Abstract: A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness T. A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension S. A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter D. The total weight of the yarn used to form the pile loop elements is G grams. Substantially all of the stitches have a thread length DKL that satisfies the relationship: DKL<=D·(1+?/2)+(2·T)+(2·S) A mass of binder material having a weight of less than G grams is disposed on the pile surface structure.

Abstract: A unitary sinker finger is attached at its first end to a sinker bar. In a first embodiment the second end of the finger is attached to a fixed support member. The sinker finger has a loop formation region and a loop cutting region disposed thereon, with the loop cutting region being disposed intermediate the loop formation region and the second end of the finger. A cutting blade that is operable in the cutting region for cutting pile loops formed on the loop formation region of the finger. In a second embodiment the sinker finger is an arcuate member that cantilevers from the sinker bar. A loop cutter cooperates with the arcuate sinker finger to cut the pile loops formed on the finger at a location adjacent to the free end of the finger. A sensing arrangement for determining operability of the cutting arrangement is also disclosed.

Abstract: A pile article having a support strand for attachment to multifilament yarn to form a velour-like pile having loosely entangled filaments in spaced apart monolithic pile rows, a helically wound package of oriented pile articles for shipping and storage, and a pile surface structure comprising pile articles arranged in spaced apart rows on a substrate to form a pile surface that may be flat or moldable, and a method for making a pile surface structure by embedding the pile articles into the backing substrate. The pile surface structures may be usefully employed in automobile mats, carpets and panels.

Abstract: A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness T. A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension S. A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter D. The total weight of the yarn used to form the pile loop elements is G grams.