cross section shown to the left in said figure, it is preferred to use an additional reed 42 for orientating the cores in the direction relative to the backing as shown in Fig. 3.
  • the beam 33 it is preferred to use a close packing of adjacent coils in order to enable easy cutting of coils in the subsequent cutting operation. Further it is preferred to choose the dimension of the beam 33 so that a plurality of layers of the composite structure consisting of backing webs and parallel row of coils are wound upon the beam 33. In this way, the lower side 21 of the core 19 (Fig. 3 to the left) presses the yarn in each coil firmly against the backing, so that the impregnated intermediate linen layer 36 locks or anchors the fibre bundles of yarn to the canvas sheet 34. After a suitable setting time, the structure shown to the left in Fig. 3 is obtained.
  • The. coils are now to be slit lengthwise and the core removed. This may be done by leading the rug past a band knife in the direction of the arrow 16 in Fig. 2 or the arrow 27 in Fig. 3.
  • the cuttingv operation may also he proceeded by means of a set of rotating knives acting in the direction of the arrow 14 in Fig. 2 and the arrow 23 in Fig. 3.
  • the adhesive it is preferred to use latex rubber in a suitable liquid state, as aforesaid.
  • the viscosity of the adhesive solution or dispersion should of course be regulated, so that it does, not penetrate through the coils and bond the yarn windings to the core, whereby t e core cannot be removed. Further, in the embodiment disclosed in Fig. 4, the liquid adhesive should not be able to penetrate out to the opposite surface of the backing, whereby the adjacent layer of the composite structure forming the half processed rug would be bonded to each other upon the beam.
  • Fig. 4 necessitates the use of at least two beams for the materials and one beam for assembling the backings and the layer of parallel rows of coil.
  • said embodiment has the advantage of high processing speed, the cost of equipment should be relatively large, in comparison with the more simple and inexpensive equipment now to be described.
  • each end of rail is supported by frame members 62, 63 forming the longitudinal sides in a rectangular frame 64, the end members 65 of which being pivotally supported by stub shafts 66 in suitable bearings 67.
  • a pressing rail 68 supported by screws 69 in one end member 65 of the frame.
  • a drum 70 having a length corresponding to the desired width of the carpet or rug, and a circumferentiallength corresponding to the desired length of a carpet is used.
  • the drum 70 may have a width of four to six meters and a diameter of two to three meters, corresponding to a rug or carpet of a width of four to six meters and a length of six to nine meters.
  • the drum '70 is-mounted' in bearings 71 for rotation upon its shafts 72 in the direction of the arrow 73 by means of a transmission comprising a sprocket wheel 74 and a chain 75 driven by another sprocket wheel 76 over a chain 76a from a motor 76b.
  • a transmission comprising a sprocket wheel 74 and a chain 75 driven by another sprocket wheel 76 over a chain 76a from a motor 76b.
  • continuous length of yarn coil 77 is wound in a single layer, forming a helical coil or screw winding upon the periphery of the drum.
  • the canvas forming the backing of the rug is mounted as may appear from Figure 9, wherein a part of the drum 70 is shown, the canvas backing being shown at 78 and adhesive at 78a.
  • a distributor 82 placed upon a screw 83 is foreseen.
  • the distributor guide 82 and the guiding screw 83 is rotated slowly at a speed adapted to distribute the yarn coil evenly and closely packed upon the circumference of the drum 70.
  • the yarn coil passes an adhesive coating device indicated at 84, in order to provide the lowermost part of the yarn coil with a suitable amount of binding agent.
  • said binding agent consists of rubber latex, and after coat ing the yarn coil will be firmly bonded to the canvas backing upon the drum 70.
  • Said cutting device comprises a supporting frame 85 guided by the screw 83 and eventually two additional guides 86 on each side of the screw.
  • an outwardly flaring arm 87 is mounted adjustably by means of a set screw 88.
  • the arm 87 carries a guiding roll 89 supported by a spindle 99.
  • Said spindle may be adjusted vertically in a slit 91, and the roll 89 being free to rotate upon its spindle 90.
  • the arm 87 has a rotating knife 92 positively driven by a spindle 93 by suitable means not shown.
  • the spindle 93 may also be adjusted vertically in a slit 94, so that the knife edge is located in the groove 22 of the core 19 of the coil 77, said yarn coil preferably having a cross section as shown to the left in Figure 3.
  • the coil of yarn remains upon the drum bonded to a sheet of canvas, as indicated in Figure .9.
  • the rug may be removed as a finished pile rug by loosening a wedge 95 indicated in Figure 9.
  • the type of yarn to be used as the adhesive may be varied in numerous ways, all falling within the scope of the present invention as Further, the type of backing to be used should be chosen accordingly.
  • a customary liquid rubber latex dispersion has shown to be useful and fulfilling most requirements. All accordingto the conditions, the hardened or solidified rubber layer may serve as a sole backing or it may be reinforced with a linen, or, as a preferred embodiment, a sheet of canvas or hessian may serve as'the real backing.
  • the liquid rubber latex will set at usual room temper ature. However, if elevated temperatures are to be used, it should be noted that precautions should be taken that the core material is able to withstand such temperatures. However, in some cases it should be possible to apply the heat from the backing face of the rug, in order to prevent the core from being subjected to excessive temperatures.
  • the interior of the drum may be provided with suitable heating means in order to obtain backing of the rug while it still remains upon the drum.
  • rugs and mats having a coloured pattern such may be produced by printing the pile face of the rug either before or after removal of the core.
  • special precautions should be taken to obtain the best penetration possible in such cases. Further, it may be ditlicult to obtain sharp and delicate patterns in this way.
  • difierent coloured yarn in different areas of the coils, whereby the location of such coloured strips give a corresponding pattern in the finished rug.
  • the correct sampling should be estimated exactly in beforehand when delicate and multicoloured patterns are to be produced.
  • the core has been shown in the drawings as either being a metal rail or a plastic monofilament, it may also consist of a number of threads spun together into a suitable structure.
  • the dimensions of the core may be varied. Usually it is preferred to use rails or monofilaments ranging from about one to several millimeters in thickness and a height giving a pile height of from ten to fifteen millimeters.
  • the rails according to the embodiment disclosed in Fig ures 5, 6 and 7 should of course have a height amounting to the double of the desired pile height.
  • a method of making pile carpets, rugs, mats and the like comprising the steps of wrapping continuous lengths of yarn about a continuous core in closely packed relationship so that a helical coil consisting of windings of said yarn enclosing said core is obtained, wrapping said coil helically upon a drum having a circumference substantially less than the continuous length of said coil and carrying a backing material to form a continuous helical coil of windings enclosing said backing material the per phen' at said.
  • each yarn winding around said core is impregnated with adhesive t Pfdfmined and localized spet during winding of a d.
  • Yar sa 29a h ai 4.
  • said core has an e ngated ross ti n, a d ya n hi ls being Won (1 on the with a shorter side of said cross sect Qn en a in sa baskin mate i 5.
  • An apparatns for forming pile carpets, rugs, mats and the like comprising a drum, a continuous core, means for winding yarn about said core, the core having a length at least a plurality of the circumference of said drum, means for forming a coil consisting of a continuous length of said yarn covered core upon the circumference of said drum, and means for removing said core While having the yard on the circumference of said drum.
  • An apparatus comprising means for slittingthe yarn upon said core in a line extending lengthwise of said core and being located opposite the line of engagement between said coil and the circumference of saiddrum.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Laminated Bodies (AREA)
  • Treatment Of Fiber Materials (AREA)
US428090A 1954-04-02 1954-05-06 Manufacture of pile rugs, carpets, and mats Expired - Lifetime US2786508A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US428090A US2786508A (en) 1954-04-02 1954-05-06 Manufacture of pile rugs, carpets, and mats

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB9672/54A GB748249A (en) 1954-04-02 1954-04-02 Improvements in the manufacture of pile rugs, carpets and mats
US428090A US2786508A (en) 1954-04-02 1954-05-06 Manufacture of pile rugs, carpets, and mats

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US2786508A true US2786508A (en) 1957-03-26

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US428090A Expired - Lifetime US2786508A (en) 1954-04-02 1954-05-06 Manufacture of pile rugs, carpets, and mats

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US (1) US2786508A (Sortimente)
BE (1) BE528779A (Sortimente)
DE (1) DE1025375B (Sortimente)
FR (1) FR1104231A (Sortimente)
GB (1) GB748249A (Sortimente)
NL (1) NL84619C (Sortimente)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4904331A (en) * 1986-10-17 1990-02-27 George-Martin Textiles Limited Apparatus for the manufacture of pile fabrics
WO1999062711A1 (en) * 1998-06-05 1999-12-09 E.I. Du Pont De Nemours And Company Method and apparatus for making articles having bristles
US6269514B1 (en) 1998-06-05 2001-08-07 Du Pont Monofilament bristle assemblies and methods of making brushes using same
US6351868B1 (en) 1998-06-05 2002-03-05 E.I. Dupont De Nemours & Company Bristle sub-assemblies having parallel pairs of bristles; and methods
US6543083B1 (en) 1998-06-05 2003-04-08 E. I. Du Pont De Nemours & Co. Bristles having varying stiffness
US20030221271A1 (en) * 1998-06-05 2003-12-04 Edwards Mark Stephen Bristle sub-assemblies and method of making same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1087558B (de) * 1956-05-15 1960-08-25 Gustin Bacon Mfg Company Verfahren zum Herstellen von glasfadenverstaerkten Baendern, Streifen, Schnueren od.dgl. und Vorrichtungen zum Durchfuehren des Verfahrens

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1854193A (en) * 1930-08-02 1932-04-19 Hopkinson Ernest Carpet fabric and method of making same
US2475019A (en) * 1944-06-10 1949-07-05 Prodesco Process of making pile yarns and fabrics
US2592201A (en) * 1948-11-15 1952-04-08 Shaw Percy Manufacture of pile fabrics

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1854193A (en) * 1930-08-02 1932-04-19 Hopkinson Ernest Carpet fabric and method of making same
US2475019A (en) * 1944-06-10 1949-07-05 Prodesco Process of making pile yarns and fabrics
US2592201A (en) * 1948-11-15 1952-04-08 Shaw Percy Manufacture of pile fabrics

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4904331A (en) * 1986-10-17 1990-02-27 George-Martin Textiles Limited Apparatus for the manufacture of pile fabrics
WO1999062711A1 (en) * 1998-06-05 1999-12-09 E.I. Du Pont De Nemours And Company Method and apparatus for making articles having bristles
US6096151A (en) * 1998-06-05 2000-08-01 E. I. Du Pont De Nemours And Company Method and apparatus for making articles having bristles
US6269514B1 (en) 1998-06-05 2001-08-07 Du Pont Monofilament bristle assemblies and methods of making brushes using same
US6351868B1 (en) 1998-06-05 2002-03-05 E.I. Dupont De Nemours & Company Bristle sub-assemblies having parallel pairs of bristles; and methods
US6434778B1 (en) 1998-06-05 2002-08-20 E. I. Du Pont De Nemours And Company Monofilament bristle assemblies and methods of making brushes using same
US6543083B1 (en) 1998-06-05 2003-04-08 E. I. Du Pont De Nemours & Co. Bristles having varying stiffness
US20030116258A1 (en) * 1998-06-05 2003-06-26 Edwards Mark Stephen Method and apparatus for making articles having bristles
US20030115703A1 (en) * 1998-06-05 2003-06-26 Edwards Mark Stephen Bristles having varying stiffness
US20030221271A1 (en) * 1998-06-05 2003-12-04 Edwards Mark Stephen Bristle sub-assemblies and method of making same

Also Published As

Publication number Publication date
BE528779A (Sortimente) 1957-03-29
NL84619C (Sortimente) 1957-03-15
DE1025375B (de) 1958-03-06
GB748249A (en) 1956-04-25
FR1104231A (fr) 1955-11-17

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