WO1993001347A1 - New and improved backing for carpets and the like - Google Patents
New and improved backing for carpets and the like Download PDFInfo
- Publication number
- WO1993001347A1 WO1993001347A1 PCT/AU1992/000329 AU9200329W WO9301347A1 WO 1993001347 A1 WO1993001347 A1 WO 1993001347A1 AU 9200329 W AU9200329 W AU 9200329W WO 9301347 A1 WO9301347 A1 WO 9301347A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fabric
- woven
- carpet
- tufted
- backing
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
- D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
- D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
-
- 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
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/08—Inorganic fibres
- D06N2201/082—Glass fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/041—Polyacrylic
-
- 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
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
- D06N2203/048—Polyvinylchloride (co)polymers
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/02—Dispersion
- D06N2205/023—Emulsion, aqueous dispersion, latex
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2205/00—Condition, form or state of the materials
- D06N2205/02—Dispersion
- D06N2205/026—Plastisol
-
- 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
- D06N2209/16—Properties of the materials having other properties
- D06N2209/1628—Dimensional stability
-
- 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
- D10B2503/041—Carpet backings
- D10B2503/042—Primary backings for tufted carpets
Definitions
- This invention relates to a fabric backing suitable for use in manufacturing tufted textile materials such as carpets and in particular carpet tiles.
- tufted textile materials such as carpets and in particular carpet tiles.
- the present invention will be discussed in reference to carpets and carpet tiles. However, the principles are equally applicable to other tufted textile materials such as fabrics used in wall coverings, seat coverings and the like, as will be appreciated.
- the invention should not be taken as restricted to its application to carpets and carpet tiles.
- thermoplastic backings include polypropylene or polyester fibres which can be in the form of solid sheets or woven material but generally are comprised of a non-woven random layered web of thermoplastic material partially melted to provide a backing sheet material.
- a support layer comprised of fibreglass in the form of a non-woven random layered sheet.
- the fibreglass sheet is generally coated with a binding material such as a polyvinylchloride resin or the like.
- the carpet is then cut into tiles. It has been found that carpet tiles so produced tend to lift at the edges particularly after printing. The edges curl upwards to make the floor unattractive and the tiles unacceptable. It has been practice to apply adhesive to keep the tiles flat to the floor. Similar problems arise with other tufted fabrics.
- the present invention provides a fabri backing for tufted textile materials such as carpe tiles and other carpets that allows for the manufactur of tufted products that have acceptable dimensiona stability and flatness such that for example the carpe can be laid onto floors without the need for adhesives.
- the invention is based on the realisation tha the penetration of the thermoplastic backing material b tufting needles introduces dimensional instability into the backing causing shrinkage to occur during subsequent processing.
- the invention provides a construction where this effect is minimized or avoided.
- the present invention provides a penetrable fabric backing material comprising a woven silica fabric having warp and weft threads, said fabric being impregnated with a lubricant comprising a stabilising amount of polyacrylic or polyacrylate resin, whereby to bind said warp and weft threads to stabilize said woven fabric and allow penetration by needles during a tufting process while said fabric remains sufficiently flexible to allow it to pass around rollers in a manufacturing process .
- a carpet construction includes a carpet backing comprised of a woven silica fabric, at least relatively dimensionally stable when penetrated by needles during the tufting process.
- the woven silica fabric is a woven fibreglass fabric.
- the fibreglass fabric may be comprised of a fabric woven with multifilament fibreglass thread.
- the thread may be between 40 and 80 tex.
- a 66 tex fibreglass thread has been found particularly satisfactory as has a fabric woven with a double weft and single warp thread.
- a single warp and weft woven construction has been found particularly satisfactory, although it should be appreciated that- more complex warp and weft thread constructions may be employed. For example, 2 2 and 3 x 3 warp and weft constructions have been found to be satisfactory.
- a thread density of between 7 and 5 threads per centimeter, that is between about 17.5 and 12.5 threads per inch both warp and weft provides a suitable thread density. It has been found that if the thread density is too high there is an increased possibility of needle damage and yarn breakage but that if the thread density is too low there may be insufficient strength in the backing material. It has also been found that a woven weight of between 80 and 150 grams per square metre is satisfactory and in one example a woven weight of about
- the backing of the ' present invention is impregnated with a stabilising amount of an acrylic material.
- Any suitable polymeric or mixture of polymeric materials may be used provided it will stabilize the fibreglass material while remaining sufficiently flexible for the material to pass around rollers during manufacture and penatrable to allow tufting needs to pass through it.
- Commercially available "acrylic" mixes are suitable for this purpose and are sufficiently stable at processing temperatures. It is important to note that impregnation occurs and a coating layer is not produced as would result if non-solubilised materials such as polyvinylchloride we used.
- the acrylic mix may include one or mor acrylic polymers or copolymers of acrylic acid, an acrylic acid ester such as butyl acrylate, ethy acrylate or methyl methacrylate for example.
- Th polymers preferably have a molecular weight of betwee 50,000 and 250,000 and a viscosity in the range of fro 50 to 1000 CPS.
- a surfactant may be included to provid increased penetration of the material into the materia of the fabric.
- a filler such as calcium carbonate ma be included if desired.
- the polymeric material is preferably i solution or emulsified.
- An aqueous emulsion has bee found to be particularly suitable in providin impregnation or penetration of fibreglass filaments.
- the stabilising polymeric material may b applied by passing the woven fibreglass material throug a bath containing the stabilising polymeric mixture t obtain a satisfactory impregnation.
- other application methods have been found to be satisfactory.
- the carpet backing of the present invention remains sufficiently flexible for the tufting needles to penetrate the backing without ripping the fibres.
- the material is able to pass around rollers and be separable when cut into carpet strips or tile shapes. It is also thermally stable at processing temperatures employed in the carpet tile manufacturing processes.
- the impregnated backing of the present invention provides a suitable backing for carpet manufacture.
- a continuous width of backing may be tufted with carpet yarn which may be comprised by wool or synthetic material or a combination of wool and synthetic material for example.
- the tufting needles easily penetrate the backing of the present invention.
- a 1.9 metre wide tufting machine has been used with success.
- the tufted backing may then have applied to it a binding coating layer which may be comprised for example by a polyvinylchloride layer or other binding layer which binds the tufted yarn to the backing material.
- Suitable binding layers include polyvinylchloride preferably in the form of a plastisol.
- a support layer may be applied.
- the support layer may include a fibreglass material such as a non-woven random layered fibreglass sheet bound with an acrylic resin as is known in the art.
- a further coating of a binding layer may be applied thereto to complete the carpet construction.
- the backing of the present invention is tufted in a tufting machine to form a carpet strip.
- a binding layer is applied to a support backing, a support layer is applied to the binding layer as it passes therethrough, a further binding layer is applied to the support layer and then the carpet strip applied thereto with the backing adjacent the binding layer.
- the laminated strip then passed to an oven for curing.
- the carpet strip may be cut into carpet strips or tile shapes as desired and printed by dyeing processes as is known in the art.
- a 66 tex multifilament glass fibre was woven in a one by one warp and weft construction to produce a woven fibreglass material having a thread density of between 5 and 7 threads per centimetre in the warp and weft direction and a woven weight of about 109 grams per square metre. It was cut into a strip having a width of 1.9 metr The fibreglass fabric was dipped through an impregnati bath containing a PRIMAL TR 407 being a 45% soli aqueous emulsion. The impregnated fibreglass backi was then cured and formed into a backing roll.
- the backing roll was then mounted onto standard tufting machine. It was found that the backi material was particularly suitable for use in t standard tufting machine and a tufted carpet stri produced.
- bindin layer and support layer structure was produced in whic the binding layer comprised polyvinylchloride an plastisol.”
- the viscosity was 5000 cps (Brookfield) .
- the support layer comprised a non-wove fibreglass material.
- the laminated structure was cured in a curin oven. After cooling the carpet strip was cut int carpet tiles and printed using standard dyein procedures .
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Carpets (AREA)
- Woven Fabrics (AREA)
- Laminated Bodies (AREA)
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP92914961A EP0646195A1 (en) | 1991-07-05 | 1992-07-03 | New and improved backing for carpets and the like |
JP5501841A JPH06508891A (en) | 1991-07-05 | 1992-07-03 | New and improved base fabric for carpets etc. |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPK7053 | 1991-07-05 | ||
AUPK705391 | 1991-07-05 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1993001347A1 true WO1993001347A1 (en) | 1993-01-21 |
Family
ID=3775523
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/AU1992/000329 WO1993001347A1 (en) | 1991-07-05 | 1992-07-03 | New and improved backing for carpets and the like |
Country Status (8)
Country | Link |
---|---|
EP (1) | EP0646195A1 (en) |
JP (1) | JPH06508891A (en) |
CN (1) | CN1070440A (en) |
CA (1) | CA2113207A1 (en) |
NZ (1) | NZ243405A (en) |
TW (1) | TW219965B (en) |
WO (1) | WO1993001347A1 (en) |
ZA (1) | ZA924931B (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112370125A (en) * | 2020-11-13 | 2021-02-19 | 哈尔滨理工大学 | Winding type flexible needle puncture mechanism |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU3063063A (en) * | 1962-05-21 | 1964-11-19 | The Theremolux Glass Company Limited. V | Improvements in or relating to glass fabric strip material |
US3959534A (en) * | 1973-04-23 | 1976-05-25 | Union Carbide Corporation | Process for producing fibers |
EP0123472A2 (en) * | 1983-04-15 | 1984-10-31 | 'w' Ribbons Limited | Woven fabrics and a method of forming the same |
AU6234890A (en) * | 1989-09-15 | 1991-03-21 | Rohm And Haas Company | High molecular weight acrylic polymers |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3320113A (en) * | 1964-04-17 | 1967-05-16 | Fiber Glass Ind Inc | Glass fabric with particulate material and pile yarns penetrating the same |
US3642516A (en) * | 1969-03-18 | 1972-02-15 | Johnson & Johnson | Carpet backing |
-
1992
- 1992-07-01 NZ NZ243405A patent/NZ243405A/en unknown
- 1992-07-02 ZA ZA924931A patent/ZA924931B/en unknown
- 1992-07-03 JP JP5501841A patent/JPH06508891A/en active Pending
- 1992-07-03 EP EP92914961A patent/EP0646195A1/en not_active Withdrawn
- 1992-07-03 CA CA002113207A patent/CA2113207A1/en not_active Abandoned
- 1992-07-03 WO PCT/AU1992/000329 patent/WO1993001347A1/en not_active Application Discontinuation
- 1992-07-04 CN CN92109182A patent/CN1070440A/en active Pending
- 1992-08-29 TW TW081105303A patent/TW219965B/zh active
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU3063063A (en) * | 1962-05-21 | 1964-11-19 | The Theremolux Glass Company Limited. V | Improvements in or relating to glass fabric strip material |
US3959534A (en) * | 1973-04-23 | 1976-05-25 | Union Carbide Corporation | Process for producing fibers |
EP0123472A2 (en) * | 1983-04-15 | 1984-10-31 | 'w' Ribbons Limited | Woven fabrics and a method of forming the same |
AU6234890A (en) * | 1989-09-15 | 1991-03-21 | Rohm And Haas Company | High molecular weight acrylic polymers |
Non-Patent Citations (3)
Title |
---|
DERWENT ABSTRACT Accession No. 83.720854/30, Class P27; & JP,A,58 104 278 (SUMITOMO CHEMICAL KK), 11 December 1981 (11.12.81). * |
DERWENT ABSTRACT Accession No. A87.20337A/11, Class A87; & JP,A,53 010 796 (MITSUBISHI GAS CHEM IND), 31 October 1978 (31.10.78). * |
See also references of EP0646195A4 * |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112370125A (en) * | 2020-11-13 | 2021-02-19 | 哈尔滨理工大学 | Winding type flexible needle puncture mechanism |
Also Published As
Publication number | Publication date |
---|---|
NZ243405A (en) | 1994-12-22 |
TW219965B (en) | 1994-02-01 |
JPH06508891A (en) | 1994-10-06 |
EP0646195A4 (en) | 1994-09-13 |
CN1070440A (en) | 1993-03-31 |
CA2113207A1 (en) | 1993-01-21 |
ZA924931B (en) | 1993-04-28 |
EP0646195A1 (en) | 1995-04-05 |
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