WO2001040561A2 - A tufted pile structure having binder concentrated on, through and in the vicinity of the backstitches - Google Patents
A tufted pile structure having binder concentrated on, through and in the vicinity of the backstitches Download PDFInfo
- Publication number
- WO2001040561A2 WO2001040561A2 PCT/US2000/032547 US0032547W WO0140561A2 WO 2001040561 A2 WO2001040561 A2 WO 2001040561A2 US 0032547 W US0032547 W US 0032547W WO 0140561 A2 WO0140561 A2 WO 0140561A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- backing
- elements
- backstitch
- binder
- lower face
- Prior art date
Links
Classifications
-
- 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
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/45—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by forming intermeshing loops or stitches from some of the fibres
-
- 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
-
- 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
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0073—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as an aqueous dispersion or latex
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
- D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/02—Dispersion
- D06N2205/023—Emulsion, aqueous dispersion, latex
Definitions
- the present invention relates to a tufted pile surface structure and to a method for producing the same in which binder material is concentrated on, through or in the vicinity of the backstitch elements of the pile yarns.
- each of a plurality of pile yarns is drawn by a tufting needle through a backing to form face fiber elements and backstitch elements.
- the face fiber elements lie adjacent to the upper face of the backing while the backstitch elements are disposed along the lower face of the backing.
- the backstitch elements are secured by a thermoset or thermoplastic binder placed on the lower face of the backing. In actuality, only a small portion of the binder material serves to hold the backstitch elements in place, while a large portion of the binder material is wasted.
- the present invention is directed to a pile surface structure and a process for manufacturing the same.
- Each of a plurality of pile yarns is tufted by a separate tuftmg needle through a plurality of needle insertion points m the backing to form face fiber elements that lie adjacent to the upper face of the backing and backstitch elements that overlay the lower face of the backing.
- the insertion points produced by the tuft g needles form a pattern of parallel lines that extend longitudinally and transversely along the back face of the backing.
- a liquid binder material is applied to the backstitch elements.
- the binder material soaks into and through and collects in the vicinity of the backstitch elements.
- the pile surface structure is heat-treated to activate the binder material to hold the backstitch elements to the backing. Those portions of the lower face of the backing not overlaid by the backstitch elements are left substantially free of binder.
- Figure 1 is a diagrammatic illustration of a tuftmg system for producing a tufted pile surface structure also m accordance with the present invention
- Figure 2A is a stylized perspective view taken along view lines A-A of Figure 1 showing a pile surface structure in accordance with the present invention as produced within the tuftmg system of Figure 1 and prior to heat treatment
- Figure 2B is a stylized perspective view taken along view lines B-B of Figure 1 showing the pile surface structure in accordance with the present invention as produced at the output of the heat treating apparatus.
- FIG. 1 is a diagrammatic illustration of an overall system 10 for producing and finishing a tufted pile surface structure in accordance with the present invention.
- the system 10 includes a conventional tuftmg apparatus generally indicated by the reference character 12 followed by a liquid binder dispenser 14. Downstream of the dispenser 14 is a heat finishing apparatus generally indicated by the reference character 16.
- the tuft g apparatus 12, the dispenser 14 and/or the heat finishing apparatus 16 may be physically disposed m the same housing, if desired.
- Downstream of the heat finishing apparatus 14 is a compression roller 18.
- the temperature of the roller 16 is typically kept at room temperature .
- the tuft g apparatus 12 produces a conventional tufted pile surface structure generally indicated in Figure 2A by the reference 24.
- a liquid binder material is applied by the dispenser 14 to produce a tufted pile surface structure 28 in accordance with the present invention.
- the tufted pile surface structure 28 having the binder thereon is heat-treated in the finishing apparatus 16.
- the finished tufted pile surface structure accordance with the present invention is generally indicated in Figure 2B by the reference character 32.
- a primary backing P having an upper face U and a lower face L, is dispensed from a roll 36 and is conveyed along a generally planar path of travel T through the tuftmg apparatus 12.
- the direction of travel of the primary backing P through the apparatus 12 is termed the "longitudinal" or the “machine” direction.
- the direction perpendicular to the longitudinal direction is termed the "transverse" direction.
- the primary backing P is conveyed in the longitudinal direction through the tufting apparatus 12 with its lower face L presented upwardly.
- a plurality of tuftmg needles N is carried by a movable needle bar M.
- Each tuftmg needle N is supplied with a pile yarn Y dispensed from a creel (not shown) .
- Each needle N is reciprocally movable in the directions R to tuft each of the pile yarns Y into the backing P at a plurality of spaced needle insertion points I ( Figures 2A, 2B) .
- the insertion points I produced by the reciprocating tuftmg needles N form a pattern of parallel lines L L , L ⁇ , that respectively extend in the longitudinal and m the transverse directions along the backing P.
- the reciprocating insertion and retraction of the needles N form looped face fiber elements F that lie adjacent to the upper face U of the primary backing P.
- the face fiber F elements may be later cut, if desired.
- the primary backing P is linearly advanced along the path of travel T lengths of yarn overlay the lower face L of the backing P between longitudinally adjacent needle insertion points I to define linear backstitch elements B shown in the foreground portion of Figure 2A.
- the needle bar M may also be transversely movable with respect to the backing P in the directions V.
- backstitch elements B 1 are formed that diagonally overlay the lower face L of the backing P across one or more longitudinal lines L L of adjacent needle insertion points I.
- the backstitch elements B' are shown in the background portion of Figures 2A, 2B.
- the tufted pile surface structure 28 in accordance with this invention includes a binder material therein.
- the binder material 38 is applied after the tufting operation in the form of a liquid coating using the dispenser 14.
- the dispenser 14 includes a kiss roller 14R positioned at the mouth of a trough 14T. The dispenser is adjusted above the lower surface L of the pile surface structure 24 such that the kiss roller 14R contacts the backstitch elements B, B' and applies a coating, indicated by the character 42, of the liquid binder to the top surfaces thereof .
- the pile surface structure 28 having the binder material applied onto the backstitches B, B' thereof is conveyed to the finishing apparatus 16.
- the liquid binder diffuses into the yarn forming the backstitch elements B, B', as is progressively indicated schematically at the reference characters 42', 42".
- the binder has soaked through the backstitches B, B' so that binder material is on, through and is collected in the vicinity of the backstitches B, B'. This condition is illustrated by the reference character 44 in Figure 2A.
- a finishing apparatus 16 that heat-treats the tufted pile surface structure 28 to activate the binder material therein.
- the application of heat from the lower face L activates the binder and causes the backstitch elements B, B 1 and the primary backing P to fuse together.
- the finished pile surface structure 32 having the activated binder thereon is illustrated in Figure 2B.
- the activated binder material indicated in selective locations in Figure 2B by the reference character 46, is disposed on, through and in the vicinity of the backstitch elements B, B' to holds the same to the backing P. However, those portions of the lower face L of the backing P not overlaid by the backstitch elements B, B' are left substantially free of binder.
- These binder-free areas are selectively illustrated in Figure 2B by the reference character 48.
- a secondary backing 50 may be optionally applied to the pile surface structure 28 (prior to activation of the binder) .
- the secondary backing 50 is drawn from a roll 52 as the pile surface structure 28 enters the finishing apparatus 14.
- binder material that flows through and about the backstitch elements B, B' may be used to attach the secondary backing 50 to the pile surface structure 28/32 without the need of any additional binder.
- the roller 18 can be useful to press together the binder material, the backstitch elements B, B', and the secondary backing 50.
- the roller 18 may be located before, within, or after the heating apparatus 16. Figure 1, wherein the roller 18 is located after of the heating apparatus 16, is the preferred arrangement for thermoplastic binders.
- Suitable liquid binder materials include latex dispersions, thermoplastic particles dispersed in liquids, and binders dissolved in solvents.
- the dispersion or solution must be chosen to have suitable viscosity and affinity to the backstitch elements and the primary backing (and secondary backing, if any) to diffuse and adhere as discussed.
- the finished pile surface structure 32 in accordance with the present invention is believed to provide significant advantages over conventional tufted pile surface structures. Since substantial areas on the lower surface L of the backing P are left binder-free (i.e. the binder is concentrated in discrete areas in, through and in the vicinity of the backstitches B, B 1 ) the finished pile surface structure 32 is lighter in weight than a conventional tufted pile surface structure. Because of the discrete bonding pattern that leaves binder- free areas 48 on the lower surface of the backing P the finished pile surface structure 32 is also softer than conventional tufted pile surface structures. Since the lower face of the backing is left substantially binder-free, pins or hooks can easily penetrate through the binder- free areas of the primary and/or secondary backings to aid installation. Also, since a secondary backing is bonded to the primary with a discrete pattern of bonds leaving binder- free areas the secondary backing may itself have "loops" allowing a "hook-loop” installation system.
- the finishing/bonding operation in the heat-treatment apparatus 16 may be performed in line with the tufting operation.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Carpets (AREA)
- Automatic Embroidering For Embroidered Or Tufted Products (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU19341/01A AU1934101A (en) | 1999-12-02 | 2000-11-30 | A tufted pile structure having binder concentrated on, through and in the vicinity of the backstitches |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16850399P | 1999-12-02 | 1999-12-02 | |
US60/168,503 | 1999-12-02 |
Publications (3)
Publication Number | Publication Date |
---|---|
WO2001040561A2 true WO2001040561A2 (en) | 2001-06-07 |
WO2001040561A3 WO2001040561A3 (en) | 2001-10-25 |
WO2001040561A9 WO2001040561A9 (en) | 2002-11-07 |
Family
ID=22611768
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/032547 WO2001040561A2 (en) | 1999-12-02 | 2000-11-30 | A tufted pile structure having binder concentrated on, through and in the vicinity of the backstitches |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU1934101A (en) |
WO (1) | WO2001040561A2 (en) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3315660A1 (en) * | 2016-11-01 | 2018-05-02 | Textile Rubber & Chemical Company, Inc. | A method of applying a thermoplastic polymer coating |
US10689803B2 (en) | 2017-03-27 | 2020-06-23 | Textile Rubber And Chemical Company, Inc. | Aqueous polymer dispersion composition and method of adhering textile materials |
US10815365B2 (en) | 2017-05-30 | 2020-10-27 | Textile Rubber and Chemical Company Inc. | Scatter coating process for synthetic turf and product |
US11351766B2 (en) | 2019-11-11 | 2022-06-07 | Textile Rubber And Chemical Company, Inc. | Process for applying film backing to synthetic turf and product |
Citations (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1074741A (en) * | 1964-05-04 | 1967-07-05 | Bigelow Sanford Inc | Improvements in or relating to pile fabrics |
US4159360A (en) * | 1976-10-15 | 1979-06-26 | Hercules Incorporated | Stabilized fabrics |
DE2935387A1 (en) * | 1979-09-01 | 1981-03-26 | J.F. Adolff AG, 71522 Backnang | Tufted floor covering with fibrous fleece - needled to sieve gauze ground just holding pile and PVC coated |
GB2140047A (en) * | 1983-03-28 | 1984-11-21 | Firth Carpets Ltd | Improvements in or relating to floor coverings |
US4624878A (en) * | 1984-08-14 | 1986-11-25 | Evans Robert D | Weatherstripping produced by tufting with flattened knuckles |
EP0347206A1 (en) * | 1988-06-16 | 1989-12-20 | The Dow Chemical Company | Method of bonding layers |
JPH0247352A (en) * | 1988-08-04 | 1990-02-16 | Morita Sangyo Kk | Tufted product |
US5102482A (en) * | 1989-05-18 | 1992-04-07 | Rogers Jr James H | Method for making a water permeable laminated, textile fabric product |
JPH06128862A (en) * | 1992-10-20 | 1994-05-10 | Morita Sangyo Kk | Water permeable tufted pile fabric |
US5445860A (en) * | 1992-12-29 | 1995-08-29 | Gff Holding Company | Tufted product having an improved backing |
DE19506845A1 (en) * | 1995-02-28 | 1996-08-29 | Wesertechno Gmbh Produktentwic | Quick, low energy binding of base and tread layers in carpets |
US5626912A (en) * | 1995-04-14 | 1997-05-06 | Dsm N.V. | Tufted fabrics |
WO2000052246A1 (en) * | 1999-03-02 | 2000-09-08 | E.I. Du Pont De Nemours And Company | Stitched pile surface structure and process and system for producing the same |
-
2000
- 2000-11-30 AU AU19341/01A patent/AU1934101A/en not_active Abandoned
- 2000-11-30 WO PCT/US2000/032547 patent/WO2001040561A2/en active Application Filing
Patent Citations (13)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1074741A (en) * | 1964-05-04 | 1967-07-05 | Bigelow Sanford Inc | Improvements in or relating to pile fabrics |
US4159360A (en) * | 1976-10-15 | 1979-06-26 | Hercules Incorporated | Stabilized fabrics |
DE2935387A1 (en) * | 1979-09-01 | 1981-03-26 | J.F. Adolff AG, 71522 Backnang | Tufted floor covering with fibrous fleece - needled to sieve gauze ground just holding pile and PVC coated |
GB2140047A (en) * | 1983-03-28 | 1984-11-21 | Firth Carpets Ltd | Improvements in or relating to floor coverings |
US4624878A (en) * | 1984-08-14 | 1986-11-25 | Evans Robert D | Weatherstripping produced by tufting with flattened knuckles |
EP0347206A1 (en) * | 1988-06-16 | 1989-12-20 | The Dow Chemical Company | Method of bonding layers |
JPH0247352A (en) * | 1988-08-04 | 1990-02-16 | Morita Sangyo Kk | Tufted product |
US5102482A (en) * | 1989-05-18 | 1992-04-07 | Rogers Jr James H | Method for making a water permeable laminated, textile fabric product |
JPH06128862A (en) * | 1992-10-20 | 1994-05-10 | Morita Sangyo Kk | Water permeable tufted pile fabric |
US5445860A (en) * | 1992-12-29 | 1995-08-29 | Gff Holding Company | Tufted product having an improved backing |
DE19506845A1 (en) * | 1995-02-28 | 1996-08-29 | Wesertechno Gmbh Produktentwic | Quick, low energy binding of base and tread layers in carpets |
US5626912A (en) * | 1995-04-14 | 1997-05-06 | Dsm N.V. | Tufted fabrics |
WO2000052246A1 (en) * | 1999-03-02 | 2000-09-08 | E.I. Du Pont De Nemours And Company | Stitched pile surface structure and process and system for producing the same |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3315660A1 (en) * | 2016-11-01 | 2018-05-02 | Textile Rubber & Chemical Company, Inc. | A method of applying a thermoplastic polymer coating |
US10202722B2 (en) | 2016-11-01 | 2019-02-12 | Larry E Mashburn | Method of applying a theromplastic polymer coating |
US10689803B2 (en) | 2017-03-27 | 2020-06-23 | Textile Rubber And Chemical Company, Inc. | Aqueous polymer dispersion composition and method of adhering textile materials |
US10815365B2 (en) | 2017-05-30 | 2020-10-27 | Textile Rubber and Chemical Company Inc. | Scatter coating process for synthetic turf and product |
US11351766B2 (en) | 2019-11-11 | 2022-06-07 | Textile Rubber And Chemical Company, Inc. | Process for applying film backing to synthetic turf and product |
Also Published As
Publication number | Publication date |
---|---|
AU1934101A (en) | 2001-06-12 |
WO2001040561A3 (en) | 2001-10-25 |
WO2001040561A9 (en) | 2002-11-07 |
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