US2983028A - Tufted structures - Google Patents

Tufted structures Download PDF

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Publication number
US2983028A
US2983028A US81758559A US2983028A US 2983028 A US2983028 A US 2983028A US 81758559 A US81758559 A US 81758559A US 2983028 A US2983028 A US 2983028A
Authority
US
United States
Prior art keywords
carpet
pile
yarn
bracing
marquisette
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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English (en)
Inventor
Cole Paul Morrison
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EIDP Inc
Original Assignee
EI Du Pont de Nemours and Co
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by EI Du Pont de Nemours and Co filed Critical EI Du Pont de Nemours and Co
Priority to US81758559 priority Critical patent/US2983028A/en
Priority to BE591266A priority patent/BE591266A/fr
Application granted granted Critical
Publication of US2983028A publication Critical patent/US2983028A/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
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • D05C15/08—Tufting machines
    • D05C15/14—Arrangements or devices for holding or feeding the base material
    • D05C15/145—Needle plates
    • 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
    • Y10T428/23914—Interlaminar
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24033—Structurally defined web or sheet [e.g., overall dimension, etc.] including stitching and discrete fastener[s], coating or bond

Definitions

  • bracing member
  • a tufted article comprising a backing member, pile yarn tuftedinto said backing member, and a bracing web parallel to the backing member and intermediate the backing member and the peaks of the pile yarn and connecting the pile yarn at or below the midpoints in the height of the pile yarn, preferably from /3 to /2 the height of the pile.
  • Figure I illustrates the product of this inventionand a procedure for producing it.
  • the backing member may be any dimensionally stable sheet material including woven, knitted and non-woven fabrics of natural or synthetic fibers, such as burlap," cotton, sisal, wool, rayon, polyamides, polyesters, acrylo I nitrile polymers and copolymers, vinyl chloride polymers and copolymers, cellulose acetate, glass, metal, paper, and
  • the bracing web is positioned at the desired distance i from the backing member while the tufts of pile yarn are carriedv through both of these layers.
  • the bracing web serves to hold the pile erect so that the. load-bearing United States Patent ability of the carpet or other structure and the apparent height of the pile are increased. Better compressional properties and aesthetics with less' pile yarn are, thereby made possible by the novel structure employing-the
  • This bracing member will usually be alightweight web which may be a knitted,v fabric, a' woven fabric, or a non-woven fabric or paper.
  • a lightweight nylon woven marquisette has been found particularly suitable as the bracingmember'and performs best when treated with a binder to inhibit the stretching
  • the binder may be prepared by making ,a 5 %"by weight solution of polyamide resin in methanol.
  • a nylon marquisette as bracingmember willgiveparticularly advantageous results when used in the novel structure in combination with a nylon pile yarn. Not only...
  • the pile yarn used in this invention may be either spun yarn or continuous filament yarn, and the fibers, yarns, and fabrics used in the invention may be made from any one of a number of well-known materials such as polyamides (e.g., polyhexamethylene adipamide); copolyamides; polyesters (e.g. polyethylene terephthalate); acrylic polymers and copolymers (e.g., polyacrylonitrile); cellulose derivatives such as cellulose acetate and regenerated cellulose; and the like. Bulked pile yarns are preferred because of better covering properties using less yarn. Suitable bulked yarns may be made according to the methods described by A. L. Breen in U.S. Patent 2,783,609, in U.S. application Serial No. 375,372, filed August 20, 1953, now Patent No. 2,852,906 granted September 23, 1958, by A. L. Breen, and in U.S. application Serial No. 698,103, filed November 22, 1957, by A. L.
  • a conventional tufting machine may be modified to provide an auxiliary needle plate at a predetermined distance from the backing fabric (i.e., the distance from the top of the conventional needle plate to the top of the auxiliary needle plate is set equal to the distance desired between the backing fabric and the bracing web).
  • the auxiliary needle plate supports the bracing Web at the desired distance from the backing fabric while the needles of the tufting machine force pile yarn first through .the backing then through the bracing web, forming loops on the under side of the bracing web. These loops may The distance between the bracing web and the backing fabric may be controlled by adjusting the spacing between the auxiliary needle plate and the conventional needle plate.
  • tufting machine may be accommodated with additional .auxiliary needle plates so that two or more bracing webs may be incorporated into the structure.
  • a bulked continuous filament nylon ' may be tufted through a burlap backing and a nylon marquisette fabric in the manner already described, .except that the marquisette bracing fabric is positioned at an elevation close to the peaks of the tufts.
  • the product may be dyed and then heat set for 10 minutes in-240 F. steam. Upon removal of the marquisette layer, the product is found to have tufts with tight, welldefined peaks providing a desirable texture of good permanence.
  • the yarn that has been unconfined below the marquisette layer has excellent covering power and A similar textured carpet but with greater permanence may be obtained by eliminating the heat setting operation just described and instead applying 'a 30% by weight solution of polyamide resin in methanol to'the tuft peaks. The marquisette layer 'is then removed after partial evaporation of the methanol.
  • 'A carpet may also be prepared with two bracing webs
  • thesame weights of pile yarn into aburlap backing bracing'webs isolate each tuft of pile yarn from its neighbors and permit the hand printing of colored patterns.
  • the tufts may be properly held in registration to, facilitate roller printing of multiple color designs without the diffusion normally associated with s'uch ractice.
  • the top bracing web may be remqve and e v i
  • a Venetian blind may be prepared by tufting widely spaced rows of nylon pile yarn through two bracing 'webs of nylon marquisette woven fabric held at a distarice of three-fourths of an inch apart.
  • Pile loops of minimum size formed on one exterior marquisette fabric are secured, and the pile yarn rows are stiffened by a light application of polyamide resin in methanol.
  • the product serves as a textile Venetian blind.
  • the pile yarn planes may be tilted by shifting the relative positions of the marquisette webs so as to modify the-transmission of light.
  • An important advantage of this invention is the provision of new carpet and other structures which employ less pile yarn and provide better compressional properties than carpet structures heretofore known. These new structures are cheaper than conventional pile carpets in that less of the most expensive ingredient (i.e., the pile) is employed in their construction. Another advantage is the provision of a carpet structure with a better definition of pile in that each pile yarn has less tendency to mat, as well as a structure which is more adaptable to dyeing and printing when employing nylon in both bracing member and pile yarn. Furthermore,
  • novel carpet structures exhibit equal recovery from a variety of applications such as carpeting and rugs
  • the pile yarn illustrated in the example is a bulky continuous filament 'yarn prepared by the process described by Breen and Lauterbach in U.S. application Serial No. 698,103 filed November 22, 1957.
  • Two samples of tufted carpet are prepared in accordance with this invention by tufting bulky continuous filament nylon yarn into a lightweight burlap backing and then through a woven nylon marquisette bracing web weighing 0.9 ounce/squareyard, employing different weights of pile yarn in the two samples.
  • bracing web 'in the carpet is positioned inch above the backing fabric, and the pile height is approximately inchiaoove the backing.
  • Two identically ponstructed conventional tufted carpets (C and D) are prepared as.
  • a carpet sample is compressed under a pressure -limit of 10 p.s.i. for two successive cycles with a relaxation time of seconds between cycles (time in which carpet'is notunder any compression).
  • the first cycle is used tocondition the sample and the actualcharacterizatio'n test parameters of work of compression and hottoming effect are taken from the second cycle.
  • the work of compression in inch pounds per, square inch of carpetis calculated.
  • the actual compression of the carpet between 6 p.s.i. and 10 p.s.i. is calculated and reported in inches as the bottoming effect.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
US81758559 1959-06-02 1959-06-02 Tufted structures Expired - Lifetime US2983028A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US81758559 US2983028A (en) 1959-06-02 1959-06-02 Tufted structures
BE591266A BE591266A (fr) 1959-06-02 1960-05-27 Structures comportant des touffes de poils.

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US81758559 US2983028A (en) 1959-06-02 1959-06-02 Tufted structures

Publications (1)

Publication Number Publication Date
US2983028A true US2983028A (en) 1961-05-09

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ID=25223409

Family Applications (1)

Application Number Title Priority Date Filing Date
US81758559 Expired - Lifetime US2983028A (en) 1959-06-02 1959-06-02 Tufted structures

Country Status (2)

Country Link
US (1) US2983028A (fr)
BE (1) BE591266A (fr)

Cited By (17)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3348992A (en) * 1963-08-13 1967-10-24 Madison Res & Dev Corp Tufted products
US3444017A (en) * 1964-10-24 1969-05-13 Hubert Kleinermanns Process for making a pile fabric
US5423928A (en) * 1993-05-10 1995-06-13 Hambright; Perry Process for creating transferrable pile yarn designs
US5494723A (en) * 1991-04-09 1996-02-27 Norddeutsche Faserwerke Gmbh Tufting carpet
WO1999009241A1 (fr) * 1997-08-14 1999-02-25 Groz-Beckert Kg Procede de fabrication d'un article ou produit tufte
US20050160955A1 (en) * 2004-01-17 2005-07-28 Brian Lovelady Tufted fabric with embedded stitches
US20060070564A1 (en) * 2004-10-05 2006-04-06 Smith Jeff D Tufting machine and process for variable stitch rate tufting
US20070095264A1 (en) * 2005-10-27 2007-05-03 Sunstar Machinery Co., Ltd. Needle Plate for Double-Needle Sewing Machine
US20070283863A1 (en) * 2006-06-13 2007-12-13 Tuftco Corporation Narrow gauge hollow needle tufting apparatus
US7717051B1 (en) 2004-08-23 2010-05-18 Card-Monroe Corp. System and method for control of the backing feed for a tufting machine
US9399832B2 (en) 2008-02-15 2016-07-26 Card-Monroe Corp. Stitch distribution control system for tufting machines
US9410276B2 (en) 2008-02-15 2016-08-09 Card-Monroe Corp. Yarn color placement system
US20170096757A1 (en) * 2015-10-01 2017-04-06 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US10233578B2 (en) 2016-03-17 2019-03-19 Card-Monroe Corp. Tufting machine and method of tufting
US11193225B2 (en) 2016-03-17 2021-12-07 Card-Monroe Corp. Tufting machine and method of tufting
US11585029B2 (en) 2021-02-16 2023-02-21 Card-Monroe Corp. Tufting maching and method of tufting
US12234587B2 (en) 2021-02-16 2025-02-25 Card-Monroe Corp. Tufting machine and method of tufting

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1012356A (en) * 1909-11-05 1911-12-19 Asbestos Brake Company Asbestos brake-band.
FR593532A (fr) * 1924-04-24 1925-08-25 Leroux Freres Procédé de fabrication d'un velours dont le dessin d'endroit est reproduit à l'envers et velours obtenu par ce procédé
US2072152A (en) * 1934-11-27 1937-03-02 Kenneth B Blake Heat insulating material
US2132530A (en) * 1935-12-13 1938-10-11 Carthage Mills Inc Decorative needled fabric
US2719542A (en) * 1955-02-18 1955-10-04 U S Plush Mills Inc Multiple ply fabric
US2748446A (en) * 1952-11-25 1956-06-05 Gen Latex & Chemical Corp Tufted rug and method of making same

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1012356A (en) * 1909-11-05 1911-12-19 Asbestos Brake Company Asbestos brake-band.
FR593532A (fr) * 1924-04-24 1925-08-25 Leroux Freres Procédé de fabrication d'un velours dont le dessin d'endroit est reproduit à l'envers et velours obtenu par ce procédé
US2072152A (en) * 1934-11-27 1937-03-02 Kenneth B Blake Heat insulating material
US2132530A (en) * 1935-12-13 1938-10-11 Carthage Mills Inc Decorative needled fabric
US2748446A (en) * 1952-11-25 1956-06-05 Gen Latex & Chemical Corp Tufted rug and method of making same
US2719542A (en) * 1955-02-18 1955-10-04 U S Plush Mills Inc Multiple ply fabric

Cited By (41)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3348992A (en) * 1963-08-13 1967-10-24 Madison Res & Dev Corp Tufted products
US3444017A (en) * 1964-10-24 1969-05-13 Hubert Kleinermanns Process for making a pile fabric
US5494723A (en) * 1991-04-09 1996-02-27 Norddeutsche Faserwerke Gmbh Tufting carpet
US5423928A (en) * 1993-05-10 1995-06-13 Hambright; Perry Process for creating transferrable pile yarn designs
WO1999009241A1 (fr) * 1997-08-14 1999-02-25 Groz-Beckert Kg Procede de fabrication d'un article ou produit tufte
US6408774B1 (en) * 1997-08-14 2002-06-25 Groz-Beckert Kg Method of producing a tufted article or product
US7431974B2 (en) * 2004-01-17 2008-10-07 Tuftco Corporation Tufted fabric with embedded stitches
US20050160955A1 (en) * 2004-01-17 2005-07-28 Brian Lovelady Tufted fabric with embedded stitches
US7717051B1 (en) 2004-08-23 2010-05-18 Card-Monroe Corp. System and method for control of the backing feed for a tufting machine
US7426895B2 (en) * 2004-10-05 2008-09-23 Tuftco Corporation Tufting machine and process for variable stitch rate tufting
US20060070564A1 (en) * 2004-10-05 2006-04-06 Smith Jeff D Tufting machine and process for variable stitch rate tufting
US7311052B2 (en) * 2005-10-27 2007-12-25 Sunstar Machinery Co., Ltd. Needle plate for double-needle sewing machine
US20070095264A1 (en) * 2005-10-27 2007-05-03 Sunstar Machinery Co., Ltd. Needle Plate for Double-Needle Sewing Machine
US7318383B1 (en) * 2006-06-13 2008-01-15 Tuftco Corporation Narrow gauge hollow needle tufting apparatus
US20070283863A1 (en) * 2006-06-13 2007-12-13 Tuftco Corporation Narrow gauge hollow needle tufting apparatus
US10400376B2 (en) 2008-02-15 2019-09-03 Card-Monroe Corp. Stitch distribution control system for tufting machines
US9410276B2 (en) 2008-02-15 2016-08-09 Card-Monroe Corp. Yarn color placement system
US10081897B2 (en) 2008-02-15 2018-09-25 Card-Monroe Corp. Stitch distribution control system for tufting machines
US9399832B2 (en) 2008-02-15 2016-07-26 Card-Monroe Corp. Stitch distribution control system for tufting machines
US10443173B2 (en) 2008-02-15 2019-10-15 Card-Monroe, Corp. Yarn color placement system
US10995441B2 (en) 2008-02-15 2021-05-04 Card-Monroe Corp. Yarn color placement system
US11072876B2 (en) 2008-02-15 2021-07-27 Card-Monroe Corp. Stitch distribution control system for tufting machines
US20170096757A1 (en) * 2015-10-01 2017-04-06 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US9657419B2 (en) * 2015-10-01 2017-05-23 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US10344413B2 (en) 2015-10-01 2019-07-09 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US11136702B2 (en) 2015-10-01 2021-10-05 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US11725320B2 (en) 2015-10-01 2023-08-15 Card-Monroe Corp. System and method for tufting sculptured and multiple pile height patterned articles
US10233578B2 (en) 2016-03-17 2019-03-19 Card-Monroe Corp. Tufting machine and method of tufting
US12146251B2 (en) 2016-03-17 2024-11-19 Card-Monroe, Corp. Tufting machine and method of tufting
US12595607B2 (en) 2016-03-17 2026-04-07 Card-Monroe, Corp. Tufting machine and method of tufting
US11702782B2 (en) 2016-03-17 2023-07-18 Card-Monroe Corp. Tufting machine and method of tufting
US11708654B2 (en) 2016-03-17 2023-07-25 Card-Monroe Corp. Tufting machine and method of tufting
US10995440B2 (en) 2016-03-17 2021-05-04 Card-Monroe Corp. Tufting machine and method of tufting
US12173439B2 (en) 2016-03-17 2024-12-24 Card-Monroe Corp. Tufting machine and method of tufting
US11193225B2 (en) 2016-03-17 2021-12-07 Card-Monroe Corp. Tufting machine and method of tufting
US12129586B2 (en) 2021-02-16 2024-10-29 Card-Monroe Corp. Tufting machine and method of tufting
US12234587B2 (en) 2021-02-16 2025-02-25 Card-Monroe Corp. Tufting machine and method of tufting
US20250230593A1 (en) * 2021-02-16 2025-07-17 Card-Monre Corp. Tufting machine and method of tufting
US12584255B2 (en) * 2021-02-16 2026-03-24 Card-Monroe, Corp. Tufting machine and method of tufting
US11585029B2 (en) 2021-02-16 2023-02-21 Card-Monroe Corp. Tufting maching and method of tufting
US12595606B2 (en) 2021-02-16 2026-04-07 Card-Monroe, Corp. Tufting machine and method of tufting

Also Published As

Publication number Publication date
BE591266A (fr) 1960-09-16

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