EP3593677B1 - Flat carpet, method and use - Google Patents

Description

TECHNICAL AREA

The invention relates to a flat mat and more particularly to an edge finish of a mat for imparting good flatness properties.

STATE OF THE ART

Carpets can be tailored based on well-defined desired characteristics or specific needs of an intended application or intended target audience. Thus, it is already known that a back layer can be applied to the back side of a carpet, e.g. in order to improve the non-slip properties, stability, comfort, sound insulation, etc.

One problem with many rugs is the edges that point upward and especially the corners of an angular rug. On the other hand, many carpets exhibit local thickening due to the finishing of the edges, which causes the edges to be higher than the central part of the carpet itself.

FROM 29 517 475 describes a mat in which this objective is achieved by curling the edge of said mat towards the mat and gluing it. The resulting difference in height between the edge and the central part is compensated by means of compensating material. The height of the compensation material depends on the height of the mat used.

US 2,952,577 describes a carpet tile with curved edges.

EP 1 709 893 relates to a method for covering the border of fabrics comprising an upper layer and a lower layer, provided with a back layer and in which the upper layer and the lower layer are at least partially joined in a first layer, the method comprising the following steps : - removal of the lower layer with the back in a second zone in which the lower layer is arranged so that it is not joined to the upper layer and which zone is located at the edge of the fabric; - fixing the upper layer of the second zone on the back.

US 2006/003130 describes a coating for exterior application to solid surfaces such as stairs, decks, patios, landing stages and walkways. The coating is formed from a top layer of fibrous material such as carpet, and a bottom layer of adhesive applied at a basis weight of 185 to 1000 gsm. The adhesive layer may have beads formed on the selvages which function as integrated seals. A release layer is attached to the glue to be removed during installation. The liner can be custom made for a step and have a pre-folded edge, which is pressed flat against the main liner portion prior to assembly and then matches the edge of a step.

Edges that point up or said raised edge finish is not only aesthetically undesirable, but can also pose a risk to user safety, as upward or raised edges are often a risk of injury. stumbling for inattentive users. Also due to the aging of the population, the target group of the elderly being particularly exposed to the risk of tripping and the consequences thereof, better solutions for the installation of flat carpets must be found. In this context, it must be ensured that the dimensional stability of the belt remains guaranteed also after commissioning. The mat can warp over time, not only with use, but also with sunlight and changes in temperature. This is why the present invention aims to provide a flat mat which has good dimensional stability at variable temperatures and at successive variations in temperature. In addition, the present invention aims to provide methods for the production of carpets, which meet the requirements mentioned above, these methods being sufficiently easy to carry out and the production of waste being avoided as much as possible.

The present invention aims to find a solution to at least some of the aforementioned problems. The document DE 635 865 C discloses a flat carpet according to the preamble of claim 1.

ABSTRACT

The invention is defined by the flat mat according to claim 1, by the method according to claim 12 and by the use according to claim 14.

In this way, it has been found that improved flatness properties are obtained compared to carpets according to the state of the art. In addition, it has been found that carpets can retain the flatness properties for longer as a result of the improvement in dimensional stability. The inventor has further discovered that the flat mat exhibits good dimensional stability at varying temperatures.

The aforementioned process makes it possible to produce in a simple manner and with the aid of already known processing machines, a carpet with excellent dimensional stability and very good flatness properties.

DESCRIPTION OF FIGURES

• The Figure 1 shows a first step of the process in which a carpet fabric 2 is already provided on its dorsal face with a dorsal layer 3 for the manufacture of a flat carpet 1 according to the present invention.
• The Figure 2 schematically shows the flat mat 1, the edge 22b of which is already folded.
• The Figure 3 shows a last step of the process, in which all the edges 21a, 21b, 21c and 21d are already folded into folded edges 22a, 22b, 22c and 22d.
• The Figure 4 schematically shows a flat mat in which the folded edges are provided with a space or intermediate layer 6.

DETAILED DESCRIPTION OF THE INVENTION

Unless otherwise defined, all terms which are used in the description of the invention, including technical and scientific terms, have the meaning as it is generally understood by those skilled in the art of the technical field of the invention. For a better evaluation of the invention, the following terms are explicitly explained.

"a", "a", "the" and "the" refer in this document to both the singular and the plural, unless the context clearly indicates another interpretation. For example, "a segment" means one or more than one segment.

When "approximately" or "approximately" is used in this document for a measurable quantity, a parameter, a duration or a moment, etc., by this is meant variations equal to or less than +/- 20%, preferably equal to or less than +/- 10%, with greater preference, equal to or less than +/- 5%, with even greater preference, equal to or less than +/- 1%, and even with greater preference again, equal to or less than +/- 0.1% of the cited value, insofar as these variations are applicable to the invention described. It should however be clearly understood here that the value of the quantity for which the term "approximately" or "approximately" is used will be specifically mentioned.

The terms "include", "comprising", "consist of", "consisting of", "endow", "include", "comprising", "include", "including", "contain", "containing" are synonyms and constitute inclusive or open-ended terms, which indicate the presence of the following, and which do not exclude or prevent the presence of other components, characteristics, elements, members, stages, known by the state of the art or described therein.

In the present invention the terms "fold" and "fold" are used in its usual sense, namely a full fold over an angle of 180 ° is a fold. To fold is to fold something on itself one or more times. A folding is the result of the action of folding something.

The quotation of numeric intervals by the extreme values includes all the whole numbers, the fractions and / or the real digits located between the extreme values, these extreme values included.

In a first aspect, the invention relates to a flat carpet comprising a carpet fabric with a visible side and a back side, and a back layer provided on the back side of said carpet fabric, one or more edges of said carpet fabric being folded back. up to its own back face and the folded edges thus obtained being fixed to said back layer by means of an adhesive tape.

It has thus been discovered that improved flatness properties are obtained with respect to carpets according to the state of the art. In addition, it has been found that carpets can retain the flatness properties for longer as a result of the improvement in dimensional stability. This offers the additional advantage that the warp and / or weft threads along the edge of the carpet fabric cannot come loose. Said adhesive strip may comprise a strip or tape of a predefined width sufficient to encompass the interface between the folded edges and the backing layer. Said adhesive tape is preferably a fabric which comprises all of said backing layer and at least part of the folded edges.

In a preferred embodiment, the present invention provides a flat carpet according to the first aspect of the invention, wherein the thickness of said backing layer corresponds to that of said carpet fabric.

This offers the advantage that the folded edges together with the double layer comprising said backing layer and said carpet fabric have the same thickness over the entire surface of the flat carpet, which improves the flatness properties of the carpet. In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said folded edges are folded back to an edge of said backing layer. This ensures a good connection from the folded edges to the back layer. In doing so, there are no areas where the effective thickness of the flat carpet is less than the double layer of the carpet fabric and the flatness properties are thus achieved.

The present invention provides a flat carpet in which said adhesive strip is partly provided on said backing layer and partly provided on said folded edge of said carpet fabric. This offers the advantage that said adhesive tape can impart a good adhesive effect between said backing layer and said folded edge.

In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said adhesive tape provides a surface density of between 80 gsm and 1000 gsm, preferably between 100 gsm and 500 gsm, with a greater preference between 150 gsm and 250 gsm. With the largest Preferably, said adhesive tape has a surface density of 160 gsm, 170 gsm, 180 gsm, 190 gsm, 200 gsm, 210 gsm, 220 gsm, 230 gsm, 240 gsm, or any value in the range.

In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said adhesive strip comprises a strip of fabric with glue. The use of a fabric strip with glue as an adhesive strip offers the additional advantage that good two-dimensional stabilization of the adhesive strip is guaranteed. As a result, the flat mat exhibits improved dimensional stability after it is put into service. The fabric strip is preferably coated with an adhesive on a first side for an adhesive effect on the backing layer and the folded edges, and is provided with a non-adhesive protective layer on the opposite second side.

In a preferred embodiment, the present invention provides a flat carpet according to the first aspect of the invention, wherein said web of fabric consists of a natural yarn, for example cotton or polyester with a surface density of 200 gsm.

This offers the advantage that the natural yarn is thermally stable and does not undergo any deformation during and after the application of the adhesive tape on the backing layer and the folded edges. The application of the adhesive tape is preferably carried out at increased temperature or by means of local heating while the adhesive tape is pressed. Both during heating and cooling, thermal stresses can thus arise, which can cause deformation of the flat mat. Since a thermally stable material is chosen, this effect is greatly reduced. Examples of natural yarns are cotton, silk, linen, and bamboo. Cotton is preferably chosen.

More preferably, said web of fabric has a surface density of greater than 50 gsm, greater than 75 gsm, greater than 100 gsm, greater than 125 gsm, greater than 150 gsm or even greater than 175 gsm, so that sufficient reinforcement can be guaranteed. More preferably, said fabric strip has a surface density of less than 500 gsm, less than 450 gsm, less than 400 gsm, less than 350 gsm, less than 300 gsm or even less than 250 gsm, so that the adhesive strip does not substantially contribute to local thickening of the flat mat.

In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said glue consists of a polymer ethylene vinyl acetate (EVA) and / or a modified ethylene vinyl acetate (EVA) polymer with a surface density between 50 and 300 gsm. More preferably, said glue is composed of an ethylene-vinyl acetate (EVA) polymer, taking into account the good processing properties and the good adhesive effect with respect to the carpet fabric.

In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said glue consists of a polyolefin (PO) polymer, copolymer and / or terpolymer. and / or modified polyolefin (PO) with a surface density between 50 and 300 gsm.

In a preferred embodiment, the present invention provides a flat mat according to the first aspect of the invention, wherein said glue consists of a polyester polymer (PET) and / or a modified polyester polymer (PET). ) with a surface density between 50 and 300 gsm.

Said glue is preferably applied with a surface density greater than 50 gsm, greater than 70 gsm, greater than 90 gsm, greater than 110 gsm, greater than 130 gsm or even greater than 140 gsm, so that sufficient reinforcement can be guaranteed. More preferably, said glue is applied with a surface density of less than 260 gsm, less than 240 gsm, less than 220 gsm, less than 200 gsm, less than 180 gsm, or even less than 160 gsm, so that the glue does not substantially contribute to local thickening of the flat mat.

In a preferred embodiment, the present invention provides a flat carpet according to the first aspect of the invention, wherein said backing layer is secured to said carpet fabric by means of a hot melt adhesive. Preferably, said hot melt adhesive is applied in a uniform amount on the interface between said backing layer and said carpet fabric, so that thermal and / or mechanical stresses do not occur in the double layer during production. More preferably, the double layer comprising the back layer and the carpet fabric is stabilized by a thermal process, also called 'heat-setting' or heat-setting, so as to attenuate or even completely eliminate any present or residual tensions.

In a preferred embodiment, the present invention provides a flat carpet according to the first aspect of the invention, wherein the folded edges of the carpet fabric are secured to the back side of said carpet fabric. The aim thus sought is to obtain improved flatness properties. Most preferably, the folded edges are glued to the back side of said carpet fabric, and still more preferably said edges are glued by means of a hot melt adhesive and at a temperature between 150 ° C and 250 ° C, more preferably at a temperature between 160 ° C and 200 ° C, and with an even greater preference, between 180 ° C and 200 ° C.

In a second aspect, the present invention provides a method of manufacturing a flat mat according to claim 12.

The aforementioned process makes it possible to produce in a simple manner and with the aid of already known processing machines, a carpet with excellent dimensional stability and very good flatness properties.

Those skilled in the art will quickly understand that different execution methods can be proposed to achieve the same result. Thus, one can choose to apply a backing layer of smaller width and length on the back side of the carpet fabric; or, the backing layer can be applied to the backing side of the carpet fabric, after which an edge of the backing layer is removed. Both possibilities make it possible to provide a predefined area of the carpet fabric, which can be folded up in a subsequent step, so as to obtain folded edges. In a preferred embodiment, the present invention provides a method of manufacturing a flat carpet according to the second aspect of the invention, wherein said backing layer is partially removed prior to folding back said carpet fabric.

Once the predefined edges are cleared, the corners of the carpet fabric are preferably cut obliquely. The aim thus aimed at is that when the edges of the carpet fabric are folded up, the latter is not folded twice. This also contributes again to the improvement of the flatness properties.

In a preferred embodiment, the present invention provides a method according to the second aspect of the invention for the manufacture of a flat carpet according to the first aspect of the invention.

In a third aspect, the present invention provides for the use of a flat carpet according to the first aspect of the invention, as a floor covering in a retirement home, hospital, hotel or holiday accommodation.

In the following, the invention is described with the aid of non-limiting examples, which illustrate the invention and which are not intended to limit its scope or cannot be interpreted in this sense.

EXAMPLES EXAMPLE 1

The figures 1 to 3 show a process for the manufacture of a flat carpet 1 according to the present invention.

The Figure 1 shows a first step of the process in which a carpet fabric 2 is already provided with a backing layer 3 on its back side. The carpet fabric 2 and the backing layer 3 provide the same thickness d , so that when folding the peripheral edges 21a, 21b, 21c to 21d during a subsequent process step, the total thickness of the flat carpet 1 over its entire area is equal to 2d. The backing layer 3 is attached to said carpet fabric 2 by means of a hot melt adhesive. The latter has a viscosity of between 5500 and 7500 mPa.s at 190 ° C, determined according to ASTM D 3236. This hot melt adhesive offers a good bond and no warping has occurred during production of the carpet. . The backing layer 3 has a smaller area (length and width) compared to the carpet fabric 2 and is provided on the carpet fabric 2 such that four edges 21a, 21b, 21c and 21d are formed along the periphery. . The corners of the carpet fabric 2 are cut obliquely so that the folding of the edges 21a, 21b, 21c and 21d in the next step does not cause two edges located next to one to overlap. other. The same hot melt adhesive as for the attachment of the backing layer 3 to the carpet fabric 2 is applied to the four edges 21a, 21b, 21c and 21d. In the Figure 1 , only the adhesive strip 4b on the edge 21b is shown.

The Figure 2 schematically shows the flat mat 1, the edge 22b of which is already folded. The folded edge 22b is stabilized by heating. This constitutes a heat-setting or heat-setting step, having the effect of stabilizing the thermal tensions in the carpet fabric 2, possibly in the back layer 3 and mainly in the folded edge 22b. This additional thermal stabilization step guarantees additional stability and therefore improved flatness properties of the flat belt 1.

The Figure 3 shows a last step of the process, in which all the edges 21a, 21b, 21c and 21d are already folded into folded edges 22a, 22b, 22c and 22d. The edge between the folded edges 22a, 22b, 22c and 22d on the one hand and the backing layer 3 on the other hand (represented by a dotted line in the Figure 3 ) has been covered with ironing tape 5a, 5b, 5c and 5d, respectively. This ironing tape 5 is made from a 100% cotton fabric with an area density of 200 gsm and an area density of the ironing tape of about 350 gsm. The ironing tape 5 is further coated with an ethylene vinyl acetate (EVA) glue, which can be activated by heating.

A flat mat 1 is thus obtained with flatness properties and improved dimensional stability. After subjecting the flat mat to intensive use, it turns out that very good flatness properties are obtained.

EXAMPLE 2

The flat mat according to the section of the Figure 4 shows a carpet fabric 2 of a thickness d with a backing layer 3 'of a thickness d2, the latter thickness being greater than the thickness d. To further obtain a flat mat, an additional support layer 6 with a thickness d1 has been provided at the level of the folded edges 22 ', so that the thickness d2 corresponds to the sum of the thicknesses d1 and d.

COMPARATIVE EXAMPLE

A mat is made according to Example 1, by not applying adhesive tape to the connecting edge between the folded edges and the backing layer. After commissioning, the belt initially has a relatively good edge finish. After being put into service for a longer period of time, however, it turns out that the folded edges detach locally in several places on the back side of the carpet fabric. In some places, the carpet therefore exhibits edge thickening, which reduces its flatness properties. In some places, it also turns out that a few warp and weft threads are coming loose from the carpet fabric. For these reasons, the flat carpet with the adhesive strip 5 therefore has a technical advantage over a carpet without the adhesive strip.

The carpets according to Example 1 and according to Comparative Example were subjected to stability tests under different conditions. Stability tests and results are shown in Table 1. Table 1. Dimensional stability of the carpet according to Example 1 and of the carpet according to the Comparative Example under different humidification and heat conditions, determined according to the ISO 2551 standard. Example 1 Comparative example average / mm interval / % average / mm interval / % Route THE T THE T THE T THE T Stabilized for two days at 20 ° C and 65% RH 297.03 298.18 0.00 0.00 297.62 297.50 0.00 0.00 2 hours at 60 ° C 295.90 296.84 -0.38 -0.45 296.52 296.34 -0.37 -0.39 2 hours in water at 60 ° C 293.15 297.82 -1.32 -0.12 290.44 296.75 -2.47 -0.25 24 hours in an oven at 60 ° C 292.34 296.88 -1.60 -0.44 291.74 295.82 -2.02 -0.57 Stabilized for two days at 20 ° C and 65% RH 294.07 297.53 -1.00 -0.22 291.63 296.66 -2.06 -0.28 L carpet length
T belt width

The results show that the carpet according to Example 1 exhibits greatly improved dimensional stability over Comparative Example after having traveled a humidification and temperature path, due to reduced shrinkage.

Claims (14)

1. Flat carpet (1) comprising a carpet fabric (2) with a visible side and a back side, as well as a back layer (3), smaller in width and length than the carpet fabric (2), provided on the back side of said carpet fabric (2), wherein one or more edges (21a, 21b, 21c, 21d) of said carpet fabric (2) are folded back, wherein said folded back edges (22a, 22b, 22c, 22d) thus obtained are fixed to said back layer (3) by means of an adhesive tape (5a, 5b, 5c, 5d), characterised in that said folded edges (22a, 22b, 22c, 22d) are folded back to an edge of said back layer (3), wherein said adhesive tape (5a, 5b, 5c, 5d) is partially provided on said back layer (3) and partially arranged on said folded edge (22a, 22b, 22c, 22d) of said carpet fabric (2).
2. Flat carpet (1) according to claim 1, wherein the thickness (d, d2) of said back layer (3) corresponds to the thickness (d) of said carpet fabric (2) and optionally to the thickness (d1) of an intermediate layer (6) of a thickness (d1) arranged between said folded edges (22').
3. Flat carpet (1) according to claim 1 or 2, wherein said adhesive tape (5a, 5b, 5c, 5d) has a surface density between 80 gsm and 1000 gsm, preferably between 150 gsm and 500 gsm.
4. Flat carpet (1) according to claim 3, wherein said adhesive tape (5a, 5b, 5c, 5d) comprises a fabric tape with glue.
5. Flat carpet (1) according to claim 4, wherein said fabric tape comprises a natural yarn, for example cotton, or polyester with a surface density of 200 gsm.
6. Flat carpet (1) according to claim 4 or 5, wherein said adhesive comprises an ethylene-vinyl acetate (EVA) polymer and/or a modified ethylene-vinyl acetate (EVA) polymer with a surface density of 50 to 300 gsm.
7. Flat carpet (1) according to claim 4 or 5, wherein said adhesive comprises a polymer, copolymer and/or terpolymer of polyolefin (PO) and/or modified polyolefin (PO) with a surface density of 50 to 300 gsm.
8. Flat carpet (1) according to claim 4 or 5, wherein said adhesive comprises a polyester polymer (PET) and/or a modified polyester polymer (PET) with a surface density of 50 to 300 gsm.
9. Flat carpet (1) according to at least one of claims 1 to 8, wherein said back layer (3) is attached to said carpet fabric (2) by means of a hot melt adhesive.
10. Flat carpet (1) according to at least one of claims 1 to 9, wherein the folded edges (22a, 22b, 22c, 22d) of the carpet fabric (2) are attached to the back side of said carpet fabric (2).
11. Flat carpet (1) according to claim 10, wherein the folded edges (22a, 22b, 22c, 22d) are glued to the back side of said carpet fabric (2).
12. Method of manufacturing a flat carpet (1), comprising the following steps:

    - Provision of a carpet fabric (2) with a visible side and a back side;

    - Attachment of a back layer (3) to the back side of said carpet fabric (2);

    - Folding of one or more edges (21a, 21b, 21c, 21d) of said carpet fabric (2) to an edge of said back layer (3), smaller in width and length than the carpet fabric (2);

    - Fixing the folded edges (22a, 22b, 22c, 22d) of said carpet fabric (2) with said back layer (3) by means of an adhesive tape (5a, 5b, 5c, 5d), wherein said adhesive tape (5a, 5b, 5c, 5d) is partially provided on said back layer (3) and partially arranged on said folded edge (22a, 22b, 22c, 22d) of said carpet fabric (2).
13. Method according to claim 12, wherein said back layer (3) is partially removed before folding the edges (21a, 21b, 21c, 21d) of said carpet fabric (2).
14. Use of a flat carpet (1) according to at least one of claims 1 to 11 as a floor covering in a nursing home, hospital, hotel or holiday home.

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