Method for manufacturing a carpet

Abstract

The invention relates to a method for manufacturing a carpet (1) from different carpet pieces (2), comprising the steps: a) cutting the carpet pieces (2), b) removing protruding carpet fringes, c) arranging the carpet pieces (2) side by side, d) applying an adhesive strip (5a) to the long sides of the edges (3), and gluing the carpet pieces (2) together to form a pre-carpet (6), e) applying a first adhesive layer (5b) to the outer edges (7) of the back of the pre-carpet (6), f) folding the outer edge (7) inwards to form a folded edge (8), g) pressing the folded edge (8) to join the outer edges (7), h) shearing the carpet pile (9) of the folded edge (8) on the back of the pre-carpet (6), i) applying a second adhesive layer (5c) to the back of the pre-carpet (6), and applying a third adhesive layer (5d) to a volume fleece (9).j) Gradually applying the adhesive side (10) of the volume fleece (9) to the back of the pre-carpet (6) and smoothing the applied volume fleece (9).

Description

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

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

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

[0004] The object of the present invention is therefore to at least partially or completely overcome the disadvantages of the prior art. A further object can be seen in providing a simple and rapid method for enabling different carpet qualities in one carpet. A further object can be seen in providing a cost-effective method for producing high-quality carpets with different carpet qualities.

[0005] These and other tasks are carried out by a A method for producing a carpet according to claim 1 solved.

[0006] The inventive method to make a carpet from different carpet pieces includes the following steps.

[0007] In a first step, the carpet pieces are cut to the desired shape. In a next step, the excess carpet fringe on the edges of the carpet pieces is removed, preferably with scissors guided along the edges. The carpet pieces are lined up in a predetermined arrangement so that the carpet pieces butt together with their edges, forming a butt line. Furthermore, an adhesive strip is applied, preferably using a hot glue gun, to the long sides of the edges along the formed butt line, and the carpet pieces are glued together at their edges to form a front carpet. A first adhesive layer is applied to the outer edges on the back of the front carpet, over a width of approximately 8 to 10 cm.The outer edges are folded inwards over a width of approximately 8 to 10 cm to form a turned-up edge on the back of the front carpet with a width of approximately 4 to 5 cm. The turned-up edge is pressed down to ensure a firm and cohesive connection of the glued outer edges. Furthermore, the carpet pile of the turned-up edge is sheared on the back of the front carpet so that the remaining pile is approximately 3 mm long. A second adhesive layer is applied to the back of the front carpet, leaving out the turned-up edge. A third adhesive layer is applied to a volume fleece approximately 5 mm thick, with the third adhesive layer being applied to the short side of the volume fleece to form an adhesive side.The adhesive side of the volume fleece is gradually placed on the back of the carpet and the applied volume fleece is smoothed, with the edges of the volume fleece essentially flush with the turn-up edges.

[0008] The carpet pieces can be of various qualities, such as 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 are made can also differ. Common carpet fibers from which carpets are made are used, including synthetic fibers such as polyester, polyamide, polypropylene, or natural fibers such as wool. Furthermore, the carpet pieces can have different colors.

[0009] The carpet pieces are cut into the desired shape, preferably rectangular or square, but other shapes are not excluded. If the carpet pieces are rectangular, the excess carpet fringe is trimmed along the long edge, as these edges will be glued together in the subsequent steps.

[0010] The carpet pieces that are connected or glued together are called pre-carpets until the volume fleece is applied and the finished carpet is formed.

[0011] Gluing the carpet pieces together, along with the additional use of adhesive when creating the hems and applying the batting, ensures seamless connections and thus an attractive appearance. This also allows for quick processing of the carpet pieces into a pre-carpet and then into a carpet.

[0012] The hem should preferably be 4 to 5 cm wide to ensure a good bond and permanent gluing of the carpet pieces. If the width is too narrow, the adhesive bond may not be strong enough to permanently hold the hem together. A shearing machine, particularly a sheep shearing machine, is preferably used to trim the carpet pile. Trimming the hem ensures that the hem of the carpet lies flat on the floor after completion.

[0013] The wadding has two sides, one of which serves as an adhesive side for attachment to the backing of the pre-carpet, while the other side preferably has an adhesive backing, which forms the backing of the finished carpet and thus provides anti-slip properties. Smoothing the applied wadding is usually done manually with the flat of the hand and / or with a roller. After bonding, the wadding and the hem edge should preferably be flush and level with each other, so that the finished carpet lies flat on the floor.

[0014] Where appropriate, the carpet pieces are intended to have a maximum length of approximately 4 m and are preferably designed as rectangular strips.

[0015] This is advantageous because the carpet pieces are easy to handle up to 4 m long. Rectangular strips are particularly easy to string together and process.

[0016] If necessary, three to ten, preferably four to six, pieces of carpet are strung together. This is advantageous because it ensures sufficient stability of the finished carpet.

[0017] Where appropriate, the applied adhesive strips should each have a width of approximately 0.5 cm to 1 cm. The adhesive strips, preferably applied with a hot glue gun, must have a minimum width to achieve sufficient bonding performance. A width between 0.5 m and 1 cm has proven advantageous in practice. The cartridges used for hot-gluing are preferably made of the plastic ethylene-vinyl acetate (EVA). This has the advantage of being solvent-free.

[0018] If necessary, 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 edges are mitered at each corner. This allows the finished carpet to lie flat and level on the floor.

[0019] If necessary, a guide line 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 layer of adhesive to the outer edge and the folding of the outer edge.

[0020] If necessary, the adhesive layers are applied as a spray adhesive, using approximately 100 g of spray adhesive per m² of surface. This has proven advantageous in practice. It achieves a strong adhesive effect, allowing the components to be bonded to one another firmly and essentially permanently. The amount of adhesive is also selected to prevent excessive saturation of the fibers, which would prevent visual defects. A suitable spray adhesive is, for example, GLUKON Spray Adhesive Premium wmc from Böker Sprühklebersysteme GmbH.

[0021] If necessary, the hem edge is pressed together by repeated blows with a rubber hammer at a pressure of approximately 3 kg / cm², followed by additional manual pressing and / or pressing with a roller. This procedure has proven advantageous in practice for a firm and positive-locking connection.

[0022] If necessary, the turn-up edge is sheared with a sheep shearing machine, with each section of the turn-up edge being sheared once or twice. Sheep shearing machines are robust and suitable for precise work, even with dense fibers.

[0023] If necessary, the third adhesive layer and the bonding of the tufting to the back of the carpet should be applied in stages, for example, in increments of approximately 20 to 40 cm. This allows for more precise work and prevents unevenness during bonding. Working in stages also makes it easier to smooth the tufting with the flat of your hand and / or a roller.

[0024] If necessary, the glued-on interfacing may be trimmed, preferably with a carpet knife. This allows the applied interfacing to be cut so that it sits flush with the folded edge on the back of the carpet.

[0025] The invention further relates to a carpet produced by a method according to the invention.

[0026] Where appropriate, the various pieces of carpet may differ from one another in terms of colour, material and / or method of manufacture.

[0027] The invention will now be explained in more detail using non-exclusive embodiments. Figure 1a shows a schematic representation of a carpet from above, which was produced according to a method according to the invention. Figure 1b shows a schematic representation of a carpet from below, which was produced according to a method according to the invention. Figure 2 shows a schematic side view of a carpet produced according to a method according to the invention.

[0028] Figures 1a and 1bshow a schematic representation of a carpet 1 produced according to a method according to the invention. The front side of the carpet 1 is formed from five rectangular carpet pieces 2, each of which has a different color and / or a different 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 strip-shaped pattern of carpet pieces 2 with different carpet qualities.

[0029] On the back, the carpet 1 has folded edges 8, which are trimmed at the corners so that the folded edges 8 are mitered to one another. The folded edge 3 has a thickness of approximately 5 mm. The carpet backing further comprises an adhesive-bonded fleece 10 that has been positively fitted into the back defined by the folded edge 8, so that the folded edge 8 and the fleece 10 are flush with one another. The fleece 10 has non-slip properties on the outward-facing side and is approximately 5 mm thick.

[0030] When the carpet 1 is laid on the floor, it lies flat or level 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.

[0031] Figure 2shows 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.

[0032] Carpet 1 is made from four different carpet pieces 2 of varying qualities. The carpet pieces 2 are of the velour, shag, Saxony, or loop pile type, with each carpet piece 2 having a different total pile height, ranging between 13 and 20 mm, and each of the carpet pieces 2 also having a different color. The material of the carpet yarns used for the carpet pieces 2 is natural fiber, polyester, or polyamide. Using a carpet knife, the various carpet pieces 2 are cut into rectangular strips of various widths. The length of the carpet pieces is 2 m and the width of the various carpet pieces 2 is between 50 cm and 1.5 m.

[0033] The strips are placed next to each other on a color template on a work table, pile side down. After checking the arrangement and size, processing begins. The protruding fringes of the carpet pile 9 are trimmed from the long edges of the carpet strips using 25 cm long scissors. To do this, the scissors are guided along the carpet edge.

[0034] The strips are placed side by side on the work table, forming a butt line 4 between the carpet pieces 2 that are adjacent along their long sides. The carpet pieces 2 are carefully glued together along the butt line 4 using a hot glue gun. To do this, the hot glue gun is guided along the butt line 4 and a line of adhesive approximately 1 cm wide is applied.

[0035] Once all carpet pieces 2 have been glued together, a so-called front carpet 6 (not shown) is created. Now, using a spacing template, an auxiliary line is drawn on the back of the front carpet 6 along the (not shown) outer edges 7 at a distance of 10 cm from all four edges 3 of the front carpet 6. These auxiliary lines intersect near the corners of the front carpet 6. At this intersection, the corners of the front carpet 6 are cut off at a 45° angle to the auxiliary line using a carpet knife, so that the edges 3 of the front carpet 6 are mitred in the corners after folding over.

[0036] The 10 cm wide area of ​​the outer edge 7 of the pre-carpet 6 is sprayed with Glukon Spray Adhesive Premium wmc using a gun in a thin first adhesive layer 5b at a consumption of approximately 100 g / m². The outer edge 7 is then bent inward by hand and pressed onto the back along the auxiliary line so that two adhesive-coated surfaces lie on top of each other. This also creates a turn-up edge 8 with a width of approximately 5 cm. A rubber hammer weighing approximately 1 kg, with a head diameter of 5 cm and a length of 8 cm, is then used to hammer the turn-up edge 8. Per meter, approximately 25 blows are applied to the turn-up edge 8, applying a pressure of approximately 3 kg / cm². The turn-up edge 8 is then checked by hand and carefully pressed down to ensure that there are no uneven areas and that a firm, cohesive bond is ensured.

[0037] Using a sheep shearing machine, 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 front carpet 6. To do this, the sheep shearing machine is moved along the carpet 1 from right to left at an approximately 45° angle to the back of the carpet. Each area is sheared once or twice as needed. At the corners, shearing is done from the inside out. Loose pile hairs are removed with a suitable vacuum cleaner.

[0038] Now a 5 mm thick volume fleece 10 is glued to the back of the front carpet 6. The volume fleece 10 provides additional stability and fixes the glued carpet pieces 2 together. It also gives the finished carpet 1 a visually appealing backing. The back of the front carpet 6 is sprayed with spray adhesive (consumption 100 g / m²< ), so that a second adhesive layer 5c is formed. The folded edge 8, however, is left out. The volume fleece 10 is sprayed with a third adhesive layer 5d along its entire length over a width of approximately 50 cm, so that an adhesive side 11 is created. The adhesive side 11 of the volume fleece 10 is placed on the second adhesive layer 5c on the back of the front carpet 6. Then the next 50 cm wide strip of the volume fleece 10 is sprayed step by step with adhesive and placed on the back of the front carpet 6.The applied areas are each smoothed by hand so that the backing of the pre-carpet 6 and the volume fleece 10 are firmly bonded together. These steps are repeated until the entire backing is bonded to the volume fleece 10, creating a finished carpet 1.

[0039] The protruding volume fleece 10 is pressed down as close as possible to the edge 3 of the turn-up edge 8 and cut off so that the volume fleece 10 and turn-up edge 8 are flush with each other, forming a flat or level carpet backing. Additionally, a label loop and an adhesive label with information can be applied to the carpet backing.

[0040] 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 back of the carpet, the carpet 1 lies flat on the floor, preventing any gaps from forming between the floor and the carpet 1.

[0041] The invention is not limited to the described embodiments, but encompasses all processes within the scope of the following patent claims and the carpets produced thereby. List of reference symbols

[0042] 1Carpet 2Carpet piece 3Edge 4Joint line 5aAdhesive strip 5b, 5c, 5dAdhesive layer 6Front carpet 7Outer edge 8Folded edge 9Carpet pile 10Volume fleece 11Adhesive side

Claims

1. Proceedingsfor producing a carpet (1) from different carpet pieces (2), comprising the steps: a) cutting the carpet pieces (2) into a desired shape, b) removing protruding carpet fringes on the edges (3) of the carpet pieces (2), preferably with scissors guided along the edges (3), c) lining up the carpet pieces (2) in a predetermined arrangement so that the carpet pieces (2) abut one another with their edges (3), thus forming a butt line (4) between the carpet pieces (2), d) applying an adhesive strip (5a), preferably using a hot glue gun, to the long sides of the edges (3) along the formed butt line (4), and gluing the carpet pieces (2) at their edges (3) to form a front carpet (6), e) applying a first adhesive layer (5b) to the outer edges (7) on the back of the front carpet (6), over a width of approximately 8 to 10 cm,f) Fold the outer edge (7) inwards over a width of approximately 8 to 10 cm, so that a , Envelope edge (8) is formed on the back of the front carpet (6), which has a width of approximately 4 to 5 cm, g) pressing the turned-up edge (8) for the cohesive and firm connection of the glued outer edges (7), h) shearing the carpet pile (9) of the turned-up edge (8) on the back of the front carpet (6) so that the remaining pile has a length of less than approximately 3 mm, i) applying a second adhesive layer (5c) on the back of the front carpet (6), leaving the turned-up edge (8) out, and applying a third adhesive layer (5d) on a Volume fleece(10) of approximately 5 mm thickness, so that an adhesive side (11) is formed, j) gradually laying the adhesive side (11) of the volume fleece (10) on the back of the front carpet (6) and smoothing the laid-on volume fleece (9), the edges of the volume fleece (10) being substantially flush with the turn-up edges (8).

2. 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. Method according to claim 1 or 2, characterized in that three to ten, preferably four to six carpet pieces (2) are lined up together.

4. Method according to one of claims 1 to 3, characterized in that the applied adhesive strips (5a) each have a width of approximately 0.5 cm to 1 cm.

5. Method according to one of claims 1 to 4, characterized in thatthe corners of the outer edges (7) of the front carpet (6) are cut at an angle of approximately 45°, so that when the outer edges (7) are turned over, the turning edge (8) is mitred at the corners.

6. Method according to one of claims 1 to 5, characterized in that an auxiliary line is drawn at a distance of 8 to 10 cm along the outer edge (7) of the preliminary carpet (6), so that the application of the first adhesive layer (5b) to the outer edge (7) and the folding of the outer edge (7) is facilitated.

7. Method according to one of claims 1 to 6, characterized in that the adhesive layers (5b, 5c, 5d) are applied as a spray adhesive, and about 100 g of spray adhesive per m 2 area can be used.

8. Method according to one of claims 1 to 7, characterized in that pressing the cover edge (8) by repeated blows with a rubber hammer with a contact pressure of about 3 kg / cm 2and additionally subsequent manual pressing and / or pressing with a roller.

9. Method according to one of claims 1 to 8, characterized in that the turn-up edge (8) is sheared with a sheep shearing machine, each point of the turn-up edge (8) being sheared one or two times.

10. Method according to one of claims 1 to 9, characterized in that the application of the third adhesive layer (5d) and the bonding of the volume fleece (9) to the back of the preliminary carpet (6) is carried out step by step, for example in steps of approximately 20 to 40 cm.

11. Method according to one of claims 1 to 10, characterized in that the glued-on volume fleece (9) is cut to size, preferably with a carpet knife.

12. Carpet (1) which is produced according to a process according to any one of claims 1 to 11.

13. Carpet (1) according to claim 12, characterized in thatthe different pieces of carpet (2) differ from one another in their colour, material and / or method of manufacture.

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