Abstract: An improved mat is formed with a biodegradable plastic body constituted by a combination of a particular natural rubber latex formation and a particular synthetic rubber formulation, a combination of the two formations having a short shelf life but its individual components having a satisfactorily long shelf life, the mat thus produced having physical characteristics equal or superior to known mats with non-biodegradable plastic bodies.

Abstract: The present invention describes a flocked stretchable design and a process for producing a flocked stretchable design or transfer. The design, when configured as a transfer, includes a carrier layer, a release adhesive applied to the carrier layer, a plurality of flock fibers releasably attached to the release adhesive, an elastic film and a first adhesive layer bonded to the flock fibers and the elastic film, and a second, discontinuously distributed, adhesive layer bonded to the other side of the elastic film. The design, when direct flocked, does not include the carrier and the release adhesive. The present invention also includes methods of producing both the designs.

Abstract: In a method of melting together axial ends of bunched fibers of thermoplastic material, the fiber ends are brought into contact with the heated surface of a stamp. The body of the stamp is heated by controlling an electric current passing through it. In one embodiment the stamp is cooled by a flow of compressed air before the stamp is separated from the fiber ends. In another embodiment, the stamp is separated from the melted fiber ends, heated to a higher temperature to vaporize any residual fiber material, and cooled by exposure to compressed air until it has no more than the temperature for melting the fiber material.

Abstract: Methods and apparatus for making elongated articles are disclosed. One method includes feeding at least one base string along an axis, wrapping at least one monofilament around the axis to produce a number of monofilament wraps per length of base string which are transported by the base string, bonding the wraps to the base string with ultrasonic energy, and cutting the wraps at a point downstream of where the wraps are bonded to the base string. The result is an article having two rows of monofilament segments connected to the base string.

Abstract: Yarn suitable for tufting comprises a base fiber ring spun or wrap spun with a second fiber at least partially comprising a heat-activated adhesive material such that the yarn includes from 0.1 to 12, preferably 0.25 to 10, weight percent adhesive material having a melting point within the range of 105° to 190° C., more preferably 165° to 190° C. A preferred base fiber is a synthetic staple fiber bundle. A preferred wrapping or insert fiber is a copolyamide fiber, including ternary copolyamides of the 6/66/12 type. When the yarn is twist set by conventional processes and then tufted into carpet, the resulting carpet displays enhanced wear and appearance properties.

Abstract: Described is a transferrable fibrous thermal interface. The interface comprises flocked thermally conductive fibers embedded in an adhesive in substantially vertical orientation with portions of the fibers extending out of the adhesive. An encapsulant fills spaces between the portions of the fibers that extend out of the adhesive and a release liner is on at least one outer surface of the interface.

Abstract: Recyclable carpet products are made by incorporating a reactive compatibilizing agent in the precoat layer which is used to bond a polymeric face fiber layer to a backing polymeric layer where the polymers of the respective layers are otherwise incompatible to make homogeneous recycled blends.

Abstract: Methods and apparatus for making elongated articles are disclosed. One method includes feeding at least one base string along an axis, wrapping at least one monofilament around the axis to produce a number of monofilament wraps per length of base string which are transported by the base string, bonding the wraps to the base string with ultrasonic energy, and cutting the wraps at a point downstream of where the wraps are bonded to the base string. The result is an article having two rows of monofilament segments connected to the base string.

Abstract: A method for making a blanket is provided. The blanket is made from a fabric that has a ground having wefts and warps, and piles inserted in spaces between the wefts and warps of the ground. The method comprises the steps of weaving the fabric from the wefts, the warps, and the piles, coloring the fabric with a predetermined pattern, heating the fabric to bind the piles firmly, cutting the fabric to a predetermined size for the blanket, and surrounding the edges of the cut fabric with a cloth. The wefts and warps are made of a ground yarn, and the piles are made of an acrylic yarn. The weight percentage of the acrylic yarn in the fabric is in the range between approximately 80 and 95, and the weight percentage of the ground yarn in the fabric is the remainder.

Abstract: A continuous carpet (10) or other flooring manufacturing process that accommodates use of a variety of materials including recycled PVC from used carpet and carpet manufacturing waste. The continuous process forms backing (12) and is capable of feeding the backing into a lamination stage for bonding with the face cloth (14). By providing a continuous process whereby the backing layer, upon formation, can be immediately laminated to the face cloth, manufacturing time and associated cost are reduced. Moreover, formation of the backing layer as a process separate from the lamination thereby protecting the face cloth from unnecessary heat and pressure and enhancing the many types of material, including recycled and waste materials, especially used carpet and used carpet by products. Use of these cheaper materials reduces both the manufacturing cost by products.

Abstract: The present invention pertains to carpet and method of making it. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one homogeneously branched linear ethylene polymer. The method includes extrusion coating at least one homogeneously branched linear ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method can include additional steps or procedures, either separately or in various combinations.

Abstract: An adhesive useful in making recyclable carpet is prepared from a copolymer dispersion and a filler. The copolymer dispersion is prepared in an emulsion polymerization of a mixture of monomers comprising styrene, butadiene, an alkylacrylic acid monomer, in which the alkyl radical of the alkylacrylic acid monomer is a C1 to C6 branched or unbranched hydrocarbyl radical, and a combination of a second ethylenically unsaturated monocarboxylic acid with an ethylenically unsaturated dicarboxylic acid, in which the alkylacrylic acid monomer is present in a quantity predominating the combination of the second ethylenically unsaturated monocarboxylic acid with the ethylenically unsaturated dicarboxylic acid. The adhesive can be completely removed from the face fibers by applied shear in the presence of aqueous alkaline solution. Recyclable carpets made with the adhesive exhibit high delamination strength, both when wet and when dry.

Abstract: A brush seal is created between two members, one of which may rotate with respect to the other. A bonding agent is applied to one or both members, each of which may include a groove for application of the bonding agent. Flexible filaments are then embedded into the bonding agent by, for example, electrostatic flocking. After the bonding agent hardens or cures, the brush seal is created.

Abstract: An upper surface layer 2 and a nonwoven fabric sound absorption layer 3 are integrally secured via an air permeable adhesive resin layer 4 formed by melting thermoplastic resin powder, and the air permeability of the thickness direction of the entire carpet 1 falls within the range of 1 to 50 cm3/cm2·second. This effectively absorbs noise from the upper side entering via a roof, doors and windows as well as noise from the lower side. The carpet can be manufactured by scattering thermoplastic resin powder on an upper surface member, heating the thermoplastic resin powder into melted thermoplastic resin, placing a nonwoven fabric on the upper surface member via the melted thermoplastic resin, and pressing the nonwoven fabric and the upper surface member in a laminated state. It is preferable that powder of particle size of 90 to 10,000 &mgr;m is scattered in the amount of 5 to 500 g/m2.

Abstract: A filter composite comprises a first layer of glass fibers having random orientation, and synthetic resinous fibers extending in close association with the glass fibers, the glass fibers having:

Abstract: A flashless floor mat or product and method are provided. At least one embodiment of this invention relates to a flashless cushioned dust control mat article wherein the mat comprises at least two distinct layers of rubber, one comprising foam rubber, the other comprising solid rubber. The solid rubber layer is present over the foam rubber layer on the side of the mat in which at least one integrated rubber protrusion is present to provide cushioning characteristics. The solid rubber layer acts as a cap or barrier for the foam rubber layer, particularly over the integrated protrusion or protrusions, in order to provide a mat which is resilient, will not easily degrade in its modulus strength after appreciable use and/or washing within industrial cleaning processes, and will not exhibit appreciable cracking or breaking, particularly within the integrated protrusion(s), after standard use for pedestrian traffic. A method of producing such an inventive cushioned floor mat article is also provided.

Abstract: An elongated pile sub-assembly having a support beam for attachment to a plurality of yarn bundles. Each of the yarn bundles attached to the beam have a pile end and a root end for anchoring the elongated pile sub-assembly. The root ends can also entangle its loose fibers for added anchoring support of the elongated pile sub-assembly. A guide assembly is used to form a rooted tuftstring article such as a brush or flooring article therefrom. The elongated pile sub-assembly may be used alone to make a brush or a pile or bristle surface structure such as a floor covering, a wall covering or an automotive component, or may be arranged with other elongated pile articles and attached to a backing substrate, as when used to make up a pile or bristle surface structure. A brush or pile surface structure may be fabricated from an elongated pile sub-assembly alone, or from the pile sub-assembly together with a brush body member or a backing substrate.

Abstract: Porous carpeting for use within vehicles, and methods of making same, are provided. A carpet backing is heated to achieve a fluid or semi-fluid state and then subjected to intense vacuum to draw air through the carpet backing to create a porous structure. A layer of porous thermoformable material may be applied to the porous carpet structure to provide mechanical strength.

Abstract: The present invention relates to an improved doctor blade and bedplate apparatus wherein there is a recess in the bedplate from some position upstream of the doctor blade to some position downstream of the doctor blade. This recess or gap in the area of the bedplate under the doctor blade allows one to form an even or uniform coating on the back of a web of material. This is particularly helpful in forming uniform coatings on the back of a greige good which has face fibers of varying lengths. The present invention also relates to an improved process for preparing a relatively uniform coating on the back of a web of material.

Abstract: A dust control mat having a pile surface and a backing layer disposed beneath the pile surface. The pile surface includes segmented portions of pile-forming material salvaged from previously used mat structures and adhered to the backing layer in a predefined arrangement to define a contact surface of recycled material for use in removing dirt from the shoes of a user.

Abstract: An artificial turf field comprises a mat with artificial grass stitched to the mat and rubber granules combined with powdered latex or other suitable powdered binding agent activated by water. Mats with the artificial grass affixed are laid on an athletic field. Rubber granules mixed with a bonding agent and the coated rubber granules are poured over the mats and raked until a depth of ½ to ¾ inches is achieved. Water is then misted onto the surface activating the bonding agent. The first layer is allowed to set. The first level of infil material will be bound particle to particle, to the grass and to the mat by the agent, thus ensuring a stablized shock absorbency pad. Additionally, the stabilized layer eliminates substantial migration of loose infil material.

Abstract: An apparatus for forming bristle sub-assemblies includes a vertically oriented slot, which is formed by two endless belts. A wheel disposed above the slot pushes a bristle string into the slot. The bristle string has a plurality of bristles connected to a base string in two rows. The bristle rows can be horizontally oriented, so that all of the bristles are co-planar in a horizontal plane, or they can be angularly oriented with the base string at the vertex of the angle. When the bristles are pushed into the slot, they bend to adopt a new, substantially parallel orientation. An ultrasonic heater heats the bent bristles to re-set the thermoplastic material from which the bristles are made so that after cooling, the parallel orientation is maintained.

Abstract: The present invention relates to a method for producing a textile product of the lapped/bonded type from fibres and/or filaments travelling in the direction of advance in the form of a web, this method comprising at least one step, called the “prelooping step”, in which the fibres and/or filaments individually undergo looping transversely to the direction of advance of the web, if appropriate accompanied by transverse drawing, characterized in that it subsequently comprises a step of confining the parallelized fibres and/or filaments in the form of loops, this latter confining step taking place directly on a support, without transport members, such as needles or transfer elements, being involved.

Abstract: An improved, washable track control mat made of varied denier fibers and method of making the same. The mat is made by first making yarn made of fine and coarse denier fibers. The fibers are twisted together. More than one yarn may be twisted together. The yarn or yarns may be heat treated. The yarn or yarns are then fed into a tufting machine where tufts of varied denier fibers are held within a substrate. The tufts are bonded to the substrate by a backing, preferably rubber.

Abstract: The present invention pertains to carpet and method of making it. In one aspect, the carpet includes (a) a primary backing which has a face and a back surface, (b) a plurality of fibers attached to the primary backing and extending from the face of the primary backing and exposed at the back surface of the primary backing, (c) an adhesive backing, (d) an optional secondary backing adjacent to the adhesive backing, and (e) at least one homogeneously branched linear ethylene polymer. The method includes extrusion coating at least one homogeneously branched linear ethylene polymer onto the back surface of a primary backing to provide an adhesive backing. The method can include additional steps or procedures, either separately or in various combinations.

Abstract: A method for producing an extruded sheet material wherein a polymeric material is formed into a sheet and a variety of materials are incorporated into the extruded material prior to hardening. The sheet materials produced incorporate, either sheet, filament or particulate matter onto either side of the finished product, allowing for great variability in the finished product.

Abstract: The disclosure relates to a carpet product, a process for manufacturing carpet, and an apparatus used in a carpet manufacturing process. The carpet product is made from tufted polymer filament yarn wherein the individual yarn filaments of the yarn back loops are integrally fused so that the carpet resists fuzzing. The primary backing preferably is modified polypropylene in the fill direction. Further, the primary backing may be coated with a polymer before tufting to adhere or integrally fuse the inside of the fiber tuft to the primary backing. An optional secondary backing is preferably made of tape yarn in both directions. The process includes providing a carpet base having a primary backing penetrated by yarn, applying heat to the underside of the primary backing, extruding a heated sheet of polymer and continuously contacting the heated extruded sheet of polymer with the base.

Abstract: A method for disposing a letter sequence onto the outer surface of a microphone wind shield made from foamed material includes the steps of producing at least one letter sequence element on a carrier; positioning the carrier onto the outer surface of the wind shield body by interposing a heat-activating adhesive; applying thermal energy using radiation, in particular, laser beams, for activating the adhesive; and removing the carrier after cooling and solidification of the adhesive. The letter sequence element thereby remains on the outer surface of the wind shield body.

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 a backing material B-side. The pre-coat B-side and the backing material B-side may include a petroleum based polyol; a vegetable oil, cross-linker, and a catylst; or a transesterified poylol.

Abstract: The present invention relates to a method for producing a textile product of the lapped/bonded type from fibres and/or filaments travelling in the direction of advance in the form of a web, this method comprising at least one step, called the “prelooping step”, in which the fibres and/or filaments individually undergo looping transversely to the direction of advance of the web, if appropriate accompanied by transverse drawing, characterized in that it subsequently comprises a step of confining the parallelized fibres and/or filaments in the form of loops, this latter confining step taking place directly on a support, without transport members, such as needles or transfer elements, being involved.

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 coated greige is then contacted with the secondary backing before complete polymerization to insure sufficient tack to hold the backings together.

Abstract: A method for manufacturing a vinyl-backed carpet is described wherein the carpet is assembled in a single continuous finishing line. The method includes the application of a vinyl plastisol reinforcing layer directly to the back of unfinished woven or tufted carpet material. The method allows the use of a thinner vinyl layer that results in savings in material, processing steps, and energy required for curing.

Abstract: The invention relates to a structured textile material made of at least two different, needled base nonwoven fabrics. The base nonwoven fabrics have a structure obtained by needling from at least one side. The needles used for the structure needling are fork needles or crown needles, and the depth of the forks and barbs, respectively, is so selected that, when piercing through, they completely fill up with fibers of the base nonwoven fabric facing the needles. The textile material have unmixed, pure fibers in the pattern, in the background and on the reverse side.

Abstract: A process for manufacturing substantially 100% nylon 6 carpet provides a nylon 6 face yarn to a nylon 6 support means so that the yarn and the support means form a carpet having a face side which is displayed when the carpet is installed and a back that binds the face yarn to the support means wherein said binding is with molten or dissolved nylon 6.

Abstract: A method for manufacturing a vinyl-backed carpet is described wherein the carpet is assembled in a single continuous finishing line. The method includes the application of a vinyl plastisol reinforcing layer directly to the back of unfinished woven or tufted carpet material. The method allows the use of a thinner vinyl layer that results in savings in material, processing steps, and energy required for curing.

Abstract: An improved low weight cushioned flooring, floor covering, carpet, carpet tile, and method is provided. The low weight, cushioned carpet includes a low weight primary carpet having a base and a plurality of pile-forming yarns projecting outwardly from one side. A layer of reinforcement material is bonded to the base on the side opposite the pile forming yarns. The reinforcement layer is adjacent to and may be embedded in, a cushion layer of a polymer such as a polyurethane. An apparatus and process for forming the low weight cushioned carpet or carpet tile of the present invention are also provided.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: Laminated carpeting consisting of a secondary backing adhered to a greige good of yarn tufted into a primary backing are prepared from polyurethane adhesives by single puddle processes which allow for lowered use of polyurethane while producing carpets exhibiting excellent delamination strength. Preferably, a reactive polyurethane system is employed as a primary adhesive, and the secondary backing is skip-coated with a minor amount of a non-advancing skip coat.

Abstract: The invention relates to a structured textile material made of at least two different, needled base nonwoven fabrics. The base nonwoven fabrics have a structure obtained by needling from at least one side. The needles used for the structure needling are fork needles or crown needles, and the depth of the forks and barbs, respectively, is so selected that, when piercing through, they completely fill up with fibers of the base nonwoven fabric facing the needles. The textile material have unmixed, pure fibers in the pattern, in the background and on the reverse side.

Abstract: Tufted carpeting can be manufactured employing polyurethane adhesives and cured face up without dripping, when one or more drip-reducing process steps of adding a non-Newtonian thickener to the adhesive or forming a viscosified or cured film on the outer surface of the adhesive are practiced prior to entry of the greige good into the curing oven.

Abstract: The method consists in applying a thermoadhesive or HF-weldable film (2) on a temporary protection paper (1), applying an adhesive layer 2a) on said film, flocking fibers (F) on this adhesive layer, preparing a pre-printed paper with multicolor designs constituted by sublimable dyes and transferring by sublimation the multicolor-designs from the pre-printed paper onto the flock-fibers by close contact between the two elements under a predetermined pressure and temperature.

Abstract: A bristle sub-assembly includes first and second base strings and a plurality of polymeric monofilaments connected to and extending between the first and second base strings. The polymeric monofilaments form a first arched row when the first and second base strings are brought together. Several types and configurations of brushes are made using either arched bristles or combinations of arched and straight bristles.

Abstract: A method of flocking a surface, and treating the flocking, achieves a decorative effect when applied to toys where the invention may be used to simulate different types of human and animal hair and fur. After applying an adhesive to a surface to be flocked, a group of flocking particles are directed onto the surface, and the result is modified using alternative techniques to achieve the desired effect. In one embodiment, the particles are in the form of fibers which “ball up” upon the application of heat, and the outwardly exposed ends of the particles are flame-treated to create a kinky appearance. Nylon fibers are suitable in this case. In an alternative embodiment, an adhesive is applied to the flocking particles attached to the surface, and additional flocking particles are applied to the adhesive-coated fibers. As further alternative embodiment, air pressure is applied to the particles before the adhesive cures, so that the particles assume a preferred orientation with respect to the surface.

Abstract: A method is disclosed for imparting a graphic design to the upper surface of a fabric suitable for use as a wall or floor covering. The graphic design is formed by an elongated pile article having a plurality of filament bundles attached to an elongated support strand. The fabric may be a tufted, woven, nonwoven, flocked fabric or a needled felt. The elongated pile article may be attached to the fabric by various methods, including ultrasonically bonding, applying an adhesive, sewing, stapling or using plastic fasteners. A transfer sheet is disclosed to aid in attaching by ultrasonically bonding, the sheet being made from a fusible material having the elongated pile article is attached thereto. The transfer sheet is positioned on the fabric, the elongated pile article is then ultrasonically bonded, melting a portion of the transfer sheet material, and the unmelted portion is then removed.

Abstract: A light-reflective decorative glittered article is made by coating a light reflective foil with a powdered resin, fixing the resin, cutting the coated foil into glitter flakes, flocking the flakes onto a curable adhesive applied on areas of a base material to be decorated, and curing the adhesive while concomitantly causing the resin on contacting flakes to become tacky Scattering and fall-off of the flakes during manufacture are reduced.

Abstract: The present invention relates to a method of preparing a woven textile surface covering. The method involves applying a resin composition layer onto a back surface of a woven layer. The woven layer is formed by weaving warp and weft yarns. The resin composition layer is effective for bonding to the warp and weft yarns. The resin composition layer is provided with a resin composition and a cross-linking agent effective to wet, penetrate, and encapsulate the warp and weft yarns. The resin composition layer occupies the interstices of the warp and weft yarns and when the resin is heated, the resin cross-links with the woven layer. A backing layer is then contacted with the surface of the heated resin composition layer thereby bonding the backing layer to the resin composition layer. The present invention also relates to a woven textile surface covering having a first layer with a decorative surface and a back surface. The first layer is formed from woven warp and weft yarns that have interstices therebetween.

Abstract: A carpet in tile or roll form is produced using an open mesh reinforced foam layer with foam nodules. The carpet is produced having a primary backing through which carpet fiber bundles are tufted and a precoat layer which locks the tufts in place to prevent easy extraction of the fibers so that a tufted face and a relatively smooth back face are provided. The foam layer with foam nodules is brought into intimate contact with the relatively smooth back face, and is substantially permanently adhered to it producing a carpet tile or roll that is substantially prevented from curling or doming (or they are significantly reduced) and may be installed without adhesive if desired. Adhering may be practiced by using a non-fused adhesive formulation which is subsequently fused at a low temperature (about 310.degree. F.

Abstract: Methods and apparatuses for making elongated articles are disclosed. One method includes feeding at least one base string along an axis, wrapping at least one monofilament around the axis to produce a number of monofilament wraps per length of base string which are transported by the base string, bonding the wraps to the base string with ultrasonic energy, and cutting the wraps at a point downstream of where the wraps are bonded to the base string. The result is an article having two rows of monofilament segments connected to the base string.

Abstract: Plush textured multicolored flock transfers are obtained which have the appearance of a direct flocked article and the manufacturing and application advantages of a flock transfer. The method of manufacture includes applying sequentially to an adhesive coated base sheet different colored flocks which can be greater than 0.5 mm long through predetermined areas of masked screens.

Abstract: The floor mat of the present process is a pliable multilayer structure having an upper face layer and a base layer. The base layer has a main body section bordered by an edge section. Preferably, the main body section is relatively thin and the edge section is relatively thick. A surface of the base layer is adapted to confront flooring overlaid by the mat. The edge section has a channel extending longitudinally thereof, and preferably opening from the bottom surface of the edge section. A portion of the main body section can have a channel molded therein such that a portion of the main body section is disposed above the remainder of the main body section to provide a decorative and aesthetically pleasing design in the main body section.