Patent GB-1182458-A (GB)
Title: Nonwoven Textile Pile Material and Method for its Production
Inventor: KANTOROWICZ JOSEF
IPC: D04H11/00
Filed: 1967-03-28
Abstract: 1,182,458. Laminate pile fabric. J. KANTOROWICZ. 28 March, 1967 [28 March. 1966], No. 1.41.57/67. Heading B5N. A laminate comprises a carrier base 26, Fig. 2, and filamentary material 22 having thickened portions 23 embedded in at least one side of the base. The laminate is produced by temporarily bonding filamentary material 12, Fig. 1, to a base layer 10 with portions of the filamentary material protruding from the base layer, then thickening part of the protruding portions of the filamentary material while supported by the base layer, embedding the thickened portions 13, 23 in a base 26; firmly bonding the base to the embedded thickened portions, then removing the base layer 10. In one example for making a laminated carpet, soluble adhesive is applied by a roller to a paper web and staple fibres of polypropylene are dropped on to the paper web and are oriented electrostatically so that they are positioned substantially perpendicularly thereto. The web then passes beneath infra-red heaters which dry the adhesive, and beneath sharp-edged heating rods which touch the end portions of the fibres to thicken them. In a separate machine a jute web is passed beneath a container for P.V.C. from which P.V.C. is discharged on to the web, arid a fibrecoated paper web prepared as above is fed fibre face downwards on to the P.V.C. layer, the thickened portions of the fibres being pressed into the P.V.C. layer by a roller. The assembly thus formed passes through an oven to harden the P.V.C. and bond the assembly. Hot steam is then sprayed on to the paper web to soften the adhesive, and the paper web is then removed. In a second example, for making a mattress, undulate yarns are adhered to a paper web by a soluble adhesive, the adhesive is dried, the exposed crests of the yarns are thickened by applying a finishing or dressing agent thereto, and this agent is heat dried. A web of the material so formed is passed yarn side upwards beneath a polyurethane foam dispenser and receives a layer of foam to the opposite face of which a similar web is applied yarn side downwards, the latter web being pressed into the foam by a press roller. The assembly so formed is pressed in an oven to polymerize the foam and bond the layers and the paper webs are subsequently removed using steam as above. The now exposed crests of the yarns may now be thickened by a finishing or dressing agent which is hardened by heat before the material is cut into mattresses. In an alternative method, for producing a mattress with loops all over, the lower paper web is equal in width to the width plus twice the height of the foam layer, and is folded up at each side of the foam layer before hardening the latter. In other embodiments, the mat 26 is of foamed rubber, polyethylene or polystyrene, and when only one surface thereof has fibres embedded therein the other surface may be covered by a flexible or rigid, or perforated, or water- or air-tight, or anti-slip backing layer 27, e.g. of rubber, plastics foil, leather, wood, metal, or glass. The fibres may be staple or continuous, e.g. yarn waste, wool knop, or yarn threads and of animal or man-made origin or of cotton. If of synthetic material, the fibres may be thickened by a flame, and if of natural fibres by a synthetic resin solution or an enamel dye. The base layer 10 may be of a water or steam soluble thermoplastic deep drawn in a mould into which the foamable mat material is subsequently applied. The laminate formed may be used in upholstery, floor covering or fastenings.