MXPA99009280A - The present invention discloses a process for producing recyclable carpets made of a single resin or polymer having a textile upper or lower surface with a secondary anchoring and lamination by thermofusion of sheets of said engraved polymer - Google Patents

Abstract

The present invention discloses a process for producing recyclable carpets made of a single resin or polymer having a textile upper or lower surface with a secondary anchoring and lamination by thermofusion of sheets of said engraved polymer.

Description

PROCEDURE FOR THE PRODUCTION OF TAPETES RECYCLABLES PRODUCED FROM A SINGLE RESIN OR POLYMER WITH TEXTILE FACE OR ANVERSE, WITH ANCHORAGE AND SECONDARY LAMINATION BY THERMOFUSION OF PLATES OF THE SAME POLYMER FINISHED WITH ENGRAVED AND THERMOMOLLED IN A SINGLE OPERATION AND PRODUCT OBTAINED 1. OBJECT OF THE INVENTION The object of this invention is to provide a product called 100% recyclable mat made of the same resin or polymer in all the parts that integrate it and its production procedure in which its anchoring of its yarns does not require latex or other polymer and that when laminated to a polypropylene thermoplastic profile with or without gravel on its outer face or to a secondary polypropylene textile present a secondary support of the same polymer, integrating either the textile or the profile without the use of adhesive vehicle in its procedure of rolling and processing. A further advantage of the process of the present invention is the non-use of adhesives in the fixing of the textile yarns or the face of the mat to its primary substrate or base, whether it is woven, tufted or non-woven, this is done through the use of infrared radiators that allow the thermofusion in certain areas of the textile that will allow the fastening of their fibers to their substrate or primary base, which allows the space to become more efficient, since normally the kilns for the drying of latex or adhesives are of enormous dimensions since they have to evaporate large volumes of water or solvents at very fast speeds, the type of infrared radiation oven used in the method of the present invention is smaller and more efficient than conventional ovens using very small spaces and does not generates pollution Another advantage that presents the 100% recyclable rug built of a The same resin or polymer in all the parts that contain it and its production process with secondary base laminated by the process of the present invention, is that because the carpet and the secondary base are joined, by means of Another advantage offered by the 100% recyclable mat made of the same resin or polymer in all the parts that integrate it and its production process with lamination to a secondary base by means of fusion of previously inserted recycled fibers, is that it is a recyclable product and ecological, because in the same since its inception is using products already recycled or intended for recycling as are the inserted fibers One more advantage of the 100% recyclable rug built of the same resin or polymer in all parts that they integrate it and its production process is that because the fibers are superimposed, the base or primary substrate, these serve to hold and tie the intermediate fibers of the threads, the threads that make up the face of the carpet of the same and the secondary coating and either with a polypropylene textile presence or a profile of the so-called TPO (Thermo Plástic Olefin) thermoplastic olefinic with or without foaming, all of them of the same type of resin or all of polyester resin, these together can be reprocessed under the same procedure without the use of chemical elements that disperse them or procedures that precipitate the products at high operating costs in their reprocessing, this advantage is that for recycling only requires the grinding of the mat and its pelletization since each of the component elements of the same can be directly recycled without additional processes because it is the same polymer.

Another advantage of the 100% recyclable rug made of the same resin or polymer in all the parts that integrate it and its production process with secondary base fused and laminated without the use of latex or adhesives using recycled fibers inserted in polypropylene as an agent of lamination by Thermo fusion of the same, is that the thermofusion process is very competitive in both energy costs and raw material used because the thermofused fibers are of recycled origin itself and its cost is low being its financial and ecological advantages very high Another object of the invention is to provide the 100% recyclable mat made of the same resin or polymer in all the parts that make it up and its production process of the present invention a sense of impermeability since at the moment of fusing the fibers between Yes and when being laminated they produce a film that will serve as a barrier that in the future will prevent the liquids that normally fall on the carpet in their daily use, helps that they do not penetrate in the same way and will not present delaminations of their rigid base. do not have any adhesive component in any of its parts that decomposes due to contact with water; in the case of polypropylene or polyester, a completely inert material makes it a product that does not create fungus.

Another advantage in the 100% recyclable mat made of the same resin or polymer in all the parts that integrate it and its production procedure is the recycled material Fibers that are used as fusion fibers integrated to the carpet to be woven, is that these fibers to merge and be of the same polymer as the fibers that make up the yarn and the fibers that make up the primary base and the secondary base that is laminated, these are laminated by the pressure given cold press tooling and thermogravure and When they are melting, they mechanically anchor the fibers that make up the yarn on the face of the carpet, not allowing it to be released in the future due to the normal abrasion process that the carpet receives on its face or exposed surface. that in the production technique of the carpet is called the sealing of the knot inserted in the case tuftin and in the case of other sealed procedure of the fibers this is done to very low cost for being the fibers of already recycled material A further advantage offered by the process and product of the present invention is that in its manufacturing process no other textile finishing process is required, since a fabric is cut from the fabric and processed under the system of the present invention, saving time, money and effort as well as investment in spaces and infrastructure this because within the process of this invention is used a heat radiator that fuses the back face of the mat leaving it finished to just cut its edges and pack for sale .. Another advantage offered by the process of the present invention is that fibers of lower melting point than conventional or other polymers are not required to be used as the melting vehicle, but with conventional fibers of the same polymer or resin of the other materials that make up the materials that make up the carpet and due to the protection that is given to both the face of the product and the This tissue use objective is achieved with the same thermal fusion point.

Another advantage that presents the 100% recyclable mat made of the same resin or polymer in all the parts that integrate it and its production procedure is that in the case of automotive mat being this same polypropylene as nowadays are the majority of parts that integrate the interior and exterior of modern automotive vehicles allows the mats to be recycled as part of the vehicle without having a different procedure for recycling, having the advantage that these are 100% recyclable as any of its external parts of olefinic resin or polypropylene. Applies the same principle with polyester in Europe BACKGROUND OF THE INVENTION The present invention is related to the field of the textile flooring industry of residential, commercial, and automotive floors and refers to the manufacture of carpet by the process of insertion of threads in so-called in the tuffing industry and the so-called punching in addition to the direct extraction on a flat profile of polypropylene in which extruded threads of polypropylene or polyester resin fall Although the present invention is particularly directed to floor mats whether residential, automotive or marine commercials, it is obvious that the present invention may be applied in any type of textile process in which fusion of the fibers or lamination of a recyclable product is required without the presence of other polymers in its construction. It is well known that floor mats represent a serious ecological problem for recycling PREVIOUS TECHNIQUE In general terms, conventional floor mats, whether automotive, marine, residential or commercial, do not have a characteristic of sealing or anchoring of threads inserted to their primary base by a thermo-fusion process without the application of sprayed resin coatings. or plastic films and therefore, to obtain the anchoring of their threads to the primary base should be used styrene butadiene latex or polyethylene or PVC resins Polyvinyl chloride or EVA Ethyl Vinyl Acetates, applied by process of direct extrusion, or sprinkled on the back of the product, or by means of fusing textile layers of different polymers with different thermal melting point previously inserted into the main product and its secondary base. For the application of the procedure and the achievement of the claimed product, none of the systems known to date are used, neither extrusion nor dusting of resins nor insertion of textile layers of different polymers or different thermal melting points.

DESCRIPTION OF THE INVENTION The invention consists of the development of a procedure for the creation of a 100% recyclable mat made in all its components of a single polymer that is the fibers, the primary substrates and the non-slip base, as well as the product obtained called 100% recyclable mat made of a single polymer. The procedure and the product obtained from it consist of the following steps and foundations. By the insertion of a layer of fibers of very low denier between the primary substrate of a tufted fabric and the threads that are woven in order to create what will be the vehicle of mechanical fastening of the threads inserted between this layer and the base or substrate primary, the insertion of a sheet of low-denier oliefin fibers per filament (DPF) produces a density change that impedes the flow of the melting temperatures within the primary base product of the carpet, which allows the oliefinic sheets applied in the the back of it and exposed to the action of high and low wave infrared rays are brought to their melting point without affecting the dimensional stability of the primary substrate of the carpet, to be exposed and reach its melting point, have a time of microseconds before affecting the substrate, melting part of the surface of the olefinic minifibre layer of low DPF at the moment of transformation of the plates from solid to melting or melting this is gradual because the plates are separated and exposed individually and their fusion goes from outside to inside plate by plate which allows having the first two plates completely melted and the third or subsequent ones are in smaller degree of fusion which gives time to remove the infrared applications and the concentrated energy continues to work until the last plates are fused, due to the uniform distances achieved between the plates of oliefinic material and those produced by the excess of low denier micro fibers a space of very low density of matter is generated and this prevents the energy from penetrating to the primary base or substrate that gives the dimensional stability of the carpet. Based on the above and once the first two sheets of oliefinic material are completely fused when the exposure of the infrared rays is removed and the energy is trapped, it continues to fuse the subsequent layers and in that interval gives time for the dual operation of lowering the tooling of pressure and engraving or cold die male female so that this at a pressure higher than 150 PSI act by pressing and coercing the displacement of the melt of the layers, driving their contact with the layer of fibers of low denier and these by having low denier are subject to an immediate meltdown by absorbing the heat energy of the melting mass which simultaneously traps the upper denier fibers of the carpet yarns making an immediate seal of the same what is known as knot sealing, this action is controlled by the exposure time of the infrared rays and the amount of heat energy displaced in the layers of oliefinic material at the same time this action is controlled by the welding action of oliefinic thermoplastic coming from the cooling that emits the cold tooling , who stops the fusion action of the plates, of the fibers of both the nappa and of the integral parts of the carpet and primary base or fibers only in case of carpets of punching or non-woven origin to the shock of temperatures the oliefinicas plates they solidify again taking the forms that in their face has the cold tooling of engraving and pressure male female, the fusion action is finished and begins the hardening action by the shock of temperatures as we already said. When the oliefinic thermoplastic cools by its very nature of being thermoformable, it takes the forms of the high and low reliefs of the tooling, being able to be conical protuberances that appear on the back of the mat or the non-slip part thereof or can present at the same time a combination of both effects of thermogravation, one that is described as a perimeter rib in high and low relief which will give the mat a cosmetic presence of aesthetic delimitation of its outline. By virtue of the exposition of the whole mass of the 100% oliefinic mat of different presentations of oliefinic material one that forms the face of the mat and is with the presence of a wooded carpet other that forms the substrate of the carpet and in the case of woven carpet has presence of a substrate based on woven polypropylene or oliefinic strips, another presentation a superposed layer between the inserted yarns, this layer being produced with recycled oliefinic fibers of low denier and finally the presentation in sheets, the sheets of oliefinic material 100% low thickness all this mass together, as we said before exposed to the action of infrared rays to achieve the fusion of part of it without damaging or altering the other parts in different presentations, to achieve the above is used a diffuser of energy on the surface of the carpet of the mat this energy diffuser is simple water that absorbs the calorific energy infr throws excess of the process and allows the expensive woven product of the mat to accept the high pressure higher than 150 PSI of the given tools without suffering any collapse or take shapes or alterations in its presence texture or image, being the only variation that suffers the volumization of the textile side of the mat that when applying the water and the heat energy left over from the process, the water decomposes by the energy develops a vapor that comes to volumize the textile giving a very beneficial appearance to the final product. Water by its very nature forms steam at 100 ° Celsius and protects the olefinic textile that has its melting point and textile thermofixed above 130 ° C, the water does not leave residuals when it evaporates completely or causes stains on the olefinic abuyonado textile of the product face. If the case so requires, a substance that repels stains and dust can be applied at the same time to help the added value and use of the product.

The characteristic details of the invention are clearly shown in the following description and in the accompanying drawings, as well as an illustration thereof and the same reference signs being used to indicate the parts of the figures shown.

FIGURE 1 is a cross section of the 100% recyclable mat already laminated to a secondary substrate of the same type of resin or polymer showing the different layers that make up the mat product as well as the gravels that appear on its floor or back after being exposed to the infrared rays and to the cold die pressure of rolling, anchoring, engraving and thermoforming showing the finished product with a cosmetic rib of its contour FIGURE 2, is a cross section of the mat 100% showing the parts that comprise it before being exposed to the action of hot melt and lamination of its secondary substrate in layers of the same type of resin or polymer FIGURE 3, is a schematic of the procedure for the insertion of the multicolored layer of low denier fibers between the primary substrate and the inserted threads of a tufted fabric or between the nonwoven substrate inserted with the nappa FIGURE 4 is a representation of the procedure for the application of energy diffusing agent and protector of the textile face of the mat where it is denoted how the ready-made textile roll is cut into canvases of the necessary dimensions and turned to be exposed to the spraying of the humidifier or repellent humidifiers FIGURE 5 describes the procedure for the thermofusion, partial controlled and modulated of the parts that make up the 100% recyclable mat object of the present invention.

FIGURE 6 describes the procedure for the lamination, the seal or anchoring of the fibers and threads, the thermoforming, the engraving, the voluminization and the cosmetic finishing of the product in the same operation, making it ready for cutting and packing FIGURE 7 describes the finished product 100% recyclable carpet product that is obtained by the procedure claimed in the present invention. duly abraded or cut, showing at the same time the high and low relief engravings obtained by the claimed procedure.

With reference to FIGURE 1, in it the number 1 refers in itself to the 100% recyclable mat of a single polymer this may be either oliefinic or polyester both polymers are susceptible to be used in the claimed procedure and be subject to integrate the raw materials that make up the product since any of them can produce fibers, yarns, sheets and sheets are obviously used individually without mixing as the objective would be lost or 100% oliefinic or 100% polyester getting the product mat 100% recyclable of a single polymer being this shown complete 1 with its back facing upwards and its front or textile part of carpet 2 downwards, in this figure the layer of low-denier fibers oliefinicas or polyester, of the nappa 4 cast by the action of the infrared rays without affecting the dimensional stability of the primary substrate of the textile 3 is completely adhered to the sheets of oliefinic material 5 When they are pressed, they are integrated in a single unit, melting into each other 5 and due to the pressure exerted on this mass by the pressure tooling and encumbered by virtue of this being high. and low reliefs and for being at a low temperature causes the thermo-recording and thermo-fixation of the high and low reliefs presented conical protuberances 9 that are translated as anti-slip as well as thermoformations that result in a perimeter rib 10 cosmetic that comes to delimit the contour of the product carpet In relation to Figure 2, each and every one of the layers that make up the 100% recyclable mat that is the object of this invention, starting with the primary base or substrate 3 to which a layer or layer 4 of low denier non-woven fibers per filament is added by simple overlap to be this nappa inserted or fastened by the action of the needles that insert the abuyoned hair 2 of the textile surface of the product to all this product processed in its initial phase will be called textile product inserted prepared 6 by having already the elements ready to receive the humidifiers and the layers or sheets of oliefinic material 7, 8, and 9 once together all these elements form the meltable product by being prepared to melt, engrave, anchor, mold and laminate 14 itself and go to the next process.

With reference to FIGURE 3, it describes the process of inserting the nap 4 to the primary substrate 3 by the needles, safeguarding the hair of the textile 2 and immediately forming the inserted textile product prepared 6 then in the same process winding it in rolls 10 for handling and transportation. This same process is used when a lamination is obtained on a punched product only that instead of the recycled fibers are inserted into the substrate or primary base as in a tufing process, the nappa or non-woven fabric is punched on the back of the product that you want to laminate and then you go to all the other procedures. With reference to FIGURE 4, it details the manner of how a roll 10 of prepared textile product 6 is cut into suitable canvases and these are turned on their front to be exposed to the action of the sprinklers that scatter the cloud of water and or liquid repellent on the face of the textile 12 In relation to FIGURE 5, in it we can see how the meltable product 14 integrated by all the elements detailed in Figure 2 is exposed to the action of infrared rays to achieve the voluminization of the textile and the controlled and modulated fusion of its integral parts. In relation to FIGURE 6, we can observe the process of lamination, sealing of the fibers, pressurized thermofence, engraving and thermoforming of the meltable product 14 already in a state of controlled fusion and modulated in the desired parts the rolling process, displacement of the mass, sealing of the fibers, thermogravure, and thermo-fixation of the dimensional stability of the product is carried out by using the cold tools the female 15 with air cooling chamber and the female 17 which based on the application of cold water 17 , 18, recirculated by their internal walls are maintained at low temperature allowing under the pressure of the tool plates to the shock of the temperatures in a single operation to provide the characteristics and processes alluded to resulting in the product shown in FIGURE 7, which presents the finished product seen from its front and with a part of its back in which the prints of protuberances are shown tiderrapantes as well as their contours all of a single polymer or resin and cosmetically delimited. As a whole, an Ecological product without any contamination, created from a single resin or polymer that for its recycling will only require grinding and after grinding it can be 100% reused all its mass. The above descriptions are the basis and foundation of the present invention, the experts of the matter will be able to vary some of the described procedures but they will not be able to depart from the principle and spirit of the present invention as well as from the claims of the same reason why without stopping me from this principle I do the following

Claims (12)

1. CLAIMS 1.- The procedure for the production and the resulting product consisting of a 100% recyclable floor mat with the characteristic of being composed of single polymer resins, each and every one of the parts that make it up, is claimed and claimed. the fibers of its abujonated textile face, like the fibers of its primary and secondary substrate all anchored by means of thermofusion and all laminated by thermofusion to a thermoplastic profile also of the same polymer or resin and its resulting product.
2. 2.- The procedure for the production and the resulting product consisting of a 100% recyclable floor mat composed of single polymer resins, each and every one of the parts that make it up in the fibers of its textile side, is claimed and claimed. abuyonada, as the fibers of its primary and secondary substrate according to claim one and with the characteristic of all its components are fused with control, laminated anchorages and thermoformed by means of thermofusion under the action of infrared rays in a single exposure with time checked.
3. 3. - The procedure for the production and the resulting product consisting of a 100% floor mat composed of single polymer resins, each and every one of the parts that make it up in the fibers of its abutted textile face, is claimed and claimed. the fibers of its primary and secondary substrate all anchored by means of thermofusion and all laminated by thermofusion to a thermoplastic profile also of the same polymer or resin according to claim one and two with the characteristic that when laminated and fused all parts of the The mat is thermoformed to be finished with or without anti-skid tape and its resulting product.
4. 4. - The procedure for the production and the resulting product consisting of a 100% recyclable floor mat composed of single polymer resins, each and every one of the parts that make it up in the fibers of its abused textile face, is claimed and claimed. as the fibers of its primary and secondary substrate anchored without the use of latex all by means of thermofusion and all laminated by thermofusion to a thermoplastic profile also of the same polymer or resin and which when laminated is thermoformed to be finished with or without anti-skid tape according to claims one, two and three with the characteristic that in its contour the moment of thermoforming is thermoformed with a perimetric rib that aesthetically delimits its contour in
5. 5. the procedure for the production and the resulting product consisting of recyclable floor mats composed of single polymer resins in both the fibers of its face and in its primary substrate and anchored, laminated and engraved in high and low relief by thermofusion means according to claim one, two, three and four characterized in that in order to prepare the textile product in order to carry out the thermofusion of the fibers of the front of the same, they have to comprise in the process tuñing to adhere by simple overlap in the Tufting process a nappa or cloth of non-woven fibers and that these at the time of passing under the action of the needles that insert the threads of the carpet is fixed and inserted to the substrate or base tufting, making a single product that between the tufting of the tufted yarns takes the non-woven fiber nappa thus being prepared and ready to be thermofused
6. 6. procedure for the production and the resulting product consisting of 100% recyclable floor mats composed of single polymer resins both in the fibers of its face and in its primary substrate and anchored, laminated and graded in high and low relief by means of thermofusion and its resulting product according to claim one, two, three, and four not limited to the use of only tufted fabric materials but also material of punched or non-woven products, characterized in that in the punching process is adhered by simple superposition a nap or cloth of non-woven fibers of very low denier by filament and that these when passing under the action of the needles that insert the fibers of the product, they will also fix the nappa or cloth of non-woven fibers to the primary substrate or base, leaving the nappa and the substrate with the insertion of the fibers and as a punched carpet prepared to be processed according to the different steps of the process claimed in points one, two, three , and four.
7. 7. - The procedure for the production and the resulting product consisting of a 100% floor mat according to claims 1,2,3,4,5 and 6 and characterized by the procedure for the protection of the face of the product is claimed and claimed. product consisting of said procedure in the application of a humidification treatment with water spray in any of its physical states or any other liquid in the textile surface of abuyonada carpet that will be the face of the product being this humidifying the protector and voluminizador of the same during the process
8. 8. - The procedure for the production and the resulting product consisting of a 100% recyclable floor mat according to claims 1,2,3,4,5,6 and 7 is claimed and claimed and the process by the p spray application of a humidification treatment, a liquid repellent agent to dust and stains that, in addition, this treatment serves during the process as a diffuser of the energy of the face of the carpet in order to protect it and prevent excess heat damage their presence.
9. 9. - The procedure for the production and the resulting product consisting of a 100% recyclable floor mat according to claims 1,2,3,4,5,6,7 and 8 characterized the process followed by the textile with the overlapping of the thermoplastic profiles of the same resin will initiate its controlled and modulated process of heating and melting both its sheets and the napkin or cloth of nonwoven fabric, this by passing a radiator with infrared ray modulation.
10. 10. - The procedure for the production and the resulting product consisting of a 100% recyclable floor mat according to claims 1,2,3,4,5,6,7,8, and characterized by claiming and claiming is claimed and claimed. the fusion of both its laminates and the nappa or cloth of non-woven fabric comes into contact with the abused side of the product with an artificially cooled female tool in order to help the humidifier maintain this part without undergoing alteration or deformation
11. 11.- It is claimed and claims the process for the production and the resulting product consisting of a 100% recyclable floor mat according to claims 1,2,3,4,5,6,7,8,9 and characterized in that to laminate, anchor , gravel, thermoforming, thermosetting its dimensional stability is used at high pressure two cold tooling dice one upper and one lower with high and low reliefs and both tooling have regulated their compression pressure and cooling temperature ento.
12. 12. - The procedure for the production and the resulting product consisting of a 100% recyclable floor mat according to claims 1,2,3,4,5,6,7,8,9,10 and 11 is claimed and claimed. because the product once molded and engraved on its face is cooled by means of injected cold air. 1?