US2913803A - Pile faced fabric - Google Patents

Pile faced fabric Download PDF

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Publication number
US2913803A
US2913803A US691559A US69155957A US2913803A US 2913803 A US2913803 A US 2913803A US 691559 A US691559 A US 691559A US 69155957 A US69155957 A US 69155957A US 2913803 A US2913803 A US 2913803A
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United States
Prior art keywords
pile
fabric
layer
foundation
faced 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
Application number
US691559A
Inventor
Frank D Dodds
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ARTLOOM CARPET Co Inc
ARTLOOM CARPET COMPANY Inc
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ARTLOOM CARPET Co Inc
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Priority to US691559A priority Critical patent/US2913803A/en
Application granted granted Critical
Publication of US2913803A publication Critical patent/US2913803A/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
    • D06N2201/045—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/06—Animal fibres, e.g. hair, wool, silk
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (co)polymers
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/08—Properties of the materials having optical properties
    • D06N2209/0807—Coloured
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/146—Soilproof, soil repellent
    • 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
    • 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

  • This invention relates to pile faced fabric. More specifically, it is concerned with needle tufted pile faced fabric intended for use as carpeting.
  • the chief aim of my invention is to provide pile faced fabric which can be economically produced from relatively inexpensive material; which is resistive to rapid wear; which is attractive in appearance; which is immune against distortion or crushing; and which, withal, is soft to the tread.
  • Fig. 1 is a fragmentary view in longitudinal section of pile faced fabric embodying my invention in one form.
  • Figs. 2 and 3 are views similar to Fig. 1 showing two alternative embodiments of my invention.
  • my improved fabric is produced on an ordinary needle tufting machine and comprises a non-woven foundation layer 1 of felt which may be of animal or other suitable textile fibers, and is penetrated by the pile 2 which may be of cotton, wool, rayon or of other synthetic fibers such as nylon or mixtures of such fibers.
  • the foundation layer 1 is coated at the back with latex or other suitable adhesive as conventionally indicated at 3.
  • the pile 2 may be left in the form of loops as at the left of the illustration, or it may be cut for creation of a tuft effect as shown at the right of the illustration.
  • the foundation layer 1 may be initially provided, as at 4, with a top facing of sponge fiber to insure a clean surface at the base of the pile and to promote the wearability of the fabric.
  • the foundation comprises a bottom layer 5 of material woven from yarn 6 of jute and cotton or any other type or types or mixtures of textile fibers, and a superposed layer 1a of felt, the layer 5 being coated at the back with latex, as at 3a, for anchorage of the pile 2a.
  • the felt layer It may be provided initially with a top facing 4a of vinyl or the like to prevent dirt, Water, and cleaning fluid or powder from seeping into the foundation layers 1a and 5.
  • the vinyl 4a will be colored to match or blend with the color or shade of the pile.
  • the felt and woven layers 1b and 5b, respectively of the foundation are reversed in position, i.e., the woven layer 5b is superimposed upon the felt layer llb.
  • the felt layer 1b is shown as being coated with latex as at 3b, and the woven layer 5b top surfaced or impregnated initially, as at 4b, with vinyl or the like.
  • the fabric will be soft to the tread, will withstand hard usage Without becoming distorted or being easily crushed, and will retain its attractiveness over long protracted periods in service. Moreover, it will be seen, that, by reason of being formed in a needle tufting machine, the fabric can be produced rapidly in quantity at relatively low cost.
  • a pile faced fabric comprising at least one foundation layer of relatively thick felted fibers; rows of pile loops each formed by passage of a thread through the foundation layer and connected one with another at the back of said layer; a coating of latex at the back of the fabric for permanently anchoring the pile; and a plastic protective coating on the top of the foundation through which the pile ends extend to prevent soil penetration, to aid in the anchorage of the pile, to increase the stiffness of said foundation, and to reinforce the fabric against rapid wear.
  • Pile fabric according to claim 1 further including a sheet of woven material plied with the felt sheet in the foundation penetrated by the threads from which the pile is formed.

Description

Nov. 24,. 1959 IF.\D. nouns PILE FACED FABRIC 2 Sheets-Sheet 1 Filed Oct. 22, 1957 INVENTOR. Fran/12D. Dadds,
Nov. 24, 1959 F. D. moons PILEFACED FABRIC 2 Sheets-Sheet 2 Filed Oct. 22, 1957 INVENTOR. Frank D. Dodds, I BY 634 z (21 ATTORNEYS.
United States Patent PILE FACED FABRIC Frank D. Dodds, Garden City, N.Y., assignor to Artloom Carpet Company, Inc., Philadelphia, Pa., a corporation of Pennsylvania Application October 22, 1957, Serial No. 691,559
2 Claims. (Cl. 28-78) This invention relates to pile faced fabric. More specifically, it is concerned with needle tufted pile faced fabric intended for use as carpeting.
The chief aim of my invention is to provide pile faced fabric which can be economically produced from relatively inexpensive material; which is resistive to rapid wear; which is attractive in appearance; which is immune against distortion or crushing; and which, withal, is soft to the tread.
Other objects and attendant advantages Will appear from the following detailed description of the attached drawings, wherein:
Fig. 1 is a fragmentary view in longitudinal section of pile faced fabric embodying my invention in one form.
Figs. 2 and 3 are views similar to Fig. 1 showing two alternative embodiments of my invention.
With more specific reference first to Fig. 1 of these illustrations, my improved fabric, as there shown, is produced on an ordinary needle tufting machine and comprises a non-woven foundation layer 1 of felt which may be of animal or other suitable textile fibers, and is penetrated by the pile 2 which may be of cotton, wool, rayon or of other synthetic fibers such as nylon or mixtures of such fibers. For firm anchorage of the pile 2, the foundation layer 1 is coated at the back with latex or other suitable adhesive as conventionally indicated at 3. The pile 2 may be left in the form of loops as at the left of the illustration, or it may be cut for creation of a tuft effect as shown at the right of the illustration. Moreover, the foundation layer 1 may be initially provided, as at 4, with a top facing of sponge fiber to insure a clean surface at the base of the pile and to promote the wearability of the fabric.
In the alternative embodiment illustrated in Fig. '2
the foundation comprises a bottom layer 5 of material woven from yarn 6 of jute and cotton or any other type or types or mixtures of textile fibers, and a superposed layer 1a of felt, the layer 5 being coated at the back with latex, as at 3a, for anchorage of the pile 2a. The felt layer It: may be provided initially with a top facing 4a of vinyl or the like to prevent dirt, Water, and cleaning fluid or powder from seeping into the foundation layers 1a and 5. Preferably, the vinyl 4a will be colored to match or blend with the color or shade of the pile.
In the alternate embodiment of Fig. 3, the felt and woven layers 1b and 5b, respectively of the foundation are reversed in position, i.e., the woven layer 5b is superimposed upon the felt layer llb. Here the felt layer 1b is shown as being coated with latex as at 3b, and the woven layer 5b top surfaced or impregnated initially, as at 4b, with vinyl or the like.
In all three instances, it will be evident that, due to incorporation of felt in the foundation, the fabric will be soft to the tread, will withstand hard usage Without becoming distorted or being easily crushed, and will retain its attractiveness over long protracted periods in service. Moreover, it will be seen, that, by reason of being formed in a needle tufting machine, the fabric can be produced rapidly in quantity at relatively low cost.
Having thus described my invention, I claim:
1. As a new product of manufacture, a pile faced fabric comprising at least one foundation layer of relatively thick felted fibers; rows of pile loops each formed by passage of a thread through the foundation layer and connected one with another at the back of said layer; a coating of latex at the back of the fabric for permanently anchoring the pile; and a plastic protective coating on the top of the foundation through which the pile ends extend to prevent soil penetration, to aid in the anchorage of the pile, to increase the stiffness of said foundation, and to reinforce the fabric against rapid wear.
2. Pile fabric according to claim 1, further including a sheet of woven material plied with the felt sheet in the foundation penetrated by the threads from which the pile is formed.
References Cited in the file of this patent UNITED STATES PATENTS 2,115,581 Johnson Apr. 26, 1938 2,303,203 Faris et al Nov. 24, 1942 2,349,236 Bodle May 23, 1944 2,748,446 Mason June 5, 1956 2,755,535 Schoenberger July 24, 1956 2,810,950 Rice Oct. 29, 1957
US691559A 1957-10-22 1957-10-22 Pile faced fabric Expired - Lifetime US2913803A (en)

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Cited By (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3060072A (en) * 1959-11-16 1962-10-23 Bigelow Sanford Inc Backed carpet and method of producing the same
US3075865A (en) * 1962-08-20 1963-01-29 Donglas C Cochran Tufted products
US3174451A (en) * 1963-03-26 1965-03-23 Du Pont Pile article of backing, cushioning and pile yarn layers
US3285796A (en) * 1963-10-28 1966-11-15 Cabin Crafts Inc Integral cushion backing for tufted rugs and process for making same
US3307990A (en) * 1962-12-03 1967-03-07 West Point Pepperell Inc Method of making a composite product
US3322607A (en) * 1964-08-17 1967-05-30 Du Pont Lubricated polypropylene polyethylene self-bonded nonwoven carpet backing
US3341386A (en) * 1966-01-11 1967-09-12 Collins & Aikman Corp Method of making frieze effect fabrics
US3348992A (en) * 1963-08-13 1967-10-24 Madison Res & Dev Corp Tufted products
US3383259A (en) * 1963-08-13 1968-05-14 Madison Res & Dev Corp Method of making a tufted fabric
US3385751A (en) * 1963-09-18 1968-05-28 Specialty Converters Tufted pile carpet and manufacture thereof
DE1635583B1 (en) * 1964-08-17 1970-10-22 Du Pont Bound, flat nonwoven material
US3707746A (en) * 1971-06-03 1973-01-02 Du Pont Process of preparing a tufted product
US3779852A (en) * 1970-07-27 1973-12-18 Textiltech Forsch Textile fabric and method of producing same
US4035533A (en) * 1976-06-01 1977-07-12 Champion International Corporation Tufted carpet with meltable-film primary-backing component
US6329016B1 (en) 1997-09-03 2001-12-11 Velcro Industries B.V. Loop material for touch fastening
US6342285B1 (en) 1997-09-03 2002-01-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US6869659B2 (en) 1997-09-03 2005-03-22 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US7048818B2 (en) 2000-03-14 2006-05-23 Velcro Industries B.V. Hook and loop fastening

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2115581A (en) * 1935-07-05 1938-04-26 American Hair & Felt Company Felt carpet or rug and method of making the same
US2303203A (en) * 1940-03-18 1942-11-24 Nat Automotive Fibres Inc Carpet
US2349236A (en) * 1941-09-15 1944-05-23 Mishawaka Rubber & Woolen Mfg Carpet
US2748446A (en) * 1952-11-25 1956-06-05 Gen Latex & Chemical Corp Tufted rug and method of making same
US2755535A (en) * 1953-03-05 1956-07-24 Ind Rayon Corp Coated flexible fabric
US2810950A (en) * 1956-04-17 1957-10-29 Mohasco Ind Inc Tufted pile fabrics

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2115581A (en) * 1935-07-05 1938-04-26 American Hair & Felt Company Felt carpet or rug and method of making the same
US2303203A (en) * 1940-03-18 1942-11-24 Nat Automotive Fibres Inc Carpet
US2349236A (en) * 1941-09-15 1944-05-23 Mishawaka Rubber & Woolen Mfg Carpet
US2748446A (en) * 1952-11-25 1956-06-05 Gen Latex & Chemical Corp Tufted rug and method of making same
US2755535A (en) * 1953-03-05 1956-07-24 Ind Rayon Corp Coated flexible fabric
US2810950A (en) * 1956-04-17 1957-10-29 Mohasco Ind Inc Tufted pile fabrics

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3060072A (en) * 1959-11-16 1962-10-23 Bigelow Sanford Inc Backed carpet and method of producing the same
US3075865A (en) * 1962-08-20 1963-01-29 Donglas C Cochran Tufted products
US3307990A (en) * 1962-12-03 1967-03-07 West Point Pepperell Inc Method of making a composite product
US3174451A (en) * 1963-03-26 1965-03-23 Du Pont Pile article of backing, cushioning and pile yarn layers
US3383259A (en) * 1963-08-13 1968-05-14 Madison Res & Dev Corp Method of making a tufted fabric
US3348992A (en) * 1963-08-13 1967-10-24 Madison Res & Dev Corp Tufted products
US3385751A (en) * 1963-09-18 1968-05-28 Specialty Converters Tufted pile carpet and manufacture thereof
US3285796A (en) * 1963-10-28 1966-11-15 Cabin Crafts Inc Integral cushion backing for tufted rugs and process for making same
DE1635583B1 (en) * 1964-08-17 1970-10-22 Du Pont Bound, flat nonwoven material
US3322607A (en) * 1964-08-17 1967-05-30 Du Pont Lubricated polypropylene polyethylene self-bonded nonwoven carpet backing
DE1635583C2 (en) * 1964-08-17 1982-06-09 E.I. du Pont de Nemours and Co., 19898 Wilmington, Del. Tufted base material
US3341386A (en) * 1966-01-11 1967-09-12 Collins & Aikman Corp Method of making frieze effect fabrics
US3779852A (en) * 1970-07-27 1973-12-18 Textiltech Forsch Textile fabric and method of producing same
US3707746A (en) * 1971-06-03 1973-01-02 Du Pont Process of preparing a tufted product
US4035533A (en) * 1976-06-01 1977-07-12 Champion International Corporation Tufted carpet with meltable-film primary-backing component
US6329016B1 (en) 1997-09-03 2001-12-11 Velcro Industries B.V. Loop material for touch fastening
US6342285B1 (en) 1997-09-03 2002-01-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US20020037390A1 (en) * 1997-09-03 2002-03-28 Shepard William H. Loop material for touch fastening
US6598276B2 (en) 1997-09-03 2003-07-29 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US6783834B2 (en) 1997-09-03 2004-08-31 Velcro Industries B.V. Loop material for touch fastening
US6869659B2 (en) 1997-09-03 2005-03-22 Velcro Industries B.V. Fastener loop material, its manufacture, and products incorporating the material
US7048818B2 (en) 2000-03-14 2006-05-23 Velcro Industries B.V. Hook and loop fastening

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