# US 4,391,866 A · Cut pile fabric with texturized loops > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 4,391,866 A - Document ID: US4391866A - Status: Granted - Kind: A - Application number: 06/328,970 - Filed: 1981-12-09 - Granted: 1983-07-05 - Earliest claimed: 1980-06-16 - Assignees: Ozite Corporation - Inventors: Robert C. Pickens, Jr.; Reese R. Thomas; Ronald Somerville - Web page: https://patentgrep.com/patent/US4391866A ## CPC - D04H 11/08: formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking (needling machines D04H18/00) - D04H 1/485: in combination with weld-bonding - D04H 1/64: the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions - Y10T 428/23957: Particular shape or structure of pile - Y10T 428/23964: U-, V-, or W-shaped or continuous strand, filamentary material - Y10T 428/23971: Continuous strand with adhesive bond to backing - Y10T 428/23979: Particular backing structure or composition - Y10T 428/23993: Composition of pile or adhesive - D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A novel cut pile fabric (10) and a method of making same is disclosed. The cut pile fabric (10) includes a needled non-woven batt (14) of staple fibers (12) that is processed on a texturizing needle loom (17) from one surface (20) (called a back surface) thereof to form texturized loops (18) on the other surface (22) (called a face surface) of said batt (14). The non-textured back surface (20) of the batt (14) has a backing (24) applied thereto which may be of latex, or the like, with the texturized loops (18) being tigered by a tigering roll (28) to cut, break or fracture a high percentage of the loops. The tigered pile is polished by a polishing roll (34) to remove the crimps in the fibers and to orient the fibers in a direction transverse to the batt (14) prior to being sheared in a shear (36). A dense, plush cut pile fabric is produced. ## Claims ### Claim 1 A cut pile fabric comprising: a needled batt of non-woven staple fibers, texturized loops of stable fibers formed from the staple fibers of said batt extend outwardly from one surface of the batt, the texturized loops of fibers are comprised of a plurality of clusters of loops of fibers with each cluster containing a plurality of different sized loops of fibers, backing means on another surface of said batt for securing fibers of said texturized loops to the fibers of said batt, a substantial portion of the fibers of said texturized loops being cut to form cut pile, and said cut pile being polished and sheared to provide a fabric with a plush cut pile. ### Claim 2 (depends on 1) A cut pile fabric as claimed in claim 1 wherein said staple fibers are selected from the group consisting of polypropylene, nylon and polyester. ### Claim 3 (depends on 1) A cut pile fabric as claimed in claim 1 wherein said staple fibers are of a length within the range of 2" to 4". ### Claim 4 (depends on 1) A cut pile fabric as claimed in claim 1 wherein said cut pile has a depth within the range of 1/8" to 3/4". ### Claim 5 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. ### Claim 6 (depends on 5) A cut pile fabric as claimed in claim 5 wherein said cut pile is polished to straighten and to orient the fibers of the pile. ### Claim 7 (depends on 6) A cut pile fabric as claimed in claim 6 wherein said polished cut pile is sheared to provide a uniform pile depth. ### Claim 8 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. ### Claim 9 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. ### Claim 10 (depends on 9) A method of manufacturing a cut pile fabric as claimed in claim 9 wherein said cut pile is polished to remove crimps and to orient said cut pile in a direction transverse to the plane of said batt. ### Claim 11 (depends on 10) A method of manufacturing a cut pile fabric as claimed in claim 10 wherein said polished cut pile is sheared to a predetermined pile height. ### Claim 12 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.