US3778330A - Tufted carpet - Google Patents

Tufted carpet Download PDF

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Publication number
US3778330A
US3778330A US00208381A US3778330DA US3778330A US 3778330 A US3778330 A US 3778330A US 00208381 A US00208381 A US 00208381A US 3778330D A US3778330D A US 3778330DA US 3778330 A US3778330 A US 3778330A
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United States
Prior art keywords
tuft
yarn
filaments
tufts
backing fabric
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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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US00208381A
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English (en)
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S Shorrock
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Individual
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Individual
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Publication date
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Publication of US3778330A publication Critical patent/US3778330A/en
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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
    • 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
    • Y10T428/23986—With coating, impregnation, or bond

Definitions

  • My' invention relates to a tufted carpet and a method of manufacture thereof.
  • a continuous yarn may be employed which is forced through a backing-fabric to provide a plurality of looped tufts in a row along the fabric,'the yarn being inserted by a needle which piercesjthe fabric.
  • the yarn then extends from one tuft to the next along the back of the fabric as a substantially cylindrical structure, and'all the yarn at the back of the carpet is then coated with adhessive such as latex in order to secure the tufts in position.
  • the tufts after insertion may be cut to form a cut pile, or may be left uncut.
  • Other methods of inserting pile are also known. Usually in such methods, a length of yarn of substantially cylindical section is left on the back of the fabric between adjacent tufts in a row, and latex applied to these stretches of cylindrical yarn.
  • the adhesive since the adhesive is applied to the outside of the yarn, it may well be that the adhesive, more particularly if of a water base, may not penetrate to the centre of the yarn, more particularly if the material of the yarn is of a substantially non-water absorbent material such as nylon, or has an oily spin finish applied to it. This means that although each tuft is more or less secured to the backing fabric by the adhesive, the centre filaments of each tuft may be left without adhesive, and may therefore be pulled out by subsequent brushing or vacuum cleaning. This reduces the quantity of pile material in the carpet unnecessarily.
  • I therefore make a carpet of individual cylindrically shaped tufts each separated from adjacent tufts, the filaments in each tuft being substantially parallel. Where the tuft penetrates the backing fabric, the latter owing to its inherent resilience, compresses the tuft so as to form a neck. The short ends of the filaments of the tufts projecting backwards through the fabric can be splayed out to form a head somewhat similar to that of a rivet, with the cut ends of each filament projecting away from the backing fabric.
  • An adhesive such as a rubber latex suspension in water is then applied to the back of the backing fabric and to the splayed heads of the tufts, and since the latex is applied only to these ends, and not to the outside of a cylindrical yarn, I find that the adhesive penetrates far better, and secures substantially every single filament of every tuft.
  • the adhesive is found not only'to hold each separate filament more firmly than in the case of the types of tufted pile carpets described above, but since the adhesive penetrates into the neck of the rivet head, i.e. the part of the tuft compressed in the backing fabric, I find that the splayed filaments of the head together with the adhesive, form an extremely firm bond so that the individual filaments of each tuft cannot be removed, and the tuft itself cannot be either pulled or pushed out of the backing fabric.
  • the cylindrical tufts may be produced by cutting off predetermined lengths from a supply of yarn, feeding them in sequence to a hollow needle, and causing the needle to deposit the tufts in the backing fabric.
  • a tufted carpet is made by the steps of inerting individual filamentary tufts of yarn of cylindrical form through a backing fabric so that a longer portion of each tuft projects to form a pile, causing or allowing the filaments at the other ends of the tufts (the fixing ends) to splay into a mushroom or rivet head form, and applying an adhesive to the splayed ends of the filaments so as to secure each one separately in po sition in the backing fabric.
  • FIG. 1 shows a tuft expanding under the effect of a resilient backing material
  • FIG. 2 shows a tuft expanding by means of an air blast from a hollow needle
  • FIG. 3 shows tuft expansion by means of a ram projecting from a hollow needle
  • FIG. 4 shows the elfect of using a specially treated yarn
  • FIG. 5 shows the effect of applying a water base latex to a hydrophilic yarn tuft.
  • a tuft of yarn of cylindrical form and composed of a plurality of filaments is inserted in a backing material, forming a pile end 3 and a fixing end 4.
  • the backing material 2 is a highly resilient material such as a non-woven sheet made for example from slit polypropylene, the threads of which are pushed apart by a needle during delivery of the tuft. On retraction of the needle, the filaments of the backing tend to revert to their original positions close to one another, thus compressing a neck 6 on the tuft and causing the filaments of the fixing end 4 to splay out.
  • the yarn should preferably be springy or crimped, and should have a relatively low twist to ensure that the twist does not bind the filaments together too tightly.
  • FIG. 2 shows the insertion of a tuft 7 in a backing fabric 8 which this time need not be of such a resilient material as that referred to in connection with FIG. 1.
  • the fixing end 9 of the tuft after insertion is subjected during withdrawal of a hollow needle 10, to a blast of air from the needle in the direction of the arrow. This splays out the filaments of the fixing end of the tuft, thus securing the tuft temporarily in position.
  • FIG. 3 shows a somewhat similar arrangement, but this time a tuft 11 is placed in the backing fabric 12 by means of a hollow needle 13, the tuft being located against a bottom stop 14. As the needle rises, a ram 15 applies pressure to the fixing end 16 of the tuft, causing the filaments thereof to splay out.
  • FIG. 4 shows two views of a tuft of pro-treated yarn when used for producing a tufted carpet.
  • a tuft 20 is inserted in a backing fabric 21, the tuft being of a twisted yarn which has been compacted before use by application of ultrasonic vibration. Because of the compaction,
  • the pile end of the tuft does not automatically expand, nor does the fixing end 22.
  • the fixing end splays as shown at 24, the heat being applied by an infra-red heater 25. Some of the heat will travel down the neck of the tuft, securing it in position with the backing fabric, and if the heat is maintained long enough, the pile end of the tuft splays out as shown at 26. Some or all of the twist in the original yarn may be lost during the process.
  • FIG. 5 shows the injection of a tuft 30 in a backing fabric 31, the fixing end 32 of the tuft being splayed by the application of a water-based latex 33 by a spray.
  • the yarn is preferably hydrophilic, and crimped prior to its use.
  • the application of the water latex possibly with the addition of heat in order to evaporate the water, causes the fixing end of the tuft to splay, and some of the latex runs down the neck of the tuft and fixes the tuft very firmly in position in the backing fabric.
  • the tufts may pass under a lightly loaded softfaced roller which applies a spreading and fixing agent such as the water based latex referred to above.
  • a spreading and fixing agent such as the water based latex referred to above.
  • the fixing ends may be subjected to a sutficiently high temperature to cause them to at least partially fuse; alternatively a tufting material may be used for the tufts having some relatively low temperature melting filaments incorporated in the yarn itself, in which case a somewhat lower temperature can be cmployed for fusing these filaments. The fusing not only fixes the filaments in place, but by bulking at least some of the filaments, cause the others to splay thus fixing the tuft ends firmly in the backing fabric.
  • FIG. 5 shows the addition of an adhesive
  • an adhesive must be applied to the splayed fixing ends of all the other figures as soon as possible after splaying, in order to ensure that the tufts are not accidentally withdrawn from their positions in the backing fabric when subject to subsequent processes such for example as the rolling up of the fabric and tufts on a take-up roller.
  • a tufted carpet comprising a backing fabric, a plurality of filamentary tufts of cylindrical form inserted in said fabric so that each tuft has a long (pile) end and a short (fixing) end, said long and short ends being on opposite sides of said backing fabric with the filaments of said fixing ends splayed apart, and an adhesive layer applied to said fixing ends.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
US00208381A 1970-12-31 1971-12-15 Tufted carpet Expired - Lifetime US3778330A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB6209370 1970-12-31

Publications (1)

Publication Number Publication Date
US3778330A true US3778330A (en) 1973-12-11

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ID=10487869

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US00208381A Expired - Lifetime US3778330A (en) 1970-12-31 1971-12-15 Tufted carpet

Country Status (6)

Country Link
US (1) US3778330A (enExample)
AU (1) AU456834B2 (enExample)
DE (1) DE2163015A1 (enExample)
FR (1) FR2121222A5 (enExample)
GB (1) GB1328240A (enExample)
ZA (1) ZA718305B (enExample)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3847719A (en) * 1971-03-17 1974-11-12 R Crowley Tufted carpet with gas-expandable pile and method
US3856596A (en) * 1970-12-31 1974-12-24 S Shorrock Backed tufted carpet and method of manufacturing the same
US3904799A (en) * 1970-12-31 1975-09-09 Stanley Shorrock Tufted carpet
US3988488A (en) * 1975-01-22 1976-10-26 Inmont Corporation Leatherlike fabrics
US4055693A (en) * 1975-01-22 1977-10-25 Inmont Corporation Leatherlike fabrics
US20080044599A1 (en) * 2006-08-18 2008-02-21 Mondo S.P.A. Synthetic grass turf and related manufacturing method
US20080095974A1 (en) * 2006-10-24 2008-04-24 Gerhard Hoffe Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method
US20080099096A1 (en) * 2006-10-25 2008-05-01 Fountainhead L.L.C. Woven-body floating island

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3856596A (en) * 1970-12-31 1974-12-24 S Shorrock Backed tufted carpet and method of manufacturing the same
US3904799A (en) * 1970-12-31 1975-09-09 Stanley Shorrock Tufted carpet
US3847719A (en) * 1971-03-17 1974-11-12 R Crowley Tufted carpet with gas-expandable pile and method
US3988488A (en) * 1975-01-22 1976-10-26 Inmont Corporation Leatherlike fabrics
US4055693A (en) * 1975-01-22 1977-10-25 Inmont Corporation Leatherlike fabrics
US20080044599A1 (en) * 2006-08-18 2008-02-21 Mondo S.P.A. Synthetic grass turf and related manufacturing method
US7670661B2 (en) * 2006-08-18 2010-03-02 Mondo S.P.A. Synthetic grass turf and related manufacturing method
US20080095974A1 (en) * 2006-10-24 2008-04-24 Gerhard Hoffe Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method
US20080099096A1 (en) * 2006-10-25 2008-05-01 Fountainhead L.L.C. Woven-body floating island

Also Published As

Publication number Publication date
AU456834B2 (en) 1974-12-13
GB1328240A (en) 1973-08-30
DE2163015A1 (de) 1972-07-06
FR2121222A5 (enExample) 1972-08-18
ZA718305B (en) 1972-09-27
AU3719671A (en) 1973-06-28

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