US3605666A - Tufted carpet with compatibly dyable needlebonded subface and method of manufacturing same - Google Patents

Tufted carpet with compatibly dyable needlebonded subface and method of manufacturing same Download PDF

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Publication number
US3605666A
US3605666A US3605666DA US3605666A US 3605666 A US3605666 A US 3605666A US 3605666D A US3605666D A US 3605666DA US 3605666 A US3605666 A US 3605666A
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US
United States
Prior art keywords
subface
scrim
dyable
tufts
compatibly
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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
Richard Kimmel
Robert G Rowan
Arthur R Hild
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Ozite Corp
Original Assignee
Ozite Corp
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
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Application granted granted Critical
Publication of US3605666A publication Critical patent/US3605666A/en
Assigned to SONICS INTERNATIONAL, INC. reassignment SONICS INTERNATIONAL, INC. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: BRUNSWICK CORPORATION
Assigned to OZITE CORPORATION reassignment OZITE CORPORATION CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: SONICS INTERNATIONAL, INC.
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • 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
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S8/00—Bleaching and dyeing; fluid treatment and chemical modification of textiles and fibers
    • Y10S8/929—Carpet dyeing
    • 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
    • Y10T428/2395—Nap type surface

Definitions

  • a patterned tufted carpet includes a thin needlebonded subface which visually masks the scrim and the bases of the tufts, and the tufts and subface fibers are equally, compatibly dyable so that the coloration and light reflectance are uniform.
  • the carpet is made by needling the subface onto the scrim, tufting through the scrim and subface, and then dying or printing.
  • This invention relates to tufted carpeting, and particularly to an improved tufted carpet which is readily uniformly dyable.
  • carpet made according to this invention With carpet made according to this invention, light is reflected from all points uniformly, including any subface areas that might be involved thus producing total reflectance. The result is a sharper, clearer, more vivid vibration of color to the eye and a truer yield of desired color and/or patterned effects that up until now could only be achieved with woven carpets as opposed to tufted carpets.
  • the invention encompasses a product and a process of manufacture that are highly satisfactory and versatile while "ice being relatively simple and inexpensive. Other objects and advantages will appear from the description to follow.
  • FIG. 1 is a schematic representation of a manufacturing line for practicing the method of the invention
  • FIG. 2 is a schematic fragmentary view in cross section, through the plane 2--2 shown in FIG. 3, illustrating a piece of carpeting formed according to the invention.
  • FIG. 3 is a schematic fragmentary top plan view of the carpet of FIG. *2.
  • FIG. 1 illustrates a preferred method of manufacturturing carpeting according to the invention.
  • the preferred method involves several types of apparatus, all of which are well known to the art so that they have been shown only in block form and will not be described in detail.
  • the carpeting is built on a scrim 1 fed from a supply roll 2.
  • the scrim 1 is preferably a weave of polypropylene filaments, although jute, burlap or other woven or non-woven scrims could be used.
  • the polypropylene scrim is preferred becuase of its other physical characteristics, but this type of scrim has not heretofore been fully satisfactory because of its poor dye charactreistics and it is a particular feature of the invention that such scrim can now be used to full advantage.
  • a conventional lapper 3 is used to deposit on the upper or face surface of the scrim 1 a uniform web or batt of garnetted staple fibers 4.
  • the use of the lapper 3 is not critical, however, and the web could, for example, be deposited directly on the scrim 1 by the web former (not shown). Fibers of 14 inches in length are preferred, and may be of any suitable material such as nylonsubject to the dyability require ments discussed hereafter.
  • the product then passes through a usual needle loom '5 which acts to needle the fibers into a layer 6 that is bonded to the face of the scrim 1, this process often being referred to as needlebonding.
  • the layer 6 serves as a subface as will be described and comprises nonwoven but intertwined fibers 4 the ends of some of Which extend through the scrim 1 to bond the layer 6 thereto.
  • the thickness and density of the layer 6 can be varied as desired, but to achieve the optimum in light reflectance, it has been found that a relatively thin but dense layer 6 which uniformly covers the scrim 1 is best.
  • the product passes through a conventional tufter 7 which tufts yarn 8 through the scrim 1 and subface layer 6 to develop a face comprising tufts 9 which extend above the subface 6.
  • the yarn 8 may also be of any suitable material such as nylon, but must be compatible with the fibers 4 as will be described.
  • the tufts 9 may be of the loop type shown or may be cut, and their spacing may be varied although it is another particular feature of the invention that relatively wide spacing can be used without detracting from the appearance of the final product.
  • the material passes through a suitable printer 10 to achieve any desired pattern.
  • a suitable printer 10 to achieve any desired pattern. This simply involves applying dyes in localized areas, and any feasible number of colors and any desired pattern may be used. Where no pattern or range of colors is desired, only a suitable dyeing apparatus (not shown) is used. It is still another particular feature of the invention that it is adapted 3 for use with continuous printers or dyers in which dyestuffs are applied from above.
  • the carpeting is subjected to any further processes that may be desiredsuch as the application of a secondary backing or foam cushionand is then wound onto a roll 11 for storage or delivery.
  • the subface 6 effectively visually covers the scrim 1 so that it cannot be seen from above and it also surrounds and effectively visually covers the bases 9' of the tufts 9.
  • the thickness and density of the subface 6 can be varied by varying the amount of fiber 4 used or the needling process, but as also previously indicated it is preferable to provide a relatively thin but dense layer 6, using no more fibers 4 than are necessary to develop a uniform layer 6 that effectively covers the scrim 1 and tuft bases 9', or in other Words that is visually continuous. For usual applications, no more than six ounces of fibers 4 per square yard of carpet should be necessary. Expressed in another way, a layer 6 that represents no more than 20% of the total thickness of the carpet will generally accomplish the desired result.
  • the yarn 8 and fibers 4 may be of any material, but they must be dyeable and must also be compatible so far as dyability is concerned.
  • compatible materials are those which will take substantially identical colors from the same dyestuff. In other words, the resulting colors should be similar enough in hue, value and chroma so as to be substantially the same to the eye. It might be most convenient in this regard to use chemically identical materials for the yarn 8 and fibers 4; but non-identical materials can be compatibly dyable and those skilled in the art can readily determine and evaluate this characteristic.
  • the line AA illustrates a line of color demarcation in a pattern, the material on one side being of one color and that on the other being a different color, and stippling has been used to distinguish one color from the other.
  • the subface 6 and tufts 9 are compatibly dyable, the color extends uniformly downwardly along a sharp vertical line, the line AA as seen in FIG. 2, for the entire visible depth of the carpet.
  • the subface 6 serves as a background or field which takes exactly the same color and pattern as is applied to the top portions of the tufts 9.
  • the resulting product has an appearance of great depth and exceptional pattern clarity.
  • the subface 6 completely visually covers the scrim 1 which might otherwise have no color or a different shade and show through to destroy the overall visual effect, and is effective in this regard even if the carpet is bent as in a stairway installation. Further, the subface 6 surrounds and visually covers the tuft bases 9' and thus avoids the problem of dying these portions to the same extent as the tuft tops, which is quite difficult ordinarily.
  • the product and process shown are especially adaptable to high speed, continuous printing or dying apparatus in which dyestuif is applied from above.
  • the subface 6 With the subface 6, it is possible to dye completely down through the visible depth of the material even with such a vertical dying process, whereas with ordinary tufted carpets dying the 4 tuft bases 9 and other areas under the enlarged tops of the tufts 9 with such processes presents a particularly serious problem.
  • the invention provides an improved product, and a process for making it, which is characterized by depth and clarity of pattern and color, due essentially to the use of the compatibly dyable subface 6 and tufts 9.
  • a method of manufacturing tufted, dyed carpeting using scrim having high longitudinal and lateral tensile strength and yarn, wherein the yarn is adapted to be dyed using a particular dye system comprising: selecting staple fibers that can be dyed using the said dye system; then needling a layer of such fibers onto one surface of the scrim to develop a thin subface of fibers which is supported by the scrim and which effectively visually covers said one scrim surface; then tufting the yarn through the scrim and subface to develop a tufted face made up of tufts extending above the subface, said scrim providing substantially all of the dimensional stability for the tufted product; and then using said dye system to simultaneously color the subface and the tufted face.
  • Dyed tufted carpeting material comprising: a scrim having high longitudinal and lateral tensile strength and which provides substantially all of the dimensional stability for the carpeting material; a layer of staple fibers of a material which can be dyed using a particular dye system, said layer being needled onto one surface of the scrim to define a thin subface which is supported by the scrim and effectively visually covers said one scrim surface; and yarn of a material which can be dyed using the said dye system, said yarn being tufted through the scrim and subface to define a tufted face supported by the scrim and extending above the subface, the subface and tufted face being colored by means of said dye system.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Coloring (AREA)
US3605666D 1969-06-13 1969-06-13 Tufted carpet with compatibly dyable needlebonded subface and method of manufacturing same Expired - Lifetime US3605666A (en)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US83308769A 1969-06-13 1969-06-13
GB5368170 1970-11-11
NL7016847A NL7016847A (enExample) 1969-06-13 1970-11-17
FR7041534A FR2069675A5 (enExample) 1969-06-13 1970-11-19
BE759135 1970-11-19
DE2057152A DE2057152C3 (de) 1969-06-13 1970-11-20 Getufteter Teppich

Publications (1)

Publication Number Publication Date
US3605666A true US3605666A (en) 1971-09-20

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ID=27543123

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Application Number Title Priority Date Filing Date
US3605666D Expired - Lifetime US3605666A (en) 1969-06-13 1969-06-13 Tufted carpet with compatibly dyable needlebonded subface and method of manufacturing same

Country Status (6)

Country Link
US (1) US3605666A (enExample)
BE (1) BE759135A (enExample)
DE (1) DE2057152C3 (enExample)
FR (1) FR2069675A5 (enExample)
GB (1) GB1316289A (enExample)
NL (1) NL7016847A (enExample)

Cited By (35)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4971729A (enExample) * 1972-11-14 1974-07-11
US3922454A (en) * 1974-11-29 1975-11-25 Armstrong Cork Co Secondary backing for carpeting
JPS5138572A (enExample) * 1974-08-05 1976-03-31 Ojito Corp
US4014645A (en) * 1975-10-08 1977-03-29 Rohm And Haas Company Dyeable polyolefin backing for tufted surface coverings
US4053668A (en) * 1974-08-05 1977-10-11 Brunswick Corporation Tufted carpenting with unitary needlebonded backing and method of manufacturing the same
US4069361A (en) * 1975-08-20 1978-01-17 E. I. Du Pont De Nemours And Company Woven carpet backing with fused staple fiber needled layer
JPS5369581U (enExample) * 1976-11-09 1978-06-10
US4140071A (en) * 1977-08-09 1979-02-20 E. I. Du Pont De Nemours And Company Process for preparing tufted carpet
JPS5432358U (enExample) * 1977-08-01 1979-03-02
US4181762A (en) * 1976-03-10 1980-01-01 Brunswick Corporation Fibers, yarns and fabrics of low modulus polymer
JPS5571861A (en) * 1979-11-13 1980-05-30 Toray Industries Tufted carpet
US4363848A (en) * 1981-06-01 1982-12-14 Standard Oil Company (Indiana) Three layered foam-containing laminate suitable for use as an automobile headliner
US4425393A (en) 1979-04-26 1984-01-10 Brunswick Corporation Low modulus, small diameter fibers and products made therefrom
US4771497A (en) * 1984-03-23 1988-09-20 Vepa Aktiengesellschaft Process and apparatus for the continuous treatment of lengths of textile material, such as carpets
US4892780A (en) * 1987-07-16 1990-01-09 Cochran William H Fiber reinforcement for resin composites
US5239734A (en) * 1989-06-30 1993-08-31 Sommer S.A. Process and device for manufacturing textile products from fibres and/or filaments and products obtained
EP0568916A1 (en) * 1992-05-01 1993-11-10 Hoechst Celanese Corporation A tufted fabric
US5445860A (en) * 1992-12-29 1995-08-29 Gff Holding Company Tufted product having an improved backing
US5474006A (en) * 1991-11-22 1995-12-12 E. I. Du Pont De Nemours And Company Elastic tufted fabric including nonwoven fibrous substrate
US6060145A (en) * 1997-07-22 2000-05-09 Synthetic Industries, Inc. Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
US6207599B1 (en) * 1998-08-27 2001-03-27 Akzo Nobel Nv Nonwoven backing and carpet comprising same
US6280818B1 (en) * 1999-03-03 2001-08-28 Wayn-Tex, Inc. Carpet backing components and methods of making and using the same
NL1016230C2 (nl) * 2000-09-21 2002-03-22 Ten Cate Nicolon B V Backingstructuur.
US20030070739A1 (en) * 1999-03-02 2003-04-17 Zafiroglu Dimitri Peter Stitched pile surface structure and process and system for producing the same
US20030096549A1 (en) * 2001-10-18 2003-05-22 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
US6740385B2 (en) 2001-03-28 2004-05-25 Bp Corporation North America Inc. Tuftable and tufted fabrics
US6849565B1 (en) 1995-03-17 2005-02-01 Bp Corporation North America Inc. Carpet construction and carpet backings for same
US20050287334A1 (en) * 2004-06-29 2005-12-29 Wright Jeffery J Cushioned flooring products
US20060204712A1 (en) * 2005-02-28 2006-09-14 Propex Fabrics, Inc. Composite secondary carpet backing, method of manufacture thereof, and carpet made therefrom
US20070172630A1 (en) * 2005-11-30 2007-07-26 Jones David M Primary carpet backings composed of bi-component fibers and methods of making and using thereof
US20080131649A1 (en) * 2006-11-30 2008-06-05 Jones David M Low melt primary carpet backings and methods of making thereof
US20100015384A1 (en) * 2008-07-15 2010-01-21 Daishin Industries Co., Ltd. Vehicle mounting carpet and producing method thereof
US20150167254A1 (en) * 2013-12-13 2015-06-18 Orotex Belgium Nv Artificial turf for landscape and sports
US10370799B2 (en) 2013-12-13 2019-08-06 Dfs Europe Nv Tufted structure for landscape and sports
US11225740B1 (en) * 2017-09-01 2022-01-18 Robert S. Weiner Element between backshift and primary backing method

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL184578B (nl) * 1976-07-08 1989-04-03 Amoco Corp Textielmateriaal geschikt als primaire ondergrond voor met een fijne steek getufte tapijten.
DE3616297A1 (de) * 1986-05-14 1987-11-19 Lentia Gmbh Badematte

Cited By (42)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS4971729A (enExample) * 1972-11-14 1974-07-11
JPS5138572A (enExample) * 1974-08-05 1976-03-31 Ojito Corp
US4053668A (en) * 1974-08-05 1977-10-11 Brunswick Corporation Tufted carpenting with unitary needlebonded backing and method of manufacturing the same
US3922454A (en) * 1974-11-29 1975-11-25 Armstrong Cork Co Secondary backing for carpeting
US4069361A (en) * 1975-08-20 1978-01-17 E. I. Du Pont De Nemours And Company Woven carpet backing with fused staple fiber needled layer
US4014645A (en) * 1975-10-08 1977-03-29 Rohm And Haas Company Dyeable polyolefin backing for tufted surface coverings
US4181762A (en) * 1976-03-10 1980-01-01 Brunswick Corporation Fibers, yarns and fabrics of low modulus polymer
JPS5369581U (enExample) * 1976-11-09 1978-06-10
JPS5432358U (enExample) * 1977-08-01 1979-03-02
US4140071A (en) * 1977-08-09 1979-02-20 E. I. Du Pont De Nemours And Company Process for preparing tufted carpet
US4425393A (en) 1979-04-26 1984-01-10 Brunswick Corporation Low modulus, small diameter fibers and products made therefrom
JPS5571861A (en) * 1979-11-13 1980-05-30 Toray Industries Tufted carpet
US4363848A (en) * 1981-06-01 1982-12-14 Standard Oil Company (Indiana) Three layered foam-containing laminate suitable for use as an automobile headliner
US4771497A (en) * 1984-03-23 1988-09-20 Vepa Aktiengesellschaft Process and apparatus for the continuous treatment of lengths of textile material, such as carpets
US4892780A (en) * 1987-07-16 1990-01-09 Cochran William H Fiber reinforcement for resin composites
US5239734A (en) * 1989-06-30 1993-08-31 Sommer S.A. Process and device for manufacturing textile products from fibres and/or filaments and products obtained
US5474006A (en) * 1991-11-22 1995-12-12 E. I. Du Pont De Nemours And Company Elastic tufted fabric including nonwoven fibrous substrate
US5634997A (en) * 1991-11-22 1997-06-03 E. I. Du Pont De Nemours And Company Elastic tufted fabric and process therefor
EP0568916A1 (en) * 1992-05-01 1993-11-10 Hoechst Celanese Corporation A tufted fabric
US5445860A (en) * 1992-12-29 1995-08-29 Gff Holding Company Tufted product having an improved backing
US6849565B1 (en) 1995-03-17 2005-02-01 Bp Corporation North America Inc. Carpet construction and carpet backings for same
US6060145A (en) * 1997-07-22 2000-05-09 Synthetic Industries, Inc. Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
US6344254B1 (en) 1997-07-22 2002-02-05 Sind, Llc Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
US6207599B1 (en) * 1998-08-27 2001-03-27 Akzo Nobel Nv Nonwoven backing and carpet comprising same
US20030070739A1 (en) * 1999-03-02 2003-04-17 Zafiroglu Dimitri Peter Stitched pile surface structure and process and system for producing the same
US6280818B1 (en) * 1999-03-03 2001-08-28 Wayn-Tex, Inc. Carpet backing components and methods of making and using the same
NL1016230C2 (nl) * 2000-09-21 2002-03-22 Ten Cate Nicolon B V Backingstructuur.
US6740385B2 (en) 2001-03-28 2004-05-25 Bp Corporation North America Inc. Tuftable and tufted fabrics
US7175902B2 (en) 2001-10-18 2007-02-13 Cerex Advanced Fabrics, Inc. Nonwoven fabrics containing yarns with varying filament characteristics
US20030096549A1 (en) * 2001-10-18 2003-05-22 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
US7174612B2 (en) * 2001-10-18 2007-02-13 Cerex Advanced Fabrics, Inc. Nonwoven fabrics containing yarns with varying filament characteristics
US20040221436A1 (en) * 2001-10-18 2004-11-11 Ortega Albert E. Nonwoven fabrics containing yarns with varying filament characteristics
US20050287334A1 (en) * 2004-06-29 2005-12-29 Wright Jeffery J Cushioned flooring products
US7670660B2 (en) * 2005-02-28 2010-03-02 Propex Operating Company, Llc Composite secondary carpet backing, method of manufacture thereof, and carpet made therefrom
US20060204712A1 (en) * 2005-02-28 2006-09-14 Propex Fabrics, Inc. Composite secondary carpet backing, method of manufacture thereof, and carpet made therefrom
US20070172630A1 (en) * 2005-11-30 2007-07-26 Jones David M Primary carpet backings composed of bi-component fibers and methods of making and using thereof
US20080131649A1 (en) * 2006-11-30 2008-06-05 Jones David M Low melt primary carpet backings and methods of making thereof
US20100015384A1 (en) * 2008-07-15 2010-01-21 Daishin Industries Co., Ltd. Vehicle mounting carpet and producing method thereof
US20150167254A1 (en) * 2013-12-13 2015-06-18 Orotex Belgium Nv Artificial turf for landscape and sports
US10190267B2 (en) * 2013-12-13 2019-01-29 Bfs Europe Nv Artificial turf for landscape and sports
US10370799B2 (en) 2013-12-13 2019-08-06 Dfs Europe Nv Tufted structure for landscape and sports
US11225740B1 (en) * 2017-09-01 2022-01-18 Robert S. Weiner Element between backshift and primary backing method

Also Published As

Publication number Publication date
GB1316289A (en) 1973-05-09
DE2057152C3 (de) 1979-03-22
DE2057152A1 (de) 1972-05-25
BE759135A (fr) 1971-05-19
NL7016847A (enExample) 1972-05-19
DE2057152B2 (de) 1978-07-13
FR2069675A5 (enExample) 1971-09-03

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Legal Events

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AS Assignment

Owner name: OZITE CORPORATION

Free format text: CHANGE OF NAME;ASSIGNOR:SONICS INTERNATIONAL, INC.;REEL/FRAME:003885/0795

Effective date: 19810727