Inventors:
Mark Edwards - Hockessin DE, US
Robert Brown - Boothwyn PA, US
William Sherman - Wilmington DE, US
International Classification:
B32B003/02, D04H011/00
US Classification:
428/092000, 428/097000, 428/371000
Abstract:
An apparatus or method for forming a pile assembly without the use of additional materials as an adhesive or preformed core, and the products/articles made therefrom. The method and apparatus uses the beam or base member of the elongated pile sub-assemblies (e.g. tuftstrings or rooted tuftstrings) to form a continuous tubular core. This method and/or apparatus can be used to form articles such as brush rollers, interior panels for various modes of transportation, or a flooring article. The melt flow of the beam adjacent to one another along a mandrel surface form a continuous base material. In the case of a roller brush this base material forms a core from which the pile for roller brushes radially extend. Making a roller brush or other article in this manner eliminates the cores adhesives and fabric support material normally required for the pile yarn. Also a mandrel can be used to form a variety of geometric shapes for the cores of the present invention.