EP3795742A1 - Produit de tapis tufté recyclable - Google Patents

Produit de tapis tufté recyclable Download PDF

Info

Publication number
EP3795742A1
EP3795742A1 EP19204778.5A EP19204778A EP3795742A1 EP 3795742 A1 EP3795742 A1 EP 3795742A1 EP 19204778 A EP19204778 A EP 19204778A EP 3795742 A1 EP3795742 A1 EP 3795742A1
Authority
EP
European Patent Office
Prior art keywords
primary backing
polymer
yarn
backing
nonwoven
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Withdrawn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
EP19204778.5A
Other languages
German (de)
English (en)
Inventor
Charles Winston Reynolds
Michael Bejon SETHNA
Christopher Lee CRAIG
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.)
Aladdin Manufacturing Corp
Original Assignee
Aladdin Manufacturing Corp
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
Application filed by Aladdin Manufacturing Corp filed Critical Aladdin Manufacturing Corp
Priority to PCT/US2020/050987 priority Critical patent/WO2021055414A1/fr
Priority to EP20865038.2A priority patent/EP4030976A4/fr
Priority to US17/753,503 priority patent/US20220333300A1/en
Publication of EP3795742A1 publication Critical patent/EP3795742A1/fr
Withdrawn legal-status Critical Current

Links

Images

Classifications

    • 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
    • D06N7/0065—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 pile
    • 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
    • D05C17/023—Tufted products characterised by the base fabric
    • 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
    • D06N7/0078—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 a hot melt
    • 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
    • D06N7/0081—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 with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • 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
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/061—Polyesters
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/121—Permeability to gases, adsorption
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
    • D10B2331/04—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products polyesters, e.g. polyethylene terephthalate [PET]
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets

Definitions

  • the presently-disclosed invention relates generally to recyclable tufted carpet products and methods of making the same, and more particularly to recyclable tufted carpet products having a primary backing with a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength and methods of making the same.
  • tufted fabrics such as carpets and rugs are made up of various components and different types of material.
  • Various components include a primary backing, secondary backing, latex adhesives and tuft material.
  • fabrics such as carpets incorporating a primary backing of natural or synthetic plastic materials such as polypropylene in a woven fabric form.
  • broadloom carpets are normally produced by having a primary backing of woven slit film polypropylene into which there is inserted a plurality of tufts by a tufting machine.
  • Tufts may be made from natural or synthetic fibers including wool, polyamides, polyester (e.g., polytrimethylene terephthalate), polypropylene, and acrylics.
  • These tufts, forming the pile of the carpet extend through the primary backing from one face to the other in the form of loops such that long loops on one side form the pile of the carpet and the short loops are located on the opposed side of the backing. Cut pile carpet is achieved by cutting the long loops on the face of the carpet.
  • An adhesive coating, e.g., of latex, is then applied as a primary anchor coat to the side of the primary backing opposite the pile side in order to lock the tufts in the primary backing.
  • the necessity for an anchor coat such as latex results in a relatively heavy fabric which in some cases lacks optimum flexibility.
  • the latex also has a water component that must be driven off during manufacture, which requires ovens that consume high amounts of energy.
  • carpets formed with a latex backing require formation on a tenter frame to prevent the latex from shrinking during drying.
  • the residual stress caused by the tenting process requires carpets made with a latex backing to be stretched when installed, which in turn requires additional labor and components such as tack strips to hold the stretched carpet in place.
  • polyester nonwovens are unfit to serve as a primary backing due to poor tear resistance, tensile strength, and tuft bind strength during and after tufting.
  • One or more embodiments of the invention may address one or more of the aforementioned problems.
  • Certain embodiments according to the invention provide fully recyclable tufted carpet products having polyester nonwoven primary backings with a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength after the fabric is tufted.
  • a tufted carpet product is provided, the carper being recyclable.
  • the tufted carpet product comprises a primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa/ 20 cm 2 , the primary backing comprising a polymer (e.g., polyester) nonwoven; a plurality of polymer yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.
  • a polymer e.g., polyester
  • the polymer of the nonwoven may be similar or identical to the polymer of the yarn.
  • the polymer of the nonwoven and the polymer of the yarn may both be a polyester.
  • the primary backing may comprise an air permeability from about 1000 to about 4000 l/m 2 /sec.
  • the primary backing may comprise a thickness greater than 0.35 mm at 0.5 Pa / 25 cm 2 . Unless otherwise mentioned, thicknesses are measured under a pressure applied, the pressure being 0.5 Pa over 25 cm 2 .
  • the adhesive may comprise a polyester hot melt adhesive.
  • the adhesive may comprise a polyester nonwoven secondary backing.
  • the tufted yarn may comprise or even consist of polyester, such as virgin polyester, e.g. virgin PET, or recycled polyester, such as recycled PET, or any combination of such.
  • a method of preparing a tufted carpet product comprises providing a primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 , the primary backing comprising a polymer (e.g., polyester) nonwoven; tufting a polymer (e.g., polyester) yarn through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and anchoring the plurality of yarn loops to the second surface of the primary backing.
  • a polymer e.g., polyester
  • the polymer of the nonwoven may b similar or identical to the polymer of the yarn.
  • the polymer of the nonwoven and the polymer of the yarn may both be a polyester.
  • the primary backing may comprise or have an air permeability from about 1000 to about 4000l/m 2 /sec at 200 Pa / 20 cm 2 .
  • the primary backing prior to the tufting step, may comprise or have a thickness greater than 0.35 mm at 0.5 Pa / 25 cm 2 .
  • the primary backing may comprise polyethylene terephthalate (PET) filaments and copolymer of polyethylene terephthalate (coPET) filaments.
  • PET polyethylene terephthalate
  • coPET copolymer of polyethylene terephthalate
  • the primary backing may comprise 80-100 wt% PET and 0-20 wt% coPET. This w% is based upon the total weight of the primary backing.
  • the primary backing may be at least one of hydroentangled, needled, calendered, and/or through air bonded prior to tufting.
  • the recyclable tufted carpet product may be free of latex.
  • anchoring the plurality of yarn loops to the second surface of the primary backing may make use of an adhesive by applying said adhesive to the second surface of the primary backing.
  • Anchoring the plurality of yarn loops to the second surface of the primary backing may comprise applying a polyester hot melt adhesive to the plurality of yarn loops and the second surface of the primary backing.
  • anchoring the plurality of yarn loops to the second surface of the primary backing my comprise applying a nonwoven secondary backing to the plurality of yarn loops and the second surface of the primary backing.
  • the nonwoven secondary backing may comprise PET and coPET.
  • the nonwoven secondary backing may comprise greater than 50 wt% coPET with the remainder being PET.
  • the invention includes, according to certain embodiments, tufted carpet products that are fully recyclable and utilize a polyester nonwoven primary backing having a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength after the fabric is tufted.
  • embodiments of the invention are directed to recyclable tufted carpet products having a polymer (e.g., polyester) nonwoven primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 , a plurality of polymer yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing, and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.
  • a polymer e.g., polyester
  • the recyclable tufted carpet product includes a primary backing with an air permeability that advantageously provides improved tear strength, tensile strength, and tuft bind strength.
  • layers of the tufted carpet product all comprise a polyester and are joined together without a latex adhesive.
  • polymer or “polymeric”, as used interchangeably herein, may comprise homopolymers, copolymers, such as, for example, block, graft, random, and alternating copolymers, terpolymers, etc., and blends and modifications thereof.
  • polymer or “polymeric” shall include all possible structural isomers; stereoisomers including, without limitation, geometric isomers, optical isomers or enantionmers; and/or any chiral molecular configuration of such polymer or polymeric material. These configurations include, but are not limited to, isotactic, syndiotactic, and atactic configurations of such polymer or polymeric material.
  • polymer or “polymeric” shall also include polymers made from various catalyst systems including, without limitation, the Ziegler-Natta catalyst system and the metallocene/single-site catalyst system.
  • air permeability may refer to the rate of airflow passing perpendicularly through a known area under a prescribed air pressure differential between the two surfaces of a material.
  • permeability refers to how easily air, or water, flows through a material having a controlled size alignment of pores. Air permeability differs from porosity in that porosity is the amount of empty space in a solid and is indicative of how much water a material can hold.
  • air permeability may be measured according to ISO 9073-15 and/or ASTM D737-96.
  • tear strength and tear resistance may refer to a measure of how well a material can withstand the effects of tearing.
  • tear strength or tear resistance may refer to a fabric's resistance to tearing once cut.
  • tear strength/tear resistance may be measured according to ISO 9073-4 and/or NWSP 100.R1.
  • nonwoven may comprise a web having a structure of individual fibers, filaments, and/or threads that are interlaid but not in an identifiable repeating manner as in a knitted or woven fabric.
  • Nonwoven fabrics or webs may be formed by any process conventionally known in the art such as, for example, meltblowing processes, spunbonding processes, hydroentangling, air-laid, and bonded carded web processes.
  • meltspun may comprise fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular or trilobal, die capillaries of a spinneret and solidifying the extruded filaments by cooling them as they emerge from the die capillaries.
  • spunbond may comprise fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular or trilobal, capillaries of a spinneret with the diameter of the extruded filaments then being rapidly reduced.
  • spunbond fibers are generally not tacky when they are deposited onto a collecting surface and may be generally continuous.
  • meltblown may comprise fibers formed by extruding a molten thermoplastic material through a plurality of fine die capillaries as molten threads or filaments into converging high velocity, usually hot, gas (e.g. air) streams which attenuate the filaments of molten thermoplastic material to reduce their diameter, which may be to microfiber diameter, according to certain embodiments of the invention.
  • the die capillaries may be circular.
  • the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers.
  • Meltblown fibers are microfibers which may be continuous or discontinuous and are generally tacky when deposited onto a collecting surface.
  • bicomponent fibers may comprise fibers formed from at least two different polymers extruded from separate extruders but spun together to form one fiber.
  • Bicomponent fibers are also sometimes referred to as conjugate fibers or multicomponent fibers.
  • the polymers are arranged in a substantially constant position in distinct zones across the cross-section of the bicomponent fibers and extend continuously along the length of the bicomponent fibers.
  • bicomponent fiber may be, for example, a sheath/core arrangement wherein one polymer is surrounded by another, or may be a side-by-side arrangement, a homo-homo arrangement, a pie arrangement, or an "islands-in-the-sea" arrangement, each as is known in the art of multicomponent, including bicomponent, fibers.
  • the "bicomponent fibers” may be thermoplastic fibers that comprise a core fiber made from one polymer that is encased within a thermoplastic sheath made from a different polymer or have a side-by-side arrangement of different thermoplastic fibers.
  • the first polymer often melts at a different, typically lower, temperature than the second polymer.
  • these bicomponent fibers provide thermal bonding due to melting of the sheath polymer, while retaining the desirable strength characteristics of the core polymer.
  • Certain embodiments according to the invention provide tufted carpet products that are fully recyclable and utilize a polyester nonwoven primary backing having a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength after the fabric is tufted.
  • certain embodiments of the invention provide tufted carpet products having a tear strength of greater than 100 N in MD and CD, tensile strength of greater than 220 N/50 mm in MD and CD, and tuft bind strength of greater than 6 lbs loop and greater than 3 lbs cut pile.
  • embodiments of the invention are directed to recyclable tufted carpet products having a polymer nonwoven primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 , a plurality of polymer yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing, and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.
  • the recyclable tufted carpet product includes a primary backing with an advantageous air permeability that provides improved tear strength, tensile strength, and tuft bind strength.
  • layers of the tufted carpet product all comprise a polyester and are joined together without a latex adhesive.
  • the primary backing 1 includes a plurality of yarns 12 tufted through the primary backing 1 such that a plurality of loops 14 of yarn 12 are provided both at a first surface 10 of the primary backing 1 and a second surface 17 of the primary backing 1.
  • the plurality of loops 14 of yarn 12 may be cut to create piles 15, shown in FIGs. 2 and 3 .
  • yarns 12 may comprise a polyester.
  • yarns 12 may comprise polyethylene terephthalate (PET).
  • Primary backing 1 may comprise a polymer nonwoven. Yarns 12 similarly may comprise a polymer that may be the same as or similar to the polymer of primary backing 1.
  • primary backing 1 may comprise a polyester nonwoven.
  • primary backing 1 may comprise PET and a copolymer of PET (coPET).
  • coPET copolymer of PET
  • primary backing 1 may comprise a plurality of PET filaments 32 and a plurality of coPET filaments 34 randomly interspersed among the plurality of PET filaments 32. This random interspersion can be achieved via, for example, a spunbonding or meltblowing process.
  • PET filaments 32 may have a larger filament titer than coPET filaments 34.
  • PET filaments 32 may be about 4-12 denier, while coPET filaments 34 may be about 2-5 denier.
  • PET filaments 32 may be about 6 denier, while coPET filaments 34 may be about 2-3 denier.
  • FIG. 4 illustrates the coPET filaments 34 as being randomly interspersed with the PET filaments 32, the coPET filaments 34 may also be distributed evenly and/or according to a pattern as understood by one of ordinary skill in the art.
  • FIG. 4 (and FIGs.
  • primary backing 1 may, in other embodiments, comprise all or a portion of bicomponent fibers having a core formed at least in part by PET and a low melt sheath formed at least in part by coPET.
  • FIG. 5 illustrates a cross-section of primary backing 1 in accordance with certain embodiments of the invention.
  • coPET may be disposed at or along, at least in part, the sheath 44 (i.e. the outside surface) of the bicomponent fiber 40
  • PET may be disposed in the core 42 (i.e. inner portion) of the bicomponent fiber 40.
  • coPET sheath 44 may melt while the PET in the core substantially maintains its fiber shape and structural integrity.
  • both the amount of coPET in the fiber of primary backing 1 and the extent of energy (e.g., heat) supplied to primary backing 1 will be determinative of the extent of melting in primary backing 1 relative to other layers heated in the same manner but having perhaps a different amount of coPET in the fiber and/or the extent of energy (e.g., heat) supplied.
  • energy e.g., heat
  • primary backing 1 may include approximately 0-20 wt% coPET and 80-100 wt% PET. In further embodiments, for instance, primary backing 1 may include approximately 15-20 wt% coPET and 80-85 wt% PET.
  • primary backing 1 may be a polyester nonwoven. According to certain embodiments of the invention, primary backing 1 may comprise a spunbond, meltblown, or meltspun fabric. In further embodiments, the primary backing 1 may comprise multiple layers having any combination of spunbond, meltblown, and meltspun fabric bonded together as understood by a person of ordinary skill in the art. In certain embodiments, for example, primary backing 1 may comprise a weight of about 2.4-4.4 oz/yd 2 . In further embodiments, for instance, primary backing 1 may comprise a weight of about 3.7 oz/yd 2 .
  • Polyester nonwovens have, to date, been unable to serve as primary backing due to poor tear resistance, tensile strength, and tuft bind strength.
  • Primary backing 1 has a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength that allows it to operate as a strong primary backing.
  • primary backing 1 has an air permeability after the fabric is formed but before it is tufted, as measured according to ISO 9073-15 and/or ASTM D737-96, greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 .
  • primary backing 1 has an air permeability greater than 1000 1/m 2 /sec at 200 Pa / 20 cm 2 .
  • primary backing 1 has an air permeability from about 1000 to about 4000 1/m 2 /sec at 200 Pa / 20 cm 2 .
  • a primary backing with such air permeability may improve tear resistance, tensile strength, and tuft bind strength, as air permeability is indicative of fiber mobility.
  • more mobile fibers during tufting means that the fibers can be more easily moved out of the way by the tufting needles rather than broken by the needles. This in turn means that there are fewer sites for tear propagation and/or more sites where overlapping filaments can form bonded nodes with each other, which in turn improves tear strength.
  • lubricants may be used to further improve fiber mobility.
  • primary backing 1 may have a thickness, as measured according to ISO 9073-2 and/or ASTM D5729-97, greater than 0.35 mm at 0.5 Pa / 25 cm 2 .
  • primary backing 1 may have a thickness from about 0.5 to about 1.5 mm at 0.5 Pa / 25 cm 2 .
  • primary backing 1 may have a basis weight, as measured according to ISO 9073-1 and/or ASTM D6242-98, of about 80-140 gsm.
  • primary backing 1 may have a basis weight of 100-120 gsm.
  • Such thickness and basis weight may also improve tear resistance, tensile strength, and tuft bind strength. However, while going beyond this thickness and basis weight may further improve tear resistance, tensile strength, and tuft bind strength, the primary backing may become uneconomical as too much raw material is required to make a saleable product.
  • Tear resistance, tensile strength, and tuft bind strength may be further improved by processing primary backing 1 prior to tufting.
  • primary backing 1 may be hydroentangled or needled prior to tufting.
  • primary backing 1 may be hydroentangled or needled in two directions, once from each side of the fabric.
  • primary backing 1 may be calendered prior to tufting to at least partially melt the coPET, as shown, for example, FIG. 8 , which is described in more detail below. Such calendering may occur with a calender gap or opening of 0.1 mm.
  • primary backing 1 may be subjected to through air bonding, i.e.
  • primary backing 1 provides most, if not all, of the tear strength to the final recyclable tufted carpet product.
  • recyclable tufted carpet product 16 may include an adhesive 11 that anchors the plurality of loops 14 of yarn 12 to the second surface 17 of the primary backing 1.
  • FIG. 2 illustrates the application of adhesive 11 to tufted primary backing 1 to form recyclable tufted carpet product 16, as illustrated in FIG. 3 .
  • adhesive 11 may be a glue.
  • adhesive 11 may be a liquid glue comprising, for example, coPET.
  • adhesive 11 may be a hot melt adhesive, e.g., molten coPET.
  • adhesive 11 may be a secondary backing.
  • adhesive 11 i.e. the secondary backing
  • adhesive 11 i.e. the secondary backing
  • the coPET filaments 54 may also be distributed evenly and/or according to a pattern as understood by one of ordinary skill in the art.
  • a substantial portion of adhesive 11 i.e. the secondary backing
  • adhesive 11 i.e. the secondary backing
  • adhesive 11 may, in other embodiments, comprise all or a portion of bicomponent fibers having a core formed at least in part by PET and a low melt sheath formed at least in part by coPET.
  • FIG. 7 illustrates a schematic view of adhesive 11 (i.e. the secondary backing) in accordance with certain embodiments of the invention.
  • the coPET may be disposed at or along, at least in part, the sheath 64 ( i.e.
  • both the amount of coPET in the fiber of adhesive 11 (i.e. the secondary backing) and the extent of energy (e.g., heat) supplied to adhesive 11 (i.e. the secondary backing) will be determinative of the extent of melting in adhesive 11 (i.e.
  • embodiments of the invention also include secondary backings where only a portion of the fibers are bicomponent, and the remaining fibers are of another type, such as coPET filaments 54 and/or PET filaments 52.
  • adhesive 11 i.e. the secondary backing
  • adhesive 11 i.e.
  • the secondary backing may include approximately 80 wt% coPET and 20 wt% PET.
  • the secondary backing may comprise a basis weight, as measured according to ISO 9073-1 and/or ASTM D6242-98, of about 100-150 gsm.
  • the secondary backing may comprise a basis weight of approximately 135 gsm. As above with the primary backing, going beyond this thickness and basis weight may further improve tear resistance, tensile strength, and tuft bind strength, but the adhesive (secondary backing) may become uneconomical as too much raw material is required to make a saleable product.
  • the resulting tufted carpet product is free of latex and is fully recyclable.
  • the recyclable tufted carpet product utilizes a polyester nonwoven primary backing having a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength.
  • certain embodiments according to the invention provide methods of preparing a recyclable tufted carpet product.
  • the method comprises providing a primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 , the primary backing comprising a polymer nonwoven; tufting a polymer yarn through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and anchoring the plurality of yarn loops to the second surface of the primary backing.
  • FIG. 9 is a block diagram of a method 90 of preparing a recyclable tufted carpet product in accordance with certain embodiments of the invention. As shown in FIG. 9 , the method 90 includes the following steps:
  • Step 91 is shown in more detail in FIG. 8 .
  • Primary backing 1 is a non-woven layer comprising continuous filaments 2, provided by spunbonding technology.
  • the filaments 2 are bicomponent filaments.
  • Two extruders 3, each for one of the components of the filaments, are fed with respective polymer chips through respective inlets 4.
  • Filaments 2 are formed by extrusion and drawing through a spinning die 5 and aspirator (not shown).
  • the filaments 2 are laid on a moving screen or belt 6 to form a web.
  • the web may optionally be subjected to a bonding step S2 e.g. by calender bonding.
  • calender bonding the web of loose filaments 2 is passed through the nip 7 of a set of rollers 8, of which preferably at least one is heated.
  • One or more of the rollers 8 may optionally be patterned.
  • FIG. 10 is a block diagram of a method 100 of preparing a recyclable tufted carpet product in accordance with certain embodiments of the invention, including options for the processing steps and options for the anchoring step.
  • the below steps are merely options and, as such, their listed order is not limiting and several listed steps are interchangeable.
  • needling and hydroentangling are interchangeable, as are calendering and through air bonding.
  • the method 100 includes the following steps:
  • the recyclable tufted carpet product may be heated following Step 106 and/or Step 107 to at least partially melt the coPET in the secondary backing.
  • tufting the plurality of yarns into the primary backing may comprise tufting with a tufting machine as understood by a person having ordinary skill in the art.
  • the method provides a tufted carpet product that is fully recyclable and that utilizes a polyester nonwoven primary backing having a minimum air permeability that provides improved tear resistance, tensile strength, and tuft bind strength.
  • a recyclable tufted carpet product comprises a primary backing having an air permeability greater than 100 1/m 2 /sec at 200 Pa / 20 cm 2 , the primary backing comprising a polymer nonwoven; a plurality of polymer yarns tufted through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and an adhesive that anchors the plurality of yarn loops to the second surface of the primary backing.
  • the polymer of the nonwoven is similar or identical to the polymer of the yarn.
  • the polymer of the nonwoven and the polymer of the yarn are both a polyester.
  • the primary backing comprises an air permeability from about 1000 to about 4000 1/m 2 /sec. In further embodiments, for instance, the primary backing comprises a thickness greater than 0.35 mm at 0.5 Pa / 25 cm 2 .
  • the adhesive comprises a polyester hot melt adhesive.
  • the adhesive comprises a polyester nonwoven secondary backing.
  • a method of preparing a recyclable tufted carpet product comprises providing a primary backing having an air permeability greater than 1000 1/m 2 /sec at 200 Pa / 20 cm 2 , the primary backing comprising a polymer nonwoven; tufting a polymer yarn through the primary backing such that a pile is provided at a first surface of the primary backing and a plurality of yarn loops are provided at a second surface of the primary backing; and anchoring the plurality of yarn loops to the second surface of the primary backing.
  • the polymer of the nonwoven is similar or identical to the polymer of the yarn.
  • the polymer of the nonwoven and the polymer of the yarn are both a polyester.
  • the primary backing comprises an air permeability from about 1000 to about 4000 1/m 2 /sec. In some embodiments, for instance, prior to the tufting step the primary backing comprises a thickness greater than 0.35 mm at 0.5 Pa / 25 cm 2 . In further embodiments, for example, the primary backing comprises polyethylene terephthalate (PET) filaments and copolymer of polyethylene terephthalate (coPET) filaments. In certain embodiments, for instance, the primary backing comprises 80-85 wt% PET and 15-20 wt% coPET.
  • PET polyethylene terephthalate
  • coPET polyethylene terephthalate
  • the primary backing is at least one of hydroentangled, needled, calendered, and/or through air bonded prior to tufting.
  • the recyclable tufted carpet product is free of latex.
  • anchoring the plurality of yarn loops to the second surface of the primary backing comprises applying a polyester hot melt adhesive to the plurality of yarn loops and the second surface of the primary backing.
  • the polyester hot melt adhesive comprises coPET.
  • anchoring the plurality of yarn loops to the second surface of the primary backing comprises applying a nonwoven secondary backing to the plurality of yarn loops and the second surface of the primary backing.
  • the nonwoven secondary backing comprises PET and coPET.
  • the secondary backing comprises greater than 50 wt% coPET with the remainder being PET.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Carpets (AREA)
EP19204778.5A 2019-09-20 2019-10-23 Produit de tapis tufté recyclable Withdrawn EP3795742A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
PCT/US2020/050987 WO2021055414A1 (fr) 2019-09-20 2020-09-16 Produit de tapis touffeté recyclable
EP20865038.2A EP4030976A4 (fr) 2019-09-20 2020-09-16 Produit de tapis touffeté recyclable
US17/753,503 US20220333300A1 (en) 2019-09-20 2020-09-16 Recyclable tufted carpet product

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US16/577,783 US20210087743A1 (en) 2019-09-20 2019-09-20 Recyclable tufted carpet product

Publications (1)

Publication Number Publication Date
EP3795742A1 true EP3795742A1 (fr) 2021-03-24

Family

ID=68342609

Family Applications (2)

Application Number Title Priority Date Filing Date
EP19204778.5A Withdrawn EP3795742A1 (fr) 2019-09-20 2019-10-23 Produit de tapis tufté recyclable
EP20865038.2A Withdrawn EP4030976A4 (fr) 2019-09-20 2020-09-16 Produit de tapis touffeté recyclable

Family Applications After (1)

Application Number Title Priority Date Filing Date
EP20865038.2A Withdrawn EP4030976A4 (fr) 2019-09-20 2020-09-16 Produit de tapis touffeté recyclable

Country Status (3)

Country Link
US (2) US20210087743A1 (fr)
EP (2) EP3795742A1 (fr)
WO (1) WO2021055414A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113622109A (zh) * 2021-06-30 2021-11-09 宿迁市神龙家纺有限公司 一种耐磨抗菌的簇绒地毯制备方法

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2022533666A (ja) * 2019-05-22 2022-07-25 ロウ アンド ボナー インク． カーペット一次基布
US11746467B2 (en) * 2020-08-07 2023-09-05 Auria Solutions Uk I Ltd Polyester tufted carpet with polyester extrusion coating
US20240279860A1 (en) * 2023-02-20 2024-08-22 Berry Global, Inc. Carpet backing based on carded technology

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5532035A (en) * 1992-05-01 1996-07-02 Hoechst Celanese Corporation Recyclable tufted fabric
US20140272262A1 (en) * 2013-03-12 2014-09-18 Milliken & Company Recyclable Single Polymer Floorcovering Article
KR20190058253A (ko) * 2017-11-21 2019-05-29 코오롱글로텍주식회사 인조잔디

Family Cites Families (23)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1406252A (en) * 1972-03-02 1975-09-17 Impeial Chemical Ind Ltd Non-woven materials and a method of making them
JPS60224831A (ja) * 1984-04-12 1985-11-09 東洋紡績株式会社 カ−ペツト用パイル糸
WO1993012285A1 (fr) * 1991-12-10 1993-06-24 Tarkett Pegulan Ag Tapis tufte entierement entierement recyclable en polymeres thermoplastiques synthetiques
US5472763A (en) * 1992-11-04 1995-12-05 Hoechst Aktiengesellschaft Recyclable carpet floor covering
US5481786A (en) * 1993-11-03 1996-01-09 Spartan Mills Method of manufacturing a recyclable carpet
DE19630523C1 (de) * 1996-07-29 1998-03-12 Freudenberg Carl Fa Spinnvliesstoff und Vorrichtung zu dessen Herstellung
US20030211280A1 (en) * 1997-02-28 2003-11-13 Shaw Industries, Inc. Carpet, carpet backings and methods
US6658835B1 (en) * 2000-11-28 2003-12-09 Honeywell International Inc. Untwisted wrapped singles yarns and carpets manufactured therefrom
NL1017941C2 (nl) * 2001-04-25 2002-10-29 Dsm Nv Smeltlijmsamenstelling en werkwijze voor het maken van een textiel voortbrengsel.
US20030175475A1 (en) * 2002-03-13 2003-09-18 Higgins Kenneth B. Textile constructions, components or materials and related methods
US6808786B2 (en) * 2003-02-04 2004-10-26 Freudenberg Nonwovens Automotive tufted carpet with enhanced acoustical properties
JP4794846B2 (ja) * 2004-10-27 2011-10-19 キヤノン株式会社 推定装置、及び推定方法
WO2008124449A2 (fr) * 2007-04-03 2008-10-16 Dow Global Technologies Inc. Stratification à chaud de film (assistée par le vide) pour des applications de support de tapis
EP1985737A1 (fr) * 2007-04-27 2008-10-29 Colbond B.V. Procédé pour fabriquer des matériaux de renfort touffetés
JP2008100681A (ja) * 2007-12-07 2008-05-01 Unitika Ltd 通気性を有する自動車内装カーペット
US9644314B2 (en) * 2009-12-09 2017-05-09 Low & Bonar B.V. Primary carpet backing
CN104662223B (zh) * 2012-07-26 2018-03-02 洛博纳有限公司 地毯基底布和包括地毯基底布的簇绒地毯
JP6669943B2 (ja) * 2013-06-10 2020-03-18 ディーエスエム アイピー アセッツ ビー．ブイ．Ｄｓｍ Ｉｐ Ａｓｓｅｔｓ Ｂ．Ｖ． テキスタイル製品の製造方法、それから取得可能な製品、および製品の再生方法
EP3256631B1 (fr) * 2015-02-09 2020-07-15 DSM IP Assets B.V. Procédé de fabrication d'un tapis a poils stratifié
EP3543397B1 (fr) * 2018-03-20 2021-07-07 Aladdin Manufacturing Corporation Procédé pour la fabrication d'un tapis ou d'une moquette
EP3908162A4 (fr) * 2019-01-07 2022-08-17 Shaw Industries Group, Inc. Compositions de tapis ayant des supports de film stratifié et leurs procédés de fabrication
JP2022533666A (ja) * 2019-05-22 2022-07-25 ロウ アンド ボナー インク． カーペット一次基布
CA3164425A1 (fr) * 2020-01-27 2021-08-05 Charles Winston Reynolds Tissu tufte recyclable et procede de production de ce dernier

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5532035A (en) * 1992-05-01 1996-07-02 Hoechst Celanese Corporation Recyclable tufted fabric
US20140272262A1 (en) * 2013-03-12 2014-09-18 Milliken & Company Recyclable Single Polymer Floorcovering Article
KR20190058253A (ko) * 2017-11-21 2019-05-29 코오롱글로텍주식회사 인조잔디

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113622109A (zh) * 2021-06-30 2021-11-09 宿迁市神龙家纺有限公司 一种耐磨抗菌的簇绒地毯制备方法

Also Published As

Publication number Publication date
US20210087743A1 (en) 2021-03-25
EP4030976A1 (fr) 2022-07-27
US20220333300A1 (en) 2022-10-20
EP4030976A4 (fr) 2023-11-22
WO2021055414A1 (fr) 2021-03-25

Similar Documents

Publication Publication Date Title
US20220333300A1 (en) Recyclable tufted carpet product
JP4619947B2 (ja) 高強力不織布
US4131704A (en) Nonwoven fabric comprising needled and selectively fused fine and coarse filaments having differing softening temperatures which is useful as a backing in the production of tufted materials
EP0619849B1 (fr) Procede de fabrication de tapis en polyolefine tufte moulable
EP3621800B1 (fr) Matériau support non tissé comprenant une première partie et une seconde partie
EP3825449B1 (fr) Tapis comprenant une structure de non tissé à fibres catalysées par un catalyseur de métallocène
EP3543397B1 (fr) Procédé pour la fabrication d'un tapis ou d'une moquette
JP3240819B2 (ja) 不織布及びその製造法
US5817403A (en) Nonwoven fabric
US20230077606A1 (en) Recyclable tufted fabric and method of making the same
EP0755331B1 (fr) Etoffe non-tissee
US20210323296A1 (en) Carrier material comprising a first part of a form-fit connection
US20240279860A1 (en) Carpet backing based on carded technology
JPH10273873A (ja) タフテッドカーペット用基布

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION HAS BEEN PUBLISHED

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

AX Request for extension of the european patent

Extension state: BA ME

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE

17P Request for examination filed

Effective date: 20210921

RBV Designated contracting states (corrected)

Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20230503