EP0837170B1 - A method for manufacturing a carpet and a carpet thus manufactured - Google Patents

A method for manufacturing a carpet and a carpet thus manufactured Download PDF

Info

Publication number
EP0837170B1
EP0837170B1 EP97203230A EP97203230A EP0837170B1 EP 0837170 B1 EP0837170 B1 EP 0837170B1 EP 97203230 A EP97203230 A EP 97203230A EP 97203230 A EP97203230 A EP 97203230A EP 0837170 B1 EP0837170 B1 EP 0837170B1
Authority
EP
European Patent Office
Prior art keywords
layer
latex
carpet
fabric
semi
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 - Lifetime
Application number
EP97203230A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0837170A2 (en
EP0837170A3 (en
Inventor
Jan Carel Van Doorn
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.)
Best Wool Carpets Bv
Interface International BV
Original Assignee
TAPIJTFABRIEK BEST BV
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
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=19763705&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=EP0837170(B1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by TAPIJTFABRIEK BEST BV filed Critical TAPIJTFABRIEK BEST BV
Publication of EP0837170A2 publication Critical patent/EP0837170A2/en
Publication of EP0837170A3 publication Critical patent/EP0837170A3/en
Application granted granted Critical
Publication of EP0837170B1 publication Critical patent/EP0837170B1/en
Anticipated expiration legal-status Critical
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Links

Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor 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
    • D06N7/0068—Floor 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 the primary backing or the fibrous top layer
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor 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
    • D06N7/0071—Floor 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
    • D06N7/0073—Floor 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 applied as an aqueous dispersion or latex
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/04—Vegetal fibres
    • D06N2201/042—Cellulose fibres, e.g. cotton
    • D06N2201/045—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/12—Fibres being in the form of a tape, strip or ribbon
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/02—Dispersion
    • D06N2205/023—Emulsion, aqueous dispersion, latex

Definitions

  • the invention relates to a method for manufacturing a carpet by starting from a fabric and tufting threads or yarns therein, and to apply a layer of latex to the semi-finished product thus obtained.
  • the invention furthermore relates to a carpet consisting of a fabric comprising thread or yarn tufted therein and a layer of latex present on the obtained semi-finished product.
  • FR-A-2 238 582 discloses a method for manufacturing a carpet by starting from a fabric and tufting threads or yarn therein, and to apply a layer of latex to the semi-finished product thus obtained, wherein the layer of latex is applied to the pile side.
  • the free ends of the tufted threads or yarn are provided with a thin layer of a latex solution, as a result of which the latex will not contact the base layer of the fabric.
  • the free ends thus provided with a thin film of latex are dipped into another fabric comprising a support layer provided which a base of a thick layer of latex. Both fabrics are passed through an oven in order to harden the layers and subsequently cut and separated into two carpet layers, i.e. a mother carpet comprising the fabric having tufted threads or yarns therein and a daughter carpet comprising a support layer provided with the latex layer and embedded yarns therein.
  • the tufted carpet according to the known prior art consists of a web or a ribbon-like fabric, into which web or fabric thread or yarn has been tufted.
  • the tufting step leads to a semi-finished product, whereby the loose ends of the thread or the yarn form the contact surface and the underside of the semi-finished product obtained by tufting is covered with a layer of latex, thus fixing the incorporated pieces of thread or yarn.
  • a flat carpet comprising various patterns can be obtained by means of a weaving technique.
  • a flat carpet was also obtained from a natural product, such as coconut fibres.
  • desired patterns can be obtained by means of a weaving technique, but this is a highly labour-intensive and thus costly technique.
  • a woven carpet having a particular surface area requires a production time of for example 8 hours, whilst a comparable tufted carpet can be produced within 10 minutes.
  • Such a carpet can be obtained by using a method as disclosed in claim 1. As a result of this the contact surface of the tufted carpet becomes the surface to which previously the layer of latex was applied.
  • the method according to the invention makes it possible to manufacture a tufted carpet which looks like a woven carpet.
  • a method for manufacturing a tufted and knotted carpet is known from WO-A-93 07790. it is not known to apply the layer of latex to the pile side.
  • the tufted carpet thus known consists of yarns which have been tufted through a primary base layer, such as jute or polypropylene, and whereby the ends of the yarns are embedded in a layer of latex, which has been applied to the back side of the primary base layer.
  • a layer of jute is applied to the layer of latex in order to reinforce the underside of the carpet thus obtained. It is also possible, however, to use another woven material to reinforce the underside, for example a plastic material, such as polypropylene, possibly mixed with natural fibre materials.
  • a plastic material such as polypropylene, possibly mixed with natural fibre materials.
  • the aggregate of layers will be smoothened on the latex side by carrying out a calender operation.
  • a ribbon fabric rather than a web, because the web, which may usually also be used for the tufting of carpet, is too stiff for obtaining a carpet according to the invention.
  • the tufting step is preferably carried out by means of a so-called sliding comb from a coarser machine whilst using a finer machine. In this manner a coarse-looking carpet is obtained, which is precisely what is desired.
  • a pre-coating consisting of a solution of a synthetic latex, in particular on a base of carboxylated styrene butadiene ribber, is applied first.
  • a solution may contain usual additives, such as fillers.
  • the applied solution is heated, so that the solvent will evaporate and the synthetic layer will remain behind in the form of a layer. Then the layer of latex is applied.
  • the layer of latex is then covered with a layer of jute, and the whole is subsequently calendered, so that the side to be laid on the floor will be smooth.
  • the contact surface of the carpet will then correspond with the underside of the semi-finished product of a tufted carpet known so far, to which the layer of latex was so far applied.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
  • Carpets (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
  • Laminated Bodies (AREA)
  • Printing Plates And Materials Therefor (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
EP97203230A 1996-10-18 1997-10-16 A method for manufacturing a carpet and a carpet thus manufactured Expired - Lifetime EP0837170B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
NL1004309A NL1004309C1 (nl) 1996-10-18 1996-10-18 Werkwijze voor het vervaardigen van een tapijt en aldus vervaardigd tapijt.
NL1004309 1996-10-18

Publications (3)

Publication Number Publication Date
EP0837170A2 EP0837170A2 (en) 1998-04-22
EP0837170A3 EP0837170A3 (en) 2000-01-05
EP0837170B1 true EP0837170B1 (en) 2004-04-07

Family

ID=19763705

Family Applications (1)

Application Number Title Priority Date Filing Date
EP97203230A Expired - Lifetime EP0837170B1 (en) 1996-10-18 1997-10-16 A method for manufacturing a carpet and a carpet thus manufactured

Country Status (6)

Country Link
EP (1) EP0837170B1 (da)
AT (1) ATE263860T1 (da)
DE (1) DE69728488T2 (da)
DK (1) DK0837170T3 (da)
ES (1) ES2219725T3 (da)
NL (1) NL1004309C1 (da)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU3665399A (en) * 1998-04-27 1999-11-16 Interface, Inc. Floor covering with inverting tufted or sewn face
AU2011273433A1 (en) 2010-06-30 2013-02-14 Erutan Bv A method for providing a textile product, the product itself and uses thereof

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL6615182A (da) * 1966-10-27 1967-02-27
NL7410072A (nl) * 1973-07-27 1975-01-29 T & A Naylor Limited Werkwijze en inrichting voor het vervaardigen van weefsel met pool.

Also Published As

Publication number Publication date
ATE263860T1 (de) 2004-04-15
EP0837170A2 (en) 1998-04-22
ES2219725T3 (es) 2004-12-01
EP0837170A3 (en) 2000-01-05
DE69728488T2 (de) 2005-02-24
NL1004309C1 (nl) 1998-04-21
DE69728488D1 (de) 2004-05-13
DK0837170T3 (da) 2004-08-02

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