WO2001098575A1 - Revetement de sol integral impermeable aux liquides et permeable aux vapeurs et procede de fabrication correspondant - Google Patents

Revetement de sol integral impermeable aux liquides et permeable aux vapeurs et procede de fabrication correspondant Download PDF

Info

Publication number
WO2001098575A1
WO2001098575A1 PCT/US2001/020150 US0120150W WO0198575A1 WO 2001098575 A1 WO2001098575 A1 WO 2001098575A1 US 0120150 W US0120150 W US 0120150W WO 0198575 A1 WO0198575 A1 WO 0198575A1
Authority
WO
WIPO (PCT)
Prior art keywords
vapor
liquid
substrate
impermeable
film
Prior art date
Application number
PCT/US2001/020150
Other languages
English (en)
Inventor
Larry E. Ellis
Michael A. Lewallyn
Original Assignee
Ellis Larry E
Lewallyn Michael A
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 Ellis Larry E, Lewallyn Michael A filed Critical Ellis Larry E
Priority to AU2001271421A priority Critical patent/AU2001271421A1/en
Publication of WO2001098575A1 publication Critical patent/WO2001098575A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one 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
    • D06N7/0068—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
    • D06N7/0078—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 applied as a hot melt
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B32B2307/7265—Non-permeable
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/121—Permeability to gases, adsorption
    • D06N2209/125—Non-permeable
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/126—Permeability to liquids, absorption
    • D06N2209/128—Non-permeable

Definitions

  • This invention relates in ' general to floor coverings and especially those having tufts of yarn, such as rugs and wall-to- wall carpets for domestic and industrial use.
  • Prior floor coverings such as rugs and wall-to-wall carpets for domestic and industrial use suffer from a number of disadvantages.
  • the current, predominant approach regarding backing material and its application is more than fifty years old and is not only outdated because of environmental issues, but also because new technology in both raw materials and equipment offer major opportunities in the areas of cost reduction, energy conservation and improved product performance.
  • the current manufacturing techniques use a conventional latex as the principle adhesive (other adhesive materials suspended in water such as polyurethane are also used) which results in a product that cannot disintegrate in land fills, is banned from some land fills and thus is creating an environmental problem, and is very expensive z manufacture because of all the natural gas that must be used to heat the carpet components during manufacture so as to drive off the water and dry the components and so as to set the latex.
  • U.S. Patent No. 5,348,785 employs a secondary backing which is substantially impervious to solutions.
  • Heim discloses a secondary backing which is substantially impervious to liquids.
  • Wyman, U.S. Patent No. 5,902,658 discloses a floor covering together with a substrate which is impervious to liquid.
  • Krotine, U.S. Patent No. 5,962,350 discloses a multi layer floor covering one layer of which is capable of "holding liquid”.
  • More recently E. I. du Pont de Nemours and Company of Wilmington, Delaware, USA (duPont) developed a breathable moisture protective barrier product that has the trademark SPILLNET. This product is a very lightweight, nonwoven sheet bonded to a breathable film and is sold in rolls seventy-four inches wide. When installed properly it catches any liquid- spills that have soaked through the carpet backing and keeps the liquid above the " cushion. It also promotes moisture vapor transfer.
  • the SPILLNET product is designed to be installed by first laying it on top of padding that has been previously installed. It cannot be adhered directly to a floor, such as is used for commercial carpet that is glued directly to a floor; and cannot be glued with an environmentally friendly hot melt adhesive because it is too thin and will be damaged.
  • the product has other disadvantages, including a low relative dimensional stability, has a tendency to wrinkle, and is susceptible to being damaged during the carpet 5 seaming process from an installer's knife, by walking on it, or scuffing it ' when the carpet is drug across it during carpet installation. •••It is then cut and tacked down. Then the carpet is laid loosely on top of the SPILLNET product, cut and tacked down or otherwise secured using conventional techniques.
  • Another object is to provide an improved floor covering which is easy and inexpensive to install, and which is a non-latex, 10 thermoplastic floor covering that is fully recyclable.
  • Such floor covering has improved properties by being waterproof, breathable, and improved physical performance characteristics.
  • When such floor covering is a carpet or rug, it is an object to provide a much improved backing composite and attendant laminated backing that 15 results in an improved carpet or rug.
  • Still another object is to provide an improved, less expensive process for producing an improved floor covering, the process having a reduced production and operator personnel requirement, a lower energy requirement, a higher production speed, and a lower 20 . requirement for floor space for the production equipment, which equipment is less expensive.
  • an integral, laminated floor covering such as a carpet
  • a microporous film barrier in which liquids can not penetrate, yet through which moisture vapors can pass thereby preventing the accumulation of liquid next to the floor and the subsequent accumulation and growth of bacteria, mildew, and mold with their attendant odors and health problems.
  • a carpet is also easier to install and has a reduced damage to the building structure due to a softer, more flexible and non-abrasive nature of the composite backing.
  • a floor covering and the method of the making thereof according to the present invention has at least the following advantages. There is a dramatic improvement in cleanability, improved aesthetics and sanitation; and there is a liquid barrier combined with a breathable floor covering.
  • the floor covering is a carpet or rug
  • Such a product is fully recyclable, has a reduced total product weight per square yard, and in one embodiment is "a totally thermoplastic product that can be very economically produced with a reduced adhesive material requirement, a reduced amount of energy needed to manufacture it, and a reduced production equipment downtime for maintenance and clean-up.
  • a liquid-impermeable, vapor-permeable floor covering which in a specific embodiment is a carpet comprising:
  • a breathable polymeric film which is liquid- impermeable and vapor-permeable, the breathable polymeric film having an upper surface and a lower surface, and
  • a secondary substrate having an upper surface and a lower surface; wherein the lower surface of the secondary substrate is bonded to the upper surface of the breathable polymeric film;
  • a primary substrate or primary substrate having an upper surface and a lower surface
  • FIG. 1 is a cross sectional schematic representation of one embodiment of the floor covering of the present invention.
  • FIG. 2 is a cross sectional schematic representation of the floor covering of FIG. 1 showing how the floor covering is both liquid-impermeable and vapor-permeable.
  • FIG . 3 is a schematic perspective representation of a portion of a non woven fibrous secondary backing enlarged approximately 300 times actual size .
  • FIG . 4 is a cross sectional schematic representation of equipment used to bond a film to the secondary backing of FIG. 3 according to one embodiment of the invention.
  • FIGs. 5,"' 6, and 7 are cross sectional schematic representations of alternative equipment for producing a composite material useful to produce the floor covering of the . present invention.
  • FIG. 8 is a plan view enlarged approximately 100 times actual size of a special film showing particularly the structure thereof, and useful as part of the floor covering of the present invention.
  • FIG. 9 is a plan view enlarged approximately 500 times actual size of the special film of FIG. 8, showing the microscopic structure thereof.
  • FIG. 1 there is shown a liquid-impermeable, vapor-permeable floor' covering 10 of the present invention that has been laid on an under flooring 11.
  • Floor covering 10 is preferably a carpet or rug having a top made of pile-carpet tufts, the tufts made from any conventional carpet fibers such as nylon, polypropylene, polyesters and wool.
  • the tufts can be of plied, cut strands of fiber yarns commonly referred to as “cut pile” (fabrics) or plied, uncut fiber • yarns commonly referred to as “loop pile” (fabrics) . Combinations of these fabric construction types are also produced.
  • any floor covering that can embody the concepts of 10 the present invention are included, such as possible future floor coverings having an upper porous laminate instead of tufts.
  • floor covering 10 will be described as a carpet.
  • Under flooring 11 is conventional and includes both a finished floor and a sub flooring.
  • L5 For example flooring 11 can be concrete, ceramic tile, planks, particle board, plywood and tongue and groove hardwood flooring.
  • Flooring 11 is depicted without any top covering, but it could have a plastic tile or solid sheet linoleum-type covering.
  • Floor covering 10 is comprised of a lower composite secondary -0 substrate or layer 15 and an upper substrate or layer 16.
  • Lower layer 15 is comprised of a breathable polymeric film 12 which is liquid-impermeable and vapor-permeable. Film 12 has a lower surface 13 and an upper surface 14.
  • Lower layer 15 is also comprised of a resilient, secondary substrate 18 having an upper surface 20 and a lower surface 22. In a currently preferred embodiment of the present invention secondary substrate 18 is non- woven.
  • Lower surface 22 of secondary substrate 18 is bonded to upper surface 14 of breathable polymeric film 12 with an adhesive 23.
  • Adhesive 23 is preferably a hot melt type of adhesive that is sprayed or otherwise applied in a pattern that partially penetrates lower surface 22 of secondary substrate 18 and that creates a lot of voids or spaces by using a process conventionally called fiberization.
  • Upper layer 16 as depicted in FIG. 1 is a tufted carpeting 24 comprising a primary substrate 26 having an upper surface 28 and a lower surface 30.
  • Lower surface 30 of primary substrate 26 is bonded by means of an adhesive 38 to upper surface 20 of secondary substrate 18 as described hereinbelow.
  • adhesive 38 is selectively located only at the lower loops of yarn 36.
  • adhesive 38 is a low viscosity adhesive.
  • the threads of primary substrate 26 are depicted in Fig. 1 " as being round, but they are usually flat and are woven together in a flat weave to make primary substrate 26.
  • Carpeting 24 also has tufts such as tufts 32 and 34 of a yarn 36 which extend away from primary substrate upper surface 28. Tufts 32 and 34 of yarn 36 extend orthogonally away from upper surface 28 of primary substrate 26, passing through primary substrate 26 and forming an uneven lower surface 30 on the lower side of primary substrate 26 with voids 35 and 35' between successive tufts 32 and 34; and adjacent parallel rows of said tufts. Thus, fiber yarn bundles 39 of the lower loops of yarn 36 are created below lower surface 30 as shown in FIG. 1.
  • Adhesive 38 ' penetrates and ..encapsulates fiber yarn bundles (backstitches) 39. Such penetration and encapsulation provide important fiberlock and bundlewrap properties which ensure continued integrity and stability of layer 16.
  • FIG. 1 is a schematic. In FIG. 1 part of primary substrate 26 is shown separated from adhesive 38, whereas in an actual embodiment primary substrate 26 is not separated but rather is bonded to carpeting 24 as described hereinbelow.
  • FIG. 2 illustrates some advantages of the present invention.
  • Floor covering 10 is supported on a floor 40 comprised in part of a poured concrete slab 42 and in part of sub-flooring in the form of a plurality of tongue and grooved planks and 46.
  • Water in the form of droplets, such as droplets 48 and 50 purposefully or accidentally spilled from any source such as a bucket 52, wet carpeting 24 and the composite secondary substrate or layer 15, as shown in Fig. 1, but cannot pass through film 12. In this manner neither slab 42 nor planks 44 and 46 can become wet. The water will, under normal living conditions, soon evaporate.
  • Normal living conditions are those generally maintained in spaces occupied by humans, namely atmospheric pressure and an ambient temperature of from about 10°C to about 30°C and preferably from about 15°C to about 25°C; with relative humidity of from about 10 percent to about 90 percent and preferably from about 30 percent to about 70 percent .
  • FIG. 2 shows an additional advantage of the present invention.
  • floor 40 such as slab 42
  • slab 42 becomes damp. This can occur if slab 42 is poured directly on the ground and moisture condenses out of the ambient air or passes through the concrete. While liquid water in slab 42 does not pass through breathable film 12, water vapor does pass through as shown by arrows 54 and 56. By permitting the water vapor an exit through the carpet, accumulation of moisture is prevented and in this manner there is no growth of fungi, algae, mildew ' , bacteria or other unwanted organisms.
  • FIG. 3 shows, approximately 300 times actual size, a portion of a secondary backing 18' useful in the present invention.
  • Secondary backing 18' includes bicomponent fibers such as fibers 58, 59 and 60.
  • Fiber 58 is representative. It has a core 62 of a high melt polymer and a coating 64 of a low melt polymer.
  • portions of coating 64 melt and bond fibers 58, 59 and 60 at their points of contact.
  • film 12 can be bonded to secondary backing 18' in a similar manner.
  • FIG. 4 shows the equipment by which film 12 can be bonded to secondary backing 18'.
  • Film 12 is fed from a source (not shown) to the nip between an idler roll 66 and a heated drum 68 which rotates in the direction of arrows 70, 71 and 72.
  • Secondary backing 18' is also fed from a source (not shown) to the same nip between roll 66 and drum 68.
  • Drum 68 is heated by means (not shown, but which could include steam) to a temperature above the melting point of coating 64 of fibers 58, 59 and 60 but below the melting point of core 62 of fibers 58, 59 and 60. In this manner coating 64 melts and bonds fibers 58, 59 and 60 together and bonds fibers 58, 59 and 60 to
  • film 12 in those locations where fibers 58, 59 and 60 contact film 12.
  • composite secondary backing 74 that becomes a lower layer, such as layer 15 in FIG. 1, and comprises secondary backing 18 ' having an upper surface 20 and a lower surface 22.
  • lower surface 22 is above upper surface 20 and vice versa.
  • upper and lower surfaces 20 and 22 are named with respect to their orientation in FIG.2 whereby floor covering 10 of the present invention is placed on a floor 40.
  • composite secondary backing 74 is manufactured upside down in FIG. ' 4.
  • lower surface 22 of secondary substrate 18 ' is bonded to upper surface 14 of breathable polymeric film 12 by melted and refrozen portions of the low-melt polymer of coating 64 of bicomponent fibers 58, 59 and 60.
  • FIG. 5 shows the equipment of an alternative method for producing a composite secondary backing 74' useful to produce floor covering 10 of the present invention.
  • Hot melt adhesive 76 is applied to upper surface 14 of film 12.
  • secondary substrate 18 is caused to contact adhesive 76 thus bonding upper surface 14 of film 12 to lower surface 22 of secondary substrate 18.
  • the resultant product is composite secondary backing 74'.
  • FIG. 6 shows yet another alternative method, and probably the most economical method once the equipment is set up and aligned, for producing a composite secondary backing 74'' useful to produce floor covering 10 of the present invention.
  • Spinnerettes 78, 79 and 80 which are capable of producing meltblown fibers, directly extrude fibers 82 onto film 12.
  • Fibers 82 can be for example polypropylene or polyethylene and are applied across the full width so as to create a sparsely assembled mat.
  • Film 12 and fibers 82 pass between the nip of heated calendar rolls 84 and 86.
  • the nip between calendar rolls 84 and 86 is * adjustable in order to determine the thickness of the final product, a composite secondary backing 74''.
  • This hot pressing process applied directly to film 12 also eliminates the need of an additional adhesive product.
  • FIG. 7 shows still another alternative method for producing a composite secondary backing 74''' useful to produce floor covering 10 the present invention.
  • Secondary substrate 18 is positioned with its lower surface 22 facing upwards.
  • Film 12 is created in situ by forcing a thermoplastic composition (not shown) through a slot 88 in an extruder 90.
  • the slot is about 2 to 3 thousandths of an inch wide and the thermoplastic composition is under very high pressure.
  • FIG. 8 shows film 12 as comprising a thermoplastic polymer sheet 92 having embedded therein particles 94 and 96 of a filler.
  • Filler particles 94 and 96 in one embodiment can be calcium carbonate and have a size in the order of microns, whereas film 12 has a size in the order of mils.
  • Film 12 is made microporous by stretching it in a two step process in which a lateral stretching is done by passing film 12 through the nip of two radially slotted, mating rollers, and a linear stretching is done by passing film 12 through the nip of two fluted rollers in which the flutes traverse the length of the roller. The two sets of rollers cause microporous stress cracks around the solid particles in the film.
  • a second method of making film 12 microporous is to fill the substrate with a soluble solid (e.g. salt particles) and then melting the particles with solvent. As a result, a large plurality of micro size holes are created through film 12 which makes film 12 vapor- permeable, but liquid-impermeable.
  • a soluble solid e.g. salt particles
  • FIG. 9 shows film 12 with embedded particle 94.
  • particle 94 are a number of stress cracks, such as stress cracks 98 and 99.
  • stress cracks 98 and 99 go entirely through film 12 from upper surface 20 to lower surface 13 shown in Fig. 1, they are so small that they do not pass liquid water. Stress cracks 98 and 99 do, however, pass water vapor. Because stress cracks 98 and 99 are short they do not destroy the structural integrity of film 12.
  • the thickness of film 12 can vary greatly as long as it remains both liquid-impermeable and vapor-permeable. Generally film 12 has a thickness of from about 0.1 to 20 mils, preferably from 1 to 8 mils and ideally from 1 to 4 mils.
  • Particles 94, which are inserted into film 12 can be any of a wide variety of particles that can be used for making the micro pores through film 12.
  • the particles are of water insoluble inorganic materials examples of which include among others silica, titanium dioxide and calcium carbonate. Calcium carbonate is presently preferred because of cost and availability.
  • sodium chloride or other water soluble crystal type particles can be used and the micro pores are made when the particles are dissolved out.
  • the particle sizes can wary widely but the particles generally have a diameter from about 5 microns to about 50 microns. Because 25 microns equal one mil, this means that the size of particles 94 are usually smaller than the thickness of film 12.
  • Core 62 of bicomponent fibers 58, 59 and 60 can be any of a wide variety of known polymers but are preferably those selected from the group consisting of poly (ethylene terephthalate), polypropylene, nylon and polyester.
  • Coating 64 of bicomponent fibers 58, 59 and 60 can be any of a wide variety of known low melt thermoplastic polymers but are preferably those selected from the group consisting of polyethylene and polypropylene.
  • the high melt fiber generally has a melting point at least 10°C and preferably at least 40°C greater than the melting point of low melt coating 64.
  • Primary substrate 26 can comprise a single woven or non woven sheet or can comprise a laminate of a plurality of sheets.
  • primary substrate 26 is made of jute or a variety of woven or nonwoven commercial products commonly known as synthetic primary carpet backings.
  • the tufts of the carpet yarn can be monofilament or can be made of yarn from any natural or synthetic fiber heretofore employed to make carpets. Examples of natural fibers include those of cotton, wool and linen. Examples of synthetic fibers include those of poly (ethylene terephthalate), polypropylene, acrylic and nylon.
  • the secondary substrate can be made of any fibers employed to make the carpet as well as jute, hair and kenaf.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un revêtement de sol, perméable aux vapeurs et imperméable aux liquides, comme une moquette ou un tapis. Selon l'un des modes de réalisation, ledit revêtement de sol (10) possède une couche de moquette supérieure ou recouverte de touffes (16) qui comporte un substrat primaire (26) et des touffes (32, 34) de fil (36) se dressant au-dessus du substrat primaire (26). Un fond secondaire composite (15) se trouve sous le substrat primaire (26) et est relié à la couche de moquette (16) par une couche adhésive (38). Un film polymérique respirable (12) imperméable aux liquides mais perméables aux vapeurs est placé dessous et collé au substrat secondaire (18) au moyen d'une couche adhésive (23). Un procédé de fabrication du revêtement de sol (10) consiste à coller de manière adhésive une surface supérieure 14) d'un film (12) microporeux imperméable aux liquides mais perméable aux vapeurs imperméable à une surface inférieure (22) d'un substrat secondaire (18), en formant ainsi un fond secondaire composite (15); puis en collant une surface supérieure (20) dudit fond secondaire composite (15) à la surface inférieure (30) d'un substrat primaire (26) au moyen d'un adhésif thermofusible (38).
PCT/US2001/020150 2000-06-22 2001-06-22 Revetement de sol integral impermeable aux liquides et permeable aux vapeurs et procede de fabrication correspondant WO2001098575A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001271421A AU2001271421A1 (en) 2000-06-22 2001-06-22 Liquid-impermeable, vapor-permeable, integral floor covering and process for themanufacture thereof

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US59900300A 2000-06-22 2000-06-22
US09/599,003 2000-06-22

Publications (1)

Publication Number Publication Date
WO2001098575A1 true WO2001098575A1 (fr) 2001-12-27

Family

ID=24397790

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/020150 WO2001098575A1 (fr) 2000-06-22 2001-06-22 Revetement de sol integral impermeable aux liquides et permeable aux vapeurs et procede de fabrication correspondant

Country Status (2)

Country Link
AU (1) AU2001271421A1 (fr)
WO (1) WO2001098575A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007059576A1 (fr) * 2005-11-25 2007-05-31 Gale Pacific Limited Fil, tissu produit a partir de ce fil et procede de fabrication du fil et du tissu
US7803446B2 (en) * 2002-11-06 2010-09-28 Martz Joel D Construction of carpet with breathable membrane for eliminating moisture from surface covered by the carpet
EP2611605A2 (fr) * 2010-09-03 2013-07-10 Transhield Technology As Structures textiles perméables à la vapeur

Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4112161A (en) * 1977-04-25 1978-09-05 Burlington Industries, Inc. Tufted pile fabric and method of making and installing the same
US4389435A (en) * 1978-09-29 1983-06-21 Mod-Sod Sports Surfaces, Inc. Top dressed plating surface with resilient underpad
JPH02139465A (ja) * 1988-11-16 1990-05-29 Unitika Ltd カーペットの二次基布用不織布
EP0624681A2 (fr) * 1993-05-10 1994-11-17 E.I. Du Pont De Nemours And Company Procédé pour la préparation des tapis ayant un premier dos textile et un deu tième dos textile
US5382462A (en) * 1993-07-28 1995-01-17 Tac-Fast Systems Sa Carpet tape
US5578357A (en) * 1992-02-10 1996-11-26 Polyloom Corporation Of America Carpet and techniques for making and recycling same
US5614281A (en) * 1995-11-29 1997-03-25 Kimberly-Clark Corporation Creped nonwoven laminate loop fastening material for mechanical fastening systems
US5763039A (en) * 1996-06-17 1998-06-09 Staubs; William E. Protective carpet system
US5800898A (en) * 1996-11-26 1998-09-01 K2, Inc. Tufted carpet and process for preparing same
US5902658A (en) * 1997-08-15 1999-05-11 Wyman; Oliver A. Dimensionally stable, water impervious rug underlay with double sided pressure sensitive adhesive and protective peelable liners
US5902637A (en) * 1997-11-10 1999-05-11 W. L. Gore & Associates, Inc. Water repellent restorative and process of use
US5945210A (en) * 1995-12-13 1999-08-31 Mitsui Chemicals, Inc. Porous film and preparation process thereof
US6162309A (en) * 1998-04-21 2000-12-19 Burlington Industries, Inc. Reinforced foam backed carpet

Patent Citations (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4112161A (en) * 1977-04-25 1978-09-05 Burlington Industries, Inc. Tufted pile fabric and method of making and installing the same
US4389435A (en) * 1978-09-29 1983-06-21 Mod-Sod Sports Surfaces, Inc. Top dressed plating surface with resilient underpad
JPH02139465A (ja) * 1988-11-16 1990-05-29 Unitika Ltd カーペットの二次基布用不織布
US5578357A (en) * 1992-02-10 1996-11-26 Polyloom Corporation Of America Carpet and techniques for making and recycling same
EP0624681A2 (fr) * 1993-05-10 1994-11-17 E.I. Du Pont De Nemours And Company Procédé pour la préparation des tapis ayant un premier dos textile et un deu tième dos textile
US5382462A (en) * 1993-07-28 1995-01-17 Tac-Fast Systems Sa Carpet tape
US5614281A (en) * 1995-11-29 1997-03-25 Kimberly-Clark Corporation Creped nonwoven laminate loop fastening material for mechanical fastening systems
US5945210A (en) * 1995-12-13 1999-08-31 Mitsui Chemicals, Inc. Porous film and preparation process thereof
US5763039A (en) * 1996-06-17 1998-06-09 Staubs; William E. Protective carpet system
US5800898A (en) * 1996-11-26 1998-09-01 K2, Inc. Tufted carpet and process for preparing same
US5902658A (en) * 1997-08-15 1999-05-11 Wyman; Oliver A. Dimensionally stable, water impervious rug underlay with double sided pressure sensitive adhesive and protective peelable liners
US5902637A (en) * 1997-11-10 1999-05-11 W. L. Gore & Associates, Inc. Water repellent restorative and process of use
US6162309A (en) * 1998-04-21 2000-12-19 Burlington Industries, Inc. Reinforced foam backed carpet

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7803446B2 (en) * 2002-11-06 2010-09-28 Martz Joel D Construction of carpet with breathable membrane for eliminating moisture from surface covered by the carpet
WO2007059576A1 (fr) * 2005-11-25 2007-05-31 Gale Pacific Limited Fil, tissu produit a partir de ce fil et procede de fabrication du fil et du tissu
EP2611605A2 (fr) * 2010-09-03 2013-07-10 Transhield Technology As Structures textiles perméables à la vapeur
EP2611605A4 (fr) * 2010-09-03 2014-07-16 Transhield Technology As Structures textiles perméables à la vapeur

Also Published As

Publication number Publication date
AU2001271421A1 (en) 2002-01-02

Similar Documents

Publication Publication Date Title
US9926657B2 (en) Floor coverings with universal backing and methods of making, installing, and recycling
US6060145A (en) Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
US7670661B2 (en) Synthetic grass turf and related manufacturing method
KR100206690B1 (ko) 저연신성 치수적 안정 바닥 피복재
US20090081406A1 (en) Textile products and methods
US20030072911A1 (en) Residential carpet product and method
US20070122586A1 (en) Recyclable tufted carpet with improved stability and durability
US20100260966A1 (en) Dimensionally-Stabilized Cushioned Carpet Tile and Methods of Manufacture Thereof
JP2004530817A (ja) 接着剤フリーカーペットタイル及び接着剤フリーカーペットタイルを設置する方法
NZ529246A (en) Tufted covering for floors and/or walls
KR20030015267A (ko) 저중량 쿠션 카페트, 카페트 타일 및 그 제조방법
EP1587672A2 (fr) Dalles de moquette composees de cadres et d'inserts et leurs procedes d'installation
US20060165949A1 (en) Moisture dissipative floor covering layer
TW415983B (en) Modified secondary backing fabric, method for the manufacture thereof and carpet containing the same
WO2001098575A1 (fr) Revetement de sol integral impermeable aux liquides et permeable aux vapeurs et procede de fabrication correspondant
US20040247821A1 (en) Textile laminate having pile-like surfac
JP2008188202A (ja) 防水性及び通気性のあるカーペット
BE1022341A9 (nl) Werkwijze en inrichting voor het produceren van watervast tapijt met een hoge waterabsorptie
US20230391043A1 (en) Sound-Absorbing Article With Perforations In Backing, Surface Coverings Comprising Same, And Systems And Methods Of Making And Using Same
US20200071886A1 (en) Novel Artificial Turf and Methods of Making Same

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A1

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CR CU CZ DE DK DM DZ EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT TZ UA UG US UZ VN YU ZA ZW

AL Designated countries for regional patents

Kind code of ref document: A1

Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE TR BF BJ CF CG CI CM GA GN GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
REG Reference to national code

Ref country code: DE

Ref legal event code: 8642

122 Ep: pct application non-entry in european phase
NENP Non-entry into the national phase

Ref country code: JP