US3767495A - Method of producing a non-woven pile product - Google Patents

Method of producing a non-woven pile product Download PDF

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Publication number
US3767495A
US3767495A US00162645A US3767495DA US3767495A US 3767495 A US3767495 A US 3767495A US 00162645 A US00162645 A US 00162645A US 3767495D A US3767495D A US 3767495DA US 3767495 A US3767495 A US 3767495A
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Prior art keywords
pile
stack
slab
frozen
sheets
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Expired - Lifetime
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US00162645A
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English (en)
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P Miller
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Thermo Weave Inc
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Thermo Weave Inc
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • 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
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y10T156/1052—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing

Definitions

  • the present invention in some of its aspects, is an extension or modification of my prior US. Pat. No. 3,359,147 and, inter alia, provides for utilization of leather and other materials available as sheet scrap from various manufacturing processes and so having irregularities in size, color, shape, cutout-pattern or other scrap characteristic.
  • the pile materials used are in sheet form and may be of plastic, leather, textile fabric and the like.
  • the sheets of pile material are arranged in layers to form a stack in which adjacent layers are either in contact or spaced. In either case, the sheets before stacking, or as stacked, are moistened and'the stack is frozen. The frozen stack is sliced at a desired angle to form slabs with pile strips extending lengthwise between the side edges of the slab.
  • each of the slabs corresponds with the characteristics of the sheets at the region where the slab cut is made. Having in mind that the stacked sheets may be either different or similar in shape, color, cut-out and other individual characteristics, the facial design may be unpredictable or predictable. For example, the facial designs of the slabs are random if the sheets are randomly placed in the stack or randomly differ in one or more of their characteristics. On the other hand, a predetermined facial design can be obtained by forming the stack with controlled spacing of the sheets having predetermined characteristics and controlling the relative longitudinal and lateral' positioning of color, cut-out, shape and other material characteristics of individual sheets of the stack.
  • One or both faces of the slab may be bonded to a backing layer depending upon the desired ultimate use of the article or product.
  • a rug, mat or carpet element requires bonding of only one face of the slab.
  • the unbonded face may be additionally cut crosswise so to form from each of the lengthwise pile strips a multiplicity of upstanding pile elements extending to or toward the coated face of the slab.
  • Both faces of the slab may be bonded to make a heat-insulating tile or cushion, or to make a double-faced pile product which can be split to form two tiles with similar pile-face design.
  • FIG. 1 schematically illustrates successive stages of a method of making non-woven pile articles from sheet material
  • FIG. 2 in perspective and in section, shows 'a nonwoven pile panel or tile which can be made by steps shown in FIG. 1 and whose exposed face present a ribbed appearance;
  • FIG. 3 in perspective, shows a parquet arrangement of panels of the rib type shown in FIG. 2;
  • FIG. 4 in perspective and in section, shows another non-woven pile panel or tile which can be made by steps shown in FIG. 1 and whose exposed face simulates cut fabric tile;
  • FIG. 5 is a cross-sectional view, on enlarged scale, of the tile shown in FIG. 4;
  • FIG. 6 is a perspective view of a heat-insulating or cushion tile which can be made by steps shown in FIG. 1.
  • a multiplicity of sheets are laid one upon another on a support 12A such as provided by a work table or conveyor to form a stack C.
  • a support 12A such as provided by a work table or conveyor to form a stack C.
  • the sheets or layers of the stack may be scrap pieces of natural or synthetic leather from which have been punched out various components of shoes, handbags and the like, or they may be scrap pieces of plastic sheet or foil from other manufacturing processes.
  • These scrap sheets may be, and usually are of irregular size and shape; and particularly when of natural leather, the locations of their cut-out areas are different in different sheets. Such irregularities and differences, for reasons which later appear, provide a random face pattern for non-woven pile tiles or panels embodying the present invention.
  • Some of the sheets may be, and preferably are, of the same preselected width and may be cut as by knife 10 from any one or more of the webs Al-An stored in roll form on a creel of supply rolls.
  • the webs maybe of different color and/or of different material such as plastic, textile fabric, foil and the like.
  • the individual sheets are moistened as by water supplied from one or more nozzles 9.
  • the sides of the stack C are squared as by .the side plates 11 which may be in position during assembly of the sheets or may be positioned after assembly of the loosely piled sheets.
  • the completed stack C of sheets is compressed, as by spaced calender rolls 13, and then passed into a freezing zone or chamber 14 where the compressed stack is converted into a frozen block of immobilized sheets.
  • the freezing chamber may be of type shown in my aforesaid patent.
  • the compression rolls 13 may be chilled as by flow of ice water or other coolant through them.
  • the stack After the stack has been frozen, it is sliced, as by the knife or other cutting means 15, to form a series of frozen slabs D in which the pile strips E extend lengthwise, as ribbon strips between ends of the slab.
  • the slab face pattern as defined by these strips varies from slab to slab because of the irregularities and discontinuities in the cross-section of the stack as advanced beyond the cutting means for slicing. Changing the angle of slicing will also vary the appearance of the slab face from an open-blind effect for a perpendicular cut to a more or less closed-blind effect for different angles of the cut.
  • the frozen slabs D in turn or as a group are passed through the defreezing/drying zone or chamber 17' or may be applied with different orientation as in FIG. 3 to obtain a parquet effect.
  • the edge bonding of the ribbon strips E to form such paneled tile T, or array of tiles T may be effected by application of a heated web or sheet consisting of or coated with thermoplastic material.
  • An electric heater may be used, as shown, to soften the web just prior to its application to a face of a defrozen slab D.
  • the bonding may be effected by passing the defrozen slab D under an extruder head from which issues a web of molten plastic. It will be understood that during transport from zone 17 and during coating of the defrozen slab, its sides and ends are engaged by confining plates or structure not shown.
  • tile T is moved beyond the coating zone to pass between closely spaced knife blades 19 which cut the individual pile strips or ribbons crosswise into a multiplicity of upstanding pile elements.
  • an individual ribbon strip E (FIG. 2) has been in effect converted to a comb whose back edge is bonded into backing layer F and whose teeth H freely extend from the backing layer as pile elements resembling the cut pile of woven fabric.
  • the variations in height of pile elements H are due to cut-outs in the corresponding scrap sheet of the particular original stack C from which the slab was cut.
  • both faces of the defrozen slab D are respectively bonded to or into the backing layers F, Fl.
  • the opposite edges of each of the ribbon strips E are respectively attached to or embedded in the backing layers F, F1, so leaving a multiplicity of elongated confined spaces each respectively extending from one side edge of the tile to the other.
  • the tiles T,T3 also are yielding, or soft, since the ribbon strips E are free to flex between their bonded edges when pressure is applied to either face of the tile.
  • a tile T3 may be split intermediate the coated faces to form two tiles T having a ribbed appearance, as shown in FIG. 2, and each ofwhich may be slitted crosswise intermediate its coated faces to form a tile T2 having the cut-pile appearance shown in FIG. 4.
  • the method above described provides not only for a preselection of the general facial appearance of the ultimate non-woven pile fabric, i.e., ribbed or cut pile, but also provides unpredictable design patterns for individual tiles which moreover differ for the different tiles.
  • Such uniqueness of the facial pattern of individual tiles arises because of the irregularities and discontinuities of the sheet scrap material incorporated in an original stack C.
  • individual tiles of different general appearance and uniquely different in appearance may be used jointly to form in any desired arrangement larger areas whose variety of appearance is limited only by the designer's imagination.
  • the spacing between the stacked sheets may be controlled as by edge-rolls or guides to leave inter-sheet voids which receive a slurry or mixture such as of liquid and lint, pulp and the like.
  • the rolls 13,13 do not compress the stack so that in the stack as frozen the sheets of pile material are held separated by the intervening frozen slurry.
  • the controlled spacing between the pile strips E is maintained. In this case, as may also be true of the methods previously described, the slab is not completely thawed in zone 17.
  • the lateral ends of the slab may be left frozen for the time-being so that the spacing between the pile strips is maintained as the slab emerges from zone 17 for bonding of one or both ofits faces.
  • the face-bonding is to the edges of the ribbon pile strips E and to the lint or other spacing material adjacent those edges.
  • the unbonded spacing material may later be removed by vacuuming when the final product has one exposed pile face.
  • the heat sources may be designed or controlled so that the thawing, depthwise of the slab, extends only partially from one face.
  • the bonding is progressively applied to the thawed face, so permanently to hold the corresponding edges of the ribbon pile strips and the adjacent spacing material between them. Again the unbonded lint, or other spacing material, may be removed by vacuuming.
  • the lint or equivalent spacing material introduced in the slurry may be of desired color or colors so that the lint retained after vacuuming of the final product provides a color background in the spaces between the pile strips and so becomes part ofa facial design.
  • Water-soluble adhesives including resins, may be used for bonding to the still frozen slab, so eliminating the need for the defreezing step and simplifying the equipment required to practice the various methods above described.
  • lint spacing material as used in the appended claims, is intended to include pulp, lint or other equivalent spacing material.
  • a method of producing a non-woven pile product which comprises,
  • a method as in claim 1 including the additional step of removing from between the pile strips of the slab, at least a portion of the lint spacing material of the in troduced slurry. 3. A method as in claim 1 wherein the ribbon-like pile strips are cut crosswise into a multiplicity of teeth to form pile elements upstanding from said backing layer.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
US00162645A 1968-11-18 1971-07-14 Method of producing a non-woven pile product Expired - Lifetime US3767495A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US77662268A 1968-11-18 1968-11-18
US16264571A 1971-07-14 1971-07-14

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US3767495A true US3767495A (en) 1973-10-23

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US (1) US3767495A (enrdf_load_stackoverflow)
BE (1) BE741796A (enrdf_load_stackoverflow)
DE (1) DE1957941A1 (enrdf_load_stackoverflow)
FR (1) FR2023521B1 (enrdf_load_stackoverflow)
GB (1) GB1287299A (enrdf_load_stackoverflow)
LU (1) LU59833A1 (enrdf_load_stackoverflow)
NL (1) NL6917138A (enrdf_load_stackoverflow)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3921368A (en) * 1973-03-05 1975-11-25 James A Hanley Method of adhesion of surfaces especially as applied to corrugated paper boards
US4567078A (en) * 1984-07-03 1986-01-28 Fiberglas Canada Inc. Process and apparatus to crimp fibres
US5433816A (en) * 1993-01-15 1995-07-18 Eastman Kodak Company Ultrasonic apparatus for forming individual pillowed chips of light lock material
US20070184742A1 (en) * 2005-10-20 2007-08-09 Sustainable Solutions, Inc., (SSI) Corp. of Delaware Composite leather material

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1012389A (en) * 1911-03-11 1911-12-19 Henri Marche Manufacture of velvet, plush, carpet, imitation fur, and the like.
US2788835A (en) * 1953-10-02 1957-04-16 Fabric Dev Company Ltd Manufacture of pile fabrics
US3085922A (en) * 1959-01-19 1963-04-16 Du Pont Porous flexible self-supporting sheet material and method of making same
US3359147A (en) * 1963-12-30 1967-12-19 Paul E Miller Non-woven patterned pile making method and apparatus

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH941761A4 (de) * 1961-08-10 1964-02-14 Schneiter Siegenthaler & Co Filzteppich und Verfahren zu seiner Herstellung

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1012389A (en) * 1911-03-11 1911-12-19 Henri Marche Manufacture of velvet, plush, carpet, imitation fur, and the like.
US2788835A (en) * 1953-10-02 1957-04-16 Fabric Dev Company Ltd Manufacture of pile fabrics
US3085922A (en) * 1959-01-19 1963-04-16 Du Pont Porous flexible self-supporting sheet material and method of making same
US3359147A (en) * 1963-12-30 1967-12-19 Paul E Miller Non-woven patterned pile making method and apparatus

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3921368A (en) * 1973-03-05 1975-11-25 James A Hanley Method of adhesion of surfaces especially as applied to corrugated paper boards
US4567078A (en) * 1984-07-03 1986-01-28 Fiberglas Canada Inc. Process and apparatus to crimp fibres
US5433816A (en) * 1993-01-15 1995-07-18 Eastman Kodak Company Ultrasonic apparatus for forming individual pillowed chips of light lock material
US20070184742A1 (en) * 2005-10-20 2007-08-09 Sustainable Solutions, Inc., (SSI) Corp. of Delaware Composite leather material

Also Published As

Publication number Publication date
DE1957941A1 (de) 1970-06-25
FR2023521B1 (enrdf_load_stackoverflow) 1974-02-01
NL6917138A (enrdf_load_stackoverflow) 1970-05-20
FR2023521A1 (enrdf_load_stackoverflow) 1970-08-21
LU59833A1 (enrdf_load_stackoverflow) 1970-01-19
BE741796A (enrdf_load_stackoverflow) 1970-05-04
GB1287299A (en) 1972-08-31

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