US3913510A - Tufted carpets with elastomeric net backing - Google Patents
Tufted carpets with elastomeric net backing Download PDFInfo
- Publication number
- US3913510A US3913510A US436214A US43621474A US3913510A US 3913510 A US3913510 A US 3913510A US 436214 A US436214 A US 436214A US 43621474 A US43621474 A US 43621474A US 3913510 A US3913510 A US 3913510A
- Authority
- US
- United States
- Prior art keywords
- net
- strands
- elastomeric
- carpet
- percent
- Prior art date
- 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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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
Definitions
- Tufted carpets are well known in the art and have been produced for quite a number of years.
- the carpets are usually produced from continuous strands of nylon, polyester, acrylic or similar materials.
- the continuous strands are poked through a fabric mesh-type backing material so that loops are formed, which loops are positioned adjacent each other.
- the material is then held in place in the backing material by a suitable adhesive such as a latex which is applied to the underside of the carpet.
- the backing materials commonly employed are woven fabrics and perhaps the most common fabric in use today is one formed from polypropylene wherein the polypropylene is first made as a film, slit into strips, and then woven to form the fabric. While these prior art carpets have proven quite satisfactory, they have a number of process disadvantages. For example, the additional step of applying the backing adhesive such as the latex is costly and expensive since additional application apparatus is required. Environmental problems have also been encountered of late with respect to disposal of the excess adhesive material and the cleaning up of equipment used in the application of the material.
- the carpet can be made with great speed as compared to the speed of existing processes. Furthermore, the relative accuracy of location of the tufts is enhanced because of the uniformity of the elastomeric net.
- the material from which the carpet backing of the present invention is formed is an elastomeric material.
- the elastomeric material must have an elongation of at least 50 percent with a tensile set under 50 percent of that elongation.
- Preferred compounds for use in the present invention are the polyurethanes, either the polyester or the polyether prepolymer being suitable.
- the carpet backing material according to the present invention could comprise more than two sets of strands.
- all of the sets of strands be of the elastomeric material.
- Elastomeric carpet backing materials in which only one of the sets of strands are elastomeric can suitably be prepared according to U.S. Pat. No. 3,700,521. Where only one set of strands is elastomeric, the other sets of strands can suitably be polyethylene, polypropylene or the like.
- FIGS. are a schematic representation of a process suitable for tufting carpet in accordance with the present invention. It will be understood that the Applicants invention is the elastomeric net backing material and is not apparatus for the tufting of carpets.
- FIGS. are a schematic representation of a process suitable for tufting carpet in accordance with the present invention. It will be understood that the Applicants invention is the elastomeric net backing material and is not apparatus for the tufting of carpets.
- FIGS. are a schematic representation of a process suitable for tufting carpet in accordance with the present invention. It will be understood that the Applicants invention is the elastomeric net backing material and is not apparatus for the tufting of carpets.
- FIG. 1 shows the carpet material before it has been poked through the net
- FIG. 2 shows the finished product
- FIG. 1 there is shown a net 10 with longitudinal strands 12, transverse strands 14 and integral joints 16 bonding the longitudinal and transverse strands to each other.
- the net is being held under tension in both the longitudinal and transverse directions by suitable means (not shown).
- a strand of carpet 18 is positioned below the net 10 with a poking apparatus 20 positioned therebeneath.
- the poking apparatus has spindles 22 thereon corresponding to each of the open areas 24 of the elastomeric net.
- the poking apparatus is oscillated in the up and down manner of arrow 26 whereby the strands of carpet 18 is inserted through the net at each of the perforations 24 of the net. This process is repeated for each row of perforations in the net.
- FIG. 2 there is shown a cut-away view of a carpet made in accordance with the present invention, as for example by the apparatus shown in FIG. 1.
- the strands of carpet material 18 with loops 28 is being held in position by net 10 comprising longitudinal strands 12 and transverse strands 14. It will be understood that loops 28 could be sheared at the top to .form a sheared pile rather than the loop pile shown. This shearing process is well known in the art.
- an elastomeric carpet backing material was made according to the apparatus of U8. Pat. No. 3,252,181.
- the backing material was extruded with integral joints and had 15 strands per inch in the direction of extrusion (machine direction) and 1 5 stands per inch in the transverse direction.
- the resin used was a polyester polyurethane resin known as Texin 591A available from Mobay Chemical Company.
- the extruded carpet backing material was cut to suitable shape and was found to have elongation in excess of 50 percent and a tensile set of under 50 percent at that elongation. More specifically, the net had a percent tensile set at 100% elongation and a 32 percent tensile set at 200 percent elongation.
- the elastomeric net was found to be suitable as a carpet backing material in accordance with the present invention and was found to have the desired properties of holding tufted carpet material in position without the need for adhesive.
- a tufted carpet consisting essentially of a carpet material and an elastomeric net backing material, said elastomeric net comprising a plurality of spaced sets of strands crossing each other at an angle whereby there are perforations in the elastomeric net, crossings formed by the strands of one set crossing the strands of another set forming integral joints at the crossings, wherein at least one of the sets of strands is composed of an elastomeric material having an elongation of at least 50 percent and a tensile set of less than 50 percent at that elongation, said carpet material passing through the perforations in the net and said elastomeric net helping to hold the carpet material in position.
- both of the sets of strands are composed of elastomeric material having an elongation of at least about 50 percent and a tensile set of less than 50 percent at that elongation.
- a process for making a tufted carpet the steps of:
- tensioning at least one set of elastomeric strands of an elastomeric net comprising a plurality of spaced sets of strands crossing each other at an angle whereby there are perforations in the elastomeric net, crossings formed by the strands of one set corssing the strands of another set forming integral joints at the crossings, at least one of the sets of strands being composed of an elastomeric material having an elongation of at least about 50 percent and a tensile set of less than 50 percent at that elongation.
Abstract
Description
Claims (7)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US436214A US3913510A (en) | 1974-01-24 | 1974-01-24 | Tufted carpets with elastomeric net backing |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US436214A US3913510A (en) | 1974-01-24 | 1974-01-24 | Tufted carpets with elastomeric net backing |
Publications (1)
Publication Number | Publication Date |
---|---|
US3913510A true US3913510A (en) | 1975-10-21 |
Family
ID=23731574
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US436214A Expired - Lifetime US3913510A (en) | 1974-01-24 | 1974-01-24 | Tufted carpets with elastomeric net backing |
Country Status (1)
Country | Link |
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US (1) | US3913510A (en) |
Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0045592A1 (en) * | 1980-07-30 | 1982-02-10 | Smith and Nephew Associated Companies p.l.c. | Elastic bandages |
US4407284A (en) * | 1980-02-11 | 1983-10-04 | Johnson & Johnson Baby Products Company | Laminated structures having gathered and ungathered marginal portions and method of manufacturing the same |
US5851935A (en) * | 1996-08-29 | 1998-12-22 | Bba Nonwovens Simpsonville, Inc. | Cross-directionally stretchable elastomeric fabric laminated by thermal spot bonding |
US6025050A (en) * | 1994-06-15 | 2000-02-15 | Bba Nonwovens Simpsonville, Inc. | Thermally appertured nonwoven laminates for wipes and coverstock for hygienic articles |
US20040178544A1 (en) * | 2003-03-13 | 2004-09-16 | Jackson Byron M. | Polymer transfer apparatus, methods, and composite webs |
US20060220271A1 (en) * | 2003-03-13 | 2006-10-05 | 3M Innovative Properties Company | Composite webs and closure systems |
US7534481B2 (en) | 2006-08-08 | 2009-05-19 | 3M Innovative Properties Company | Shaped elastic tab laminates |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2486963A (en) * | 1945-12-18 | 1949-11-01 | Callaway Mills Co | Method of making tufted terry products |
US2725835A (en) * | 1953-04-27 | 1955-12-06 | Robert I Mather | Composite carpet and method of making same |
US3110905A (en) * | 1961-09-26 | 1963-11-19 | Lees & Sons Co James | Tufted pile fabric comprising a flat woven synthetic plastic backing |
US3240176A (en) * | 1963-07-05 | 1966-03-15 | John R Morrison | Method for making simulated needlepoint embroidery |
US3377973A (en) * | 1965-07-07 | 1968-04-16 | Grace W R & Co | Tufting method and article |
US3694873A (en) * | 1970-04-02 | 1972-10-03 | Richard P Crowley | Method of preparing a tufted rug with cellular fibers |
-
1974
- 1974-01-24 US US436214A patent/US3913510A/en not_active Expired - Lifetime
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2486963A (en) * | 1945-12-18 | 1949-11-01 | Callaway Mills Co | Method of making tufted terry products |
US2725835A (en) * | 1953-04-27 | 1955-12-06 | Robert I Mather | Composite carpet and method of making same |
US3110905A (en) * | 1961-09-26 | 1963-11-19 | Lees & Sons Co James | Tufted pile fabric comprising a flat woven synthetic plastic backing |
US3240176A (en) * | 1963-07-05 | 1966-03-15 | John R Morrison | Method for making simulated needlepoint embroidery |
US3377973A (en) * | 1965-07-07 | 1968-04-16 | Grace W R & Co | Tufting method and article |
US3694873A (en) * | 1970-04-02 | 1972-10-03 | Richard P Crowley | Method of preparing a tufted rug with cellular fibers |
Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4407284A (en) * | 1980-02-11 | 1983-10-04 | Johnson & Johnson Baby Products Company | Laminated structures having gathered and ungathered marginal portions and method of manufacturing the same |
EP0045592A1 (en) * | 1980-07-30 | 1982-02-10 | Smith and Nephew Associated Companies p.l.c. | Elastic bandages |
US6025050A (en) * | 1994-06-15 | 2000-02-15 | Bba Nonwovens Simpsonville, Inc. | Thermally appertured nonwoven laminates for wipes and coverstock for hygienic articles |
US5851935A (en) * | 1996-08-29 | 1998-12-22 | Bba Nonwovens Simpsonville, Inc. | Cross-directionally stretchable elastomeric fabric laminated by thermal spot bonding |
US20060220271A1 (en) * | 2003-03-13 | 2006-10-05 | 3M Innovative Properties Company | Composite webs and closure systems |
US20040180186A1 (en) * | 2003-03-13 | 2004-09-16 | 3M Innovative Properties Company | Composite webs and closure systems |
US20040178544A1 (en) * | 2003-03-13 | 2004-09-16 | Jackson Byron M. | Polymer transfer apparatus, methods, and composite webs |
US7195729B2 (en) | 2003-03-13 | 2007-03-27 | 3M Innovative Properties Company | Composite webs and closure systems |
US20070141300A1 (en) * | 2003-03-13 | 2007-06-21 | 3M Innovative Properties Company | Composite webs and closure systems |
US7238314B2 (en) | 2003-03-13 | 2007-07-03 | 3M Innovative Properties Company | Polymer transfer apparatus, methods, and composite webs |
US20070176325A1 (en) * | 2003-03-13 | 2007-08-02 | 3M Innovative Properties Company | Polymer transfer apparatus, methods, and composite webs |
US7390451B2 (en) | 2003-03-13 | 2008-06-24 | 3M Innovative Properties Company | Composite webs and closure systems |
US7669297B2 (en) | 2003-03-13 | 2010-03-02 | 3M Innovative Properties Company | Composite webs and closure systems |
US20100112274A1 (en) * | 2003-03-13 | 2010-05-06 | 3M Innovative Properties Company | Composite webs and closure systems |
US7534481B2 (en) | 2006-08-08 | 2009-05-19 | 3M Innovative Properties Company | Shaped elastic tab laminates |
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Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: LEUCADIA, INC., 315 PARK AVENUE SOUTH, NEW YORK, N Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:CONWED CORPORATION;REEL/FRAME:004655/0504 Effective date: 19861204 Owner name: LEUCADIA, INC., 315 PARK AVENUE SOUTH, NEW YORK, N Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:CONWED CORPORATION, A CORP. OF DE.;REEL/FRAME:004660/0016 Effective date: 19861204 Owner name: LEUCADIA, INC., A CORP OF NY.,NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CONWED CORPORATION;REEL/FRAME:004655/0504 Effective date: 19861204 Owner name: LEUCADIA, INC., A CORP. OF NEW YORK,NEW YORK Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:CONWED CORPORATION, A CORP. OF DE.;REEL/FRAME:004660/0016 Effective date: 19861204 |