US3694873A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of preparing a tufted rug with cellular fibers
Assignee: Individual
•
Filing: 1970-04-02
•
Granted: 1972-10-03
•
Expires: 1990-04-02
Abstract
Abstract A sheet material, such as a needle-punched or tufted fabric, is prepared employing gas-expandable polymeric fibers, such as a polypropylene resin containing an undecomposed blowing agent, and, thereafter, expanding the diameter of the polymeric fibers by heating the fibers to form cellular polymeric fibers, the expansion locking such cellular fibers into the sheet material. The gas-expandable polymeric fibers may be employed either in the backing sheet or as the face fabric.
Inventors
- 👤 Richard P Crowley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 13:09
CPC Classifications
D; D05; D05C; D05C17/00; D05C17/02; D05C17/023; C; C08; C08K; C08K5/00; C08K5/16; C08K5/22; C08K5/23; D01; D01D; D01D5/00; D01D5/24; D01D5/247; D04; D04H; D04H1/00; D04H1/40; D04H1/44; D04H1/46; D04H1/48
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
17 words
The method of claim 1 wherein the base sheet comprises a solid, flexible nonexpandable polymer sheet material.
Claim 2
Dependent Claim
17 words
The method of claim 1 wherein the polymeric composition comprises an olefinic resin or vinyl chloride resin.
Claim 3
Dependent Claim
24 words
The method of claim 1 wherein the polymeric composition is extruded about a solid high strength inner core material to form a composite fiber.
Claim 4
Dependent Claim
19 words
The method of claim 4 wherein the inner core comprises a different material than the outer gas-expandable polymeric material.
Claim 5
Dependent Claim
13 words
The method of claim 4 wherein the inner core is formed of nylon.
Claim 6
Dependent Claim
66 words
The method of claim 1 wherein the base sheet comprises a gas-expandable thermoplastic material, and after tufting the gas-expandable polymeric fibers into or through the base sheet, heating the base sheet to a temperature sufficient to cause the expansion of the thermoplastic material of the base sheet, thereby providing expansion of the base sheet and fibers so as to lock the fibers to the base sheet.
Claim 7
Dependent Claim
15 words
The method of claim 7 wherein the thermoplastic base sheet comprises a vinyl chloride resin.
Claim 8
Dependent Claim
80 words
The method of claim 1 wherein the base sheet comprises nonwoven gas-expandable polymeric fibers containing an undecomposed blowing agent, and after tufting the polymeric fibers into or through the nonwoven base sheet, heating said base sheet to a temperature above the decomposition temperature of the blowing agent in the fibers of the base sheet to expand the diameter of the fibers, whereby the expansion of the diameter of all fibers locks the cellular face fibers to the cellular base sheet.
Claim 9
Dependent Claim
72 words
The method of claim 1 which includes the steps of: a. securing a backing gas-expandable vinyl chloride sheet material to the base sheet prior to heating the gas-expandable polymeric face fibers; and, thereafter, b. heating said backing material so as to effect gas expansion of the vinyl chloride sheet, thereby providing a tufted rug having a vinyl foam backing secured to one side of the base sheet and a cellular fiber face.
Claim 10
Independent Claim
126 words
The method of preparing a synthetic tufted product such as a tufted rug or floor tile product, which method comprises: a. extruding a vinyl chloride resin or an olefinic resin containing a blowing agent into a fiber over an inner core material, the temperature of extrusion being below the decomposition temperature of the blowing agent to provide a solid gas-expandable polymeric fiber; b. tufting the gas-expandable solid polymeric fiber into or through a base sheet comprising a thermoplastic resin material; and c. heating the gas-expandable polymeric fibers to a temperature above the decomposition temperature of the blowing agent to expand the diameter of the fibers and to form cellular polymeric fibers, the expansion of the diameter of the fibers locking the fibers to the base sheet.
Claim 11
Dependent Claim
18 words
The method of claim 11 wherein the same polymer is employed in the base sheet and the fibers.
Claim 12
Dependent Claim
15 words
The method of claim 11 wherein the temperature of extrusion is below about 170* C.
References Cited (Backward Citations)
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US2960750A
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US3091017A
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US3100926A
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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) | 1975-10-03 | 1976-04-03 | 1976-10-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-10-03 | 1980-04-03 | 1980-10-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-10-03 | 1984-04-03 | 1984-10-03 | $7700.00 | Window Closed / Lapsed |