WO2000061853A1 - Tapis et technique de fabrication - Google Patents

Tapis et technique de fabrication Download PDF

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Publication number
WO2000061853A1
WO2000061853A1 PCT/US2000/009537 US0009537W WO0061853A1 WO 2000061853 A1 WO2000061853 A1 WO 2000061853A1 US 0009537 W US0009537 W US 0009537W WO 0061853 A1 WO0061853 A1 WO 0061853A1
Authority
WO
WIPO (PCT)
Prior art keywords
carpet
primary backing
yarn
fibers
coating
Prior art date
Application number
PCT/US2000/009537
Other languages
English (en)
Inventor
Wilbert E. Fink
Jean-Claude Auguste
Original Assignee
Tennessee Valley Patent Development Company
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 Tennessee Valley Patent Development Company filed Critical Tennessee Valley Patent Development Company
Priority to AU42249/00A priority Critical patent/AU4224900A/en
Publication of WO2000061853A1 publication Critical patent/WO2000061853A1/fr

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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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • 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
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • 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
    • 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
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • 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
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • 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
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • 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
    • D06N2201/02—Synthetic macromolecular 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0245—Acrylic resin 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide 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
    • D06N2203/042—Polyolefin (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
    • D06N2213/00—Others characteristics
    • D06N2213/06—Characteristics of the backing in carpets, rugs, synthetic lawn
    • D06N2213/065—Two back coatings one next to the other

Definitions

  • the application relates to pile carpet and, in
  • the facing yarn extend through the backing and are exposed on
  • tufted carpets may be cut pile or loop
  • carpets such as Berber carpets and certain sports surfaces
  • the carpet face fiber is needled through
  • carpet precursor or base sometimes called greige goods.
  • Greige goods are typically backed with an adhesive
  • the marine backed carpets are backed with a latex
  • adhesive coating that is water and/or mildew resistant.
  • tufted carpet is typically made of any one of a number of
  • fiber e.g., nylon, acrylic, polypropylene
  • Face yarns used in carpet include spun staple yarn and bulk
  • BCF continuous filament
  • Fibrillated polypropylene grass yarn is also often used as a
  • the individual yarn, once made, is often twisted by
  • the total denier For example, two yarns of 1500 denier each
  • the two or more yarns can be the same color or
  • twisting, texturing and air entangling may require that
  • the yarn receive a spin finish that makes the yarn surface
  • processing for example, in coating the yarns.
  • Primary backings for tufted pile carpets are typically
  • ethylene-propylene copolymers may also be used to form the tape for weaving the primary backing.
  • tape yarns are
  • the carpet face fiber is usually embedded in the
  • greige goods with a latex polymer binder such as a styrene-
  • greige goods are passed through an oven to dry the latex
  • a secondary backing may be bonded to the
  • greige goods is coated with a latex polymer binder.
  • the resulting structure is passed through an oven to dry the
  • tufted pile carpets are open weave or leno weave, having
  • tape yarn in the warp direction usually of polypropylene
  • the spun staple fiber in the fill direction.
  • the spun stable fiber is hairy when formed and, after the
  • yarn is woven, it is actually run against an abrasive roll to
  • spun staple yarn is not as strong as tape yarn. Therefore, a strong and less expensive
  • the drying step increases the cost of the
  • Hot-melt adhesives are amorphous polymers that soften
  • the hot-melt compositions are selected for their
  • compositions are generally amorphous or
  • composition after application is eliminated and, further,
  • composition application without requiring an intervening
  • doctor blade is ordinarily employed to control the amount of adhesive which is transferred from the application roll to
  • melt adhesive is extruded from a die and falls onto the
  • the activation temperature of a hot-melt adhesive i.e.,
  • backing and face yarns may suffer other damage due to
  • compositions which work best as adhesives are those
  • the adhesive composition may include modified olefins such as
  • polar monomers such as, but not limited to, methyl
  • hot-melt adhesives is very low, on the order of one-tenth the
  • adhesive carpets generally are deficient in tuft pull
  • the carpet is then inspected for
  • carpet further acts as a heat sink for the heat of the hot-
  • Nip pressure can be applied to help the hot-melt adhesive to
  • carpet can be made from yarns that have been twisted
  • the tufting process may also stitch several
  • primary backing include compositions which require lengthy
  • melt adhesive compositions conventionally employed in the
  • individual carpet yarns may fuzz and form pills) .
  • thermoplastic polymer
  • Cut pile carpet is presented as exemplifying the use
  • the present application includes disclosure of improved
  • the present disclosure relates to a novel carpet product
  • present disclosure further relates to an improved carpet
  • the present disclosure particularly relates to a carpet
  • thermoplastic fibers wherein the yarn is tufted
  • polyolefin polymer having recurring polar moieties which
  • the present disclosure further relates to a process for
  • thermoplastic polyolefin polymer having
  • a further object of the invention is a carpet having a
  • thermoplastic polyolefin polymer having recurring
  • a greige goods coating comprising a second thermoplastic
  • polyolefin polymer having recurring polar moieties contacting
  • Another object of the invention is a method for
  • thermoplastic polyolefin polymer having
  • the primary backing comprises at least in either
  • thermoplastic polyolefin polymer is thermoplastic polyolefin polymer
  • having recurring polar moieties is in the fill direction.
  • thermoplastic polyolefin is thermoplastic polyolefin
  • primary backing is a propylene copolymer or polypropylene
  • the present disclosure further provides a secondary
  • the present disclosure also relates to carpet making
  • a carpet precursor is supplied
  • rollers including a fluid heated roller
  • the belt is
  • polymer sheet have been adhered or integrally fused.
  • Figure 1 is a cross-sectional view of a carpet being
  • Figures 2a is a cross-sectional view of a cut pile
  • Figure 2b is a cross-sectional view of a cut pile carpet
  • Figure 3a is a cross-sectional view of a carpet
  • Figure 3b is a cross-sectional view of a loop pile
  • Figure 3c is a cross-sectional view of a loop pile
  • Figure 4a is a side schematic view of an apparatus used
  • Figure 4b is a pictorial view of an apparatus of the
  • Figures 5a and 5b are graphs illustrating the estimated
  • Figure 6 is a side schematic view of an apparatus used
  • Figure 7 is a side schematic view of an apparatus used
  • Figure 8 is a cross-sectional view of a loop pile carpet
  • thermoplastic resin According to the present invention, a thermoplastic resin
  • polymer sheet is laminated with a carpet precursor to form a
  • the carpet precursor is made of a face yarn which
  • the carpet precursor may be woven or
  • the carpet precursor has face
  • thermoplastic polyolefin itself.
  • the carpet of the present disclosure is desirably
  • carpet face yarn is also fed into the tufting machine wherein
  • tufting machine are called greige goods.
  • the greige goods taken from the tufting machine are
  • the greige goods are preferably heated to melt the
  • a temperature sufficiently high to create a heat bond is a
  • greige goods coating is polypropylene
  • preferred temperature is at least about 450°F, more
  • Figure 1 illustrates some of the features of a carpet
  • a primary backing layer is designated by the numeral 10.
  • Face yarn is tufted in the primary backing forming a yarn
  • the tufted primary backing 16 is
  • the carpet precursor carpet base or
  • the precursor is not sufficiently
  • the carpet precursor is desirably heated to a
  • the precursor is then laminated with a greige goods
  • coating 18 in a thickness of from about 3 to 15 mils to form
  • the carpet product 20 is the carpet product 20.
  • thermoplastic polyolefin polymer having recurring polar moieties.
  • the carpet precursor is adhered to
  • Figure 1 illustrates a preferred embodiment of the
  • a carpet product including a face yarn
  • a primary backing may comprise a face yarn protruding from a face yarn
  • thermoplastic polyolefin polymer having recurring polar
  • the primary backing may preferably be a polypropylene
  • the primary backing may be coated with a
  • thermoplastic polyolefin polymer having recurring polar moieties before tufting. Again, this facilitates better
  • the carpet product of the present invention may also be any suitable carpet product of the present invention.
  • the secondary backing comprises tape
  • the primary backing layer may be of any of the conventionally
  • thermoplastic synthetic materials when the fibers are thermoplastic synthetic materials.
  • the yarns can be integrally fused to themselves.
  • the yarns can be integrally fused to themselves.
  • backing may be made of the same material as the primary
  • coating may comprise the same thermoplastic polymer.
  • thermoplastic polymer is a thermoplastic
  • polyolefin polymer having recurring polar moieties also known as polyolefin polymer having recurring polar moieties
  • polar modified polyolefin As used herein, the
  • polar moieties or "polar modified polyolefin,” is meant to
  • the polyolefin copolymer comprises, for example,
  • ethylene, propylene or butylene and polar monomers including,
  • the graft polymers comprise, for example,
  • the primary and secondary backing are identical in another embodiment.
  • the face yarn is formed of a different polymer.
  • the polymer for example, the
  • thermoplastic polyolefin polymer having recurring
  • polar moieties and the face yarn is formed of nylon or
  • polyester or of natural materials such as cotton or wool.
  • some or all of the backing may be
  • thermoplastic polyolefin polymer having recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring polyethylene ethylene ethylene terethacrylate, polystylene glycol dimethacrylate, polystylene glycol dimethacrylate, stylene glycol dimethacrylate, stylene glycol dimethacrylate, stylene glycol dimethacrylate recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring
  • the bottom layer (either the greige
  • goods coating or secondary backing may be formed from a
  • thermoplastic polyolefin polymer having recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring recurring
  • properties of the elastomer such as flexibility, non-skid
  • the primary backing of the carpet product may include
  • goods coating may be, for example, a woven or non-woven
  • the primary backing is
  • thermoplastic polyolefin polymer made of a thermoplastic polyolefin polymer, copolymer or
  • thermoplastic in the warp direction, with a thermoplastic
  • polyolefin polymer having recurring polar moieties in the
  • the primary backing may be coated with a
  • thermoplastic polymer such as a thermoplastic polyolefin
  • the primary backing coating is preferably in an
  • the secondary backing material if applied, may
  • the secondary backing will comprise the same
  • the carpets of the present disclosure may comprise a woven or
  • a woven secondary backing may be an open
  • the open weave is not necessary to obtain a suitable bond as may be
  • the greige goods coating may be formed from a
  • a preferred greige goods coating is a copolymer of
  • the greige goods coating is applied in an amount of from
  • thermoplastic polyolefin polymer having recurring
  • polar moieties used in the greige goods coating may be
  • Such fillers may include calcium
  • an exceedingly stiff board like material may be made
  • trunk liner e.g., a trunk liner, molded floor mat or
  • the polymer, filled systems may be designed to satisfy a
  • fire-retardant may be added to the feedstock used to produce
  • elastomers may be used to make the greige goods coating or
  • thermoplastic elastomers are thermoplastic elastomers (TPE's).
  • vulcanized rubbers may be processed and recycled as
  • thermoplastics A listing of some suitable TPE's is given in
  • thermosetting polymers not merely substitutes for thermosetting polymers, but may
  • TPE ' s that may be suitable for use in the
  • the four general groups include
  • polymer provides some of the properties of the elastomer at a
  • the compatibility is good for blends ranging from about 10 to 97% elastomer based on the total amount of
  • the TPE's may provide toughness, flexibility
  • carpet layers (yarn, primary backing, primary
  • thermoplastics which melt together
  • Adhered materials typically include
  • integral fusion of the various carpet components as disclosed may provide a carpet having improved strength, fuzz
  • a carpet product according to the invention is generally
  • Heat and pressure are applied (for example, by
  • preheating of the carpet precursor causes a portion of
  • moieties 18 is brought into contact with the heated carpet
  • the carpet product may either be the
  • FIGS 2 and 3 illustrate, by way of example, two types
  • Figure 2 relates to a cut pile, or
  • grass, carpet and Figure 3 relates to a loop pile carpet with
  • Figure 2a depicts a carpet precursor 200 from which a
  • carpet for example, grass carpet
  • backing 202 is interpenetrated by fibrillated isotactic
  • ends or tufts 206 form the pile of the carpet.
  • the yarn is
  • backing 202 is a woven fabric made of polypropylene.
  • Figure 2b depicts a carpet product 210 made from the
  • goods coating 212 may be larger or smaller depending on the
  • coating may more or less conform to the shape of the bottom
  • the back loops 208 may be heated
  • backing and integrally fused fibrils of yarn also may
  • the integral fusing of the fibers lessens the need for the greige goods coating to fully wet and penetrate the
  • the primary backing sufficiently secures the fibers in place
  • the primary backing comprises a
  • precursor allows the fill yarn to bond with the inside of the
  • polyolefin polymer having recurring polar moieties
  • graft polyolefin polymer such as maleic
  • the primary backing may be coated with a
  • the primary backing coating is
  • the primary backing coating is preferably in an
  • the coated primary backing will adhere or integrally fuse to
  • coating may adhere or integrally fuse with the greige goods
  • Figure 3a depicts a carpet precursor 300 from which a
  • Such yarn may be a
  • the BCF yarn is made of polypropylene and the backing
  • woven fabric 302 is a woven fabric also made of polypropylene.
  • Figure 3b depicts a carpet product 310 made from the
  • goods coating may partially or totally encapsulate the back
  • the back loops 308 are preferably
  • the heat of the greige goods coating may
  • carpet product and secures the tufts and component yarn fibers to a sufficient degree that the carpet product can
  • Figure 3c depicts a carpet product 320 which includes an
  • coating 312 and integrally fuses with it.
  • the coating 312 and integrally fuses with it.
  • secondary backing is a tape yarn in both the weave and fill
  • the tape yarn is a
  • An apparatus for producing a carpet product is
  • the heated carpet precursor 434 travels
  • the greige goods coating may be a thermoplastic
  • polyolefin polymer having recurring polar moieties, such as a
  • the coating may be applied as
  • a hot extrusion such as from a die as shown in Figure 4, or
  • the greige goods coating may be heated
  • the heated roller 432 may advantageously be a fluid or
  • the fluid inlet is typically at the center of the
  • surface temperature of the roller is dependent on a number of variables, including the structure and composition of the
  • roller 432 is 5.9
  • the surface of the roller may be any material that has dimensions inches in diameter.
  • the surface of the roller may be any material that has dimensions.
  • the roller 432 may be provided with a surface or coating
  • the roller 432 is wrapped with teflon tape.
  • blade 442 may be provided to remove built-up polymer melted
  • Water cooled nip roll 444 may be provided which,
  • rollers 444 ' are rotatably mounted to a pivoting bar assembly 446. The pressure of the carpet precursor against the heated
  • roller is controlled by applying pressure to the pivoting bar
  • hydraulic pressure may typically be set at 460 to 480 pounds
  • rollers 444 may be any rollers 444.
  • An additional roller 447 may be
  • rollers 44 are positioned along line 449. During line start-up, rollers 44
  • rollers 444 along lines 445 may be
  • the heated roller temperature can be maintained constant and
  • the heated carpet precursor 434 As shown in Figure 4a, the heated carpet precursor 434
  • this distance is as short as
  • the heated carpet precursor 434 preferably may contact the
  • greige goods coating is formed by forcing a thermoplastic
  • the extrusion die temperature is about 510°F.
  • the greige goods coating may be a preformed
  • carpet precursor advantageously 100°F or more above its
  • nip roll 454 passes between nip roll 454 and casting or chill roll 456.
  • the nip roller 454' may be rotatably
  • pivoting arms exert a pressure against the upper side of the
  • chill roller 456 of between 1 and 4 pounds per linear inch of
  • the casting roller is
  • a carpet product 460 is produced which may be subjected
  • backing or non-woven backing may be any suitable backing or non-woven backing (not shown) may be any suitable backing or non-woven backing (not shown)
  • a tenter frame (not shown) may be employed during the preheating and lamination operations or
  • thermoplastic polyolefin (50/50 blend) .
  • thermoplastic polyolefin (50/50 blend) .
  • thermoplastic polyolefin (50/50 blend)
  • polybutylene with polar moieties such as maleic anhydride
  • the greige goods used in the trials included a
  • the secondary backing was found to exhibit good adhesion with all the polymer types
  • the extruder had a 20 horsepower DC drive and a
  • the extruder was equipped with three
  • Typical extruder temperatures range from 340°F to 600°F and
  • the die width was 12 inches.
  • the casting roll assembly was 3 inches in diameter.
  • the factor limiting line speed may be any factor limiting line speed.
  • Figure 5a presents a calculated temperature profile for
  • time/position is
  • Trace 500 represents the
  • Trace 504 represents the carpet face temperature at the
  • FIG. 5a illustrates a temperature profile in which the back
  • Figure 5b is an example of such a simulation, and contains
  • the simulation is based on the following
  • Cast roller diameter 5.9 ft .
  • time B corresponds
  • the time t 3 is the time when the carpet product
  • Examples 4 and 5 employ a 5 mil extruded coating and compare the process for a heated roll
  • Example 5 has a cast roller wrap angle of 200°.
  • present invention is a woven polypropylene primary carpet
  • This backing is woven from polypropylene tapes
  • tape thickness 1.0 to 2.0 mils.
  • one tape is a
  • thermoplastic polyolefin polymer having recurring polar
  • moieties may consist of an ethylene, propylene or butylene
  • copolymer or graft polymer of polyethylene, polypropylene or
  • the modified tape is a graft polymer of polypropylene and maleic anhydride.
  • the tapes are
  • thermoplastic polyolefin polymer involves organization of
  • the backing cannot be heated for too long to a temperature
  • wrap angles may be used at a constant line speed to change

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)

Abstract

L'invention concerne un tapis, une technique de fabrication d'un tapis ainsi qu'un appareil utilisé dans la fabrication de tapis. Ledit tapis est fabriqué à partir de fils continus polymères tuftés, chaque fil continu compris dans le retour continu est intégralement thermofixé afin que le tapis ne peluche pas. Le support de base est fait de polypropylène dans le sens de la trame. Ultérieurement et avant le tuftage, ledit support de base peut être recouvert d'un polymère de façon à coller ou à thermofixer l'intérieur de la touffe de fibres sur ledit support de base. Un support secondaire optionnel est, de préférence, composé de fil de bandelettes dans les deux sens. Ladite technique consiste à fournir une base de tapis présentant un support de base traversé par le fil ; appliquer de la chaleur sur la face inférieure du support de base ; extruder une feuille polymère chauffée ; puis continuellement presser ladite feuille sur ladite base. L'appareil comprend une source de précurseur de tapis, un cylindre chauffé permettant de chauffer la face inférieure dudit tapis, une extrudeuse et un rouleau enducteur contre lequel la feuille extrudée et le tapis chauffé sont pressés.
PCT/US2000/009537 1999-04-12 2000-04-11 Tapis et technique de fabrication WO2000061853A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU42249/00A AU4224900A (en) 1999-04-12 2000-04-11 Carpet and carpet making methods

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US28958199A 1999-04-12 1999-04-12
US09/289,581 1999-04-12

Publications (1)

Publication Number Publication Date
WO2000061853A1 true WO2000061853A1 (fr) 2000-10-19

Family

ID=23112154

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/009537 WO2000061853A1 (fr) 1999-04-12 2000-04-11 Tapis et technique de fabrication

Country Status (3)

Country Link
US (1) US20020039636A1 (fr)
AU (1) AU4224900A (fr)
WO (1) WO2000061853A1 (fr)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004025018A1 (fr) * 2002-09-13 2004-03-25 E.I. Du Pont De Nemours And Company Procede de production d'une moquette
WO2004024438A1 (fr) * 2002-09-13 2004-03-25 E.I. Du Pont De Nemours And Company Moquette presentant une retention de touffes amelioree
NL1026245C2 (nl) * 2004-05-21 2005-11-22 Klieverik Heli Bv Werkwijze voor het vervaardigen van tapijt.
BE1016602A3 (nl) * 2005-05-25 2007-02-06 Dakota Coatings Nv Inrichting en werkwijze voor het aanbrengen van een rug op een tapijt en een volgens zo'n werkwijze vervaardigd tapijt.
EP1916330A1 (fr) 2006-10-24 2008-04-30 Maltzahn Carpets GmbH Procédé destiné à la fabrication d'un tapis et tapis fabriqué selon ce procédé
NL2003763C2 (nl) * 2009-11-06 2011-05-10 Klieverik Heli Bv Decoratieve bedekking en werkwijze voor de vervaardiging daarvan.
NL2005608C2 (en) * 2010-11-01 2012-05-02 Interface Internat B V Method of manufacturing a carpet or carpet tile, carpet or carpet tile obtained by performing the manufacturing method, and support material for use in the method.
WO2014198732A1 (fr) 2013-06-10 2014-12-18 Dsm Ip Assets B.V. Procédé de production de produits textiles, produits pouvant être obtenus à partir de celui-ci et procédé pour recycler les produits
WO2016110547A1 (fr) 2015-01-09 2016-07-14 Dsm Ip Assets B.V. Procédé de fabrication de produit textile, utilisation associée et dispositif d'application du procédé
EP3222766A1 (fr) * 2016-03-22 2017-09-27 Polytex Sportbeläge Produktions-GmbH Machine de fabrication de gazon artificiel
CN111868320A (zh) * 2018-03-20 2020-10-30 美国阿拉丁制造公司 用于生产大地毯或小地毯的方法及由此获得的大地毯或小地毯

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US20070237921A1 (en) * 2006-04-10 2007-10-11 Knapp Timothy A Woven artificial turf
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WO2010075098A1 (fr) * 2008-12-15 2010-07-01 Textile Management Associates, Inc. Procédé de recyclage de gazon synthétique et produit de remplissage
JP2012110403A (ja) * 2010-11-22 2012-06-14 Suminoe Textile Co Ltd タイルカーペットの製造方法及びその製造方法で製造されたタイルカーペット
AU2011340827B2 (en) * 2010-12-06 2017-11-23 Covestro (Netherlands) B.V. A method to produce a pile textile product and a textile product resulting from the same
WO2012165871A2 (fr) * 2011-05-31 2012-12-06 코오롱글로텍주식회사 Structure de pelouse artificielle et procédé et appareil permettant de la fabriquer
US9855682B2 (en) * 2011-06-10 2018-01-02 Columbia Insurance Company Methods of recycling synthetic turf, methods of using reclaimed synthetic turf, and products comprising same
US9775457B2 (en) 2012-12-10 2017-10-03 Higgins Research & Development, LLC Floor covering with universal backing and methods of making and recycling
US10132019B2 (en) 2012-12-10 2018-11-20 Higgins Research & Development, LLC Floor covering with universal backing and methods of making and recycling
US9339136B2 (en) * 2012-12-10 2016-05-17 Higgins Research & Development, LLC Floor coverings with universal backing and methods of making, installing, and recycling
US9681768B2 (en) 2012-12-10 2017-06-20 Higgins Research & Development, LLC Floor covering with universal backing and methods of making and recycling
US9924820B2 (en) 2012-12-10 2018-03-27 Higgins Research & Development, LLC Floor covering with universal backing and methods of making and recycling
US10501878B2 (en) 2012-12-10 2019-12-10 Higgins Research & Development, LLC Floor covering with universal backing and methods of making and recycling
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US3551231A (en) * 1968-05-01 1970-12-29 Du Pont Process for preparing a tufted carpet using a hot melt backsizing composition
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Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004025018A1 (fr) * 2002-09-13 2004-03-25 E.I. Du Pont De Nemours And Company Procede de production d'une moquette
WO2004024438A1 (fr) * 2002-09-13 2004-03-25 E.I. Du Pont De Nemours And Company Moquette presentant une retention de touffes amelioree
NL1026245C2 (nl) * 2004-05-21 2005-11-22 Klieverik Heli Bv Werkwijze voor het vervaardigen van tapijt.
EP1598476A1 (fr) 2004-05-21 2005-11-23 Klieverik Heli B.V. Procédé pour la fabrication d'un tapis
BE1016602A3 (nl) * 2005-05-25 2007-02-06 Dakota Coatings Nv Inrichting en werkwijze voor het aanbrengen van een rug op een tapijt en een volgens zo'n werkwijze vervaardigd tapijt.
EP1916330A1 (fr) 2006-10-24 2008-04-30 Maltzahn Carpets GmbH Procédé destiné à la fabrication d'un tapis et tapis fabriqué selon ce procédé
NL2003763C2 (nl) * 2009-11-06 2011-05-10 Klieverik Heli Bv Decoratieve bedekking en werkwijze voor de vervaardiging daarvan.
NL2005608C2 (en) * 2010-11-01 2012-05-02 Interface Internat B V Method of manufacturing a carpet or carpet tile, carpet or carpet tile obtained by performing the manufacturing method, and support material for use in the method.
WO2012060698A1 (fr) * 2010-11-01 2012-05-10 Interface European Manufacturing B.V. Procédé de fabrication de moquette ou de dalle de moquette, moquette ou dalle de moquette ainsi obtenue et matériau de support destiné à être utilisé dans ce procédé
WO2014198731A1 (fr) * 2013-06-10 2014-12-18 Dsm Ip Assets B.V. Procédé permettant de produire des produits textiles, produits obtenus à partir de ce dernier, et procédé permettant de mettre en valeur les produits
WO2014198732A1 (fr) 2013-06-10 2014-12-18 Dsm Ip Assets B.V. Procédé de production de produits textiles, produits pouvant être obtenus à partir de celui-ci et procédé pour recycler les produits
JP2016526610A (ja) * 2013-06-10 2016-09-05 ディーエスエム アイピー アセッツ ビー．ブイ． テキスタイル製品の製造方法、それから取得可能な製品、および製品の再生方法
AU2014280263B2 (en) * 2013-06-10 2018-11-08 Covestro (Netherlands) B.V. Method for producing textile products, products obtainable therefrom and method to reclaim the products
AU2014280264B2 (en) * 2013-06-10 2018-11-08 Covestro (Netherlands) B.V. Method for producing textile products, products obtainable therefrom and method to reclaim the products
US10428250B2 (en) 2013-06-10 2019-10-01 Dsm Ip Assets B.V Method for producing textile products, products obtainable therefrom and method to reclaim the products
US11060006B2 (en) 2013-06-10 2021-07-13 Dsm Ip Assets B.V. Method for producing textile products, products obtainable therefrom and method to reclaim the products
WO2016110547A1 (fr) 2015-01-09 2016-07-14 Dsm Ip Assets B.V. Procédé de fabrication de produit textile, utilisation associée et dispositif d'application du procédé
CN107208342A (zh) * 2015-01-09 2017-09-26 帝斯曼知识产权资产管理有限公司 制造纺织产品的方法、该纺织产品的用途以及应用该方法的设备
EP3222766A1 (fr) * 2016-03-22 2017-09-27 Polytex Sportbeläge Produktions-GmbH Machine de fabrication de gazon artificiel
WO2017162643A1 (fr) * 2016-03-22 2017-09-28 Polytex Sportbeläge Produktions-Gmbh Machine de fabrication de gazon artificiel
US10738401B2 (en) 2016-03-22 2020-08-11 Polytex Sportbelage Produktions-Gmbh Machine for manufacturing artificial turf
CN111868320A (zh) * 2018-03-20 2020-10-30 美国阿拉丁制造公司 用于生产大地毯或小地毯的方法及由此获得的大地毯或小地毯

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AU4224900A (en) 2000-11-14

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