STITCHED PILE SURFACE STRUCTURE AND PROCESS AND SYSTEM FOR PRODUCING THE SAME

摘要

A stitched pile surface structure and a process and apparatus for producing and finishing the same is disclosed. The stitched pile surface structure includes a backing having a thickness (T). A plurality of parallel lines of stitches extends longitudinally along the backing. Each stitch has a predetermined stitch length dimension (S). A plurality of rows of pile elements (either as loop pile or cut pile) is formed from one or more pile yarn(s) having an effective predetermined yarn diameter (D). The total weight of the yarn used to form the pile loop elements is (G) grams. Substantially all of the stitches have a thread length (DKL) that satisfies the relationship: DKL(1 + PI /2) + (2<.>T) + (2<.>S). A mass of binder material having a weight of less than (G) grams is disposed on the pile surface structure. The major portion of the binder material is concentrated in the vicinity of the root portions of the pile elements so that substantially all of the filaments in the distended regions of the root portion of substantially all of the pile elements have binder material thereon. The upper two-thirds of substantially all of the pile elements are substantially free of binder.