US4389443A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Cut pile fabric with fused carrier and method of making same
Assignee: ENERFLO Inc A CORP OF
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Filing: 1981-12-10
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Granted: 1983-06-21
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Expires: 2001-12-10
Abstract
Abstract A novel cut pile fabric (210) and a method of making same is disclosed. The cut pile fabric (210) includes a needled non-woven batt (14) of staple fibers (12) that has an integral carrier member (74) formed by fusing a face surface (22) of the needled batt. A texturized surface is formed on the batt (14) using a texturized needle loom (17) which punches through the batt (14) from the one surface (20) (called the back surface) of the batt so that texturized loops (76) project from the carrier member (74). The non-texturized back surface (20) of the batt (14) has a backing (24) applied as by latexing, fusing, or the like, with the texturized loops (76) being tigered by a tigering roll (28) to break, fracture or cut a high percentage of the loops (76). The tigered pile is polished by a polishing roll (34) to remove the crimps in the fibers and to orient the fibers in a direction transverse to the plane of the batt (14) prior to being sheared in a shear (36). A denser, plusher, lighter weight cut pile fabric is produced having increased stability and strength.
Inventors
- 👤 Reese R. Thomas
- 👤 John W. Ellicson
- 👤 Ronald Somerville
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 14:47
CPC Classifications
D; D04; D04H; D04H11/00; D04H11/08; Y; Y10; Y10T; Y10T428/00; Y10T428/23907; Y10T428/23957; Y10T428/23964; Y10T428/23971; Y10T428/23979; Y10T428/23993
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
118 words
A cut pile fabric comprising: a needled batt of non-woven staple fibers, a carrier member fused on one surface of said batt from said staple fibers, a plurality of texturized loops of staple fibers pushed from said batt and extending upwardly through the fused carrier member, the texturized loops of fibers comprising a plurality of clusters of loops of staple fibers with each cluster containing a plurality of different sized loops of staple fibers, means formed on the other surface of said batt for backing said batt and for securing the staple fibers of said texturized loops and of said batt to said batt, and a substantial portion of said texturized loops being cut to form cut pile.
Claim 2
Dependent Claim
118 words
A cut pile fabric comprising: a needled batt of non-woven staple fibers, a carrier member fused on one surface of said batt from said staple fibers, a plurality of texturized loops of staple fibers pushed from said batt and extending upwardly through the fused carrier member, the texturized loops of fibers comprising a plurality of clusters of loops of staple fibers with each cluster containing a plurality of different sized loops of staple fibers, means formed on the other surface of said batt for backing said batt and for securing the staple fibers of said texturized loops and of said batt to said batt, and a substantial portion of said texturized loops being cut to form cut pile.
Claim 3
Dependent Claim
25 words
A cut pile fabric as claimed in claim 1 wherein said cut texturized loops are polished and sheared to provide a plush cut pile fabric.
Claim 4
Dependent Claim
27 words
A cut pile fabric as claimed in claim 1 wherein said carrier member is a fused layer of staple fibers forming the face surface of the batt.
Claim 5
Dependent Claim
22 words
A cut pile fabric as claimed in claim 1 wherein said staple fibers have lengths within the range of 1" to 4".
Claim 6
Dependent Claim
19 words
A cut pile fabric as claimed in claim 1 wherein said staple fibers have a length of approximately 11/2".
Claim 7
Independent Claim
172 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers into a batt, fusing the staple fibers on one surface of said batt to form a carrier member on said batt, using a plurality of forked needles to push a plurality of texturized loops of staple fibers from said batt to project outwardly through said fused carrier member, the texturized loops of staple fibers comprising a plurality of clusters of loops of staple fibers with each cluster containing a plurality of different sized loops of staple fibers, applying a backing on the other surface of said batt for adding stiffness to said batt and for securing the staple fibers of said texturized loops and of said batt to said batt, tigering said texturized loops of staple fibers to cut a substantial portion of said texturized loops into cut pile, polishing said cut pile to orient the cut pile in a direction substantially transverse to the carrier member, and shearing said cut pile to a predetermined pile height.
Claim 8
Independent Claim
172 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers into a batt, fusing the staple fibers on one surface of said batt to form a carrier member on said batt, using a plurality of forked needles to push a plurality of texturized loops of staple fibers from said batt to project outwardly through said fused carrier member, the texturized loops of staple fibers comprising a plurality of clusters of loops of staple fibers with each cluster containing a plurality of different sized loops of staple fibers, applying a backing on the other surface of said batt for adding stiffness to said batt and for securing the staple fibers of said texturized loops and of said batt to said batt, tigering said texturized loops of staple fibers to cut a substantial portion of said texturized loops into cut pile, polishing said cut pile to orient the cut pile in a direction substantially transverse to the carrier member, and shearing said cut pile to a predetermined pile height.
Claim 9
Dependent Claim
47 words
A method of manufacturing a cut pile fabric as claimed in claim 6 wherein said fusing of the batt is performed by a heated roll travelling over said one surface to fuse a substantial portion of the fibers of said surface into an integrally formed carrier member.
References Cited (Backward Citations)
US3152381A
Cited
US3867243A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1986-06-20 | 1986-12-20 | 1987-06-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-06-20 | 1990-12-20 | 1991-06-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-06-20 | 1994-12-20 | 1995-06-21 | $7700.00 | Window Closed / Lapsed |