US3928694A - Pile carpet and a process for its manufacture - Google Patents

Pile carpet and a process for its manufacture Download PDF

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Publication number
US3928694A
US3928694A US342084A US34208473A US3928694A US 3928694 A US3928694 A US 3928694A US 342084 A US342084 A US 342084A US 34208473 A US34208473 A US 34208473A US 3928694 A US3928694 A US 3928694A
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United States
Prior art keywords
strips
pile
fabric
base
carpet
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Expired - Lifetime
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US342084A
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English (en)
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Ruedi Reinhard
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Individual
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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
    • Y10T156/1062—Prior to assembly
    • Y10T156/1075—Prior to assembly of plural laminae from single stock and assembling to each other or to additional lamina
    • 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
    • Y10T156/1084—Methods of surface bonding and/or assembly therefor with cutting, punching, tearing or severing of continuous or running length bonded web
    • Y10T156/1085—One web only
    • 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
    • Y10T428/23957—Particular shape or structure of pile
    • 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

  • ABSTRACT A pile carpet having a pile of textile yarn perpendicular to a base.
  • the base includes fabric strips abutting each other by their lateral edges and standing on edge on one of their edges.
  • the pile comprises free, unbound ends of yarn running perpendicular to the base in the fabric strips with their free ends projecting beyond the other edges of the fabric strips.
  • the method of making the pile carpet includes cutting a fabric run, having warp threads in groups so spaced that the weft threads float between the warp thread groups, into fabric strips each provided with adjoining domains extending over each ones entire length, the warp threads being tied off by weft threads extending freely from the tied-off domain towards an edge of the fabric strips, placing the fabric strips on edge, and adhesively bonding the lateral areas of the fabric strips so that the tied-off domains will result in the base and the free weft threads in the pile of the carpet.
  • the present invention relates to a pile carpet having a pile of textile yarn perpendicular to the base and to a manufacturing process for such carpet.
  • Pile carpets with piles consisting of textile yarns that are normal to the base have long been known. Due to their better quality, which also makes them the more expensive carpets, they represent the most widespread kind of carpet. Many basically different methods are known for the manufacture of such carpets. Probably the most expensive manufacturing method for carpets with piles normal to the floor is the manual kind of manufacture as still occurs today in the East, wherein the pile yarn is tied into knots with a yarn warp in the carpet base. The same manufacturing principle as regards machine production also is being used, resulting in such a quality that only an expert may distinguish between handmade and machine made kinds of oriental rugs. However, large investment in machinery is required for machine production of knotted carpets and the possible production capacity is fairly small.
  • Tufted carpets represent another technological advance with respect to production rates.
  • the pile yarn normal to the base fabric is made to pass through the latter by the use of hollow needles.
  • the reverse side of such carpets will be usually coated so as to fasten the pile yarns.
  • needle felt carpet wherein a tangled web is pierced from the reverse side by the use of barbed needles in such a manner that part of the fibers from the horizontal binding are torn therefrom and are pushed out above the webs surface thereby resulting in a pile perpendicular to the base.
  • This kind of needle felt carpet must be provided with a back coating for fixation. They are economical but are not comparable as regards quality with woven or knotted carpets.
  • Block formation requires placing the layers individually one on top of the other, the setting medium requires drying after block formation and prior to plate cutting, and the block forming mold allows filling only after the entire supply in it has been cut into plates. A sequence of operations must be followed which not only is time-consuming, but also necessitates working in fits and starts.
  • British Pat. specification No. 589,908 describes the manufacture of a pile carpet made of fabric strips glued on a support.
  • the strips are obtained by cutting a length of fabric, the warp yarn of which is consolidated into bands that are spaced from one another and are distributed over the width of the fabric web in such an array that the weft yarn floats between warp bands.
  • the cutting lines strictly lie within the strips of the floating weft yarns, whereas the woven strips will be formed in the interlacing range of the weft and warp yarns.
  • the side surfaces of the strips are placed one against another and are fastened by adhesives or by stitching and the like on the support.
  • the free weft yarns which are perpendicular to the support on account of the longitudinal folding of the fabric strip, therefore form the carpet pile, the thickness of which may be controlled by the spacings between the individual fabric strips running one along the other. This process is quite cumbersome and requires much labor, while simulta-- neously allowing manufacturing only one carpet at a time.
  • Swiss Pat. specification No. 377,773 describes a process for the manufacture of a felt carpet with felt strips running parallel to a support to which the strips are glued, wherein strips are cut in a direction perpendicular to the prevailing fiber direction, these strips being arrayed one against another and so glued to the support by one of the free cutting edges that the main fiber direction of the strips will be perpendicular to the support.
  • This Swiss patent therefore, refers to a felt carpet with felt in the entire cross-section and without free pile.
  • the process described therein discloses no teaching making it evident to the expert as to how to make a carpet of higher quality, and, where desired, one of an arbitrary pattern that would consist of free yarn pile.
  • German Pat. specification No. 830,042 describes a process for the manufacture of carpets wherein textile strips are placed on edge and compressed into bales, the latter then being arrayed themselves on edge and densely packed one against the other. The bales are then provided with a base layer at one of the two free surfaces or are glued to a support. This process too is complex and costlyin labor, while permitting the manufacture of only one carpet at a time. Furthermore, the pattern variability is limited. If a free standing pile is desired, further treatment must be applied to the free surface of the carpet so manufactured.
  • French disclosed application No. 2,044,778 describes a process for the manufacture of pile carpets which are reproducibly patterned, a length of fabric being made the weft yarn of which will provide the carpet pile the weft yarns being fastened by only few warp yarns.
  • the fabric so obtained will then be folded in a zig-zag in such a manner that a block is achieved with lateral surfaces consisting of the end surfaces of the weft yarns.
  • One of those lateral surfaces then is glued to a support with a slice of the desired pile height then being cut off the block.
  • This process is extremely complicated and difficult to carry out. Complex equipment is required for making the block by folding the fabric and for fixing the block.
  • auxiliary equipment is needed for the patterning of the weft yarn.
  • a carpet is described in Swiss Pat. specification No. 40l,892, wherein the pile stands in rows perpendicularly to the plane of the carpet, the individual pile rows being firmly connected to one another by intermediate band like layers extending from the base of the pile over part of the pile height and being glued on both sides to the neighboring pile rows.
  • the latter achieves extraordinary cohesion and such stability that any additional measure for strengthening, such as backside coating and the like, is superfluous.
  • This Swiss patent specification also describes a process for making a carpet such that spaced, parallel, transverse strips, forming the intermediate layers, are glued on a continuously moving fibrous web which then will be divided into individual elements by means of cuts in the longitudinal axes of these transverse strips. The remaining free surfaces of the intermediate layers are then coated with adhesive and the individual elements are so placed one on top of the other that the intermediate layers will be located one above another and will be glued to the pile of the next element. As previously explained, the structure so achieved will then be cut in the center plane parallel to both outer surfaces, two carpets thus being obtained, the back sides of which each will be formed by one of the outer surfaces.
  • This procedure allows the simultaneous feeding of the band like intermediate layer material in several, parallel, spaced intermediate layers. After combining all such continuously supplied intermediate layers forming in their spaced arrangement one fabric width with the textile fiber material, an endless fabric band structure will be thus achieved.
  • This structure may be divided into individual strips by cuts in the longitudinal axes of the intermediate layer bands and parallel thereto in the region of the textile fiber material located between the individual bands, the textile fiber material being snug with one of the longitudinal edges of the band like material in those strips and projecting beyond the other longitudinal edge.
  • Textile yarn is used for the manufacture of the best quality achievable according to the processes described above where the pile may be patterned.
  • This requires laying the pile yarn in the form of a bond of yarns, by means of a gripper in repeats, transversely across the intermediate layer bands being supplied in spaced parallel relationship.
  • the yarn warp being amenable to Jacquard to attachment control if a particular pattern is desired.
  • a preferred embodiment of the process suffers from the drawback that the intermediate layer bands no longer may be moved on continuously, but must be moved step wise, and must be advanced each time by the width of the deposited yarn warp.
  • the step wise advance, the gripper device required for gripping and depositing the yarn warp, the parallel feeding of the individual intermediate layer bands and possibly the patterning by a Jacquard attachment do however require high expenditures for equipment and high precision in the devices used for this purpose.
  • the present invention addresses the task of providing a high-quality carpet in which the upright standing pile is not only bonded to the back side at the cross-sectional surface of the pile and, which requires no back side coating of any kind, but in which the pile consists of carpet yarn of any desired fibers or fiber mixtures, whereby the carpet may be patterned, and may be manufactured with high productivity while maintaining the desired quality.
  • the object of the invention is a pile carpet having a pile perpendicular to a base and including textile yarn wherein the base comprises woven fabric strips abutting each other by their lateral areas and being connected to one another, said strips standing upright on edge on one of their edges, and wherein the pile comprises free, unbound ends of said yarn running perpendicularly to said base in said fabric strips, said free ends projecting beyond the other edges of said fabric strips.
  • the fabric strips of the carpet of the invention are connected to one another within the region of the fabric by an adhesive.
  • the fabric strips contain synthetic, thermo-weldable textile fibers and are bonded to one another within'the region of the fabric by th'ermo-welding.
  • the endless strips obtained following cutting of the fabric web in the process of the invention in principle are similar in construction to the strips described in the above-mentioned Swiss Pat. specification No.; however, they may be obtained in a far simpler manner from yarn alone and no longer necessitate a complex procedure with intermediate layer bands.
  • An essential advantage of the process of the invention consists of the feasibility of using any kind of loom for the manufacture of the fabric web.
  • a further advantage consists of the ability to pattern the weft yarn in the loom forming the pile of the carpet. Hence, the pile may be patterned, while the warp yarn consolidated into bands may consist of any yarn material of appropriate mechanical strength.
  • FIG. 1 is a top view of a fabric web for the manufacture of the carpet of the invention.
  • FIG. 2 illustrates a fabric strip obtained by cutting the fabric web of FIG. 1,
  • FIG. 3 shows a schematic representation of abutting fabric strips of FIG. 2 connected to one another in the process of making a carpet according to the invention.
  • Warp bands 1 in the fabric web of FIG. 1 may be of synthetic, multi-filament yarns.
  • the weft yarn 2 is carpet yarn which, according to the desired quality of carpet, may be uniform or varied, of one color or of patterned coloring, of uniform or varied titer, and of synthetic or natural fibers and/or a mixture of such fibers.
  • the fabric web may be stored at the take-off end of the loom and be cut in'a known manner at any desired time, for example, by circular knives appropriately spaced from one another and arrayed along a common axis, into continuous strips along cutting lines 3. A strip so obtained is shown in FIG. 2.
  • the strips obtained then may be arrayed one against the other in a known manner and as schematically shown in FIG. 3, a formation being obtained, one surface of which consists of the cut edges of the individual fabric strips arrayed one against another, the other surface of which consists of the free, unbound weft yarn ends projecting beyond the other edges of the fabric strips.
  • the dimensions of the carpet so achieved may be varied, the length depending on that of the individual fabric strips, the width of the thickness and number of fabric strips arrayed against each other and connected to one another, the thickness of the reverse side of the carpet depending on the width of the part of the woven fabric of the individual strips, and the pile height depending on the length of the free, unbound weft yarn ends projecting beyond the edge of the fabric strips.
  • connection of the abutting strips may be effected in any manner, for instance by means of glue.
  • the bonding of the fabric strips may also be achieved by thermo-welding.
  • Another possibility is the purely mechanical connection of the strips, for instance, by means of staples or by sewing.
  • FIG. 2 Various methods are known for abutting and connecting the strips of FIG. 2, which are achieved by cutting a fabric web as in FIG. 1, so as to make the carpet described.
  • Swiss Pat. specification No. 521,114 one will find several preferred embodiments.
  • a pile carpet having a pile perpendicular to a base and including textile yarn wherein the base comprises woven fabric strips abutting each other by their lateral areas and being connected to one another, said strips standing upright on edge on one of their edges, and
  • pile comprises free, unbound ends of said yarn running perpendicularly to said base in said fabric strips, said free ends projecting beyond the other edges of said fabric strips.
  • thermo-welding comprises thermo-welding
  • a process for manufacturing according to claim 4 wherein the step of bonding comprises adhesively bonding said lateral edges.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Nonwoven Fabrics (AREA)
  • Woven Fabrics (AREA)
US342084A 1972-03-23 1973-03-16 Pile carpet and a process for its manufacture Expired - Lifetime US3928694A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CH435072 1972-03-23

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USB342084I5 USB342084I5 (de) 1975-01-28
US3928694A true US3928694A (en) 1975-12-23

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US342084A Expired - Lifetime US3928694A (en) 1972-03-23 1973-03-16 Pile carpet and a process for its manufacture

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US (1) US3928694A (de)
JP (1) JPS4913934A (de)
AU (1) AU471992B2 (de)
CA (1) CA991974A (de)
CH (2) CH546564A (de)
FR (1) FR2177052B1 (de)
GB (1) GB1399780A (de)
IT (1) IT981241B (de)
ZA (1) ZA731664B (de)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4138514A (en) * 1978-05-25 1979-02-06 Terpay John M Pile surface resembling turf and method of making it
US4709453A (en) * 1986-10-14 1987-12-01 Foster-Miller, Inc. Separable fastening device
US5168000A (en) * 1988-10-04 1992-12-01 Textilma Ag Flat textile body
US5674585A (en) * 1995-11-15 1997-10-07 United Technologies Corporation Composite thermal insulation structure
US5716689A (en) * 1996-09-19 1998-02-10 Integrated Process Technologies Hollow fiber membrane carpet manufacturing method and an elementary carpet member and carpet

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5679765A (en) * 1979-11-29 1981-06-30 Toray Industries Production of leather like structure

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3174451A (en) * 1963-03-26 1965-03-23 Du Pont Pile article of backing, cushioning and pile yarn layers

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3174451A (en) * 1963-03-26 1965-03-23 Du Pont Pile article of backing, cushioning and pile yarn layers

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4138514A (en) * 1978-05-25 1979-02-06 Terpay John M Pile surface resembling turf and method of making it
US4709453A (en) * 1986-10-14 1987-12-01 Foster-Miller, Inc. Separable fastening device
US5168000A (en) * 1988-10-04 1992-12-01 Textilma Ag Flat textile body
US5674585A (en) * 1995-11-15 1997-10-07 United Technologies Corporation Composite thermal insulation structure
US5716689A (en) * 1996-09-19 1998-02-10 Integrated Process Technologies Hollow fiber membrane carpet manufacturing method and an elementary carpet member and carpet

Also Published As

Publication number Publication date
ZA731664B (en) 1973-12-19
AU5328773A (en) 1974-09-19
CH435072A4 (de) 1973-06-29
JPS4913934A (de) 1974-02-06
USB342084I5 (de) 1975-01-28
GB1399780A (en) 1975-07-02
CH546564A (de) 1974-03-15
AU471992B2 (en) 1976-05-13
FR2177052A1 (de) 1973-11-02
FR2177052B1 (de) 1977-04-29
CA991974A (en) 1976-06-29
IT981241B (it) 1974-10-10

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