Abstract: A textile fabric with a three-dimensional contour that blocks fluid penetration at the surface is created by attaching a solid liquid-blocking polymeric layer conforming to the contours of the surface to a fabric layer. The surface includes elevated areas, depressed areas, a plurality of surface fibers and gaps among the plurality the plurality of surface fibers. The liquid-blocking polymeric layer is forced to follow the contours of the surface fibers and gaps using vacuum, heat and forced air. The resulting textile fabric maintains a textile appearance.

Abstract: A planar floor covering is formed having a top face and a bottom face opposite the top face, a length, a width perpendicular to the length, a top surface, a bottom surface opposite the top surface, a height between the top surface and the bottom surface, and physical properties or characteristics that vary across at least one of the length, the width and the height. The physical properties or characteristics include material composition, weight, density, directionality, stiffness, compressibility, elasticity and thickness.

Abstract: Resin dissolved or suspended in liquid is applied to a greige fabric formed with finer denier yarns forming surface loops before the fabric is bulked and after the liquid has been removed by low-temperature drying. The dried fabric is then bulked at a higher temperature setting the resin, resulting in superior loop tip resilience, and superior surface durability. Bulking and simultaneous resin setting optionally includes shrinking in area by 10-20%. Print appearance retention is also superior when printing follows bulking and setting of the resin.

Abstract: A textile composite contains a sublayer coated with unactivated solid sublimation dyes and incorporated with the layers of the textile composite or placed between a fabric layer and a backing layer. The sublimation dyes are activated with heat and pressure, and dying or coloring the inner strata of the textile composite.

Abstract: A textile fabric having improved properties, variously including surface stability, abrasion resistance, resistance to edge fraying, moisture control, and resistance to fluid penetration is created by introducing a polymeric solution or a plurality of low-melting particles suspended in a liquid into the textile fabric while leaving a plurality of surface fibers exposed and maintaining a textile feel on the surface.

Abstract: Textiles are re-cycled by grinding and scatter-laying onto a needle-punched web optionally containing low-melting material, followed by laying a second needle-punched web over the scattered layer and re-needling the three layers before applying heat or heat and pressure to activate the low-melting ground material present within the layers. Additional low-melt ground material is optionally blended into the ground textile if low melt components are absent or insufficient to bond the composite. The ground material is driven and dispersed into the surrounding web layers with at least part of the material being adjacent the two outer surfaces. The physical properties of the composite can be adjusted by selecting suitable combinations including but not limited to needling stroke depth, needling density, needle gage, low-melt content, heat finishing conditions, and relative layer weights.

Abstract: Stabilizing a textile sheet structure was achieved by forming a plurality of discrete fiber tufts extending from a first face of a fibrous layer of the textile sheet structure, through the fibrous layer and beyond a second face opposite the first face. Each discrete fiber tuft included a plurality discrete fibers. Each discrete fiber tuft was anchored to the first face and the second face of the fibrous layer by joining together the plurality of each discrete fiber tuft at the first face and the second face and bonding the joined plurality of discrete fiber tuft to the first face and the second face.

Abstract: Stabilizing a fabric layer and simultaneously laminating a fabric to a bulky and cushioning backing layer using multiple internal adhesive layers placed within the fabric layer forms a composite textile. The melt index, weight and chemical compatibility of the adhesive layers versus the adjacent fabric sub-strata and the backing layer are adjusted to achieve the desired penetration of molten adhesive, mechanical bonding and chemical bonding. An optional external adhesive layer with a low melt index can be added between the fabric layer and the backing layer to facilitate attachment to a highly porous backing.

Abstract: A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

Abstract: An adhesive layer carrying a uniform color or a color-scheme is placed within or under a colored or color-printed conformable fabric that is simultaneously or subsequently molded into a three-dimensional shape or embossed with a three-dimensional pattern. The thermoplastic adhesive layer proceeds towards the fabric surface and matches or masks the color gaps opened on the surface by molding or embossing. The fabric can also be laminated to a backing during the molding or embossing process.

Abstract: A method for directing adhesive places blocking layers adjacent to adhesive layer within a textile sheet structure or between textile sheets, directing adhesive flow in a preferred direction away from the blocking layers. When the blocking layers are partially open to allow some adhesive flow through, adhesive flow is also directed in the planar direction away from closed areas towards open area, and can reform the adhesive layers into a preferred final three-dimensional configuration.

Abstract: A fabric made of yarns interlooping with each other or passing through an inner layer at looping intervals. The fabric is embossed with a micro-pattern extending into the yarns or into a layer underneath the fabric. The micro-pattern contains a pre-defined pattern of a plurality of binding points attaching the yarns to the inner layer or to the added underlayer. This micro-pattern has an inter-point spacing between adjacent binding points that is less than the interlooping intervals. The fabric can also be embossed with a macro-pattern separate from and coarser than the micro-pattern. The macro-pattern establishes a desired aesthetic in the fabric, and the micro-pattern does not interfere with the desired aesthetic.

Abstract: A method of tufting carpet using multiple yarns directed through at least one single needle, if not a plurality of such situations, whereby the needles tuft a carpet having unique specifications. Specifically, the yarns are pre-twisted together, and can be solution dyed and/or of have different twist characteristics, such as selected from the group of high twist, standard twist, low twist, no twist, flat yarns and/or pre-twisted flat yarns.

Abstract: Vacuum printing a fabric involves forming a fabric having a top face and a bottom face and placing a barrier layer below the top face. A plurality of holes is established in the barrier layer, and dye is applied to at least a portion of the top face of the fabric. Vacuum applied to the bottom face pulls the dye through the fabric and the plurality of holes in the barrier layer.

Abstract: A composite floor-covering comprising a fabric face layer, a barrier layer and a cushion backing layer is disclosed. The fabric face layer is attached to the barrier layer by a first adhesive layer and the barrier layer is attached to the cushion backing layer by a second adhesive layer. The fabric face layer on the composite floor covering can stretch up to an initial amount under a first pressure and can stretch beyond under a second pressure wherein the second pressure is higher than the first pressure. The composite floor-covering has a water vapor transmission rate of less than about 5.0 cm3/m2/24 hour at 100° F. and 90% RH.

Abstract: A rug a methods of manufacturing and packaging the rug. The rug, once manufactured, can be folded one or more times from an unfolded configuration to a folded configuration such that the area thereof is substantially reduced. In example embodiments, the rug is packaged in the folded configuration. A bag, shrink wrap or other packaging is provided for retaining the folded rug.

Abstract: A multicolored and accented carpet includes a plurality of tufts of color accented fiber including two or more differently colored extruded solution dyed yarns and a base yarn twisted together whereby a plurality of color transitions are provided along the length of the single accented fiber. A cut pile carpet is produced, having the appearance of a space dyed carpet, with the fade and bleach resistance of a solution dyed carpet.