Met Ribbon

pp woven bag

SUMMARY OF THE WOVEN BAG

In its broadest aspect, this invention relates to a woven bag having a synthetic warp and fill members, at least one of the members being heavily fibrillated. In another aspect, this invention relates to a synthetic woven carpet backing fabric having synthetic warp and fill members, at least one of the members being heavily fabrillated. In still another aspect, this invention relates to a synthetic woven fabric, useful as a backing in a carpet fabric or the like, having as one of its warp and fill members a substantially unfibrillated or an unfibrillated ribbon and a heavily fabrillated ribbon as the other member. In yet another aspect, this invention relates to a synthetic primary or secondary backing for carpets and the like, comprising polyolefin ribbon as the warp or fill member, heavily fibrillated polyolefin ribbon as the other member, characterized by a delamination strength greater than 7.5 pounds when laminated to a faced fabric structure such as a soft carpet fabric. In yet still another aspect, this invention relates to a carpet structure comprising a ground member or primary backing, face materials such as a face pile secured to the ground member and a woven secondary backing laminated to the faced ground member, the secondary backing comprising polyolefin ribbon as the warp or fill component and heavily fabrillated polyolefin ribbon as the fill or warp component, the delamination strength of the secondary backing being in excess of 7.5 pounds, the tensile strength of the fabric in the heavily fabrillated member direction being in excess of 25 pounds and of the other member being in excess of 30 pounds.

In another aspect, this invention relates to a method of making a synthetic fabric useful as a primary or secondary carpet backing comprising weaving synthetic ribbon warp or fill members and a heavily fabrillated fill or warp member into the fabric described above and treating the fabric by brushing and/or needling to raise the ends of the fibrils of the fabrillated warp or fill above the surface of the fabric and thereafter laminating it to a pile fabric as above described for its use as a secondary backing.

DESCRIPTION OF THE INVENTION

In the manufacture of quality pile fabrics such as carpets and the like, a face is secured to a fabric which can be denominated the ground member or primary backing as by weaving, tufting or needle-punching a staple fiber thereinto. An adhesive, often rubber latex, or the so called hot melt adhesives, is then applied to the backside and a second backing denominated the secondary backing is laminated thereto. Until recently, the secondary backing in quality pile fabrics, particularly carpet fabrics, was almost exclusively a jute fabric. This natural material however, is now in relatively short supply and attempts have been made to prepare synthetic secondary backings to replace those heretofore made of jute. The criteria for a successful material are that it should not only perform like a jute fabric in terms of adhesion and fabric strength but, perhaps most importantly, it should be as inexpensive as jute.

In terms of price and strength, the polyolefins in particular among synthetics, are extremely attractive and offer in addition, their renowned resistance to chemicals, water, mildew etc. The use of polyolefins has not met with complete success however, mainly because of their poor adhesive qualities and because polyolefin materials treated so as to improve adhesion either have no fabric strength or have an aesthetically unacceptable appearance.

The present invention is predicated on a discovery that a broadly utilitarian fabric can be prepared which is woven from synthetic components and has the combination of good strength, where required, the appearance and low cost of a jute fabric and good adhesion when used as a synthetic secondary backing for pile fabrics such as carpets and the like.

The fabric is preferably woven in a conventional plain weave using synthetic ribbons as either the warp or fill members and heavily fabrillated material as the other members. Other weave constructions, for example, twill, broken twill, satin or sateen, basket, etc., can all be used to good advantage and may sometimes be preferred if it is desired to have more or less fabrillated material exposed on one side of a fabric. In general, almost any weave construction known to the textile artisan can, with his ordinary skill, be used in carrying out the invention. In the following description all fabrics are plain weave as this is a most common weave construction, is broadly used, and is a most durable, strong, firm and most dimentionally stable method of interlacing warp and fill components into a fabric.

When the fabric is intended to be used as a secondary backing, it is usually woven so as to have an open structure to facilitate passage of the adhesives normally used to adhere the backing to pile fabrics or carpet structures. In this context, the weave can be one that has from about 10 to about 30 ribbon ends per inch (warp) or picks (fill), of about 500 to about 1000 denier and from about 8 to about 12 heavily fabrillated ribbon picks (fill) or ends per inch (warp) of about 800 to about 2800 denier. Useful secondary backings are obtained when the fabric has 12 ribbon warp ends per inch and 9 heavily fabrillated fill picks (12 × 9), as well as when the fabric has 14 to 15 ribbon warp ends per inch and about 9 heavily fabrillated fill picks (14 × 9). Useful primary backings are obtained when the fabric has from 10 to about 30 warp ends per inch and from about 6 to about 12 heavily fabrillated fill picks. The weaving specifics are not critical, and as noted above are considered to be within the skill of the art and will depend upon the characteristics desired for the resultant fabric in its end use.

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