Pile faced fabric

F. D. DODDS

PILE FACED FABRIC

Nov. 24, 1959

Filed Oct. 22, 1957

2,913,803

Sheets-Sheet 1

JWr-l-

<img file="US2913803A_D0001.tif" />

inventor:

FranKD.Dodds, ^BY

ATTORNEYS.

F. D. DODDS

PILE FACED FABRIC

Nov. 24, 1959

Filed Oct. 22. 1957

2,913,803

Sheets-Sheet 2

<img file="US2913803A_D0002.tif" />

inventor:

Frank Ό. Dodds, ^BY

ATTORNEYS.

2,913,803

Patented Nov. 24, 1959

United States Patent Office

2,913,803

PILE FACED FABRIC

Frank D. Dodds, Garden City, N.Y., assignor to Artloom Carpet Company, Inc., Philadelphia, Pa., a corporation of Pennsylvania

Application October 22, 1957, Serial No. 691,559

Claims. (Cl. 28—78)

This invention relates to pile faced fabric. More specifically, it is concerned with needle tufted pile faced fabric intended for use as carpeting.

The chief aim of my invention is to provide pile faced fabric which can be economically produced from relatively inexpensive material; which is resistive to rapid wear; which is attractive in appearance; which is immune against distortion or crushing; and which, withal, is soft to the tread.

Other objects and attendant advantages will appear from the following detailed description of the attached drawings, wherein:

Fig. 1 is a fragmentary view in longitudinal section of pile faced fabric embodying my invention in one form.

Figs. 2 and 3 are views similar to Fig. 1 showing two alternative embodiments of my invention.

With more specific reference first to Fig. 1 of these illustrations, my improved fabric, as there shown, is produced on an ordinary needle tufting machine and comprises a non-woven foundation layer 1 of felt which may be of animal or other suitable textile fibers, and is penetrated by the pile 2 which may be of cotton, wooi, rayon or of other synthetic fibers such as nylon or mixtures of such fibers. For firm anchorage of the pile 2, the foundation layer 1 is coated at the back with latex or other suitable adhesive as conventionally indicated at

3. The pile 2 may be left in the form of loops as at the left of the illustration, or it may be cut for creation of a tuft effect as shown at the right of the illustration. Moreover, the foundation layer 1 may be initially provided, as at 4, with a top facing of sponge fiber to insure a clean surface at the base of the pile and to promote the wearability of the fabric.

In the alternative embodiment illustrated in Fig. 2 the foundation comprises a bottom layer 5 of material woven from yarn 6 of jute and cotton or any other type or types or mixtures of textile fibers, and a superposed layer la of felt, the layer 5 being coated at the back with latex, as at 3a, for anchorage of the pile 2a. The felt 5 layer la may be provided initially with a top facing 4α of vinyl or the like to prevent dirt, water, and cleaning fluid or powder from seeping into the foundation layers la and 5. Preferably, the vinyl 4α will be colored to match or blend with the color or shade of the pile.

In the alternate embodiment of Fig. 3, the felt and woven layers lb and 5b, respectively of the foundation are reversed in position, i.e., the woven layer 5b is superimposed upon the felt layer lb. Here the felt layer lb is shown as being coated with latex as at 3b, and the 15 woven layer 5b top surfaced or impregnated initially, as at 4b, with vinyl or the like.

In all three instances, it will be evident that, due to incorporation of felt in the foundation, the fabric will be soft to the tread, will withstand hard usage without 2o becoming distorted or being easily crushed, and will retain its attractiveness over long protracted periods in service. Moreover, it will be seen, that, by reason of being formed in a needle tufting machine, the fabric can be produced rapidly in quantity at relatively low cost.