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EP0009993A1 - Improvements relating to methods and apparatus for plastic coating sheet material - Google Patents

Improvements relating to methods and apparatus for plastic coating sheet material

Info

Publication number
EP0009993A1
EP0009993A1 EP19790302144 EP79302144A EP0009993A1 EP 0009993 A1 EP0009993 A1 EP 0009993A1 EP 19790302144 EP19790302144 EP 19790302144 EP 79302144 A EP79302144 A EP 79302144A EP 0009993 A1 EP0009993 A1 EP 0009993A1
Authority
EP
Grant status
Application
Patent type
Prior art keywords
material
plastics
carpet
coating
sheet
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.)
Withdrawn
Application number
EP19790302144
Other languages
German (de)
French (fr)
Inventor
Ian David Slack
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
PLASTICISERS ENG
PLASTICISERS ENGINEERING Ltd
Original Assignee
PLASTICISERS ENGINEERING LIMITED
PLASTICISERS ENG
Priority date (The priority date 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 date listed.)
Filing date
Publication date

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING LIQUIDS OR OTHER FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00Processes for applying liquids or other fluent materials
    • B05D1/26Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material, e.g. fibrous top layer with resin backing, plastic naps or dots on fabrics
    • D06N7/0063Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00Condition, form or state of the materials
    • D06N2205/04Foam
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00Treatments by energy or chemical effects
    • D06N2207/08Treatments by energy or chemical effects using gas
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00Properties of the materials
    • D06N2209/12Permeability or impermeability properties
    • D06N2209/121Permeability to gases, adsorption
    • DTEXTILES; PAPER
    • D06TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06NWALL, FLOOR OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00Others characteristics
    • D06N2213/06Characteristics of the backing in carpets, rugs, synthetic lawn
    • D06N2213/063Porous back coating or pre-coat

Abstract

The present specification discloses a method and apparatus for applying a coating of a plastics material to sheet-like material which is pervious to air, for example, the back of a carpet. Basically plastics material (P) is extruded onto the back of the carpet (1) and the carpet (1) is passed over suction means (3) which draws the plastic material (P) against and between the fibres of the carpet base (1). The composite (1,P) is then cooled to solidify the plastics material and bond the plastic to the carpet back (1).

Description

  • [0001]
    The present invention relates to a method and apparatus for applying a coating of a plastics material to a sheet-like material which is pervious to air.
  • [0002]
    Many types of sheet or film material can be plastic-coated by passing them underneath an extrusion die so that a film of molten plastic is spread over the surface of the material being coated. Immediately after the molten plastic-is applied, the material passes between a pair of nip rollers. Usually one roller is rubber-covered and the other is a metal roller which has water circulating therethrough to remove the heat from the plastic. The pressure of the nip rollers ensures a bonding.of the plastic on to the other material.
  • [0003]
    If this known method is used for coating the back of carpets of any type, certain problems arise. Firstly, due to the sponginess of the carpet material, it is not possible to get the plastics coating to adhere to the back of the carpet without the nip rollers flattening the pile on the carpet. Further, the plastics coating tends to lie on the top of the fibres projecting from the back of the carpet and a very poor bond is obtained i.e., when the plastic has cooled it can be easily peeled off.
  • [0004]
    The aim of the present invention is to provide a method and apparatus which enables a plastics coating to be satisfactorily bonded to the back of a carpet without damaging the carpet or to any other sheet material which is pervious to air e.g. filter paper or a woven fabric.
  • [0005]
    According to the present invention there is provided a method of applying a coating of a plastics material to a sheet of material which is pervious to air, comprising the steps of extruding molten plastics material onto the sheet of material and passing the material over suction means to thereby draw the plastics material 'against the material.
  • [0006]
    According to a further aspect of the present invention there is provided a machine for applying a coati. g of a plastics material to a sheet of material which is pervious to air, said machine comprising an extrusion die for dispensing molten plastics material onto the sheet of material as it passes therebeneath,. and suction means arranged beneath the path of the material for drawing the plastics material against the sheet of pervious material.
  • [0007]
    In a preferred embodiment of the present invention the suction means comprises a box, the top of which has a perforated metal grid with a polished surface, a vacuum fan being arranged to draw air through the grid into the box so that as the sheet material is passed over the box, air is drawn through the material. Preferably, the box with the material sliding over it, is placed directly beneath the extrusion die from which the molten plastics material flows. Thus the film of plastics material is drawn onto the material by the air flow, the pressure drop beneath the plastic material causing atmospheric pressure to force the plastics material in to all the crevices and pores formed in the material.
  • [0008]
    The plastics coating can be any extrudable thermoplastic material or a mixture of such thermoplastic material with a filler such as chalk, talc, wood flour, etc. Further the plastic coating material with or without a filler may contain a foaming agent which is activated in the plastic extruder machine or in the die so that the plastics coating may have sponge-like properties. This latter plastic coating is especially suited for backing carpets.
  • [0009]
    Preferably the sheet of material is passed beneath the extrusion die at a slightly faster speed than that at which the plastic flows from the die, thereby stretching the plastics material to provide a more even layer and creating a degree of orientation i.e. aligning the polymer molecules to a certain extent to thus strengthen the coating. This may be facilitated by having the extrusion head angled so that the extruded plastics emerges from the die at an angle to the plane of the sheet material, the orifice of the die being in close proximity to the leading edge of the vacuum box.
  • [0010]
    After the extrusion die and suction box the material is preferably passed through a press nip with the plastics coating in contact with a water cooled roller to remove the heat from the plastic. Alternatively the plastics coating may be cooled by blowing a stream of air or gas onto the plastic surface. This latter alternative is especially suited to sponge backed carpet wherein the sponge would be flattened by a cooled press nip.
  • [0011]
    When a carpet is backed utilising the present invention a very strong bond is formed between the coating and the carpet, the plastics coating interlocking with the fibres in the back of the carpet. By varying the suction applied i.e. varying the effect of atmospheric pressure, it is possible to control the degree of penetration of the plastics coating into the carpet.
  • [0012]
    It has been found that carpets backed according to the present invention can be vacuum formed to form, for example, motor"car carpets, door panels etc.
  • [0013]
    The present invention will now be further described, by way of example, with reference to the accompanying drawing in which one embodiment of a machine according to the present invention for backing carpet, is diagrammatically illustrated.
  • [0014]
    In the embodiment of the present invention illustrated in the accompanying drawing the carpet 1 is moved along a generally horizontal path in the direction oi arrow A with its pile side down. The carpet passes through a first station comprising an extrusion die 2 and suction means 30 The suction means 3 comprises a vacuum box 4 which has a perforated uppermost wall 5 over which the carpet is drawn, the vacuum box 4 being connected to a suction pump 6. The suction pump 6 may take the form of an extraction fan. Directly above the suction means 3 is located extrusion die 2, the die 2 being arranged to dispense molten plastics material P onto the back of the carpet adjacent to the upstream end of perforated wall 5 taken in the direction of travel A. Thus downstream of extrusion die 2 the suction means 3 creates a low pressure region beneath the plastics material causing gravity and atmospheric pressure to force the plastics coating into the back of the carpet.
  • [0015]
    The plastic coating is preferably extruded at a slower speed than the speed at which the carpet passes the die 2, thereby stretching the plastics material and both providing a more even layer and creating a degree of orientation. This is facilitated by the die 2 being arranged so that the extruded plastics sheet is angled to the plane of the carpet at approximately 200, the orifice of die 2 being in close proximity to the leading edge of the vacuum box 4. This preferred facility can be applied to the treatment of any other material within the scope of the present invention, with equal effect.
  • [0016]
    After this first station the carpet is passed through a second station comprising an adjustable, rubber-covered, nip roller 7, a water-cooled roller 8, and a guide roller 9. The carpet 1 passes through the nip formed by rollers 7 and 8, and continues around water cooled roller 8 which removes heat from the plastics coating P; the carpet being guided around roller 8 by virtue of roller 9. The pressure of this nip can be adjusted by varying the position of roller 7 by means of pneumatic ram 10. The carpet is then passed to a collection station (not illustrated) where it is wound ready for storage and future use.
  • [0017]
    Whilst in the illustrated embodiment the plastic .coating is cooled by passing the carpet around a cooled roller, alternatively a stream or streams of cooling air or gas may be played onto the coating via, for example, nozzle 11 which is shown in dashed lines in the drawing. This latter cooling method is especially suited to carpets or other sheet material, when coated with a sponge-like plastics layer as referred to herebelow, wherein the press nip and roller arrangement 7,8,9, would flatten the foam.
  • [0018]
    The plastics coating used in the present invention can be any extrudable thermoplastic material or a mixture of such thermoplastic material with a filler such as chalk, talc, wood flour etc. Further, the plastic coating material with or without filler may contain a foaming agent which is activated in the plastic extruder machine or in the die so that the plastic coating may have sponge-like propertieso
  • [0019]
    The present invention thus enables a plastic coating to be satisfactorily bonded to the back of a carpet without requiring any excessive pressure to be applied which might damage the carpet pile. Such carpets can be subsequently vacuum formed to provide moulded motor car carpets or door panels. In such an event cooling of the plastics material coating can be delayed to obviate the necessity for reheating.

Claims (15)

1. A method of applying a coating of a plastics material to a sheet of material which is pervious to air, comprising the steps of extruding molten plastics material (P) onto the sheet of material (1) and passing the sheet of material over suction means (3) to thereby draw the plastics material (P) against the sheet of material (1).
2. A method as claimed in claim 1, when said sheet of material (1) is a carpet, the plastics material (P) being applied to the back of the carpet.
3. A method as claimed in claim 1 or 2, characterised in that the sheet of material (1) is passed over the suction means (3) at a speed which is greater than the speed at which the plastics material (P) is extruded onto said sheet of material (1).
4. A method as claimed in claim 1, 2 or 3, characterised in that the plastics material (P) is cooled after being passed over said suction means (3).
5. A method as claimed in claim 1, 2 or 3, characterised in that the sheet material (1) and plastics coating (P) are vacuum formed to a desired shape after passing over said suction means (3).
6. A method as claimed in any one of the preceding claims, characterised in that the plastics material (P) is an extrudable thermoplastic material.
7. A method as claimed in claim 6, characterised in that the plastics material (P) incorporates a filler.
8. A method as claimed in claim 6 or 7, characterised in that the plastics material (P) incorporates a foaming agent.
9. A machine for applying a coating of a plastics material to a sheet of material which is pervious to air, especially carpets, said machine comprising an extrusion die (2) for dispensing molten plastics material (P) onto the sheet of material (1) as it passes therebeneath, and suction means (3) arranged beneath the path of the material (1) for drawing the plastics material '(P) against the sheet of pervious material (1).
10. A machine as claimed in claim 9, characterised in that the extrusion die (2) is arranged so that the initially extruded plastics material makes an acute angle with the surface of said sheet of material (1).
11. A machine as claimed in claim 9 or 10, characterised in that said suction means (3) comprises a vacuum box (4) having a polished, perforated inlet surface (5) through which air is drawn by a fan (6), said sheet of material (1) being passed over said inlet surface (5) when the machine is in use.
12. A machine as claimed in claim 11, characterised in that the extrusion die (2) is located near to the upstream edge of said inlet surface (5) of the vacuum box (4).
13. A machine as claimed in any one of claims 9 to 12, characterised in that cooling means (8,11) are provided downstream of said suction means (3) for cooling the plastics material (P) drawn against said sheet of material (1).
14. A machine as claimed in claim 13, characterised in that said cooling means (8,11) is formed by a cooled roller (8), the sheet of material (1) and plastic coating (P) being passed around said cooled roller (8).
15. A machine as claimed in claim 13, characterised in that a nozzle (11) for producing a stream of cooling gas, acts as the cooling means.
EP19790302144 1978-10-10 1979-10-09 Improvements relating to methods and apparatus for plastic coating sheet material Withdrawn EP0009993A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB7839909 1978-10-10
GB3990978 1978-10-10

Publications (1)

Publication Number Publication Date
EP0009993A1 true true EP0009993A1 (en) 1980-04-16

Family

ID=10500216

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19790302144 Withdrawn EP0009993A1 (en) 1978-10-10 1979-10-09 Improvements relating to methods and apparatus for plastic coating sheet material

Country Status (3)

Country Link
EP (1) EP0009993A1 (en)
DK (1) DK424379A (en)
ES (1) ES484843A1 (en)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018233A1 (en) * 1979-04-24 1980-10-29 Plasticisers Engineering Limited Fire resistant carpets
EP0596457A2 (en) * 1992-11-03 1994-05-11 Hoechst Aktiengesellschaft Film-coated recyclable carpeting
WO1998038374A2 (en) * 1997-02-28 1998-09-03 The Dow Chemical Company Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
WO1998038375A2 (en) * 1997-02-28 1998-09-03 Shaw Industries, Inc. Carpet, carpet backings and methods
US7910194B2 (en) 1997-02-28 2011-03-22 Columbia Insurance Company Homogenously branched ethylene polymer carpet backsizing compositions
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1316765A (en) * 1962-02-16 1963-02-01 British Cellophane Ltd A method for applying a coating on strips
US3418198A (en) * 1964-03-06 1968-12-24 Du Pont Non-roughening microporous laminate and process for producing the same
GB1194886A (en) * 1966-10-27 1970-06-17 Greenbank Engineering Company Improvements in the Production of Tufted or Pile Carpets
US3843760A (en) * 1972-04-04 1974-10-22 Riegel Textile Corp Channel cloth extrusion apparatus and process

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1316765A (en) * 1962-02-16 1963-02-01 British Cellophane Ltd A method for applying a coating on strips
US3418198A (en) * 1964-03-06 1968-12-24 Du Pont Non-roughening microporous laminate and process for producing the same
GB1194886A (en) * 1966-10-27 1970-06-17 Greenbank Engineering Company Improvements in the Production of Tufted or Pile Carpets
US3843760A (en) * 1972-04-04 1974-10-22 Riegel Textile Corp Channel cloth extrusion apparatus and process

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018233A1 (en) * 1979-04-24 1980-10-29 Plasticisers Engineering Limited Fire resistant carpets
EP0596457A2 (en) * 1992-11-03 1994-05-11 Hoechst Aktiengesellschaft Film-coated recyclable carpeting
EP0596457A3 (en) * 1992-11-03 1995-05-17 Hoechst Ag Film-coated recyclable carpeting.
WO1998038374A2 (en) * 1997-02-28 1998-09-03 The Dow Chemical Company Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
WO1998038375A2 (en) * 1997-02-28 1998-09-03 Shaw Industries, Inc. Carpet, carpet backings and methods
WO1998038375A3 (en) * 1997-02-28 1998-12-03 Shaw Ind Inc Carpet, carpet backings and methods
WO1998038374A3 (en) * 1997-02-28 1998-12-10 Dow Chemical Co Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
US7910194B2 (en) 1997-02-28 2011-03-22 Columbia Insurance Company Homogenously branched ethylene polymer carpet backsizing compositions
US8283017B2 (en) 1997-02-28 2012-10-09 Columbia Insurance Company Carpet, carpet backings and methods
US8496769B2 (en) 1997-02-28 2013-07-30 Columbia Insurance Company Carpet, carpet backings and methods
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods
US9376769B2 (en) 1997-02-28 2016-06-28 Columbia Insurance Company Homogeneously branched ethylene polymer carpet backsizing compositions

Also Published As

Publication number Publication date Type
DK424379A (en) 1980-04-11 application
ES484843A1 (en) 1980-10-01 application

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Legal Events

Date Code Title Description
AK Designated contracting states:

Designated state(s): BE DE FR IT NL

17P Request for examination filed
18W Withdrawn

Withdrawal date: 19810105

RIN1 Inventor (correction)

Inventor name: SLACK, IAN DAVID