US3019508A - Cushioned carpeting and method of making the same - Google Patents

Cushioned carpeting and method of making the same Download PDF

Info

Publication number
US3019508A
US3019508A US76794958A US3019508A US 3019508 A US3019508 A US 3019508A US 76794958 A US76794958 A US 76794958A US 3019508 A US3019508 A US 3019508A
Authority
US
United States
Prior art keywords
backing
carpeting
pile
pad
cushioned
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
Other languages
English (en)
Inventor
Henry A Reinhardt
David B Parlin
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.)
Bigelow Sanford Inc
Original Assignee
Bigelow Sanford Inc
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 LU38054D priority Critical patent/LU38054A1/xx
Application filed by Bigelow Sanford Inc filed Critical Bigelow Sanford Inc
Priority to US76794958 priority patent/US3019508A/en
Priority to GB2882859A priority patent/GB870324A/en
Priority to FR805314A priority patent/FR1235231A/fr
Priority to DEB54888A priority patent/DE1155086B/de
Application granted granted Critical
Publication of US3019508A publication Critical patent/US3019508A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/07—Lubricating the moulds
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • Y10T428/23964—U-, V-, or W-shaped or continuous strand, filamentary material
    • Y10T428/23971—Continuous strand with adhesive bond to backing
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • the present invention relates to cushioned carpeting j and method of making the same.
  • the present invention relates, more particularly, to cushioned carpeting which includes a pile fabric having a back coating and a cushion detachably attached thereto and the method of making l the same.
  • An object of the present invention is to provide a cushioned carpet which can be produced at low cost and which -has improved Ifeel and draping qualities.
  • the present invention is particularly useful in attaching a cushion or pad to a back coated carpet such as a carpet of the tufted type where the pile is formed on a loosely woven fabric, such as burlap, light-weight duck or the like, with the pile elements being held or locked in place by a coating of latex or other suitable back coating compound.
  • a cushioning material is attached thereto in accordance with the present invention, it has been found that the thickness or weight of the layer of coating material may be reduced considerably without adversely affecting the feel or handle of the carpeting.
  • this invention eliminates the need for an open mesh burlap or similar support for making a needled jute underlay separately.
  • cushioned carpeting made in accordance with the present invention can be produced at lower cost than carpeting and cushioning when produced separately.
  • the cushioning material is secured to the carpeting in such a way that it can be readily delaminated so as to permit taped or sewn seams or joints to be made between adjoining sections of cushioned carpeting made in accordance with the invention.
  • the incorporation of the cushioning material as part of the composite carpet structure in accordance with the present invention makes it unnecessary for the user to purchase and install cushioning material separately.
  • the cushioning material when the cushioning material is formed as part of the carpeting in accordance with the present invention, it will conform accurately in size to the carpeting and its accumulated bulk and weight will resist any tendency for the carpeting to be sucked up by a vacuum cleaner.
  • this invention provide the additional advantage of reducing the tendency of the carpet to pucker; it reduces the shrinkage normally resulting from wet shampooing of tufted products. it also enhances the drapability of the product whereby it readily and conveniently conforms to uneven surfaces.
  • FIG. 1 is a side elevation view of cushioned carpeting embodying and made in accordance with the present invention
  • FIG. 2 is a fragmentary longitudinal section view with parts broken away at different planes of the carpeting shown in FIG. 1, but on an enlarged scale;
  • HG. 3 is a fragmentary section view taken along the line 3 3 of FIG. 2 with parts broken away;
  • FIG. 4 is an end elevation illustrating a joint between two sections of the carpeting shown in FG. l;
  • FIG. 5 is a diagrammatic longitudinal sectional view of a machine for attaching the cushion to the carpeting in accordance with the present invention.
  • FIG. 6 is a diagrammatic view illustrating the size of a needle of the machine shown in FlG. 5 in comparison with a strand of the backing material.
  • the carpeting 1d comprises a pile fabric of the tufted type in which pile elements in the form of stitched loops l1 are sewn on a backing 12 of loosely woven material such as burlap, lightweight duck or the like.
  • the pile loops extend from one face of the backing and the other ⁇ face of the backing has a backcoating applied thereto.
  • the backcoating is a relatively thin layer 13 of a latex compound or other suitable adhesive material which binds or anchors the loops 11 of the pile fabric to the backing 12.
  • the backcoating 13 which is applied to the backing can be considerably thinner and lighter in weight than the backcoating usually used for tufted carpeting.
  • a backcoating weighing about l5 ounces per square yard may be employed satisfactorily in carpeting embodying the present invention as compared to a backcoating weighing about 2l ounces per square yard which is conventionally used on such fabric.
  • the coating compounds used for this purpose represent a substantial item of cost and the reduction in the amount of the coating made possible by the present invention represents an irnportant saving.
  • the backcoating retain a rubbery or iiexible texture when it is dry so that it is not brittle or subject to crumbling during further processing of the carpeting in accordance with the present invention.
  • the cushioned carpeting lil* also includes a cushion or pad 14 of a fibrous material such as jute, which is attached to the rear or coated face of the backing by a needling operation in such a way that the pad can be readily stripped or delaminated from the ybacking to permit a suitable seam or joint to be formed between adjoining sections of the cushioned carpeting.
  • a cushion or pad 14 of a fibrous material such as jute
  • the needling operation by which the pad or cushion 14 is attached to the coated pile yfabric may be carried out on a conventional needling machine of the type ordinarily used for forming pads or cushions of jute or similar brous material. ln this machine, the tufted pile fabric with the backcoating thereon is carried in inverted position by a belt 1d and passes between a pair of perforated needle plates 17. Before enlaces the pile Ifabric reaches the needle plates, a bat of fibrous material from which the pad or cushion is formed is laid on top of the coated rear face of the fabric and is then carried between the needle plates and the fabric.
  • a series of barbed needles 1:2 which extend across the machine and are carried by a needle frame i9 are reciprocated vertically with respect to the fabric and the cushion.
  • the barbs f tia on the needles engage with and carry fibers of the rfibrous material downward.
  • fibers ⁇ from the portion of the pad contacting the backing are forced at random through the coating and the woven backing material.
  • the needling forms the cushion and at the same time, attaches the cushion to the pile fabric.
  • the penetration o-f the needles should lbe limited so that the fibers on which the needles act will extend as short a distance as possible beyond the front face of the woven backing material.
  • the needles of smaller diameter than the strands from which the backing material is woven should be used in order to prevent damage to the structure of the backing material.
  • the baclrcoating has a tendency to hold the strands from which the backing material is woven in a fixed position during the needling operation and if the needles are of a larger diameter than the strands of the backing material, the strands may be completely severed if they happen to be struck by the needles. lf the strands of the backing are severed in this manner, it seriously weakens the carpeting and causes it to rip or tear easily.
  • FIG. 6 A comparison of a suitable size of needle with a strand of the backing material is illustrated in FIG. 6.
  • a suitable arrangement in this respect is to use a No. 30 needle with l0 ounce, l5 x i3 weave burlap backing.
  • lt should be noted in this connection, that in actual practice the spacing of the pile elements and the location of the fibers from the pad in relation to the baclcn@ may vary somewhat due to the manner in which a tufted product is made and the random manner in which the pad is attached thereto in accordance with the present invention.
  • the pad can be attached to the pile fabric at the time it is formed without additional cost and the cost of a separate support or carrying member for the cushion is eliminated. In addition, separate handling of the cushion or padis also eliminated.
  • the bottom surface may be finished by spraying it with a material such as water glass (silicate of soda) and then burnishing it with a smooth roll to prevent the pad from shedding heavily and to improve the feel or handle of the carpeting.
  • a material such as water glass (silicate of soda) and then burnishing it with a smooth roll to prevent the pad from shedding heavily and to improve the feel or handle of the carpeting.
  • the cushioned carpeting described above is a laminated structure which comprises a pile fabric, a backcoating and a cushion or pad of fibrous material attached thereto in a manner which permits delamination of the cushion from the coated pile fabric. While the invention has been illustrated and described herein in conjunction with a tufted type of pile fabric, it will be understood that the present invention is equally applicable to other types of pile fabrics either with or without backcoatings.
  • a cushioned carpet which comprises a pile fabric having a front face and a rear face with pile elements extending from the front face thereof; a backcoating of adhesive material applied to the rear face of the pile fabric; and a pad of fibrous material contacting with the baclrcoating on the rear face of the pile fabric, said fibrous pad having fibers extendin T through the backcoating and the pile fabric but not substantially beyond the front face thereof whereby the pad may be readily stripped from the baclrcoating.
  • a cushioned carpet comprising a pile fabric which includes a woven backing, said backing having a front face and a rear face with pile elements extending from the front face thereof, a coating of adhesive material applied to the rear face of the woven backing; and a pad of fibrous material extending over and contacting with the coated rear face of the backing, said pad including bers extending through the coating and interstices in the woven backing but not substantially beyond the front face of the backing whereby the pad is readily removable from the backing.
  • a cushioned carpet comprising a pile fabric which includes a loosely woven backing having a front face and a rear face and tufted pile elements extending from the front face of said backing; a thin coating of adhesive material applied to the rear face of the backing and binding the tufted pile elements thereto; and a pad of fibrous material removably attached to the coated rear face of the backing, said pad including fibers extending through said coating and interstices in the loosely woven backing but not substantially beyond the front face of the backing.
  • a cushioned carpet comprising a pile fabric which includes a loosely woven backing having a front face and a rear face with tufted pile elements extending from the front face thereof and a thin coating of adhesive material applied to the rear face of the backing and binding the tufted pile elements thereto, the improvement which comprises a pad of fibrous material removably attached to the coated rear face of the backing, said pad including fibers extending through said coating and interstices in the loosely Woven backing but not substantially beyond the front face of the backing.
  • the method of removably attaching a cushioning layer of fibrous material to the back of a pile carpet having a backing element with pile elements extending from the front face thereof and a backcoating applied to the back thereof which comprises forcing fibers from a layer of fibrous material in contact with the back of the carpet through the backcoating and the backing by means of barbed needles with the movement of said needles beingl restricted so that said bers extend only a relatively short distance beyond the front face of the backing and do not support the pile elements.
  • a cushioning layer of fibrous material to the back of tufted carpeting having a backing formed of woven strands with pile elements extending from the front thereof and a backcoating adhered to the back thereof
  • the improvement which comprises forcing fibers from the layer of brous material through the backcoating and the backing by means of barbed needles with the movement of said needles being restricted so as not to carry said fibers beyond the base of the pile elements extending from the front of the backing, said needles being smaller in diameter than the strands forming the backing whereby said strands Will not be severed by movement of the needles through the backing.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Laminated Bodies (AREA)
US76794958 1958-10-17 1958-10-17 Cushioned carpeting and method of making the same Expired - Lifetime US3019508A (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
LU38054D LU38054A1 (nl) 1958-10-17
US76794958 US3019508A (en) 1958-10-17 1958-10-17 Cushioned carpeting and method of making the same
GB2882859A GB870324A (en) 1958-10-17 1959-08-24 Cushioned carpeting and method of making the same
FR805314A FR1235231A (fr) 1958-10-17 1959-09-17 Tapis rembourrés, et procédé pour les fabriquer
DEB54888A DE1155086B (de) 1958-10-17 1959-09-22 Polsterteppich und Verfahren zum Herstellen desselben

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US76794958 US3019508A (en) 1958-10-17 1958-10-17 Cushioned carpeting and method of making the same

Publications (1)

Publication Number Publication Date
US3019508A true US3019508A (en) 1962-02-06

Family

ID=25081062

Family Applications (1)

Application Number Title Priority Date Filing Date
US76794958 Expired - Lifetime US3019508A (en) 1958-10-17 1958-10-17 Cushioned carpeting and method of making the same

Country Status (5)

Country Link
US (1) US3019508A (nl)
DE (1) DE1155086B (nl)
FR (1) FR1235231A (nl)
GB (1) GB870324A (nl)
LU (1) LU38054A1 (nl)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3707746A (en) * 1971-06-03 1973-01-02 Du Pont Process of preparing a tufted product
WO1994020283A1 (en) * 1993-03-12 1994-09-15 American Rug Craftsmen, Inc. Custom fabricated and bordered rug
US5630896A (en) * 1992-05-01 1997-05-20 Hoechst Celanese Corporation Method of making recyclable tufted carpets
US6105223A (en) * 1997-04-30 2000-08-22 The B. F. Goodrich Company Simplified process for making thick fibrous structures

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3904526C2 (de) * 1989-02-15 1993-10-07 Dietrich Boelling Bodenbelag und Verfahren zu seiner Herstellung

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1816574A (en) * 1929-03-07 1931-07-28 Mechanical Rubber Co Pile or tufted sheet fibrous material
US2706324A (en) * 1953-03-13 1955-04-19 Mohawk Carpet Mills Inc Pile fabrics and method for making them
US2810950A (en) * 1956-04-17 1957-10-29 Mohasco Ind Inc Tufted pile fabrics

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1825827A (en) * 1924-10-16 1931-10-06 Lea Fabrics Inc Single texture fabric and process of making the same
US2331321A (en) * 1941-02-28 1943-10-12 Beckwith Mfg Co Process of making composite fabric
FR64356E (fr) * 1952-07-12 1955-11-10 Pièce textile

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1816574A (en) * 1929-03-07 1931-07-28 Mechanical Rubber Co Pile or tufted sheet fibrous material
US2706324A (en) * 1953-03-13 1955-04-19 Mohawk Carpet Mills Inc Pile fabrics and method for making them
US2810950A (en) * 1956-04-17 1957-10-29 Mohasco Ind Inc Tufted pile fabrics

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3707746A (en) * 1971-06-03 1973-01-02 Du Pont Process of preparing a tufted product
US5630896A (en) * 1992-05-01 1997-05-20 Hoechst Celanese Corporation Method of making recyclable tufted carpets
WO1994020283A1 (en) * 1993-03-12 1994-09-15 American Rug Craftsmen, Inc. Custom fabricated and bordered rug
US6105223A (en) * 1997-04-30 2000-08-22 The B. F. Goodrich Company Simplified process for making thick fibrous structures

Also Published As

Publication number Publication date
LU38054A1 (nl)
DE1155086B (de) 1963-10-03
FR1235231A (fr) 1960-07-01
GB870324A (en) 1961-06-14

Similar Documents

Publication Publication Date Title
US3922454A (en) Secondary backing for carpeting
US3862522A (en) Needled scouring pad
US2866206A (en) Pile fabric with resilient lining
US4307145A (en) Decorative fabric and method of making the same
US2552114A (en) Carpet joining device and method
US2580202A (en) Reinforced fibrous porous cushioning material
US4242394A (en) Reinforced primary backing for tufted pile fabrics
JPH06346356A (ja) ベロアニードルフエルトの製造方法
US2706324A (en) Pile fabrics and method for making them
US3337387A (en) Stitched and needled non-woven fabric
US3019508A (en) Cushioned carpeting and method of making the same
US2458588A (en) Upholstery pad
JPH05230755A (ja) 不織布積層材
US2810950A (en) Tufted pile fabrics
GB894234A (en) Backed carpet and method of producing same
US3257259A (en) Method of making non-woven fabrics
TW415983B (en) Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
US3535178A (en) Method of producing tufted pile fabric and nonwoven backing fabric for the same
US2303203A (en) Carpet
US2512727A (en) Pile fabric
US3635786A (en) Laminated nonwoven fabric utilizing a foam layer and a stitched fibrous layer
GB450689A (en) Improvements relating to the manufacture of padding, particularly for upholstery, from cotton wool or like fibrous material
US2755215A (en) Method of making reinforced fibrous porous cushioning material
US3459631A (en) Bendable,high loft,bonded,non-woven,textile fabric
US3059598A (en) Tufted fabric