Method of Producing a Carpet or Rug, and a Carpet or Rug Produced by Such Method

Abstract

A method of producing a carpet or rug pursuant to a tufting process, including tufting pile threads into a tuft substrate, and guiding the back side of the tuft substrate along while pressing the back side, together with the loops of the pile threads pierced through the tuft substrate, against a heated drum. At a predetermined temperature, the loops of the pierced-through pile threads begin to melt, and at a predetermined pressure are pressed flat against the tuft substrate.

Description

[0001]The instant application should be granted the priority date of 24 Oct. 2006, the filing date of the corresponding German patent application DE 10 2006 050 704.5.BACKGROUND OF THE INVENTION[0002]The present invention relates to a method of producing a carpet or rug pursuant to a tufting process, and also relates to a carpet or rug produced pursuant to such a method.[0003]Carpets or rugs manufactured using the tufting process serve primarily as design goods for flooring, for floor coverings in vehicles, or for similar purposes. In order to hold the loops of the pile threads that are pierced through the tuft substrate securely in place during the tufting process, a liquid or plastic, synthetic or natural adhesive / binder or latex is applied to the underside of the tuft substrate.[0004]The adhesive that is applied during the manufacture using the tufting process must be dried, for which purpose a large quantity of energy and time is required, and whereby, depending upon the type of...

AI Technical Summary

Benefits of technology

[0012]A satisfactory anchoring of the pile loops in the tuft substrate is achieved by the melting and pressing of the pile loops. The melted and pressed pile loops thus by themselves provide a satisfactory pile anchoring. Although a fusion of the pile loops with the tuft substrate is not necessary, it can, if desired, be achieved, for example in those cases where the pile and the tuft substrate are made of the same material. An adhesive layer for the pile binding can be entirely eliminated without limitation. An emission of noxious vapors is precluded. Furthermore, the quality of the carpet or rug is improved since the back side of the carpet or rug is smooth and has an increased flexibility. By pressing the loops of the pile threads that are pierced through the tuft substrate against the tuft substrate, it is possible, using the same length of threads, to achieve a higher pile layer than can be achieved with a carpet or rug that is provided with an adhesive layer, thus requiring less material for the manufacture of the carpet or rug.

Problems solved by technology

This reduces the ability of the carpet or rug to deform or be worked, which is a drawback in particular when it is to be used as a floor covering in vehicles.

The applied adhesive layer also has the aforementioned drawbacks with regard to drying and evaporation of noxious vapors.

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