Carpet backing components and methods of making and using the same
AssigneeWayn-Tex, Inc.
InventorsKirk D. Smith, Gary T. Graves
Life of this patent
Estimating the term…
Abstract
A carpet backing, such as a primary carpet backing is a composite material comprising a woven fabric mechanically coupled to a bonded non-woven fabric. The woven fabric component may include monofilament warp yarns and monofilament fill yarns. The yarns may be woven using a plain weave. The bonded non-woven fabric component comprises synthetic fibers. The carpet backing combines the dimensional stability of non-woven fabric backings and the healability of woven fabric backings.
Claims22
A method of making a carpet comprising the steps of:
- forming a primary backing by needle-punching a woven fabric component having warp and fill yarns to a bonded non-woven fabric component, wherein the weight ratio of the woven fabric component to the non-woven fabric component is between about 1 to about 5, said backing having a dimensional stability of about 3 pounds to about 20 pounds, wherein the dimensional stability is determined by grabbing and pulling the backing at a 45 degree angle in relation to the warp and fill yarns of the backing such that the backing incurs approximately a 5% elongation;
- and
- thereafter, inserting a piling yarn through the primary backing.
The carpet of claim of 1, further comprising a secondary backing attached to the primary backing.
A method of making a carpet comprising the steps of:
- forming a primary backing by needle-punching a woven fabric component having warp and fill yarns to a bonded nonwoven fabric component, said woven fabric component having a weight of about 2 ounces per square yard to about 8 ounces per square yard and a weave construction of between about 20 ends per inch to about 35 ends per inch and between about 10 picks per inch to about 30 picks per inch, wherein said warp yarns, said fill yarns, or combinations thereof comprise synthetic fibers, wherein the weight ratio of said woven fabric component to said nonwoven fabric component is between about 1 to about 5, wherein said primary backing has a dimensional stability of about 3 pounds to about 20 pounds as determined by grabbing and pulling the backing at a 45 degree angle in relation to the warp and fill yarns of the backing such that the backing incurs approximately a 5% elongation;
- and
- thereafter, inserting a piling yarn through the primary backing.
Dependencies are inferred from the claim text.