Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1993-12-01
1996-09-03
Engel, James
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156 72, 156238, 156247, 156344, 156322, 156540, 156327, B32B 3108
Patent
active
055520103
DESCRIPTION:
BRIEF SUMMARY
INDUSTRIAL UTILIZATION FIELD
The present invention relates to a method for producing a tile carpet such as tufted carpet or needle punch carpet used as a material to be laid on the floor of a store, office, house or the like.
PRIOR ART
Tile carpet is a plate-like carpet of a small area capable of being combined in a plural number as laying units to constitute floor surfaces of various sizes and shapes. It is advantageous in that the laying work is easy, the tile carpet is easy to carry and permits an easy and partial replacement, and various design constructions can be effected by combinations of colors and shapes. But it is required that the tile carpet be difficult to undergo displacements and dimensional changes caused by changes in temperature or stresses induced by walking on the carpet.
Generally, as means for improving the standing stability (laying stability), shape stability and dimensional stability of tile carpet, there is adopted a method wherein a thermoplastic resin composition such as an asphaltic, ethylene/vinyl acetate copolymer or polyvinyl chloride composition is applied in a molten condition to the back side of a carpet cloth formed of a pile yarn-implanted fibrous material, using a doctor knife, or a method wherein such composition is once formed into sheet by means of an extruder or a calendering equipment and then laminating the sheet to the carpet cloth under heating to form a laminate having a lining layer.
According to the former, conventional method for lining the carpet cloth, the carpet cloth is placed on an endless belt and a melted thermoplastic resin composition is applied onto the carpet cloth using a doctor knife or the like while the endless belt is allowed to travel continuously.
The latter, conventional method involving once forming a sheet of thermoplastic resin composition and then laminating it to the carpet cloth under heating is not so popular because this method is uneconomical in point of heat energy due to repeated heating and cooling.
According to the conventional method of applying a melted thermoplastic resin composition onto the carpet cloth which is travelling, the melt which has been brought into contact with the carpet cloth is difficult to cool and solidify because the carpet cloth is a heat insulating material. This is apt to cause deformations such as wrinkles or surface strains of the carpet obtained, in the case of a carpet cloth of low heat resistance. Further, unsolidified melt of the composition may enter irregular concaves and convexes on the carpet surface or between stiches of the carpet surface which are not always arranged in a regular form, thus sometimes resulting in that the lining layer is substantially not uniform in its thickness. That is, it becomes impossible to obtain a uniform coating, and this poses a problem in the quality control of carpet.
Thus, in such conventional method, it is relatively easy for the lining melt to enter between the carpet cloth stiches. This means that the melt is apt to deteriorate the carpet cloth thermally, coupled with the fact that the carpet cloth is a heat insulator. On the other hand, such a phenomenon leads to a further improvement of the bonding strength between the lining layer and the carpet cloth.
In the case of using a lining material whose melt viscosity is relatively low, if there is adopted a method wherein the lining material melted and applied onto the carpet cloth and the lining layer thickness is adjusted by pushing a doctor knife or the like against the lining layer, as in the foregoing conventional method, the melted lining material may flow too much and excessively permeate into the carpet cloth.
OBJECT OF THE INVENTION
It is the object of the present invention to provide a method for producing a tile carpet superior in both shape stability and dimentional stability and also superior in the bonding strength between a lining layer and a carpet cloth, further, capable of being easily laid on a floor, and which method permits adjustment to obtain a uniform thickness of the lining
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Japanese International Search Report.
Ganno Yasuhiko
Kajikawa Teruo
Takeda Junichi
Yonezawa Syuichi
Engel James
Helmer Steven J.
Nippon Petrochemicals Co. Ltd.
Suminoe Orimono Kabushiki Kaisha
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