CN1051691C - Carpet construction - Google Patents

Abstract

The present invention relates to a carpet structure with a built-in foam layer and a loop base layer. Fabric covering layers are manufactured on the two surfaces of the foam layer, and a base covering layer has loops. The base layer of the carpet is fixed to a foam interlayer in a conventional method. At the same time, the foam interlayer can be fixed to a carpet plush bundling layer by materials identical to the materials used for felting and sealing the carpet plush bundling layer. Besides, the foam interlayer can also be prefabricated and stored and then can be stuck onto the carpet precoated with a binding agent.

Description

Carpet backing and installation system

The present invention relates to a kind of new carpet backing and installation system, particularly relate to the carpet that adopts suede hook and pile loop erecting device.

As represented at my No. 4,822,658, United States Patent (USP), I find, can produce a kind of new laying carpet, utilize suede hook and pile loop mode that carpet for example is used in wall to the laying of wall.Utilize the invention before this, in its preferred embodiment, carpet is shaped on the lower surface that is being covered with circle, and this carpet utilizes a kind ofly has that the suede hook that temporarily covers is additional to bring installation.These bands are placed on certain position on the floor, and the width of pressing carpet along the edge on floor is perhaps placed in the place that requires the floor to be made additional fastening with certain escapement.These bands are covered, and make placement, sectility and fixedly during carpet, and they do not adhere on these pile loops prematurely.Then the covering of band is peelled off and the suede hook is exposed and carpet is adhered on the floor.

My early stage patent also disclose the main stor(e)y that contains carpet suede bundle and below the possibility of adding a froth bed between the bottom of pile loop is arranged.

My early stage patent has been represented a kind of carpet with foam build-up layer 4,822, No. 658.When making the carpet of this structure, bottom pile loop layer can be laminated to when foam forms on the foam, makes foam solidify on the back side of carpet, thereby makes the following pile loop layer of carpet be fixed in suede bundle layer on the top of carpet.

The major defect of this way is, the carpet semi-finished product must be delivered to foam production factory, makes it to carry out lamination on the foam production line, and perhaps another kind of possible alternative is that carpet manufacture merchant must buy foam mechanical in his plant investment.

And, directly be fixed to the method for carpet with foam, foam there is quite difficulty.Do not have covering to go the DIMENSIONAL STABILITY that guarantees that foam is certain, the foam that does not have supporting can be easy to be sheared, and spreads to split or break away from from carpet.

In addition, in many cases, wish very much to adopt more low-density foam.Yet, when adopting the method that directly foam is applied on the carpet main stor(e)y, all need foam usually, so that foam obtains enough stability with higher density.

Some carpets have a kind of bottom such as polypropylene or jute " effect bottom " on the carpet back side really.Foam directly is fixed on this bottom may reduces the difficulty relevant, but realize that this purpose way brought the delamination problems between foam and the effect bottom with foam.

At last, foam directly is added to this way on the carpet main stor(e)y, require usually when foam solidifies, on foam, to place covering or pile loop bottom, and foam can produces some extra disadvantages in being shaped.

The purpose of this invention is to provide a kind of improved carpet backing and installation system that includes a built-in foam and a band pile loop bottom.

Have found that this can be fixed to a substrate with conventional method with this foam layer and reach then by making at its two-sided fabric covering layer froth bed of (end covering has pile loop) that has.Can be simultaneously this foam layer be fixed on the carpet matte layer, also foam layer can be made, stored and attach it to subsequently on the carpet that scribbles binding agent in advance in advance with the same material of bonding and sealing carpet matte layer.

This improvement can make the carpet that contains the pile loop bottom make with existing machinery, makes it to utilize binding agent and utilizes present commercially available conventional carpet machinery that one the sixth of the twelve Earthly Branches is ready, and the froth bed of previously having made adheres to the back side of carpet.

And, the foam that can preserve different-thickness by the carpet manufacture merchant more on request with it attached on the different carpet matte layers.

The fabric covering layer that is positioned over prefabricated froth bed can also increase the holding property of size of foam, allows to adopt more low-density foam, and in a preferred embodiment, also allows to use to be independent of the foam that the carpet remainder is made, for example sheet foam.

Fabric is chemistry or polymer preferably, because it can bring size stability to foam, and provides some flexibilities for foam simultaneously and prevents that foam from tearing and break.

In addition, in a preferred embodiment, the upper surface fabric covering layer can be a kind of fabric that a rough external surface is arranged, and such as shape or multi-turn fabric with upright line, this will improve its bonding to substrate.

Though can adopt conventional method that fabric covering layer is positioned on the foam, in a preferred embodiment, wish putting again behind the foam forming on the surface of covering at foam.Can prevent that like this foam from infiltrating through fabric covering layer because this infiltration is undesirable, particularly for have for the foam under-clad layer that carpet is fixed to the required pile loop in floor be like this.

Therefore, one aspect of the present invention is that the laminate carpet that is routed to the floor by no independent heelpiece constitutes, it comprises that (i) has fully the main stor(e)y with the suede bundle of its first covering, (ii) one thereon the surface one first fabric covering layer is housed and the froth bed with second covering that exposes pile loop is housed at its lower surface, (iii) first and second coverings are fixed to the material of froth bed, and (iv) the upper surface of first covering of froth bed is fixed to main stor(e)y, thereby make suede bundle and pile loop be exposed to material on the outer surface of carpet.

The present invention's carpet on the other hand comprises: one has and inserts and the main stor(e)y by this layer and the suede bundle that fully its first covering got up, one has surperficial from it first fabric covering layer that exposes knitting wool of stretching out and the froth bed that exposes second fabric covering layer of pile loop at its lower surface, and first tissue layer of froth bed is fixed to main stor(e)y, thereby make the upright line of the first covering upper surface and the suede bundle by main stor(e)y sealed together, and make the suede bundle of froth bed lower surface and the binding agent of the outer surface that pile loop is exposed to laminate carpet.

In conjunction with the accompanying drawings some embodiment of the present invention is narrated now.Wherein,

Fig. 1 is according to the cutaway view of a preferred laminate carpet embodiment of the present invention before froth bed installs to substrate;

Fig. 2 is the cutaway view that this its froth bed of preferred laminate carpet embodiment and substrate have been installed together.

With reference to the accompanying drawings, Fig. 1 has represented the conventional substrate 1 of polypropylene or other conventional material, and these materials form to contain and pass the main stor(e)y that bottom forms the yarn 3 of bunch shape suede bundle 5.

There is shown froth bed 7.This froth bed can utilize the method for any routine such as chemistry blowing, foaming or preformed foam sheet, or any other can produce the method manufacturing of needed elasticity, shear strength and TENSILE STRENGTH.In this preferred embodiment, foam make the back and do not have excessively to infiltrate under the situation of pile loop fabric covering layer, utilize binding agent, flame stacked, or ultrasonic wave maybe can produce satisfied any other method of tearing stripping intensity, the covering with circle 9 and circle 11 of one multi-turn braided fabric is attached on the froth bed, thereby has kept flexibility highly.

Yet, in some cases,, can when foam is forming or solidifying, on foam, put a covering though often be not desirable.In this case, though, as previously mentioned, still can from independently the sealing and make of foam, obtain some favourable parts favourable aspect the impermeability of THICKNESS CONTROL and covering not as the carpet backing and installation system that has at first formed froth bed.

The shortcoming of just foam being put covering before foam curing is, many pile loops fabric is penetrated into worthless degree sometimes, and may produce tabular effect, because foam is around many pile loops fabric and interior hardening.

Owing to lost directional motion, contingently ooze choosing and also may damage or hinder all or the functions of some their expections of fabric pile loops performance.And this layered manner has reduced by expanding the ability that its thickness reduces many pile loops fabric weight.Expand its thickness and reduce many pile loops fabric weight and may cause that liquid foam further permeates, thereby cause that liquid foam is seeped into the another side of pile loop fabric, thereby some or all fabric pile loops can not be used.

The extensibility on length and width is favourable to make the pile loop layer keep very.The thickness and the less pile loop layer that is penetrated into of foam of expansion make the pile loop layer flexible.This carpet finished product that can make it be built-in with foam pad is easier to roll with more soft.

In addition, at the method for the online deposition foam thickness of control foam most effectively during attached to the carpet yarn bottom with foam.Because this layered manner requires to make foam when foam is attached to substrate, and is difficult to the precise thickness or the height of control foam layer in this process.

In any case major advantage of the present invention can for some manufacturers, be utilized their existing mechanical earlier by with fabric acquisition being wrapped on the foam two sides, adds this covering when foam curing, this is than being easier to, and even now has other shortcoming.

More preferably, multi-turn fabric 11 is a kind of circles of remaining silent, and this means these pile loops or utilization bonding covering and the used binding agent of froth bed, or utilize the method that foam is penetrated into fabric (in not preferred embodiment), it is fixed firmly on many pile loops bottom.Have found that be used to make circle to be fixed in fabric and reach desired level, knitted fabric is desirable, particularly warp-knitted fabric.The multi-turn layer is preferably two-layer all to adopt this warp-knitted fabric, but also can adopt woven material or other material." fabric " speech be meant any natural or artificial fiber with weaving or non-weaving or pressing and material.

Many pile loops layer with circle 9 and circle 11 needs not be identical materials or has identical intensity.Last multi-turn layer requires not too strict, preferably has pile loop 9 or upright line so that help to adhere on the bottom 1.Multiple covering may be suitable for, as long as they have necessary strength, flexibility and adhere to ability on the foam.

As previously mentioned, have circle 9 last multi-turn covering preferably knitwear or other " coil of remaining silent " material, but can be the fabric with upright line, these upright lines be the coils such as the unfixed knop cloth in position of many needling materials or felt or other circle yet.Can contemplate that these upright lines stretch into the carpet main stor(e)y and help froth bed is adhered on the carpet main stor(e)y.Generally, carpet all has one polyacrylic " bottom ", but carpet of the present invention under the situation that does not have the tangible bottom that forms main stor(e)y by the warp and the parallel of carpet, has same good performance.

In the embodiment in figure 1, after wrap with many pile loops fabric on the two sides of foamed material, being easier to transportation and storing than bag not.Bao foam is not torn easily, is torn and makes dirty, is unsuitable for loading and unloading, transportation and storage.In addition, the multi-turn covering on foam two sides has been strengthened the shearing and the TENSILE STRENGTH of foam greatly, keeps even can improve the natural elasticity of foam simultaneously.

Preferred structure adopts the sheet foam, because the sheet foam is than the easier control thickness made from other method of foam.

Fig. 2 shows the carpet that is contained on the foam substrate.Foam can be installed with the routine techniques of any use binding agent 13.If employing multi-turn fabric preferably utilizes binding agent to infiltrate and sealing will have the multi-turn material of circle 9 and the suede bundle 5 of carpet sticks together.

This binding agent can be used conventional carpet machinery, apply with once-through method, or off-line applies behind line end or lamination, so-called once-through method is that used binding agent is done encapsulation simultaneously, the stacked work of the bottom second time of sticking bundle and prefabricated cloth bag froth bed, and off-line process is to utilize skim (i.e. " contact layer ") binding agent will be installed with the conventional main bottom of yarn and prefabricated sheet foam layer sticks together.The product of gained can increase size stability, obtains better suede bundle adhesiveness flexibility.

This carpet can be made into brick-shaped or makes volume to be used to be laid between the walls.Yet the present invention is at the long term dimensional stability of carpet and lay aspect the carpet of bigger wall of difficult problem and the laying between the wall, has biggest advantage.

Claims (20)

1. laminate carpet that does not have independent heelpiece to be used for laying ground, it comprises:

(i) main stor(e)y, it has the suede bundle that fully its first covering got up;

A (ii) froth bed, it has first fabric covering layer that wraps in its upper surface and second fabric covering layer two that exposes circle is arranged at its lower surface

(iii) first and second coverings are fixed to the material of froth bed;

(iv) the upper surface with first covering of froth bed is fixed on the main stor(e)y, makes the outer outer proximal surface that is exposed at carpet of suede bundle and circle.

2. carpet according to claim 1 is characterized in that it exposes the lower surface that circle covers froth bed fully.

3. carpet as claimed in claim 2 is characterized in that, the circle that exposes of second covering is sealed by the fabric of second covering.

4. carpet as claimed in claim 3 is characterized in that, its second covering is a knitted fabric.

5. carpet as claimed in claim 3 is characterized in that, its second covering is a braided fabric.

6. carpet as claimed in claim 3 is characterized in that, first covering is a kind of fabric that exposes upright line that has.

7. carpet as claimed in claim 6 is characterized in that, first covering is to utilize to be coated with all over second whole surface of main stor(e)y and the binding agent that is penetrated in the upright line of first covering to be fixed on the main stor(e)y.

8. carpet as claimed in claim 7 is characterized in that, the upright line of first covering is sealed the circle in the fabric of covering.

9. carpet as claimed in claim 2 is characterized in that, the circle of second covering is sealed in the froth bed during foam curing.

10. carpet as claimed in claim 9 is characterized in that, first covering has the surperficial from it circle that exposes that protrudes upward, and these circles are sealed by froth bed by sticking being linked on first covering and during foam curing.

11. carpet as claimed in claim 2 is characterized in that, carpet is produced with complete uniform cross-sectional area, and it can be cut and be fixed on the certain position when being laid between the walls.

12. carpet as claimed in claim 3 is characterized in that, last under-clad layer fabric is to be fixed to foam surface there not being foam to penetrate under the situation of fabric basically.

13. carpet as claimed in claim 12 is characterized in that, froth bed is a kind of prefabricated sheet foam.

14. carpet as claimed in claim 12 is characterized in that, froth bed is the chemistry blowing.

15. a laminate carpet that is routed to the floor, it comprises:

(i) main stor(e)y, the suede bundle that it has insertion and also fully its first bread is lived by this layer;

A (ii) froth bed, it has first fabric covering layer of the outer naked wire that surface from it stretches out and second fabric covering layer that exposes circle is arranged at its lower surface;

(iii) first fabric covering layer with froth bed is fixed to main stor(e)y, make first covering upper surface outer naked wire and to pass the suede bundle of main stor(e)y sealed together, and make the suede bundle and the outer binding agent that is exposed at the opposite face of carpet lamination of circle of froth bed lower surface.

16. carpet as claimed in claim 15 is characterized in that, these circles are sealed in the fabric of second covering.

17. require 16 described carpets, it is characterized in that second covering is not infiltrate basically under the situation condition of second covering at foam, adheres to the lip-deep of froth bed as profit.

18. carpet as claimed in claim 17 is characterized in that, first covering is not adhere to the lip-deep of froth bed under foam is seeped into the situation of first covering basically.

19. a method of making laminate carpet, it comprises the steps;

(i) make the foam layer that there are a froth bed and at least two surrounding layers in a centre, one of them covering almost all has circle on its whole surface;

(ii) make a carpet suede bundle layer, on surface thereof, have the carpet of exposing suede bundle;

(iii) foam layer is fixed on the suede bundle layer, carpet suede bundle and circle are exposed on the apparent surface of carpet.

20. method as claimed in claim 19 is characterized in that, also is included in the additional step that at first makes foam curing before the fixing covering, to prevent that foam from penetrating in the fabric covering layer significantly.

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