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Патент USA US3066523

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Dec. 4, 1962
H. S. LEYBOURNE
3,066,513
KNITTED CARPET
Filed March 28, 1960
LA
TA
?A
ilnited States Patent O??ce
1
3,066,513
KNITTED CARPET
Harold S. Leyhourne, Wiilowdale, Ontario, Canada, as
signor to Texama Limited, Toronto, Ontario, Canada, a
corporation of Ontario, Canada
Filed Mar. 28, 1960, Ser. No. 18,128
1 Claim. (Cl. 66--1�
3,65 6,513
Patented Dec. 4, i�
2
circular knitted fabric is then subjected to a scouring or
cleansing treatment after which the fabric is opened to
a ?at width for processing. This step is followed by a
napping operation or pile rising, and it is one in which
care must be given in order to obtain the full rich cover
desired and needed for the end use of the fabric. The
length of the pile is then established by a close shearing
or cropping process in order to obtain the desired pile
This invention relates to improvements in floor cover
height.
ings or carpets.
10
The accompanying drawing shows how the layin is
More particularly, the invention relates to a knitted
formed in the loops in the knitting process. The pile
floor covering or carpet having a durable resilient backing
yarns are designated A and de?ne the surface ply while
of sponge rubber or like material.
the knitted threads of the weft knitted fabric are desig
It is believed that the particular ?oor covering de
nated B and are of 1/ l6?s carded cotton dyed to resemble,
15
scribed herein has never been successfully accomplished
as nearly as possible, the facing of the ?nished carpet.
before. An aspect which makes it particularly feasible
As has been said the layin A is made up of a blend con
and attractive to the consumer is the addition of the foam
sisting of approximately 70% nylon and 30% rayon. The
rubber or similar backing.
rayon is dope dyed and the nylon kettle dyed. This un
The main disadvantage in the provision of the thick
usual blending of ?bres prepared on the conventional
living room or executive type of carpet presently obtain
woolen yarn system yields a thread which is very strong,
able is decidedly one of expense. Carpets of this type
lofty and adapts itself to future operation and end re
are almost out of reach of the average man?s income at
sult.
the present time.
It will be appreciated that various other ?bres, ratios
The present invention is comparatively cheap and ex
and blends may be employed, for instance, mohair or any
tremely useful. It is also wear resistant and will ?ll a 25 synthetic or animal ?bre may be used but it has been
public need from the standpoint of economy.
found that a ratio of approximately 70% nylon and 30%
Therefore, an object of this invention is to provide the
rayon produces the best results.
combination of a knitted carpet having a resilient backing
An important feature in the manufacture of the inven
of sponge rubber, or the like, which will also act to pre
tion is the manner in which the cotton back and the pile
vent slipping or creeping of the carpet.
yarns, which are the face, are inter-connected, thus form
According to the present invention a floor covering
ing a ?rm fabric 'which will withstand the action of raising
or the like comprises an intermediate ply of a weft knitted
fabric de?ning a surface backing ply, a surface ply or
layer of pile yarns laid in one surface of the weft knitted
fabric, there being at least two pile yarns interconnected
to each course of the knitted fabric, without being knitted,
at spaced points along the course, and a base layer in
tegrally combined or bonded with the opposite surface
of the weft knitted fabric. The pile yarns are raised and
de?ne a pile surface on the side of the intermediate layer 4-0
or pile opposite the base layer.
There is no special novelty residing in the process in
volved in the production of the present invention or the
machinery employed in the process. Applicant has
knitted a circular knitted fabric with the kinds of mate
the pile.
The foam rubber backing or base layer C may be ap
plied directly to the back of the fabric and spread by
means of a doctor blade. The foam is then cured on the
fabric in drying ovens. A sponge rubber could also be
employed as the backing or base layer C for the knitted
carpet and in this event it would be applied by a calender
roll.
The nature of the backing layer C may vary with the
preference of the manufacturer. While a wide variety of
plastics and elastomers may be used such as rubber and
synthetic rubber in unaerated form, polyvinyl chloride,
and the like, it has been found best to employ aerated
plastics and elastomers such as sponge or foam rubber.
rials normally used in carpets rather than the kinds and
It will be understood that the employment conditions
types normally used on knitting machines. This is be
of vulcanizing will depend on the character of the back
lieved to be a complete departure from the previous uses
ing material which is employed.
of a circular knitting machine.
A sponge or foam backing produces a very desirable
50
In the process of producing the present invention, it
resiliency in the tread of the carpet.
has been found preferable to obtain a blend comprising
The sponge rubber backing or base layer C may also
approximately 70% nylon and 30% rayon. This ratio
be applied to the underside of the cotton backing by vul
provides an end product which Wears particularly well
canized rubber cement or by any other suitable adhesive.
and has a very good appearance. Having obtained this
In this event, the fabric is ?rst knitted as described and
ratio the blended ?bres are then subjected to a carding
then the backing is coated with an application of cemen
process. This process will be well known to a man skilled
titious binding material. The sponge rubber layer C
in the art.
which has been cut to size is then applied to the cement
Following the carding process the blended ?bers in the
and the cement is allowed to set for a reasonable period
form of strands of material are wound onto spinning
to secure adhesion. After vulcanization, the composite
frames and subjected to a cone 'winding process. At this
stage of the process, the individual blended strands of
carpets are trimmed to exact size as required.
It may be restated in conclusion that during the knit
ting and ?nishing process of the fiber yarns, the blended
pile yarn is combined with the intermediate ply of knitted
cular knitting machine along with a series of cotton hold 65 cotton strands after which the resilient base layer or ply
ing cones. The circular knitting machine operates in a
is integrally bonded to form a ?nished carpet being of
manner well known to a man skilled in the art. The
?ne appearance, resilient, and extremely wear resistant.
presence of the cotton in the knitting process provides a
I claim:
knitted fabric having a cotton backing in which the nylon
A floor covering or the like comprising: a ?at inter
rayon yarns are incorporated without being themselves
mediate ply including a weft knitted fabric having courses
knitted. Nylon or acrilon may also be used to provide
and wales, a surface ply on one side of said weft knitted
an intermediate ply or backing instead of cotton. The
fabric and including at least two pile yarns laid in each
?bres are wound onto separate cone shaped holders. The
?bre holding cones are then set up on a conventional cir
3,066,513
4,
course of said weft knitted fabric, one of said two pile
yarns of each course being interconnected to the course
without being knitted at spaced points along the course
and the other of said two pile yarns of each course being
interconnected to the course 'Without being knitted at 6
spaced points along the same and at spaced points from
the points of interconnection of said one pile yarn, said
pile yarns being raised and de?ning a- pile surface for the
?oor covering, and a resilient base layer ply integrally
bonded to the opposite side of the Weft knitted fabric.
References Cited in the ?le of this patent
UNITED STATES PATENTS
561,558
2,388,140
2,480,004
2,531,718
2,622,998
2,836,970 I
Bellis ________________ __ June 9, 1896
Hall ________________ __ Oct. 30, 1945
Dildilian _____ _._' ______ .__ Aug. 23, 1949
Rice ________________ __ Nov. 28, 1950
Stahl ________________ .. Dec. 23, 1952
Deiss et al _____________ __ June 3, 1958
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