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
• • 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
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M7/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made of other substances with subsequent freeing of the treated goods from the treating medium, e.g. swelling, e.g. polyolefins
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
  • D06M2200/00—Functionality of the treatment composition and/or properties imparted to the textile material
  • D06M2200/40—Reduced friction resistance, lubricant properties; Sizing compositions
• • 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 invention relates to a high-strength tufted pile fabric having a woven primary backing material of polypropylene or copolymer of propylene yarn, at least some of the yarn having a relatively flat cross section, which has been coated with about 0.2 to 12 percent, based on the weight of the yarn, of a lubricant material prior to penetrating tufts through the bodies of the yarn.
• the presence of the lubricant material on the yarns of the backing enhances penetration of the tufting needles and tufts into the yarns without the tufting needles causing the otherwise serious rupturing and shattering of the penetrated yarns which occurs during tufting of otherwise similar, but unlubricated, woven primary backing.
• This invention relates to improved primary backings for tufted pile fabrics, to improved pile fabrics comprising these packings and to methods for producing each.
• 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 a high strength tufted pile fabric co prising a primary backing of synthetic plastic material.
• Yet another object is to provide a method for increasing the fabric strength of tufted pile fabrics comprising a primary backing of synthetic plastic material.
• Still another object of the present invention is to provide a method for producing high-strength, high-quality tufted pile fabrics comprising a synthetic plastic primary backing material.
• the present invention is directed to improved woven synthetic plastic primary backings treated with sufficient amounts of lubricant to provide, after tufting, a tufted pile fabric having a fabric strength of at least about 50 percent of the fabric strength of the primary backing prior to tufting. In most cases fabric strength retention is as high as 70 to percent or more.
• the specific amount of lubricant needed to accomplish the stated objectives will vary according to the specific lubricant used, the specific primary backing to be treated, the specific type of tufting operation, etc. In general it has been found that desired results can be accomplished by treating synthetic plastic primary backing material (for example primary backing materials like those disclosed in the previously mentioned Rhodes patent) prior to tufting with from about 0.2 to about 12, and preferably with about 0.6 to about 8 percent by weight, of a lubricant.
• synthetic plastic primary backing material for example primary backing materials like those disclosed in the previously mentioned Rhodes patent
• the synthetic plastic primary backings to which this invention may be applied include those comprised of any of the synthetic plastic materials capable of formation into weavable yarns.
• Such plastics include, for example, polyethylene, polypropylene, ethylene/propylene copolymers, numerous other polymers and copolymers of other alpha olefins, polyesters, polyamides, rayon, polyvinyl chloride and many other synthetic plastic materials.
• the invention is most especially applicable to those primary backings comprised of polypropylene yarns.
• the geometry of the plastic yarns used in forming the woven primary backing may be varied considerably.
• the invention is most efficacious with those backings in which both the warp and the fill (or weft) yarns have a relatively flat, e.g., substan-, tially rectangular, cross section, such as those backings disclosed in the Rhodes patent previously mentioned.
• the lubricant used in the practice of the present invention can be any lubricating substance that does not react with, have solvent action on, or otherwise materially affect the properties of the synthetic plastic yarns in the primary backing by chemical action.
• Suitable exemplary materials include mineral oil; oxyethylated higher fatty acids (i.e., fatty acids having about eight carbon atoms or more) more commonly known as polyethylene glycol esters, e.g., polyethylene glycol linoleate, polyethylene glycol stearate, polyethylene glycol oleate, polyethylene glycol laurate, oxyethylated mixtures of the fatty acids in naturally occurring higher fatty acids in various been woven experience to date has indicated that treatment can range from about i to about 12 and preferably from about 2 to about 8 percent by weight of lubricant based on the total weight of the primary backing.
• the lubricant should be a relatively lowing the same to the plastic yarn prior to weaving, or to viscosity liquid either as such or when in water emulsion, so as the P y hacking after it is wevehto provide easy application and spreading.
• the invention is broadly directed to lubricant treatment sufficient to provide percent or more fabric strength retention in tufted pile fabrics utilizing synthetic plastic primary backings.
• the basic purpose of the lubricant treatment is to deter physical damage to the fill yarns by the tufting needles in the tufting machine. This could per- I haps be accomplished by lubricating the needles themselves but this is believed to be impractical for the tufter.
• EXAMPLE 2 A polypropylene yarn primary backing identical to that of Run number 2 of example 1 was prepared and tufted by a commercial carpet manufacturer in a zigzag, 7% stitches per inch and 6% rows per inch. Average fabric strengths, in the fill direction, determined as described in footnote 1, table 1 were:
• Example A polypropylene yarn primary backing identical to that of Run number 4 of example 1 was prepared and tufted by a commercial carpet manufacturer 9% stitches per inch, 9% rows per inch with a cut pile one-fourth inch high after which the tufted pile fabric was piece dyed. Average fabric strength (3 samples) in the fill direction after tufting and dyeing was 82 pounds per fabric inch. All samples tested in the warp direction gave fabric strength results greater than 200 pounds per inch.
• EXAMPLE 4 In this example further polypropylene ribbon primary backings substantially like those in Runs 1 and 2 of example 1 were prepared.
• the backings of this example were woven 12 feet wide on a commercial loom using a Unifil quiller with no lubricant applied to the fill yarns.
• the warp yarns were very heavily lubricated with Napcostat 2152-? prior to placement on the loom beam used in the weaving operation.
• Paired samples of the primary backings so prepared were tufted with and without preliminary heat setting of the backing on a tenter frame. Tufting was substantially identical to that used in example 1, the only difference being tufts at 9% stitches per inch instead of 10 stitches per inch. in addition still further backing samples were tufted at 6% stitches per inch with no preliminary heat setting of the backing. Results are summarized in table ii.
• the average fabric strengths were determined as described in example 1 except that untufted strengths represent an average of three instead of four readings.
• a high-strength tufted pile fabric comprising a woven primary backing material, said primary backing woven of yarn of a plastic selected from the group consisting'of polypropylene and copolymers of propylene, at least some of said yarn in said primary backing having a relatively flat cross section; said substantially flat year being coated with a lubricant in an amount in the range of about 0.2 to 12 percent based on the weight of said yarn, and a plurality of tuft, a substantial number of said tufts penetrating some of said lubricated substantially flat yarn, said penetrated yarn being relatively free of ruptured and shattered areas compared to an unlubricated penetrated yarn in otherwise similar fabric.
• a high-strength tufted pile fabric comprising a woven primary backing material, said primary backing woven of yarn made from a polymer selected from the group consisting of polypropylene and copolymers of propylene, at least some of said yarn in said primary backing having a substantially flat cross section, said substantially flat yarn coated with an agent that is essentially nonreactive with and having essentially no solvent action on said yarn, said agent being present in an amount of about 0.6 to 8 percent based on the weight of said yarn, said agent being selected from the group consisting of mineral oil and oxyethylated higher fatty acids, and a plurality of tufts, a substantial number of said tufts being inserted through said woven primary backing with a frequency of more than 6% tufts per inch, some of said tufts that are inserted with a frequency of more than 6 /2 tufts per inch penetrating some of said lubricated substantially fiat yarn, said penetrated yarn being relatively free of ruptured and shattered areas, said high-stre

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Automatic Embroidering For Embroidered Or Tufted Products (AREA)
• Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
• Carpets (AREA)
• Woven Fabrics (AREA)

Applications Claiming Priority (1)

Publications (1)

Family

ID=23800729

Family Applications (1)

Country Status (5)

Cited By (8)

Families Citing this family (2)

• 1965
  • 1965-05-05 US US453478A patent/US3613612A/en not_active Expired - Lifetime
• 1966
  • 1966-05-03 DE DE1685121A patent/DE1685121B2/de not_active Withdrawn
  • 1966-05-04 NL NL6606010A patent/NL6606010A/xx unknown
  • 1966-05-04 GB GB19778/66A patent/GB1126536A/en not_active Expired
  • 1966-05-04 BE BE680533D patent/BE680533A/xx unknown

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