Abstract:
A process for forming a carpet, and the carpet formed thereby are provided. The process includes forming a thread comprising low melt fiber and high melt fiber. The thread is then heated above a temperature sufficient to melt the low melt fiber. The thread is tufted in a carpet backing to form a tufted carpet. The tufted carpet is then printed or dyed with an image. A process for forming a low melt content yarn and the yarn formed thereby are provided.
Abstract:
A composite backing (38) suitable for use in the manufacturing of carpeting, particularly tufted synthetic turf carpeting, or any other fabric product where dimensional stability in the presence of thermal or moisture gradients is desirable. The composite backing (38) comprises reinforcement strands (20) integrated into a woven backing fabric (10). The reinforcement strands (20) may be laid in an open network structure and needlepunched into a woven backing (10) or may also be integrated into the woven backing by directly weaving the reinforcement strands (20) into the woven backing (10) as it is being fabricated. A synthetic turf product may be constructed by tufting the composite backing.
Abstract:
Seam strips (50) are provided in a textile covering for a floor, wall or ceiling which are exposed and afford an aesthetic surface treatment. The seam strips comprise inverted T-shaped strips with an upstanding web (52) terminating in a margin short of the pile height and a pair of flanges (54, 56) projecting laterally from each of the lower opposite sides of the web (52). The flanges (54, 56) have holes (60) for securing, by way of screws or nails, the strips (50) to the underlying floor, wall or ceiling. The adjacent edges of the textile covering are secured to the upper surfaces of the flanges (54, 56). The textile coverings preferably have the backstitches (14) of tufts and portions of the primary backing forming an exposed surface which, together with the exposed margin of the strips (50), form an aesthetically pleasing surface treatment.
Abstract:
A floor covering includes a primary backing having yarns tufted through the primary backing forming wear surface portions comprised of the back stitches of the tufted yarns in conjunction with non-tufted areas of the primary backing, also forming exposed wear surfaces. Both exposed wear surfaces portions form an aesthetic design pattern whereby a low, dense broadloom or modular carpet is provided at reduced materials and costs. Preferably, the primary backing is comprised of a woven polypropylene and a secondary backing is provided with the cut or loop yarns on the back side of the primary backing being fixed in place by a resin. A secondary backing formed of a composition of EVA, calcium carbonate and resin, overlaid by a woven scrim, is provided. The secondary backing may be formed of a needle-bonded synthetic fiber. Additionally, the primary backing may be formed of a non-woven material such as nylon and polyester.
Abstract:
The invention is directed to fabric-based inserts and layers for use with tires in order to provide an improved level of puncture resistance to the tire. Disclosed embodiments of the invention include tire anti-puncture layers including puncture-resistant layers that comprise a single or multiple layers of fabric. Prererably, for low cost and low abrasion, the puncture-resistant layers comprise fibers having a tensile strength or tenacity of less than about 15g/denier. In some preferred constructions, especially where the puncture-resistant layer comprises a single layer of fabric, the puncture-resistant layer comprises a high cover factor, tightly woven fabric, for example having a round packed cover factor of at least about 40 % of full in the warp direction and at least 65 % of full in the fill direction. In other embodiments, especially where the puncture-resistant layer comprises multiple layers of fabric, lower cover, less tightly woven fabrics can be used, or, alternatively, non-woven fabrics such as knitted or felted fabrics (felts) can be used. Some such preferred, less tightly-woven fabrics are woven from untwisted yarns, enabling the fibers or filaments comprising the yarns to spread out into a tape-like configuration under compression, thereby increasing the effective cover factor and level of puncture resistance over that predicted from the round packed cover factor. A "taped fiber density" calculation is presented for predicting the effective cover factor of such tape-out woven fabrics, and certain preferred embodiments of such fabrics have a tape fiber density of at least about 80 % of full in at least one of the warp and fill directions. In some embodiments, the puncture-resistant layer, or one or more layers of fabric comprising the layer, are coated with polymeric coatings to increase the level of puncture resistance. In some embodiments, the tire anti-puncture device is configured as a separable strip that can be placed within a tire to act as a liner. In other embodiments, the puncture-resistant device is incorporated within the cross-section of the tire body itself. While the tire anti-puncture device in some embodiments comprises just the puncture-resistant layer, in other embodiments, one or more low abrasion layers can be added to isolate and protect the tire and/or inner tube, if present, from the puncture-resistant layer. Such law abrasion layer(s) are particularly useful for embodiments involving puncture-resistant layers coated with polymeric coatings containing fillers, which can server to increase puncture resistance but tent also to increase abrasiveness of the puncture-resistant layer.
Abstract:
A ground fabric for use in tufted carpets; and a tufted carpet made using the ground fabric. The ground fabric is constituted of a nonwoven fabric made of long fibers of a polylactic acid polymer. The long fibers have a circular cross section and have a birefringence of 12x10-3 to 30x10-3 and a crystallinity of 15 to 25 wt. %. The long-fiber nonwoven fabric has a thermal shrinkage through 3-minute heating at 120 DEG C of 1 % or lower in each of the MD and the CD. In the case of using long fibers having a different cross-sectional shape, these long fibers have a crystallinity of 15 to 25 wt. % and the nonwoven fabric made of these has a thermal shrinkage through 3-minute heating at 120 DEG C of 1 % or lower in each of the MD and the CD.
Abstract:
The invention pertains to a nonwoven primary carpet backing comprising thermoplastic polymer filaments or fibres bonded by means of a binder polymer, wherein the backing comprises at least a distinguishable thermoplastic woven layer, a distinguishable thermoplastic continuous layer, or a distinguishable nonwoven layer also comprising filaments or fibres bonded by means of a binder polymer, which layer reduces the delamination strength of the backing, measured in accordance with DIN 54310, by at least 30 % and preferably by at least 50 %, with respect to the same backing without the said distinguishable layer. Although the breaking strength of the untufted backing according to the invention is lower than that of untufted prior art backings, the tufted backing according to the invention actually has a higher breaking strength and elongation than tufted prior art backings.
Abstract:
A carpet underlay comprising a fibrous nonwoven substrate composed of natural or synthetic fibers having in or on it a repellent finish which makes said substrate substantially impervious to liquids, and a carpet having an underlay substantially impervious to liquids affixed to the carpet back rendering said carpet substantially impervious to liquids are disclosed.
Abstract:
A pattern-tufted, fusion-bonded carpet, particularly a backed carpet tile, having a polymeric latex primary adhesive layer and a plurality of fibrous yarns bonded to and extending from the layer to form a face surface, the fusion-bonded carpet having a woven polyester sheet material and glass fiber tissue sheet material both secured to the primary adhesive base layer, and the fusion-bonded carpet overtufted by an overtufted pattern on the face wear surface. A method of preparing a pattern-tufted, fusion-bonded carpet which comprises overtufting a fusion-bonded carpet with the fusion-bonded carpet having a primary adhesive base layer composed of a polymeric latex material and containing a woven fiberglass sheet and a glass fiber tissue sheet material and optionally to prepare carpet tile applying a solid, thermoplastic backing to the pattern-tufted, fusion-bonded carpet material.
Abstract:
A non-flammable fabric having a face of pile fabric comprising a blend of wool and permanently flame retarded rayon, and a backing of permanently flame retarded rayon and a high strength material having good heat resistant and flame retardant qualities. The fabric preferably includes a latex type back coating for providing stability to the fabric and for locking the pile in place. The method for manufacturing the fabric is also disclosed.