WO1994020662A1 - Tapis colle utilisant un fil a forte torsion - Google Patents

Tapis colle utilisant un fil a forte torsion Download PDF

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Publication number
WO1994020662A1
WO1994020662A1 PCT/AU1994/000094 AU9400094W WO9420662A1 WO 1994020662 A1 WO1994020662 A1 WO 1994020662A1 AU 9400094 W AU9400094 W AU 9400094W WO 9420662 A1 WO9420662 A1 WO 9420662A1
Authority
WO
WIPO (PCT)
Prior art keywords
yarns
yarn
adhesive layers
carpet
tension
Prior art date
Application number
PCT/AU1994/000094
Other languages
English (en)
Inventor
Patrick Devlin
Peter John Murray
Original Assignee
Feltex Modular Carpets Pty. Ltd.
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 Feltex Modular Carpets Pty. Ltd. filed Critical Feltex Modular Carpets Pty. Ltd.
Priority to AU62549/94A priority Critical patent/AU684753B2/en
Publication of WO1994020662A1 publication Critical patent/WO1994020662A1/fr

Links

Classifications

    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/38—Making pile fabrics or articles having similar surface features by inserting loops into a base material by passing thread material in zig-zag manner through spaced layers of base material and subsequently cutting along a central plane
    • 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
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/20—Cured materials, e.g. vulcanised, cross-linked

Definitions

  • This invention concerns the manufacture of carpet. It has particular application to the production of a new product comprising a high twist yarn adhesively bonded to a thermoplastic backing but is not limited thereto.
  • the invention also concerns a new method for the manufacture of bonded carpets.
  • the first is a tufting process. In this process yarn is threaded through a series of needles and the needles then sew the yarn onto a backing. The yarn so attached forms the carpet pile.
  • the second process is a fusion bonding process where yarn is pressed, usually by a series of blades, into an adhesive plastisol which is then cured. The cured adhesive and yarn is thereafter laminated with a backing.
  • Carpet made by the tufting process is more expensive to make as about 30% of the yarn is inoperative as a pile as it is lost in the back of the carpet. Bonded carpets are more efficient in this respect as almost all of the yarn is operative in the pile. Bonded carpet also has better dimensional stability than tufted carpet as it doesn't have the same tendency to curl at the edges. This makes it more suitable for products such as carpet tiles.
  • a process for making a bonded carpet substrate comprising a thermoplastic material into which there is bonded a plurality of textile yarns, said process comprising:- (a) forming two adhesive layers and positioning said layers in spaced face to face relation;
  • the tension of each respective yarn is in the range of between 3 to 10 grams force at the point of introduction between the said adhesive layers. Most preferably, it is about 7 grams force.
  • the yarns are fed through tension reducing means (such as a series of rollers and tensioners) adapted to reduce the tension of the yarns such that the yarns may be easily folded in the required zig zag manner.
  • the invention enables one to produce carpets of more uniform yarn distribution and this is particularly important when carpet is dyed. If the density of yarns in different areas of the carpet substrate varies then these areas will present different colour shades on the application of the same amount of dye. This can cause matching problems especially when the substrate is cut into carpet tiles. In addition, when the tensions of the respective yarns being embedded into the adhesive layers are significantly different this generally results in different tuft lengths as the yarns are not embedded into the adhesive by the same amount by the apparatus moving the yarn into the alternate layers of adhesive material.
  • the advantage of the invention is more manifest. It is the ability to use such yarns at all as this has not previously been possible in methods for the production of bonded carpets.
  • Bonded carpet offers significant advantages over tufted carpet, but it has not previously been possible to manufacture a bonded carpet using a high twist yarn on conventional fusion bonding apparatus.
  • High twist yarn is popular for both aesthetic and functional reasons. Such yarn does not hang or stand as a straight thread but rather is kinked. Accordingly, carpet made from high twist yarn gives an uneven surface which has proved to be a popular appearance commercially. Further because of the uneven surface, areas of use are less visible when a high twist yarn is used.
  • Low and medium twist yarn can be introduced between the folding blades in conventional apparatus in a uniform manner.
  • high twist yarns when delivered at varying tensions have been found in the past to respond erratically and less uniformly. Twists and kinks in some of the fibres can cause bunching and tangling.
  • conventional equipment includes a series of combs located between the yarn supply means and the bonding apparatus. Generally the combs are located immediately prior to the point at which the yarns enter into the bonding apparatus.
  • high twist yarn is intended to encompass any yarn, the length of which will not hang straight down in an unkinked fashion. Without limiting the generality of the above definition, such yarn is deemed to include any yarn having a twist constant of over 5500.
  • a twist constant of any yarn may be measured in accordance with the following formula:-
  • Twist constant / " linear density of yarn (tex) x twists per metre
  • a yarn having a linear density of 750 tex and having 250 twists per metre has a twist constant of:-
  • a medium twist yarn conventionally used in fusion bonding apparatus has a twist constant of about 5,000.
  • a process for making a bonded carpet substrate comprising a thermoplastic material into which there is bonded a plurality of high twist textile yarns, said process comprising:-
  • each of the yarns have a twist constant above 5,500.
  • each respective yarn has a twist constant between 6,000 and 7,500.
  • High twist yarns tend to respond to tensional variations to a greater extent than medium or low twist yarns.
  • the yarns are fed to the tension reducing means at a substantially higher tension than that to which they are to be reduced, at the point of tension reduction, high twist yarns have a greater propensity to kink, bend and hence entangle. Therefore, it is preferred that the yarns be fed to the tension reducing means at a tension which is not substantially greater than the tension to which the yarns are to be reduced prior to introduction between the said adhesive layers.
  • the tensional variation of the yarn prior to and after being fed through the tension reducing means is no greater than 20%. Most preferably, it is less than 10%.
  • the propensity of the all yarns may be further reduced by increasing the moisture content of the yarn so that when introduced between the respective adhesive layers it is 10% (by weight) or greater. If the moisture content of the yarn is modified in this way, it is preferred that the tension in the yarns be controlled so that they are uniform and at the desired level after the moisture content has been varied and prior to any further tension reduction. In conventional bonding processes, the moisture content of the yarn is often no more than about 5%. It has been found by the applicant that by increasing the moisture content of the yarn, it swells and bulks and that by increasing the moisture content to 10% or greater, a yarn becomes easier to control and thus easier to fold in a uniform manner between the adhesive layers.
  • woollen yarns are increased in moisture content to between 12 to 20%. Most preferably, the moisture content is about 15%. When nylon yarns are used, the preferred moisture content is about 10 to 15% and most preferably about 12%.
  • the moisture content of the yarn is increased to the required level by passing the yarn through a steaming mechanism prior to the introduction of the yarn between the adhesive layers. Most preferably, the yarns are passed through the steaming mechanism and the tension of the yarns is controlled (by apparatus known in the art) so that the yarns are delivered from the steaming mechanism having the desired moisture content and at substantially uniform tension across the yarn run. The yarns are then fed through tension reducing means following which they are introduced between the respective adhesive layers.
  • the adhesive layers used in any of the embodiments of this invention are preferably formed from a vinyl chloride resin polymer. Desirably, this resin bonding layer is incorporated about an inert structural layer such as a fibreglass matt.
  • the thermoplastic adhesive is usually in the form of a plastisol which will cure on heating. After the composite structure has been formed and separated into two separate carpet layers, it is preferable that a separate backing layer (again preferably reinforced PVC) be laminated so to form a more rigid and stable carpet structure.
  • the respective yarns be passed over a support means which is adapted to do this. It is desirable that the support means be positioned such that the respective yarns are physically supported on at least one portion of the surface of the support means as they are fed to the adhesive layers.
  • the support means may be of any suitable shape. Preferably, it is a bar of circular, square or rectangular cross section and of such length to extend across the full width of the yarn run.
  • the bar is placed above the level of the travel of the yarn preceding the bar so that the angle of contact between the yarn and the bar is greater than 0°. Preferably, it is between 0 to 10°, most preferably between 2 to 5°.
  • a high twist yarn could not be effectively separated using a comb as the yarn would become entangled in the comb.
  • the applicants have found that low and high twist yarns can be uniformly separated without a comb if the tensions of the yarns are uniform especially if their bulk has been increased by humidification. The replacement of such a comb with a single support surface was not expected by the applicant to provide and encourage the maintenance of the required yarn separation.
  • this simple expedient of passing the yarn over such support means in conjunction with the uniform tensions of the yarns has been found to very effectively maintain yarn separation without any additional separating apparatus.
  • such separating means is located between the steamer and the folding blades of the bonding apparatus.
  • the start ends of new yarns and the ends of existing yarns which have already been introduced between the respective adhesive layers (and in conventional apparatus hence introduced between the folding blades), are secured together by a joining band which is preferably at least one sheet of adhesive material positioned across the full width of the yarns to be introduced into the bonding apparatus.
  • a joining band which is preferably at least one sheet of adhesive material positioned across the full width of the yarns to be introduced into the bonding apparatus.
  • this method of yarn connection can only be contemplated when using the method of the present invention when there is no separating comb near the entrance of the bonding apparatus. A joining band could not pass through the comb.
  • this simplified method of starting a new yarn run is a further consequent advantage brought about by the present invention.
  • a single sheet of heat sensitive tape is positioned between the respective layers of the new and old yarns.
  • heat sensitive adhesive tape can be used both above and below the joined yarns. Once the tape is correctly positioned, heating means may be applied to the tape so to effect the securement to both ends of the respective yarns. The applicants have found that this process works well for all yarns. In the case of high twist yarns it is of particular value as no practical atlernative exists.
  • This process may be utilized when an existing roll of high twist yarn is about to be exhausted and a new roll of high twist yarn is to be introduced into the bonding apparatus or alternatively, on initial start up, a length of low twist yarn may be introduced into the bonding apparatus in the normal fashion, this yarn cut, and new high twist yarn attached thereto in accordance with the methodology described above.
  • an apparatus for making a bonded carpet substrate which includes:- (a) yarn supply means;
  • yarn tension adjustment means adapted to simultaneously receive a plurality of textile yarns at different tensions and adjust the tensions of the yarns so that they are substantially uniform
  • yarn bonding means adapted to simultaneously receive a plurality of textile yarns and bond each of said yarns in zig-zag manner between two respective adhesive layers so to form a carpet composite comprising two adhesive layers sandwiching a layer of yarn
  • separating means for separating the carpet composite into two bonded carpet substrates; the said apparatus being configured so that a plurality of yarns can pass from the yarn supply means to the yarn tension adjustment means and thereafter to the yarn bonding means for the formation of a carpet composite which is then fed to the separating means for the formation of carpet substrates.
  • the yarn tension adjustment means is adapted to reduce the tensions of the respective yarns to tensions of between 3 to 10 grams force.
  • the apparatus also desirably includes humidifying means adapted to raise the moisture content of the yarns to between 10 to 20%.
  • the apparatus does not include a comb yarn separator. However, if further yarn separation is required, it has been found that a shallow coil spring can be used to separate yarns.
  • the separator is preferably a coil spring over which the yarns can lie.
  • a support is positioned within the coil spring and located so to hold the yarns passing through the spring at the desired height. In such an embodiment it is preferred that the support include a plurality of spaced pegs oriented so to pass between various coils of the spring. This enables an operator to adjust the tension of the coil spring in different locations along its length and thus the number of coils per unit length. This is useful in quickly and easily adjusting the yarns passing over the separator to a substantially uniform density across the run.
  • the present invention also relates to a new carpet structure comprising a cured thermoplastic adhesive layer into which there is bonded a plurality of high twist yarns.
  • the high twist yarns have a twist constant of 5,500 or greater. Most preferably, it is between 6,000 and 7,500.
  • the thermoplastic adhesive layer includes an inert structural layer such as a fibreglass mat.
  • the thermoplastic may be selected from a range of suitable materials but is preferably a vinyl chloride polymer, a latex rubber or polypropylene.
  • the carpet structure may optionally include further support layers laminated to the adhesive layer.
  • the high twist yarn is preferably wool yarn between 650 and 900 tex which has 240 or more twists per metre or nylon yarn between 680 and 920 tex which has 225 or more twists per metre.
  • Figure 1 is a schematic representation of apparatus used in the process of the present invention
  • Figure 2 is a cross sectional view of a composite substrate formed in accordance with the invention
  • Figure 3 illustrates the joining of a new set of yarns to existing yarns using a joining tape
  • Figure 4 illustrates a preferred bonded carpet substrate as formed in accordance with the invention.
  • Figure 5 illustrates a coil spring separator as used in the apparatus of this invention.
  • a fusion bonding machine 1 adapted to support bonding layers 2 and 3 positioned in face to face relation.
  • An example of such a machine is manufactured by Deering Milliken Research Corporation.
  • the respective layers are generally separated by between 10 mm to 30 mm.
  • Bonding layers 2 and 3 may be made from any suitable thermoplastic resin preferably in the form of a plastisol reinforced with fibreglass material.
  • High twist yarn 4 is delivered from a roll 5 and maintained in generally separate and uniform relation by passing through coil spring 6. In one preferred bonded carpet, the high twist yarn has a twist constant of about 6,850.
  • the coil spring 6 is preferably stretched so that there is between 3 to 4 mm between each coil of the spring and the yarns are uniformly distributed along the length of the coil spring by adjusting the gaps between the coils by pegs 7 located in a support rod 8 (see Figure 5).
  • the yarns 4 can be separated by a wide amount (designated W), a small amount (designated S) or a normal amount (designated N) by adjusting the coil spring in various locations and maintaining it in place by pegs 7.
  • the tensions of the respective yarns at this stage vary significantly across the run from, for example, 45 grams force to 90 grams force.
  • High twist yarns 4 are thereafter introduced and taken through a humidifier 9 in the nature of a steam box.
  • the yarns pass through the steam box 9 at such rate so that the moisture content of the yarn increases to about 15% on a weight basis.
  • a tensioner (not shown) within the steam box 9 is provided so to reduce and moderate the tension of the fibres so that each is substantially the same as the yarn leaves the steam box 9. Preferably, the tension of each respective yarn is reduced to about 7 to 15 grams force.
  • the yarn is thereafter drawn over bar 10 which acts to maintain the uniform separation of the yarns one from the other.
  • These yarns then enter the fusion bonding apparatus 1 through a series of rollers and tensioners (generally shown at 11) which further reduce the tension of the yarns uniformly to about 5 grams force.
  • the yarn is then fed through folding blades 12 which are adapted to fold the yarn and introduce it between the adhesive layers 2 and 3 in a zig zag pattern as generally shown in Figure 2.
  • the composite product generally illustrated in Figure 2 is thereafter conveyed to a heating station (not shown) wherein the resin plastisol is cured.
  • the composite product is then separated in half by cutting generally down the centre of the yarn (shown by the dashed line if Figure 2) .
  • Separate layers are then laminated with a further reinforced PVC layer to form a carpet product as shown in Figure 4.
  • Adhesive tape 17 extends between old yarns 18 and new yarns 19. The old yarns effectively draw the new high twist yarns into the folding blades 12 of the fusion bonding apparatus. Once the adhesive tape 17 has passed through the bonding apparatus, this section of carpet is simply cut from the roll and discarded.
  • the product produced by this methodology is illustrated in Figure 4.
  • the preferred carpet structure comprises a fibreglass reinforced backing layer 20, a fibreglass reinforced bonding layer 21 (both layers are preferably of a PVC resin) and a pile 22 embedded in the bonding layer comprised of high twist yarn.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Carpets (AREA)

Abstract

Procédé de fabrication d'un substrat collé pour tapis, comprenant un matériau thermoplastique sur lequel sont collés une multitude de fils. Ledit procédé consiste à: (a) former deux couches adhésives et les positionner face à face, (b) transférer une multitude de fils textiles séparés entre lesdites couches adhésives de façon à ce que chacun des fils soit collé en des points intermédiaires successifs à chacune des couches adhésives, (c) vulcaniser les couches adhésives de façon à former une structure composite de couches adhésives vulcanisées de part et d'autre d'une couche de fils placée entre elles, (d) séparer la structure composite en deux couches de tapis distinctes en tranchant en son milieu la couche de fils placée en sandwich. La tension de chacun des fils est contrôlée de façon à être sensiblement constante aux points d'introduction entre lesdites couches adhésives.
PCT/AU1994/000094 1993-03-04 1994-03-04 Tapis colle utilisant un fil a forte torsion WO1994020662A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU62549/94A AU684753B2 (en) 1993-03-04 1994-03-04 High twist yarn bonded carpet

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPL762193 1993-03-04
AUPL7621 1993-03-04

Publications (1)

Publication Number Publication Date
WO1994020662A1 true WO1994020662A1 (fr) 1994-09-15

Family

ID=3776744

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1994/000094 WO1994020662A1 (fr) 1993-03-04 1994-03-04 Tapis colle utilisant un fil a forte torsion

Country Status (2)

Country Link
NZ (1) NZ262707A (fr)
WO (1) WO1994020662A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012020624A1 (de) * 2012-10-19 2014-04-24 Wolfgang Hoeck Führungsvorrichtung zum Führen einer Mehrzahl von Fäden zur Herstellung eines Faserverbundbauteils

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3013511A (en) * 1955-10-21 1961-12-19 Inst Textilmaschinen Means for making plush-like products such as carpets and the like
GB2106154A (en) * 1981-09-22 1983-04-07 Milliken Res Corp Adhesive bonded pile fabrics
GB2225351A (en) * 1988-11-10 1990-05-30 Carpets Of Worth Limited Method of and apparatus for manufacturing pile fabrics
WO1991000804A1 (fr) * 1989-07-07 1991-01-24 G R F Sports Services Limited Materiau pour revetir une surface
EP0582214A2 (fr) * 1992-08-05 1994-02-09 PILLER, Helmut Dispositif pour la fabrication d'articles implantés de touffes par piquage

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3013511A (en) * 1955-10-21 1961-12-19 Inst Textilmaschinen Means for making plush-like products such as carpets and the like
GB2106154A (en) * 1981-09-22 1983-04-07 Milliken Res Corp Adhesive bonded pile fabrics
GB2225351A (en) * 1988-11-10 1990-05-30 Carpets Of Worth Limited Method of and apparatus for manufacturing pile fabrics
WO1991000804A1 (fr) * 1989-07-07 1991-01-24 G R F Sports Services Limited Materiau pour revetir une surface
EP0582214A2 (fr) * 1992-08-05 1994-02-09 PILLER, Helmut Dispositif pour la fabrication d'articles implantés de touffes par piquage

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102012020624A1 (de) * 2012-10-19 2014-04-24 Wolfgang Hoeck Führungsvorrichtung zum Führen einer Mehrzahl von Fäden zur Herstellung eines Faserverbundbauteils

Also Published As

Publication number Publication date
NZ262707A (en) 1997-07-27

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