WO1994020283A1 - Tapis fabriques sur commande et bordes - Google Patents

Tapis fabriques sur commande et bordes Download PDF

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Publication number
WO1994020283A1
WO1994020283A1 PCT/US1993/008688 US9308688W WO9420283A1 WO 1994020283 A1 WO1994020283 A1 WO 1994020283A1 US 9308688 W US9308688 W US 9308688W WO 9420283 A1 WO9420283 A1 WO 9420283A1
Authority
WO
WIPO (PCT)
Prior art keywords
backing
rug
carpet
segments
hot melt
Prior art date
Application number
PCT/US1993/008688
Other languages
English (en)
Inventor
John C. Thornton
Stanton J. Pool
Dennis R. Doll
Original Assignee
American Rug Craftsmen, Inc.
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 American Rug Craftsmen, Inc. filed Critical American Rug Craftsmen, Inc.
Priority to AU51283/93A priority Critical patent/AU5128393A/en
Publication of WO1994020283A1 publication Critical patent/WO1994020283A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/10—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
    • B32B37/1027—Pressing using at least one press band
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
    • A47G27/0437—Laying carpeting, e.g. wall-to-wall carpeting
    • A47G27/0443—Laying carpeting, e.g. wall-to-wall carpeting using hot-melt adhesives; Irons therefor
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/435—Making large sheets by joining smaller ones or strips together
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
    • B29C66/7234—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered comprising a barrier layer
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/727—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being porous, e.g. foam
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/82—Pressure application arrangements, e.g. transmission or actuating mechanisms for joining tools or clamps
    • B29C66/822—Transmission mechanisms
    • B29C66/8223—Worm or spindle mechanisms
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83411—Roller, cylinder or drum types
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/83—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools
    • B29C66/834—General aspects of machine operations or constructions and parts thereof characterised by the movement of the joining or pressing tools moving with the parts to be joined
    • B29C66/8341—Roller, cylinder or drum types; Band or belt types; Ball types
    • B29C66/83421—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types
    • B29C66/83423—Roller, cylinder or drum types; Band or belt types; Ball types band or belt types cooperating bands or belts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B5/00—Presses characterised by the use of pressing means other than those mentioned in the preceding groups
    • B30B5/04—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band
    • B30B5/06—Presses characterised by the use of pressing means other than those mentioned in the preceding groups wherein the pressing means is in the form of an endless band co-operating with another endless band
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/80—General aspects of machine operations or constructions and parts thereof
    • B29C66/81—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps
    • B29C66/818—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps
    • B29C66/8181—General aspects of the pressing elements, i.e. the elements applying pressure on the parts to be joined in the area to be joined, e.g. the welding jaws or clamps characterised by the cooling constructional aspects, or by the thermal or electrical insulating or conducting constructional aspects of the welding jaws or of the clamps ; comprising means for compensating for the thermal expansion of the welding jaws or of the clamps characterised by the cooling constructional aspects
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/932—Measuring or controlling the joining process by measuring or controlling the speed by measuring the speed
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/934—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed
    • B29C66/93431—Measuring or controlling the joining process by measuring or controlling the speed by controlling or regulating the speed the speed being kept constant over time
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/90—Measuring or controlling the joining process
    • B29C66/93—Measuring or controlling the joining process by measuring or controlling the speed
    • B29C66/939—Measuring or controlling the joining process by measuring or controlling the speed characterised by specific speed values or ranges
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/732—Floor coverings
    • B29L2031/7324—Mats

Definitions

  • the present invention relates to the manufacture of rugs, and more
  • Bordered rugs typically have a central segment which is referred to as the field, and a border that surrounds the field.
  • the field itself can be formed
  • the border for a rectangular field is generally formed from at least four
  • segments of carpeting each cut to a desired size and shape to surround the field.
  • the field and the border generally have different colors to provide a unique, aesthetic appearance.
  • Each segment of carpet usually has a so-called "grain,” that is, the
  • carpet fibers of the segments all tend to slant in the same direction.
  • Border segments are usually positioned so that their grains all slant toward the field; it
  • bordered rugs have been formed by initially preparing the field. The border pieces are cut individually. For a rectangular rug, there will be four generally elongated border segments, each border segment having two mitered ends to provide a rectangular frame pattern around the field. The segments of carpet are then arranged pile down, edge to edge, and the field and borders are bonded together to form a unitary rug.
  • melt seam tape can be applied to bond abutting segments together. This does not add strength to the seams or rug, and the seams are detectable.
  • the rug may be large and quite heavy; applying the backing material to it requires handling or turning of the rug which can cause the sections to separate during assembly. Also, opposing grain directions can cause the separation of the segments if vertical pressure is applied to the seams between segments prior to final bonding. Further, if seam tape is applied, the tape makes the seam area slightly "higher" than the remaining area of the rug
  • the present invention provides a semi-automated method for making composite rugs such as bordered rugs and custom fabricated rugs which greatly improves the rate of manufacture, yet at the same time provides rugs of greater strength.
  • a rug is assembled by cutting and assembling the respective segments and mechanically holding them together temporarily while spot bonding the segments with a first hot melt adhesive on the abutting seams.
  • a backing material is applied by passing the
  • the first (high temperature) hot melt holds the sections together while the second is melted and cooled, to bond them more completely. This permits continuous travel of the assembled but
  • This additional hot melt adhesive is a lower melting point adhesive, and may be significantly less expensive than the first
  • the rug backing material is preferably an open weave mesh material having a continuous, impervious coating such as a latex rubber coating.
  • a reinforcing mesh material is interleaved and bonded between the rug backing material and the carpet segments to provide added strength.
  • the rug backing is laminated to the carpet segments by passing the temporarily bonded carpet segments and the rug backing together as a "sandwich" between parallel platens under heat and pressure. At least one of the platens is heated and acts to melt the low temperature hot melt adhesive, both the adhesive on the backing and the adhesive strip along the seams. In a subsequent section, the composite is cooled while still under pressure by passing it between the parallel platens in a
  • carpet segments together permits the automated application of the backing material with a lower temperature hot melt adhesive.
  • the temperature of the press does not affect the high temperature hot melt adhesive sufficiently to permit the segments (even those with opposed grain) to separate under the bonding pressure. Therefore, even though there may be opposed grain directions in adjacent carpet segments, the high temperature hot melt adhesive holds the segments together as the low temperature adhesive flows through the reinforcing mesh, contacts and bonds the carpet backing as well as to the rug backing.
  • Fig. 1 is a diagrammatic depiction of a preferred form of rug made
  • Fig. 2 is a diagrammatic plan view of a rug made according to the present invention.
  • Fig. 3 is an enlarged cross-section taken at line 3-3 of Fig. 2;
  • Fig. 4 is a diagrammatic depiction of the preferred manufacture of the rug backing used in the present invention.
  • Fig. 5 is a diagrammatic depiction of the preferred method of bonding mesh reinforcement to the rug backing used in the present invention
  • Fig. 6 is a fragmented perspective view of a preferred assembly step useful for the manufacture of rugs according to the method of the present invention
  • Fig. 7 is a perspective view of the preferred rug bonding apparatus of the present invention.
  • Fig. 8 is an elevation, partially in cross-section, of the apparatus shown in Fig. 7;
  • Fig. 9 is an enlargement of the heating section of the apparatus shown in Fig. 8.
  • Fig. 10 is a cross sectional view of an alternate embodiment of the present invention. Detailed Description
  • present invention includes a central field segment 12 which has a peripheral
  • border 14 Bonded to and surrounding the peripheral edge 13 of the field segment 12 is a border 14 which includes the side segments 15 and 16, and end segments 17 and 18.
  • Field 12 may be rectangular and each one of the border segments 15, 16, 17, and 18 an elongated, narrow section having an outside edge 19 and inside edge 21 that abuts the peripheral edge 13 of the field.
  • the border sections 15-18 may (but need not necessarily)
  • the field 12 and the borders 15-18 are all formed from segments
  • the field segment usually has a contrasting color, design, and/or pattern from the border segments.
  • composite bordered rug 1 1 includes a pile upper surface 31 on a carpet backing 32 formed, in known manner.
  • Carpet backing 32 is in turn bonded to a rug backing material 33. Between the carpet backing 32 and the rug backing 33 is
  • a reinforcing mesh 34 All three layers 32, 33, and 34 are bonded together by a hot melt adhesive layer 37 which extends from the rug backing 33 through
  • the rug 1 1 is formed by initially shaping the field segment 12 as
  • the carpet segments may be temporarily held together with elastic straps 41 which have toothed claws 42 at either end which engage and grasp the backing of the carpet segments pulling them together.
  • Adjacent segments 12 and 14 are partially bonded together by applying patches or spots 43 of a first, high temperature hot melt adhesive 43 along the abutting seams 44 between the field 12 and the border segments 15- 18 as well as on the seams between the mitered edges 22a and 22b of the border segments (see Fig. 1 ).
  • the high temperature hot melt adhesive 43 can be applied as a continuous strip along the entire seam, however, because of its high cost, it is preferably applied as discrete patches 43, for example about .5
  • Adjacent patches are separated by a spacing preferably of about 6 to 12 inches.
  • the elastic straps 41 are removed and the seams 44 and 45 are preferably further adhered
  • the first (higher temperature) is higher.
  • hot melt adhesive 43 preferably does not soften at the ring and ball temperature of the lower temperature hot melt adhesive 46.
  • the softening point such as Hysol brand 7393 is preferred as the first (high temperature activated) adhesive, although other adhesives may be used.
  • the softening point such as Hysol brand 7393 is preferred as the first (high temperature activated) adhesive, although other adhesives may be used.
  • the softening point such as Hysol brand 7393 is preferred as the first (high temperature activated) adhesive, although other adhesives may be used.
  • the of the high temperature hot melt adhesive is greater than 290 "F. and preferably 350 * F. or higher; and it has a melting temperature of 400 "F. or higher.
  • the low temperature second hot melt adhesive 46 is preferably an ethyiene vinyl acetate. This has a ring and ball temperature which is below the softening temperature of the high temperature adhesive and preferably is about 225 ⁇ F.
  • a preferred type of lower temperature hot melt adhesive is HM4501 sold by Mydrin Inc. of Calhoun, Georgia.
  • a strip about one inch wide of the low temperature hot melt adhesive 46 is applied along each abutting seam 44, 45. This, adhesive further holds the adjoined carpet segments together while the assembly is turned over and positioned for further bonding.
  • the adjoined carpet segments 48 are then bonded to the rug backing material 33, using a low temperature hot melt adhesive 37.
  • the low temperature hot melt adhesive 46 has a ring and ball temperature lower than the softening point of the high temperature hot melt adhesive 48. Preferably it is the same low temperature hot melt adhesive used to bond the carpet
  • the rug backing material 33 can be any backing material which is
  • Suitable backing materials include so called “Action Bac”TM open mesh backing sold by Patchogue (Amoco), jute backing, monk's cloth or synthetic monk's cloth.
  • the backing material 33 is preferably coated with an
  • impervious layer such as latex, in order to confine the hot melt coating 37 to its
  • Such a backing 33 can be formed by applying a liquid latex onto a
  • this mesh material is a relatively open weave mesh having a density of about 3-5 oz/yd 2 .
  • One preferred material is "Action Bac" brand style 3808 from Patchoque (Amoco). This is a Leno Weave material which is 100% polypropylene. Its density is 4.15 oz/yd 2 .
  • a preferred latex material is synthetic rubber latex such as carboxylated styrene butadiene copolymer latex such as T ⁇ lac brand sold by Reichold Chemicals. However, there are many other suitable materials which can be used.
  • the coating on the rug backing 33 is formed by coating the open weave mesh material 51 with a liquid latex material 52 using a
  • the latex material 52 is applied so as to have a density of 15-16 oz/yd 2 dry weight.
  • the latex closes the meshes of the material 51 , and remains primarily on the top surface; it need not substantially pass through to the lower side, though small "bumps" projecting through provide a desirable anti-slip surface on the bottom.
  • the latex provides
  • the latex backing composite may be either immediately used or stored in a roll 53 for subsequent use.
  • mesh layer 34 are next laminated or applied to the rug backing material 33.
  • the intervening mesh material 34 is preferably an open weave polypropylene
  • One preferred material is Action Bac 3824. This is also a Leno Weave material, 100% polypropylene with a 16 X 6 construction. Its density is 2.24 oz/yd 2 . Preferably it has larger mesh openings than the rug backing in order to permit the adhesive to pass easily through it. Other reinforcing materials can be used or, in the alternative, it can be omitted entirely, but with loss of strength.
  • this mesh 34 is bonded to the rug backing 33 by a continuous layer of a second hot melt adhesive 37.
  • the backing 33 and the mesh are fed at equal speeds from rolls 53 and 55 and pass between a roller 56 and a slot die adhesive applicator 57.
  • the slot die 57 applies about 24 mils of adhesive 37 across the width of the secondary backing bonding the mesh 34 to the backing 33.
  • the adhesive 37 cools but remains
  • the hot melt adhesive 37 is again a low temperature hot melt
  • melt adhesive layer 37 is the same low temperature adhesive composition 46 applied along seams 44 and 45 as previously described.
  • the apparatus 61 includes low friction, "no-stick” (e.g., Teflon coated) fiberglass, upper and lower endless belts 62 and 63.
  • the belts have horizontal, parallel runs 62a, 63a which are closely spaced.
  • the upper belt 62 runs on an
  • upper press frame section 64 which presses upper belt run 62a and carpet captured below it towards the lower belt run 63a, which runs on a lower press section 68 and which includes heating section 66 and cooling section 67.
  • the upper press section 64 includes a supporting frame that includes four beams or legs 69 which in turn are connected by four
  • the legs 69 in turn support an inner belt supporting apparatus 71 which has a rectangular frame 72 supported from
  • the upper apparatus 71 supports a heavy horizontal metal plate or platen 81 which runs the length of the upper apparatus 71 . At its forwardmost portion (the right end in Fig. 8), plate 81 has an upper turned edge or lip 80.
  • the metal plate 81 is itself supported by a series of I beams 82 welded to its upper surface 83.
  • the distal ends of I beams 82 are welded to side beams 84 (Fig. 8).
  • Upper belt 62 passes around three slave rollers 86, 87, 88 and one
  • a speed sensor 99 measures the speed of the belt 62 at drive roll 89 and is coupled to ensure that the upper and lower belts run at the same speed.
  • the lower press section 68 is separately moveable from the upper section 64. It includes four support legs 101 which rest on casters 102 which in turn run on transverse metal tracks 103. The legs 101 support an upper frame 104 which in turn supports a metal plate 105. A series of quarter inch
  • thick metal shims 100 (three shown in Fig. 7) support the upper apparatus 71 in use. I beam 82 rests on these shims preventing the upper and lower belts 62 and 63 from resting on each other when no rug is running between this.
  • Plate 105 itself can be formed from sections that abutted each other. The forwardmost portion of this plate 105 is a downwardly turned edge or lip 106. Immediately downstream of this edge 106 is heating section 66. Heating section 66 is simply a series of strip heaters 107 which rest on a lower
  • the heating section is as wide as metal plate 105 and about four feet long. Following the heating section is a "dead" or neutral zone
  • cooling section 67 is formed from a series of loops of copper tubing 121 which runs beneath the metal plate 105. The tubing is held in physical contact with the lower surface 109 of metal plate 105 by a second metal plate 122 and in turn is
  • the copper tubing 121 is connected to a chilled water unit (not shown) which provides adequate heat exchange.
  • the endless lower belt 63 runs on the top surface 124 of the metal plate 105 around three slave rollers 125, 126, 127, and a drive roller 128.
  • roller 129 There is also a take up roller 129. All these rollers are supported by the frame 104. As with the upper belt, there is a belt guide 130 controlled by a guide eye
  • the lower belt includes a speed sensor 132 which is electronically coupled to the speed sensor 99 on the upper belt to maintain both belts 62, 63 at the same speed.
  • Upstream of apparatus 61 is a table 133
  • the adjoined carpet segments 48 are turned pile side up, and are placed on the mesh reinforced backing section 59 with the carpet backing 32 contacting the adhesive layer 37.
  • the edge adhesives 43, 46 hold the
  • the upper and lower belts 62 and 63 move in the direction of arrow 142 and capture the forward edge of the carpet sections 48 and the backing material 59 and carry them together into the apparatus.
  • the rug sandwich assembly is thus captured between the belts as it passes through the press.
  • the belts slide along the platens, and the assembly is held motionless relative to the belts.
  • Speed sensors 99 and 132 will keep the belts 62 and 63 moving at the same speed, preferably about 4 feet per minute.
  • the downwardly and upwardly turned lips of the upper and lower plates will permit the combined carpet and backing, between the respective belts, to be easily fed between the upper and lower plates. Since the belts move at the same speed, there is no friction against the carpet sections or the backing sections tending to pull them apart.
  • the heating section does not melt the patches of the first (high temperature) hot melt.
  • the strip of adhesive 46 is shown separately in this Figure, it actually melts and blends in with adhesive layer 37.
  • the carpet and backing will next pass through the dead zone to the cooling zone where, as pressure is continually applied, the assembly is cooled to
  • Fig. 10 shows an alternate embodiment of the present invention.
  • the formed rug includes the central field segment 18
  • Fabric segment 180 includes a foam pad 181 which has an upper surface 182 and a lower surface 183.
  • Fabric 184 is bonded to the upper surface 182 of foam pad 181 using a
  • This portion is tacked to the foam pad with a hotmelt.
  • the fabric segment 180 is then bonded to the carpet segment 18 in the same manner previously described.
  • the first high temperature hot melt adhesive 43 adheres the fabric segment 180 to the carpet segment 18 along adjoined edges.
  • the second layer of lower temperature hot melt adhesive 46 is applied along the same adjoined edges. This is then bonded to the rug backing
  • the foam must be a foam which can withstand the temperature applied to the hot melt adhesive 37 to bond the segments together.
  • Poiyurethane foam is preferred.
  • One such foam with the pressure sensitive adhesive pre-applied can be purchased from Foam Products of Calhoun, Georgia.
  • any fabric which can withstand normal foot traffic can be employed.
  • the fabric can also be applied to a foam pad using a
  • pressure sensitive adhesive is preferred due to the simplicity of assembly.
  • the rug formed according to the method of the present invention is a rug formed according to the method of the present invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Carpets (AREA)

Abstract

Des tapis fabriqués sur commande et bordés (11) sont constitués en collant bord à bord (44, 45) des segments de tapis (12, 15, 17) à l'aide d'un adhésif thermofusible à haute température (43). Ensuite, un matériau à revêtement de préférence en latex est collé sur le dossier de segments joints à l'aide d'un second adhésif thermofusible mais à température moins élevée (37). Il est préférable de coller une trame de renfort (34) entre une sous-couche porteuse (33) et le dossier du tapis (32). L'appareil servant à coller la sous-couche (33) au dossier du tapis (32) se compose de 2 courroies circulaires opposées qui transportent l'ensemble soumis à pression à travers une section chauffante puis à travers une section de refroidissement. La section chauffante fait fondre l'adhésif à faible température (37), qui s'écoule alors sous pression, mais ne fait pas fondre l'adhésif à haute température (42). Les jointures des tapis ainsi obtenus sont remarquablement résistantes à la séparation.
PCT/US1993/008688 1993-03-12 1993-09-15 Tapis fabriques sur commande et bordes WO1994020283A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU51283/93A AU5128393A (en) 1993-03-12 1993-09-15 Custom fabricated and bordered rug

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US3063193A 1993-03-12 1993-03-12
US08/030,631 1993-03-12
US9593593A 1993-07-22 1993-07-22
US08/095,935 1993-07-22

Publications (1)

Publication Number Publication Date
WO1994020283A1 true WO1994020283A1 (fr) 1994-09-15

Family

ID=26706263

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1993/008688 WO1994020283A1 (fr) 1993-03-12 1993-09-15 Tapis fabriques sur commande et bordes

Country Status (2)

Country Link
AU (1) AU5128393A (fr)
WO (1) WO1994020283A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016018768A1 (fr) * 2014-07-28 2016-02-04 Cascade Designs, Inc. Matelas pneumatique et procédé de construction associé

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3019508A (en) * 1958-10-17 1962-02-06 Bigelow Sanford Inc Cushioned carpeting and method of making the same
US5104475A (en) * 1990-05-11 1992-04-14 Orcon Corporation Method and apparatus for seaming carpets

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3019508A (en) * 1958-10-17 1962-02-06 Bigelow Sanford Inc Cushioned carpeting and method of making the same
US5104475A (en) * 1990-05-11 1992-04-14 Orcon Corporation Method and apparatus for seaming carpets

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016018768A1 (fr) * 2014-07-28 2016-02-04 Cascade Designs, Inc. Matelas pneumatique et procédé de construction associé

Also Published As

Publication number Publication date
AU5128393A (en) 1994-09-26

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