WO2006041440A1 - Procede ameliore/alternatif pour appliquer des adhesifs thermofusibles sur les tapis - Google Patents

Procede ameliore/alternatif pour appliquer des adhesifs thermofusibles sur les tapis Download PDF

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Publication number
WO2006041440A1
WO2006041440A1 PCT/US2004/031048 US2004031048W WO2006041440A1 WO 2006041440 A1 WO2006041440 A1 WO 2006041440A1 US 2004031048 W US2004031048 W US 2004031048W WO 2006041440 A1 WO2006041440 A1 WO 2006041440A1
Authority
WO
WIPO (PCT)
Prior art keywords
primary backing
backing material
yarn
carpet
coating
Prior art date
Application number
PCT/US2004/031048
Other languages
English (en)
Inventor
Todd M. Shail
Robert D. Hutchison
Original Assignee
Mohawk Brands, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mohawk Brands, Inc. filed Critical Mohawk Brands, Inc.
Priority to PCT/US2004/031048 priority Critical patent/WO2006041440A1/fr
Publication of WO2006041440A1 publication Critical patent/WO2006041440A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1284—Application of adhesive
    • 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
    • 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
    • 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
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (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
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/045—Vinyl (co)polymers
    • D06N2203/048—Polyvinylchloride (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
    • D06N2203/065—Polyamides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/06—Melt
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/14—Fibrous additives or fillers
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/18—Scraps or recycled materials
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear

Definitions

  • This invention relates to carpets and methods of making carpets employing an efficient procedure for applying hot melt adhesive to a carpet backing.
  • Carpets are constructed with a primary backing material in which yarns are tufted through a primary backing material having a face surface and a back surface.
  • An adhesive is used on the back side of the primary backing to secure the face yarns to the primary backing.
  • these adhesives may be latex or PVC-based materials.
  • This invention uses hot melt adhesives based upon polymers which when heated have reduced viscosity and are flowable but upon cooling secure the carpet yarns to the primary backing.
  • roller coating and extrusion coating are two methods that have been used to successfully apply a hot melt adhesive to the back of the carpet primary backing.
  • the hot melt adhesive has many purposes and advantages over conventional latex and PVC backed carpets.
  • the purposes of the adhesives used in carpet manufacturing are to encapsulate the individual fibers or filaments in the fiber bundle of such yarns to lock them in place to prevent foot traffic from causing the fibers or filaments to break and pill.
  • the adhesive also locks the bundles of yarn in place so that they are unable to be pulled out of the carpet, as well as adhere a secondary backing, if desired, to the back of the carpet, prevent moisture from being able to pass through the adhesive layer, and allows the carpet to be easily recycled by constructing the entire carpet product of recoverable polymers.
  • roller coating though effective, typically requires a large mass of adhesive in order to be effective. Extruders, which are very effective, are extremely expensive. [0004]
  • hot melt adhesives can be applied to the back of a carpet primary backing and effectively meet all the objectives stated above by using a slot coat system.
  • a slot coat system has proven to be more successful than roll coaters and just as effective as extruders while being much more cost effective. In appearance, a slot coater visually looks very similar to an extruder.
  • a conventional extruder melts a polymer and forces it through a die via the use of screws. Extrusion coating using an ethylene polymer-based adhesive is described in WO 98/38374, WO 98/38375 and WO 98/38376.
  • a slot coater melts the polymer which is then gravity fed to a series of pumps which pump the material through any number of application heads such as sprayers, misters, slot dies, and the like.
  • the adhesive backing material is applied as a single coating or layer which affixes the yarn to the primary backing material.
  • the extent or tenacity to which the yarn is affixed is referred to as tuft lock or tuft bind strength. Carpets with sufficient tuft bind strength exhibit good wear resistance and have long service lives. It is also desirable that the adhesive material should substantially penetrate the yarn or fiber bundle exposed on the back side of the primary backing material and should substantially consolidate individual fibers within the yarn. Good penetration of the yarn and consolidation of fibers leads to good abrasion resistance and improved wear characteristics.
  • Hot melt adhesive materials suited to the process of the present invention are primarily thermoplastic polyolefins such as ethylene vinyl acetate copolymers, polyethylenes, particularly low density polyethylene as well as polyethylene, polypropylene, polyamide, polyvinyl chloride, ethylene vinyl acetate, polyester or copolymers thereof.
  • a hot melt adhesive that it is advantageous to employ a secondary amount or minor amount of a tackifying resin that is blended with the hot melt adhesive.
  • the choice of tackifying resin will depend on several factors including compatibility with the hot melt adhesive both in terms of processing conditions and application conditions and as well as relative costs. Generally the tackifying resins are more costly than the hot melt adhesives.
  • Described are methods of making a carpet by (a) providing a primary backing material having a front side and a back side, (b) tufting a yarn into the primary backing material to produce a carpet pile on the front side of the primary backing material and loops of the yarn on the back side of the primary backing material, (c) applying by slot coating a layer of a first melted coating composition onto the back side of the tufted primary backing material, (d) applying by slot coating a layer of a second melted resin/adhesive coating composition onto the coating applied in step (c) thereby fixing the loops of the yarn to the primary backing material, and (e) applying and pressing a secondary backing onto the slot coated tackifying resin layers and pressing it to join the first and second tackifying resins and the primary backing and secondary backing and yarn loops together to form a cohesive carpet product.
  • the first coating composition may include a tackifying resin and a hot melt adhesive. Typically between about 2 to about 12 ounces per square yard of the first resin coating composition is applied to the primary backing material.
  • the second resin coating composition may contain up to 80% by weight of a tackifying resin blended together with a hot melt adhesive. Between about 5 to about 50 ounces per square yard of the second coating composition is applied to the primary backing. Overall, between about 24 and about 50 ounces per square yard of the first and second coating compositions combined are applied to the primary backing.
  • the hot melt adhesive is preferably a composition based upon a polyethylene, polypropylene, polyamide, polyvinyl chloride, ethylene vinyl acetate, polyester or their copolymers.
  • the second coating composition may include an inorganic particulate filler. Desirably the carpet is constructed substantially entirely of recyclable polymer.
  • Also described are methods of making a carpet including the steps of providing a primary backing material having a front side and a back side, tufting a yarn into the primary backing material to produce a carpet pile on the front side of the primary backing material and loops of the yam on the back side of the primary backing material, and thereafter applying by slot coating a layer of a melted adhesive composition onto the back side of the tufted primary backing material thereby fixing the loops of the yarn to the primary backing material.
  • the method of this invention provides a carpet comprised of yarn attached to a primary backing material and secured to the backing by applying to a back side of the primary backing material a slot coated melted adhesive composition thereby flexibly securing the yarn to and retaining it in the primary backing material.
  • FIGURE 1 is a schematic illustration of applying by slot coating an adhesive composition to a primary carpet backing, applying a secondary backing and preparing a carpet.
  • the invention is further described with respect to the attached Figure illustrating an embodiment of the invention in which two slot coating stations are employed.
  • the first applies a tackifying resin or a blend of tackifying resin and a hot melt adhesive as a pre-coat and a second slot coat station applies a blend of a tackifying • resin and a hot melt adhesive, optionally including a filler, such as calcium carbonate or flyash, applied as a main coat.
  • the two slot coaters are positioned in close proximity to one another to apply both layers of adhesive composition while hot and somewhat fluid.
  • the number of slot coaters used depends upon factors such as physical properties the carpet is required to satisfy, and cost. For example, physical properties achieved with one unit may be sufficient for residential carpet but not for commercial carpet or carpet tile.
  • the process of the present invention is characterized by the use of one or more slot coating devices which are distinguished from other application devices, in particular extruders, that, have been used in this art, as noted above.
  • An extruder uses a series of screws and pumps to force the adhesive material through a die onto the primary backing.
  • a slot coater uses only pumps to force the adhesive through a die and then onto the primary backing. Slot coating holds the advantage of efficiently and precisely applying a desired amount of adhesive composition to the carpet but at a rate of application lower than that of other coating techniques including extrusion coating.
  • the carpets made according to the present invention are strong, lightweight and more flexible as a result of employing smaller quantities of adhesive, yet meet the necessary product specifications and requirements.
  • the secondary backing is joined to the back coated primary and compressed together by squeeze rolls or the like to unify the primary and secondary backing with the adhesive layer or layers therebetween and secure the tufted fibers to the back surface of the primary backing.
  • the finished carpet is then rolled in open width or further processed into smaller units, for instance, carpet tiles.
  • the secondary backing material may be a woven fabric or a non-woven fabric, such as spun-bond, wet-laid, melt-blown or air entangled and is preferably made from a polyolefin to facilitate recycling.
  • the use of two separate slot coating stations allows for considerable flexibility in not only the amounts of adhesive applied but also the content of the adhesive composition in particular when blends of adhesive components are employed.
  • the coating weight of all adhesive layers is in the range of about 24 to about 50 ounces per square yard and if two layers are applied the tackifying layer is generally in the range of two to 12 ounces per square yard, preferably about nine ounces per square yard and the second adhesive layer is generally applied in an amount of five to about 50 ounces per square yard, preferably about 15 ounces per square yard.
  • the first adhesive composition applied consists entirely or substantially entirely of a tackifying resin or it may be a blend of tackifying resin and a hot melt adhesive in which case the amount of tackifying resin exceeds that of the hot melt adhesive. Conversely, if the blend of tackifying resin and hot melt adhesive is employed as the second adhesive composition, the amount of tackifying resin is less than that of the amount of hot melt adhesive.
  • the first coating layer may consist entirely of a tackifying resin or up to 30 parts by weight of an adhesive may be included together with the tackifying resin in the composition.
  • Compositions for the second layer may range from 80 to 20 parts by weight of tackifying resin and 20 to 80 parts by weight adhesive.
  • the tackifying resin component ranges from 10 to 70 parts by weight, the adhesive component 22 to 52 parts by weight, and the filler component 8 to 38 parts by weight, with a total of 100 parts by weight.

Landscapes

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

Abstract

L'invention concerne des procédés de fabrication d'un tapis consistant (a) à utiliser un matériau de dossier primaire possédant un côté recto et un côté verso, (b) à procéder au tufting d'un fil dans le matériau de dossier primaire pour produire un poil de tapis sur le côté recto du matériau de dossier primaire et des boucles du fil sur le côté verso du matériau de dossier primaire, (c) à appliquer par revêtement en rainures une couche d'une première composition de revêtement fondue sur le côté verso du matériau de dossier primaire tufté, (b) à appliquer par revêtement en rainures une couche d'une deuxième composition de revêtement fondue sur le revêtement appliqué à l'étape (c), ce qui fixe les boucles du fil au matériau de dossier primaire, et (e) à appliquer et comprimer un dossier secondaire sur les couches de résine rendant adhésif revêtues en rainures et à comprimer le tout pour joindre les première et deuxième résines rendant adhésif, le dossier primaire, le dossier secondaire et les boucles de fil ensemble pour former un tapis.
PCT/US2004/031048 2004-09-22 2004-09-22 Procede ameliore/alternatif pour appliquer des adhesifs thermofusibles sur les tapis WO2006041440A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2004/031048 WO2006041440A1 (fr) 2004-09-22 2004-09-22 Procede ameliore/alternatif pour appliquer des adhesifs thermofusibles sur les tapis

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2004/031048 WO2006041440A1 (fr) 2004-09-22 2004-09-22 Procede ameliore/alternatif pour appliquer des adhesifs thermofusibles sur les tapis

Publications (1)

Publication Number Publication Date
WO2006041440A1 true WO2006041440A1 (fr) 2006-04-20

Family

ID=36148596

Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4939036A (en) * 1987-10-14 1990-07-03 Amoco Corporation Method for preparing tufted pile carpet and adhesive therefor
US20040079468A1 (en) * 2002-09-13 2004-04-29 Reisdorf Raymond Joseph Process for producing carpet

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4939036A (en) * 1987-10-14 1990-07-03 Amoco Corporation Method for preparing tufted pile carpet and adhesive therefor
US20040079468A1 (en) * 2002-09-13 2004-04-29 Reisdorf Raymond Joseph Process for producing carpet

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