US3060072A

US3060072A - Backed carpet and method of producing the same

Info

Publication number: US3060072A
Authority: US
Inventors: David B Parlin; William J Elliott
Original assignee: Bigelow Sanford Inc
Current assignee: Bigelow Sanford Inc
Priority date: 1959-11-16
Filing date: 1959-11-16
Publication date: 1962-10-23
Anticipated expiration: 1979-10-23
Also published as: GB894234A; LU38499A1; FR1253594A; CH425360A4; CH372268A; DE1238430B

Description

Oc`t. 23, 1962 D. B. PARLIN Erm.

BACKED CARPET AND METHOD OF PRODUCING THE SAME 2 Sheets-Sheet 1 Filed Nov. 16, 1959 x :3.: :ggg QWKVWKM,

INVENTORS DAVID Bw PQELIN WILLJHM J. ELLIOTT ATTORNEYS Oct. 23, 1962 D. B. PARLIN ETAL BACKED CARPET AND METHOD OF PRODUCING THE SAME 2 Sheets-Sheet 2 Filed NOV. 16, 1959 INVENToRS DAVID B. PQEL/IN gflLLmM J ELLIOTT wedWv/ Qrvjo @News United States Patent 3,060,072 BACKED CARPET AND METHOD F PRDUCWG TIE SAME David B. Parlin, Thompsonvilie, Conn., and William Ii.

Elliott, Longmeadow, Mass., assignors to Bigelow-Sanford, Inc., a corporation of Delaware Filed Nov. 16, 1959, Ser. No. 853,368 Claims. (Q1. 156-72) The present invention relates to backed carpet and the method of producing the same. `lt relates, more particularly, to a backing which is especially useful in conjunction with tufted carpet and the -method of forming such backing on a carpet.

An object of the present invention is to provide a backed carpet which is dimensionally stable and which has substantial bulk or body. Carpet embodying the present invention is substantially immune to shrinkage and thus, can be washed or shampooed without fear of dimensional changes. Another object of the invention is to provide an economical method of forming such a backed carpet.

A further object of the present invention is to provide a method of applying a layer of reinforcing material and the binding of the pile elements to the base of the carpet without materially increasing the cost of the carpet while at the same time producing a carpet of superior quality.

Although the present invention is not necessarily limited to tufted carpet, it is particularly advantageous in conjunction with tufted carpet. Generally speaking, tufted carpet lacks bulk or body and dimensional stability because the pile elements are ordinarily formed on a relatively imsy base, such as burlap or lightweight canvas and the present invention corrects these deficiencies to a large extent. In this connection, it should be noted that it has been customary to apply a backcoating of an adhesive material such as a latex compound to carpet, especially tufted carpet, to bind the pile elements in place and to protect the back of the carpet. However, it has also been found necessary in many instances to apply reinforcing materials of various kinds and thicknesses to the back of the carpet in order to obtain the desired dimensional stability. This of course, adds materially to the cost of the carpet and due to the nature of the reinforcing material has not been entirely satisfactory.

In accordance with the present invention, increased bulk and dimensional stability in the carpet are obtained by attaching a layer of fibrous material to the base of the carpet in such a way that fibers from the layer not only extend into the material forming the base of the carpet but in some instances penetrate the yarns forming the pile elements. An adhesive material in liquid form is then applied to the layer of fibrous material, and the layer of fibrous material with the adhesive thereon is then compacted into a relatively thin layer impregnated with the adhesive material. The adhesive material binds the fibers forming the layer of fibrous material together while at the same time bonding the layer to the base of the carpet and securing the pile elements in place.

Other objects and advantages of the present invention will be apparent and better understood from the following description and the accompanying drawing in which:

FIG. l is a side view in vertical section diagrammatically illustrating a tufted carpet on an enlarged scale;

FIG. 2 is a side view in vertical section diagrammatically illustrating the carpet shown in FIG. l with a layer of fibrous material attached thereto;

FIG. 3 is a side view in vertical section diagrammatically illustrating the carpet of FIG. 2 after final treatment in accordance with and embodying the present invention;

FlG. 4 is a diagram-matic view illustrating the manner attenta Patented Get. 23 1962 ice `ly illustrating a base for a tufted carpet with a layer of fibrous reinforcing material attached thereto;

FIG. 7 is a side view in vertical section diagrammatically illustrating the structure shown in FIG. 6 with tufted carpet loops formed thereon; and

FIG. 8 is a side view in vertical section diagrammaticalp 1y illustrating the carpet in FIG. 7 after treatment in accordance with the present invention.

With reference to the drawings, it will be noted that illustrations are schematic because of the nature of the structures involved. However, the following description when read in conjunction with such illustrations will provide a full and complete understanding of the invention.

As shown in FlG. l of the drawings, there is a tufted pile fabric 1d comprising pile elements 11 in the form of loops which are supported on a base 12 of loosely woven material, such as burlap or a lightweight canvas.

The looped pile elements 11 are formed on the base 12 in the usual manner by a tufting machine with the thread or yarn forming the pile elements extending through the base and beyond the upper face thereof. As shown in FIG. 2, a layer 13 of loosely compacted fibrous material such as jute, nylon, fiber glass or the like, is next attached to the underside of the base of the pile fabric.

The layer 13 of fibrous material is attached to the base of the pile fabric by a needling operation which may be carried out on a needling machine, as indicated in FIG. 4. In such an operation, the fabric is fed forward in inverted position (with the pile facing down) beneath a series of `vertically reciprocating barbed needles 15 with the layer 13 of fibrous material in the form of a web on top of the base of the fabric. The layer of fibrous material is fed onto the pile fabric beneath a guide plate 16 by a rotating feed wheel 17. As the fabric with the layer of fibrous material advances to a point beneath the needles, they are supported on a base plate 18 and they pass beneath a needle plate 19 which contains openings '2G through which the needles pass in movement through the layer of fibrous material and the base of the fabric. The construction of the needling machine and its operation is conventional and need not be described in detail.

The needling of the fibrous layer to the pile fabric is done in a random manner and the needles employed should be smaller in diameter than the strands from which the base of the fabric is formed so that such strands will not be severed and the fabric weakened thereby. The vertical movement of the needles with respect to the fabric will carry some of the fibers from the layer of fibrous material through the base of the fabric, as indicated at 13a, but this movement should be limited so that such fibers will not extend substantially beyond the face of the fabric from which the pile elements extend. In addition, the needles will, in some instances, strike the yarns forming the pile elements, with the result that small punctures or openings are made therein into which fibers from the layer of fibrous material are forced, as indicated at 13b. The penetration of the pile yarns by the fibers in this manner adds to the bulk or body of these elements in the carpet.

The fabric with the layer of fibrous material attached thereto is then treated in accordance with the procedure illustrated in FIG. 5. As shown therein, the fabric with the layer of fibrous material attached thereto is fed from a roll 21 with the pile facing upwardly over a steaming device 22 which directs steam against a layer of fibrous material on the bottom of the fabric to condition it for reception of an adhesive material. The layer of fibrous material is then impregnated with an adhesive material by passing it over a roll 23 4of an adhesive applying device. The -roll 23 with which the layer of fibrous material contacts, is rotatably mounted in a tank 24 and is partially immersed in a supply of suitable adhesive material 25 in liquid form which is capable of penetrating the layer of fibrous material.

The adhesive material used may be a Water-based emulsion of a vulcanizable latex compound containing suitable fillers, pigmenting agents, vulcanizing accelerators, dispersants, antioxidants and the like of the type which are commonly used. The adhesive material should be fluid enough so that it will penetrate the layer of fibrous material readily and it should be of a flexible and rubbery character when cured.

An example of a suitable composition for such an adhesive 1s as follows:

Wet, Dry, lbs. lbs.

Vulcanizable Type 2000 SBR Latex 42% solids (a medlum solids latex containing copolymer of butaldiene and styrene) 760 319 Piccopale A20 (an anionic petroleum hydrocarbon resin emulsion produced by the polymerization of unsaturates occurring in coal tar, light oil and some petroleum distillate fractions and consisting essentially oan indene polymer) used as a modifier to help achieve the desired hand and also serving as an extender for the latex 340 170 Georgia Marble #l (Calcium carbonate type inorgame filler to add stiffness) 500 600 Titanium dioxide-Whitening agent 20() 200 Tamol 731 (40% sodium salt of a carboxylated polyelectrclyte) serving as a dispersng agent for the pigment and the filler 12 3 Sodium silicate (40%) used as pH stabilizer to keep the latex alkalinity high during the filler addition 12 5 Water 86() The formulation of the 319 parts of Type 2000 SBR latex referred to above is as follows:

Dry parts 2000 SBR 100.00 KOH, pH stabilizer to keep latex alkaline 0.25

Wingstay S (alkyl aryl phenol) inhibits degradation and discoloration of the compounded latex The adhesive applying roll 23 preferably rotates in a direction opposite to the movement of the fabric and the layer of brous material. A doctor blade 26 which contacts the bottom of the carpet after application of the adhesive material spreads the coating of adhesive material over the bottom of the carpet uniformly and returns the excess to .the supply tank. Sufficient adhesive material is applied to the back of the carpet to impregnato the layer of fibrous material and to penetrate into the base of the pile fabric and -any small punctures or openings therein.

After the adhesive material has been applied, the layer of fibrous material is then subjected to the action of a burnishing roll 27 which rotates in the same direction as the fabric and the layer of brous material is moving, but at a greater speed. The burnishing wheel compacts the impregnated layer of fibrous material to a thin layer 30 of substantially uniform thickness having a relatively smooth bottom surface and it also aids in forcing the adhesive material through the layer of fibrous material into contact with the base of the pile fabric and into small openings or interstices therein. Thereafter, the adhesive material is dried and cured by passing `fhe fabric with the compacted layer of impregnated fibrous material through a suitable drying and curing oven 28. After leaving the drying and curing oven, the finished carpet may then be wound into a roll 29. Rolls 3S apply tension to the carpet as it passes over the adhesive applying roll and the burnishing roll.

In :the finished carpet, the pile elements are securely bound in place in the base by the adhesive material and the compacted layer 30 of fibrous material is firmly attached to the base by the fibers which extend into the base and the bonding action of the adhesive material. In addition, the adhesive material bonds the fibers of the compacted layer together and imparts substantial strength to it. As a result, the layer of fibrous material resists dimensional changes in the fabric due to stretching, shrinkage or the like.

The web or layer of fibrous material, as initially applied, may have a thickness of approximately one-eighth of an inch or slightly more. After the adhesive material has been applied and the layer has been subjected to the action -of the burnishing wheel, its thickness will have been reduced to one-sixteenth of an inch or less and the individual fibers will be securely bonded together by the adhesive material. This imparts considerable tensile strength to the layer which will resist any tendency of the fabric to stretch or shrink. After burnishing, the lower surface of the layer is relatively smooth and lint free.

The compacted layer of fibrous material not only adds dimensional stability to the carpet and increases its body or bulk, but it also provides a tough flexible covering which protects the base of the fabric and the pile elements formed thereon.

As shown in FiGS. 6, 7, and 8, the construction of the carpet may be modified by first attaching a layer 31 of fibrous material to a base 32 of burlap or the like, by a needling operation and then forming pile elements 33 thereon by a tufting operation. The pile fabric with the layer of fibrous material attached thereto are then subject to the operations described above in conjunction with FIG. 5 so that the layer of fibrous material is impregnated with an adhesive material and is reduced in thickness to form a compacted layer 34.

It will be understood that various other modifications may be made in the embodiments of the invention illustrated and described herein without departing from the spirit or scope of the invention as defined by the following claims.

We claim:

l. Pile carpeting having improved dimensional stability which comprises a base element, a plurality of pile elements supported by and extending from one face of said base Yelement and a dirnensionally stable compacted layer of fibrous material extending over and being permanently secured to an opposite face of the base element, said compacted layer being comprised of fibers distributed at random with fibers therefrom extending into engagement with the base element and a flexible adhesive extending throughout said layer and bonding the fibers of the layer against movement relative to each other in a compacted condition `whereby said layer is rendered dimensionally stable, said adhesive also bonding the layer to the base element of the carpeting and bonding the pile elements to the base element of the carpeting.

2. Pile carpeting having improved dimensional stability which includes a base element comprising a loosely woven material, tufted pile elements formed on said base element, said pile elements having portions extending from one face of the base element and avcompacted layer of fibrous material extending over and being bonded to an opposite face of the base element, said layer being needled to the base element and being comprised of fibers distributed at random with bers therefrom extending into interstices of the woven material forming the base element and a exible adhesive extending throughout said layer and bonding the fibers of the layer against movement relative to each other in a compacted condition, said adhesive also extending into the interstices in the woven material forming the base element and bonding the compacted layer and the pile elements to the base element.

3. Pile carpeting having improved dimensional stability as defined in claim 2 wherein the adhesive penetrates portions of the pile elements through needle punctures therein and lends body thereto.

4. A method of forming pile carpeting having improved dimensional stability which comprises the steps of forming a layer of brous material on a rear face of a piece of pile carpeting having a base and pile elements extending from a front face of the base, applying an adhesive in a flowable state to the layer of brous material, compressing the layer of fibrous material while the adhesive is in a owable state into a compacted condition and simultaneously forcing the adhesive throughout the layer and into the base of the pile carpeting, and then drying the adhesive whereby the bers of the layer are bonded together in a compacted condition and the layer is bonded to the base of the pile carpeting.

5. A method of forming pile carpeting as defined in claim 4 wherein the layer of fibrous material is formed on the rear face of the carpeting by a needling operation, said needling forming punctures in the pile elements and the adhesive material is forced into the pile elements through said punctures in compressing the layer to a cornpacted condition.

References Cited in the le of this patent UNITED STATES PATENTS 1,825,827 Smith Oct. 6, 1931 2,303,203 Faris et al Nov. 24, 1942 2,349,236 Bodle May 23, 1944 2,675,337 Walker et al Apr. 13, 1954 2,913,803 Dodds Nov. 24, 1959 UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3,060,072 October 23, 1962 David Bo Parlin et al.l

It is hereby certified that error appears in the above numbered patent requiring correction and theft the said Letters Patent should read as corrected below.

Column 3, in the example, first column, line 2 thereof,

before "copolymer" insert a same example, under the heading Dry, 1bs", last line, for the total "1,19" read M197 Signed and sealed this 2nd day of April 1963.,

(SEAL) Attest:

ESTON G. JOHNSON DAVID L, LADD Commissioner of Patents Attesting Officer

Claims

1. PILE CARPETING HAVING IMPROVED DIMENSIONAL STABILITY WHICH COMPRISES A BASE ELEMENT, A PLURALITY OF PILE ELEMENTS SUPPORTED BY AND EXTENDING FROM ONE FACE OF SAID BASE ELEMENT AND A DIMENSIONALLY STABLE COMPACTED LAYER OF FIBROUS MATERIAL EXTENDING OVER AND BEING PERMANENTLY SECURED TO AN OPPOSITE FACE OF THE BASE ELEMENT, SAID COMPACTED LAYER BEING COMPRISED OF FIBERS DISTRIBUTED AT RANDOM WITH FIBERS THEREFROM EXTENDING INTO ENGAGEMENT WITH THE BASE ELEMENT AND A FLEXIBLE ADHESIVE EXTENDING THROUGHOUT SAID LAYER AND BONDING THE FIBERS OF THE LAYER AGAINST MOVEMENT RELATIVE TO EACH OTHER IN A COMPACTED CONDITION WHEREBY SAID LAYER IS RENDERED DIMENSIONALLY STABLE, SAID ADHESIVE ALSO BONDING THE LAYER TO THE BASE ELEMENT OF THE CARPETING AND BONDING THE PILE ELEMENTS TO THE BASE ELEMENT OF THE CARPETING.

4. A METHOD OF FORMING PILE CARPETING HAVING IMPROVED DIMENSIONAL STABILITY WHICH COMPRISES THE STEPS OF FORMING A LAYER OF FIBROUS MATERIAL ON A REAR FACE OF A PIECE OF PILE CARPETING HAVING A BASE AND PILE ELEMENTS EXTEND-DING FROM A FRONT FACE OF THE BASE, APPLYING AN ADHESIVE IN A FLOWABLE STATE TO THE LAYER OF FIBROUS MATERIAL, COMPRESSING THE LAYER OF FIBROUS MATERIAL WHILE THE ADHESIVE IS IN A FLOWABLE STATE INTO A COMPACTED CONDITION AND SIMULTANEOUSLY FORCING THE ADHESIVE THROUGHOUT THE LAYER AND INTO THE BASE OF THE PILE CARPETING, AND THEN DRYING THE ADHESIVE WHEREBY THE FIBERS OF THE LAYER ARE BONDED TOGETHER IN A COMPACTED CONDITION AND THE LAYER IS BONDED TO THE BASE OF THE PILE CARPETING.