US3633974A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of making tufted constructions
Assignee: TUCEL INDUSTRIES
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Filing: 1970-03-18
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Granted: 1972-01-11
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Expires: 1990-03-18
Abstract
Abstract This invention, consisting of a new method for making brushes, allows tufted brushes and tufted mat components to be manufactured having pretrimmed synthetic filament tufts supported by thin foamed substrates. The method comprises first picking synthetic filament tufts and subsequently assembling the tufts in a predetermined tuft pattern. Secondly, the tufts are then attached to a weblike support. Third, the supported tufts are then set in a foam composition whereby the base of each tuft is surrounded and supported by foam.
Inventors
- 👤 John C Lewis Jr
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-29 23:59
CPC Classifications
A; A46; A46B; A46B3/00; A46B3/04
Claims Analysis
Total Claims: 13
Claim 1
Independent Claim
135 words
The method of making tufted constructions comprising: assembling a plurality of cut-to-length synthetic filaments to form at least one tuft; heating the nonworking end of said tuft until said filaments fuse and said tuft extends from a fused mass of filamentary material; mounting the fused end of said tuft on a flexible filamentary connector before said end cools so that said connector extends laterally through at least a portion of the fused end, thereby retaining said tuft on said connector when said end cools; coating said connector and fused tuft end with a foam premix composition; allowing said composition to foam and cure to form a tuft support, so that said composition forms a supporting cellular substrate with said connector and fused tuft end embedded therein and said working end of said tuft extending therefrom.
Claim 2
Independent Claim
135 words
The method of making tufted constructions comprising: assembling a plurality of cut-to-length synthetic filaments to form at least one tuft; heating the nonworking end of said tuft until said filaments fuse and said tuft extends from a fused mass of filamentary material; mounting the fused end of said tuft on a flexible filamentary connector before said end cools so that said connector extends laterally through at least a portion of the fused end, thereby retaining said tuft on said connector when said end cools; coating said connector and fused tuft end with a foam premix composition; allowing said composition to foam and cure to form a tuft support, so that said composition forms a supporting cellular substrate with said connector and fused tuft end embedded therein and said working end of said tuft extending therefrom.
Claim 3
Dependent Claim
85 words
The method of claim 1 further comprising the steps of supporting a plurality of cut-to-length synthetic filaments to form a plurality of tufts; heating the nonworking end of each of said tufts until said filaments fuse; mounting the fused end of said tufts on said connector in a mutually spaced relationship before said ends cool to form an array of interconnected tufts extending from a fused mass of filamentary material, interconnected by said connector; coating said connector and tuft ends with said foam premix composition.
Claim 4
Dependent Claim
27 words
The method of claim 2 wherein the nonworking ends of said tufts are simultaneously heated and fused; and subsequently, said tufts are simultaneously mounted on said connector.
Claim 5
Dependent Claim
42 words
The method of claim 2 further comprising orienting the connector in a preselected configuration before coating said connector and said fused tuft ends with said foam premix composition to form a tufted construction having said configuration when said coating foams and cures.
Claim 6
Dependent Claim
10 words
The method of claim 4 wherein said configuration is circular.
Claim 7
Dependent Claim
18 words
The method of claim 4 wherein said connector is oriented by wrapping said connector around a mandrel element.
Claim 8
Dependent Claim
31 words
The method of claim 6 wherein said foam premix composition is simultaneously applied to said connector and fused tuft ends mounted thereon as said connector is wrapped around said mandrel element.
Claim 9
Dependent Claim
45 words
The method of claim 7 further comprising continuously wrapping said connector, having said tufts mounted thereon, around a rotating mandrel in abutting rows and simultaneously applying said foam premix composition; and continuously removing said tufted construction from said mandrel as said composition foams and cures.
Claim 10
Dependent Claim
44 words
The method of claim 2 wherein said connector is a network of filaments and said tufts are mounted thereon in a preselected, mutually spaced array to form a tufted mat, after said connector and fused tuft ends are coated with said foam premix composition.
Claim 11
Dependent Claim
19 words
The method of claim 9 wherein said connector is woven and said foam premix composition is flexible when cured.
Claim 12
Dependent Claim
14 words
The method of claim 2 wherein said foam premix composition is rigid when cured.
Claim 13
Dependent Claim
14 words
The method of claim 2 wherein said foam premix composition is flexible when cured.
References Cited (Backward Citations)
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1975-01-10 | 1975-07-12 | 1976-01-11 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-01-10 | 1979-07-12 | 1980-01-11 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-01-10 | 1983-07-12 | 1984-01-11 | $7700.00 | Window Closed / Lapsed |