Tufted carpenting with unitary needlebonded backing and method of manufacturing the same
AssigneeBrunswick Corporation
InventorsRichard Kimmel, Robert C. Pickens, Jr.
Life of this patent
Estimating the term…
Abstract
Tufted carpeting has a unitary primary backing comprising a woven synthetic scrim with a backing layer of staple fibers needled onto its back surface before tufting. The tuft bases are at least partially surrounded by the fibers of the backing layer, and sizing is applied to the underside of the carpet after tufting. The resulting product has excellent dimensional stability, stiffness and flame retardance, and requires no secondary backing. In the preferred embodiment, the staple fibers are needled through the scrim to provide, in addition to the backing layer, a dyeable subface on the face side.
Claims4
A ribbon scrim tufted carpet having a unitary backing with two staple faces that does the job of both a primary backing and secondary backing, the carpet comprising:
- a. a unitary backing with two staple faces having:
- 1. a woven ribbon scrim with a first scrim side and a second scrim side, and
- 2. a deposit layer of staple fibers needled through the scrim to form a bottom fiber layer on one of the scrim sides and a subface fiber layer on the other scrim side, the bottom fiber layer being thicker than the subface fiber layer;
- and
- b. yarn tufted through the unitary backing from the side having the bottom fiber layer to develop tufts, the tufts so developed:
- 1. being partially surrounded by fibers of bottom fiber layer to provide better tuft lock, and
- 2. extending above the subface fiber layer.
A method of manufacturing ribbon scrim tufted carpeting using a unitary backing with two staple faces to do the job of both a primary backing and a secondary backing, the method comprising the steps of:
- a. providing a unitary backing with two staple faces by steps comprising:
- 1. providing a woven ribbon scrim having a first scrim side and a second scrim side,
- 2. depositing a deposit layer of staple fibers on the first scrim side, and
- 3. needling a portion of the deposit layer through the scrim to form a bottom fiber layer on one of the scrim sides and a subface fiber layer on the other scrim side, the bottom fiber layer being thicker than the subface fiber layer;
- and
- b. tufting yarn through the unitary backing from the side having the bottom fiber layer to develop tufts, the tufts so developed:
- 1. being partially surrounded by fibers of the bottom fiber layer to provide better tuft lock, and
- 2. extending above the subface fiber layer.
Dependencies are inferred from the claim text.