Abstract: In a method for the manufacture of a plush-type cleaning cloth from pile fabric in which a layer of thermoplastic pile fibers is anchored by fusing to a base structure of thermoplastic fibers at temperatures from 423 to 433 K (150.degree.-160.degree. C.), pile fibers of different melting and shrinking temperature properties are used in a distribution over the entire surface, so that a first portion of the pile fibers shrinks at the fusing temperature and a second portion of the pile fibers does not shrink or shrinks less than the first portion. The first portion of the pile fibers comprises approximately 60% of the total amount of the pile fibers and provides increased scrubing properties due to their crimped, harder structure.

Abstract: According to the invention, a web of material presenting periodic string parts is provided with garnishing material by forming loops of garnishing material around the net yarn, and subsequently fastening the loops together by applying high frequency energy. This is effected in an automatic machine in which string parts together with accompanying garnishing are inserted into apertures formed on a drum by means of electrodes which are mutually separated during the process of insertion and which are then clamped together and supplied with high frequency energy, whereafter the electrodes are again separated to release the string material and garnishing.

Abstract: A pattern is impressed on flocked fabric by applying a patterned cylinder to the flocked surface before the adhesive that retains the flocking has cured. The projections on the cylinder surface tilt the flock fibers contacted by them to a new orientation, thereby forming the pattern in the flocked surface. Subsequent curing of the adhesive preserves the pattern.

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 tufting carpet is described which comprises a tufting base, a pile material and a carpet back and essentially consists exclusively of polyamide 6. Through the use of a chemically uniform material in all components of the tufting carpet, the latter can be recycled as a whole for recovery of the monomeric starting material without the need for separation into the individual components, which has hitherto hampered the recycling of tufting carpets and led to major waste disposal problems.

Abstract: A method of making a moldable, nonwoven composite material. The method includes blending a mix of first fibers and second thermoplastic fibers. The second fibers have a melting point lower than that of the first fibers and comprise approximately 40-80 percent of the blend. The blend is then processed into a fibrous batt. The batt is then consolidated into a nonwoven structure with the first fibers being thoroughly intermixed with the second fibers. The nonwoven structure is then heated to a temperature below the melting point of the first fibers and above the melting point of the second thermoplastic fibers to substantially liquefy the second fibers and form a thermoplastic resin. The heated nonwoven structure is compressed to flow the liquefied resin to displace air voids in the nonwoven structure and encapsulate the first fibers. Finally, the nonwoven structure is cooled to form a composite material having substantially reduced air voids therein with the first fibers thoroughly encapsulated by the resin.

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 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.

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 kit for making a decorative article includes a fabric backing having a grid thereon. The grid is sized in predetermined segments to facilitate making a decorative article therefrom. A plurality of differently colored yarn segments and a liquid adhesive are provided with a template showing the decorative article design. In use, one end of each of the yarn segments is adhesively attached to a square within the predetermined segments on the fabric backing. The yarn segments are attached to the fabric backing by following a key in conjunction with the template which has a corresponding grid printed thereon. A decorative article can be produced from the yarn segments which is adaptable for wall or floor use.

Abstract: A method for making tufted carpet, as well as the tufted carpet made by this method, are provided. Pile yarn fibers are tufted into a tufting backing, which is composed of a primary backing, a secondary backing, and an elastomer sandwiched between the primary and secondary backings. In another embodiment, the tufting backing comprises a primary backing and an elastomer applied to the primary backing, but does not include a secondary backing. In a preferred embodiment, the elastomer is applied to the primary backing in a non-contiguous form whereby voids are provided within the arrangement for the tufting backing to be tufted without the primary backing fibers being immobilized. After the pile yarn fibers are tufted into the tufting backing, the elastomer is heated such that it softens, allowing the elastomer to flow in and around the pile yarn fibers. The elastomer may then be cooled, thereby hardening the elastomer and bonding the pile yarn fibers to the primary backing.

Abstract: A process for creating a pile yarn design and transferring it to a substratum, such as an article of clothing, involves the creation of the design on a temporary supporting medium, utilizing the medium to secure the design to the substratum, and then removing the medium from the pile yarn design. More particularly, a thin sheet of non-stick, moisture-proof plastic sheet material is stretched within a peripheral support, such as an embroidery hoop. Lengths of yarn are placed over the pattern, and a tweezer tool is utilized to punch the yarn through the plastic sheet so that loops extend outwardly from a side thereof. This process is utilized to create the pile yarn design on the plastic sheet. When the design is completed, glue is applied over a base portion of the pile yarn design, and the plastic sheet medium is then utilized to place the glue-coated yarn base portions into contact with the substratum.

Abstract: A floor covering with at least two colors using thermoplastics elastomers as its base material wherein the first base material is formed and set in the first work station of a multistation rotary injection molding machine having a turntable to transfer the first finished material to the second work station for punching, then to the third work station where a second base material with different color is melted and filled up the holes and bottom parts of the first finished material, at last the copolymers with at least two colors is being unloaded, calendered and extruded to form a flat and flexible floor covering.

Abstract: A method of producing a textile product has the steps of applying an adhesive coating to a first surface of a backing material having a first and second surface; passing a fluid towards the backing material to form a plurality of spaces through the adhesive and the backing material; and adhering the backing material to a textile fabric.

Abstract: To make a velour needle felt, an optionally pre-needled staple fiber non-woven web is applied to a revolving brushlike support and is then needled to form a pile on the side which faces the support. To increase the resistance of the velour needle felt to distortion, it is proposed that a layer which has a higher resistance to distortion than the staple fiber non-woven web and consists particularly of a spun-bonded web is applied to the brushlike support before the staple fiber non-woven web is applied thereto and that the pile fibers are pulled in the needling operation through the layer which has the higher resistance to distortion.

Abstract: For coating, a flat body is inserted into a mold having a base and side walls. The mold and the flat body are dipped into a coating material- After hardening of the coating material the flat body is removed from the mold and laterally trimmed.

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: Method for the manufacture of a nap mat having a rubber backing with nap free rubber edge zones, whereby the nap layer is fastened into a woven and/or non-woven primary texture which along with the nap layer is fastened to the upper side of an unvulcanized rubber backing by a press vulcanizing operation. Placing rubber strips in total or partial abutment against the underside of the rubber backing, before the press vulcanizing operation is initiated, so that said strips during the press vulcanizing operation are joint vulcanized with the rubber backing so that they form integrated parts thereof.

Abstract: Pile weatherstripping having rows of pile sandwiching a fin is fabricated so as to precisely locate the height of the fin with respect to the height of the pile. A travelling endless band receives webs providing the fins on opposite sides thereof with the edge of each web, which defines the height of the fin, precisely positioned on a side of the band and the other edge overhanging the edges of the band. 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 webs and the band and serves to wrap the overhanging portions of the webs around the band, or a guide may be used to facilitate wrapping of the webs around the band, prior to winding of the yarn. 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 process for producing a carpet is disclosed, comprising laminating a backing material composition comprising 100 parts by weight, on a resin solid basis, of an aqueous emulsion of a resin having a glass transition point of not higher than 5.degree. C., from 120 to 400 parts by weight of hydraulic inorganic cement, and up to 600 parts by weight of a non-hydraulic inorganic filler on a carpeting surface base material and heating the laminate to harden and dry the backing material composition. A carpet in which a carpeting surface base material and a backing material (and a carpeting back base material, if used) are firmly and integrally bonded can easily be obtained. The carpet has excellent properties, such as flexibility (softness), dimensional stability (resistance to shrinkage), fit to a floor, and workability, in a good balance.

Abstract: The disclosure relates to a carpet, a process for manufacturing a carpet and a method for recycling a carpet. The carpet of the present disclosure includes a primary backing having tufts of synthetic carpet fibers protruding from a top surface and, optionally, a secondary backing, with an extruded sheet of an isotactic polyolefin polymer between and integrally fused to a bottom surface of the primary backing and an upper surface of the secondary backing. The process for manufacturing the recyclable carpet includes contacting the extruded sheet with the primary backing and, optionally, the secondary backing, at a temperature sufficiently high to integrally fuse the extruded sheet to the respective backing. The method for recycling synthetic carpet of the type described includes manufacturing the carpet, collecting portions of the carpet, and melting the collected portions to make a feedstock.

Abstract: A nonwoven polyolefin sheet useful as a primary carpet backing in making a moldable, tufted automotive carpet. The polyolefin sheet, preferably polypropylene, is prepared by melt spinning filaments from a plurality of spinnerets and then drawing the spun filaments to a draw ratio of less than 2.0 to maintain high filament elongation as the filaments move from high to low elongation as the draw increases. The drawn filaments are deposited in both the machine and cross-machine directions on a moving collection belt to form a nonwoven sheet having a unit weight of 100 to 150 g/m.sup.2. The resulting sheet is lightly bonded using a steam bonder and then debonded such that sheet thickness increases by between 2.5 and 3.5 times. The tufted sheet has an elongation of at least 40%.

Abstract: The disclosure relates to a carpet, a process for manufacturing a carpet and a method for recycling a carpet. The carpet of the present disclosure includes a primary backing having tufts of synthetic carpet fibers protruding from a top surface and, optionally, a secondary backing, with an extruded sheet of an isotactic polyolefin polymer between and integrally fused to a bottom surface of the primary backing and an upper surface of the secondary backing. The process for manufacturing the recyclable carpet includes contacting the extruded sheet with the primary backing and, optionally, the secondary backing, at a temperature sufficiently high to integrally fuse the extruded sheet to the respective backing. The method for recycling synthetic carpet of the type described includes manufacturing the carpet, collecting portions of the carpet, and melting the collected portions to make a feedstock.

Abstract: A photographic film cassette containing of a photographic film whose leading end is initially positioned in a cassette shell and advanced through a film passageway out of the cassette shell by rotation of a spool. Light-trapping members are attached to upper and lower surfaces of the film passageway. After assembling the photographic film cassette, and before loading it into a camera, the leading end is advanced through the film passageway out of the cassette shell and returned to an inside of the cassette shell so that tips of piles of the light-trapping members are arranged so as to push against each other with tips thereof inclined in a film moving direction. In a preferred embodiment, a sheet member is inserted into and drawn from a film passageway to arrange the piles so as to make them incline in a film advancing direction.

Abstract: A golf mat of grass-like material includes top and bottom pads each of which includes belting material which substantially strengthens them and protects the base mat form damage from golf clubs striking it. The golf tee extends only through the top pad and not through the base mat and the belting material of the top pad presents any enlargement of the hole through the top pad which includes felt carpet which also gives a grass-like appearance. The top pad is loosely secured to the base pad and may be raised at its center for replacement of the tee and the top pad absorbs energy from the golf club due to its ability to move relative to the base mat when it is struck. The pad may be replaced through operation of the bolts at its opposite ends. The turf layer includes filaments of yarn such as tufts partially exposed on the bottom side adjacent fabric-like material exposed on the top side of the layer of belting material.

Abstract: A pattern-tufted, fusion-bonded carpet, particularly a backed carpet tile, having a polymeric latex primary adhesive layer and a plurality of fibrous yarns bonded to and extending from the layer to form a face surface, the fusion-bonded carpet having a woven polyester sheet material and glass fiber tissue sheet material both secured to the primary adhesive base layer, and the fusion-bonded carpet overtufted by an overtufted pattern on the face wear surface. A method of preparing a pattern-tufted, fusion-bonded carpet which comprises overtufting a fusion-bonded carpet with the fusion-bonded carpet having a primary adhesive base layer composed of a polymeric latex material and containing a woven fiberglass and a glass fiber tissue sheet material and optionally to prepare carpet tile applying a solid, thermoplastic backing to the pattern-tufted, fusion-bonded carpet material.

Abstract: An automotive floor mat and process of forming the same is provided. The floor mat comprises an uppermost face layer, a base layer of thermoplastic material and a lowermost polyurethane foam layer. The base layer includes a main body and a plurality of elongate nib elements connected to and projecting downwardly therefrom, and in contact with and projecting through the polyurethane foam layer.Formation of the nib elements, projection of them throughout polyurethane layer, and joining together of the base and polyurethane layers are accomplished substantially simultaneously.

Abstract: A method for manufacturing a fiber laminate used in a fiber reinforced material comprises a step for preparing double-pile fabrics made of reinforced fibers, on opposite sides of which pile is implanted. The method further comprises a step for laminating the double-pile fabrics so that pile of each of the fabrics is inserted into a layer of pile of adjacent double-pile fabrics, thereby obtaining a three-dimensional laminated form of said fabric.

Abstract: A pile fabric is formed by pressing lengths of yarn through a slot into a layer of adhesive on a pre-formed web. The yarn is pressed through the slot by a presser having at opposite faces respective grooves for receiving end portions of the yarn. While in the grooves, the end portions are constrained to have an upstanding relation with respect to the web.

Abstract: An apparatus for forming non-woven pile fabric comprises a pair of folding blades which oscillate to form ballows folds in warp threads passing between them. The folder blades are carried on forward ends of supports pivotally hung on pairs of suspension members. One suspension member of each pair is driven from a crank to impart oscillatory motion, while the other is adjustable in effective length to set the travel of the folder blade. Such length adjustment is effected by the upper ends of the suspension members being mounted on adjustable eccentric mountings.

Abstract: A floor mat and method of making same to be used in vehicles or as a passageway carpet that is characterized by having several areas of different tufting densities and thus of different resistances to wear. The method of the invention is accomplished by selectively feeding and non-feeding selected needles of a tufting machine of conventional construction. Machinery to bond the nap to the backing web and to apply a thermoplastic anti-skid lining is modified to accommodate the uneven napping densities and prevent irregular conveying of the carpet roll through the various processing stations.

Abstract: A method of producing a water permeable, laminated textile product having the steps of applying an adhesive coating to the rear surface of the textile fabric having a front and rear surface, passing a fluid into a portion of the front surface to form a pluality of openings through the adhesive and the textile fabric and adhering a water permeable backing to the textile fabric.

Abstract: A method of making an applique by printing a release adhesive upon a release sheet; flocking flock through an open section of a barrier into the adhesive to result in at least two patterns arranged to form a predetermined design adhered to the release sheet; applying a binding adhesive to free ends of the flock; transferring at least one of the predetermined designs of flock to a substrate material; and affixing the substrate material; with said predetermined design of flock to an article. An applique composed of substrate material adapted to be affixed to an article; and flock having end portions coated with a binder adhered in a predetermined design to the substrate material. A article composed of a surface area; a substrate material affixed to the surface area; a layer of binding adhesive on the substrate; and flock having end portions adhering to the layer of binding adhesive to form a predetermined design on the substrate material.

Abstract: A golf mat of grass-like material includes top and bottom pads each of which includes belting material which substantially strengthens them and protects the base mat from damage from golf clubs striking it. The golf tee extends only through the top pad and not through the base mat and the belting material of the top pad prevents any enlargement of the hole through the top pad which includes felt carpet which also gives a grass-like appearance. The top pad is loosely secured to the base mat and may be raised at its center for replacement of the tee and the top pad absorbs energy from the golf club due to its ability to move relative to the base mat when it is struck. The pad may be replaced through operation of the bolts at its opposite ends.In an alternate embodiment the turf layer includes filaments of yarn such as tufts partially exposed on the bottom side adjacent fabric-like material exposed on the top side of the layer of belting material.

Abstract: A buff adapted for self centering engagement with a backup pad comprising a circular body with a first fastener portion on its face surface. The buff includes a stiff flexible backing having a generally planar circular central portion and an annular flange only slightly larger than the diameter of the backup pad projecting from one side surface of its central portion, a second fastener portion fixed on the side surface of its central portion and adapted for engagement with the fastener portion on the backup pad, and a multiplicity of projecting tufts having central portions adhered in the backing by a thermoplastic adhesive that melts and adheres at a temperature under 100.degree. C.

Abstract: Bristle articles can be manufactured in that the bristle carrier and optionally the ends of the bristles are melted and brought together under pressure, or the bristles are introduced into an injection or foaming mould for the bristle carrier and are embedded in the bristle carrier material by injection moulding or foaming. The cycle time of these processes is extremely long as a result of the thermal processes (heating, melting, injection moulding, cooling). It is possible to significantly reduce the same in that the tools for holding or producing the bristle carrier on the one hand and the clamping devices for the bristles on the other are moved on closed paths and the clamping devices at at least one common station are transferred to the path of the tools and at least during the thermal processes are jointly moved with the tools and are subsequently returned to their movement path.

Abstract: A method for forming a sheet material adapted to be cut into smaller pieces to form portions of a fastener. The method comprises providing a self supporting polymeric film that provides the structural strength to retain the integrity of the sheet material, and stitching a plurality of yarns through the film to form loops projecting from one surface of the film and locking portions of the stitches adjacent the opposite surface of the film. The sheet material can also include a layer of heat softenable polymeric material adhered to the film over the locking portions.

Abstract: A method for making a sheet material adapted to be cut into smaller ravel resistant pieces to form portions of a fastener by intersecting (e.g., weaving or knitting) portions of base yarns to form a backing, with at least some of the base yarns being bonded yarns including a first portion formed of a polymeric structural material and a second portion formed of a thermoplastic binding material having a significantly lower melting temperature than the softening temperature of the structural material. Portions of pile yarns are entwined in the backing with the entwined portions of the pile yarns contacting at least one of the bonding yarns, while other portions of the pile yarn project from the backing to form loops or hooks. The backing is heated to soften the binding material so that it flows and, upon cooling, adheres to adjacent portions of the yarns, thereby anchoring the pile yarns in the backing.

Abstract: A fabric, useful as a primary carpet backing, woven in both the warp and weft directions from filmy elements in the form of longitudinally-oriented, splittable ribbons formed from a blend of a major amount of polyester and a minor amount of a polyolefin. The ribbons split longitudinally when punctured by a tufting needle, thus providing for a more secure grip on the tufted carpet yarn than that given by conventional polyester backings. The use of polyester as a principal component overcomes certain drawbacks of polypropylene backings. Alternative processes for making these fabrics, each involving a heat-treating step at a temperature of at least 150.degree. F. (66.degree. C.) for a sufficient period of time to render the ribbons splittable, are also disclosed.

Abstract: The invention provides apparatus for manufacturing pile fabrics, a method of using the apparatus and pile fabrics produced by the method. The apparatus is particularly suitable for use in the production of pile fabrics incorporating natural woollen fibers by adhesion of a series of courses of wool fiber to a backing sheet of appropriate material.

Abstract: Artificial athletic turf has a simulated grass surface provided by tufting strips into a backing fabric. The tufts are held in place by a precoat of polyurethane, and a reinforcing sheet is embedded within the precoat to provide tear resistance. A formed polyurethane is placed on the precoat, and one or more reinforcing sheet are also embedded within the foamed polyurethane. The strips are hydrophobic plastic with strength to prevent damage, and the coatings are polyurethane reinforced for tear resistance, which also yields a resilience as needed for an athletic mat. A hole can be cut into the mat, and the hole reinforced with a sleeve, to receive a tee for use as a golf mat.

Abstract: Composite laminates having improved delamination resistance and useful for aircraft, marinecraft, automobiles, armor, and furniture are formed from plies of substrate which include fibers extending generally normal to the plane of the substrate. These plies of substrate can be, for example, tufted textiles wherein the tufts are formed by the fibers extending in the "z" direction. The fibers interlock with or are anchored in the substrate. Fibers from one ply intermesh with the fibers of an opposing ply. An organic binder sandwiched between the plies is cured to form the composite matrix. A method of making the laminates comprises applying the uncured binder to a tufted substrate to form a ply, stacking the plies, and applying heat and pressure to transform the binder to a matrix which substantially saturates the plies.

Abstract: A pile-surfaced toy ball is made by affixing to the exterior of a hollow rubber ball, such as a tennis ball, the inner end portions of stubs in closely spaced relationship by hotmelt, and when the hotmelt has set, the outer end portions of the stubs which can be of twisted strand rope or slit film in roll form can be fluffed by tumbling or combing to provide a dense pile surface. A tail such as of twisted strand rope can be attached to the ball during its manufacture by inserting in the core of the ball a knot on the end of the tail by movement through a slit in the core ball spread apart to enable the knot to pass into the interior of the ball by movement transversely of the length of the tail.

Abstract: A multilayer composite sheet, especially for use as a padding layer underneath artificial grass, or turf includes a bottom layer of expanded synthetic resin, particularly of closed-cell polyethylene foam, and a metallic foil flatly bonded to the foam material. The multilayer composite sheet exhibits low weight per unit area, low water absorption, and low thermal linear expansion suitable for exposure to ambient weather conditions especially sunlight.

Abstract: The present invention relates to a method for manufacturing carpet tiles having excellent dimensional stability which comprises the steps of:(a) allowing a reticulated fabric base having a small thermal coefficient of linear expansion to be contact with the whole surface of the back of a carpet base material,(b) applying a backing material prepared from a composition containing a thermoplastic material as the major component to the resulting composite material, and(c) optionally laminating a fabric backing onto the above backing material.

Abstract: Pile carpet of nylon, polyester, or other pile yarn, is coated with 0.1 to 5 weight percent, based on weight of the pile yarn of a heat-activated adhesive powder having a melting point within the range of 100.degree. to 170.degree. C., preferably 110.degree. to 150.degree. C. For nylon pile yarn a preferred adhesive powder is a ternary copolyamide selected from the group consisting of 6/6,6/12; 6/6,6/11; and 6/6,6/12,12. The powder is heat-activated, for example to 195.degree. C. for about 60 seconds. The treated carpet displays enhanced carpet tuft appearance, improved resilience, carpet surface cleanness, and improved wear performance.

Abstract: A vehicle floor mat is provided with a high density, long-wearing heel engaging band, wherein the band is formed integral with and simultaneously with the remainder of the mat. This is accomplished by employing double tufting in a band of an elongated strip of carpeting to provide the high density area.

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: Mats for covering surfaces or for cleaning purposes, particularly doormats, which comprise a basic material, mainly of plastic with a fibrous layer and a support layer fixing the latter and fibres with a bristle-like structure applied to the basic material. The basic material is zonally melted by heating the fibres and optionally the support layer and compressed onto or into the support layer 50 as to form depressions in fibrous layer. The bristles are inserted substantially in parallel to each other in the in depressions and are joined to the compressed basic material by melting their ends or by a homogeneous weld.

Abstract: A ceramic fiber mat attached to the interior wall or surface of a high temperature chamber or furnace or adapted to overlie an intermediate insulating member positioned between the mat and a furnace wall, the fibers in the mat lying in planes generally perpendicular to the wall, the mat constituting an improved insulation for the wall where the interior of the chamber or furnace will be operating at temperatures in excess of 1600.degree. F.