US3377973A - Tufting method and article - Google Patents

Tufting method and article Download PDF

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Publication number
US3377973A
US3377973A US47001365A US3377973A US 3377973 A US3377973 A US 3377973A US 47001365 A US47001365 A US 47001365A US 3377973 A US3377973 A US 3377973A
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US
United States
Prior art keywords
yarns
warp
backing
fabric
primary
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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
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English (en)
Inventor
Joseph C Whitesel
Henry D Dawbarn
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WR Grace and Co
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WR Grace and Co
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Filing date
Publication date
Priority to GB1143817D priority Critical patent/GB1143817A/en
Application filed by WR Grace and Co filed Critical WR Grace and Co
Priority to US47001365 priority patent/US3377973A/en
Priority to DE19661685122 priority patent/DE1685122C/de
Priority to BE683612D priority patent/BE683612A/xx
Priority to FR1574661D priority patent/FR1574661A/fr
Priority to NL6609314A priority patent/NL6609314A/xx
Priority to FR139313A priority patent/FR95484E/fr
Application granted granted Critical
Publication of US3377973A publication Critical patent/US3377973A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2321/00—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D10B2321/02—Fibres made from polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds polyolefins
    • 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

Definitions

  • This invention relates to primary backings for tufted pile fabrics, tufted pile fabrics comprising such primary backings, and to methods for preparing the backings and the tufted pile fabrics.
  • the present invention permits the provision of a pile fabric having much lower pile projections, particularly in a loop pile construction, than has previously been possible and still produce a commercially saleable fabric.
  • Another object of this invention is to provide relatively strong tufted pile fabric comprising a primary backing of synthetic plastic material.
  • Still .another object of the present invention is to provide ia method for increasing the fabric strength and quality of tufted pile fabrics comprising a synthetic plastic primary backing material.
  • the axes of the yarns in one of the pluralities of yarns in woven primary backings adapted for use in tufted pile fabrics are at an angle of from about 3 to about 10 degrees (preferably about 7 degrees), from a right angle to the axes of the other of the pluralities of yarns.
  • the ases of the lill yarns are at an angle to the axes of the warp yarns, so that the bank of tufting needles in the usual tufting machines (c g., about 1400 needles in a 12 foot span) will strike at least several different fill yarns in each reciprocal piercing operation, reducing the incidence of lill yarn shattering and thus increasing the fabric strength of the tufted pile fabric product.
  • the present invention provides primary backings as Adescribed, tufted pile fabrics comprising such backings, and methods for making the backings and tufted pile fabrics.
  • FIGURE l is a bottom view, on an enlarged scale, schematically illustrating a tufted pile fabric of the present invention
  • FIGURE 2 is a cross sectional view taken substantially on the line 2-2 of FIGURE 1;
  • FIGURE 3 is a bottom view like that of FIGURE l schematically illustrating several modifications thereof.
  • FIGURE 4 is a plan view, on an enlarged scale, schematically illustrating a woven primary backing of the present invention.
  • one form of tufted pile fabric is made up of a primary backing comprised of a plurality of closely spaced, relatively flat (i.e., essentially rectangular cross section) polyolen warp yarns 2 and a plurality of closely spaced, relatively flat polyolefin fill yarns 1; and rows of tufting material 3 piercing the yarns of the primary backing.
  • the lill yarns '1 are lbiased at an angle of from about 3 to about 10 degrecs (preferably about 7 degrees) to the warp yarns 2.
  • the tuftng stitches in any single row perpendicular to the axes of the warp yarns occur in at least several different till yarns (see FIGURE 2).
  • FIGURE 3 illustrates possible variations of the construction of FIGURES 1 and 2. Thus it is permissible'to originally form ribbons much wider than the iin-al desired width and to fold these one or more times to provide U- shaped or Z-shaped cross-sections.
  • the upper portion of FIGURE 3 illustrates the use of folded U-shaped till yarns 4 with unfolded warp yarns 5.
  • the lower portion of FIGURE 3 illustrates the use of folded U-shaped fill yarns 4 with folded U-shaped warp yarns 6.
  • the tufting 3 is like that shown in FIGURES 1 and 2.
  • FIGURE 3 In connection with FIGURE 3 it will be understood that folded ribbons will be used as lill yarns or warp yarns or both ll and Warp yarns throughout the primary backing and that FIGURE 3 is merely an illustration of these variations as opposed to an illustration of an actual tufted pile fabric.
  • relatively round monoor multifilament warp yarns 8 are used with relatively round monoor multitilament fill yarns 7 to form a primary backing. As in the other illustrationsthe till yarns are biased at an angle of from about 3 to about 10 ⁇ degrees from a right angle to the Warp yarns.
  • the individual yarns in the primary backings and tufted pile fabrics of this-invention can be comprised of any polyolen such as polyethylene, polypropylene, copolymers of ethylene and propylene and the like.
  • the yarns whether they be relatively flat, relatively round, foamed, unfoamed, folded or unfolded, are comprised of polypropylene.
  • the individual relatively at yarns 1 and 2 may have an individual denier of from about 300 to about 2000. Preferably individual denieris from about 350 to about 1200 and most preferably about 400 to about 1100, eg., 1080. These yarns, as is the usual oase, are oriented during 4 manufacture by stretching from about 4 to about 10 (e.g., 5, 51/2 or 6 times) times the length as originally extruded or otherwise shaped.
  • the width of the relatively at yarns may range from about 20 to about 110 mils (i.e., 0.020 to 0.110 inch) with corresponding thicknesses of from about 6 to 8 mils down to about 2 or 21/2 mils.
  • a typical relatively at yarn used in the embodiment illustrated is a 1080 denier polypropylene ribbon of essentially rectangular cross section, about 100 to 105 mils wide and 2 to 21/2 mils thick. The following tabulation indicates the variation in make-up of the primary backing with the varying deniers (relaively flat, unfoamed ribbons in all cases):
  • a typical preferred woven primary backing of the type illustrated in FIGURES 1 and 2 is made from 1080 denrer polypropylene ribbon as both the warp yarns and the ll yarns.
  • the denier of the warp yarns 8 may range from about 70 to about 800.
  • the warp yarns are from about 100 to about 600 and most preferably from about 200 to about 500 denier, e.g., about 400 denier.
  • the ll yarns 7 on the other hand should have an individual denier of from about 600 to about 1100.
  • the denier of the ll yarns should be about 700 to .about 1000 and most preferably about 750 to about 900, e.g., 800.
  • relatively at yarns of foamed polypropylene having a density of from yabout 0.4 to about 0.85, more preferably about 0.58 to about 0.78, may also be used.
  • Most especially preferred are relatively at foamed polypropylene yarns having a density of from about 0.65 to about 0.75, e.g., 0.68 or 0.70.
  • Denier of foamed polypropylene ribbons may be from about 300 to about 2000, preferably about 350 to about 1200 and most preferably from about 400 to about 1100, e.g., 750 or 1000.
  • Typical of such foamed polypropylene ribbons are ones having a density of 0.68, about 980 denier, 3 mils thick and mils wide; or having a density of about 0.70,
  • the bias angle between the axes of the respective warp and fill yarns is most readily accomplished by tentering in the usual manner with slight modification.
  • tentering in the usual manner with slight modification.
  • bias is preferably imparted to the ll yarns and is in the range of from about 3 to about degrees. Bias angles lower than 3 degrees do not provide substantial fabric strength increase. Bias angles greater than 10 degrees could be used but provide no substantial further benefits and may result in increased wastage.
  • the preferred bias angle is about 7 degrees.
  • Heat setting temperatures for primary backings comprised of polypropylene yarns are from about 270 to about 310 Fahrenheit.
  • the preferred heat setting cycle is about 30 seconds at a temperature of about 290 Fahrenheit.
  • the primary backings of this invention can be woven and tufted in conventional manner with commercially available equipment. Typical tufting procedures will give about 6 to 10 (e.g., 7) tufts per inch of ll and about 5 to 10 (e.g., 6 or 8) rows of tufting per inch of warp.
  • Method for producing tufted pile fabrics having increased fabric strength comprising weaving the primary backing with polyolen warp and fill yarn, biasing said warp and till yarns relative to one another at an angle more than 3 degrees prior to tufting; inserting rows of tufts in said primary back with each row extending diagonally across more than one of said warp and ll yarns and perpendicular to said other wrap and fill yarns.
  • a tufted pile fabric comprising a woven primary backing, said backing woven of polyolen yarn with the warp yarns closely spaced and of substantially uniform dimension and the fill yarns of substantially uniform dimension with the axes of one of said warp and ll yarns at an angle of from about 3 to about 10 degrees from a right angle to the axes of the other of said yarns; rows of tufts engaged through said primary backing and extending diagonally across more than one of said warp and ll yarns and perpendicular to said other warp and ll yarns.
  • the tufted fabric of claim 6 wherein the yarns are comprised of polypropylene, the warp yarns have an individual denier of from 400 to 1100 and the fill yarns have an individual denier of from about 700 to about 960 and the primary backing has about l2 fill ends per inch.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Woven Fabrics (AREA)
  • Carpets (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
US47001365 1965-07-07 1965-07-07 Tufting method and article Expired - Lifetime US3377973A (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
GB1143817D GB1143817A (enrdf_load_stackoverflow) 1965-07-07
US47001365 US3377973A (en) 1965-07-07 1965-07-07 Tufting method and article
DE19661685122 DE1685122C (de) 1965-07-07 1966-07-01 Grundgewebe für Tuftfederzeugnisse
BE683612D BE683612A (enrdf_load_stackoverflow) 1965-07-07 1966-07-04
FR1574661D FR1574661A (enrdf_load_stackoverflow) 1965-07-07 1966-07-04
NL6609314A NL6609314A (enrdf_load_stackoverflow) 1965-07-07 1966-07-04
FR139313A FR95484E (fr) 1965-07-07 1968-02-08 Canevas primaires, tissus a poil en touffes comprenant ces canevas, et procédés pour la préparation des canevas et des tissus.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US47001365 US3377973A (en) 1965-07-07 1965-07-07 Tufting method and article

Publications (1)

Publication Number Publication Date
US3377973A true US3377973A (en) 1968-04-16

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ID=23865948

Family Applications (1)

Application Number Title Priority Date Filing Date
US47001365 Expired - Lifetime US3377973A (en) 1965-07-07 1965-07-07 Tufting method and article

Country Status (5)

Country Link
US (1) US3377973A (enrdf_load_stackoverflow)
BE (1) BE683612A (enrdf_load_stackoverflow)
FR (1) FR1574661A (enrdf_load_stackoverflow)
GB (1) GB1143817A (enrdf_load_stackoverflow)
NL (1) NL6609314A (enrdf_load_stackoverflow)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3654884A (en) * 1969-12-11 1972-04-11 Thiokol Chemical Corp Tufted pile fabric
US3788364A (en) * 1971-09-13 1974-01-29 Thiokol Chemical Corp Tufted pile fabrics and backings therefor
US3913510A (en) * 1974-01-24 1975-10-21 Conwed Corp Tufted carpets with elastomeric net backing
US20050260380A1 (en) * 2004-05-20 2005-11-24 Moon Richard C Tuftable carpet backings and carpets with enhanced tuft holding properties

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1227426A (en) * 1917-02-08 1917-05-22 Charles Schwartz Tire-casing.
US3106507A (en) * 1958-04-03 1963-10-08 Electric Storage Battery Co Expanded fabric-like material composed of core yarns
US3110905A (en) * 1961-09-26 1963-11-19 Lees & Sons Co James Tufted pile fabric comprising a flat woven synthetic plastic backing
US3237578A (en) * 1960-12-06 1966-03-01 Deutsche Linoleum Werke Ag Machine for making pile fabric formed by tufts of yarn on a web of backing material
US3317366A (en) * 1962-05-18 1967-05-02 Beaunit Corp Woven polyester carpet backing and tufted carpet incorporating the same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1227426A (en) * 1917-02-08 1917-05-22 Charles Schwartz Tire-casing.
US3106507A (en) * 1958-04-03 1963-10-08 Electric Storage Battery Co Expanded fabric-like material composed of core yarns
US3237578A (en) * 1960-12-06 1966-03-01 Deutsche Linoleum Werke Ag Machine for making pile fabric formed by tufts of yarn on a web of backing material
US3110905A (en) * 1961-09-26 1963-11-19 Lees & Sons Co James Tufted pile fabric comprising a flat woven synthetic plastic backing
US3317366A (en) * 1962-05-18 1967-05-02 Beaunit Corp Woven polyester carpet backing and tufted carpet incorporating the same

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3654884A (en) * 1969-12-11 1972-04-11 Thiokol Chemical Corp Tufted pile fabric
US3788364A (en) * 1971-09-13 1974-01-29 Thiokol Chemical Corp Tufted pile fabrics and backings therefor
US3913510A (en) * 1974-01-24 1975-10-21 Conwed Corp Tufted carpets with elastomeric net backing
US20050260380A1 (en) * 2004-05-20 2005-11-24 Moon Richard C Tuftable carpet backings and carpets with enhanced tuft holding properties

Also Published As

Publication number Publication date
GB1143817A (enrdf_load_stackoverflow) 1900-01-01
BE683612A (enrdf_load_stackoverflow) 1967-01-04
NL6609314A (enrdf_load_stackoverflow) 1967-01-09
FR1574661A (enrdf_load_stackoverflow) 1969-07-18
DE1685122A1 (de) 1971-05-06

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