Abstract: An improved carpet product includes a pile fabric layer and a stabilizing layer adhered to the back of the pile fabric layer to provide dimensional stability against concentrated stresses exerted against the upper surface of the carpet. A balancing layer disposed below the stabilizing layer has thermal response and moisture absorption characteristics selected for compatibility with the pile fabric layer. When the carpet product is exposed to temperature extremes or changes in ambient humidity, stresses exerted by the expansion or contraction of the pile fabric layer create a bending moment around the stabilizing layer. However, the balancing layer creates comparable stresses on the lower side of the stabilizing layer and exerts an equal-but-opposite bending moment which balances the moment exerted by the pile fabric layer. The resulting carpet product exhibits enhanced flatness and floor hugging characteristics when subjected to temperature extremes or changes in the ambient humidity.

Abstract: An improved method and apparatus for applying adhesive to a backing fabric, such as for adhesively laminating a secondary fabric backing to a carpet. The adhesive is formed into a layer of predetermined thickness on the surface of a rotating casting roller, and the backing fabric is conveyed along a path adjacent to the casting roller in a direction opposite to the direction of rotation of the casting roller. A press blade brings sucessive portions of the backing fabric into contact with a portion of the casting roller, and the adhesive layer on the casting roller is transferred to the backing fabric at an adhesive contact point. The backing fabric is then conveyed abruptly away from the casting roller at the adhesive contact point in a substantially radial direction.

Abstract: A method of forming a layer of blown cellular urethane on a primary carpet backing comprising the steps of preparing a mixture of reactive urethane forming agents, controlling the temperature of the reactive mixture, shaping the reactive mixture into a layer upon a latex film, heating the urethane forming mixture to initiate chemical blowing of the mixture, applying the underside of a previously tufted and heated primary carpet backing directly to the upper surface of the mixture, heating the mixture to a predetermined temperature, applying pressure to the carpet and mixture and stripping the carpet and cellular urethane layer from the conveyor belt.

Abstract: An improved system and method for applying adhesive to a secondary backing fabric for adhesively laminating the secondary backing to a carpet. A secondary backing fabric is conveyed along a path at a predetermined speed, while an adhesive is deposited onto the surface of a casting roller rotating in a direction opposite to the direction of movement of the secondary backing fabric. A doctoring means spaced a predetermined distance from the surface of the casting roller doctors the adhesive into a layer of predetermined thickness on the casting roller. The secondary backing fabric is then brought into contact with a portion of the adhesive-coated casting roller so that a layer of adhesive is transferred onto the backing fabric.

Abstract: A method and apparatus for coating the back of carpet products providing improved control over coating weight, uniformity, and penetration. A layer of adhesive is formed on a rotating coating roll, and the upper edge of an applicator blade is brought into contact with the coated roll. The layer of adhesive is transferred to the upper edge of the applicator blade and flows under the effect of gravity to the lower edge of the blade. The back of the carpet is then pressed against the lower edge of the blade, simultaneously applying and spreading the adhesive.

Abstract: A method of forming a layer of blown cellular urethane on a primary carpet backing comprising the steps of preparing a mixture of reactive urethane forming agents, controlling the temperature of the reactive mixture, shaping the reactive mixture into a layer upon a latex film, heating the urethane forming mixture to initiate chemical blowing of the mixture, applying the underside of a previously tufted and heated primary carpet backing directly to the upper surface of the mixture, heating the mixture to a predetermined temperature, applying pressure to the carpet and mixture and stripping the carpet and cellular urethane from the conveyor belt.

Abstract: A method of forming a layer of blown cellular urethane on a primary carpet backing comprising the steps of preparing a mixture of reactive urethane forming agents, controlling the temperature of the reactive mixture, shaping the reactive mixture into a layer upon a latex film, heating the urethane forming mixture to initiate chemical blowing of the mixture, applying the underside of a previously tufted and heated primary carpet backing directly to the upper surface of the mixture, heating the mixture to a predetermined temperature, applying pressure to the carpet and mixture and stripping the carpet and cellular urethane layer from the conveyor belt.

Abstract: Apparatus for treating yarn ends while plaited in unstressed condition on a conveyor belt. In different portions of a machine the treatment consists in fixing dye-stuffs printed upon the yarns and drying the yarns after fixing and subsequent washing. A pair of rolls form a nip through which the conveyor belt and the plaits thereon pass upon leaving each of the treatment means. Yarn pulling means pull the yarns from the nip and off the belt, applying tension against the reaction of the nip without applying stress to the plaits advancing toward it.

Abstract: A method of forming a layer of blown cellular urethane on a carpet backing comprising the steps of providing a mixture of reactive urethane forming agents, shaping the reactive mixture into a layer upon a latex film, applying the underside of a heated carpet backing directly to the layer of reactive mixture, and heating the layer of reactive mixture to expedite reaction of the reactive mixture and chemical blowing of the reactive mixture into an enlarged layer of cellular urethane on the carpet backing between the backing and the latex film. Apparatus for performing the method is disclosed as is the resultant product.

Abstract: A method of forming a layer of blown cellular urethane on a primary carpet backing comprising the steps of preparing a mixture of reactive urethane forming agents, controlling the temperature of the reactive mixture, shaping the reactive mixture into a layer upon a latex film, heating the urethane forming mixture to initiate chemical blowing of the mixture, applying the underside of a previously tufted and heated primary carpet backing directly to the upper surface of the mixture, heating the mixture to a predetermined temperature, applying pressure to the carpet and mixture and stripping the carpet and cellular urethane layer from the conveyor belt.

Abstract: Apparatus and method for coloring yarn continuously in sheets thereof, the apparatus including a spatial sequence apparatus for testing the yarn by pre-stressing; a yarn tension relaxing means; a printing apparatus for coloring the yarn in an accurately predetermined longitudinal pattern; control means for correcting wet yarn length increase as the yarn progresses through the printer; wet hot box for fixation of the dye stuff onto the yarn fiber; yarn washing means; combined apparatus for yarn drying and/or stress relieving by raising the yarn temperature; yarn relative lateral displacement means; yarn longitudinal displacement means; and finally a tufting machine or a take up means such as a beam.