Pile fabric production
I United States Patent 1191 1111 3,876,482 Rowe Apr. 8, I975 PILE FABRIC PRODUCTION 2.512.727 6/1950 Rice 156/254 2,521.83l 9/1950 Con et al... 156/254 [76] Inventor: Church 3.287 196 11/1966 1461121 156/254 Cottage, Hartlebury, worcesler- 3,411,966 11/1968 Couquet 156/72 England [22] Filed: 1972 Primary Examiner-Douglas .ll. Drummond 2 App] 295 1 Attorney, Agent, or Firm-Kurt Kelman [30] Foreign Application Priority Data [57] ABSTRACT Mar. 30, 1972 United Kingdom 2648/72 Mar. 30. 1972 United Kingdom 47610/72 A ethod and apparatus for producing a pile fabric which comprises a ground member including a barrier [52] US. Cl 156/72; 156/254 y r n a plurality of ufts having their ends embed- [51] Int. Cl D05c 15/00; B32b 31/00 ded erein, each tuft comprising a length of pile yarn [58] Field of Search 156/72, 254, 390, 510, severed from a respective tuft on an already existing 156/578 pile fabric after establishment of an adherent relation between the barrier layer and the ground member and [56] References Cited Sa d tuft UNITED STATES PATENTS 1.7351937 12/1930 Curtis 156/254 9 9 Draw F&#39;gures PATENTEBAPR 8|975 SHEET 1 BF 2 my m m J om 0N PATENTEUAPR ms 3,876,482  
 sum 2 9 2 QAV/WWW/ WNW WWW PILE FABRIC PRODUCTION BACKGROUND OF THE INVENTION This invention relates to pile fabrics and concerns firstly a method of producing same, and secondly apparatus for carrying out the method, and thirdly the pile fabric itself.  
  The invention has been developed primarily in relation to the production of pile fabrics in the form of carpets, but it will be understood that it may be applied generally to pile fabrics comprising a ground member and a plurality of tufts protruding from at least one face of the ground member, each tuft comprising a plurality of fibres.  
  In respect of pile fabrics formed as carpets, it is possible to distinguish two broad types herein called traditional and tufted. In traditional carpets the ground member is a woven fabric composed of warp threads and weft threads and the pile tufts are introduced or formed in the fabric at the weaving point or fell during the weaving of the ground member. In tufted carpets the ground member is at least partly preformed and exists in the form of flexible sheet material preparatory to the introduction of the tufts of pile yarn, the latter being inserted by needle means into the sheet material of the ground member. Thereafter the latter may be coated on its side remote from that to which the tufts of pile yarn protrude with material for retaining the tufts against withdrawal, such material being in flow able form and caused or permitted to set after its application.  
  Tufted carpets are capable of being produced at a high rate and generally at lower cost than traditional carpets. On the other hand, there are certain problems or disadvantages in tufted carpets which have not been fully solved at the present date.  
  Firstly, the maximum density of pile tufts which can be attained in tufted carpets is less than can be attained in the highest quality traditional carpets, more especially the high grade Wilton and Axminster carpets.  
  Secondly, the formation of patterns in tufted carpets is very limited. In general, production of patterned carpets on a commercial scale is confined to random patterns composed of randomly distributed tufts of different colours rather than an organised pattern, or if the latter is required, it is achieved by printing the necessary dye on to white, or approximately white, tufts of pile yarn already inserted into the ground member.  
  It has been proposed to form semi-artificial pile fabrics from wooled animals skins. Such skins have pile fibres individually anchored in the hide of the skin and substantially uniformly distributed as individual, unentangled (i.e., not twisted together fibres) after a carding or other straightening process. A semi-artificial fabric is derived from the wooled animal skin by adhering a layer to the ends of the fibres and shearing the pile fibres at a position between the hide and the layer.  
  In order to straighten the fibres and maintain them in substantially parallel relation and extending perpendicular to the hide during the adherence of the layer, suction or electrostatic action may be employed. Alternatively, a fluid adhesive may be sprayed over the ends of the pile fibres in a fine mist or fog and, subsequently, a more viscuous film or foam is applied. After setting, the pile fibres may be sheared from the hide leaving the animal skin with shortened pile fibres and a semiartificial pile fabric comprising a synthetic base layer and animal fibres anchored therein.  
  The present invention is concerned with the production of pile fabric from an already existing pile fabric comprising a plurality of tufts protruding from a ground member, each tuft being composed of a plurality of individual fibres. The problem which arises here is not how to maintain the tufts in substantially parallel relation since they are intrinsically quite stiff by virtue of being composed of a plurality of individual fibres. The problem encountered is quite different, namely how to prevent each tuft acting like a wick when adhesive is applied to the end thereof. If this happens adhesive can travel along the tuft by capillary action to an excessive extent so that the individual fibres of each tuft can become cemented together along appreciable proportions of their lengths. This can result, after shearing, in the production of both an unsatisfactory new pile fabric and possibly also an unsatisfactory existing pile fabric since either (a) the tufts of the new fabric may have their effective lengths reduced. to an acceptable extent by the cementing referred to above thereby reducing the resilience and feel of the carpet, or (b) if the limbs are sheared more closely to the ground member of the existing pile fabric to increase the length of the tufts of the new fabric, this may render the existing pile fabric unsaleable in view of the shortness of the tufts.  
  The object of the present invention is to overcome or reduce these disadvantageous effects.  
 SUMMARY OF THE INVENTION According to one aspect of the present invention there is provided a method of producing a pile fabric comprising applying a barrier substance in fluid form to the ends of tufts each composed of a plurality of individual fibres and protruding from a ground member of an already existing, preferably patterned, pile fabric, controlling the quantity of the barrier substance applied per unit area to confine penetration of the barrier substance to end portions only of the tufts leaving at least the major proportion of the protruding length of each tuft free from penetration by such substance, causing or permitting the barrier substance to set or harden to form a substantially solid state barrier layer in which said end portions of the tufts are embedded, applying further material to the barrier layer to adhere thereto and in combination therewith to form a further ground member, and severing the tufts between the two ground members.  
  By forming the substantially solid state barrier layer by controlling the quantity of the barrier substance to confine penetration of the barrier substance to end portions only of the tufts, the fibres in the remaining portions of each tuft are free of the barrier substance and thus remain free from each other and, moreover, may remain so during the application of subsequent liquid substance in the application of the further material to adhere to the barrier layer to form, in combination therewith, the further ground member. Also, the barrier layer may also prevent the subsequently applied liquid substance from penetrating between adjacent tufts.  
 DESCRIPTION OF THE DRAWINGS FIG. I is a diagrammatic view in side elevation illustrating one embodiment of apparatus in accordance with the invention for carrying out the method thereof;  
  FIG.. 1A is a fragmentary view on an enlarged scale in longitudinal cross-section showing the arrangement for supporting the severing means;  
  FIGS. 2 to 6 show respective stages in the performance of the method;  
  FIG. 7 is a view in cross-section on an enlarged scale illustrating the finished structure of the pile fabric made by the method; and  
  FIG. 8 illustrates a modification applicable to the embodiment of FIG. 1.  
 DESCRIPTION OF A PREFERRED EMBODIMENT Referring firstly to FIGS. 2 to 6, the basic material employed for the performance of the invention may be a length of existing pile fabric made by a traditional method, such, for example, as a piece of carpet or Axminster weave.  
  This comprises a ground member formed of binding chains 10, wefts 11, and a stuffer warp 9, which constitute a woven ground member. Tufts 12 protrude from the ground member at one side and are constituted by lengths of pile-forming yarn which are looped around the wefts in the surface of the ground member as shown.  
  The first stage of the method illustrated in FIG. 3 comprises the application to the protruding ends of the tufts 12 of a liquid substance which sets to substantially solid state to form a substantially continuous coating 13, the setting preferably being assisted by the application of heat. The coating 13 penetrates for a certain distance lengthwise of the tufts 12 before setting and thus becomes interlocked with these in a retentive manner. The depth to which the substance penetrates lengthwise of the tufts is carefully controlled by controlling the quantity of the substance delivered onto the surface presented collectively by the tufts, as well as by providing means for accelerating the setting of the substance. The substance is preferably delivered by one or more spray heads extending in a row transversely of the existing pile fabric, i.e., in the direction of the wefts. A suitable substance is a dispersion of latex in water. Satisfactory results have been obtained utilising Dunlop curing latex A655. The amount applied per unit area, e.g., per square yard of the surface area presented by the free ends of the pile tufts may be approximately fluid ounces. However, the quantity may be varied between 2.5 fluid ounces and 10 fluid ounces as required, depending upon variable factors, such as the density of the pile tufts and the depth thereof.  
  The means for accelerating setting comprises heaters preferably furnishing heat by way of radiation. Typically infra-red energised heating elements may be utilised.  
  The coating 13 is preferably applied to the tufts 12 with the latter presented in a generally upward direction i.e. either horizontal or at some inclination to the horizontal. With this arrangement, the weight of the liquids, as well as capillary action, tends to cause the penetration of the coating 13 with the tufts to the desired extent, e.g., typically 1/16th inches and the layer sets to present a substantially continuous exposed surface although there may be minute pockets or voids, the presence of which, however, is unimportant. The second stage illustrated in FIG. 4 consists in the application of a second coating 14. This is applied to the exposed surface of the coating 13 which has set, and again composed of a substance in liquid form. The  
 same substance as is utilised for the coating 13 which has set, and again composed of a substance in liquid form. The same substance as is utilised for the coating 13 may be employed and the rate of delivery may be 5 the same or approximately the same as that using the coating 13. The manner of application may also be by spray nozzles arranged in a row extending weft-wise of the fabric.  
  At a position downstream of this row of spray nozzles, again, means may be provided for accelerating the setting, for example, electrically energised heaters providing heat by way of infra-red radiation.  
  The two coatings 13 and 14 collectively constitute a barrier layer which prevents penetration of subsequently applied liquid substances through to the portions of the tufts 12 which remain free from each other, i.e., in the sense that the individual fibres of which each tuft is componsed, as well as adjacent tufts, do not become cemented together, and hence remain free to present the pile surface of the two pieces of fabric eventually produced by the method. It will be noted that the end portions of the tufts adjacent to their free ends are embedded in the coating 13 and may protrude somewhat therethrough to be embedded to some extent also in the coating 14. Due to the character of the surface which is presented collectively by the ends of the tufts, the exposed surface of the coating 14, although of substantially continuous form is uneven i.e., has local depressions and protuberances which, however, assist in establishing adherence or keying of a further adhesive substance.  
  This further adhesive substance is applied as a coating 15 also illustrated in FIG. 4(right-hand end portion only).  
  Adhesive substance is preferably applied by means of a lick roller, as hereinafter described in more detail. A suitable adhesive substance comprises a latex, for example Dunlop AC Latex DS6568. This adhesive substance is preferred when further constituents of the ground member comprise materials such as scrim and hessian formed by vegetable fibres, such as cotton or jute. However, one or more further constituents of the ground member may be composed of other substances, for example a plastics material, such as nylon, PVC, polyethylene, and in this case the adhesive substance may be of plastics material selected to have satisfactory adhesive properties with respect to the plastic sheet: material which it is desired to secure to the barrier, layer.  
  In the present example now described, the subsequent stage in the process illustrated in FIG. 5 is the application of two sheet materials, one of which namely scrim 16, is less closely woven than the other, namely hessian 17.  
  At least the scrim, and preferably both these materials are subjected to dampening either by passing the material through a water bath or by subjecting it to a steam spray prior to application to the exposed surface of the barrier layer.  
  The dampened scrim readily takes up latex and thus becomes embedded at least partially in the coating 15 establishing a very secure bond with the barrier layer. Pressure is exerted in a direction transverse to the plane of the pile fabric to press both the hessian and the scrim towards the barrier layer and the adhesive coating 15 intermingles with both the sheet materials;  
 namely scrim and hessian and causes these to become! securely attached to the barrier layer. The pressure is preferably exerted by rollers on opposite sides of the feed path along which the materials, namely the existing pile fabric and the scrim and hessian are advanced. In FIGS. 5 to 7 the adhesive coating is not shown as intermingling with the scrim and hessian merely to avoid obscuring the showing of these formed fomed components of the newly formed ground member.  
  The subsequent stage is illustrated in FIG. 6 after passage of the material through a chamber in which it is heated to cause the coating 15 to set. This stage comprises severing the tufts 12 at a position intermediate the existing ground member 9, 10, ill and the newly formed ground member comprising the components 13, 14, 15, 16 and 17. Such severing may be effected by means of an endless metal band 18 having a cutting edge 19, the band passing over pulleys, one of which at least is a driving pulley at opposite lateral boundaries of the fabric so that the cutting edge 19 effects severing of the tufts of each weftwise extending row simultaneously with each other.  
  The newly produced fabric is illustrated in FIG. &#39;7 wherein it will be noted that the fabric comprises a ground member composed of the coatings l3 and M, the latter adhering to the layer of scrim 16 which is superposed on the hessian layer 17 with the coating 15 permeating both the scrim and the hessian. The tufts indicated at 12a (and which have a height dependent upon the position selected for the knife 1% between the two ground members) are firmly secured in at least the coating 13 and to some extent also in the coating M. The fibres incorporated in these tufts tend, at their lower ends, to be somewhat splayed divergently from each other thereby improving the degree of retention in the coatings 13 and 14 which constitute the barrier layer. This feature arises from upwardly divergent splayed form of the fibres in the initial fabric, as seen in FIG. 2. The invention may be applied to the production of the plain fabric, i.e., wherein all the pile tufts are of one colour, but it is especially advantageous as applied to the production of fabrics in which different coloured pile tufts are utilised and arranged to present an organised pattern. Such organised pattern is deter mined by the operation of known means in forming the initial fabric e.g., Jacquard means, when the existing pile fabric is produced by the gripper Axminster method of weaving and by selective presentation of tube frames containing spools on which the pile yarns are arranged as side-by-side windings of a predetermined colour sequence for each weftwise extending row of pile in the case where the existing fabric is produced by the spool Axminster method of weaving.  
  It will of course, be understood that the method may be applied to other pile fabrics produced by traditional methods, such as Wilton, Brussels carpets.  
  Referring now to FIG. ll, an apparatus is shown for carrying out the method illustrated in FIGS. 2 to 6. The apparatus comprises a supporting structure which includes a means for supporting a roll 21 of an existing pile fabric such as that already referred to relative to FIG. 2.  
  The supporting means further includes rollers and other support members defining a feed path along which an extended length of the fabric from the roll 21 can be fed. Thus, the supporting means may include a guide roller 20, a guide plate 22, arcuate guide member 23 and a breast-plate 24.  
  The supporting means may further comprise means for supporting a roll 25 onto which newly formed fabric is wound and a further roll 26 onto which the remaining portion of the existing fabric is wound. Both the rolls 25 and 26 may be driven in any suitable manner, for example, an electric motor through a suitable transmission means providing for either continuous or stepwise rotation of the rolls 25 and 26.  
  At a station above the supporting plate 22, the apparatus includes a first applying means 27 comprising a row of spray nozzles 2%, a longitudinally spaced row of spray nozzles 29 situated downstream of the row 28 and two infrared heaters 30 and 31 which are respectively downstream of the nozzles rows 28 and 29.  
  The row of nozzles 25% is utilised for applying the coating 13 and the row of nozzles 29 for applying the coating M. I-leat supplied by the heaters 30 and 32 serves to evaporate the liquid. constituent of the substances used to form these coatings leaving same in substantially solid state on the free end portion of the tufts of the existing fabric to constitute the barrier layer already mentioned.  
  For application of the adhesive substance to form the coating 15 it is preferred that the exposed surface of the barrier layer be presented downwardly, and this is achieved by passage of the existing fabric over the arcuate guide member 23.  
  The radius of curvature of the guide member 23 is large, for example, of the order of 6 feet so that the risk of rupture of the barrier layers by flexing is substantially eliminated.  
  The second applying means indicated generally at 32 for applying the adhesive to form the coating 15 comprises a lick. roller 33 driven from a motor (not shown) to rotate in the direction of the arrow 34 so that the peripheral portion of the roller which is in contact with the exposed surface of the barrier layer is actually travelling in a direction opposite to the direction of travel of the barrier layer. Preferably the roller 33 is rotated at a speed such that its peripheral speed is greater than the speed of travel in the opposite direction of the barrier layer. Typically, this peripheral speed may be three times the speed of travel of the existing fabric and hence barrier layer.  
  The thickness of the coating 15 is controlled by a doctor blade 35. The adhesive substance 36 from which the coating is formed is fed to a container 37 which retains a suitable quantity thereof at a level such that the lick roller 33 dips into it.  
  The existing fabric, with the barrier layer l3, l4 and the further coating 15 applied thereto passes along the feed path into the nip afforded between pressure rollers 3% above and below the feed path respectively. Bulk supplies of two forms of sheet material in the forms of rolls 39 and 49 are carried by part of the supporting means of the apparatus. The rolls 39 and 49 may comprise rolls of scrim and hessian respectively as already mentioned. The scrim may be passed through a bath 40 of water retained in a container 41 above which are arranged suitable guide rolls 42, t3 and 414. Above the latter, a pressure roll 45 which is loaded downwardly by means of a spring 46 to squeeze surplus water from the scrim before passage beneath a further guide roll 47, and entry into the nip between the rolls 3%.  
  The hessian l2 may also be subjected to dampening, for example, by means of steam jets (not shown) preparatory to passage into the nip.  
  A wetting agent such as Lissapol may be used in relation to both the scrim and hessian as necessary.  
  The rolls 38 exert gentle pressure to the assembly comprising the existing fabric, barrier layer, adhesive coating scrim and hessian. This pressure forces the adhesive material constituting the coating 15 into the scrim and the hessian and ensures that these materials become securely attached over the entire surface of the fabric to the barrier layer.  
  The adhesive material 36 which forms the coating 15 is preferably latex. To convert this into the set or solid state, the assembly is passed through a drying chamber 48 which may contain electrical heaters, such as infrared heaters.  
  The residence time within the chamber 48 depends upon the nature and amount of latex applied by the lick roller and doctor blade. Typically, the drying temperature may be heated to have an internal temperature of between 130C and 180C and the length of the drying chamber may be of the order of 50 feet for relative advancement of the assembly along the feed path at a speed of to 6 feet per minute. This would evidently give a drying time of the order of 8 to 10 minutes. How ever, longer drying times may be provided if desired by lengthening the chamber 48 by up to 100 feet or more.  
  Upon exit from the drying chamber, the assembly passes over a breast-plate 24 and the pile is severed by a severing means as already mentioned in connection with FIG. 6.  
  The endless metal band which constitutes the operative part of the severing means is supported on rolls 18a rotatable about horizontal axes extending longitudinally of the fabric and situated at opposite sides thereof. The upper run of the band is supported in a guide member 18b in the form of a plate or block extending transversely of the fabric between the separated components i.e., the newly formed fabric such guide member having a slot 18c in which the major proportion of the width of the upper run of the band is supported leaving only a relatively small portion protruding as seen is FIG. 1A.  
  Modification of the apparatus as illustrated in FIG. 8 is intended to be used where it is desired that the height of the pile in a newly formed fabric and in the remainder of the existing fabric is varied from place to place to present an organised pttern.  
  For this purpose, a pair of rollers may be provided between the exit from the chamber 48 and the severing means 18. Such rollers would each have a plurality of sequential axially extending zones which incorporate raised male portions and depressed female portions in selected positions along the zone. The rollers are so arranged that the complementary depressed female portions and raised male portions are provided in a corresponding zone of the other roll so that the two rolls can mesh with each other, thereby to cause portions of the assembly to be raised or depressed relative to a reference plane disposed medially of the feed path. For convenience in FIG. 8, the two rolls 50 and 51 are shown separated from each other, i.e., not in meshing relation. By way of example, axially extending zones presented at the nip between the rolls and include complementary portions 52a, 52b, 53a, 53b, 54a, 54b, and are male in one roll and female in the other. Different complementary formations 55a, 55b, 56a, 56b, are shown by way of example at the position on each row which is diametrically opposed to the nip. It will be understood that as many pairs of zones with complementary formations will be required as are necessary to make up a complete unit with the relief or figured pattern which it is required that the tufts should present. If the diameter of the rolls becomes excessive to accommodate the requisite number of axially extending zones, an alternative arrangement would be to provide a pair of endless bands carrying bar-like elements (corresponding to respective zones) presenting male and female portions, the endless bands passing over suitable guide and driving rolls and meshing&#34; with each other at a nip through which the assembly passes.  
  The rolls 50 and 51, and the driving rolls when an endless band is employed, will require to be driven in synchronisation with the take-up rolls 25 and 26 either stepwise or continuously. Similarly, the speed of the severing device 18 will require to be such to effect severing of the pile tufts during the time when the assembly is raised and depressed locally by meshing with the complementary male and female formations on the rolls or elements carried by the endless band.  
  Instead of utilising the preformed sheet members e.g., woven fabrics such as scrim or hessian as represented at 39 and 40, the preformed material may be composed of strands or filaments applied to the exposed surface of the barrier layer and held in place by a fluid substance such as the adhesive substance such as the coating 15.  
  The layers may comprise sets of parallel, or substantially parallel, filaments extending along a selected direction, for example, a generally lengthwise of the fabric. One or both sets of filaments may be subjected to shedding in a plane parallel to that of the fabric relatively to the other set so that the filaments of each such set are caused to have a zig-zag configuration along the selected direction, with the two sets crossing each other to form a mesh. Anchorage of the already zig-zag portions of each set of filaments whilst shedding the still straight portions may be effected either by the settable substance (in set condition) or by other means.  
  Typically, two sets of filaments would each be subjected to shedding by lateral excursions of about 1 inch from a mean position. The frequency of the shedding may be such as to produce an elongated diamond mesh with the longer diagonal dimension of each diamond extending longitudinally of the fabric.  
  If desired, straight(unshed) stuffer elements could be incorporated.  
 The material of the filaments may be jute, cotton,  
 synthetic fibres or mixtures thereof.  
 The employment of two sets of filaments extending by virtue of the shedding operations in relative transverse directions at any point will provide a high degree of dimensional stability in any direction.  
  In a further alternative, the ground member of the newly formed pile fabric may include no generally continuous strands or filaments. Thus the ground member may be elastic.  
  Pile fabric formed without generally continuous strands or filaments in the ground member may be employed generally where a pile fabric is required but it is not necessary for such fabric to have dimensional stability. For example, the pile fabric may be employed as a floor covering or wall covering if the fabric is adhered to an underlying member, for example the wall of floor itself or a sheet member separate therefrom, which has the required dimensional stability. In some applications such as upholstery and the covering of car floors, a pile fabric having an elastic ground member may be advantageous.  
  If desired, the newly formed ground member may consist solely of a material applied in the fluid state and caused or permitted to set. Thus the second coating of the barrier layer may be made thick enough to act as a backing member providing the requisite strength.  
  Alternatively, the fluid substance such as latex or a fluid plastics material may be applied to the exposed surface of the barrier layer after the latter has been caused or permitted to set using a conventional form of apparatus for applying foam backing. In this form of apparatus the fluid material is applied by a delivery head having an outlet extending transversely of the fabric from one edge to the other and the latter is moved past the delivery head, the thickness of the applied layer being controlled by a doctor blade situated downstream of the delivery head. Means may be provided for controlling the lateral spread of the fluid material delivered to prevent this from spilling over beyond the edges of the fabric.  
 What I claim is:  
  1. A method of producing a pile fabric comprising applying a barrier substance in fluid form to the ends of tufts, each composed of a plurality of individual fibres and protruding from a ground member of an already existing pile fabric, controlling the quantity of the barrier substance applied per unit area to confine penetration of the barrier substance to end portions only of the tufts, leaving at least the major proportion of the protruding length of each tuft free from penetration by such substance, causing or permitting the barrier substance to set or harden to form a substantially solid state barrier layer in which said end portions of the tufts are embedded, applying further material to the barrier layer to adhere thereto and in combination therewith to form a further ground member, the establishment of an adherent relation between the exposed surface of the barrier layer and a further constituent of the ground member of the newly formed pile fabric being effected by coating the exposed surface with an adhesive substance and applying at least one preformed member of sheet form to the so-coated surface, and severing the tufts between the two ground members.  
  2. A method according to claim 1, in which the existing pile fabric is a patterned traditional pile fabric as herein defined.  
  3. A method according to claim 1, comprising forming the barrier layer by successive applications of respective barrier substance s, the earlier applied substance setting preparatory to application of the succeeding barrier substance.  
  4. A method according to claim 1, comprising evaporating the liquid constituent of the barrier substance to leave a solid state constituent adhering to the end portions of the tufts thereby collectively forming a matrix like barrier layer.  
  5. A method according to claim 4, in which the barrier layer is applied by spraying.  
  6. A method according to claim 1, in which the preformed sheet member comprises a closely woven member such as hessian and a less closely woven member such as scrim, the latter lying between the barrier layer and said more closely woven member.  
  7. A method according to claim 6, comprising dampening the preformed sheet prior to bringing it into pressure contact with the adhesively coated barrier layer, and in which the adhesive substance is of a composition such that improved adhesion between the coated barrier and the preformed sheet member is attained when the latter is dampened.  
  8. A method according to claim 1 comprising applying the barrier substance to the free ends of the tufts while the tufts extend upwardly from the existing ground member, and applying the further material to the solid state barrier layer while the tufts extend downwardly from the existing ground member.  
  9. A method according to claim 1 in which at least one layer of strand or filaments is applied to the exposed surface of the barrier layer, and is held in place by a settable substance in liquid form which is caused or permitted to set or harden.