US4035533A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Tufted carpet with meltable-film primary-backing component
Assignee: Champion International Corp
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Filing: 1976-06-01
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Granted: 1977-07-12
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Expires: 1996-06-01
Abstract
Abstract A low-melting point layer of thermoplastic synthetic film is superimposed upon the rear side of a primary backing layer. Pile-forming yarns are then tufted from this rear side through both of these layers to form at the front side of the primary backing layer a pile, while forming at the exposed rear side of the film layer respective loops. The film layer is then exposed to heat, causing it to melt and to bond the loops to the primary backing layer.
Inventors
- 👤 Philip Wayne Chambley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 09:33
CPC Classifications
B; B32; B32B; B32B27/00; B32B27/06; D; D05; D05C; D05C17/00; D05C17/02; B32B33/00; B32B2471/00; B32B2471/02; Y; Y10; Y10S; Y10S428/00; Y10S428/913; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23979
Claims Analysis
Total Claims: 12
Claim 1
Independent Claim
87 words
A tufted pile carpet, comprising a primary backing layer having a front side and a rear side; a thermally meltable film layer of synthetic plastic material on said rear side; and pile-forming yarn tufted from said rear side through both of said layers to form a pile at said front side and loops at said rear side, said film layer being melted subsequent to tufting of said yarn through said layers so as to bond said loops firmly to said rear side of said primary backing layer.
Claim 2
Dependent Claim
87 words
A tufted pile carpet, comprising a primary backing layer having a front side and a rear side; a thermally meltable film layer of synthetic plastic material on said rear side; and pile-forming yarn tufted from said rear side through both of said layers to form a pile at said front side and loops at said rear side, said film layer being melted subsequent to tufting of said yarn through said layers so as to bond said loops firmly to said rear side of said primary backing layer.
Claim 3
Dependent Claim
40 words
A tufted pile carpet as defined in claim 1, wherein said film layer is of a material having a low melting point so that damage to said yarn and primary backing layer is avoided when said film layer is melted.
Claim 4
Dependent Claim
15 words
A tufted pile carpet as defined in claim 1, wherein said film layer is polyethylene.
Claim 5
Dependent Claim
44 words
A tufted pile carpet as defined in claim 1, wherein portions of said film layer are interposed between said rear side of said primary backing layer and said loops and when said film layer is melted, bond said loops to said primary backing layer.
Claim 6
Dependent Claim
34 words
A tufted pile carpet as defined in claim 1, wherein said primary backing layers have pores, and the melted material of said film layer closes said pores and prevents passage of flame-feeding oxygen therethrough.
Claim 7
Independent Claim
87 words
A method of making a tufted pile carpet, comprising the steps of superimposing a thermally meltable film layer onto the rear side of a primary backing layer; tufting pile-forming yarn from said rear side through the superimposed layers so as to form a carpet pile at the front side of said primary backing layer and loops on the exposed side of said film layer; and exposing said film layer to heat so as to cause it to melt and bond said loops to said primary backing layer.
Claim 8
Independent Claim
87 words
A method of making a tufted pile carpet, comprising the steps of superimposing a thermally meltable film layer onto the rear side of a primary backing layer; tufting pile-forming yarn from said rear side through the superimposed layers so as to form a carpet pile at the front side of said primary backing layer and loops on the exposed side of said film layer; and exposing said film layer to heat so as to cause it to melt and bond said loops to said primary backing layer.
Claim 9
Dependent Claim
31 words
A method as defined in claim 6, wherein the step of superimposing comprises withdrawing said layers from respective supplies in paths which are at least in part parallel to each other.
Claim 10
Dependent Claim
55 words
A method as defined in claim 6, wherein said film layer is of a material having a low melting point, and the step of exposing said layer to heat involves the application of heat sufficient to cause said film layer to melt, but insufficient to cause damage to said yarn and said primary backing layer.
Claim 11
Dependent Claim
42 words
A method as defined in claim 6, wherein the step of exposing said film layer to heat includes melting of those portions of said film layer which are located between said rear side of said primary backing layer and the respective loops.
Claim 12
Dependent Claim
23 words
A method as defined in claim 6, and further comprising the step of securing a secondary backing layer over the melted film layer.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-07-11 | 1981-01-10 | 1981-07-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-07-11 | 1985-01-10 | 1985-07-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-07-11 | 1989-01-10 | 1989-07-12 | $7700.00 | Window Closed / Lapsed |