Abstract: A position detector senses an undulating pile tuft edge position of a carpet as it is processed in a carpet making machine by detecting attenuated light passing through the carpet's primary backing material to determine the exact position of the carpet's undulating pile tuft edge at any given time. Sensor signals from the detector are digitally filtered through one pole cascaded filters to produce an average pile edge position signal which, in turn, controls actuators for secondary and primary backing material guide rolls to not only center the carpet for aligned entry into the carpet machine's tenter, but also apply the secondary backing material to the primary backing material at a precise position.

Abstract: A coated synthetic resin tile comprising a base portion and a veneer said base comprising a moisture impervious material such as a thermoset or thermoplastic resin. A filler of up to about 10% calcium carbonate having a 2 (two) sigma particle size between about 5.11 and 6.18 microns and an aluminum trihydrate flame retardant of about 60%-70% having a two (2) sigma particle size of between about 42.38 and 58.72 microns and an aluminum trihydrate of about 20%-40% having a two (2) sigma particle size of between about 8.26 and 9.68 microns to provide a class A flame spread rating. The veneer comprising a layer selected from the group consisting of an acrylic impregnated wood veneer and a hardwood veneer having a vinyl upper layer bonded to said base portion with a polyurethane adhesive.

Abstract: A method is disclosed for sealing and bonding the seams and edges of resilient and other types of floors, whereby specially formulated hot-melt sealants/adhesives are applied in molten form at the flooring installation site using a heated gun equipped with a specially designed tip. The hot-melt sealant/adhesive flows into and completely fills the seam and bonds to the edges of the flooring producing a bead of material that extends above the surface of the flooring. The specially designed tip facilitates this process by guiding along easily in the groove of the seam or joint and directing the molten sealant/adhesive accurately into the seam. The tip allows the seam or joint width to be very narrow and enhances sealing and adhesion by imparting heat to the edges of the flooring material. Upon cooling, a spatula knife or other appropriate tool is used to skive off the excess bead of material leaving it flush with the flooring.

Abstract: A method of making coated synthetic resin tile. A resin admixture is formed and cured to form a tile base. The tile base is sized and gauged to a desired size, followed by mating an upper veneer layer on the tile. The upper layer is selected from the group consisting of an acrylic impregnated wood veneer and a hardwood veneer having a vinyl upper layer. The veneer is bonded to the tile base with a fabric and an adhesive and pressure. The veneer mated tile is then sized to a final desired tile size and configuration.

Abstract: A method and system whereby an abrasive ring having an axis and a given number of abrasive sheet elements projecting with respect to the axis is formed by forming an orderly first pack of abrasive sheet elements having a first number of elements smaller than the given number of the ring; forming at least a second pack of elements having a second number of elements at most equal to the difference between the given number and the first number; curving the first pack to form a base ring; circumferentially compacting the elements in the base ring to form at least one gap; and inserting at least a second pack of elements inside the gap.

Abstract: A process for the application of tear resistant side and edge strip materials to a rubber base sheet of a launderable dust control mat is provided. The process involves the in-line mating of first and second strips of carboxylated rubber to the longitudinal borders of a rubber sheet and the in-line mating of third and fourth strips of carboxylated rubber to the leading and tailing edges of a rubber sheet, respectively, all by means of a series of pressure rolls. The process permits separate rubber sheet and side strip materials to be joined in a continuous or semicontinuous operation immediately prior to assembly of a mat thereby enhancing material handling efficiencies. Dust mats produced thereby are also provided.

Abstract: A floor material which generates no harmful gas such as hydrogen chloride at the time of a fire, is suitable for dry maintenance with a high speed buffing machine and has excellent resistances against flaws, stains, abrasion and the like, which is also a floor material having markedly excellent adhesiveness to the floor ground. This invention is characterized in that a wax is contained in an amount of from 1 to 10% by weight in at least the surface layer of the floor material in which an olefinic resin is used as the base material and an inorganic filler is blended therein. Preferably, a back side layer of an ethylene-vinyl acetate copolymer or a mixed resin of said copolymer and other olefinic resin is used as its base material having an inorganic filler is blended therein is laminated on the under side of the surface layer, and 1 to 10% by weight of rosin is included in said back side layer.

Abstract: A method for producing a heel mat-attached floor rug for a motor vehicle. A floor rug proper is prepared which has been previously compression-molded to have a three-dimensionally projected portion. Then, the floor rug proper is put on a lower die of a depression-molding device in such a manner that the three-dimensionally projected portion of the rug proper neatly covers a projected portion formed on a shaping surface of the lower die. Then, a heel mat of thermoplastic material is put on a shaping surface of an upper die of the compression-molding device. The shaping surface of the upper die has a depressed portion which is shaped to neatly receive the projected portion of the lower die. Then, the upper die is pressed against the lower die having the heel mat and the floor rug proper put therebetween. Then, a lower surface of the heel mat is melted, by means of high frequency induction welding, thereby to bond the heel mat to the floor rug proper.

Abstract: The use of a copolymer consisting in polymerized form ofa) from 70 to 90% by weight of at least one C.sub.2 -C.sub.4 -olefin andb) from 10 to 30% by weight of at least one monomer selected from the group consisting of .alpha.,.beta.-mono-ethylenically unsaturated C.sub.3 -C.sub.8 -monocarboxylic acids, .alpha.,.beta.-monoethylenically unsaturated C.sub.4 -C.sub.8 -dicarboxylic acids and anhydrides of these mono- and dicarboxylic acids,as adhesion promotor between a first and a second material, the first material comprising not more than 70% by weight of at least one C.sub.2 -C.sub.4 -olefin in polymerized form and the second material comprising not less than 70% by weight of at least one C.sub.2 -C.sub.4 -olefin in polymerized form.

Abstract: An article of composite design for attachment to another fabric article, comprising an underlying layer of twill on one side of which an ink portion of the composite design has been screen printed and heat cured. The twill is cut into a desired shape so that the twill and the ink portion form the composite design, the portion of the twill without ink printed thereon forming a substantial portion of the composite design. Methods of making and attaching the composite design are disclosed.

Abstract: A lightweight dust control mat having enhanced resistance to oxidation and ozonation is provided. The mat includes a rubber backing sheet with a base rubber of NBR or SBR mixed with a polar polymer additive and a chemical blowing agent. The ratio of the base rubber to the polymer additive is between about 1.2 and 9. Following vulcanization, the rubber sheet has a specific gravity of less than about 0.98 and a Bayer ozone cracking incidence factor of 4 or less.

Abstract: In accordance with the present invention, there is provided a method of increasing the surface bond strength characteristics of a resin composite material. The method begins with providing a peel-ply sheet which defines opposed planar faces. A multitude of elongate bond fibers are embedded into the peel-ply sheet in a manner in which a majority of the bond fibers do not extend in co-planar relation to the planar faces of the peel-ply sheet. A resin composite material is provided. The peel-ply sheet is applied to the resin composite material such that the bond fibers are partially embedded therein. The resin composite material is cured. The peel-ply sheet is removed from the cured resin composite material such that the bond fibers remain implanted therein.

Abstract: An improved stitchbonded nonwoven fabric having repeating patterns of stitches in a fibrous layer is prepared with a stitching thread that consists essentially of fiber of partially molecularly oriented synthetic organic polymer. The fabric can be stretched, shrunken, and/or heat set and is particularly suited for thermoforming operations.

Abstract: A method for manufacturing a laminated assembly having a first layer with a face secured by an adhesive to a first face of a second layer having a meshed structure and having loops projecting from its second face. The method includes the step of depositing and adhering a thin film onto the first face of the second layer under controlled adhesive quantity and viscosity conditions so that the deposited film divides by itself to clear the mesh zones and to be converted into longitudinal and/or transverse beads.

Abstract: A covering for lining acoustically excited surfaces includes an upper cover layer and a flush fitting lining that adheres to the rear side of the cover layer. The lining has sound deadening properties and is made of a plurality of lining modules. A method of manufacturing such a covering for acoustically excited surfaces includes the steps of forming a cover layer and lining the modules and applying the modules to the cover layer.

Abstract: A fibrous product is produced by providing a collection of fibrous material, and encapsulating the fibrous material by covering the fibrous material with a film to form an encapsulated blanket of the fibrous material. The encapsulated blanket is then needled to cause entanglement of the fibrous material, thereby producing a needled, encapsulated fibrous product.

Abstract: A self-adhesive part of a hook and loop fastener has a multiplicity of layers of pressure-sensitive adhesive on a back surface of the base material, for adhering the part to a mating substrate. The adhesive is water based and a plurality times of coating and drying processes are repeated so as to have successive coatings. This reduces the overall drying time and efficiency is secured and minimization of requred space can be realized without impairing adhesive function.

Abstract: A method of producing an plush transfer applique is disclosed. The method employs and improved diminished bleed or lower density applique border allowing for a reduction or elimination of an impression line at the periphery of the transferred applique caused by the heat transfer process. The diminished bleed applique border is created by arranging a pattern at the edge or periphery of the transferred applique instead of an abrupt line of continuous density fiber, so that the resulting gradual reduction in fiber density causes the fibers to lie flat during the heat transfer process.

Abstract: A process for the application of tear resistant edge strip material to a rubber base sheet of a launderable dust control mat is provided. The process involves the in-line mating of first and second strips of carboxilated rubber to the longitudinal borders of a rubber sheet by means of a series of pressure rolls. The process permits separate rubber sheet and side strip materials to be joined in a continuous or semi-continuous operation immediately prior to assembly of a mat thereby enhancing material handling efficiencies. An apparatus for carrying out the invention is also provided.

Abstract: There is provided a loop fastening material for engaging a suitable male mechanical fastening element for a backing substrate of an oriented sheet material having a first face and a second face and substantially continuously attached to at least the first face a plurality of discrete, multi-filament transversely expanded yarns, such yarn filaments providing open loop structures. The yarns are expanded by transverse orientation of the backing to which it has been previously attached by extrusion bonding, adhesive bonding or the like. The resulting loop fastener provides a low cost, readily manufactured loop having good fastening properties to hook materials.

Abstract: A lining material of a woven, knitted or non-woven substrate. The fibers of the substrate are coated with a gripping agent. The coated fibers grip a second structure to eliminate or diminish relative motion between the second structure and the substrate including the coated fibers.

Abstract: Pile weatherstripping having rows of pile and longitudinal fins both within and external to the rows of pile. The heights of the fins with respect to the height of the pile may be independently varied and controlled. A travelling endless band receives a pair of first webs providing internal fins on opposite sides of the band. The first webs are indexed to the edges of the band, which defines the heights of the fins. Each web may be independently indexed. Alignment of the webs on the band is provided either by an aligning fixture or by coining the webs to provide lines of indentations which index the webs at the edges of the band. The yarn which forms the pile is wound around the first webs. Second webs providing the external fins are indexed through the yarn and first webs to the edges of the band and are also aligned by a second aligning fixture or by coining. Backing strips are attached, as by ultrasonic welding, along the edges of the band. Then the yarn is slit without cutting into the webs.

Abstract: A method and apparatus for making a carpet formed from a plurality of tuftstrings bonded to a backing. Methods and apparatii for accurately positioning the tuftstring and ultrasonically bonding multiple tuftstrings to the backing is disclosed.

Abstract: A method of manufacturing a composite fiber sheet comprising: forming the first pile layer on the surface of the first fiber sheet by needling; laminating the second fiber sheet on the back-side of the first fiber sheet; and forming the second pile layer on the surface of the first fiber sheet by needling. The composite fiber sheet so obtained has an excellent feeling, an attractive appearance and a variety functionality.

Abstract: A carpet having pile which is made up of fibers adhered to each other at points along their lengths with a chemically activated adhesive, as well as a process for treating a carpet, are disclosed. The carpet of the present invention is characterized by improved initial appearance and superior wear resistance when compared to prior art carpet constructions.

Abstract: A dust-control mat having excellent dimensional stability during the processing, good pile-erecting property and excellent pattern expression, and a method of producing the same. The dust-control mat having excellent dimensional stability comprises a base in which a base fabric is composed of a woven fabric or a nonwoven fabric and a floss-like nonwoven fiber layer coupled to the base, wherein the floss-like nonwoven fiber layer contains low-melting fibers and is thermally fixed after pile yarns are implanted thereon. The invention further provides a method of producing the dust-control mat.

Abstract: This invention relates to a method of installing wall to wall carpeting of a selected width over an underpad of a selected thickness by attaching hooked tapes of a thickness substantially equal to the thickness of the underpad along the perimeter of the area to be covered by the carpeting. The underside of the carpeting, which is substantially covered with loops, is then attached to the upper surface of the tapes through hook and loop technology. The hooked tape and the underpad are of substantially equal thickness so that the loops on the underside of the carpet will attach to the hooks on the upper surface of the tape. In a further aspect, the underpad has loops substantially covering its lower surface so that the underpad is attached to the floor by a second hooked tape of lower profile than the carpet tape which is used to attach the underpad to the floor.

Abstract: A method of manufacturing a hollow fiber membrane carpet includes the steps of laying out a multiplicity of hollow fibers, forming a pair of strips of non-permeable adhesive material on the hollow fibers in a transverse relationship thereto and in a spaced relationship from one another such that main portions of the hollow fibers extend between the spaced strips, cutting selected portions of the hollow fibers adjacent to the spaced strips so as to open the hollow fibers to communication at least at one of a pair of opposite end portions of the hollow fibers, and assembling the hollow fibers and spaced strips into a plurality of elementary carpet members and thereafter into a hollow fiber membrane carpet.

Abstract: A method of making a dyed nylon walk-off mat having improved washfastness includes dyeing nylon yarn, or a tufted nylon mat, in a fiber reactive dye solution having a pH in the range of about 0.5 to about 2.5. The yarn is then heated, such as by steam, at a temperature above 200.degree. F., after which the yarn is treated with an alkaline solution followed by a heat treatment. A backing, such as of rubber or vinyl, is applied to the mat at an elevated temperature. The application of the backing at elevated temperature, and the heat treatment subsequent to application of the alkaline solution, may be performed simultaneously.

Abstract: A fusion-bonded carpet system and method of manufacture which method includes providing as all or a portion of the wear face surface cut yarn material in rope form prepared in rope bundles and implanting one or both ends of the rope bundle in an adhesive layer on a backing sheet to provide one or two I-bond, fusion-bonded carpet material having a selected pattern on the wear face surface. The fusion-bonded carpet has a wear face surface composed of all or part of a yarn material in rope bundle form, for example, of a multicolored random or selected pattern. The carpet material may have a backing layer and form carpet tile.

Abstract: A composite thermal insulation structure particularly suited for gas turbine engine applications is disclosed. An aspect of the present invention includes a composite thermal insulation structure having a backing, a ceramic pile woven substantially perpendicular into the backing, and a ceramic matrix material infiltrated in the ceramic fiber pile.

Abstract: A tufted carpet is described in which the tufting yarns (2) are tufted into a tufting backing (1) and firmly joined to it. The back side (1a) of the tufted carpet (1) has a layer (5) comprising pieces of thermoplastic plastic sheet material joined together under the influence of pressure and temperature. Back ends (2a) of the tufting yarns (2) are firmly bound into the layer (5).

Abstract: A method of making a floor covering having decorative inlays therein is disclosed. The method comprises the steps of cutting and removing portions of the floor covering, providing inlays from another floor covering material having substantially the same shapes and sizes as the removed portions, and joining the inlays and floor covering to create a seamless structure. The seamless structure results from the application of a volatile solvent which causes the thermoplastic properties of the materials within the inlays and floor covering to fuse.

Abstract: Described is a loop pile material composed of a textile backing composed of a knit or woven and bound-in loop-forming pile yarns, whereinthe textile backing consists of a multifilament hybrid yarn composed of at least 2 varieties A and B of filaments with or without cofilaments C, wherein said filaments A are textured,the melting point of said filaments B being at least 20.degree. C., preferably at least 40.degree. C., in particular at least 80.degree. C., below the melting point of filaments A,the weight ratio of the filaments A:B being within the range from 20:80 to 80:20, preferably from 40:60 to 60:40, and the multifilament hybrid yarn additionally containing up to 40% by weight of cofilaments C, and the pile consists of loops with a length of 1 to 4 mm formed from a multifilament yarn having a yarn linear density of 30 to 200 dtex and filament linear densities of 5 to 25 dtex and/or from monofilaments having a linear density of 20 to 70 dtex.

Abstract: A tufted pile nonwoven fabric with an elastomeric backing has an elastic stretch of at least 10% and is particularly suited for floor coverings, upholstery, seat covers, etc. A stitchbonded fabric is employed as a preferred substrate for the elastic tufted fabric.

Abstract: A recyclable thermoplastic tufted fabric made of a partially meltable primary backing and tufts tufted into the primary backing. The tufts are bonded to the backing by partially melting the backing to bond the tufts and applying a secondary backing. Such a carpet can be recycled through processes known to recycle polyester.

Abstract: A filter composite comprising a first layer of glass fibers having random orientation, the layer being porous to gas flow therethrough; a porous mat of sufficient stiffness as to support the glass fiber layer during use as a filter, the mat consisting of compacted glass fibers, and; an additional porous layer carried by the mat to block escape of glass fibers or particles from the filter composite during gas flow therethrough. The first layer fibers have diameters between about 0.000035 and 0.00015 inch.

Abstract: A composition of matter and a process for the preparation thereof is disclosed for a fibrous composite (e.g., synthetic wood). The fibrous composite contains 50 to 95% by weight carpet and 5 to 50% by weight of a structural adhesive. Structural adhesives effective in this application would include phenol-formaldehyde resins, either of the resole or novalac type, phenol-formaldehyde resins that have at least one other co-monomer present, e.g., bis-phenol A, resorcinol, and other substituted phenols, urea-formaldehyde resins, melamine urea formaldehyde resins, tannin-phenol-formaldehyde resins, diisocyanate resin, epoxy resins, crosslinkable polyvinyl acetate, proteins, e.g., soy flour, blood and polyester resins.

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.

Abstract: A fusion-bonded carpet system and method of manufacture which method includes providing as all or a portion of the wear face surface cut yarn material in rope form prepared in rope bundles and implanting one or both ends of the rope bundle in an adhesive layer on a backing sheet to provide one or two I-bond, fusion-bonded carpet material having a selected pattern on the wear face surface. The fusion-bonded carpet has a wear face surface composed of all or part of a yarn material in rope bundle form, for example, of a multicolored random or selected pattern. The carpet material may have a backing layer and form carpet tile.

Abstract: The invention is directed to a method of tufting and molding a carpet module which is sized and shaped to fit the interior of a motor vehicle to form its floor carpeting. The method includes tufting the module in such a manner that selected areas have pile tufts arranged at a lower densities than the selected high density area. This construction provides that the selected high density area has the greater resistance to wear and the remaining areas have selected lesser resistance to wear while the entire module maintains substantially a uniform appearance.

Abstract: A process for forming a bonded pile fabric of enhanced stability using low levels of adhesive is provided. In the process pile forming yarn is tacked by heat fusion an open weave base layer prior to the application of adhesive. The adhesive which is preferably a low viscosity latex is applied through an open weave base layer to further bond the pile. An apparatus for making the bonded pile fabric is also provided.

Abstract: A cotton room-size rug, having dimension between 3 feet.times.5 feet, and 12 feet.times.15 feet, is made from a heat set blend of about 70-90% cotton fibers and about 30-10% low melting temperature polyester fibers. The polyester impregnates the cotton fibers to give them enhanced properties. The fibers are tightly tufted to a primary backing, and latex adhesive connects the primary backing to an open weave polypropylene secondary backing. A stain resistant finish is applied and the sides serged, and fringe attached. A cabled 3.0/2/2 yarn configuration is preferred.

Abstract: As a method for producing a tile carpet having a a lining layer, there is provided a means for obtaining a tile carpet superior in the uniformity of thickness and adhesion of the lining layer and also superior in all of standing stability, shape and dimensional stability and durability, in high applicability of a sealing material in carpet cloth and a lining material and that in high production efficiency. The method of the present invention for producing such tile carpet comprises applying a heat-melted, amorphous olefin polymer composition (11) onto a travelling endless belt (3), then laminating onto this coating surface a carpet cloth (1) which has been sealed beforehand with an amorphous olefin polymer composition (7), to obtain an integral laminate, thereafter cooling the laminate forcibly using a cooling plate (14), separating the laminate from the endless belt (3) and cutting it into a tile shape.

Abstract: An elongated pile article having a support strand for attachment to a plurality of yarn bundles, the yarn bundles including a dense portion with the filaments bonded to each other and bonded to the support strand, pile surface structure comprised of a plurality of elongated pile articles placed one next to the other, and a method and apparatus for making the elongated pile article.

Abstract: A process for producing a needled multilayered carpet is described in which an intermediate layer (6) containing thermoplastic film material is arranged between a layer of backing (5) and a top layer (7). The three layers are bonded together into a carpet by means of a process of needling through fibers (9). The intermediate layer (6) is formed by lumpy, three-dimensional plastic film material (8), and the needled fibers are tightly integrated into the intermediate layer (6) by the influence of temperature.

Abstract: A fabric which prevents outerwear from being noticed, heard or smelled by prey when worn. The fabric includes a flocked woven substrate with flattened flock fibers with the fibers adhered to the substrate. The substrate is quiet and soft. Preferably a printed layer is transferred on said flattened flock fibers and preferably is of a camouflage print pattern. The substrate is drapeable as an apparel item and more abrasion resistant than foamed knitted fabrics. Further the fabric is resistant to burr retention, wind and rain.

Abstract: A cushioned carpet tile is provided. The cushioned carpet tile includes a primary carpet fabric having a plurality of pile-forming yarns projecting from one side thereof. A mass of polymer cushioning is dispersed on the side of the primary carpet fabric from which the pile-forming yarns do not extend. A heat-fused nonwoven backing of polyester and polypropylene is disposed on the bottom of the polymer cushioning. The ratio of polyester to polypropylene in the nonwoven backing is between about 0.43 and about 2.3.

Abstract: Processes for the formation of flocked automotive molding members of the type adapted to border windshield and door windows are disclosed. The processes include coextrusion of a thermoplastic polymer and reactive hot melt adhesive in a common die orifice or head onto a profiled metal strip. The hot melt provides an adhesive layer for subsequent flock adherence to the thermoplastic polymer. The hot melt is moisture curable, thereby eliminating need for a curing oven or the like downstream from the flocking station.

Abstract: An elongated pile article having a support strand for attachment to a plurality of yarn bundles, the yarn bundles including a dense portion with the filaments bonded to each other and bonded to the support strand, pile surface structure comprised of a plurality of elongated pile articles placed one next to the other, and a method and apparatus for making the elongated pile article.