Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1998-03-18
2001-03-20
Dixon, Merrick (Department: 1774)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S073200, C156S166000, C156S173000, C156S271000
Reexamination Certificate
active
06203636
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method, and the article produced thereby, for imparting a graphic design to a substrate, such as a pile fabric used as a floor or wall covering, wherein the graphic design is in the form of an elongated pile article having a plurality of filament bundles attached to an elongated support strand.
2. Description of the Prior Art
It is believed desirable in some instances to enhance the aesthetics of a living or work space by imparting a graphic design to the fabric coverings on the floor or walls of the space. The fabric covering for a floor can take the form of a wall-to-wall carpet or an area rug. Both the wall-to-wall carpet or an area rug typically have a support backing and a pile yarn surface. The pile yarn surface of a fabric floor covering may be customized with inlaid yarns. Heretofore, this customization requires the removal of pile yarns in order for the pile yarn surface to receive the inlay yarns. In view of the foregoing, it is believed to be desirable to impart a graphic design to a pile yarn surface without the need to remove pile yarns.
SUMMARY OF THE INVENTION
The present invention relates to a method for imparting a graphic design to a substrate, and to the article produced thereby. Preferably, the substrate is a fabric, such as a pile fabric, that includes a support backing having pile yarns extending therefrom. The predetermined graphic design is configured as a decoration or at least one alphanumeric symbol. In accordance with the present invention the predetermined graphic design is imparted by positioning an elongated pile article on the substrate in the configuration of the predetermined graphic design and attaching the article to the substrate. The elongated pile article has a plurality of filament bundles attached to an elongated support strand. When attached to the substrate the filament bundles of the elongated pile article project from the surface of the substrate. The elongated pile article may be attached to the substrate by ultrasonic bonding, sewing, gluing with a hot melt adhesive, or by mechanical attachment using staples or plastic attachment fasteners.
The invention also relates to a transfer sheet for imparting a predetermined graphic design to a substrate. The transfer sheet comprises a planar foundation layer formed of a fusible material having an elongated pile article attached thereto in the configuration of a predetermined graphic design. The melting temperature of the planar foundation layer is lower than the melting temperatures of the fabric, the support strand and the filament bundles. Preferably, the planar foundation layer is formed of a translucent material.
To impart a predetermined graphic design to a substrate using the transfer sheet, the transfer sheet is positioned at a predetermined location on the substrate, and ultrasonic energy is applied to the elongated pile article thereby attaching the elongated pile article to the fabric and simultaneously melting the planar foundation layer in the vicinity of the elongated pile article. Thereafter, the unmelted, remaining portion of the planar foundation layer is removed from the substrate.
REFERENCES:
patent: 3884743 (1975-05-01), Kunak et al.
patent: 4733864 (1988-03-01), Casteel
patent: 4911773 (1990-03-01), Leighton
patent: 5470629 (1995-11-01), Mokhtar et al.
patent: 5472762 (1995-12-01), Edwards et al.
patent: 8505767 (1987-06-01), None
patent: 25 06 720 (1976-08-01), None
Edwards Mark Stephen
Popper Peter
Walker William Charles
Dixon Merrick
E.I. Du Pont de Nemours and Company
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