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Carpet compositions having laminated film backings and methods for making same

a technology of laminated film backing and carpet composition, which is applied in the field of carpet compositions and carpet products, can solve the problems of large production lines, difficult recycling, and high cost of manufacturing processes

Inactive Publication Date: 2019-11-21
COLUMBIA INSURANCE CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention is a carpet that has a certain design on its backside. To create this design, there is a layer of fibers attached to a primary backing with a portion of the fibers on the back surface and another portion on the face surface. These fibers are secured in place by a film that is laminated onto the backside. The technical effect of this design is that it provides a more visually appealing carpet with a unique textured backside.

Problems solved by technology

These conventional carpet coatings are expensive, difficult to recycle, and, in some cases, their use results in low strength, and often require large production lines and costly manufacturing processes.

Method used

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  • Carpet compositions having laminated film backings and methods for making same
  • Carpet compositions having laminated film backings and methods for making same
  • Carpet compositions having laminated film backings and methods for making same

Examples

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Effect test

example 1

[0153]The inventive turf composition was prepared according to the aspects described above. In this example, the inventive film used for lamination was an engineered film having a thickness of 5 mil or 0.005 inch and comprised of three layers with the outer layers comprising polyethylene and the inner layer comprising polypropylene. The backstitches were preheated using IR radiation immediately prior to lamination. It is understood that other types of preheat can be also utilized. The lamination was performed at 5-10 FPM, preheat temperature in a range from about 200° F. to about 260° F., lamination temperature of about 346° F., pressure of about 100 psi, and a lamination gap of 10-20 thousandth of inch (10-20 mils). The performance of the inventive carpet composition having a film laminated to the backstitches was compared to a number of the carpet compositions having their backstitches locked in place by other known in the art methods. The carpet compositions tested and compared t...

example 2

[0154]The inventive carpet compositions having the backstitches locked in place by a film lamination were made using various types of turfs. The tested turfs comprised a polypropylene woven primary backing, slit tape or monofilament yarn tufted into the primary backing to provide a turf having various face densities. Fresh Rye-polypropylene and Fresh-Rey polyethylene samples refer to the turf samples having a polymer type of the relaxed thatch yarn that makes turf appearance more similar to natural grass. Performance data for such compositions was measured. The comparative results shown in Table 2 represent an average of multiple (minimum 5) measurements. Specifically, Table 2 shows tuft and slip bind strengths, along with grab / tear and dimensional stability properties for various inventive carpet compositions having their backstitches locked in place by laminating a film.

TABLE 2Performance data of the carpet compositions havinga laminated film on different turf types.FreshFreshFabr...

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Abstract

A carpet composition comprising a tufted yarn locked in place by a laminated film and methods of making same are disclosed.

Description

CROSS REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of priority to copending U.S. Provisional Patent Application No. 62 / 672,694, filed May 17, 2018. The entire disclosure of the aforementioned patent application is incorporated by reference herein.FIELD OF THE INVENTION[0002]The present invention pertains to carpets and carpet products having an improved recyclability and lower cost. The present invention further pertains to carpets and carpet products comprising a greige good and an adhesive layer. More particularly, the present invention pertains to carpets and carpet products where the adhesive layer is attached to the greige good by lamination and provides for locking of the turf fibers in place. The present invention further pertains to methods of making such carpet or carpet product as described herein.BACKGROUND OF THE INVENTION[0003]Most conventional carpets comprise a primary backing with yarn tufts in the form of cut or uncut loops extending up...

Claims

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Application Information

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IPC IPC(8): D06N7/00
CPCD06N7/0076D06N2203/041D06N2203/045D06N7/0068D06N7/0065D06N7/0081E01C13/08D06N7/0063A47G27/02B32B5/024B32B2250/40B32B27/308B32B2262/101B32B27/306B32B27/30B32B5/262B32B5/02B32B27/34B32B2307/5825B32B2272/00B32B2307/54B32B27/36B32B2307/734B32B3/085B32B27/12B32B2471/02B32B2307/732B32B5/022B32B5/263B32B2270/00B32B2262/0253B32B27/08B32B27/32B32B38/06Y10T428/23979D06N2203/065D06N2203/042D06N2203/061
Inventor COON, JEFFREY THOMASALDAHIR, PHILIPEFISHER, RACHEL
Owner COLUMBIA INSURANCE CO
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