Stock material or miscellaneous articles – Pile or nap type surface or component – Particular backing structure or composition
Patent
1995-07-28
1997-08-26
Morris, Terrel
Stock material or miscellaneous articles
Pile or nap type surface or component
Particular backing structure or composition
428 85, 28112, 156 72, 156148, B32B 302, B32B 516, D04H 146
Patent
active
056609116
DESCRIPTION:
BRIEF SUMMARY
This application is a .sctn.371 of international patent application No. PCT/EP93/00383, filed Dec. 2, 1993.
The invention relates to a tufted carpet or carpeting having tufted yarns tufted into a tufting backing and joined to it, and to a method for producing it.
Tufted carpets have a tufting backing and tufting yarns, tufted into it, which form loops on the back of the tufting backing. In a finished carpet, the loops are either left in that form or cut, then forming the carpet pile. The tufting yarns are tufted relatively loosely into the tufting backing and extend intermittently parallel to the plane of the tufting backing. To assure that the tufting yarns will be retained in the backing and will not pull out of it, such a carpet must be treated with latex. Latex coating systems are expensive, and in particular the actual latex coating process is followed by a complicating drying process. They require rooms of a size on the order of 8 m.times.40 m. A drying process presents problems of ventilation. In some cases, the operation of tuft insertion and coating with latex are even made separate from one another; that is, the tufted intermediate products are taken to a special coating system at a different place. This is disadvantageous and makes the production process of such carpets more expensive.
U.S. Pat. No. 4,705,706 discloses a tufted carpet in which the tufting backing comprises three backing layers, for the sake of firmly anchoring the tufting yarns. The solid connection of the tufted yarns to the backing is achieved by heating during the production process. The aforementioned tufting backing layers are needed to prevent the vulnerable carpet material from being destroyed by the effect of heat.
The object of the present invention is to embody a tufted carpet of this generic type such that no latex is needed in its manufacture. The method for producing such a carpet should be economical and simple, while avoiding the aforementioned disadvantages.
This object is attained by the invention as defined by the main claim. The process for producing such a carpet characterized in that pieces of plastic sheet material are applied uniformly to make a layer on the back side of a tufting backing tufted with tufting yarns and are joined to the tufting yarns and to one another under heat and pressure, causing firm binding in the back ends of the tufted yarns.
The heat and temperature may be applied by a warm rolling or pressing operation. The tufting backing may be needle-punched with binding fibers, in particular polyethylene binding fibers, prior to the tufting operation. The tufting backing may be provided with an adhesive layer prior to the tufting process.
Furthermore, a secondary backing may be applied to the layer of pieces of thermoplastic material and may be joined to the plastic sheet layer by means of a simultaneous or subsequent warm rolling or pressing operation, causing firm bonding of the back ends of the tufting yarns into the plastic sheet layer. That is, the object is attained by the tufted carpet or carpeting of the present invention which comprises a tufted primary backing having pile tufts extending from one side thereof with back ends of tufts on the opposite surface and thermally bonded to said opposite surface a layer composed of pieces of thermoplastic sheet material wherein the pieces of thermoplastic sheet material have been fused to the tufted backing under heat and pressure sufficient to embed said back ends in the layer and to the primary backing.
The tufted carpet according to the invention comprises a tufting backing, in which the tufting yarns, initially inserted loosely, are firmly anchored by the provision that their back ends are bound into a layer, disposed on the back of the tufting backing, of sheet-like plastic material in the form of piece goods, which has been made sticky by pressure and the effects of temperature. The tufting yarns are so firmly joined to the tufting backing that the addition of latex is no longer necessary, and the yarns do not pull out of the finished ca
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patent: 4035533 (1977-07-01), Chambley
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patent: 4294876 (1981-10-01), Camden et al.
patent: 4371576 (1983-02-01), Machell
patent: 5080951 (1992-01-01), Guthrie
patent: 5547731 (1996-08-01), Tesch
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