Hugh C Gardner

US Patent:

6506695, Jan 14, 2003

Filed:

Apr 20, 1999

Appl. No.:

09/294947

Inventors:

Hugh C. Gardner - Roswell GA
Jeffrey H. Mumm - Marietta GA
Kam C. Lui - Kennesaw GA

Assignee:

Rheinische Kunststoffewerke GmbH - Worms

International Classification:

B32B 518

US Classification:

442 76, 442 79, 442394, 442398, 428196, 428198

Abstract:

This invention provides breathable composite materials with good liquid barrier properties comprising a laminate of a nonwoven web layer and a breathable film layer wherein breathability of the composite is provided by a plurality of point-like deformations of the film layer. In one embodiment, the composites also have a soft, cloth-like texture at at least one surface thereof. Also provided is a process for making such composites comprising applying a molten film-forming resin composition capable of developing breathability on deformation to a nonwoven web, cooling the molten composition to form a coated web having a web layer bonded to a film layer, and subjecting the coated web to heat and pressure at a plurality of points on a surface thereof wherein the heat, pressure and density of, and proportion of the composite surface occupied by, the deformations are effective to impart breathability to the film without loss of liquid barrier properties. In another embodiment of the process, web and cast film components are subjected to heat and pressure at a plurality of points to bond the film and the web and provide a plurality of point-like deformations of the film layer, thereby imparting breathability without loss of liquid barrier properties.

US Patent:

6740385, May 25, 2004

Filed:

Mar 28, 2001

Appl. No.:

09/820237

Inventors:

Hugh Chester Gardner - Roswell GA
Thomas Lee Baker - Winston GA
Stephen G. Ceisel - Marietta GA
Richard C. Moon - Dalton GA
Thomas L. Oakley - Marietta GA
Mark B. Williams - Dalton GA

Assignee:

BP Corporation North America Inc. - Warrenville IL

International Classification:

B32B 3300

US Classification:

428 85, 428 95, 442186, 442270, 442402, 28107, 28109, 28 15

Abstract:

Tuftable primary backings comprise a closed-weave, woven tape fabric to which is affixed a coherent web layer comprising staple fibers with fibers oriented in at least two directions and a plurality of the fibers being fused. The web layer is affixed to the fabric by penetration of fibers from the web into the fabric. The backings have substantial weftline straightness and stability against deformations in the machine, cross and off-axis directions. Improved tufted goods and methods for making the composites and tufted goods are also provided.

US Patent:

6849565, Feb 1, 2005

Filed:

Aug 8, 2000

Appl. No.:

09/634474

Inventors:

Hugh C. Gardner - Roswell GA, US
Jack F. Godfrey - Cohutta GA, US
Kenneth R. Jones - Rossville GA, US
Larry M. Bailey - Decatur GA, US
Edward Barkis - Marietta GA, US
Eric J. Bryant - Kennesaw GA, US
Gregory P. Shelnutt - Douglasville GA, US

Assignee:

BP Corporation North America Inc. - Warrenville IL

International Classification:

B32B 506
B32B 508
B32B 526
B32B 708
B32B 710

US Classification:

442 35, 442 2, 442268, 442270, 442275, 442277, 428 95

Abstract:

Carpet backings and use thereof in tufted carpets with good tuft bind and fuzz resistance and free of inorganic and latex materials are disclosed. Backings suitable as tuftable primary backings or as secondary backings have a nonwoven fabric with thermoplastic filaments and a thermoplastic supporting fabric operatively attached as by needling, thermal calendaring or point bonding.

US Patent:

7018492, Mar 28, 2006

Filed:

Oct 25, 2000

Appl. No.:

09/696519

Inventors:

Jeffrey H. Mumm - Marietta GA, US
Hugh Chester Gardner - Roswell GA, US

Assignee:

Propex Fabrics, Inc. - Austell GA

International Classification:

D05C 15/00

US Classification:

156 72, 428 95, 428 96

Abstract:

Tufted carpets bonded with thermoplastic binders and having improved resistance to fuzz formation due to removal of pile yarn filaments from tuft bundles comprise one or more backings, face yarn that forms a pile on one side and stitches on an opposite side, a thermoplastic binder that binds stitches and the backing or backings, and an organic polymer that bonds filaments of the stitches. Processes for making carpets comprise applying to a stitched side of a tufted backing a liquid stitch bind composition comprising an organic polymer component, removing a liquid component of the composition to bond filaments of the stitches and bonding stitches and one or more backings with a thermoplastic binder that is melted or applied as a melt in contact with the stitched side and the backing or backings and solidified.

US Patent:

7670660, Mar 2, 2010

Filed:

Feb 27, 2006

Appl. No.:

11/362700

Inventors:

Hugh C. Gardner - Roswell GA, US
Thomas L. Baker - Winston GA, US
Richard C. Moon - Dalton GA, US
Robert J. White - Ringgold GA, US
James E. Haire - Colquitt GA, US
Charles W. Galpin - Bainbridge GA, US

Assignee:

Propex Operating Company, LLC - Chattanooga TN

International Classification:

B32B 33/00
D05C 17/02
D04H 1/48

US Classification:

428 95, 442185, 442208, 442270

Abstract:

A two-layer secondary carpet backing including a woven scrim layer and a fibrous layer is described. The woven scrim layer is characterized as having a low open area and a flat weave. The two-layer secondary backing is capable of having a non-abrasive, textile back surface. The secondary carpet backing is also capable of having a construction that permits high carpet manufacturing speeds due to high air permeability and is capable of providing high dimensional stability, seam strength, and delamination strength to tufted carpets made therefrom.

US Patent:

8246873, Aug 21, 2012

Filed:

Oct 31, 2008

Appl. No.:

12/263264

Inventors:

Hugh C. Gardner - Roswell GA, US
Josef Uesbeck - Gronau, DE
Andy Rakovac - Gronau, DE
Philippe Combier - Chattanooga TN, US
Kam Lui - Chattanooga TN, US

Assignee:

Propex Operating Company, LLC - Chattanooga TN

International Classification:

C08J 9/06

US Classification:

264 54, 264 51, 264146, 264147, 2642101, 2642106, 26421113, 26421114, 264237

Abstract:

Making foamed polyolefin tapes can include combining a polyolefin resin and a chemical blowing agent to form a mixture. This mixture can then be heated in an extruder to create a supersaturated solution of gas within the polyolefin resin. A cooling device can be positioned adjacent to a die at a set distance for receiving extruded resin and for allowing exposure of the extruded resin to ambient air between a die outlet and the cooling device. This predetermined distance or space between the cooling device and die outlet allows bubbles to grow in the extruded resin and to be shaped such that voids or empty spaces can be generated within the extruded polyolefin resin. The voids or empty spaces allow the formation of tapes which use less material but have adequate strength for various applications, such as for carpet backings, geotextiles, packaging, housewrap, bags, wire insulation, and reinforcement elements in concrete.

US Patent:

20040091664, May 13, 2004

Filed:

Nov 13, 2002

Appl. No.:

10/293119

Inventors:

Hugh Gardner - Roswell GA, US
Thomas Baker - Winston GA, US
Barclay Payne - Dalton GA, US
Carroll Yawn - Powder Springs GA, US

International Classification:

B32B001/00
B32B003/02
B32B033/00

US Classification:

428/085000, 428/219000, 428/094000, 428/095000, 442/185000, 139/399000

Abstract:

Secondary carpet backings woven in a flat weave construction from warp tapes and multifilament picks with to about 100% theoretical coverage in the warp but less than full effective coverage and average pick counts of 12 to 20 per inch, such that the fabrics have weights of about 1.5 to about 7 osy and air permeability, provide dimensional stability and peel strength in carpets and facilitate robust cure rates in carpet manufacture.

US Patent:

20040142142, Jul 22, 2004

Filed:

Nov 6, 2003

Appl. No.:

10/701519

Inventors:

Hugh Gardner - Roswell GA, US
Thomas Baker - Winston GA, US
Barclay Payne - Dalton GA, US
Carroll Yawn - Powder Springs GA, US

International Classification:

B32B033/00
D04H011/00
D03D015/00

US Classification:

428/095000, 442/192000, 442/195000, 442/208000, 139/38300R

Abstract:

Secondary carpet backings woven in a flat weave construction from warp tapes and multifilament picks with 50 to about 100% theoretical coverage in the warp but less than full effective coverage and average pick counts of 10 to 20 per inch impart dimensional stability and high peel strength in carpets incorporating the backings and facilitate robust drying rates in manufacture of carpets.