METHOD FOR MAKING A CARPET

Description

[0001] The invention relates to a method for manufacturing a carpet from different carpet pieces.

[0002] Carpets with varying pile heights and / or made up of carpet pieces of different quality are typically produced using hand-tufting techniques. While this allows for highly individualized carpets, the process is complex, time-consuming, and expensive.

[0003] Machine-tufted carpets typically have a homogeneous pile height and quality, as producing different pile heights and qualities is technically complex and therefore expensive. Machine-tufted carpets therefore usually have a uniform pile height and quality, although different pile heights can be created later by shearing the carpet pile. However, this results in additional waste.

[0004] DE 295 17 475 U1 discloses a known method for manufacturing a carpet from different pieces of carpet.

[0005] The object of the present invention is therefore to overcome the disadvantages of the prior art, at least partially or completely. A further object may be seen in providing a simple and quick method for enabling different carpet qualities within a single carpet. Another object may be seen in providing a cost-effective method for manufacturing high-quality carpets with different carpet qualities.

[0006] These and other tasks are performed by a Method for manufacturing a carpet according to claim 1 solved.

[0007] The inventive method The process of making a carpet from different carpet pieces includes the following steps.

[0008] In a first step, the carpet pieces are cut into the desired shape. In a further step, the excess carpet fringe is removed from the edges of the carpet pieces, preferably with scissors guided along the edges. The carpet pieces are then arranged in a predetermined pattern so that their edges butt against each other, forming a butt joint. Next, a strip of adhesive, preferably applied with a hot glue gun, is applied to the long sides of the edges along the butt joint, and the carpet pieces are glued together at their edges to form a backing. A first layer of adhesive is applied to the outer edges on the back of the backing, over a width of approximately 8 to 10 cm.The outer edges are folded inwards over a width of approximately 8 to 10 cm, creating a folded edge on the back of the undercarriage that is about 4 to 5 cm wide. This folded edge is pressed down to create a tight and secure bond between the glued outer edges. Next, the carpet pile of the folded edge on the back of the undercarriage is sheared, leaving a pile length of approximately 3 mm. A second layer of adhesive is applied to the back of the undercarriage, leaving the folded edge uncovered. A third layer of adhesive is applied to a 5 mm thick wadding, specifically to the short side of the wadding, creating a bonded surface.The adhesive side of the volume fleece is gradually applied to the back of the carpet and the applied volume fleece is smoothed, with the edges of the volume fleece being essentially flush with the folded edges.

[0009] The carpet pieces can have different carpet qualities, for example, velour, shag, or Saxony. In the context of the present invention, the term "carpet quality" refers to the manufacturing method and the resulting pile of the carpet piece—such as velour, shag, Saxony, or loop pile. The materials from which the carpet fibers of the carpet pieces are made can also differ. Common carpet fibers used in carpet production include synthetic fibers such as polyester, polyamide, and polypropylene, as well as natural fibers such as wool. Furthermore, the carpet pieces can be of different colors.

[0010] The carpet pieces are cut into the desired shape, preferably rectangular or square, although other shapes are not excluded. If the carpet pieces are rectangular, the excess fringes are trimmed along the long edge, as these edges will be glued together in subsequent steps.

[0011] The carpet pieces that are joined or glued together are called a pre-carpet until the volume fleece is applied and the finished carpet is formed.

[0012] Gluing the carpet pieces together and using adhesive for the folded edges and applying the backing ensures seamless connections and an attractive appearance. This also allows for quick processing of the carpet pieces into a base layer and then into a finished carpet.

[0013] The folded edge preferably has a width of 4 to 5 cm to ensure good adhesion and a durable bond between the carpet pieces. If the width is too narrow, the adhesive bond might not be strong enough to hold the folded edge together permanently. A shearing machine, particularly a sheep shearing machine, is preferably used to shear the carpet pile. Shearing the folded edge ensures that the finished carpet lies flat on the floor.

[0014] The loft fleece has two sides: one side is designed as an adhesive surface for attaching it to the back of the carpet, and the other side preferably has a bonding agent that forms the carpet backing in the finished carpet, thus providing non-slip properties. The applied loft fleece is typically smoothed manually with the flat of the hand and / or with a roller. After bonding, the loft fleece and the folded edge preferably meet flush and in the same plane, so that the finished carpet lies flat on the floor.

[0015] If necessary, the carpet pieces are provided to have a maximum length of approximately 4 m and are preferably designed as rectangular strips.

[0016] This is advantageous because the carpet pieces are easy to handle up to a length of 4 meters. Rectangular strips are particularly easy to join together and process further.

[0017] If necessary, three to ten, preferably four to six, carpet pieces are arranged side by side. This is advantageous because it ensures sufficient stability of the finished carpet.

[0018] The adhesive strips may be applied with a width of approximately 0.5 cm to 1 cm. These strips, preferably applied with a hot glue gun, must have a minimum width to achieve sufficient adhesion. A width between 0.5 cm and 1 cm has proven advantageous in practice. The cartridges used for hot gluing are preferably made of ethylene-vinyl acetate (EVA). This material has the advantage of being solvent-free.

[0019] If necessary, the corners of the outer edges of the pre-carpet are cut at an angle of approximately 45°, so that when the outer edges are folded over, the folded edge at the corners is mitered. This allows the finished carpet to lie flat and evenly on the floor.

[0020] If necessary, a guideline is drawn at a distance of 8 to 10 cm along the outer edge of the pre-carpet to facilitate the application of the first adhesive layer to the outer edge and the folding over of the outer edge.

[0021] If necessary, the adhesive layers are applied as a spray adhesive, using approximately 100 g of spray adhesive per m². This has proven advantageous in practice. It achieves a high adhesive strength, ensuring that the components to be bonded are firmly and essentially permanently joined. The amount of adhesive is also carefully selected to prevent over-saturation of the fibers, thus avoiding any visual defects. A suitable spray adhesive is, for example, GLUKON Premium wmc spray adhesive from Böker Sprühklebersysteme GmbH.

[0022] If necessary, the folded edge is pressed down by repeated blows with a rubber mallet at a pressure of approximately 3 kg / cm², followed by manual pressing and / or pressing with a roller. This procedure has proven advantageous in practice for a firm and positive-locking connection.

[0023] If necessary, the folded edge will be sheared with sheep shearing machines, with each section of the folded edge being sheared once or twice. Sheep shearing machines are robust and suitable for precise work, even with dense fibers.

[0024] If necessary, the application of the third adhesive layer and the bonding of the volume fleece to the back of the underlayment can be carried out in stages, for example, in increments of approximately 20 to 40 cm. This allows for more precise work and prevents unevenness during application. Working in stages also makes it easier to smooth the volume fleece with the flat of the hand and / or a roller.

[0025] If necessary, the glued-on volume fleece is to be cut to size, preferably with a utility knife. This allows the applied volume fleece to be trimmed so that it is flush with the folded edge on the carpet backing.

[0026] The invention further relates to a carpet which is manufactured using a method according to the invention.

[0027] It may be intended that the different carpet pieces differ from each other in their color, material and / or manufacturing method.

[0028] The invention will now be explained in more detail using non-exclusive exemplary embodiments.

[0029] Figure 1a shows a schematic representation of a carpet from above, which was produced according to a method according to the invention.

[0030] Figure 1b shows a schematic representation of a carpet from below, which was produced according to a method according to the invention.

[0031] Figure 2 shows a schematic side view of a carpet produced according to a method according to the invention.

[0032] Figures 1a and 1bFigure 1 shows a schematic representation of a carpet 1 produced according to the invention. The front of the carpet 1 is formed from five rectangular carpet pieces 2, each of which has a different color and / or carpet quality. The total pile height of the respective carpet pieces 2 is between 13 mm and 20 mm. The carpet pieces 2 are glued together along their long edges by adhesive strips 5a, creating a striped pattern of carpet pieces 2 with different carpet qualities.

[0033] On the reverse side, the carpet has 1 folded edges 8, which are cut at the corners so that the folded edges 8 are mitered together. The folded edge 3 is approximately 5 mm thick. The carpet backing also includes an adhered volume fleece 10, which is fitted into the back surface defined by the folded edge 8, so that the folded edge 8 and the volume fleece 10 are flush. The volume fleece 10 has non-slip properties on its outward-facing side and is approximately 5 mm thick.

[0034] When the carpet 1 is laid on the floor, it lies flat or even on the floor without forming any unevenness due to the same thickness of the folded edge 8 and the volume fleece 10 and the precise fitting of the volume fleece 10.

[0035] Figure 2Figure 1 shows a schematic side view of a carpet 1 produced according to a method according to the invention. The method for producing this carpet 1 is explained below.

[0036] Carpet 1 is made from four different carpet pieces 2 with varying qualities. The carpet pieces 2 are of the velour, shag, Saxony, or loop pile type, each with a different total pile height between 13 and 20 mm and a different color. The carpet yarns used for the carpet pieces 2 are natural fiber, polyester, or polyamide. Using a carpet knife, the different carpet pieces 2 are cut into rectangular strips of varying widths, with each carpet piece 2 being 2 m long and 50 cm to 1.5 m wide.

[0037] The strips are laid side by side on a color template on a worktable, pile side down. After checking the arrangement and size, processing begins. Using 25 cm long scissors, the excess fringe of the carpet pile is cut off along the long edges of the carpet strips. The scissors are guided along the edge of the carpet to do this.

[0038] The strips lie side by side on the worktable, so that a butt joint 4 is formed by the carpet pieces 2 that abut each other along their long sides. The carpet pieces 2 are carefully glued together at the butt joint 4 using a hot glue gun. To do this, the hot glue gun is guided along the butt joint 4 and a bead of glue approximately 1 cm wide is applied.

[0039] Once all the carpet pieces 2 are glued together, a so-called (not shown) pre-carpet 6 is created. Now, using a spacing template, a guideline is drawn on the back of the pre-carpet 6 along the (not shown) outer edges 7 at a distance of 10 cm from all four edges 3 of the pre-carpet 6. These guidelines intersect near the corners of the pre-carpet 6. At this intersection, the corners of the pre-carpet 6 are cut at a 45° angle to the guideline using a carpet knife, so that the edges 3 of the pre-carpet 6 are mitered at the corners after being folded over.

[0040] The 10 cm wide area of ​​the outer edge 7 of the carpet 6 is sprayed with Glukon Premium wmc spray adhesive using a spray gun to apply a thin first layer of adhesive 5b at a consumption of approximately 100 g / m². The outer edge 7 is then folded inwards by hand and pressed along the guideline onto the back side, so that two adhesive-coated surfaces meet. This also creates a folded edge 8 approximately 5 cm wide. A rubber mallet weighing approximately 1 kg with a head diameter of 5 cm and a length of 8 cm is then used to hammer the folded edge 8. Approximately 25 blows per meter are applied, with a pressure of approximately 3 kg / cm². The folded edge 8 is then checked by hand and carefully pressed down to ensure that there are no irregularities and that a firm, bonded connection has been achieved.

[0041] Using sheep shears, the carpet pile 9 is sheared to a length of 3 mm along the 5 cm wide folded edge 8 on the back of the undercarriage 6. The sheep shears are guided along the carpet 1 from right to left at approximately a 45° angle to the back of the carpet. Each section is sheared once or twice as needed. At the corners, shearing is done from the inside out. Loose pile hairs are vacuumed up with a suitable vacuum cleaner.

[0042] Now, a 5 mm thick volume fleece 10 is glued to the back of the undercarriage 6. The volume fleece 10 provides additional stability and fixes the glued carpet pieces 2 together. It also gives the finished carpet 1 an aesthetically pleasing backing. The back of the undercarriage 6 is sprayed with spray adhesive (consumption 100 g / m²) to form a second adhesive layer 5c. The folded edge 8 is left uncovered. The volume fleece 10 is sprayed with a third adhesive layer 5d along its entire length and to a width of approximately 50 cm, creating an adhesive surface 11. The adhesive surface 11 of the volume fleece 10 is placed onto the second adhesive layer 5c on the back of the undercarriage 6. Then, the next 50 cm wide strip of the volume fleece 10 is sprayed with adhesive and placed onto the back of the undercarriage 6.The applied areas are each smoothed by hand so that the backing of the underlay 6 and the volume fleece 10 are bonded together tightly and securely. These steps are repeated until the entire backing is bonded to the volume fleece 10, resulting in a finished carpet 1.

[0043] The excess volume fleece 10 is pressed down as close as possible to the edge 3 of the folded edge 8 and cut off, so that the volume fleece 10 and folded edge 8 are flush with each other, forming a flat carpet backing. Additionally, a label loop and an adhesive label with information can be applied to the carpet backing.

[0044] The finished carpet 1 can now be laid on the floor. Thanks to the combination of the folded edge 8 and the volume fleece 10 on the carpet backing, the carpet 1 lies flat and level on the floor, and no gaps are formed between the floor and the carpet 1.

[0045] The invention is not limited to the described embodiments, but is defined by the attached claims. Reference symbol list

[0046] 1 Carpet 2 Carpet piece 3 Edge 4 Butt joint 5a Adhesive strip 5b, 5c, 5d Adhesive layer 6 Backing carpet 7 Outer edge 8 Folded edge 9 Carpet pile 10 Volume fleece 11 Adhesive side

Claims

1. A method for producing a carpet (1) from various carpet pieces (2) comprising the steps of: a) cutting the carpet pieces (2) into a desired shape, b) removing projecting carpet fringes at the edges (3) of the carpet pieces (2), preferably using scissors, which are guided along the edges (3), c) arranging the carpet pieces (2) in a row in a predefined arrangement such that the edges (3) of the carpet pieces (2) abut each other, thereby forming an abutment line (4) between the carpet pieces (2), d) applying an adhesive strip (5a), preferably by means of a hot glue gun, to the long sides of the edges (3) along the formed abutment line (4), and gluing the carpet pieces (2) at their edges (3) to form a preliminary carpet (6), e) applying a first adhesive layer (5b) to the outer edges (7) on the back side of the preliminary carpet (6) at a width of about 8 to 10 cm, f) folding the outer edge (7) inward by a width of about 8 to 10 cm, such that a fold-over edge (8) is formed on the back side of the preliminary carpet (6), which has a width of about 4 to 5 cm, g) pressing the fold-over edge (8) to form a material bond and firm bond of the glued outer edges (7), h) shearing the carpet pile (9) of the fold-over edge (8) on the back side of the preliminary carpet (6), such that the remaining pile is less than about 3 mm, i) applying a second adhesive layer (5c) on the back side of the preliminary carpet (6), the fold-over edge (8) being left out, and applying a third adhesive layer (5d) to a volume fleece (10) having a thickness of about 5 mm, thereby forming an adhesive side (11), j) successively placing the adhesive side (11) of the volume fleece (10) onto the back side of the preliminary carpet (6) and smoothing the placed volume fleece (10), the edges of the volume fleece (10) being essentially flush with the fold-over edges (8).

2. The method according to claim 1, characterized in that the carpet pieces (2) have a maximum length of about 4 m and are preferably formed as rectangular strips.

3. The method according to any one of claims 1 or 2, characterized in that three to ten, preferably four to six carpet pieces (2), are lined up next to each other.

4. The method according to any one of claims 1 to 3, characterized in that each of the applied adhesive strips (5a) has a width of about 0.5 cm to 1 cm.

5. The method according to any one of claims 1 to 4, characterized in that the corners of the outer edges (7) of the preliminary carpet (6) are cut off at an angle of about 45°, such that when folding over the outer edges (7) the fold-over edge (8) lies mitered at the corners.

6. The method according to any one of claims 1 to 5, characterized in that an auxiliary line is drawn spaced 8 to 10 cm from the outer edge (7) of the preliminary carpet (6), thereby facilitating the application of the first adhesive layer (5b) to the outer edge (7) and the folding over the outer edge (7).

7. The method according to any one of claims 1 to 6, characterized in that the adhesive layers (5b, 5c, 5d) are applied as spray adhesive, and about 100 g spray adhesive per m2 of surface area is used.

8. The method according to any one of claims 1 to 7, characterized in that pressing the fold-over edge (8) is carried out by repeated strikes with a rubber mallet at an application pressure of about 3 kg / cm2, followed by additional manual pressing and / or pressing with a roller.

9. The method according to any one of claims 1 to 8, characterized in that the fold-over edge (8) is sheared using a sheep shearing machine, each position of the fold-over edge (8) being sheared one to two times.

10. The method according to any one of claims 1 to 9, characterized in that the application of the third adhesive layer (5d) and the gluing of the volume fleece (10) to the back side of the preliminary carpet (6) is performed stepwise, for example in steps of about 20 to 40 cm.

11. The method according to any one of claims 1 to 10, characterized in that the glued volume fleece (9) is cut, preferably with a carpet knife.

12. A carpet (1) produced in accordance with a method according to any one of claims 1 to 11.

13. The carpet (1) according to claim 12, characterized in that the various carpet pieces (2) differ from one another in their colour, material and / or manufacturing process.