WO2001045942A1 - Procede de fabrication de tapis moulables 100 % recyclables, faits d'une seule resine ou polymere, a ancrage et laminage secondaire par thermofusion de lamines composes du meme polymere, avec ou sans isolant en mousse, thermomoules en une seule operation, et produit obtenu - Google Patents

Procede de fabrication de tapis moulables 100 % recyclables, faits d'une seule resine ou polymere, a ancrage et laminage secondaire par thermofusion de lamines composes du meme polymere, avec ou sans isolant en mousse, thermomoules en une seule operation, et produit obtenu Download PDF

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Publication number
WO2001045942A1
WO2001045942A1 PCT/MX2000/000054 MX0000054W WO0145942A1 WO 2001045942 A1 WO2001045942 A1 WO 2001045942A1 MX 0000054 W MX0000054 W MX 0000054W WO 0145942 A1 WO0145942 A1 WO 0145942A1
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WO
WIPO (PCT)
Prior art keywords
fibers
carpet
thermofusion
recyclable
resin
Prior art date
Application number
PCT/MX2000/000054
Other languages
English (en)
Spanish (es)
Inventor
Marco Alfonso Lepe Cisneros
Original Assignee
Marco Alfonso Lepe Cisneros
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 Marco Alfonso Lepe Cisneros filed Critical Marco Alfonso Lepe Cisneros
Priority to AU22349/01A priority Critical patent/AU2234901A/en
Publication of WO2001045942A1 publication Critical patent/WO2001045942A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
    • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
    • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
    • B60N3/048—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets characterised by their structure
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/556—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by infrared heating
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H13/00—Other non-woven fabrics
    • 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
    • D06N7/0086—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 characterised by the cushion backing, e.g. foamed polyurethane
    • 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
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B2037/148—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers whereby layers material is selected in order to facilitate recycling of the laminate
    • 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
    • B32B2310/00—Treatment by energy or chemical effects
    • B32B2310/08—Treatment by energy or chemical effects by wave energy or particle radiation
    • B32B2310/0806—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation
    • B32B2310/0825—Treatment by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation using IR radiation
    • 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
    • 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
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • 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
    • B32B2471/04—Mats
    • 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
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/061—Polyesters
    • 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
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/12—Treatments by energy or chemical effects by wave energy or particle radiation
    • D06N2207/123—Treatments by energy or chemical effects by wave energy or particle radiation using electromagnetic radiation, e.g. IR, UV, actinic light, laser, X-ray, gamma-ray, microwave, radio frequency
    • 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
    • D06N2213/02—All layers being of the same kind of material, e.g. all layers being of polyolefins, all layers being of polyesters

Definitions

  • the object of this invention is to provide a product called moldable, 100% recyclable carpet constructed of the same resin or polymer in all the parts that integrate it and its production process in whose anchoring of its threads does not require latex or other polymer and that when laminated to a thermoplastic profile and this in turn to another foamed insulating thermoplastic integrating both without the use of adhesive vehicles in its lamination and processing process, being molded at the same time as laminated.
  • One of the advantages of the 100% recyclable moldable carpet constructed of the same resin or polymer in all the parts that integrate it and its production process with secondary base laminated by the process of the present invention is that because the carpet is joined and the secondary base, by means of the fusion of the materials of the same resin (polypropylene or polyester) without the intervention of other resins or foreign elements that contaminate the final product for recycling purposes, or that make it difficult and expensive for The presence of other polymers in the initial production process, results in this product the first 100% recyclable thermoformable automotive carpet on the market.
  • thermoformable carpet constructed of the same resin or polymer in all the parts that integrate it and its production process is that its insulator being foamed from a resin similar to the other parts that integrate it allows the reduction of costs radically in the use of the carpet since the weights of the product are lightened in a large percentage comparatively with the current processes therefore the cars that use the product obtained with the procedure of this patent will reduce the weight of the carpet and by In addition to the car in which it is installed and this will have as a consequence the lower use of fuel for the displacement of the car, bringing the benefit of lower pollutant emissions into the atmosphere, something that does not happen with the current conventional methods of producing thermoformable automotive carpets.
  • thermoformable carpet constructed of the same resin or polymer in all the parts that integrate it and its production procedure is that in the case of being automotive being this same of polypropylene as at present they are the Most parts that make up the interior and exterior of modern automotive vehicles allow the rugs to be recycled as part of the vehicle without needing a different procedure for recycling, having the advantage that these are 100% recyclable as any of its external parts of olefinic resin or polypropylene Apply the same principle with polyester in Europe
  • thermoformable carpet constructed of the same resin or polymer in all the parts that integrate it and its production process is that its insulator being foamed from a resin similar to the other parts that integrate it allows the reduction of costs radically both in the machines of the carpet finishing process and in the thermoforming machines since the operation is carried out in a single exposure and not in two as in the current conventional methods
  • thermoformable carpet constructed of the same resin or polymer in all the parts that make it up and its production process is that since the fibers are superimposed, the base or primary substrate, these serve to hold and tie the intermediate fibers of the threads, the threads that make up the face of the carpet and the secondary coating either with a polypropylene textile presence or a profile of those known as thermoplastic olefinic TPO (Thermo Plastic Olefin) with or without foaming, all they of the same type of resin or all of polyester resin, these together can be reprocessed under the same procedure without the use of chemical elements that disperse them or procedures that precipitate the products at high operating costs in their reprocessing, this advantage is that for the recycling only demands the grinding of the carpet and its pelletization since each of the products integrating elements of the same, can be directly recycled without additional processes for being the same polymer ..
  • an advantage of the process of the present invention is in the non-use of adhesives in fixing the threads of the textile or carpet face to its primary substrate or base either woven, tufted fabric or nonwoven fabric, this is done by using radiators infrared that allow thermofusion in certain areas of the textile that will allow the fastening of its fibers to its sutrate or primary base, which allows space efficiency since normally the ovens for drying latex or adhesives are of enormous dimensions since they have to evaporate large volumes of water or solvents at very fast speeds, the type of infrared radiation furnace used in the process of the present invention is smaller and more efficient than conventional furnaces using very small spaces and does not generate pollution
  • thermoformable carpet constructed of the same resin or polymer in all the parts that integrate it and its production process with a secondary base fused and laminated without the use of latex or adhesives using recycled fibers inserted from polypropylene or Polyester as a thermo fusion laminating agent thereof, is that the thermofusion process is very competitive in both energy and raw material costs used because the thermofused fibers are of recycled origin itself and their cost is low being their very high financial and ecological advantages.
  • Another object of the invention is to provide a 100% recyclable thermoformable carpet constructed of the same resin or polymer in all the parts that comprise it and its production process of the present invention a sense of impermeability since at the time of fusing the fibers between Yes and when they are laminated they produce a film that will serve as a barrier that in the future will prevent the liquids that normally in the daily use of the carpets fall on it, it helps that they do not penetrate in the same way it will not present delaminations of its rigid base by not having any of its parts any adhesive component that decomposes on contact with In addition, in the case of polypropylene or polyester being a completely inert material, this makes it a product that does not create a fungus.
  • Fibers that are used as fusion fibers integrated into the carpet when it is woven is that when these fibers merge and because they are of the same polymer as the fibers that make up the yarn and the fibers that make up the primary base and the secondary base that are laminated, you are laminated by the pressure given cold pressure tool and thermoforming and when they are in a melting point they make the mechanical anchoring of the fibers that make up the thread of the face of the carpet not allowing it to be released in the future by the normal abrasion process that the carpet receives on its face or exposed surface, term that in the carpet production technique is called the sealing of the knot inserted in the tufting case and in the case of other fibr sealing procedure This is done at a very low cost because the fibers of material are already recycled.
  • a further advantage offered by the process and product of the present invention is that in its manufacturing process no other textile finishing process is required, since a canvas is cut from the fabric and processed under the system of the present invention, saving time, money and effort as well as investment in spaces and infrastructure this because in the process of this invention a heat radiator is used that fuses the back face of the carpet leaving it finished to only cut its flanges and pack it for sales and installation
  • Another advantage offered by the process of the present invention is that it is not required to use fibers of lower melting point than conventional or other polymers as a fusion vehicle, but with the Conventional fibers of the same polymer or resin of the other materials that make up the carpet components and due to the protection given both to the face of the product and to the fabric substrate, this objective of fiber use is achieved with the same thermal melting point.
  • the present invention is particularly directed to automotive or marine carpets, it is obvious that the present invention may be applied in all types of textile and carpet manufacturing processes in which fiber fusion or lamination of a recyclable product is required. without the presence of other polymers in its construction.
  • thermoformable floor mats represent a serious ecological problem for recycling
  • thermoformable carpets do not have a characteristic of sealing or anchoring threads inserted to their primary base by a thermofusion process but the application of coatings of pulverized resins or plastic films and therefore, for obtaining the anchor from their threads to the primary base, styrene Butadiene latex or polyethylene or PVC resins should be used, Polyvinyl Chloride or EVA Ethil Vinyl Acetates, applied by direct extrusion process, or sprinkled on the back of the product, or good through of fusion of textile layers of different polymers with different thermal melting point previously inserted in the main product and in its secondary base.
  • styrene Butadiene latex or polyethylene or PVC resins should be used, Polyvinyl Chloride or EVA Ethil Vinyl Acetates, applied by direct extrusion process, or sprinkled on the back of the product, or good through of fusion of textile layers of different polymers with different thermal melting point previously inserted in the main product and in its secondary base.
  • the invention consists in the development of a process for the creation of a thermoformable carpet with its integrated 100% recyclable insulator made in all its components of a single polymer that is the fibers, the primary substrates and the foamed or insulating base, as well as the product obtained called automotive thermoformed carpet with integrated 100% recyclable insulation made of a single polymer.
  • the procedure and the product obtained from it consist of the following steps and basics.
  • the insertion of a very low denier fiber nap between the primary substrate of a tufting fabric and the threads that are woven in order to create what will be the vehicle of mechanical support of the threads inserted between this nappa and the base or substrate primary the insertion of a very low denier olympic fibers per filament (DPF) layer produces a change in densities that prevents the flow of melting temperatures within the primary base product of the carpet which allows the oliefinic sheets applied in the back of the same and exposed to the action of high and low wave infrared rays are brought to their melting point without affecting the dimensional stability of the primary substrate of the carpet or the fibers of the face thereof.
  • DPF denier olympic fibers per filament
  • thermoformable carpet of a single resin 100% of different presentations of material one that conforms the face of the product and is with the presence of abuyonada carpet another that forms the substrate of the carpet and in the case woven carpet has a substrate based on woven strips of polypropylene or oliefinic or polyester depending on the case but with the common denominator that if they are oliefinic all parts will be oliefinic or if they are polyester all parts will be polyester
  • Another presentation is a layer superimposed between the inserted threads being this napa produced with recycled fibers of low denier and finally the presentation in sheets, sheets of 100% low thickness polymeric material all this mass together, as we said exposed to the action of infrared rays to achieve the fusion of part of it without damaging or altering the other parts in different present
  • an energy diffuser is used on the surface of the carpet.
  • This energy diffuser is simple water that absorbs the infrared heat energy left over from the process and allows the woven face product of the mat to accept the high pressure higher than the 150 PS1 of the given tools without suffering any collapse or taking forms or alterations in their presence texture or image, the only variation that the volumization of the textile face undergoes the carpet that when applying the water and the heat energy left over from the process, the water When decomposing by energy develops a vapor that comes to volumize the textile giving a very beneficial appearance to the final product.
  • Water by its very nature forms steam at 100 degrees Celsius and protects the olefinic textile that has its melting point and textile heat setting above 130 degrees Celsius, the water does not leave residuals when it evaporates completely or causes stains on the Olefinic boned textile on the face of the product. If the case so it is necessary to apply at the same time water a substance that repels stains and dust that helps the added value and use of the product.
  • FIGURE 1 is a section of the 100% recyclable thermoformable carpet already laminated to a secondary substrate of the same type of resin or polymer showing the finished product
  • FIGURE 2 is a cross-section of the 100% recyclable thermoformable carpet showing the parts that integrate it
  • FIGURE 3 is a cross-section of the 100% recyclable thermo-moldable carpet showing the parts that integrate it before being exposed to the thermofusion and lamination action of its secondary substrate in layers of the same type of resin or polymer
  • FIGURE 4 is a schematic of the procedure for the insertion of the multicited low denier fiber nap between the primary substrate and the inserted threads of a tufting fabric or between the non-woven substrate inserted with the nappa
  • FIGURE 5 is a representation of the process for the application of energy diffusing agent and protector of the textile face of the 100% ⁇ recyclable thermoformable carpet where it is denoted as the ready-made textile roll is cut into canvases of the necessary dimensions and turned to be exposed to the spraying of the humidifier or repellent humidifiers
  • FIGURE 6 describes the process for thermofusion, partially controlled and modulated of the parts that make up the 100% recyclable thermoformable carpet object of the present invention.
  • FIGURE 7 describes the process for thermofusion, partially controlled and modulated of the parts that make up the 100% recyclable thermoformable carpet object of the present invention and the insertion into the process of the foamed sheet of insulation and molding
  • FIGURE 8 describes the procedure for lamination, seal or anchoring of the fibers and threads, thermoforming, volumization and cosmetic termination of the product in the same operation, being ready for cutting and packing.
  • the number 1 refers to itself the 100%) recyclable thermoformable carpet of a single polymer, either it can be oliefinic or polyester both polymers are capable of being used in the claimed procedure and are subject to Integrate the raw materials that make up the product since with any of them you can produce fibers, threads, sheets and sheets with or without foaming obviously they are used individually without mixing as the objective would be lost or 100%) oliefinic or 100% polyester obtaining the 100% recyclable carpet product of a single polymer being shown complete 1 with its back facing up and its front or textile part of carpet 2 facing down and the insulation 8 or moldable foam on its back.
  • FIGURE 4 it describes the process of inserting the sheet 4 to the primary substrate 3 by means of the needles safeguarding the hair of the textile 2 and forming the inserted textile product prepared 5 immediately and then in the same process to wind it in rolls 9 for handling and transportation.
  • This same process is used when it obtains a lamination on a punched product only that instead of the recycled fibers they are inserted in the substrate or primary base as in a tufting process, the napa or non-woven fabric is punched on the back of the product that is desired to be laminated and subsequently passed to all other procedures.
  • FIGURE 5 it details how a roll 9 of inserted textile product prepared 5 is cut into suitable canvases and these are turned by their obverse to be exposed to the action of the sprinklers that spread as an element of protection 12 the cloud of moisturizer and of liquid repellent on the face of the textile 7 which from this moment is ready to be processed 11 together with the other elements under the action of infrared rays.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)
  • Carpets (AREA)

Abstract

L'invention concerne un tapis thermomoulable avec isolant 100 % recyclable fait d'un seul polymère laminé à un substrat secondaire par thermofusion à unités infrarouges. On utilise comme véhicule d'ancrage mécanique des fibres de faible denier par filament recyclées, composées du même polymère ou résine dont sont composées la face et la base primaire du tapis, ne devant pas nécessairement être d'un poids moléculaire différent ou posséder un point de fusion différent. Les fibres forment une nappe ou couche, et sont appliquées par simple superposition et ancrées lors de l'insertion des fils dans le processus de tufting du tapis, ou dans le produit non tissé. Le tapis est laminé de couches secondaires de laminé, l'une d'elles étant un isolant en mousse, du même polymère ou résine dont sont composées les autres éléments déjà intégrés dans le tapis. Les composants du tapis possèdent tous un dénominateur commun, à savoir une résine thermoplastique qui les rend 100 % recyclables sans nécessité d'aucun autre processus de sélection de polymères comme la précipitation ou d'autres processus. Afin d'obtenir ce tapis thermomoulable recyclable, la face et l'envers du tapis sont protégés lors du processus de fabrication par humidification et refroidissement au moyen d'asperseurs, d'outils à recirculation d'eau, et de chambres d'application d'air froid.
PCT/MX2000/000054 1999-12-21 2000-12-15 Procede de fabrication de tapis moulables 100 % recyclables, faits d'une seule resine ou polymere, a ancrage et laminage secondaire par thermofusion de lamines composes du meme polymere, avec ou sans isolant en mousse, thermomoules en une seule operation, et produit obtenu WO2001045942A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU22349/01A AU2234901A (en) 1999-12-21 2000-12-15 Method for producing 100 per cent recyclable carpets from a single resin or polymer having backing and secondary lamination by thermofusing laminae made of the same polymer with or without foam insulator and thermomolded in a single operation and product thus obtained

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
MX9900892 1999-12-21
MX000892 1999-12-21

Publications (1)

Publication Number Publication Date
WO2001045942A1 true WO2001045942A1 (fr) 2001-06-28

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PCT/MX2000/000054 WO2001045942A1 (fr) 1999-12-21 2000-12-15 Procede de fabrication de tapis moulables 100 % recyclables, faits d'une seule resine ou polymere, a ancrage et laminage secondaire par thermofusion de lamines composes du meme polymere, avec ou sans isolant en mousse, thermomoules en une seule operation, et produit obtenu

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AU (1) AU2234901A (fr)
WO (1) WO2001045942A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103386912A (zh) * 2013-07-02 2013-11-13 无锡吉兴汽车部件有限公司 一种一体化汽车地毯的生产方法
US11084186B2 (en) 2013-03-12 2021-08-10 Milliken & Company Recyclable single polymer floorcovering article

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4035533A (en) * 1976-06-01 1977-07-12 Champion International Corporation Tufted carpet with meltable-film primary-backing component
GB2012615A (en) * 1977-12-19 1979-08-01 Exxon Research Engineering Co Foam coated primary backing material
US4482595A (en) * 1984-03-20 1984-11-13 Chisso Corporation Primary backing of foamed polypropylene tapes and tufted carpets produced from the same
CA2032599A1 (fr) * 1990-12-18 1992-06-19 Thomas E. De Journo Tapis recyclable et methode de fabrication connexe
WO1993015909A1 (fr) * 1992-02-10 1993-08-19 Polyloom Corporation Of America Moquette veloutee aux aiguilles - techniques de fabrication et de recyclage
EP0568916A1 (fr) * 1992-05-01 1993-11-10 Hoechst Celanese Corporation Article implanté de touffes
EP0604897A1 (fr) * 1992-12-28 1994-07-06 Hoechst Celanese Corporation Tapis contenant une couche de polyester thermofusible
ES2072650T3 (es) * 1991-05-27 1995-07-16 Huels Chemische Werke Ag Alfombras de suelo moldeables.

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4035533A (en) * 1976-06-01 1977-07-12 Champion International Corporation Tufted carpet with meltable-film primary-backing component
GB2012615A (en) * 1977-12-19 1979-08-01 Exxon Research Engineering Co Foam coated primary backing material
US4482595A (en) * 1984-03-20 1984-11-13 Chisso Corporation Primary backing of foamed polypropylene tapes and tufted carpets produced from the same
CA2032599A1 (fr) * 1990-12-18 1992-06-19 Thomas E. De Journo Tapis recyclable et methode de fabrication connexe
ES2072650T3 (es) * 1991-05-27 1995-07-16 Huels Chemische Werke Ag Alfombras de suelo moldeables.
WO1993015909A1 (fr) * 1992-02-10 1993-08-19 Polyloom Corporation Of America Moquette veloutee aux aiguilles - techniques de fabrication et de recyclage
EP0568916A1 (fr) * 1992-05-01 1993-11-10 Hoechst Celanese Corporation Article implanté de touffes
EP0604897A1 (fr) * 1992-12-28 1994-07-06 Hoechst Celanese Corporation Tapis contenant une couche de polyester thermofusible

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11084186B2 (en) 2013-03-12 2021-08-10 Milliken & Company Recyclable single polymer floorcovering article
US11673291B2 (en) 2013-03-12 2023-06-13 Milliken & Company Recyclable single polymer floorcovering article
US11883984B2 (en) 2013-03-12 2024-01-30 Milliken & Company Recyclable single polymer floorcovering article
CN103386912A (zh) * 2013-07-02 2013-11-13 无锡吉兴汽车部件有限公司 一种一体化汽车地毯的生产方法

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