Abstract: A new method of making and manufacturing pile weather stripping is described using a non-woven, e.g. a knitted pile that is either cropped or slit to the correct pile height. The pile is then precisely introduced to a singer using guides. After the singing process the knitted pile is guided into the extruder head where the base is extruded around the knitted pile. The density of the knitted pile weather stripping is controlled by adding or removing filling yarns, picks and changing of the yarn denier. The base thickness and configuration is a direct function of the extrusion head. A pile fin or fins can be added as a purchased raw good or extruded as part of the process. The inventive pile weather stripping allows for the fabrication of any pile height, pile density and backing configuration to include throat width, T-slot width, T-slot base depth and varying fin heights.

Abstract: Polyurethane carpet backings are made using a polyurethane-forming composition that includes hydroxymethyl-containing polyester polyols. The formulation allows a significant replacement of conventional polyols with polyols derived from annually renewable resources, while maintaining important properties like edge curl, tuftbind, viscosity and good curing rates.

Abstract: The invention is directed generally to stretchable flocked articles and/or assemblies, more specifically stretchable flocked articles and/or assemblies having at least one elastomeric adhesive and a method for making the same. One aspect of the invention is an elastomeric textile product comprising a textile design and a self-supporting, elastomeric adhesive layer. In one preferred embodiment, the self-supporting, elastomeric adhesive layer comprises an elastomeric film position between opposing first and second adhesive films.

Abstract: An appliqué for applying a design to a fabric includes a flock in a pre-determined multi-colour pattern retained by a flock adhesive and an application adhesive suitable for adhering the appliqué to a fabric. A garment or piece of fabric having an appliqué and a method of decorating a fabric by applying an appliqué using an application adhesive are disclosed.

Abstract: A tufted nonwoven includes a face material which tufts a bonded nonwoven having a mixture of a plurality of bicomponent filaments 1 with a plurality of bicomponent filaments 2. At least bicomponent filaments 1 have component 11 and component 12. Component 11 exhibits a melting temperature Tm(11), and component 22 of the bicomponent filaments 2 exhibits a melting temperature Tm(22). Component 12 exhibits a melting temperature Tm(12), and component 21 of the second bicomponent filaments exhibits a melting temperature Tm(21), and Tm(12) is higher than Tm(21). The melting temperatures of components 11 and 22 and the melting temperatures of components 12 and 21 obey a relationship in which Tm(11) and Tm(22)>Tm(12)>first Tm(21) and optionally wherein the face material is bonded to bicomponent filaments 2 by a solidified melt of component 21. Also described are a bonded nonwoven and methods for their manufacture.

Abstract: Low weight and non-square carpet tile suitable for use in mass transit vehicles, particularly passenger aircraft. The carpet tile preferably weighs less than about 82 ounces per square yard. The carpet tile of this invention may have a carpet pile and at least one backing layer. The backing layer may use low weight filler material. Secondary backing plastic material may be compressed into the tile structure with pressure rollers or other pressure applying process on an improved tile production line.

Abstract: A synthetic-grass covering, usable, for example, for making artificial pitches for sports activities, consisting of a substrate made of sheet material and filiform formations, implanted in the sheet material so as to present a looped part that extends up against one of the surfaces of the sheet material and lateral branches that extend in order to simulate the grassy sward of natural turf from the opposite surface of the sheet material. The substrate made of sheet material comprises a pad with coupled thereto a layer made of heat-meltable material, and the filiform formations are also made of heat-meltable material, with the aforesaid looped parts that extend in an area corresponding to the layer made of heat-meltable material, heat-welded to the aforesaid layer.

Abstract: A vehicle mounting carpet including a carpet matrix including a carpet matrix side base cloth mounted on a carpet member for a matrix laid on a floor panel of an automobile, and a pile implanted from a surface side of the carpet matrix side base cloth, and a back face side member constituted by a nonwoven cloth bonded to a back face side of the carpet matrix, in which a face of the back face side member brought into contact with the carpe member for the matrix is formed with a number of slender cords which can be arranged along a width direction of a vehicle body when mounted onto the carpet member for the matrix.

Abstract: A method for preparing carpet by using polyurethane to anneal secondary backing to a greige, comprising fibers attached to a primary backing. The polyurethane monomers are mixed just prior to application to the greige primary backing allowing the relatively low viscosity polyurethane to penetrate the fibers of the primary backing to aid in fiber lock. The polyurethane is puddle between two rollers that coat a layer of polyurethane onto the greige. The polyurethane coated greige is then contacted with the secondary backing before complete polymerization to insure sufficient tack to hold the backings together resulting in a durable carpet requiring a relatively low weight of polyurethane monomers.

Abstract: A carpet according to the present invention includes: a first air-impermeable layer (surface layer), a sound absorbent layer provided on a reverse side of the first air-impermeable layer, and a second air-impermeable layer (backing material layer) provided on a reverse side of the sound absorbent layer. In the carpet, a pile yarn is implanted through the first air-impermeable layer and the sound absorbent layer.

Abstract: A pile stripping comprising pile extending from a backing is described whereby the pile is made from pile yarns and the backing is bonded to the pile. A synthetic fibre is interlaced with the pile yarns, and the backing traps at least a part of the synthetic fibre in the backing. The stripping can further comprise a fin, whereby the fin can be located within the pile or alongside the pile. The backing and the fin may be constructed so that the backing is inserted in the fin.

Abstract: A recyclable tufted carpet meeting EPA recyclable content standards and having improved dimensional stability that reduces skew, bow, and wrinkles during manufacture and installation is formed by combining prior art primary and secondary backings into a single, fiber-reinforced primary backing layer. Consolidating either a glass fiber fabric layer, a glass veil, or a glass mat with a fiber-reinforced extruded film forms the fiber-reinforced primary backing layer. An additional glass fabric fiber layer can also be introduced to the primary backing to provide additional dimensional stability.

Abstract: A method of making a bio-based carpet material that includes the steps of: providing a griege goods having a top surface and a bottom surface; applying a pre-coat material to the bottom surface of the griege goods to form a pre-coated griege good; and applying a backing material to the bottom surface of the pre-coated griege good. The backing material includes the reaction product of a backing material A-side that has an isocyanate and a backing material B-side that has a transesterified blown vegetable oil which is the result of a heated combination of a blown vegetable oil, a multifunctional compound and a catalyst.

Abstract: A support panel structure includes at least one panel which extends in longitudinal and cross direction of the support panel structure and essentially forms one integrated structure, which integrated structure is at least partly built up of at least one composite resin laminate building block comprising at least a first and a second face sheet of a fibrous reinforced material with sandwiched in between a sheet of a foamed core material, wherein the first and second face sheet and the sheet of core material are mutually connected by means of fibrous reinforcing material at least part of which extends in height direction of the resin laminate building block, further with the support panel structure including in height direction a multiplicity of composite resin laminate building blocks stacked on top of each other and bonded to each other, at least a first and a second superposed resin laminate building blocks which sandwich between them a layer of a foamed material, the resin laminate building blocks and foame

Abstract: A method of producing a decorative carpet tile may include providing a carpet tile in accordance with the prior art techniques and then treating the carpet tile in one of various manners to provide a separation internal to side edges of the carpet tile. The treatment can include tip shearing side portions relative to an internal portion to provide at least one discontinuity, dripping colors to provide a frame, carving, burning, or otherwise providing a separation internal to the side edges of the carpet tile in various disclosed embodiments.

Abstract: The present invention includes a method for making a bio-based carpet material by providing tufts, a backing, a pre-coat, and a backing material wherein the pre-coat includes the reaction product of a pre-coat A-side having a pre-coat isocyanate and a pre-coat B-side and the backing material includes the reaction product of a backing material A-side having an isocyanate and a backing material B-side. The pre-coat B-side and the backing material B-side may include a polyol derived from petroleum; a vegetable oil, cross-linker, and a catalyst; or a transesterified polyol.

Abstract: A method of fabricating optical energy collection and conversion devices using carbon nanotubes (CNTs), and a method of anchoring CNT's into thin polymeric layers is disclosed. The basic method comprises an initial act of surrounding a plurality of substantially aligned nanostructures within at least one fluid layer of substantially uniform thickness such that a first end of the plurality of nanostructures protrudes from the fluid layer. Next, the fluid layer is altered to form an anchoring layer, thereby fastening the nanostructures within the primary anchoring layer with the first ends of the nanostructures protruding from a first surface of the primary anchoring layer. Finally, a portion of the anchoring layer is selectively removed such that a second end of the nanostructures is exposed and protrudes from the anchoring layer. The resulting product is an optically absorbent composite material having aligned nanostructures protruding from both sides of an anchoring layer.

Abstract: Disclosed are a carpet for a vehicle and a method of manufacturing the same. A first material is scored to define a gap. A portion of the first material interior to the gap is compressed, and then folded out of the gap. A second material is adhered to the first material. The second material may be adhered to the compressed portion of the first material. The volume of the compressed portion may be decreased by about half. The first material may be a sound-absorbing material.

Abstract: A fibrous glass insulation building product includes a fibrous glass body of fibrous materials having at least one binder material that emits gaseous materials, and a gas absorbent material.

Abstract: An insulation product includes a fibrous web of first fibers, rotary glass fibers, and textile glass fibers. A binder is blended with the fibrous web. The binder bonds the fibers together to form the insulation product. The binder includes a thermoplastic binder component and a powdered binder component.

Abstract: A carpet underlay for a floor carpet, the underlay having a foam base layer having an upper surface, and a cross-linked closed cell polyolefin foam upper layer having a first surface and a second surface, wherein the first surface is bonded to the upper surface of the base layer and the second surface is adapted to contact the carpet in abutment. Preferred foam base layer comprises a polyurethane foam, particularly, chipfoam; and the cross-linked closed cell foam layer comprises polyethylene, polyolefine, polyamide and mixtures, thereof. Apparatus and process of manufacture are provided. The underlay provides improved resistance to odour and toxic vapour penetration from the base foam layer through the carpet into the atmosphere above the carpet.

Abstract: A sheet-form loop product includes a flexible paper substrate and a layer of staple fibers disposed on a first side of the substrate, exposed loops of the fibers extending from holes through the substrate to a second side of the substrate, with bases of the loops being anchored on the first side of the substrate. The loops can be fastening loops. The product is formed by needling the fibers through the paper and then bonding the fibers. Examples include loop fastener materials, towels, abrasive scrubbing pads and sanding materials.

Abstract: An improved mat is disclosed. Long and short legs support the mat and cause it to feel resilient although it is fabricated from hard rubber. The mat has drain holes on vertical surfaces. Ribs prevent the mat from embedding within grating. Grit is selectively placed upon the mat and physically supported. Adhesive for bonding the grit is retained by retention lips. Also disclosed is a process for creating drain holes on vertical surfaces of mats by attaching a grooving tool to a robot and programming the robot to cut through molded mat channels to create the desired drain holes. The claimed process uses the robot to selectively place adhesive upon the mat. An adhesive dispenser is attached to the robot and the robot is appropriately programmed.

Abstract: A three layer coated fabric has a bottom backing layer, a top coating layer and a middle coating layer that contains recycled coated fabric material. All of the constituent parts of coated fabrics being recycled are included in the middle layer. The middle layer also sometimes contains other materials that can blend with the recycled coated fabrics or other recycled post-consumer materials. The three layer coated fabric is manufactured by transforming the recycled coated fabrics and other materials into a form that can be used to create the middle layer.

Abstract: A tufted PET carpet assembly and a method of forming the same. The carpet assembly comprising a face layer comprised of polyethylene terephthalate (PET) yarn comprised of PET fibers and tufted at a pre-determined gauge, the face layer having a face weight, a first backing layer adjacent the face layer, and a first back coating layer adjacent the first backing layer. A method of forming a tufted PET carpet assembly with PET yarn comprising the steps of tufting the PET yarn at a pre-determined gauge onto a backing, applying a back coating to the tufted PET via extrusion to lock the tufted PET to the backing, and applying heat to the tufted PET to enhance the look and feel of the PET.

Abstract: A conventional method for producing pile carpet, e.g. pile carpet whose pile fibers are tufted into a support layer, consists in providing the back side of the support layer with a non-woven and in linking said nonwoven with the support layer and with the dorsal fibers of the pile fibers by hydrodynamic needle-punching. The aim of the invention is to provide the support layer with a back of its own which preferably consists of a fusible fiber. The support layer may also contain said fibers. The pile fibers are tufted into the composite support layer, the back of the intermediate product is covered with an additional fleece which consists preferably of the fusible fibers, all the components are hydrodynamically needle-punched, and the product is heat-treated in order to melt the fibers.

Abstract: A laminated multilayer textured composite has an embossed fibrous outer layer bonded to one side of an adhesive layer to form a three-dimensional structure defined by all of fibers in depressed areas between elevated areas being fully embedded in the adhesive and most of the fibers in the elevated areas of the elevated areas being free of adhesive. The composite provides an abrasion resistant, surface stable material for covering floors, walls, furniture and the like. An optional backing layer can be simultaneously adhered to the second side of the adhesive layer primarily for improved cushioning and dimensional stability. The composite can be formed by a simultaneous pressure embossing and thermal laminating process.

Abstract: Polyurethane carpet backings are made using a polyurethane-forming composition that includes fatty acid amide polyols. The formulation allows a significant replacement of conventional polyols with polyols derived from annually renewable resources, while maintaining important properties like edge curl, tuftbind, viscosity and curing rates.

Abstract: The object of the invention is to provide a method which is as simple and economical as possible for manufacturing a tufted product, in particular a tufted top layer of a carpet, having improved nep adhesion properties. For this purpose splittable fibers are used which split on or in the region of the puncture site during tufting.

Abstract: The invention relates to a method for the manufacture and use of a tufted nonwoven fabric, wherein fibers for tufts in tuft backing which deviate from a circular fiber cross section are used which exhibit an adhesive force of greater than 40 mN with respect to a tuft yarn, the adhesive force being determined transverse to the longitudinal direction of the fibers. According to the invention, such nonwoven fabrics are used as carpet backing for the manufacture of carpet.

Abstract: Pile weatherstripping (20) having an integral fin is made by wrapping a fin material around a traveling mandrel or band (14), winding pile material around the fin material and the band (14), attaching a pair of backer elements to the pile material along opposite edges of the band, and then cutting the fin material and the pile material to produce simultaneously two pile weatherstrips. Stationary and traveling elements may be employed to facilitate cutting and produce fin above the pile weatherstrips (20).

Abstract: Process for producing an injected article to which a flocked decoration is applied that comprises the production of a flocked substrate (11) based on a temporary substrate (1) covered by a temporary adhesive (2) that keeps the flock fibers (3) in place, positioning of said flocked substrate in an injection mold of said article to be produced, injection of a polymer (12) being melted in said closed mold through an injection opening (4), removal of the injected article from the mold and the peeling off of the temporary substrate (1) and the temporary adhesive (2) from the injected article, characterized in that the flocked substrate (11) is positioned in said mold so that the flock fibers (3) are oriented toward the interior of said mold.

Abstract: The yarns of the invention include untwisted wrapped singles yarns having a core strand and a wrapper yarn. The wrapper yarn is a base synthetic fiber and a heat-activated binder fiber with a melting point substantially below that of the base synthetic fiber. The Saxony carpets of the invention are made from untwisted singles yarn tufts and are possessed of surface appearance, individual tip retention, pile density, resilient hand and wear resistance comparable or superior to conventional Saxony carpets made from multiple plied twist set yarns.

Abstract: Another object of the present invention is therefore a process for the preparation of a carpet comprising an upper fibrous layer, an intermediate thermoplastic protective laminate and a polyurethane foam layer wherein the polyurethane foam layer is formed on the surface of the protective laminate which is hot bonded to the upper fibrous layer characterized in that said protective laminate comprises a first outer layer which is facing the upper fibrous layer comprising an ethylene homo- or copolymer, a core layer comprising a polyamide and a second outer layer comprising a thermoplastic polyurethane.

Abstract: The present invention relates to a method of manufacturing a fibre-reinforced laminate (101), which laminate comprises at least one area on the surface of the laminate configured with projecting fibres for being joined to one or more other elements. This is accomplished by arrangement of a hybrid mat (505) most distally in the laminate which comprises at least two layers with fibres (105) transversally across the joining face (402) of the layers. The outermost layer (301) of the hybrid mat is removed prior to joining, whereas the innermost layer (506) of the hybrid mat remains a constituent of the laminate (101). The invention relates to different methods of causing fibres to project from the surface of the laminate, said fibres thus having a reinforcing effect on the joints. The invention also relates to a laminate manufactured by the disclosed methods and a blade for a wind power plant comprising such laminate.

Abstract: Described herein are primary carpet backings that possess improved physical properties such as tuft binding strength. The backings described herein can be easily recycled and re-used. Also described herein are methods for making and recycling primary carpet backings.

Abstract: The present invention relates to a method for preparing a composite product, comprising bonding a polyolefinic article together with a woven or non-woven cloth, wherein at least the surface of the cloth that is bonded with the article is provided with a backing-layer comprising a polyolefin, wherein said bonding comprises the steps of contacting the cloth and the article at a temperature above the DSC softening point of the backing layer, and pressurizing the cloth and the article at a temperature below the DSC softening point of the backing layer. The invention further relates to a composite product obtainable by a method according to the invention.

Abstract: An artificial turf is provided that resists migration of rubber infill into the space above the turf. Artificial grass is attached to and extends upward from a backing material, which may be one or more layers. The artificial grass includes groups of at least two different kinds of fiber sewn through a common path in the backing material. One of the kinds of fibers is an artificial grass blade shaped so as to appear like a blade of grass. The other kind of fiber in each group is pre-stressed/crimped so that the relaxed shape of the fiber is nonlinear, resembling a curlicued or articulated form having lateral excursions. The lateral excursions cause portions of one such pre-stressed fiber to overlap and interfere with another, forming a mesh. The height of the pre-stressed fibers in their relaxed state in the turf is less than the height of the relatively unstressed fiber(s). Resilient granules are embedded in the mesh, and are captivated by the interfering pre-stressed fibers.

Abstract: A design and process are provided in which a fully activated thermosetting adhesive layer and multi-layered thermoplastic adhesive are positioned between a flock layer and a substrate.

Abstract: According to one aspect of the present invention there is provided an acoustic laminate including: a first layer of viscoelastic acoustic barrier material; a sound absorbing/decoupling batt affixed to the first layer of viscoelastic acoustic barrier material, the batt at rest defining a batt plane; the batt including a plurality of batt fibres; the batt further including retaining fibres, wherein the batt fibres and/or retaining fibres are disposed perpendicular to the batt plane and having end portions thereof disposed at a batt surface, the end portions affixed to the viscoelastic barrier material so that either the first layer of viscoelastic acoustic barrier material or the sound absorbing/decoupling batt itself may be retained in spaced relation from a mounting surface when the laminate is so mounted, the retention being achieved in any orientation by bearing a mass load of the batt or first layer of viscoelastic material along the axis of the affixed batt fibres and/or retaining fibres.

Abstract: A tufted nonwoven includes a face material which tufts a bonded nonwoven having a mixture of a plurality of bicomponent filaments 1 with a plurality of bicomponent filaments 2. At least bicomponent filaments 1 have component 11 and component 12. Component 11 exhibits a melting temperature Tm(11), and component 22 of the bicomponent filaments 2 exhibits a melting temperature Tm(22). Component 12 exhibits a melting temperature Tm(12), and component 21 of the second bicomponent filaments exhibits a melting temperature Tm(21), and Tm(12) is higher than Tm(21). The melting temperatures of components 11 and 22 and the melting temperatures of components 12 and 21 obey a relationship in which Tm(11) and Tm(22)>Tm(12)>first Tm(21) and optionally wherein the face material is bonded to bicomponent filaments 2 by a solidified melt of component 21. Also described are a bonded nonwoven and methods for their manufacture.

Abstract: Color, pattern, design, and/or the like is applied by means of a jet dye process, or any other secondary or post pattern application process, including but not exclusively, silk screen printing, rotary printing, etc., to a bonded carpet, where the yarn in the carpet is all white (no dye applied) or light colored or where the yarn is pre-dyed with a single or multiple colors or where the yarn is treated chemically. The bonded carpet preferably has a low face weight and flat, short, dense, vertical cut pile.

Abstract: A tufted carpet includes a primary backing having a back side and a face side, and a secondary backing. The carpet includes tufts of yarn sewn through the primary backing so as to be exposed on the face side and to form a plurality of back stitches on the back side. The yarn of the tufted carpet is a thermoplastic material having a yarn melting point. The secondary backing is a thermoplastic material in the form of a fluid-impervious film or a fabric having a softening temperature that is no lower than the yarn melting point, or a laminate having an inner and an outer layer, in which the outer layer comprises a thermoplastic material having a softening temperature that is no lower than the yarn melting point.

Abstract: A method of producing a carpet or rug pursuant to a tufting process, including tufting pile threads into a tuft substrate, and guiding the back side of the tuft substrate along while pressing the back side, together with the loops of the pile threads pierced through the tuft substrate, against a heated drum. At a predetermined temperature, the loops of the pierced-through pile threads begin to melt, and at a predetermined pressure are pressed flat against the tuft substrate.

Abstract: In the case of pile carpeting, e.g. whose pile fibres are tufted in a support layer, it is known to provide the backing of the support layer with a nonwoven and bond this to the support layer and the backing fibres of the pile fibres by means of hydrodynamic needle-punching. It is furthermore known to apply an intermediate layer to the support layer between support layer and nonwoven comprising at least partly fusible fibres and to bond the two by means of hydrodynamic needle punching to the carpet backing. The invention proposes that the intermediate layer is formed of a hot melt powder, short-staple fusible fibres or a fusible film and these should initially be moved into the backing of the support layer by hydrodynamic needling before the melting process effects the actual fixing of the pile fibres in the support layer.

Abstract: A tufted carpet includes a primary backing and a plurality of tufts. The plurality of tufts are attached to the primary backing by looping each yarn tuft through different openings of the primary backing with strand sections from adjacent tufts going through each opening. The tufted carpet further includes an adhesive or polymeric material contacting the tufts such that the tufts are bonded together. A system and method for forming the tufted carpets is also provided.

Abstract: This invention relates to a low cost loop material for a hook and loop fastener having at least one sheet of flexible nonwoven material intermittently bonded to inelastic oriented film. The invention further relates to methods for producing these loops.

Abstract: Carpet tile, carpet tiles, or modular flooring include a carpet face or show surface in overlying relation to a backing of or including adjoined particle elements. In particular, but not exclusively, the carpet tiles incorporate a carpet surface or carpet face, having, for example, a pile or non-pile surface. In one embodiment, the carpet of the carpet tile has a tuft bind or precoat layer, such as a urethane precoat, disposed in overlying relation to a resilient backing formed from a mass, mixture, or slurry, for example, of particles or crumbs, bonded together in adjoined relation by a binder. One or more optional stabilizing and/or backing layers may be included. Methods of making such carpet tiles are also provided.

Abstract: A primary carpet backing is provided for use in the formation of a tufted carpet which eliminates or reduces the need for a latex adhesive layer or the use of a secondary backing. The external surfaces of a woven or non-woven fibrous mat are coated with thermoplastic polymer particles having a lower melting temperature than the fibers of the mat. The mat possesses sufficient openings between fibers to be capable of undergoing tufting. Following tufting the tufted mat is heat treated so as to melt the thermoplastic polymer particles and to create a bond between the tufted carpet yarn fibers and the primary backing mat.

Abstract: A solid adhesive for use in roofing construction comprising an asphalt, a polymer, a tackifier, and a plasticizer.