Note: Descriptions are shown in the official language in which they were submitted.
~04Z;~3~
METHOD OF MAKING PILE FABRICS FROM A
8LOCK OF PILE MATERIAL
This invention relates to pile fabrics and more especially
to nonwoven pile fabrics of the type having a substrate to which pile
yarns are adhesively or fusibly secured.
It is an object of this invention to provide a method of
making nonwoven "shag" type carpets or rugs wherein the pile is
unusually long as compared to normal heigfit carpet and generally is
about an inch or more in height, and wherein the num~er of TOWS per
inch are few in number and do not exceed four per inch. Another
object is to provide a method of obtaining a carpet having any desired
height of pile while so controlling the pile strands during tbeir
placement on a substrate, for adhesive or fusible securement thereto,
that the pile strands are arranged in a clearly defined row foTmation
with the pile strands also being maintained in generally perpendicular
relation to the substrate when the strands are deposited on the substrate
to aid in proper securement of the ends of the pile strands to the
substrate.
According to the present invention, there is provided a method
of making pile fabrics, such as carpets, rugs and the like which comprises
providing a pile strand block of rows of substantially parallel strands of
pile forming material in an open-ended container with the block having
dividers of sheet material therein separating adjacent rows of the strands,
incrementally feeding from the container the pile strand block parallel
to the axes of the pile strands in successive increments of an amount equal
to the desired length of pile, treating the ends of the dividers in the
block to cause them to foreshorten relative to the adjacent ends of the
pile strands so that relatively short lengths of the pile strands are
exposed and project beyond the adjacent ends of the dividers, and severing
each fed increment of pile strands and the foreshortened dividers trans-
B
~: 1042333
versely of the pile strand axes while ~ringing the projecting ends of
the severed pile strands into contact with a layer of adhesive for
securement thereto and to form spaced rows of cut pile tufts thereon.
Also, the dividers are formed of a compressible sheet
material which is in a compressed state in the pile strand block and
will expand thereafter when the block is being severed and rows of cut
pile tufts formed therefrom are being brought into contact with a moving
substrate for securement thereto. Thus, by varying the rate of movement
of the substrate relative to the rate at which the pile strand block is
being severed, and de~irably within the range of expansion of the
dividers, pile surfaces of correspondingly varying density may be obtained
due to the variance in the number of rows of cut pile tufts per inch
being formed.
Although the invention is particularly concerned with the making
of "shag" carpets and rugs, it will be appreciated that the invention has
- wider utility, since it will be more apparent hereinafter that the
dividers may be utilized for making normal height carpets and rugs, if
desired, since the dividers serve to maintain the pile forming strands in
the desired parallel relationship and in the desired patterned relation-
-- 20 ship for permitting obtaining enhanced definition of design, particularly
where intricate pile patterns are being produced.
~:'
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333
Some of the objects and advantages of the invention
having been stated, others will appear as the description
proceeds when taken in connection with the accompanying
drawings, in which --
Figure 1 is a somewhat schematic perspective view ofthe bottom and two sides of a confined block of parallel
strands of pile forming material with divid~rs of sheet material
separating adjacent rows of the pile strands;
Figures lA, lB, lC and lD are schematic views illus-
trating successive stages in a first embodiment of the method
of making pile fabrics utilizing the block of strands of pile
forming material shown in Figure l;
Figure 2 is a fragmentary schematic perspective view
of a portion of pile fabric having tufts formed of pile yarns,
rovings or similar pile strands glued to a backing in accordance
with the first embodiment of the method of this invention;
Figure 3 is a fragmentary sectional view of a portion
of pile fabric taken in the longitudinal or machine direction
of the fabric, but wherein the tufts thereof are formed of
slivers or tows of synthetic filaments glued to a backing in
accordance with the first embodiment of the method of this
. invention;
Figures 4 and 4A collectively illustrate a suitable
apparatus for carrying out the successive stages of the method
illustrated in Figures lA-lD;
Figure 5 is an enlarged fragmentary view similar
to Figure lD, but more clearly illustrating the preferred
manner in which each successive increment of pile strands
and foreshortened dividers is severed transversely of the
pile strand axes while the pro~ecting ends of the severed
pile strands are brought into contact with an adhesive-coated
backing;
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Figure 6 is a view simllar to Figure lD, but showing
a second embodiment of the method ln which the pile tufts are
secured to the backing by ~using; and
Figures 7 and 8 are longitudinal vertical sectional
views through fabrics similar to those shown in the respective
Figures 2 and 3, but wherein the cut pile tufts are secured to
the respective backing by fusing in each instance.
Referring more specifically to the drawings, the
first embodiment of the method is best illustrated in Figures 1
to lD, wherein there is shown a confined block 10 of sub-
stantially parallel strands 11 of pile forming material
arranged in rows in an open-ended container 12, which rows
are separated from each other by dividers 13 of any suitable
sheet material. The block 10 is utilized for forming pile
~` fabrics according to the method of this invention as will be
later described.
` The strands 11 of pile forming material, which will
be termed as "pile strands" hereinafter, may be of any desired
color, kind or size or combinations thereof, and may be of any
, desired t~pe of pile forming material; e.g., carpet yarns,slivers, rovings and/or tows of synthetic continuous filaments
or any desired combinations thereof. The block 10 is formed
by arranging pile strands 11 in substantially parallel
relationship to form sheets or layers thereof. Such sheets or
layers of pile strands are stacked in alternation with
dividers 13 of relatively thin sheet material.
The dividers 13 preferably are compressible with a
.,! memory so that they may recover to substantially their original
thickness followlng compres~lon thereof and upon being released
from such compresslon. From time to time during the stacking
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of the layers of pile strands 11 and dlviders 13, the stack
may be compressed so that the block 10 is in compacted
condition when it is confined within the open-ended container
12. Corresponding ends of the pile ~trands are visible at
one open end of container 12 as best shown in Figure 1.
The arranging of the pile strands may be carried out
by any suitable method. For example, a patterned block of
pile yarns may be formed by successively interconnecting
sections of woven fabric utilizing pile strands for the wefts
thereof by selectively interweaving with a plurality of binder
warp yarns a plurality of weftwise pile strands of different
colors in a predetermined patterned order. Thereafter, a
compact stack of layers of the woven fabric is formed by
folding the same into equal-length layers to form a stack of
.
superposed fabric layers while aligning the successive layers
with each other so that the ends of the pile strands therein
collectively form a composite pattern. The compact stack
,
of folded fabric then is enclosed in an open-ended container
to form a confined block of the pile strands with the ends
of the pile strands exposed and forming the composite pattern
at an open-end of the container. However, as indicated
earlier herein and according to this invention, as the
'~ .
compact stack of layers are formed of the woven fabric,
dividers 13 are alternately arranged with the layers of woven
fabric to result in a block 10 of rows of substantially
parallel pile strands 11 in the apen ended container 12 with
the divider~ 13 therein separating ad~acent rows of the
parallel strands. These dividers 13 are especially useful,
as will be later explained, for holding relatively long
pile tufts, up to one inch or more in length, in substantially
perpendicular relation to a backing during production of shag
pile fabrics and thereby greatly facilitating such production.
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10`4Z333
As stated above, it is preferred that dividers 13 are
made from a compressible sheet material; e.g., foam polystyrene
sheets or other sheets of material which will compress readily
and may be severed easily. Since the pile strands and the
dividers 13 are ~mpressed during the formation of the pile
strand block 10, it is apparent that the dividers 13 are main-
tained in compressed condition while pile strand block 10 is
confined within container 12.
As heretofore indicated, the pile strands ll may be
arranged according to a predetermined pattern which would be
visible at the open end of container 12. If desired, the pile
strands 11 may be arranged in a random pattern of different
colors, or shades, or all of the strands 11 in block 10 may be
white or of the same color and/or kind.
As shown in Figure lA, after the pile strand block
10 is formed, it preferably is positioned so that an open end
` of container 12 faces downwardly with the axes of the pile
, strands ll extending substantlally vertically. A downward
force then-is applied to a pressure plate 20 movable within
and relative to container 12 and engaging the upper ends of
all of the pile strands 11 and the dividers 13, with a
predetermined incremental downward movement thus being imparted
to the compacted pile strand block 10 relative to container
12 so that the pile strands ll and dividers 13 project
-~ downwardly a predetermined distance "X" below the lower edge
of container 12. The distance "X" is equal to the desired
length of pile.
Followlng the feeding of each successive lncrement
- of pile strands 11 and dividers 13 from container 12, the
ends of the dividers in block lO are treated to cause them
to foreshorten relative to the adjacent ends of the pile
strands 11 so that relatively short lengths of the pile
lU4;~333
strands are exposed and project beyond the adjacent ends
of dividers 13.
Such treatment may include sub~ecting the ends of
the dividers to a heated liquid or chemical treatment,
although it is preferred that the dividers are foreshortened
simply by applying heat thereto as by subjecting the same
to radiant heat for example.
As indicated in Figure lB, according to the preferred
embodiment of the invention, dividers 13 are made from a heat-
shrinkable sheet material. The nature of the dividers should
be such that, when their lower ends are subjected to heat at
an elevated temperature, but which will not burn or scorch the
lower ends of the pile strands 11, the lower ends of the
dividers 13 will shrink and recede relative to the adjacent
ends of the pile strands 11. Thus, after the feeding of the
, . .
~` desired increment of the pile strand block 10 from container
12, the container 12 with the pile strand block 10 is moved
over and in close proximity to a heat source 30 which may be
: in the form of infraredla~s-and which heat the lower end of
the pile strand block 10 the desired amount to cause the
dividers to shrink and recede relative to the adjacent ends
of the pile strands 11.
~; For example, if polystyrene sheets are used as the
: dividers 13, it has been found that when the lower ends of
the dividers are heated momentarily to a temperature of about
100 to 120 centigrade, the lower ends of the dividers will
shrink and recede about 0.025 to 0.050 inch relative to the
lower ends of the pile strands. In other words, the lower
ends of dividers 13 may shrink and recede approximately one
to two millimeters relative to the adjacent ends of pile
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104;~333
strands 11 during each movement of pile strand block 10
over heat source 30. The plle strand block 10 then move9
forwardly over an adhesive applying station 40 which applies
a liquid adhesive to the exposed lower ends of plle strands
11 as in Figure lC.
The adhesive applying station 40 may take the form
of an adhesive applicator roll 41 partially immersed in a
supply of adhesive 42 carried by a suitable container 43.
The recession of the lower ends of dividers 13 relative to
pile strands 11 permits some of the adhesive from the roll 41,
being engaged by the lower ends of the pile strands 11, to
also be applied to the side peripheral surfaces of the lower
end portions of the pile strands 11. It is preferred that
dividers 13 do not have an affinity for the particular type
of liquid adhesive 42 being used so that, even though the
.,
lower ends of dividers 13 may be contacted by the adhesive 42
~-~ as it is transferred from roll 41 to the lower ends of pile
strands 11, such adhesive will not bond to the lower ends of
~- dividers 13. It has been determined that polyvinyl chloride
adhesive, for example, will not bond to polystyrene sheets
when the~ are used as the dividers 13.
Following the treatment of the lower ends of dividers
13 to cause them to foreshorten relative to the adjacent ends
of pile strands 11, the corresponding previously fed increment
of the pile strands 11 and the foreshortened dividers 13 are
severed transversely of the pile strand axes, at a pile strand
severing station 50, while bringing the projecting ends of
the severed pile strands into contact wlth a substrate for
securement thereto. The substrate may be in the form of a layer
of adhesive without any underlying support and with or without
a reinforcement, such as a scrim, embedded therein. However,
1042333
it ls preferred that the ~ubstrate, as illustrated in the
drawings, is in the form of an adhesive-coated backing B.
This forms rows of cut pile tufts T on the backing B and thus
forms the pile fabric F. The divider portions 13a between
the rows of tufts T then are of lesser height than tufts T
so that divider portions 13a will not interfere with the
pressing of tufts T against the adhesive-coated backing as
will be later described and as shown in Figure lD.
It can be appreciated that there may be instances in
which the application of adhesive to the ends of pile strands
- 11 prior to securement thereof to the adhesive-coated backingmay be omitted. Conversely, there may be instances in which
the application of adhesive to backing B may be omitted
provided that the projecting ends of the pile strands then
have a layer or coating of adhesive thereon. In other words,
in this first embodiment of the method, it is necessary that
adhesive is applied to either the projecting ends of the pile
strands 11 or to the upper surface of backing B, or to both,
prior to bringing the respective ends of the pile strands
- 20 into contact with the backing B so as to insure effective
securement of the pile tufts being formed to the backing.
i It is apparent that, during forward movement of pile
strand block 10 and container 12 in their course over heat
source 30 and adhesive applying station 40 of Figures lB and
lC to the pile strand severing station 50 of Figures lD,
3 and 4, the pile strand block 10 and container 12 pass over
a portion of the backing B which also i9 in its course from
a supply source or roll R to severing ~tation 50. Also, as
shown a coating 61 (Figure 5) of liquid adhesive is applied
to backing 9 by a suitable adhesive applicator 60 (Figure 4)~
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104~333
The adhesive applicator 60 may be of any well-known type
which will apply a thin coating of liquid adhesive of the
desired thickness upon the upper surface of backing B in its
course from supply source R (Figure 4) to severing station 50.
The thickness of the liquid adheslve-coating applied to
backing B may be in the range of about 0.1 to 1.0 millimeter
or more, depending upon the type of backing and pile strands
being used in forming the pile fabric F.
The preferred adhesives may be thermoplastic or
thermosetting materials, or mixtures of thermoplastic and
thermosetting materials. The adhesive may conveniently be a
plastisol or latex, or if desired, may be in granular or
powder form. Illustrative but non-limiting examples of suitable
adhesives include polyvinyl chloride, polyurethane, natural
or synthetic latex, urea resin, melamine resin, and/or any
:
other suitable resin.
As the backing B advances forwardly it passes upwardly
in converging relation to the path of travel of container 12
- and then passes downwardly in diverging relation to the path
of travel of container 12. As the backing B approaches
severing station 50, it passes over a suitable supporting
roll 51 which is a part of severing station 50 and is spaced
a predetermined distance below a severing means embodied in
`- a stationarily mounted endless band type of cutter blade 52.
Cutter blade 52 is positioned closely adjacent and beneath
the path of container 12 and is arranged to sever the lower
ends of the pile strands 11 and the foreshortened dividers 13
` in the portion of pile strand block 10 projecting from the
open lower end of container 12 so as to form the pile tufts
T during each forward movement of container 12 past cutter
blade 52.
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104Z333
As heretofore stated, it i5 preferred that dividers
13 are made from a compresslble sheet material which has been
compressed durlng formation of pile ~trand block 10. Accord-
ingly, it is important to note that, if the backing B then is
being advanced faster than the rate at which successive rows
of pile strands ll are being severed by cutter blade 52; i.e.,
if the forward speed of backing B is greater than that of
container 12, the previously compressed divider portions 13a
will expand substantially concurrently with the severing of
the same from the main body portions of the dividers 13
~ remaining in pile strand block lO. Thus, the transverse rows
: of pile tufts T may be spaced apart from each other a greater
distance than that of ad~acent rows of pile strands ll in
block 10.
: By way of example, each divider 13 may be in the range
of about 1/16 to 5/16 inch thick before it is assembled and
compacted with strands 11 and formed into block 10. Also,
dividers 13 may be compressed to about 25-30 percent of their
original thickness during formation of pile strand block 10.
In such instances it follows that, if the rate of forward
~:~ movement of backing B is 25-30 percent greater than that of
container 12, the distance between adjacent transverse rows
of tufts T in fabric F will be 25-30 percent greater than the
:, distance between adjacent rows of pile strands 11 in block 10.Therefore, assuming that dividers 13 are of a sheet
material, such as polystyrene, and are each about 5/16 (0.3125)
inch thick before being compressed 30 percent or about 3/32
(0.0938) inch during formation of pile strand block 10, and
also assuming that dividers 13 are capable of recovery to their
original thickness following release ~rom such compression
104Z333
thereof, the dividers 13 in block 10 will be about 7/32 ~0.2188)
inch thick while ln block 10. However, adjacent rows of tufts
T will be about 5/16 inch apart if backing B is being advanced
30 percent faster than container 12 during the severing of
tufts T from block 10. If desired, it is contemplated that
backing B may be advanced relative to block 10 at a rate
exceeding the range of expansivity of dividers 13 if greater
spacing is desired between the rows of tufts T.
,
- On the other hand, since adjacent lower end portions
of dividers 13 in block 10 and the severed divider portions 13a
between tufts T may effectively oppose expansion of each other
during the severing operation and as long as adjacent divider
-~ portions 13a remain in the pile fabric F, the backing B may be
~, advanced relative to container 12 at any desired rate less than
the expansion range of the previously compressed dividers.
However, backing B should advance no slower than the forward
speed of container 12 to insure effective transfer of the
tufts T being severed from block 10 to backing B.
-~ Acsordingly, utili2ing dividers of the type mentioned
in the foregoing example, it can be seen that the distance
, . . .
`~ between adjacent rows of tufts may be anywhere in the range
of about 7/32 (0.2188) inch to 5/16 inch or more. Thus, under
such conditions, if backing B is advancing 20 percent faster
than container 12, adjacent tuft rows will be spaced
"~
~;~ approximately I7/64 (0.2626) inch apart from each other. It
is to be understood that at least some of the compressible
dividers 13 may be of different thickness than others in
block 10, or several different thickneqseq of dividers 13
may be provided in block 10, 80 as to obtain rows of tufts T
which are spaced varlous dlstances apart from each other, if
desired.
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The severed divider portions 13a may be removed from
between the rows of tu~ts T manually or by any suitable means,
-
not shown, any time after the adhesive, which secures the tufts
to the backing, has been cured or set, it is apparent that any
divider portions 13 then under compression in the pile fabric F
may expand to their original thickness as they are removed from
the pile fabric F. The resulting pile fabric then may appear
as shown in either of the Figures 2 or 3, depending upon the
type of pile strands of which the pile tufts are formed. For
example, the tufts T of the pile fabric F in Figure 2 are
formed of pile strands such as carpet yarns or rovings of
relatively low bulk. The fabric F-a of Figure 3, on the other
hand, has relati~ely bulky tufts T-a secured to its backing
B-a by an adhesive 61a. The latter tufts T-a may be formed
of relatively bulky pile strands such as synthetic continuous
filament tows or slivers, for example.
Referring again to severing station 50, with the
exception of blade 52 having a smooth or straight cutting edge
which faces rearwardly with respect to the direction in which
container 12 is moving during the severing operation, the
severing apparatus may be in the form of a conventional band
saw assembly with the endless blade 52 being mounted on a
pair of pulleys 53, only one of which is shown in Figure 4,
and which may be driven by an electric motor 54. Pulleys 53
are arranged so that cutter blade 52 occupies a substantially
horizontal position transversely of the path of travel of
pile strand block 10 pro~ecting from the lower end of container
12. A~ shown ln Figure 5, blade 52 may be guided and
maintained in the latter posltlon during movement thereof by
a suitably ~lotted guide bar 55 overlying the path of travel
of backing B and the cut pile tufts T of the now formed pile
fabric F.
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104Z333
It should be noted, however, that the backing
supporting roll 51 at the pile strand severing station 50
is ~ournaled in suitable bearings 56, only one which is shown
in Figure 5, and which are adjustable by respective screws 57
for adjusting roll 51 so that the path of travel of backing
B over roll 51 is very nearly the same as the path of travel
of the lower surface of pile strand block 10 in the course of
forward movement thereof. This facilitates the progressive
depositing onto backing B of tufts T and divider portions 13a
being severed from block 10. Also, the height of roll 51
may be adjusted to accommodate changes in the extent "X"
(Figure lA) of each incremental feeding of pile strand block
10 as effected for obtaining different heights of pile tufts
T on backing B.
:: It should be noted that, not only do the divider
portions 13a aid in insuring that the tufts T are deposited on
backing B in the desired spaced relationship to form
transversely extending parallel rows of tufts thereon, but
the divider portions 13a also support adjacent rows of tufts T
in substantially perpendicular relation to the downward and
forward path of travel of the backing B forwardly of roll 51
during the curing of the adhesive. This insures that the pile
tufts T, even though they may be quite long as in forming
"shag" pile fabrics, will not tilt or bend and become matted
in the adhesive at other than the desired lowermost end
portions thereof during production of the pile fabric F.
In this regard, it will be observed in Figures lD, 4
and 5 that, immediately after the backing B passes over the
supporting roll 51 at severing station 52, the backing passes
over and in close proximity to or in engagement with a heated
hollow platen or plenum 70 whose upper surface is of a width
104;~333
at least about equal to that of the pile fabric F being
formed and which may be heated by any suitable hea~ing mean~,
such as an electrical heater, a circulating hot oil, or other
hot fluid. For example, if a polyvinyl chloride plastisol
type of adhesive is being used for the coating 61, platen 70
may be heated up to about 220 centigrade or higher for effect-
ively curing or setting the adhesive on backing B. Thus, the
: heated platen 70 forms a curing zone thereabove through which
the pile fabric F is advanced from severing station 50 for
curing the adhesive coating previously applied to the upper
.
surface of backing B. It follows that the heated platen 70
must be of such length and must be heated to such a temperature
as to effectively cure the adhesive coating so that the tufts
T will be firmly anchored to the backing B. A cooling platen
may be disposed forwardly of the heated platen 70 for forming
a cooling zone thereabove through which the pile fabric F
passes for cooling the same to facilitate subsequent take-up
and handling of the pile fabric.
To aid in securing the tufts T to the adhesive coating
61 on backing B as the tufts are being progressively deposited
on the advancing backing B, a suitable pressure applying belt
or conveyor 71 is suitably supported above and extends through-
out the width of the pile fabric F as it moves above heated
platen 70. The conveyor 71 is driven intermittently at a rate
corresponding to the rate at which the pile fabric _ is being
advanced forwardly over the heated platen 70. Also, the lower
run of conveyor 71 is spaced above platen 70 a distance
corresponding substantially to the desired height of the pile
tufts T combined with the thickness of the backing B of the
pile fabric _. As shown in Figure 5, the lower run of
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1l)42333
conveyor 71 is disposed immediately downstream of the blade
guide bar 55 and cooperates therewlth to press the deposlted
cut pile tufts T into the ~dhesive coating 61 on backing B.
Since the air above platen 70 is maintained at a
relatively high temperature, this causes the lower edges of
severed divider portions 13a to shrink and recede further
relative to the cut pile tufts T and backing B as shown in
Figure 5. This insures that the severed divider portions 13a
will not interfere with the pressing of the tufts T toward
backing B by the lower run of conveyor 71.
Conveyor 71, (Figure 4) as well as a suitable
advancing roll 72 (Figure 4A) for the backing B and pile
fabric F, may be interconnected through shaft 71a and b.~th
then intermittently driven by a suitable clutch mechanism 73
coupling the conveyor 71 and advancing roll 72 to an electric
motor 74. As shown in Figure 4A, after passing over advancing
roll 72, the pile fabric _ may be taken up by a.suitable
take-up mechanism generally designated at 80.
;.s
It will be observed in Figure 4 that motor 74, which
is preferably a reversible motor, imparts reciprocatory motion
to a carriage 90 through intervening chain and sprocket
connections 8g. Carriage 90 is mounted for forward and
rearward movement in a substantially horizontal path on
tracks 91, only one of which is shown in Figure 4. Carriage
90 is adapted to support container 12 therein and is also
provided with suitable fluid operated rams 92 thereon for
engaging a frame 93 in which the container 12 is suitably
secured. The rams 92 serve for elevating container 12 and
its block 10 of pile ~trands 11 as they reach the right-hand
- end of a stroke in forward movement thereof so that the lower
ends of the pile strands 11 (Figure 5) will pass above and
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iO42333
out of engagement with cutter blade 52 ln the course of
rearward movement of container 12 from right to le~t in
Figures 4 and 5.
As shown by way of example in Figure 4, lncremental
downward feeding movements may be imparted to pressure plate
20, to feed the pile strand block 10 from container 12 adjacent
the end of each rearward stroke of carriage 90, by suitable
screws 95 which are operatively interconnected by suitable
sprockets and chains 96, which, in turn, are driven by an
electric motor 97. Screws 95 are suitably mounted on the upper
portion of container 12 or frame 93 of carriage 90, and the
lower ends of screws 95 engage the upper surface of and apply
downward force to pressure plate 20. Thus, screws 95 move the
pile strand block 10 downwardly within container 12 a pre-
determined distance each time carriage 90 and the container 12
therein are positioned adjacent the rearmost position in
; movement thereof and rearwardly of heat source 30.
It is apparent that, each time carriage 90 and
container 12 move rearwardly of severing station 50 in the -
. course of each rearward stroke of carriage 90, the rams 92
are so controlled as to permit frame 93 to move downwardly
against carriage 90 and thereby return container 12 to its
normal level preparatory to a succeeding slice of tufts
being prepared and positioned on the backing in the manner
heretofore described. It is preferred that the backing B
is stationary in the interim between successive slices of
tufts T being severed from the pile strand block 10 90 that
each successlve slice of tufts T may be positioned in proper
relation to the immedlately preceding tuft slice to facilitate
the forming of a continuous pile fabric of any desired length.
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~04Z333
In thi~ regard it will be observed ln Figures lA-lD
and 5 that block 10 includes the same number of divider~ 13 as
there are rows o~ pile strands, with a row of pile strands 11
defining the ~ront of the block 10 and a divider 13 defining
the rear of the block 10 within container 12. This arrange-
ment of the pile strands 11 and the dividers 13 is desirable
so that, when desired, the leading row of pile strands 11
in each slice severed from block 10 may be positioned
against the trailing divider portion 13a of the slice
~` 10 previously deposited onto backing B. Also, the trailing
divider 13 in block 10 serves as a back-up to stabilize the
~` rearmost pile strands during both the incremental feeding
of block 10 and the severing of the rearmost row of pile
.
~` strands.
Referring now to Figure 6, there is shown a second
embodiment of the invention in which securement of the pile
tufts to a substrate is effected by fusion instead of by
~ adhesive. In other respects, the method carried out by
;~ t~e apparatus of Figure 6 is substantially as described with
2~ respect to the first embodiment with particular reference to
Figures 1, lA-lD, 4, 4A and 5. Therefore, those elements
of Figure 6 which are similar to elements of Figures 1,
a-lD~ 4, 4A and 5 will bear the same reference characters
with the letter "b" added, where applicable, to avoid
` repetitive description.
While the pile strands 11 of the first embodiment may
be of any desired type, the second embodiment differs in this
respect ln that each of the pile gtrand# llb of Flgure 6 must
be at least partially thermoplastic capable of being melted,
. .
- and strands llb preferably are entirely thermoplastic. Also,
although dividers 13b of Figure 6 may be the ~ame as dividers
~ .
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104~333
13 of the first embodiment, they may be of foam poly~tyrene
sheet material formulated to include fillers or additives
which will impart thereto a higher temperature shrinkage point
than that of the dividers 13, because the melting point of
thermoplastic strands may be about twice the temperature of
heat required to shrink the foam polystyrene dividers 13 of
the first embodiment of the invention. It should be noted,
however, that the divider portions 13ab may expand from their
previously compressed state to aid in supporting and effecting
the desired spacing between successive transverse rows of
tufts T-b during production of the pile fabric F-b. Thus, in
addition to permitting varying spacing of the rows of tufts
T-b in production of various pile fabrics, the divider
portions 13ab facilitate the forming of tufts one inch or
more in length for making "shag" type fabrics, for example.
- The method of Figure 6 also differs from that of
Figures 1 and lA-lD in that, during each forward movement or
stroke of pile strand block lOb and container 12b, the lower
surface of the increment of block lOb last fed downwardly from
container 12b passes over and in close proximity to a suitable
heat source 100 which melts the free projecting ends of the
pile strands llb while causing the lower ends of dividers 13b
~ to shrink and recede relative to the free ends of pile strands
: llb.
Heat source 100 is disposed rearwardly of but in close
. proximity to severing station 50b in Figure 6 so that the heat
applied to the exposed projecting ends of pile strands llb may
be effective closely adjacent cutter blade 52b, or at least,
the free ends of pile strands llb will still be ~n melted
condition when they are being severed by blade 52b and progres-
sively brought into contact with and deposited as tufts T-b on,
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104Z~33
substrate ~-b to be fusibly secured thereto. The fusible or
previously melted lower end portions of tufts T-b fused to
substrate B-b are indicated at 101 in Flgure 7.
Since the severing of successive rows of pile strands
llb and dividers 13b, the progressive depositing of the pile
tufts T-b and divider portions 13ab, and the pressing of tufts
T-b against substrate B-b by conveyor 71b may be effected in
substantially the same manner as that described with respect
to pile strands 11, dividers 13, tufts T, divider portions 13a
and conveyor 71, a further description in this respect is
deemed unnecessary.
` To aid in the fusion of the tufts T-b to substrate
~-b during forward movement thereof, platen 70b may be
maintained at a temperature approximating the melting
temperature, or less than the melting temperature, of the
thermoplastic-containing cut pile tufts T-b. Additionally,
for obtaining better securement of the pile tufts, it is
contemplated that the substrate B-b may be entirely of
a thermoplastic or fusible material or it may be in the
form of a non-fusible backing having a fusible material in
the form of a film, for example, defining the upper surface
~ thereof.
`` As indicated above, heat source 100 may shrink the
lower portions of dividers 13b concurrently with the melting
of the free ends of pile strands llb. If desired, since the
` pile strand block lOb is moved rearwardly, from right to left
,.
` in Figure 6, at a higher level than that in which it is moved
forwardly, the heat from heat source may be 90 controlled as
to effect shrlnkage and recession of the lower ends of dividers
13b during rearward movement of block lOb and without melting
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104Z333
the lower ends of pile strands llb at that time. Thus,
relatively short lengths of pile strands llb would be exposed
and pro~ecting beyond the ad~acent ends of dividers 13b prior
to each time sufficient heat is applied to the ends of the
pile strands in block lOb to effect melting thereof. It is
contemplated that the heating effect of heat source 100 may
be reduced or heat source 100 may be rendered inoperative
during each rearward pass of block lOb thereover, and that
a separate source of heat, not shown, may be provided
rearwardly of heat source 100 to effect the shrinking of
dividers 13b before block lOb passes forwardly over and is
subjected to heat from heat source 100 for melting the free
` ends of pile strands llb.
Of course, as explained heretofore with respect to
dividers 13 of the first embodiment of the invention, the
lower edges of dividers 13b may be subjected to a treatment
other than that effected by heat source 100 so as to fore-
shorten the di~iders 13b relative to strands llb prior to
melting their free lower ends.
The fabric F-b shown in Figures 6 and 7 is provided
with tufts T-b of carpet yarns or rovings, for example. The
fabric F-c of Figure 8 also is produced according to the method
.
~; of Figure 6 and includes a backing B-c, tufts T-c and fusible
:,,
connections lOlc between tufts T-c and backing B-c. Fabric
F-c differs from fabric F-b however in that the tufts T-c are
~- formed of synthetic continuous filament tows or slivers and
- thus may flare or blossom outwardly to a greater extent than
tufts T-b of Figure 7. In other respects, the fabrics F-b,
F-c may be the same and, therefore, a further description
thereof is deemed unnecessAry.
~,
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104;~333
It ls thus seen that I have provided a method of
making pile fabrics, such as carpets, rugs and the like, and
especially "shag" type pile fabrics, permittlng the use of
practically an~ kind of textile strand material for the pile
regardless of whether the material is highly compacted such
as highly twisted yarns, or the material is a very bulky
material such as crimped tow of fine denier monofilaments,
or slivers of synthetic or natural staple fibers. More
specifically, it can be seen that I have provided a method
of making pile fabrics in which a block 10 or lOb of rows
of substantially parallel strands 11 or llb of pile forming
material is provided in an open-ended container 12 or 12b
with the block having dividers 13 or 13b of sheet material
therein separating adjacent rows of the parallel pile
strands, and wherein the pile strand block is incrementally
fed parallel to the pile strand axes from the container 12
or 12b in successive increments of an amount equal to the
:~ desired length of pile, then the ends of the dividers are
treated to cause them to foreshorten or shrink and recede
relative to the adjacent ends of the pile strands so that
: -
--~ predetermined lengths of the pile strands are exposed and
:~- project beyond the adjacent ends of the dividers, whereupon
. each fed increment of pile strands 11 or llb and their fore-
~; shortened dividers 13 or 13b are severed transversely of the
pile strand axes while arranging the severed strands to
form cut pile tufts which are secured together in spaced
rows.
.'
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