BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an embodiment of a tufted carpet of the present invention;
FIG. 2A is a top-view schematic illustration of a linear bead formed across the width of the tufted carpet;
FIG. 2B is a top-view schematic illustration of adhesive or polymeric material spatially localized in the vicinity of the position at which adjacent strands are proximate;
FIG. 3 is a schematic illustration of a system for forming the tufted carpet of the invention;
FIG. 4A provides a perspective view of a variation of an adhesive or polymeric material applicator nozzle useable to apply adhesive or polymeric material to the tufts of the present invention via a slot;
FIG. 4B is a perspective view of a variation of an adhesive or polymeric material applicator nozzle used to apply adhesive or polymeric material to the tufts of the present invention via a plurality of orifices;
FIG. 5 is a schematic illustration of a variation of an adhesive or polymeric material applicator nozzle using air to spray the adhesive or polymeric material;
FIG. 6 is a schematic illustration of a variation of the tufting system described in connection with FIG. 3;
FIG. 7 is a schematic illustration of another variation of the system described in connection with the system of FIG. 3; and
FIG. 8 is a schematic illustration of a variation of the application of adhesive or polymeric material to the tufts used in various embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to presently preferred compositions or embodiments and methods of the invention, which constitute the best modes of practicing the invention presently known to the inventors.
The term “tuft” as used herein means projections of yarns drawn through a fabric or making up a fabric so as to produce a surface of raised loops or cut pile.
The term “cut pile” as used herein refers to a type of carpet in which the yarn loops are cut to create a textured look and feel.
The term “yarn” as used herein refers to a bundle of fibers that is twisted together to form a continuous strand.
With reference to FIG. 1, a schematic illustration of an embodiment of a tufted carpet of the present invention is provided. Tufted carpet 10 includes primary backing 12 to which a plurality of tufts 14 are attached. The plurality of tufts 14 comprise a plurality of flexible strand sections. In a variation of the invention, a plurality of tufts 14 is formed from a yarn. Examples of suitable material from which the yarns are formed include, but are not limited to, nylon yarns, polypropylene yarns, polyester yarns, and the like. In a variation of the primary embodiment, primary backing 12 is a fabric or textile. Examples of materials from which primary backing 12 is formed include, but are not limited to, polyester, polypropylene, nylon, and combinations thereof. Adhesive or polymeric material 16 attaches adjacent tufts together. Adhesive or polymeric material 16 comprises any material that is capable of adhering adjacent tufts together. Examples of such materials include but are not limited to, latex. FIG. 1 illustrates a variation of the carpet in which the piles are cut thereby forming a cut pile carpet. In another variation of the invention, the piles are not cut (see FIG. 3 below).
Still referring to FIG. 1, each of a plurality of flexible strands are attached to primary backing 12 by passing each end of a given strand through different openings in primary backing 12. For example, consider adjacent strands 14′, 14″, and 14′″. Strand section 20 of yarn 14′ and strand section 22 of strand 14″ pass through opening 24 in primary backing 12. Strand 14′ is attached to adjacent strand 14″ by adhesive or polymeric material 16′. Strand section 30 of strand 14″ passes through adjacent opening 32, forming strand loop 34 positioned on back side 36 of tuft carpet 10. Loop 34 is a base for the tufts with ends edge emanating therefrom. Similarly, strand section 40 of strand 14′″also passes through opening 32. Strand 14″ is attached to adjacent strand 14′″ by adhesive or polymeric material 16″. This pattern of attaching adjacent strands with one end from each adjacent strand passing through the same opening in primary backing 12 and being attached to each other with an adhesive or polymeric material is repeated throughout tufted carpet 10. Accordingly, the ends of strands 14 are visible from face side 42 of tufted carpet 10.
With reference to FIGS. 2A and 2B, variations of the attachment of adjacent strands together in accordance with the present invention are provided. FIG. 2A provides a top schematic illustration of a linear bead of adhesive or polymeric material formed across the width of the tufted carpet. In this variation, adhesive or polymeric material that attaches adjacent strands together is formed into rows 50 that are substantially perpendicular to machine direction d1. Machine direction d1, is the direction that tufted carpet 10 transverses during the tufting process. In this variation, the rows of adhesive or polymeric material contact primary backing 12 between successive rows of tufts. FIG. 2B provides a top schematic illustration of adhesive or polymeric material 54, spatially localized in the vicinity of the position at which adjacent strands are proximate. In this variation, there is minimal contact of the adhesive or polymeric material to primary backing 12. In another variation of the of the invention, linear beads of adhesive or polymeric material are applied to form rows substantially parallel to the machine direction.
With reference to FIG. 3, a schematic illustration of a system for forming the tufted carpet set forth above is provided. Tufting systems 60 includes tufting needle 62, which moves substantially along direction d2 as flexible strand 64 is punched through primary backing 66. During tufting, primary backing 66 moves along machine direction d1. After being punched through primary backing 66, flexible strand 64 passes through openings 70 in primary backing 66 which two strands section 72, 74 pass through each of the openings 70 to form tufts 76. Adhesive or polymeric material applicator nozzle 78 is used to apply adhesive or polymeric material 80 on back side 82 at a position in the vicinity of openings 70 from which strand section emanate from back side 82 to face side 84. Strand loop 86 is located on back side 82 between adjacent openings 70 while strand loops 88 are located on the face side of the carpet. If tufts 76 are not cut, the resulting carpet is a loop pile carpet. In a variation of the present embodiment, tufting system 60 includes tuft cutter 90 which cuts the tops off of tufts 76 to form cut pile tufted carpet 92. Tufted carpet 92 includes a plurality of strand sections 94, 96 (with the tops cut off) passing through openings 70. The details of the composition of primary packing 66, flexible strand 64, and adhesive or polymeric material 80 are the same as that set forth above in connection with the description of FIG. 1.
With reference to FIGS. 4A and FIG. 4B, variations for adhesive or polymeric material applicator nozzle 78 are schematically illustrated. FIG. 4A provides a perspective view of a variation of adhesive or polymeric material applicator nozzle 78 in which adhesive or polymeric material passes through slot 100 while being applied to tufts 76. In a further refinement of this variation, the application of adhesive or polymeric material is pulsed so that material is applied when the adjacent strand sections are under application nozzle 78 to produce a distribution of material as illustrated in FIG. 2A. FIG. 4B provides a perspective view of a variation of adhesive or polymeric material applicator nozzle 78 in which adhesive or polymeric material passes through orifices 102 while being applied to the tufts 76. In a further refinement of this variation, the application of adhesive or polymeric material is pulsed so that material is applied when the adjacent strand section is under application nozzle 78 to produce a distribution of material as illustrated in FIG. 2B.
With reference to FIG. 5, a schematic illustration of another variation of adhesive or polymeric material applicator nozzle 78 is provided. In this variation, adhesive or polymeric material is sprayed or expelled onto the carpet using orifice(s) 102. In this variation, adhesive or polymeric material enters the nozzle 78 through inlet port 104. Expulsion of the adhesive or polymeric material is gas assisted with a gas such as air or nitrogen being introduced into the inlet port 108.
With reference to FIG. 6, a variation of the tufting system described in connection with FIG. 3 is provided. In this variation, the motion of tufting needle 62 along direction d2 is utilized to apply adhesive or polymeric material to the carpet. Pusher section 110 moves in unison with needle 62 contacting piston 112 so that adhesive or polymeric material is pushed out of nozzle 78 and applied to the carpet.
With reference to FIG. 7, a schematic illustration of a variation of the system described in connection with the system of FIG. 3 is provided. In this variation, the adhesive material is provided from reservoir 120 to nozzle 78 via fluid control device 122. Such flow control devices include, but are not limited to, gear pumps, mass flow controllers, and the like. Optionally, gas is used to assist the application of adhesive or polymeric material to tufts 76. Such gas is introduced via gas inlet 126. The gas/material combination enters nozzle 78 via inlet port 128.
With reference to FIG. 8, a schematic illustration of the application of adhesive or polymeric material to tufts 76 is provided. FIG. 7 provides a cross-section view substantially parallel to the tufting machine direction d1. In this variation, nozzle 78 applies adhesive or polymeric material 80 in a wedge-like manner to tufts 76 building up on one side of tufts 78.
In yet another embodiment of the present invention, a method for making the tufted carpet of the present invention is provided. The method of this embodiment comprises forming a plurality of tufts by punching a flexible strand through the primary backing. Next, an adhesive or polymeric material is applied to the plurality of tufts at a position such that the adhesive or polymeric material contact adjacent tufts at the position proximate to the openings and the back side of the primary backing. In variations of the present invention, the systems described in connection with FIGS. 3-8 are advantageously utilized.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.
Patent Application
20070292655
