Cut pile fabric with texturized loops

A cut pile fabric comprising:

• a needled batt of non-woven staple fibers having a face surface and a back surface,
• a plurality of clusters of loops of non-woven staple fibers formed from the fibers of said batt and projecting outwardly from said face surface of the batt, each cluster of loops containing a plurality of different sized loops of fibers,
• backing means on said back surface of the batt securing the fibers of said clusters of loops to the fibers of said batt, and
• a substantial portion of said loops being cut to form cut pile.

A method of manufacturing a cut pile fabric comprising the steps of:

• lapping and needling non-woven staple fibers into a batt,
• forming from the staple fibers of said batt texturized loops of fibers projecting from one surface of the batt, with the loops being formed in clusters which are aligned in the cross-machine direction and in the machine direction,
• applying a backing on another surface of the batt for securing the stable fibers of said texturized loops to said batt,
• tigering said texturized loops to cut a substantial portion of said loops to form cut pile,
• polishing said cut pile to straighten the pile and to orient the cut pile in a transverse direction with respect to said batt, and
• shearing said cut pile to a predetermined pile height.

A method of manufacturing a cut pile fabric comprising the steps of:

• lapping and needling non-woven stable fibers to form a batt,
• texturizing said batt to form a plurality of clusters of loops of fibers from the fibers of said batt and projecting from one surface of the batt, each cluster having a plurality of different sized loops of fibers,
• applying a backing on another surface of the batt for stiffening said batt and for securing the staple fibers of said loops to said batt, and
• cutting a substantial portion of said loops to form cut pile on the batt.

A method of manufacturing a cut pile fabric comprising the steps of:

• lapping and needling non-woven staple fibers into a batt,
• texturizing between 20% and 65% by weight of said batt on a texturizing needle loom to form a plurality of clusters of loops of fibers projecting from one surface of the batt, each cluster having a plurality of loops of different sizes,
• applying a backing selected from the group consisting of latex, sintered polyethylene, thermoplastic sheeting or fushion to another surface of the batt for stiffening said batt and for securing the staple fibers of said clusters of loops to said batt,
• tigering said clusters of loops of fibers by cutting a substantial portion of said loops to form cut pile,
• polishing said cut pile to orient said cut pile transversely with respect to said batt, and
• shearing said last-named individual fibers to a predetermined pile height.