US3856596A - Backed tufted carpet and method of manufacturing the same - Google Patents

Backed tufted carpet and method of manufacturing the same Download PDF

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Publication number
US3856596A
US3856596A US00210507A US21050771A US3856596A US 3856596 A US3856596 A US 3856596A US 00210507 A US00210507 A US 00210507A US 21050771 A US21050771 A US 21050771A US 3856596 A US3856596 A US 3856596A
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United States
Prior art keywords
tufts
fabric
layer
adhesive
backing
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Expired - Lifetime
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US00210507A
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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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    • 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
    • D05D—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES D05B AND D05C, RELATING TO SEWING, EMBROIDERING AND TUFTING
    • D05D2305/00—Operations on the work before or after sewing
    • D05D2305/22—Physico-chemical treatments
    • D05D2305/30—Physico-chemical treatments using adhesive
    • 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

  • ABSTRACT A method of manufacturing a backed tufted carpet consisting of cylindrical tufts of pile yarn inserted in a backing fabric, includes the steps of coating the fixing (short) ends of the tufts with an adhesive, producing a backing less sheet of foamed rubber, and sticking the sheet on the backing fabric.
  • the adhesive may be caused to fill any gaps between the: tuft ends thus improving the resilience of the carpet.
  • Tufted carpets are often made by inserting tufts of pile yarn into a backing fabric such as woven jute cloth, and securing the tufts in position by the use of a layer of adhesive on the back or lower side of the carpet.
  • a backing fabric such as woven jute cloth
  • a resilient backing material such as foamed rubber, felt or other foamed or fibrous material, of lesser cost than the carpet itself and not decorative, to act as an underlay. This gives the carpet a very soft springy feel.
  • a method of manufacturing a tufted carpet comprising the steps of traversing a backing fabric past a row of tufting needles, causing the needles to insert cylindrical tufts of pile yarn in the backing fabric, applying an adhesive to the tufts to secure them in the fabric, separately producing a layer of resilient foamed rubber without the use of a backing sheet, and sticking said layer to the'backing fabric and tufts with or without the use of further adhesive.
  • a latex formed as a suspension of rubber in a water base is entirely satisfactory both for securing the tufts ofthe pile fabric in the backing material, and for securing the foamed rubber sheets to the back of the tufted carpet.
  • I therefore propose to provide means for applying a thin layer of adhesive to the tufts in a tufted carpet as soon as possible after the tufts are lodged in position.
  • I may spray on a thin coating of adhesive such as latex, and then heat the adhesive as for example, by an infra-redradiator, or high frequency electric current, to polymerise, dry or set the adhesive before the carpet passes round a forwarding roller or has the foamed layer applied to it.
  • the tufts are firmly secured in the backing, and the foamed layer is applied later in a separate machine, on top of a thicker coating of adhesive material such as latex, in which case a certain amount of pressure may have to be applied to the said layer in order to make it adhere securely to the carpet originally formed.
  • adhesive material such as latex
  • a non-woven material made from a fleece of natural or artificial filaments adhering together may be employed.
  • a fabric made'of a plurality of interlaced tapes may be used, the tapes themselves being of thermoplastic materials which have previously been'extruded or rolled into sheet form and then slit.
  • Such a fabric even if woven or knitted, has a much more uniform consistency throughout the whole of its area than a backing fabric woven from jute or like yarns.
  • a backing material may be made by partially shattering a sheet of artificial resin, this being effected along lines of strain caused in the material during its manufacture. The shattering may be effected by ultrasonic vibrations, and is preferably incomplete, so that the sheet as a whole holds together.
  • FIG. I shows the application of a foamed backing layer to a tufted carpet immediately after the insertion of the tufts in the backing material
  • FIG. 2 shows the application of a thin layer of an adhesive to the tufts after their insertion, the layer being dried thereafter;
  • FIG. 3 shows the application of a foamed backing layer to the carpet as intermediately produced in FIG. 2.
  • FIG. 1 a single tufting machine for directly applying a foamed backing layer to a carpet is shown.
  • Backing fabric 1 passes beneath a row of needles 2 which re ciprocate up and down, inserting straight tufts 3 of pile yarn in the backing fabric.
  • each of the tufts 3 has a relatively long (pile) end at the front side of the fabric and a short (fixing) end at the back of the fabric.
  • the backing fabric travels in the direction of the arrow to the right, and passes underneath an adhesive applicator 4 which sprays the short ends (fixing ends) of the tufts with a latex material or an adhesive in a volatile solvent, which by the time it reaches the roller 7 has become tacky.
  • the backing fabric and tufts are joined by a layer 8 of resilient foamed rubber, this layer being separately produced without the use of a backing sheet.
  • a layer has an improved performance as compared with previously known types of resilient layers, and after application to the adhesive, the backing layer and fabric pass between nip rollers 9, this causing adequate adhesion to take place between the resilient layer and the adhesive, the short ends of the tufts being splayed apart first by the adhesive and second by the nip rollers, so that the tufts are firmly held in the backing fabric, and the resilient layer is firmly held onto the tufts and backing fabric.
  • The-finished carpet can then be wound up on the takeup roll. If required, the nip rollers may be heated to set the adhesive and swell the pile yarn.
  • FIG. 2 shows a machine in which a backing fabric 11 passes under a row of needles 12 which apply rows of tufts 13 to the backing fabric.
  • the upper or short ends of the tuft are sprayed with a latex adhesive from a spray l4, and the backing fabric and tufts then pass underneath a dryer 15 which uses infra-red or ultra high frequency radiation to dry or polymerise the adhesive.
  • the application of the latex and drying thereof flattens the upper ends of the tufts as seen at 16, so that they are very firmly fixed in the backing fabric.
  • the fabric and tufts can then be wound up onto a take-up roll to be processed later as shown in FIG. 3.
  • the backing fabric may be of normal type such as woven jute, but is perferably of non-woven material composed for example of polyethylene threads which are laid randomly to form a sheeting, and then caused to adhere to one another by means of pressure applied by heated rollers.
  • polystyrene threads made by pulling apart or shattering a sheet of oriented molecule polystyrene may be used instead.
  • Such materials since they do not contain a definite pattern of threads as in a woven fabric, enable better location of the tufts and more secure holding thereof, until the tufts are secured in the fabric by the adhesive.
  • a method of manufacturing a tufted carpet comprising the steps of traversing a backing fabric which has a front and a back past a row of tufting needles, causing said needles to insert straight tufts of pile yarn through said backing fabric with each tuft having a relatively long, pile end projecting forwardly from the front of the backing fabric and an opposed relatively short fixing end projecting from the back of the fabric, applying an-adhesive to said short ends of said tufts at the back of the fabric to secure them in said fabric, separately producing a layer of resilient foamed rubber, sticking said layer to said back of said backing fabric and said short ends of said tufts by means of an adhesive, and splaying said short ends apart and situating them in flattened condition against the back of the fabric, said splaying and flattening of said short ends being carried out at a time no later than the sticking of said layer to said back of said backing fabric.
  • a method as recited in claim 1 in which the insertion of said tufts and the application of a first layer of adhesive are effected on one machine, whereafter the part-finished carpet is transferred to another machine where said part finished carpet receives a second coating of adhesive on the first, said second coating filling any gaps between said short ends of said tufts, said foamed layer being applied to said second layer of adhesive.
  • a method as recited in claim 1 including the step of setting said adhesive by radiation.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
  • Laminated Bodies (AREA)
US00210507A 1970-12-31 1971-12-21 Backed tufted carpet and method of manufacturing the same Expired - Lifetime US3856596A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB6209470 1970-12-31

Publications (1)

Publication Number Publication Date
US3856596A true US3856596A (en) 1974-12-24

Family

ID=10487871

Family Applications (1)

Application Number Title Priority Date Filing Date
US00210507A Expired - Lifetime US3856596A (en) 1970-12-31 1971-12-21 Backed tufted carpet and method of manufacturing the same

Country Status (7)

Country Link
US (1) US3856596A (fr)
JP (1) JPS4845035A (fr)
AU (1) AU458232B2 (fr)
DE (1) DE2162200B2 (fr)
FR (1) FR2120967A5 (fr)
GB (1) GB1329110A (fr)
ZA (1) ZA718592B (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5370757A (en) * 1991-08-30 1994-12-06 Basf Corporation Process for manufacturing substantially 100% nylon 6 carpet
US5403640A (en) * 1993-08-27 1995-04-04 Reichhold Chemicals, Inc. Textile coating and method of using the same
WO2001091606A1 (fr) * 2000-05-26 2001-12-06 Deforest Bishop Tampon universel de polissage et de nettoyage
US6453502B1 (en) 1998-12-22 2002-09-24 Bishop Deforest Universal cleaning and polishing pad
US20100129571A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US20100129570A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US8968502B1 (en) * 2009-11-06 2015-03-03 John H. Bearden Method for coating a tufted athletic turf backing

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3616297A1 (de) * 1986-05-14 1987-11-19 Lentia Gmbh Badematte

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2495666A (en) * 1947-06-24 1950-01-24 Elizabeth H Taubert Method of making pile fabrics
US2563478A (en) * 1951-08-07 Electronic vulcanization of sponge
US3250661A (en) * 1958-02-18 1966-05-10 Avco Mfg Corp Reinforced material and method of making the same
US3285797A (en) * 1964-05-04 1966-11-15 Bigelow Sanford Inc Axminster carpet
US3332828A (en) * 1965-12-28 1967-07-25 Monsanto Co Monofilament ribbon pile product
US3385751A (en) * 1963-09-18 1968-05-28 Specialty Converters Tufted pile carpet and manufacture thereof
US3573147A (en) * 1968-01-24 1971-03-30 Monsanto Co Synthetic turf products having variable blade widths
US3600261A (en) * 1964-04-15 1971-08-17 Girmes Werke Ag Flame retarding backing for inflammable webs
US3674618A (en) * 1970-11-16 1972-07-04 Phillips Petroleum Co Imitation sliver knit pile fabric
US3778330A (en) * 1970-12-31 1973-12-11 S Shorrock Tufted carpet

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2563478A (en) * 1951-08-07 Electronic vulcanization of sponge
US2495666A (en) * 1947-06-24 1950-01-24 Elizabeth H Taubert Method of making pile fabrics
US3250661A (en) * 1958-02-18 1966-05-10 Avco Mfg Corp Reinforced material and method of making the same
US3385751A (en) * 1963-09-18 1968-05-28 Specialty Converters Tufted pile carpet and manufacture thereof
US3600261A (en) * 1964-04-15 1971-08-17 Girmes Werke Ag Flame retarding backing for inflammable webs
US3285797A (en) * 1964-05-04 1966-11-15 Bigelow Sanford Inc Axminster carpet
US3332828A (en) * 1965-12-28 1967-07-25 Monsanto Co Monofilament ribbon pile product
US3573147A (en) * 1968-01-24 1971-03-30 Monsanto Co Synthetic turf products having variable blade widths
US3674618A (en) * 1970-11-16 1972-07-04 Phillips Petroleum Co Imitation sliver knit pile fabric
US3778330A (en) * 1970-12-31 1973-12-11 S Shorrock Tufted carpet

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5370757A (en) * 1991-08-30 1994-12-06 Basf Corporation Process for manufacturing substantially 100% nylon 6 carpet
US5464677A (en) * 1991-08-30 1995-11-07 Basf Corporation Process for manufacturing substantially 100% nylon 6 carpet
US6398891B1 (en) 1991-08-30 2002-06-04 Basf Corp Recyclable carpet
US5403640A (en) * 1993-08-27 1995-04-04 Reichhold Chemicals, Inc. Textile coating and method of using the same
US6453502B1 (en) 1998-12-22 2002-09-24 Bishop Deforest Universal cleaning and polishing pad
US20020184723A1 (en) * 1998-12-22 2002-12-12 Bishop Deforest Universal cleaning and polishing pad
US6811629B2 (en) 1998-12-22 2004-11-02 Bishop Deforest Method of fabricating an all synthetic universal cleaning and polishing pad
WO2001091606A1 (fr) * 2000-05-26 2001-12-06 Deforest Bishop Tampon universel de polissage et de nettoyage
US20100129571A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US20100129570A1 (en) * 2008-11-25 2010-05-27 Precisionjet, Inc. Method for making artificial turf
US8647452B2 (en) * 2008-11-25 2014-02-11 John H. Bearden Method for making artificial turf
US8968502B1 (en) * 2009-11-06 2015-03-03 John H. Bearden Method for coating a tufted athletic turf backing

Also Published As

Publication number Publication date
GB1329110A (en) 1973-09-05
JPS4845035A (fr) 1973-06-28
DE2162200B2 (de) 1975-04-30
AU458232B2 (en) 1975-02-20
DE2162200A1 (de) 1972-07-06
ZA718592B (en) 1972-09-27
AU3719571A (en) 1973-06-28
FR2120967A5 (fr) 1972-08-18

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