GB2160469A - Foam-backed carpet pieces - Google Patents

Foam-backed carpet pieces Download PDF

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Publication number
GB2160469A
GB2160469A GB08511273A GB8511273A GB2160469A GB 2160469 A GB2160469 A GB 2160469A GB 08511273 A GB08511273 A GB 08511273A GB 8511273 A GB8511273 A GB 8511273A GB 2160469 A GB2160469 A GB 2160469A
Authority
GB
United Kingdom
Prior art keywords
foam
shaping
carpet
backing
backed
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Withdrawn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
GB08511273A
Other versions
GB8511273D0 (en
Inventor
Klaus Lukoschek
Hanns Jurgen Roskothen
Manfred Schweizer
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.)
Chemiegesellschaft Gundernhausen mbH
Original Assignee
Chemiegesellschaft Gundernhausen mbH
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 Chemiegesellschaft Gundernhausen mbH filed Critical Chemiegesellschaft Gundernhausen mbH
Publication of GB8511273D0 publication Critical patent/GB8511273D0/en
Publication of GB2160469A publication Critical patent/GB2160469A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/34—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station
    • B29C33/36—Moulds or cores; Details thereof or accessories therefor movable, e.g. to or from the moulding station continuously movable in one direction, e.g. in a closed circuit
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/02—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
    • 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
    • D06N7/0086—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 characterised by the cushion backing, e.g. foamed polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • 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
    • D06N2203/068—Polyurethanes
    • 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
    • D06N2205/04—Foam
    • 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
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked
    • 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
    • D06N2209/02—Properties of the materials having acoustical properties
    • D06N2209/025—Insulating, sound absorber
    • 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
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/065—Insulating
    • 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
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/26—Vehicles, transportation
    • D06N2211/263—Cars

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Passenger Equipment (AREA)
  • Carpets (AREA)

Abstract

A carpet piece is shaped to the desired shape in a shaping device (18) comprising upper and lower shaping mould parts. The carpet piece is left in the lower mould part after shaping, and foam-backing device (26) is connected to the lower mould part for foam-backing the shaped carpet piece contained in the lower shaping mould part. After shaping the lower shaping mould may be conveyed to the foam-backing unit (26), or the upper shaping mould part may be removed from the lower shaping mould part and replaced by the foam-backing device for foam-backing in situ. As the carpet piece remains in the lower mould part both during shaping and during foam backing shrinkage is avoided. <IMAGE>

Description

SPECIFICATION A method and an apparatus for the production of foam-backed carpet pieces The present invention relates to a process and an apparatus for the production of foam-backed carpet pieces, particularly but not exclusively for motor vehicles.
Foam-backed carpets are used as silencing and insulating material in motor vehicles. They are used for the internal lining, in particular, of the passenger compartments of motor vehicles and provide temperature insulation as well as noise insulation and silencing. Foam-backed motor vehicle carpet pieces are described, for example, in DE-OS 25 57 719.
It is known to produce foam-backed motor vehicle carpet pieces in a multi-stage process in which it is first necessary to shape the carpet piece to the desired shape, for example by deep drawing, in a shaping device, optionally with addition of suitable shaping means and then to remove the shaped carpet piece from the shaping device and to convey it to a foam mould. The shaped carpet piece is then foam-backed in the foam mould, preferably with the interposition of a sealing layer. This process is accompanied by a high reject rate which is frequently due to shrinkage of the carpet after the shaping operation. The shrinkage is due to the defective fit of the carpet in the foam mould which leads to the formation of folds.
An object of the invention is to provide a method and an apparatus for the production of foambacked carpet pieces in which the reject and defect rate is substantially reduced.
The invention provides a method of producing foam-backed carpet pieces as claimed in claim 1.
Preferably, the said one of the shaping parts containing the shaped carpet piece is conveyed from the shaping device to the foam-backing device.
Alternatively, after shaping of the carpet piece, the other of the shaping parts is removed from the said one shaping part containing the shaped carpet piece and the foam-backing device is moved up to and connected to the said one shaping part for foam backing.
The invention also provides apparatus for producing foam-backed carpet pieces as claimed in claim 8. Preferably, the other of the shaping devices is removable from the said one of the shaping devices and the foam-backing device is movable to the said one of the shaping devices and connectable therewith for foam-backing a carpet piece contained therein.
It has surprisingly been found that the reject rate is substantially reduced by the method according to the invention in which the carpet piece remains in the same shaping part both during shaping and during foam-backing.
The foam-backed carpet pieces produced have no folds and are of high quality and optimum fit.
The acoustic properties of the foam-backed carpet pieces are substantially improved. This is due to the fact, among other things, that a rigid coating, for example of polyethylene, which provides less sound insulation and which formerly was normal for stabilising the shape of the carpet in the multistage process can be dispensed with in the method according to the invention. A flexible sound-insulating sealing and nap-bonding layer composed, for example, of thermoplasts or elastomers can be used instead. This produces a flexible moulding having the following advantages: easier fitting in the vehicle, better ductility with improved contact with the floor and thus improved acoustic coupling between sound radiators and moulding.
The method and apparatus according to the invention allow fully automated production, and handling can be reduced to a minimum. As it is unnecessary to exchange the shaping part containing the formed carpet piece, the carpet piece does not cool down before the foam-backing operation.
The mould release time is therefore reduced substantially. The foam-backed carpet pieces are surprisingly stable in shape even at elevated mould release temperatures.
An embodiment of the invention will now be described with reference to the accompanying drawing which shows in plan view apparatus for carrying out the method of the invention in which a lower mould tool is transportable.
In a carpet positioning device 10, carpet pieces 14 are removed from carpet stacks 16 and conveyed into a heating device 28 by means of extraction devices 12. The carpet pieces 14 pass from the heating device 28 into a shaping device 18. Here, a stationary upper shaping part is placed on a lower tool part and the carpet pieces are subjected to a deep drawing process.
The lower tool part with the shaped carpet piece is then fed by a conveyor system 20 to a foambacking station 22. Each lower tool part is directed via a distribution 24 to one of two or three foambacking device 26 as required. The number of foam-backing devices 26 used depends on the speed of foam-backing and curing. If these speeds are low in comparison with the speed at which the carpet pieces are deep drawn, a correspondingly larger number of foam- backing devices have to be provided to ensure continuous operation of the apparatus.
On completion of foam-backing and curing, the finished carpet pieces are removed from the lower tool parts and the lower tool parts are recirculated into the shaping device where a new shaping and foam-backing cycle begins.
Instead of moving the lower tool part containing the shaped carpet piece to the foam backing device, the upper tool part may be removed and a foam-backing device moved, e.g. by a change-over device, to the lower tool part and connected therewith for foam backing of the carpet piece contained therein.
1. A method of producing foam-backed carpet pieces in which a carpet piece is shaped into a de
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (12)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION A method and an apparatus for the production of foam-backed carpet pieces The present invention relates to a process and an apparatus for the production of foam-backed carpet pieces, particularly but not exclusively for motor vehicles. Foam-backed carpets are used as silencing and insulating material in motor vehicles. They are used for the internal lining, in particular, of the passenger compartments of motor vehicles and provide temperature insulation as well as noise insulation and silencing. Foam-backed motor vehicle carpet pieces are described, for example, in DE-OS 25 57 719. It is known to produce foam-backed motor vehicle carpet pieces in a multi-stage process in which it is first necessary to shape the carpet piece to the desired shape, for example by deep drawing, in a shaping device, optionally with addition of suitable shaping means and then to remove the shaped carpet piece from the shaping device and to convey it to a foam mould. The shaped carpet piece is then foam-backed in the foam mould, preferably with the interposition of a sealing layer. This process is accompanied by a high reject rate which is frequently due to shrinkage of the carpet after the shaping operation. The shrinkage is due to the defective fit of the carpet in the foam mould which leads to the formation of folds. An object of the invention is to provide a method and an apparatus for the production of foambacked carpet pieces in which the reject and defect rate is substantially reduced. The invention provides a method of producing foam-backed carpet pieces as claimed in claim 1. Preferably, the said one of the shaping parts containing the shaped carpet piece is conveyed from the shaping device to the foam-backing device. Alternatively, after shaping of the carpet piece, the other of the shaping parts is removed from the said one shaping part containing the shaped carpet piece and the foam-backing device is moved up to and connected to the said one shaping part for foam backing. The invention also provides apparatus for producing foam-backed carpet pieces as claimed in claim 8. Preferably, the other of the shaping devices is removable from the said one of the shaping devices and the foam-backing device is movable to the said one of the shaping devices and connectable therewith for foam-backing a carpet piece contained therein. It has surprisingly been found that the reject rate is substantially reduced by the method according to the invention in which the carpet piece remains in the same shaping part both during shaping and during foam-backing. The foam-backed carpet pieces produced have no folds and are of high quality and optimum fit. The acoustic properties of the foam-backed carpet pieces are substantially improved. This is due to the fact, among other things, that a rigid coating, for example of polyethylene, which provides less sound insulation and which formerly was normal for stabilising the shape of the carpet in the multistage process can be dispensed with in the method according to the invention. A flexible sound-insulating sealing and nap-bonding layer composed, for example, of thermoplasts or elastomers can be used instead. This produces a flexible moulding having the following advantages: easier fitting in the vehicle, better ductility with improved contact with the floor and thus improved acoustic coupling between sound radiators and moulding. The method and apparatus according to the invention allow fully automated production, and handling can be reduced to a minimum. As it is unnecessary to exchange the shaping part containing the formed carpet piece, the carpet piece does not cool down before the foam-backing operation. The mould release time is therefore reduced substantially. The foam-backed carpet pieces are surprisingly stable in shape even at elevated mould release temperatures. An embodiment of the invention will now be described with reference to the accompanying drawing which shows in plan view apparatus for carrying out the method of the invention in which a lower mould tool is transportable. In a carpet positioning device 10, carpet pieces 14 are removed from carpet stacks 16 and conveyed into a heating device 28 by means of extraction devices 12. The carpet pieces 14 pass from the heating device 28 into a shaping device 18. Here, a stationary upper shaping part is placed on a lower tool part and the carpet pieces are subjected to a deep drawing process. The lower tool part with the shaped carpet piece is then fed by a conveyor system 20 to a foambacking station 22. Each lower tool part is directed via a distribution 24 to one of two or three foambacking device 26 as required. The number of foam-backing devices 26 used depends on the speed of foam-backing and curing. If these speeds are low in comparison with the speed at which the carpet pieces are deep drawn, a correspondingly larger number of foam- backing devices have to be provided to ensure continuous operation of the apparatus. On completion of foam-backing and curing, the finished carpet pieces are removed from the lower tool parts and the lower tool parts are recirculated into the shaping device where a new shaping and foam-backing cycle begins. Instead of moving the lower tool part containing the shaped carpet piece to the foam backing device, the upper tool part may be removed and a foam-backing device moved, e.g. by a change-over device, to the lower tool part and connected therewith for foam backing of the carpet piece contained therein. CLAIMS
1. A method of producing foam-backed carpet pieces in which a carpet piece is shaped into a de sired shape in a shaping device comprising first and second shaping parts, wherein the carpet piece is left in one of the shaping parts after shaping and a foam-backing device is connected to the said one of the shaping parts, and the shaped carpet piece is foam backed in the said one of the shaping parts.
2. A method as claimed in claim 1, wherein the said one of the shaping parts containing the shaped carpet piece is conveyed from the shaping device to the foam-backing device.
3. A method as claimed in claim 2, wherein the foam-backing device is one of a plurality of foambacking devices arranged in a foam-backing station.
4. A method as claimed in claim 1, wherein after shaping of the carpet piece, the other of the shaping parts is removed from the said one shaping part containing the shaped carpet piece and the foam-backing device is moved up to and connected to the said one shaping part for foam backing.
5. A method as claimed in any one of claims 1 to 3, wherein the first and second shaping parts are upper and lower tool parts, respectively, of the shaping device.
6. A method of producing foam-backed carpet pieces substantially as herein described with reference to the accompanying drawing.
7. Foam-backed carpet pieces produced by the method as claimed in any one of the preceding claims.
8. Apparatus for producing foam-backed carpet pieces comprising a shaping device comprising first and second shaping parts, and a foam-backing device, wherein one of the shaping parts is movable to the foam-backing device and connectable therewith for foam backing of the carpet piece in the said one of the shaping parts.
9. Apparatus as claimed in claim 8, wherein there are a plurality of foam-backing devices contained in a foam-backing station to which the said one of the shaping parts is selectively conveyed.
10. Apparatus as claimed in claim 8, wherein the other of the shaping devices is removable from the said one of the shaping devices and the foambacking device is movable to the said one of the shaping devices and connectable therewith for foam-backing a carpet piece contained therein.
11. Apparatus as claimed in claim 8, 9 or 10 wherein the first and second shaping parts are upper and lower tool parts, respecively, of the shaping device.
12. Apparatus for producing foam-backed carpet pieces substantially as herein described with reference to the accompanying drawing.
GB08511273A 1984-05-04 1985-05-03 Foam-backed carpet pieces Withdrawn GB2160469A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19843416413 DE3416413A1 (en) 1984-05-04 1984-05-04 METHOD AND DEVICE FOR THE PRODUCTION OF REAR-FOAMED CARPET CUTTERS FOR MOTOR VEHICLES

Publications (2)

Publication Number Publication Date
GB8511273D0 GB8511273D0 (en) 1985-06-12
GB2160469A true GB2160469A (en) 1985-12-24

Family

ID=6234897

Family Applications (1)

Application Number Title Priority Date Filing Date
GB08511273A Withdrawn GB2160469A (en) 1984-05-04 1985-05-03 Foam-backed carpet pieces

Country Status (4)

Country Link
DE (1) DE3416413A1 (en)
FR (1) FR2563850A1 (en)
GB (1) GB2160469A (en)
IT (1) IT1200465B (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IT1213070B (en) * 1986-05-02 1989-12-07 Afros Spa POLYURETHANE MOLDING PLANT WITH AUTOMOTIVE AND MOBILE MOLD-HOLDING TROLLEYS ALONG A SUSPENDED SINGLE RAIL.

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1430479A (en) * 1972-04-28 1976-03-31 Matec Holding Composite trim members and the manufacture thereof

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1350894A (en) * 1970-07-16 1974-04-24 Vitafoam Ltd Laminated article
IT1102536B (en) * 1977-06-16 1985-10-07 Freudenberg Carl PROCEDURE FOR THE PRODUCTION OF A MATTRESS FOR ACOUSTIC DAMPING
DE3230178A1 (en) * 1982-08-13 1984-02-16 Dlw Ag, 7120 Bietigheim-Bissingen Process for manufacturing a moulded body of foamed plastics material and moulded body made of foamed plastics material

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1430479A (en) * 1972-04-28 1976-03-31 Matec Holding Composite trim members and the manufacture thereof

Also Published As

Publication number Publication date
IT1200465B (en) 1989-01-18
IT8520562A0 (en) 1985-05-03
FR2563850A1 (en) 1985-11-08
DE3416413A1 (en) 1985-11-07
GB8511273D0 (en) 1985-06-12

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)