US3066513A - Knitted carpet - Google Patents

Description

H. S. LEYBOURNE KNITTED CARPET Filed March 28, 1960 ilnited States Patent Ofifice 3,65 6,513 Patented Dec. 4, i62

3,066,513 KNITTED CARPET Harold S. Leyhourne, Wiilowdale, Ontario, Canada, as-

signor to Texama Limited, Toronto, Ontario, Canada, a corporation of Ontario, Canada Filed Mar. 28, 1960, Ser. No. 18,128 1 Claim. (Cl. 66--10) This invention relates to improvements in floor coverings or carpets.

More particularly, the invention relates to a knitted floor covering or carpet having a durable resilient backing of sponge rubber or like material.

It is believed that the particular floor covering described herein has never been successfully accomplished before. An aspect which makes it particularly feasible and attractive to the consumer is the addition of the foam rubber or similar backing.

The main disadvantage in the provision of the thick living room or executive type of carpet presently obtainable is decidedly one of expense. Carpets of this type are almost out of reach of the average mans income at the present time.

The present invention is comparatively cheap and extremely useful. It is also wear resistant and will fill a public need from the standpoint of economy.

Therefore, an object of this invention is to provide the combination of a knitted carpet having a resilient backing of sponge rubber, or the like, which will also act to prevent slipping or creeping of the carpet.

According to the present invention a floor covering or the like comprises an intermediate ply of a weft knitted fabric defining a surface backing ply, a surface ply or layer of pile yarns laid in one surface of the weft knitted fabric, there being at least two pile yarns interconnected to each course of the knitted fabric, without being knitted, at spaced points along the course, and a base layer integrally combined or bonded with the opposite surface of the weft knitted fabric. The pile yarns are raised and define a pile surface on the side of the intermediate layer or pile opposite the base layer.

There is no special novelty residing in the process involved in the production of the present invention or the machinery employed in the process. Applicant has knitted a circular knitted fabric with the kinds of materials normally used in carpets rather than the kinds and types normally used on knitting machines. This is believed to be a complete departure from the previous uses of a circular knitting machine.

In the process of producing the present invention, it has been found preferable to obtain a blend comprising approximately 70% nylon and 30% rayon. This ratio provides an end product which Wears particularly well and has a very good appearance. Having obtained this ratio the blended fibres are then subjected to a carding process. This process will be well known to a man skilled in the art.

Following the carding process the blended fibers in the form of strands of material are wound onto spinning frames and subjected to a cone 'winding process. At this stage of the process, the individual blended strands of fibres are wound onto separate cone shaped holders. The fibre holding cones are then set up on a conventional circular knitting machine along with a series of cotton holding cones. The circular knitting machine operates in a manner well known to a man skilled in the art. The presence of the cotton in the knitting process provides a knitted fabric having a cotton backing in which the nylonrayon yarns are incorporated without being themselves knitted. Nylon or acrilon may also be used to provide an intermediate ply or backing instead of cotton. The

circular knitted fabric is then subjected to a scouring or cleansing treatment after which the fabric is opened to a fiat width for processing. This step is followed by a napping operation or pile rising, and it is one in which care must be given in order to obtain the full rich cover desired and needed for the end use of the fabric. The length of the pile is then established by a close shearing or cropping process in order to obtain the desired pile height.

The accompanying drawing shows how the layin is formed in the loops in the knitting process. The pile yarns are designated A and define the surface ply while the knitted threads of the weft knitted fabric are desig nated B and are of 1/ l6s carded cotton dyed to resemble, as nearly as possible, the facing of the finished carpet. As has been said the layin A is made up of a blend consisting of approximately nylon and 30% rayon. The rayon is dope dyed and the nylon kettle dyed. This unusual blending of fibres prepared on the conventional woolen yarn system yields a thread which is very strong, lofty and adapts itself to future operation and end result.

It will be appreciated that various other fibres, ratios and blends may be employed, for instance, mohair or any synthetic or animal fibre may be used but it has been found that a ratio of approximately 70% nylon and 30% rayon produces the best results.

An important feature in the manufacture of the invention is the manner in which the cotton back and the pile yarns, which are the face, are inter-connected, thus forming a firm fabric 'which will withstand the action of raising the pile.

The foam rubber backing or base layer C may be applied directly to the back of the fabric and spread by means of a doctor blade. The foam is then cured on the fabric in drying ovens. A sponge rubber could also be employed as the backing or base layer C for the knitted carpet and in this event it would be applied by a calender roll.

The nature of the backing layer C may vary with the preference of the manufacturer. While a wide variety of plastics and elastomers may be used such as rubber and synthetic rubber in unaerated form, polyvinyl chloride, and the like, it has been found best to employ aerated plastics and elastomers such as sponge or foam rubber.

It will be understood that the employment conditions of vulcanizing will depend on the character of the backing material which is employed.

A sponge or foam backing produces a very desirable resiliency in the tread of the carpet.

The sponge rubber backing or base layer C may also be applied to the underside of the cotton backing by vulcanized rubber cement or by any other suitable adhesive. In this event, the fabric is first knitted as described and then the backing is coated with an application of cementitious binding material. The sponge rubber layer C which has been cut to size is then applied to the cement and the cement is allowed to set for a reasonable period to secure adhesion. After vulcanization, the composite carpets are trimmed to exact size as required.

It may be restated in conclusion that during the knitting and finishing process of the fiber yarns, the blended pile yarn is combined with the intermediate ply of knitted cotton strands after which the resilient base layer or ply is integrally bonded to form a finished carpet being of fine appearance, resilient, and extremely wear resistant.

I claim:

A floor covering or the like comprising: a fiat intermediate ply including a weft knitted fabric having courses and wales, a surface ply on one side of said weft knitted fabric and including at least two pile yarns laid in each course of said weft knitted fabric, one of said two pile yarns of each course being interconnected to the course without being knitted at spaced points along the course and the other of said two pile yarns of each course being interconnected to the course 'Without being knitted at spaced points along the same and at spaced points from the points of interconnection of said one pile yarn, said pile yarns being raised and defining apile surface for the floor covering, and a resilient base layer ply integrally bonded to the opposite side of the Weft knitted fabric.

References Cited in the file of this patent UNITED STATES PATENTS Bellis June 9, 1896 Hall Oct. 30, 1945 Dildilian Aug. 23, 1949 Rice Nov. 28, 1950 Stahl Dec. 23, 1952 Deiss et al June 3, 1958

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