Pile fabrics and systems and methods for forming pile fabrics

a pile fabric and fabric technology, applied in the field of pile fabrics and the formation of pile fabrics, can solve the problems of reducing the ability to recycle spent or discarded pile fabrics, and wasting pile fabrics in landfills

Inactive Publication Date: 2021-09-23
PROGLOBAL PROD LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

The application of binders can be an expensive method and process for producing pile fabric with tuft bind and delamination.
Additionally, the utilization of such binders can reduce the ability to recycle sp...

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
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  • Pile fabrics and systems and methods for forming pile fabrics
  • Pile fabrics and systems and methods for forming pile fabrics
  • Pile fabrics and systems and methods for forming pile fabrics

Examples

Experimental program
Comparison scheme
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Embodiment Construction

[0044]As will be described in greater detail, pile fabrics, systems for forming pile fabrics and methods for forming pile fabrics preferably avoid the use of binder compositions, thus potentially reducing material and / or energy costs and enabling the recycling of a larger quantity of spent pile fabrics, which reduces the accumulation of pile fabric waste. In some applications, such as those that utilize olefin-based primary backing materials, thermal stability may be improved by heat stabilizing (pre-shrinking) the materials prior to use. In some applications, the omission of binder compositions is facilitated by a melt bond that secures pile tufts to a primary backing material of the pile fabric. The melt bond, which may be disposed only at the back side of the primary backing material, is formed of melted material of the back stitch portions of the pile tufts and melted material of a layer of thermoplastic material. In some applications, only the back of the pile fabric is heated ...

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Abstract

An example method for forming a pile fabric includes: providing a primary backing material (configured as a sheet), a layer of thermoplastic material (disposed at the back side of the primary backing material), and a plurality of pile tufts extending through the primary backing material and at least partially into the layer of thermoplastic material with back stitch portions of the pile tufts being disposed at the back side of the primary backing material; and heating only the back of the pile fabric to melt the back stitch portions of the pile tufts and the layer of thermoplastic material to form a melt bond disposed at the back side of the primary backing material to secure the pile tufts to the primary backing material.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This utility patent application claims the benefit of and priority to U.S. Provisional Patent Application 62 / 991,897, filed on 19 Mar. 2020, which is incorporated by reference herein in its entirety.BACKGROUNDTechnical Feld[0002]The disclosure relates to pile fabrics and the formation of pile fabrics.Description of the Related Art[0003]Pile fabrics (which include tufted carpets, carpet tiles, artificial turf, rugs and mats, for example) generally are formed of pile tufts that are stitched into a backing layer and then bonded to the backing layer by a binder. Currently in the art, binders such as styrene butadiene rubber, vinyl acetate ethylene, natural rubber, hot melt thermoplastics and polyurethane are utilized to create a tuft bind and delamination in the pile fabric. The application of binders can be an expensive method and process for producing pile fabric with tuft bind and delamination. Additionally, the utilization of such binders...

Claims

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Application Information

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IPC IPC(8): D05C17/02D06N7/00
CPCD05C17/023D06N7/0065D06N2205/06D05D2305/30D06N7/0068A47G27/00D06N7/0076D06N7/0081E01C13/08
Inventor PAYNE, BARCLAYJAQUITH, FORREST
Owner PROGLOBAL PROD LLC
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