CA1116504A - Profiled sound insulating carpet - Google Patents
Profiled sound insulating carpetInfo
- Publication number
- CA1116504A CA1116504A CA000296429A CA296429A CA1116504A CA 1116504 A CA1116504 A CA 1116504A CA 000296429 A CA000296429 A CA 000296429A CA 296429 A CA296429 A CA 296429A CA 1116504 A CA1116504 A CA 1116504A
- Authority
- CA
- Canada
- Prior art keywords
- carpet
- sound insulating
- layer
- latex
- backing
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- G—PHYSICS
- G10—MUSICAL INSTRUMENTS; ACOUSTICS
- G10K—SOUND-PRODUCING DEVICES; METHODS OR DEVICES FOR PROTECTING AGAINST, OR FOR DAMPING, NOISE OR OTHER ACOUSTIC WAVES IN GENERAL; ACOUSTICS NOT OTHERWISE PROVIDED FOR
- G10K11/00—Methods or devices for transmitting, conducting or directing sound in general; Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
- G10K11/16—Methods or devices for protecting against, or for damping, noise or other acoustic waves in general
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
- B60R13/0815—Acoustic or thermal insulation of passenger compartments
- B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/08—Insulating elements, e.g. for sound insulation
Landscapes
- Physics & Mathematics (AREA)
- Acoustics & Sound (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Multimedia (AREA)
- Laminated Bodies (AREA)
- Carpets (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Passenger Equipment (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
Abstract
Abstract of the Disclosure A method of taking sound insulating floor or wall covering in which carpet is backed with a layer of sound insulating material and a layer of contour retaining material for holding the carpet in a desired contoured shape. The latter material, which is conveniently a carpet precoat, is made formable for instance by heating, the carpet and its backing is shaped to desired form, and the retaining material is allowed to set thus holding the carpet and sound insulating layer to that shape.
Desirably, the insulating material is a curable rubbery polymer which is cured before carpet shaping takes place.
For improved sound insulating properties, deaerated insulating material is used.
Desirably, the insulating material is a curable rubbery polymer which is cured before carpet shaping takes place.
For improved sound insulating properties, deaerated insulating material is used.
Description
~ 5~
This invention relates to methods of making sound insulation and i5 particularly concerned wi~h insulation to be used for sound insulation of vehicles Sound insulation in vehicles is conventionally in the form of sound insulation pads which are disposed against surfaces of the vehicle bodywork such as on the floor, in the roo and wheel arches and in the doors and fire wall, to deaden sound to the vehicle interior such as may be caused by movement of the vehicle in contact with a road surface, engine operation and mechanically moving parts, and vehicle vibration.
The sound insulation pads are formed rom cellulose or other fibres which may have been compacted and compressed, impregnated with a condensation resin such as phenolform-aldehyde, the pads then being shaped to fit substantiallyin overall engagement ~ith their associated bodywork sur-faces. As low frequency sound which is transmitted through vehicles requires a particularly dense sound insulation significantly to lessen its transmission to the driver or passenger compartment, a special treatment is normally carried out in the making of the sound insulation pads.
This treatment takes the form of coating the pads with bitumen or with polyvinylchloride containing a filler to increase pad density, the minimum weight requirements in the pads for insulating against low frequency sound being of the order of 60 ounces per square yard.
Where sound lnsulation pads are placed in driving or passenger compartments, either on the floor or on wall areas di~ectly behind the engine compartment, then ior com-fort and aesthetic purposes they are often covered by carpet.
~ ~ 6~
The carpets are of tufted or needlepunch construction.Polyethylene powder is normally shaken onto the primary backing of a continuously formed length of carpet and is then heated to cause it to melt and flow around the bases S of the carpe~ tufts extending to the carpet back. Upon se~ting, the polyethylene holds the tufts in place. After individual carpets have been cut from the length of carpet, the polyethylene is softened boy reheating and the individual carpets are shaped complementary to the shape of the sound insulation pads over which they are to be laid, this shape being retained by the polyethylene after it has reset.
As may be realized from the above discussion, the provision o~ sound insulation pads and carpeting for cover-ing the pads is a laborious process. The present invention providas a method by which this disadvantage is avoided.
Accordingly, the present :invention relates to a method of making profiled sound insulating floor or wall covering from a carpeting in the form of a carpet to the underside of which has been attached a sound insulating backing and a layer of material for forming a carpet contour retaining layer, the met~od comprising conditioning said layer of material to make it formable, and with the sound insulating backing in a flexible condition, contouring the carpeting to a desired configuration, and setting the material so as to form the contour retaining layer~ the contour retain-ing layer in its set condition havin~ a stiffness sufficient to retain the carpeting in its desired configuration.
The carpet is preferably of tufted or needlepunch construction, but may be of any other construction such as woven if desired.
More particularly, the invention includes a method of making profiled sound insulating floor or wall covering comprising at~aching to the underside of a carpet length, a sound insulating backing and a layer of material for form-ing a carpet contour retaining layer to form a backed carpetlength, cutting backed individual carpets from the carpet length, conditioning said material on each individual carpet to make i~ formable, and with the sound insulating backing in a flexible condition, contouring the individual carpet to a desired configuration, and setting the material so as to form the carpet contour retaining layer, the retaining layer in its set condition having a sti~ness sufficient to retain the individual carpet in its desired configuration.
The carpet contour retaining layer may be dis-posed either between the primary backing of the carpet and the sound insulating backing or on the underside of the so~d insulating backing. However, an additional contour retaining layer may be incorporated whereby one layer is dispo~ed on each side of the sound insulating backing.
Preferably, a contour retaining layer is disposed between the primary backing and the sound insulating backing to additionally form a precoat for holding the carpet tufts to the primary backing fabric.
The carpet contour retaining layer is preferably a layer of a polymer which is stiff at normal ambient tempera-tures and is obtained by providing a coating of a latex of the polymer and at least partly evaporating the water from the latex. To condition the layer to make it formable and then to stiffen it, it is necessary firstly to heat the layer to soften it, after which the individual carpet is provided q)~
with its desired configuration and the contour retaining layer is allowed or caused to cool so as to reset it and hold the carpet in its desired configuration. The latex, if i~ is a latex of a stif polymer, may be for example a latex of a resinous polymer or a blend of a latex of a resinous polymer with a latex of a rubbery polymer~ but in this latter case, the ratio of resinous to rubbery poly~er must be such as to provide the required stiffness to the carpet. Examples of resinous polymer are polystyrene and resinous copolymers of styrene with butadiene containing 70% or more of co-polymerized styrene. The blend may be substantially of the order of 10% rubber latex to 90% resin latex to provide the necessary stiffness after setting of the layer to retain the desired configuration to the individual carpet. As an alternative to a stiff polymer, thermoplastic powder such as polyethylene powder may be applied to the primary backing, the powder then being heated to cause it to soften and flow around the bases of the tufts issuirlg from the underside of the primary backing, and then allowed or caused to set so as to lock the tufts to the primary backing. As further alternatives, non-aqueous hot melt naterials and plastisols of PVC may be employed as the contour retaining layer.
The effectiveness of sound insulation is dependent upon its density. A minimum weight of 60 ounces per square yard dry weight for the insulating backing has been recom-mended for each finished individual carpet for the purpose of absorbing low frequency sounds so as to reduce them to a comfortable level inside the passenger compartment of a vehicle. Density of insulating compounds is increased with increase in high density filler content. In a preferred .s~
method, a curable rubbery polymer is included in forming the insulating backing and suitable filler contents to pro-vide minimum acceptable sound insulating properties are of the order of 200 parts of filler per 100 parts by weight of rubber in the polymer. Although higher levels of filler are obviously preferred for sound deadening, when as high as 700 parts of filler per 100 parts of rubber solids are used, the sound insulating backing may have a low hot flex strength which can lead to cracking in cases where the backed carpet is fed around small diameter rolls such as occurs where it is fed through a multi-pass oven. In such instances, lower filler levels, around 300 to 450 parts, may be used as these give an acceptable balance of good sound insulation and hot strength requirements. Density is also increased where the sound insulation compound is deaerated. While it is recognized that foamed sound insulation compound may be used or making carpet according to this invention and may offer a pronounced increase in softness under~oot in a vehicle, nevertheless foamed material is less attractive because for a given sound insulation requirement, the required thickness of foamed insulation backing may be impractical. Unfoamed compound is of a more practical nature and deaerated is to be preferred for its increased sound insulating and mechanical strength properties.
Instead of rubbery polymer compositions bein~
employed in the compound for sound insulating backing, non-aqueous hot melt materials, plastisols, liquid rubbers curable at room temperature, polyurethane or asphalt com-positions may be employed.
Preferably, when rubbery polymer is included in the sound insulating backing, the backing is applied to the carpet length and îs then cured before individual carpe~s are cut from the length. Conveniently, the rubbery polymer is obtained from a rubbery polymer latex compound capable of being gelled and gelling is effected before drying and curing.
For purposes of gelling, known gelling agents may be used such as the delayed action types as exemplified by sodium silicofluoride and the heat gelling types as exemplified by compounds of zinc oxide, ammonia and ammonium salt, e.g.
ammonium acetate, ammonium sulfamate systems. In the above preferred case where curing takes place before cutting, the backed carpet length may be rolled up for storage purposes preparatory to cutting it into individual carpets.
When using a rubbery latex compound for the in-sulating backing, it is preferred to perform the method by applying the precoat to the primary backing of the carpet (the precoat in this case being a lcltex of a stiff polymer), at least partially drying the latex~ applying a rubbery latex compound as the sound insulating backing, gelling and drying and curing the bac~ing, cutting an individual carpet from the backed carpet length, heating the individual carpet to soften the precoat, shaping the individual carpet to its desired configuration with the precoat in a softened con-dition, and allowing or causing the precoat to cool so as to hold the carpet in that shape. Alternatively, where a thermoplastic powder, for instance, is used as a precoat, then it is heated to soften it and cause it to flow around the bases of the carpet tuf~s prior to application of the sound insulating backing. A second softening is required before carpet shaping, followed by cooling o~ the precoat 5 ~
~o set it and hold the desired shape of the carpet.
In an alternative method, the backed carpet length is fed directly to a cutting station wherein individual carpets are cut from the l~ngth and each is formed into its desired configuration before the sound insulating backing is cured.
The above method according to the invention includes a further alternative in which an indefinite length of sound in~ulating backing is prepared separately and is adhered to the underside of the indeinite carpet length, the carpet contour retaining layer having been previously applied to the primary backing.
The invention also includes a sound insulating floor or wall covering comprising a carpet having a carpet pile carried by and extending from one side of a primary fabric backing and a sound insulating backing and a carpet contour retaining layer carried upon the other side of the primary fabric bac~ing, the carpet being in a non-planar configuration and held in said configuration by the stiffness of the carpet contour retaining layer which is in a set condition.
In addition, the invention further pro~ides a sound insulating floor or wall covering comprising a carpet having a carpet pile carried by and extending from one side of a ~25 primary fabric backing, and an unfoamed sound insulating backing and a carpet contour retaining layer carried upon the other side of the primary fabric backing, the sound insulating backing comprising cured rubber polymer having at least 200 parts by weight of filler per 100 parts by weight of rubber in the polymer.
s~
The invention fur~her includes a sound insulating floor or wall covering made by any one of the methods accord-ing to ~he invention as described above.
To illustrate the invention, the following examples will now be described wlth reerence to the accompanying drawings in which:-FIGURE 1 is a cross-sectional view of part of an indefinite length of backed carpeting;
FIGURE 2 is a schematic side elevational view of apparatus to be used for making the backed carpeting of Figure l;
FIGURE 3 is a cross-sectional view of an individual carpet being shaped between formers; and FIGURE 4 is a view similar to Figure 1 of another lS indefinite length of backed carpeting.
In Figure 1, there is shown an indefinite length of backed carpet, generally shown by numeral lO, the carpet being of conventional tufted constru.ction and having a pile 11 o synthetic fibres extending from a woven or non-woven primary backing 12. The primary backing is provided with a precoa~ 13 of a material or forming a carpet contour retain-ing layer which is a latex of a stiff polymer, e.g. a latex of a resinous styrene-butadiene copolymer as given below in Table A. This precoat is sandwiched between the primary backing 12 and a sound insulating backing 14. The sound insulating backing is a cured latex compound prepared accord-ing to any of the examples given below in Table B.
The backed carpeting of Figure l is produced upon apparatus shown in Figure 2. The indefinite length of un-backed carpet consisting of primary backing 12 and pile ll is fed with pile uppenmost from a roll 15 and across a bath16 containing resinous styrene-butadiene latex at which point the precoat is applied in conventional manner by a rotating lick roller 17. The precoated carpet is then fed beneath a radiant heater 18> which may be an infra-red heater, to partially dry the precoat.
The sound insulating backing 14 is then applied to the precoat by feeding the carpet beneath a doctor roll 19 which controls the thickness and rate of distribution o~ the uncured latex backing compound from a bank 20 of the compound maintained on the ingoing side of the doctor roll. The backed carpet is passed under another radiant heater 21 to gel the backing and from thence through a hot air circulating oven 21a to completely dry and cure the backing. Each point along the carpet takes approximately from 10 to 30 minutes to pass through the oven, the time taken to cure the backing depending upon the precise weight applied. The temperature of the air in the oven in this example is around 265F, but it is to be understood that the chosen temperature may be higher or lower than this and may be dependent upon the compound used for the backing, the speed at which drying and curing is required to take place and the capability of the carpeting to withstand high temperatures.
As may be seen from the examples in Table D below, the sound insulating backing may be extremely thin compared with normal foam backing provided for carpets while providing the required degree of insulation against low frequency sounds in vehicles. The maximum thickness shown by the examples is slightly greater than 0.08". The cured backing material in this maximum thickness may be shaped with the remainder of the carpet into a desired configuration and held in that configuration by the precoat material after heat has been applied to the carpet to raise ~he temperature of the precoat material above its softening point and the S precoat material has reset. Accordingly, to make preshaped individual carpets for fitting into the required sound insulating areas of a vehicle, the indefinite length of carpet 10 in planar condition is subsequently treated in one of two ways. In one way, it is rolled up for storage pur-poses for subsequent cutting, heating and heat forming. Thisoperation takes the form of die-cutting the carpet into individual carpets with minimum wastage, the die-cut carpets being of shapes projected ~rom their final desired configura-tion. After being cut into individual carpets, each carpet is heated up to a temperature sufficient to heat so~ten the resinous styrene-butadiene layer forming the precoat. In this instance, this temperature is around 350F. With the precoat in its softened condition, the carpet is formed into its desired configuration. One example of this is shown in Figure 3 in which an individual carpet 22 is being heat formed between shaped surfaces of two formers 23 and 24 which provide a configuration to the carpet to make it suit-able to be fitted onto the floor at the rear of the passenger compartment of a car. The formers may themselves be heated to maintain the softening temperature of the precoat u~til the desired configuration of the carpet has been attained.
The carpet is then allowed or caused to cool while remaining in its sandwiched position during which the precoat resets.
After removal of the carpet from between the formers, it is held in its desired configuration by the stiffness of the precoat layer which thereby acts as a carpet contour retaining layer.
In the second way of treating the indefinite length of backed carpet, it is fed directly from the hot air drying and curing oven ~o a cutting station to be formed into individual carpets and shaped between ormers in the manner described above.
Complete drying and curing of the sound insulating backing is considered to be most desirable and possibly essential if the indefinite length of carpet is to be rolled up for storage. However, it may be possible to shape in-dividual carpetsl if they are cut and shaped after having the insulating backing applied to them and gelled with little or no curing action having taken place. For instance, vacuum forming techniques may be used upon individual carpets to urge them into intimate contact with former sur~aces with the carpet edges being clamped so as to seal them. The sealed edges which would obviously be distorted would then be removed to make the carpet into its desired size and shape after forming it into its required configura-tion.
In another example, a carpet 25 is of inde~inite length, as shown in Figure 4. The carpet has a pile 26, woven primary backing 27, precoat layer 28 formed from a latex of a resinous styrene-butadiene copolymer and sound insulating backing 29 similar to those described with re~er~
er.ce to Figure 1. In this present example, however, the carpet is provided with a second carpet contour retaining layer 30 of resinous styrene-butadiene copolymer. This second layer is located on the side of the backing 29 remote 5 ~ ~
~rom the precoat 28. The carpet is made in the manner described with reference to Figure 2 above and is conveniently provided with its second layer 30 of copolymer by the known coating techniquesg after drying and curing of the sound insulating backing.
In alternative methods of formlng the sound insulating backlng on lndefinite or individual lengths of carpet, curtaln coater techniques are employed. Such techniques are well known in practice and will be clear to those skilled in the general art of applying coating layers to surfaces of conveyed lengths of textile materials.
TABLE A
For the purpose of providlng the carpet contour retaining layer in the above examples, a latex compound was used of the following formulation.
TAB~E A
Parts by Weight Polystyrene Latex 95.0 Potassium oleate 2.0 Sodium hexametaphosphate 0.5 SBR latex (27~/o bound styrene) 5.0 Antioxidanta 0.1 Calcium carbonate filler 50.0 Polyacrylate thickener Sufficient to give viscosity of 7~000 ~ 12~000 cps .
Calculated compound total solids 51.5%
a - Butylated reaction product of p-cresol and dicyclopentadiene sold under the trade name WINGSTAY~L by Goodyear Tire and Rubber Co.
TAB~E B
For the purposes of providing sound insulating backing in the above examples, a rubbery latex was used according to each of the following formulations.
5g:~
O~ JO OC~JI~Oooo~Oo ,n h 1 0 ~ 0 O
~ ~ o ~ o ~ ~ o ,~ a ~ ~
O ~-rl P~
Cd U~ h ~u ~ ,a u~ O ~ 0 o ~ u~ o ~ ~ o a~ o c~ o o ra ~
~10...... ' ..... I ..... o. a)~ao 0 ~1 O ~ r~ O ~ C~
O
~ 0 D C~ Q~
o ~ u~ c~1 0O C~O O ~ O O
O r~ O ~1 ~1 0 ~ O ~ ~~
_ ~d O~ O O~,~OU~OU~O,,Oo æ ~ P~
~ ~ 1 0 ~ o H rl 1:
.~ ~O~o ~o~,lo~l~,l~r~ 3E~
~ ~1 ~
u~ a) ~ ~
u~ u~ ~
o~u~c~o OC`Jl'~Dou~oooc)oo JJ
... I.............. o P~ ~ ~ 0 ~ 0 ,l ~ o ~ ~ o ~ ~ ,~
i~3 ~) S~ ~ ~0 ~_ ~ O ~q ~
O H O ~: ~J
4-1 ~ O C~
~ ~ ~ O rl ~ a u~ a ,1~ pa) o h ~ h u~ u~ o4 O ~ ~ ~ ~O ~I ~d u~
P~ ~ C ra ~ u~ tJ ~, .~0 ~~ Ph~
~ U~ O O r~ td ~d c ~ ~ . . ~ u~
u~ o u~ O
o U~ o O ~ ~ rl E3 h ,1 ~
~: u~ ~ ~ o ~ ~ a ~ ~ ~u~
~a o ~ o o ~ ~ o ~
0 ~ ~ a ~ o a J ~ o z l ¢ rl p ~ )V ~ rl~I H
U ~ ~ O ~1 El .0 ~ ~ ~ cd C.G ~ a ~ a X W a~ 1 O ~ 1 .G rl /
,G ~ a ~ ~ rO ~1 rl ~1 ~1 U~ 4~1 E U~ O ~rl ~ tl0 ~3JJ t~ ~ h ,i V ,1 rl X O ~ O EV ~ Q~ El O ,1 V
v ~~ o ~ aa,G ¢ 5~ ~ .G
a ~a~ 5~ ~ s~ ~ I ,, Pq o o ~ o o~ a ~ o o ~
c/~ v u~ a P~ ¢ U) C~ ¢ 1~ U~ U ) c P~ rQ c,) r~
' ~ -- 14 --,j;, "
Tn ~he above compounds in Table B, the latex was high solids latex with 68% solids~
Compounds 1 and 3 were applied as sound insulating backings in both deaerated and non-deaerated form~ Com-pounds 2 and 5 were applied in non-deaerated form only while compound 4 was applied in deaerated form only. The pro-perties of the compounds were as set out by Table C.
-- ----~
l ~ u~ ~ o ~
~ h, . eo 1`
u~l O ~ ~ O _ , _ _ :
o CO
hO O ~`
~ cr~
__.
a~
U~ ~ O
~d C~
Q ~1 ~ O O
a~ u~ o æ ~ 00 O ~1 ~
P~
o I ~ ~ ~D O
. .
o a~ ~ o ~ ~d co ~ c~
C~ C~ ~
~ _ - _ P~ ~- O
¢ I ~d oo ,1 0 o~
E-l !:: h . . 1~ O
~11 o a~ , c~ ^
t~ oa ~a aJ
~ CO o o O ~ O O
~d co ~ oo ~1 _ ~ O
I ~ oo ~ O O
~ ~ . . C~1 ,1 o a~ ~ o ~
a) ~a ..
~ _ _..
IJ ~ ~
0~ P P~
.~ ~ ~ _ bJ
P~
a~ t~ ~ ~,1 h t~
P~ ~1 ~
O ~ 00 ~rl U
51 U ~1 U
~4 ~1 ~d O
~ b.O ' .. ~ .. . _ .. _ ~
Compound l was deaerated by allowing it to stand for one day.
Compound 3 was deaerated by diluting it from
This invention relates to methods of making sound insulation and i5 particularly concerned wi~h insulation to be used for sound insulation of vehicles Sound insulation in vehicles is conventionally in the form of sound insulation pads which are disposed against surfaces of the vehicle bodywork such as on the floor, in the roo and wheel arches and in the doors and fire wall, to deaden sound to the vehicle interior such as may be caused by movement of the vehicle in contact with a road surface, engine operation and mechanically moving parts, and vehicle vibration.
The sound insulation pads are formed rom cellulose or other fibres which may have been compacted and compressed, impregnated with a condensation resin such as phenolform-aldehyde, the pads then being shaped to fit substantiallyin overall engagement ~ith their associated bodywork sur-faces. As low frequency sound which is transmitted through vehicles requires a particularly dense sound insulation significantly to lessen its transmission to the driver or passenger compartment, a special treatment is normally carried out in the making of the sound insulation pads.
This treatment takes the form of coating the pads with bitumen or with polyvinylchloride containing a filler to increase pad density, the minimum weight requirements in the pads for insulating against low frequency sound being of the order of 60 ounces per square yard.
Where sound lnsulation pads are placed in driving or passenger compartments, either on the floor or on wall areas di~ectly behind the engine compartment, then ior com-fort and aesthetic purposes they are often covered by carpet.
~ ~ 6~
The carpets are of tufted or needlepunch construction.Polyethylene powder is normally shaken onto the primary backing of a continuously formed length of carpet and is then heated to cause it to melt and flow around the bases S of the carpe~ tufts extending to the carpet back. Upon se~ting, the polyethylene holds the tufts in place. After individual carpets have been cut from the length of carpet, the polyethylene is softened boy reheating and the individual carpets are shaped complementary to the shape of the sound insulation pads over which they are to be laid, this shape being retained by the polyethylene after it has reset.
As may be realized from the above discussion, the provision o~ sound insulation pads and carpeting for cover-ing the pads is a laborious process. The present invention providas a method by which this disadvantage is avoided.
Accordingly, the present :invention relates to a method of making profiled sound insulating floor or wall covering from a carpeting in the form of a carpet to the underside of which has been attached a sound insulating backing and a layer of material for forming a carpet contour retaining layer, the met~od comprising conditioning said layer of material to make it formable, and with the sound insulating backing in a flexible condition, contouring the carpeting to a desired configuration, and setting the material so as to form the contour retaining layer~ the contour retain-ing layer in its set condition havin~ a stiffness sufficient to retain the carpeting in its desired configuration.
The carpet is preferably of tufted or needlepunch construction, but may be of any other construction such as woven if desired.
More particularly, the invention includes a method of making profiled sound insulating floor or wall covering comprising at~aching to the underside of a carpet length, a sound insulating backing and a layer of material for form-ing a carpet contour retaining layer to form a backed carpetlength, cutting backed individual carpets from the carpet length, conditioning said material on each individual carpet to make i~ formable, and with the sound insulating backing in a flexible condition, contouring the individual carpet to a desired configuration, and setting the material so as to form the carpet contour retaining layer, the retaining layer in its set condition having a sti~ness sufficient to retain the individual carpet in its desired configuration.
The carpet contour retaining layer may be dis-posed either between the primary backing of the carpet and the sound insulating backing or on the underside of the so~d insulating backing. However, an additional contour retaining layer may be incorporated whereby one layer is dispo~ed on each side of the sound insulating backing.
Preferably, a contour retaining layer is disposed between the primary backing and the sound insulating backing to additionally form a precoat for holding the carpet tufts to the primary backing fabric.
The carpet contour retaining layer is preferably a layer of a polymer which is stiff at normal ambient tempera-tures and is obtained by providing a coating of a latex of the polymer and at least partly evaporating the water from the latex. To condition the layer to make it formable and then to stiffen it, it is necessary firstly to heat the layer to soften it, after which the individual carpet is provided q)~
with its desired configuration and the contour retaining layer is allowed or caused to cool so as to reset it and hold the carpet in its desired configuration. The latex, if i~ is a latex of a stif polymer, may be for example a latex of a resinous polymer or a blend of a latex of a resinous polymer with a latex of a rubbery polymer~ but in this latter case, the ratio of resinous to rubbery poly~er must be such as to provide the required stiffness to the carpet. Examples of resinous polymer are polystyrene and resinous copolymers of styrene with butadiene containing 70% or more of co-polymerized styrene. The blend may be substantially of the order of 10% rubber latex to 90% resin latex to provide the necessary stiffness after setting of the layer to retain the desired configuration to the individual carpet. As an alternative to a stiff polymer, thermoplastic powder such as polyethylene powder may be applied to the primary backing, the powder then being heated to cause it to soften and flow around the bases of the tufts issuirlg from the underside of the primary backing, and then allowed or caused to set so as to lock the tufts to the primary backing. As further alternatives, non-aqueous hot melt naterials and plastisols of PVC may be employed as the contour retaining layer.
The effectiveness of sound insulation is dependent upon its density. A minimum weight of 60 ounces per square yard dry weight for the insulating backing has been recom-mended for each finished individual carpet for the purpose of absorbing low frequency sounds so as to reduce them to a comfortable level inside the passenger compartment of a vehicle. Density of insulating compounds is increased with increase in high density filler content. In a preferred .s~
method, a curable rubbery polymer is included in forming the insulating backing and suitable filler contents to pro-vide minimum acceptable sound insulating properties are of the order of 200 parts of filler per 100 parts by weight of rubber in the polymer. Although higher levels of filler are obviously preferred for sound deadening, when as high as 700 parts of filler per 100 parts of rubber solids are used, the sound insulating backing may have a low hot flex strength which can lead to cracking in cases where the backed carpet is fed around small diameter rolls such as occurs where it is fed through a multi-pass oven. In such instances, lower filler levels, around 300 to 450 parts, may be used as these give an acceptable balance of good sound insulation and hot strength requirements. Density is also increased where the sound insulation compound is deaerated. While it is recognized that foamed sound insulation compound may be used or making carpet according to this invention and may offer a pronounced increase in softness under~oot in a vehicle, nevertheless foamed material is less attractive because for a given sound insulation requirement, the required thickness of foamed insulation backing may be impractical. Unfoamed compound is of a more practical nature and deaerated is to be preferred for its increased sound insulating and mechanical strength properties.
Instead of rubbery polymer compositions bein~
employed in the compound for sound insulating backing, non-aqueous hot melt materials, plastisols, liquid rubbers curable at room temperature, polyurethane or asphalt com-positions may be employed.
Preferably, when rubbery polymer is included in the sound insulating backing, the backing is applied to the carpet length and îs then cured before individual carpe~s are cut from the length. Conveniently, the rubbery polymer is obtained from a rubbery polymer latex compound capable of being gelled and gelling is effected before drying and curing.
For purposes of gelling, known gelling agents may be used such as the delayed action types as exemplified by sodium silicofluoride and the heat gelling types as exemplified by compounds of zinc oxide, ammonia and ammonium salt, e.g.
ammonium acetate, ammonium sulfamate systems. In the above preferred case where curing takes place before cutting, the backed carpet length may be rolled up for storage purposes preparatory to cutting it into individual carpets.
When using a rubbery latex compound for the in-sulating backing, it is preferred to perform the method by applying the precoat to the primary backing of the carpet (the precoat in this case being a lcltex of a stiff polymer), at least partially drying the latex~ applying a rubbery latex compound as the sound insulating backing, gelling and drying and curing the bac~ing, cutting an individual carpet from the backed carpet length, heating the individual carpet to soften the precoat, shaping the individual carpet to its desired configuration with the precoat in a softened con-dition, and allowing or causing the precoat to cool so as to hold the carpet in that shape. Alternatively, where a thermoplastic powder, for instance, is used as a precoat, then it is heated to soften it and cause it to flow around the bases of the carpet tuf~s prior to application of the sound insulating backing. A second softening is required before carpet shaping, followed by cooling o~ the precoat 5 ~
~o set it and hold the desired shape of the carpet.
In an alternative method, the backed carpet length is fed directly to a cutting station wherein individual carpets are cut from the l~ngth and each is formed into its desired configuration before the sound insulating backing is cured.
The above method according to the invention includes a further alternative in which an indefinite length of sound in~ulating backing is prepared separately and is adhered to the underside of the indeinite carpet length, the carpet contour retaining layer having been previously applied to the primary backing.
The invention also includes a sound insulating floor or wall covering comprising a carpet having a carpet pile carried by and extending from one side of a primary fabric backing and a sound insulating backing and a carpet contour retaining layer carried upon the other side of the primary fabric bac~ing, the carpet being in a non-planar configuration and held in said configuration by the stiffness of the carpet contour retaining layer which is in a set condition.
In addition, the invention further pro~ides a sound insulating floor or wall covering comprising a carpet having a carpet pile carried by and extending from one side of a ~25 primary fabric backing, and an unfoamed sound insulating backing and a carpet contour retaining layer carried upon the other side of the primary fabric backing, the sound insulating backing comprising cured rubber polymer having at least 200 parts by weight of filler per 100 parts by weight of rubber in the polymer.
s~
The invention fur~her includes a sound insulating floor or wall covering made by any one of the methods accord-ing to ~he invention as described above.
To illustrate the invention, the following examples will now be described wlth reerence to the accompanying drawings in which:-FIGURE 1 is a cross-sectional view of part of an indefinite length of backed carpeting;
FIGURE 2 is a schematic side elevational view of apparatus to be used for making the backed carpeting of Figure l;
FIGURE 3 is a cross-sectional view of an individual carpet being shaped between formers; and FIGURE 4 is a view similar to Figure 1 of another lS indefinite length of backed carpeting.
In Figure 1, there is shown an indefinite length of backed carpet, generally shown by numeral lO, the carpet being of conventional tufted constru.ction and having a pile 11 o synthetic fibres extending from a woven or non-woven primary backing 12. The primary backing is provided with a precoa~ 13 of a material or forming a carpet contour retain-ing layer which is a latex of a stiff polymer, e.g. a latex of a resinous styrene-butadiene copolymer as given below in Table A. This precoat is sandwiched between the primary backing 12 and a sound insulating backing 14. The sound insulating backing is a cured latex compound prepared accord-ing to any of the examples given below in Table B.
The backed carpeting of Figure l is produced upon apparatus shown in Figure 2. The indefinite length of un-backed carpet consisting of primary backing 12 and pile ll is fed with pile uppenmost from a roll 15 and across a bath16 containing resinous styrene-butadiene latex at which point the precoat is applied in conventional manner by a rotating lick roller 17. The precoated carpet is then fed beneath a radiant heater 18> which may be an infra-red heater, to partially dry the precoat.
The sound insulating backing 14 is then applied to the precoat by feeding the carpet beneath a doctor roll 19 which controls the thickness and rate of distribution o~ the uncured latex backing compound from a bank 20 of the compound maintained on the ingoing side of the doctor roll. The backed carpet is passed under another radiant heater 21 to gel the backing and from thence through a hot air circulating oven 21a to completely dry and cure the backing. Each point along the carpet takes approximately from 10 to 30 minutes to pass through the oven, the time taken to cure the backing depending upon the precise weight applied. The temperature of the air in the oven in this example is around 265F, but it is to be understood that the chosen temperature may be higher or lower than this and may be dependent upon the compound used for the backing, the speed at which drying and curing is required to take place and the capability of the carpeting to withstand high temperatures.
As may be seen from the examples in Table D below, the sound insulating backing may be extremely thin compared with normal foam backing provided for carpets while providing the required degree of insulation against low frequency sounds in vehicles. The maximum thickness shown by the examples is slightly greater than 0.08". The cured backing material in this maximum thickness may be shaped with the remainder of the carpet into a desired configuration and held in that configuration by the precoat material after heat has been applied to the carpet to raise ~he temperature of the precoat material above its softening point and the S precoat material has reset. Accordingly, to make preshaped individual carpets for fitting into the required sound insulating areas of a vehicle, the indefinite length of carpet 10 in planar condition is subsequently treated in one of two ways. In one way, it is rolled up for storage pur-poses for subsequent cutting, heating and heat forming. Thisoperation takes the form of die-cutting the carpet into individual carpets with minimum wastage, the die-cut carpets being of shapes projected ~rom their final desired configura-tion. After being cut into individual carpets, each carpet is heated up to a temperature sufficient to heat so~ten the resinous styrene-butadiene layer forming the precoat. In this instance, this temperature is around 350F. With the precoat in its softened condition, the carpet is formed into its desired configuration. One example of this is shown in Figure 3 in which an individual carpet 22 is being heat formed between shaped surfaces of two formers 23 and 24 which provide a configuration to the carpet to make it suit-able to be fitted onto the floor at the rear of the passenger compartment of a car. The formers may themselves be heated to maintain the softening temperature of the precoat u~til the desired configuration of the carpet has been attained.
The carpet is then allowed or caused to cool while remaining in its sandwiched position during which the precoat resets.
After removal of the carpet from between the formers, it is held in its desired configuration by the stiffness of the precoat layer which thereby acts as a carpet contour retaining layer.
In the second way of treating the indefinite length of backed carpet, it is fed directly from the hot air drying and curing oven ~o a cutting station to be formed into individual carpets and shaped between ormers in the manner described above.
Complete drying and curing of the sound insulating backing is considered to be most desirable and possibly essential if the indefinite length of carpet is to be rolled up for storage. However, it may be possible to shape in-dividual carpetsl if they are cut and shaped after having the insulating backing applied to them and gelled with little or no curing action having taken place. For instance, vacuum forming techniques may be used upon individual carpets to urge them into intimate contact with former sur~aces with the carpet edges being clamped so as to seal them. The sealed edges which would obviously be distorted would then be removed to make the carpet into its desired size and shape after forming it into its required configura-tion.
In another example, a carpet 25 is of inde~inite length, as shown in Figure 4. The carpet has a pile 26, woven primary backing 27, precoat layer 28 formed from a latex of a resinous styrene-butadiene copolymer and sound insulating backing 29 similar to those described with re~er~
er.ce to Figure 1. In this present example, however, the carpet is provided with a second carpet contour retaining layer 30 of resinous styrene-butadiene copolymer. This second layer is located on the side of the backing 29 remote 5 ~ ~
~rom the precoat 28. The carpet is made in the manner described with reference to Figure 2 above and is conveniently provided with its second layer 30 of copolymer by the known coating techniquesg after drying and curing of the sound insulating backing.
In alternative methods of formlng the sound insulating backlng on lndefinite or individual lengths of carpet, curtaln coater techniques are employed. Such techniques are well known in practice and will be clear to those skilled in the general art of applying coating layers to surfaces of conveyed lengths of textile materials.
TABLE A
For the purpose of providlng the carpet contour retaining layer in the above examples, a latex compound was used of the following formulation.
TAB~E A
Parts by Weight Polystyrene Latex 95.0 Potassium oleate 2.0 Sodium hexametaphosphate 0.5 SBR latex (27~/o bound styrene) 5.0 Antioxidanta 0.1 Calcium carbonate filler 50.0 Polyacrylate thickener Sufficient to give viscosity of 7~000 ~ 12~000 cps .
Calculated compound total solids 51.5%
a - Butylated reaction product of p-cresol and dicyclopentadiene sold under the trade name WINGSTAY~L by Goodyear Tire and Rubber Co.
TAB~E B
For the purposes of providing sound insulating backing in the above examples, a rubbery latex was used according to each of the following formulations.
5g:~
O~ JO OC~JI~Oooo~Oo ,n h 1 0 ~ 0 O
~ ~ o ~ o ~ ~ o ,~ a ~ ~
O ~-rl P~
Cd U~ h ~u ~ ,a u~ O ~ 0 o ~ u~ o ~ ~ o a~ o c~ o o ra ~
~10...... ' ..... I ..... o. a)~ao 0 ~1 O ~ r~ O ~ C~
O
~ 0 D C~ Q~
o ~ u~ c~1 0O C~O O ~ O O
O r~ O ~1 ~1 0 ~ O ~ ~~
_ ~d O~ O O~,~OU~OU~O,,Oo æ ~ P~
~ ~ 1 0 ~ o H rl 1:
.~ ~O~o ~o~,lo~l~,l~r~ 3E~
~ ~1 ~
u~ a) ~ ~
u~ u~ ~
o~u~c~o OC`Jl'~Dou~oooc)oo JJ
... I.............. o P~ ~ ~ 0 ~ 0 ,l ~ o ~ ~ o ~ ~ ,~
i~3 ~) S~ ~ ~0 ~_ ~ O ~q ~
O H O ~: ~J
4-1 ~ O C~
~ ~ ~ O rl ~ a u~ a ,1~ pa) o h ~ h u~ u~ o4 O ~ ~ ~ ~O ~I ~d u~
P~ ~ C ra ~ u~ tJ ~, .~0 ~~ Ph~
~ U~ O O r~ td ~d c ~ ~ . . ~ u~
u~ o u~ O
o U~ o O ~ ~ rl E3 h ,1 ~
~: u~ ~ ~ o ~ ~ a ~ ~ ~u~
~a o ~ o o ~ ~ o ~
0 ~ ~ a ~ o a J ~ o z l ¢ rl p ~ )V ~ rl~I H
U ~ ~ O ~1 El .0 ~ ~ ~ cd C.G ~ a ~ a X W a~ 1 O ~ 1 .G rl /
,G ~ a ~ ~ rO ~1 rl ~1 ~1 U~ 4~1 E U~ O ~rl ~ tl0 ~3JJ t~ ~ h ,i V ,1 rl X O ~ O EV ~ Q~ El O ,1 V
v ~~ o ~ aa,G ¢ 5~ ~ .G
a ~a~ 5~ ~ s~ ~ I ,, Pq o o ~ o o~ a ~ o o ~
c/~ v u~ a P~ ¢ U) C~ ¢ 1~ U~ U ) c P~ rQ c,) r~
' ~ -- 14 --,j;, "
Tn ~he above compounds in Table B, the latex was high solids latex with 68% solids~
Compounds 1 and 3 were applied as sound insulating backings in both deaerated and non-deaerated form~ Com-pounds 2 and 5 were applied in non-deaerated form only while compound 4 was applied in deaerated form only. The pro-perties of the compounds were as set out by Table C.
-- ----~
l ~ u~ ~ o ~
~ h, . eo 1`
u~l O ~ ~ O _ , _ _ :
o CO
hO O ~`
~ cr~
__.
a~
U~ ~ O
~d C~
Q ~1 ~ O O
a~ u~ o æ ~ 00 O ~1 ~
P~
o I ~ ~ ~D O
. .
o a~ ~ o ~ ~d co ~ c~
C~ C~ ~
~ _ - _ P~ ~- O
¢ I ~d oo ,1 0 o~
E-l !:: h . . 1~ O
~11 o a~ , c~ ^
t~ oa ~a aJ
~ CO o o O ~ O O
~d co ~ oo ~1 _ ~ O
I ~ oo ~ O O
~ ~ . . C~1 ,1 o a~ ~ o ~
a) ~a ..
~ _ _..
IJ ~ ~
0~ P P~
.~ ~ ~ _ bJ
P~
a~ t~ ~ ~,1 h t~
P~ ~1 ~
O ~ 00 ~rl U
51 U ~1 U
~4 ~1 ~d O
~ b.O ' .. ~ .. . _ .. _ ~
Compound l was deaerated by allowing it to stand for one day.
Compound 3 was deaerated by diluting it from
2,400 to 960 cps. ~from 88~/o to 85.2V/o T~S.~, standing 1 day, and then thickening it to 5,000 cps. by adding 0.41 p hls.
of a polyacrylate thickener.
Deaeration of compound 4 was carried out after addition of Barytes 22 by applying a vacuum of 28~5 inches of mercury or about 1 hour. Then the ammonia and gelant were added.
For purposes of determining characteristics of cured sound insulation backings applied to carpet according to the examples described above, portions of compounds 1 to 5 were applied at uniform thickness to fabric coated with polytetra1uoroethylene. After curing, the inished backings were removed from the fabric and the characteristics shown in the following Table D were obtained.
~$5~
_ _ _ .
, ~ oo ~ U~
u-) l ~ h O ~ ~ O
tl) cr~ O .-i o ~co ~1 ~ __ __ __ O ~
h O ~ C~l O 1--o ~a ~DO ~ O~ o~
_ .
F~
I~ I~
~ ~ O ~ ~Ul æ aJ ~
H t~ I`OC`J O00 ~I C`J 1--¢
O c~l _ . . _ _ _ .. .
c~ a) H C~ ~
~ ~ ~ O C~ O O
c~ o a~ ~ L~
¢ ~ ~ ~ O ~ O
I:q Zi _ . ._ _ _ H ~
~ ~ ~ I~
h O ~ O
u~C`~l o a) o oo o ~1 z~ ~a ~DO ~`1 0 `;tC`I r-l ~ ~ -- ~
~ a~
c~ ~ u~
~d o ~ o o s - o o~
a~ ~ ~ c~
~ ~l o ~ o ~ ~ ~
~o ~1 _ ~ c~
u ~ o o o o o ~ ~ ~ ~ c~ oo ~ ~ ~ o ~l o l~
- - - - - - - - - ---~ aJ ¢
u~
aJ
h h C~ ~ ^ rl O U
~ ~ ~ ~ ~ U~
,1 U~ ~ o U~
c~ O a~
~^ bO ~0~rl ~ ~ ^~ I
ra ~ o O,~ l ~,~
~0 ^ u ~ O~ C~l tn U U ~ Ir~) I
u tq ,~ ~ a.
,s a).~ E-~
~ h ~~a ~
~ O ~
i3 0 ~ ~ ¢ ~ ¢ ~, Th~ a~ove figures o Table D show that for each compound made in dea~rated and non deaerated form, insulating backing made from deaerated material has a greater tensile and tear strength and Shore Hardness than non-deaerated material. Its percentage elongation is less than for non-deaerated material. The maximum calculated thickness to produce minimum density requirements for sound insulation, i~e. 6Q ounces/square yard was 0.07.~ inches for the non-deaerated material of compound 1~ The thickness requirements for deaerated materials contrasted s~rongly with the non-deaerated materials. The use of such thin insulating layers has the effect of minimizing any resistance to flexing of the layers during shaping and setting of the individual carpets into their desired configurations.
of a polyacrylate thickener.
Deaeration of compound 4 was carried out after addition of Barytes 22 by applying a vacuum of 28~5 inches of mercury or about 1 hour. Then the ammonia and gelant were added.
For purposes of determining characteristics of cured sound insulation backings applied to carpet according to the examples described above, portions of compounds 1 to 5 were applied at uniform thickness to fabric coated with polytetra1uoroethylene. After curing, the inished backings were removed from the fabric and the characteristics shown in the following Table D were obtained.
~$5~
_ _ _ .
, ~ oo ~ U~
u-) l ~ h O ~ ~ O
tl) cr~ O .-i o ~co ~1 ~ __ __ __ O ~
h O ~ C~l O 1--o ~a ~DO ~ O~ o~
_ .
F~
I~ I~
~ ~ O ~ ~Ul æ aJ ~
H t~ I`OC`J O00 ~I C`J 1--¢
O c~l _ . . _ _ _ .. .
c~ a) H C~ ~
~ ~ ~ O C~ O O
c~ o a~ ~ L~
¢ ~ ~ ~ O ~ O
I:q Zi _ . ._ _ _ H ~
~ ~ ~ I~
h O ~ O
u~C`~l o a) o oo o ~1 z~ ~a ~DO ~`1 0 `;tC`I r-l ~ ~ -- ~
~ a~
c~ ~ u~
~d o ~ o o s - o o~
a~ ~ ~ c~
~ ~l o ~ o ~ ~ ~
~o ~1 _ ~ c~
u ~ o o o o o ~ ~ ~ ~ c~ oo ~ ~ ~ o ~l o l~
- - - - - - - - - ---~ aJ ¢
u~
aJ
h h C~ ~ ^ rl O U
~ ~ ~ ~ ~ U~
,1 U~ ~ o U~
c~ O a~
~^ bO ~0~rl ~ ~ ^~ I
ra ~ o O,~ l ~,~
~0 ^ u ~ O~ C~l tn U U ~ Ir~) I
u tq ,~ ~ a.
,s a).~ E-~
~ h ~~a ~
~ O ~
i3 0 ~ ~ ¢ ~ ¢ ~, Th~ a~ove figures o Table D show that for each compound made in dea~rated and non deaerated form, insulating backing made from deaerated material has a greater tensile and tear strength and Shore Hardness than non-deaerated material. Its percentage elongation is less than for non-deaerated material. The maximum calculated thickness to produce minimum density requirements for sound insulation, i~e. 6Q ounces/square yard was 0.07.~ inches for the non-deaerated material of compound 1~ The thickness requirements for deaerated materials contrasted s~rongly with the non-deaerated materials. The use of such thin insulating layers has the effect of minimizing any resistance to flexing of the layers during shaping and setting of the individual carpets into their desired configurations.
Claims (14)
1. A method of making profiled sound insulating floor or wall covering from a carpeting comprising attaching to the underside of the carpeting (1) a sound insulating layer which includes a curable rubbery polymer made by preparing a latex composition which includes at least 200 dry parts by weight of filler per 100 dry parts by weight of solids in the latex and (2) a layer of material for forming a carpet contour retaining layer, conditioning said carpet contour retaining layer of material to make it formable, and with the sound insulating backing in a flexible condition, contouring the carpeting to a desired configuration, and setting the material so as to form the contour retaining layer, the contour retaining layer in its set condition having a stiffness sufficient to retain the carpeting in its desired configuration.
2. A method of making profiled sound insulating floor or wall covering comprising attaching to the underside of a carpet length, (1) a sound insulating backing layer which includes a curable rubbery polymer made by preparing a latex composition which includes at least 200 dry parts by weight of filler per 100 dry parts by weight of solids in the latex and (2) a layer of material for forming a carpet contour retaining layer to form a backed carpet length, cutting backed individual carpets from the carpet length, conditioning said carpet contour material on each individual carpet to make it formable, and with the sound insulating backing in a flexible condition, contouring the individual carpet to a desired configuration, and setting the material so as to form the carpet contour retaining layer, the contour retaining layer in its set condition having a stiffness sufficient to retain the individual carpet in its desired configuration.
3. A method according to Claim 2 wherein the sound insulating backing is unfoamed.
4. A method according to Claim 2 wherein the rubbery polymer is applied to the carpet length in the form of a latex compound, the method including deaerating the compound before it is applied to the carpet length.
5. A method according to Claim 2 wherein the carpet length is treated with the material for forming the carpet contour retaining layer and then with the sound insulating backing.
6. A method according to Claim 5 wherein the material for forming the carpet contour remaining layer is a blend of a latex of a resinous polymer with a latex of a rubbery polymer.
7. A method according to claim 6 wherein another layer of material for forming an additional carpet contour retaining layer is applied to the carpet length, said additional material being disposed on the side of the sound insulating layer remote from the first carpet contour retaining layer.
8. A method according to Claim 6 wherein the sound insulating layer comprises a latex of a rubbery copolymer of butadiene and styrene and the contour retaining layer comprises a blend of a polystyrene latex with a latex of a rubber copolymer of butadiene and styrene.
9. A method according to Claim 2 wherein the rubbery polymer of the sound insulating backing is cured before cutting the individual carpets from the carpet length.
10. A method according to Claim 9 wherein the rubbery polymer is formed from a rubber latex compound which is capable of being gelled, the method comprising effecting gelling of the latex compound before curing the polymer.
11. A method according to Claim 2 wherein the rubbery polymer of the sound insulating backing is formed from a latex compound which is capable of being gelled, applying the layer of material for forming the carpet contour retaining layer and the sound insulating layer to the carpet length, gelling the sound insulating layer, passing said length directly to a cutting station wherein individual carpets are cut from the length and forming each into its desired configuration before said polymer is cured.
12. A method according to Claim 2 comprising applying the layer of material for forming the contour retaining layer to the carpet as a latex of a stiff polymer, at least partly drying the latex, and after application of the sound insulating backing, heating the polymer on each individual carpet so as to soften it and render it formable, and providing each carpet with its desired configuration before the polymer cools and resets.
13. A method according to Claim 2 comprising coating the underside of the carpet length with a precoat layer of material for forming the carpet contour retaining layer as a latex of a stiff polymer, at least partially drying the precoat layer, applying the sound insulating backing in the form of a rubbery polymer latex compound onto the precoat layer, gelling, drying and curing the backing, and after cutting backed individual carpets from the carpet length, heating each individual carpet to soften the precoat and render it formable, and providing each carpet with its desired configuration after which the polymer cools and resets.
14. A sound insulating floor or wall covering comprising a carpet having a carpet pile carried by and extending from one side of a primary fabric backing and an unfoamed latex-based sound insulating backing and a carpet contour retaining layer carried upon the other side of the primary fabric backing, the sound insulating backing comprising cured rubbery polymer having at least 200 parts by weight of filler per 100 parts by weight of rubber in the polymer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US77447677A | 1977-03-04 | 1977-03-04 | |
| US774,476 | 1991-10-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1116504A true CA1116504A (en) | 1982-01-19 |
Family
ID=25101354
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000296429A Expired CA1116504A (en) | 1977-03-04 | 1978-02-07 | Profiled sound insulating carpet |
Country Status (6)
| Country | Link |
|---|---|
| CA (1) | CA1116504A (en) |
| DE (1) | DE2809347C2 (en) |
| FR (1) | FR2382737A1 (en) |
| GB (1) | GB1601677A (en) |
| IT (1) | IT1109748B (en) |
| SE (1) | SE431309B (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE3430775A1 (en) * | 1984-08-21 | 1986-03-06 | Dr. Alois Stankiewicz GmbH, 3101 Adelheidsdorf | CARPET PART, METHOD FOR ITS PRODUCTION AND USE |
| DE3510722A1 (en) * | 1985-03-23 | 1986-09-25 | Schaeffler Teppichboden Gmbh, 8600 Bamberg | VEHICLE FLOOR PAD |
| DE3800779A1 (en) * | 1987-08-21 | 1989-03-02 | Dura Tufting Gmbh | DEFORMABLE TEXTILE SURFACE FOR LINING NOISED ROOMS AND METHOD FOR THE PRODUCTION THEREOF |
| CN111762108A (en) * | 2019-04-02 | 2020-10-13 | 上海汽车集团股份有限公司 | Sound insulation pad and manufacturing method thereof |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE1233584B (en) * | 1967-02-02 | Phoenix Gummiwerke Ag | Method for producing a mat for motor vehicles from a rubber base plate, a plastic film and a textile cover layer | |
| US3978263A (en) * | 1971-04-02 | 1976-08-31 | Verton & Wellensiek | Water-permeable floor covering boards |
-
1978
- 1978-02-07 CA CA000296429A patent/CA1116504A/en not_active Expired
- 1978-02-27 SE SE7802191A patent/SE431309B/en not_active IP Right Cessation
- 1978-03-02 GB GB8272/78A patent/GB1601677A/en not_active Expired
- 1978-03-03 FR FR7806253A patent/FR2382737A1/en active Granted
- 1978-03-03 IT IT67456/78A patent/IT1109748B/en active
- 1978-03-03 DE DE2809347A patent/DE2809347C2/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| IT1109748B (en) | 1985-12-23 |
| FR2382737A1 (en) | 1978-09-29 |
| GB1601677A (en) | 1981-11-04 |
| SE431309B (en) | 1984-01-30 |
| DE2809347A1 (en) | 1979-01-25 |
| DE2809347C2 (en) | 1985-03-07 |
| IT7867456A0 (en) | 1978-03-03 |
| FR2382737B1 (en) | 1984-08-10 |
| SE7802191L (en) | 1978-09-05 |
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