Process of thermal transfer using hot melt adhesive lamination for forming a carpet backing and finished carpet or tile product

Inactive Publication Date: 2006-04-13
DONEY GRANT WILLIAM
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0021] It therefore would be desirable to bind a greige carpet with a secondary backing material using a hot melt adhesive in a single-pass process that provides for excellent penetration of the hot melt adhesive into the yarn fiber tufts of the greige carpet while minimizing s

Problems solved by technology

However, such an adhesive often does not have adequate mechanical strength to impart dimensional stability to the greige carpet.
Higher process temperatures may cause the greige carpet to shrink and may damage the primary backing material and fiber tufts, resulting in a loss of finished carpet and increased manufacturing costs.
The dichotomy between low viscosity and low application temperature sometimes makes application of hot melt adhesives difficult.
Nipping at pressures, however, may

Method used

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  • Process of thermal transfer using hot melt adhesive lamination for forming a carpet backing and finished carpet or tile product
  • Process of thermal transfer using hot melt adhesive lamination for forming a carpet backing and finished carpet or tile product
  • Process of thermal transfer using hot melt adhesive lamination for forming a carpet backing and finished carpet or tile product

Examples

Experimental program
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Effect test

example 1

[0064] Beaulieu straight stitched greige carpet type, 24 inches wide was provided. Secondary backing material comprising heat set PET woven fibers with 45 threads per inch count in both the warp and weft directions was also provided (commercially available from Alice Manufacturing). Hot melt adhesive produced from PET modified with a modifying formulation in accordance with U.S. application Ser. No. 10 / 827,028 filed on Apr. 19, 2004, was provided. The hot melt adhesive had a viscosity of 35 centipoise at 325° F. and was mixed at equal parts per weight with a magnetite filler. The heating vessel and heated extrusion die were heated to 325° F. The heated application roll and heated doctor bar were heated to 335° F. The heated doctor bar was set 65 thousandths of an inch from the surface of the secondary backing material. The first unheated nip roll was set at a 250 thousandths of an inch gap from the heated application roll. The second unheated nip roll was set at a 90 thousandths of ...

example 2

[0065] Beaulieu straight stitched greige carpet type, 24 inches wide was provided. Secondary backing material comprising heat set PET woven fibers with 45 threads per inch count in both the warp and weft directions was also provided (commercially available from Alice Manufacturing). The hot melt adhesive described in Example 1 was used. The hot melt adhesive had a viscosity of 30 centipoise at 325° F. and was mixed at equal parts per weight with the same magnetite filler used in Example 1. The heating vessel and heated extrusion die were heated to 335° F. The heated application roll and heated doctor bar were heated to 340° F. The heated doctor bar was set 65 thousandths of an inch from the surface of the secondary backing material. The first unheated nip roll was set at a 250 thousandths of an inch gap from the heated application roll. The second unheated nip roll was set at a 90 thousandths of an inch gap from the heated application roll. The idler tension roll was set at a ¾ inch...

example 3

[0066] Beaulieu straight stitched greige carpet type, 24 inches wide was provided. Secondary backing material comprising heat set PET woven fibers with 45 threads per inch count in both the warp and weft directions also was provided (commercially available from Alice Manufacturing). The hot melt adhesive described in Example 1 was used. The hot melt adhesive had a viscosity of 25 centipoise at 325° F. and was mixed at equal parts per weight with the same magnetite filler used in Example 1. The heating vessel and heated extrusion die were heated to 325° F. The heated application roll and heated doctor bar were heated to 330° F. The heated doctor bar was set 65 thousandths of an inch from the surface of the secondary backing material. The first unheated nip roll was set at a 250 thousandths of an inch gap from the heated application roll. The second unheated nip roll was set at a 90 thousandths of an inch gap from the heated application roll. The idler tension roll was set at a ¾ inch...

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Abstract

A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.

Description

[0001] This application claims priority to provisional application Ser. No. 60 / 614,966, filed Oct. 4, 2004, entitled, “Process of Thermal Transfer Using Hot Melt Adhesive Lamination for Forming a Carpet Backing and Finished Carpet or Tile Product,” Ser. No. ______ attorney docket No. 62136.000032, the disclosure of which is incorporated by reference herein in its entirety.FIELD OF THE INVENTION [0002] Embodiments of the invention relate generally to finishing systems for tufted primary backing carpets and more specifically to systems that bind greige carpet and secondary backing material using hot melt adhesives. DESCRIPTION OF RELATED ART [0003] The primary component of conventional broadloom carpet products such as carpet tiles is tufted “greige” carpet. Greige carpet generally comprises fiber tufts looped around a primary backing fabric. Primary backing fabrics may be woven, nonwoven, or spun bonded natural or synthetic materials. The tufted loops of fiber may be left intact or s...

Claims

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Application Information

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IPC IPC(8): D05C15/00
CPCB32B37/06Y10T156/10B32B37/1284B32B2037/1215B32B2471/02D05C15/00D06N2203/042D06N2201/0263D06N2201/02D06N7/0078D06N2209/1678D06N2203/061D06N2209/1628D06N2201/042D06N2209/067D06N2205/06D06N2209/1671D06N2201/0245D06N2203/065B32B37/08
Inventor DONEY, GRANT WILLIAM
Owner DONEY GRANT WILLIAM
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