Abstract: Weatherstripping is produced continuously by two or more spaced apart tufting heads, which may be operating at different stitch rates. The or each strip of weatherstripping comprises at least two rows of tufts sequentially inserted by two tufting heads. Heated dies may be located between the tufting heads for transforming rows of tufts inserted by the first tufting head at least partially into film to form barrier fins. The knuckles of the tufts are flattened, a secondary backing applied, and then individual strips of weatherstripping separated by ultrasonically slitting, all as a continuous process enabling weatherstripping of various constructions to be efficiently and economically produced by tufting.

Abstract: A method of manufacturing weatherstripping comprises forming a row of pile fiber on a substrate, compressing the row widthwise between a pair of dies, heating the row while so compressed, and cooling the heated row. In this way the sides of the row can be heat set for appearance, or formed into a continuous film, or the whole row converted into a barrier fin in the form of a film, depending upon the degree of compression and the temperature. Preferably the row is formed by tufting and the dies disposed immediately downstream of the tufting station. Pile fiber of conjugate polyethylene and polypropylene is advantageous in forming such films which are integrally attached to the substrate by pile fiber roots extending from the base of the film into the substrate.

Abstract: A method and apparatus for tufting weatherstripping involves forming a barrier fin on a substrate, advancing the substrate with the barrier fin extending downwardly from the underside thereof past a tufter head, and passing the downwardly extending barrier fin through a channel in the needleplate of the tufter head while the substrate passes over and is supported by the needleplate. A row of tufts is then tufted along one or both sides of the barrier fin. The barrier fin may be formed by folding the substrate, adhering a strip to the underside of the substrate, or by forming a film from a row of previously inserted tufts. Preferably, the substrate is guided transversely to ensure alignment of the barrier fin or fins between the rows of tufts.

Abstract: A method of manufacturing weatherstripping includes tufting synthetic yarn into a primary backing fabric to form tufts on one side thereof and tuft "knuckles" on the other side. Then, the tuft knuckles are contacted with a heated surface of controlled temperature to deform and flatten them, the combined thickness of the primary backing and the tuft knuckles thus being reduced and the tufts being more securely attached to the primary backing. Preferably, there is relative motion between the tuft knuckles and the heated surface to effect a smearing of the tuft knuckles onto the primary backing. The flattened tuft knuckles may form a thin continuous strip adhering to the primary backing and locking the tufts thereto.

Abstract: An improved process, optimizing quality and growth rate with independent control of residual stress, is disclosed for the growing of membranes for use as X-ray lithography mask blanks. The process comprises providing a mounting fixture and a low-cost substrate material thereon, cooling the substrate to about the boiling point of hydrogen by passing a liquid coolant in contact with the fixture, depositing by a low-temperature plasma-enhanced method a thin membrane onto the cooled substrate, removing the substrate and the thereon deposited membrane from the fixture, and allowing the substrate thermally to expand by gradually assuming ambient room temperature, whereby the membrane will acquire optimum tensile stress. Preferably, the low-cost substrate is low grade industrial silicon and the membrane is formed of boron nitride, silicon carbide, silicon nitride, amorphous silicon, diamondlike carbon, aluminum oxide, beryllium and silicon oxide.

Abstract: A process and apparatus for providing metal material having an improved structure for forming into a desired article is disclosed herein. The improved structure is obtained by slurry casting a material into a continuous member and then hot working the slurry cast material. Upon reheating to a semi-solid state, the hot worked, slurry cast material will exhibit finer particles and fewer eutectic melting rosettes than would be exhibited by the slurry as-cast material in an unworked and heated condition. The hot working of the slurry cast material produces an article having a deformed structure exhibiting directionality.

Abstract: A secondary carpet backing fabric woven from man-made fiber warp and weft yarns, the warp yarns preferably being ribbon, including fibrillated, yarns, and at least some of the weft yarns having a random intermingled array of loops and filaments, weft yarns not having a random intermingled array of loops and filaments preferably being such ribbon yarns. Preferably, the secondary backing fabric has an open weave construction of leno structure. These backing fabrics having unusually strong adhesion because of the open structure of the weft yarns which have the random intermingled array of loops and filaments. Air textured core and effect yarns are especially suitable. Carpets having this secondary backing can be glued down to a floor with good adhesion.