DE2354665A1 - METHOD OF MANUFACTURING RUGS AND RUGS - Google Patents

Description

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65-21.6l5P (21.6l6H) October 31, 1973

Tillotson Corporations Needham, Massachusetts, V.St.A.

Process for the manufacture of pile carpets and carpets ''

The invention relates to a method for the production of pile carpets or carpets (hair or Loops) with a primary underlay or a base fabric with a pile of yarn on one side and a bundle or yarn blanket on the other, with A resin coating is provided. The invention comprises furthermore, the products obtained by the process, the underside of which is provided with a thermoplastic resin is to set the carpet pile in the primary underlay with sufficient strength and durability O

The main part of the current carpet production at all takes place through pile formation - with yarn, that on

65- (312 666) NöGs

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a primary backing or a base fabric with the formation of a pile of yarn (hair or loops) on the base fabric is pinned or chained on, with part of the yarn, known as a bundle or yarn blanket, on the opposite side of the primary pad protrudes or can be seen. After pinning or chaining on the primary underlay with the thread or bundle corner, a secondary underlay is adhered, so that one To achieve dimensional stability, draping and increasing the blocking of the pile yarn, i.e. the strength, with which the yarn is retained in the primary backing. In most cases, using a secondary underlay is necessary in order to achieve a carpet with the desired dimensional stability and draping. That used to lay the second backing on top of the yarn or bundle top and primary backing Adhesive holds the yarn firmly in place while securing and preventing the individual fibers of the yarn Pilling in the yarn and controls the dimensional stability (handle or draping) and secures the connection of the secondary underlay to the carpet. It is extremely important that the adhesive not migrates through the primary backing into the protruding yarn hairs or loops, otherwise the pile is stiff and the quality of the final carpet will suffer.

The most widespread adhesive system currently in use is based on a latex or carboxylated latex, the is applied to the underside of the primary backing. The water from the latex system then travels through the primary Backing into the protruding pile yarn, while the adhesive from the primary backing and the yarn or Bundle cover is retained. The latex is then cured and the end product (the carpet) in large ovens

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dried at elevated temperatures. This process is because of the large ovens required, the energy requirements, the space required, and the labor involved Operation of the ovens is relatively expensive.

A second adhesive system known as the "hot melt system" known is based on the use of vinyl resins. This system is also unfavorable, as there are specially heated containers for transport, storage, handling and application of the resin to the bottom the primary document requires. In addition, the molten resins have a tendency to get into the pile of yarn to wander, which leads to carpets of poor quality.

The fixing or blocking of the yarn or pile in the carpet, which is done with the two systems (latex system or hot melt system with vinyl adhesives) is undesirably low and the yarn can easily pulled from the primary support. This slight blockage of the pile makes the laying out of Carpets in one or a few large piece (s) necessary, which match the shape of the surface to be covered, while the use of small ones rectangular pieces to cover the same area is less desirable because of the risk of thread being pulled out of the underlay when using small pieces of carpet is significantly increased. If carpets with a desirable feel and "drapery" provide better pile security · than is currently achievable, they could be in "small." rectangular parts are designed, which would significantly reduce the cost of laying work.

It has been suggested to use stronger adhesives 40982 5/0997

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to be used between the layers to increase the security of the pile. The adhesion of a secondary document on the yarn or bundle cover of the carpet, however, leads to extraordinary problems, which the application this has prevented stronger adhesive or glue.For the full effectiveness of the adhesive in terms of the attachment of the yarn to the primary backing, it must be all or substantially all of the yarn or Penetrate the bundle cover. Further penetration of the adhesive beyond the primary backing into the however, protruding pile into it must be practically prevented if the protruding yarn pile is not stiff and the quality of the resulting carpet should not be degraded.

A pile carpet having improved Florsicherung without increasing the hardness or stiffness of the preceding yarn (hair or S hlingen _c) .Therefore, would be very desirable, in particular, the existing in the current systems, significant requirements should be limited in terms of heat treatments. Also, a pile carpet with desirable hand feel and "drape" with or without a second or secondary backing would be desirable.

Developed for this purpose according to the invention Procedure based on finding that the bottom a pile carpet on which the yarn or bundle cover of the pile yarn protrudes or is visible, with a thermoplastic resin composition can be coated by having the primary backing (with yarn or Bundle cover) impregnated with a plasticizer for the resin 'and subsequently practically plasticizer-free

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powdered resin applied to the impregnated base. Since the resin applied in this way is practically free of plasticizer, it has a considerable affinity for the plasticizer present in the base, which is thereby absorbed by the resin and enriched on the resin-coated surface of the base. Thanks to this "attraction" of the resin, the side of the primary substrate provided with the pile is not or hardly coated with resin, so that this does not make the protruding pile yarn stiff. The resin powder is then melted by heating. The melted resin ensures the adhesion between the yarn or bundle cover and the primary base and thus leads to a. better pile protection. According to one embodiment, a secondary or second backing, impregnated with plasticizer or without plasticizer, can be applied to the resin-coated primary backing and adhered thereto while the resin is being melted .

In practice, the impregnation of the primary backing with plasticizer can take place before or after the pile formation on the primary pad. The plasticizer can be used neat or diluted with a solvent for the plasticizer. After impregnation and pile formation becomes the primary backing with powdered unplasticized resin composition on top of the yarn or Bundle top side coated »The plasticizer is sucked into the resin coating, so that the surface the primary backing, which is opposite the resin-coated surface, is practically free of plasticizer will. After that, the coated resin is melted, for example by heating in an oven. Thanks to the absorption of the plasticizer, there is little or no resin in the The above pile yarn is present and if so, then only

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on the surface of the primary support. Preferably, the primary backing or the base fabric is in front the impregnation with the softener provided with pile, so that the yarn or bundle cover then lighter can be impregnated with plasticizer, which improves the subsequent resin adhesion to it.

The method according to the invention has the same characteristics compared to the method according to the prior art significant advantages that the pile protection obtained far better than that achieved with current adhesives. Furthermore, the better the pile security becomes less or no impregnation of the foregoing pile yarn so that it has the desired appearance (and behavior) maintains, even if a relatively open (or permeable) primary underlay material how jute is used.

Any method which is practical for applying the resin to the impregnated substrate can be used uniform resin coating is obtained. For example, the impregnated base be brought into a gas dispersion of the resin. This is expedient by placing the pad in a Chamber and sprinkling resin powder on the base accomplished in such a way that only the yarn or bundle cover side of the backing is in contact with the resin comes. Alternatively, the surface of the impregnated base can be placed on top of a resin bed or spread the resin on the underside of the pile provided with a scraper, for example will. Since the resin powder contains little or no plasticizer, excess powder falls off

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Pad "at the same distance, from the contact with the resin from. The resin is melted at a temperature between about 275 and 35O ⁰ C, preferably 300 and 325 ° C.

It has been found that it is essential to clean the backing with the plasticizer prior to contact with the resin to impregnate, since it has been found that stiff products with an easily breaking or tearing The coating can be obtained if the substrate is not impregnated with plasticizer. With the resin you can different amounts of plasticizer are mixed, as long as the amount mixed is not so large that the Resin becomes liquid or caked and loses its free flowability as a powder.

Suitable resins which can be used in the process of the invention are those disclosed by Plasticizers are solvated and can adhere to the substrate; these include vinyl polymers such as Polyvinyl chloride, polyvinyl acetate, vinyl chloride-vinyl acetate copolymers, Polyvinylidene chloride and the like.

There can be some plasticizer that will coat the resin plasticized without damaging the base. Examples of suitable plasticizers include adipic acid esters such as diethyl adipate, di-n-hexyl adipate; Glycol derivatives such as diethylene glycol dipelargonate, Triethylene glycol dipelargonate; chlorinated paraffins; Phosphoric acid derivatives such as tri- (2-ethylhexyl) phosphate, Tributoxyethyl phosphate, triphenyl phosphate, Cresyl diphenyl phosphate, tricresyl phosphate and the like; Phthalic acid derivatives such as dimethyl phthalate, dibutyl phthalate, dioctyl phthalate, butyl cyclohexyl phthalite

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or similar; Sebacic acid derivatives such as dimethyl sebacate, Dibutyl sebacate, diisooctyl sebacate or the like.

Any suitable material can be used to form the primary backing, that of the incorporated Plasticizer is not plasticized like jute or polypropylene in fabric form. Furthermore, any Yarn composition currently used in carpets are used such as polyamides (types of nylon), Polyester, acrylic fibers and wool.

The resin composition used as the coating can contain 100% resin or the usual resin additives such as fillers, dyes, pigments, blowing agents, heat stabilizers, light stabilizers, etc. As was mentioned above, the resin can also contain a plasticizer, but only in a low concentration, so that the resin composition remains in the form of a free flowing powder. The plasticizer can be used alone or diluted with any suitable solvent for the plasticizer such as a mineral oil, with a 5O: 5O mixture of plasticizer and solvent as has been found particularly suitable.

When using a resin with an additive such as a filler, it has proven to be useful First, apply a light resin coating to the primary base and then a second layer of powdered filler-containing resin. It was found, that a second coat of about 10 parts filler per part resin gives excellent results.

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The primary backing is impregnated with enough plasticizer so that the resin that comes with the fabric or tissue is in contact, is plasticized and practically all plasticizers are absorbed by the resin, thereby rendering the opposite surface of the backing free or substantially free of resin coating will.

According to a particular feature of the invention, a secondary backing, which is a woven or knitted Fabric or sheet material, which may or may not be impregnated with plasticizer, with the resin coating layering of the primary base provided with pile brought into intimate contact. Dana.ch becomes the resin melted by the action of heat to create adhesion between the primary and secondary support and the top of the yarn or bundle on the primary. Document. To bring about the adhesion of the two documents to one another the relative ratio of the plasticizer in both documents to the resin is within those specified above Values held. ^

The invention is described below with reference to the attached Drawing explained; Fig.l shows a scheme for a system for carrying out the inventive method and

2 shows a section through a product according to the invention without secondary support.

According to Fig.l, a primary base 1 (or a base fabric or base material) is a woven fabric such as jute or polypropylene, unwound from a storage roll 2 and to a conventional pile

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formation device 3 passed, where yarn 4 to form a pile surface 5 and a yarn or bundle cover 6 on the underside 7 of the primary base is incorporated into this. The primary base provided with pile is guided along under the guide roller 8 onto the drum 9. The drum 9 is coated with an absorbent material such as felt and rotates in a bath of liquid plasticizer 10 and is in contact with the primary base provided with the pile in such a way that liquid plasticizer absorbed by the coating of the drum 9 adheres to the primary base 1 and the Yarn or bundle cover 6 is passed on by absorption. The plasticizer-impregnated, provided with pile primary pad 11 runs under the guide _{roller 12 along and over the upper open end of a B e} container 14, which contains a fluidized or fluidized bed of powdered resin, which with the underside of the impregnated with the pile provided with impregnated primary Pad 11 comes into contact and remains adhered to it. Das.Harz -Fließoder -Wirbelbett 15 is formed by production of gas in the manifold or reservoir chamber 16, through the holes 17 in the plate 18 and into the container B _e fourteenth The resin powder adhering to the primary base 11 sucks the plasticizer from the primary base, thereby solvating the resin. The resin coated primary pad 19 travels under the guide roller 20 over the surface of a heated roller 21 which is maintained at a temperature at which the resin on the underside of the primary pad melts. The resin-coated primary backing 22 provided with pile is then wound onto a storage roll 23.

The carpet according to the invention comprises a crimean backing 1 with a pile 4 on one side and yarn or Bundle covers 6 on the other, which are coated with a molten thermoplastic resin 24.

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Claims (9)

Claims U) Process for the production of pile carpets or carpets with a primary backing with a thread pile on one side and a thread or bundle cover on the other, which has a resin coating, marked by the fact that the primary base is impregnated with a liquid plasticizer, the impregnated base on the Garnbzw. Bundle top side coated with a solid resin powder that can be plasticized by the plasticizer and heating the resin to melt it onto the primary backing and yarn or bundle cover. 2. The method according to claim 1, characterized-characterized, that pile and bundle blankets before the impregnation of the primary backing with the plasticizer in the primary Base to be formed. 3. The method according to claim 1 or 2, characterized in that a secondary or second pad on the resin coating of the primary substrate before or applied during the melt treatment of the resin to bond the primary backing to the secondary backing will. . 4. The method according to any one of claims 1 to 3, characterized in that the resin is polyvinyl chloride includes. 5. The method according to any one of the preceding claims, characterized in that on the solid resin powder before it is heated to melt the resin Coating is applied which is a mixture of 4 0 9 8 2 5/0997 - 12 - 235Λ665 a solid resin powder which can be plasticized by the plasticizer and comprises a filler. 6. Carpet or Tetrpichwaren with a primary Underlay with a pile of yarn on one side and a yarn or bundle cover on the other, which with a fused thermoplastic resin composition is coated with a plasticizer for the resin, while the pile is practically resin-free, obtainable according to one of the preceding claims. 7. Carpet according to claim 6, characterized by a melted-together resin with the primary Underlay connected secondary underlay. 8. Carpet according to claim 6 or 7, dadiarch characterized, that the resin is polyvinyl chloride. 9. Carpet according to one of claims 6 to 8, characterized by an additional coating with co-molded thermoplastic. Resin and filler on the thermoplastic melted together Resin composition. 409825/0 9 97