US4390582A
Expired / Lapsed
US
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Cut pile fabric with carrier and texturized loops
Assignee: Foss Manufacturing Co Inc
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Filing: 1981-12-10
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Granted: 1983-06-28
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Expires: 2001-12-10
Abstract
Abstract A novel cut pile fabric (110) and a method of making same is disclosed. The cut pile fabric (110) includes a needled non-woven batt (14) of staple fibers (12) that has a carrier member (60) which may be a separate sheet of material carried by a face surface (22) of the batt. A texturized surface is formed using a texturizing needle loom (17) which punches through the batt (14) from the one surface (20) (called the back surface) of the batt (14) so that texturized loops (70) project from the carrier (60) on the other face surface (22) of the batt. The one non-texturized back surface (20) of the batt (14) has a backing (24) applied thereto as by latexing, fusing, or the like, with the texturized loops (70) being tigered to break, fracture or cut a high percentage of the loops (70). 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 substantially perpendicular to the batt prior to being sheared in a shear (36). A denser, plusher cut pile fabric is produced having increased stability and strength.
Inventors
- 👤 Robert C. Pickens, Jr.
- 👤 Reese R. Thomas
- 👤 John W. Ellicson
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 09:47
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: 19
Claim 1
Independent Claim
157 words
A cut pile fabric comprising: a needled batt of non-woven staple fibers, a carrier member attached to one surface of said batt, texturized loops of staple fibers needled from the batt and projecting through said carrier member, said loops defined by fibers extended selectively through the carrier member, said fibers defining the loops are needled from the batt and have fiber ends interlocked with fibers in the needled batt, the texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster containing a plurality of different sized loops of fibers, backing means formed on another surface of said batt for backing said batt and for securing the fiber ends of the staple fibers of said texturized loops to said batt, a substantial portion of said different sized loops of fibers being cut to form individual cut pile, and said cut pile being polished and sheared to provide a plush cut pile fabric.
Claim 2
Dependent Claim
157 words
A cut pile fabric comprising: a needled batt of non-woven staple fibers, a carrier member attached to one surface of said batt, texturized loops of staple fibers needled from the batt and projecting through said carrier member, said loops defined by fibers extended selectively through the carrier member, said fibers defining the loops are needled from the batt and have fiber ends interlocked with fibers in the needled batt, the texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster containing a plurality of different sized loops of fibers, backing means formed on another surface of said batt for backing said batt and for securing the fiber ends of the staple fibers of said texturized loops to said batt, a substantial portion of said different sized loops of fibers being cut to form individual cut pile, and said cut pile being polished and sheared to provide a plush cut pile fabric.
Claim 3
Dependent Claim
29 words
A cut pile fabric as claimed in claim 1 wherein said carrier member is a sheet of material selected from the group of materials comprising polyethylene, nylon and polyester.
Claim 4
Dependent Claim
29 words
A cut pile fabric as claimed in claim 1 wherein said backing is a material selected from the group consisting of latex, sintered polyethylene, and a fused thermoplastic sheet.
Claim 5
Dependent Claim
36 words
A cut pile fabric as claimed in claim 1 wherein said staple fibers are selected from the group consisting of polypropylene, nylon and polyester and the fiber lengths are 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
Dependent Claim
36 words
A cut pile fabric as claimed in claim 1 wherein said carrier member is a sheet of thermoplastic material that has been heated to lock the fibers of the loop to the fibers of the batt.
Claim 8
Dependent Claim
29 words
A cut pile fabric as claimed in claim 1 wherein said carrier member is a sheet of polyethylene having a thickness within the range of 4 to 8 mils.
Claim 9
Dependent Claim
26 words
A cut pile fabric as claimed in claim 7 wherein said fabric is molded to a particular shape which shape is retained by said carrier member.
Claim 10
Dependent Claim
23 words
A cut pile fabric as claimed in claim 1 wherein said carrier member is needle bonded to said one surface of said batt.
Claim 11
Independent Claim
166 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers to form a batt having a face surface and a back surface, applying a carrier means on said face surface, forming texturized loops of fibers from said batt by needling the fibers selectively outwardly through said carrier means, whereby the fiber ends of the loops are interlocked with fibers in the batt, said texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster having a plurality of different sized loops of fibers, applying a backing on said back surface of said batt for adding stiffness to said batt and for securing the staple fibers of said texturized loops to said batt, tigering said texturized loops to cut a substantial portion of said different sized loops into cut pile, polishing said cut pile to orient the pile in a direction substantially transverse to the carrier member, and shearing said cut pile to a predetermined pile height.
Claim 12
Independent Claim
166 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers to form a batt having a face surface and a back surface, applying a carrier means on said face surface, forming texturized loops of fibers from said batt by needling the fibers selectively outwardly through said carrier means, whereby the fiber ends of the loops are interlocked with fibers in the batt, said texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster having a plurality of different sized loops of fibers, applying a backing on said back surface of said batt for adding stiffness to said batt and for securing the staple fibers of said texturized loops to said batt, tigering said texturized loops to cut a substantial portion of said different sized loops into cut pile, polishing said cut pile to orient the pile in a direction substantially transverse to the carrier member, and shearing said cut pile to a predetermined pile height.
Claim 13
Dependent Claim
27 words
A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said carrier means is a sheet of material bonded to said face surface.
Claim 14
Dependent Claim
26 words
A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said backing is latex applied to said back surface with an applicator.
Claim 15
Dependent Claim
24 words
A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said texturized loops are formed with a texturizing needle loom.
Claim 16
Dependent Claim
31 words
A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said fabric is placed in a mold and heated to provide the fabric with a molded shape.
Claim 17
Dependent Claim
21 words
A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said carrier means is attached by tacking.
Claim 18
Independent Claim
128 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers into a batt, applying a carrier member on one surface of said batt, forming texturized loops of fibers from the fibers in said batt by needling the fibers selectively outwardly through said carrier member, whereby the fiber ends forming the loops are interlocked with the fibers in the batt, said texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster having a plurality of different sized loops of fibers, applying a backing on another surface of said batt to stiffen said batt and to secure the staple fibers of said texturized loops to said batt, and tigering said texturized loops to cut said loops into cut pile.
Claim 19
Independent Claim
128 words
A method of manufacturing a cut pile fabric comprising: lapping and needling non-woven staple fibers into a batt, applying a carrier member on one surface of said batt, forming texturized loops of fibers from the fibers in said batt by needling the fibers selectively outwardly through said carrier member, whereby the fiber ends forming the loops are interlocked with the fibers in the batt, said texturized loops of fibers comprising a plurality of clusters of loops of fibers with each cluster having a plurality of different sized loops of fibers, applying a backing on another surface of said batt to stiffen said batt and to secure the staple fibers of said texturized loops to said batt, and tigering said texturized loops to cut said loops into cut pile.
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) | 1986-06-27 | 1986-12-27 | 1987-06-28 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1990-06-27 | 1990-12-27 | 1991-06-28 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1994-06-27 | 1994-12-27 | 1995-06-28 | $7700.00 | Window Closed / Lapsed |