Tufted fabric with embedded stitches

• US 7,431,974 B2
• Filed: 01/15/2005
• Issued: 10/07/2008
• Est. Priority Date: 01/17/2004
• Status: Expired due to Fees

• Current Assignee: Tuftco Corporation
• Original Assignee: Tuftco Corporation
• Inventors: Lovelady, Brian, Frost, Steven, Boyd, Ernest S
• Primary Examiner(s): JUSKA, CHERYL ANN
• Application Number:
  US11/036,900
• Publication Number:
  US 20050160955A1
• Time in Patent Office: 1,361 Days
• Field of Search: 428/88, 428/89, 112/80.01, 112/80.7, 112/475.23
• US Class Current: 428/89
• CPC Class Codes: D05C 15/32 by altering the loop length
• CPC Class Codes: D05C 17/026 characterised by the tufted pile surface
• CPC Class Codes: Y10T 428/23929 Edge feature or configured or discontinuous surface
• CPC Class Codes: Y10T 428/23936 Differential pile length or surface

Abstract

The present invention provides for tufted needlefelts with partially or totally obscured loop bights that provide good tuft bind.

Claims

1. A tufted fabric having a face and an opposite back surface defining a thickness there between wherein

a first group of tufted bights of yarn extend from the face;

a second group of tufted bights of yarn extend through the thickness of the fabric to about the face; and

a third group of tufted bights extend into the thickness of the fabric but do not extend to the face such that the back surface has back stitches for stitches forming the first, second and third groups of tufted bights of yarn.

2. The tufted fabric of claim 1 wherein the fabric is a needlefelt.

3. The tufted fabric of claim 1 wherein the thickness is between 1 and 7 millimeters.

4. The tufted fabric of claim 3 wherein the thickness is between 1.5 and 2 millimeters.

5. The tufted fabric of claim 1 wherein the weight of the yarns forming first, second and third groups of bights and associated backstitches is between 5 and 30 ounces per square yard.

6. The tufted fabric of claim 5 wherein the weight of the yarns forming first, second and third groups of bights and associated backstitches is between 12 and 17 ounces per square yard.

7. The tufted fabric of claim 1 wherein a binder is applied to the back surface and cured such that the resulting tufted fabric has substantially uniform tuft bind.

8. The tufted fabric of claim 7 wherein the binder is selected from the group of latex and polyurethane.