CONSTRUCTION OF CARPET AND CARPET BASES FOR THE SAMED E S C R I P C I O NField of the invention:This invention relates to carpets with tassels that are practically without thermoplastic components. The invention also relates to new primary and secondary carpet bases suitable for the manufacture of such carpets, comprising at least two layers of thermoplastic fabric, wherein one of The layers is made of a fusible thermoplastic adhesive. Furthermore, the invention also relates to a process for the manufacture of such carpets wherein the adhesive for joining the yarns of the front of the carpet with tassels to the primary base and also for attaching the secondary base to the primary base, is conveniently provided in the form of a fabric made from a fusible thermoplastic adhesive.
Background of the invention:The manufacture of carpets with tassels usually involves three basic operations: putting tassels to a primary base; wash, dye and dry the base with tassels; and then subjecting it to a finishing operation. The tassels are usually fixed by inserting needles threaded with reciprocating wires through the primary base to form tassels or yarn gauzes. Cursors or hooks, typically work in timed relationship with the needles, and are positioned in such a way that the deceptors are positioned just above the eye of the needle, when the needles are at an extreme point in their travel through the fabric of the needle. base. When the needles reach that point, the thread is picked up from the needles by the deceptors and held briefly. Gazas or tassels of thread, result from the return step of the needles through the primary base. Typically, this procedure is repeated when the gauzes move in the opposite direction of the deceptors due to the advance of the base through the needle apparatus. If desired, the gauzes can be cut to form a cut pile, for example, by using a combination of knife and cutter in the tasseling process.
Alternatively, the gauzes may remain uncut.
In 1992, total carpet production in the United States was 1.3 trillion square yards. Of that amount, 95% was made by the formation of tassels, with the remainder made by weaving. The main types of yarns of the front used in the manufacture of carpets with tassels are nylon yarns, normally composed of poly (epsilon-caprolactam). ) or poly (hexamethylene adipamide), also known as nylon 6 and nylon 6,6, respectively; propylene polymer yarns, typically propylene homopolymer compounds; and polyester threads, normally composed of polyethylene terephthalate. In 1993, according to Carpet & Ruy Industry. October 1993, page 6, the market for thread for the carpet front in the United States was projected up to approximately 2.7 billion pounds. The nylon yarns considered by approximately 68% of this market, polypropylene yarns for approximately 19% and polyester yarns considered for approximately 10%. Yarns of wool, cotton, acrylic and other yarns considered for approximately 3% of the total. In accordance with the above, it will be appreciated that the vast majority of carpets manufactured in the United States are carpets with tassels and that of all carpets with tassels, the vast majority are manufactured with thermoplastic threads facing.
The primary bases for tassel carpets are typically woven fabrics made of synthetic yarns, although non-woven fabrics can also be used. The most common synthetic material used in primary carpet bases is polypropylene, although it also finds use in polyester industry. Again, it will be appreciated that the vast majority of carpet bases with tassels are manufactured from thermoplastic materials.
The carpet finishing operation typically comprises the application of a latex binder (typically a filled thermosetting resin emulsion) and a secondary base. In accordance with "Carpet Laminatinop-Journal of Coated Fabrics, Volume 19, July 1989, pp. 35-52, the most typically used material for carpet base coating is styrene butadiene latex (SBR), usually carboxylated SBR. overwhelming majority of carpets with tassels, nowadays they are finished by rolling a baae secondary to the primary with tassels with latex.
More particularly, the finishing is typically done in the following manner: The back side is a carpet (ie, the hairless side) of a primary base for carpet is covered with a mixture containing latex (100 parts), ground lime or another filler in inert particles (300-500 parts) and processing aids such as surfactants, penetrants, defoamers, dispersants, chelating agents, stabilizers and thickeners (1 - 3 parts). Next, a woven polypropylene secondary base is attached to the primary base with back-coated tassels, passing the structure through a set of rollers, typically at the entrance to a large circulating air oven. The carpet stays stiff on a frame that stretches it with hooks as it passes through the oven, hardening the latex and carrying out the water. Then, the finished carpet comes out of the oven, cooled slightly by passing it over a series of rollers and then inspected and rolled up. Although there are different variations in this basic procedure, such as the use of a "double pallet" to apply the latex binder mixture in two applications (the mixture in each application has a different viscosity), regardless of the method of application, the total weight of latex binder, it is typically 25-30 ounces per square yard. A typical line speed through the drying oven is 75 * per min.
Latex binders dominate the carpet industry because of its ability to provide good performance properties at low cost. Among the properties provided by the latex binders to the final carpet product are a strong tassel joint, (anchorage of the yarn bundles), fraying resistance (resistance of the fibers in the bundles of yarns to be removed) and adhesion to the secondary base (sometimes referred to as delamination or resistance to hair loosening). These properties can be provided at a raw material cost for the latex binder mixture in roughly one cent per pound per square yard or 25 cents, approximately per square yard for a typical carpet.
Problems faced by the carpet industryBecause of the combination of economic and physical properties, the above-described method for making carpets is used in 80-90% of all carpets made in the U.S.A. However, this method for manufacturing carpets has both procedural and environmental disadvantages. On the procedural side, the method for manufacturing conventional carpets has the disadvantage of requiring a drying step for the latex to harden. The drying stage increases the cost of the carpet and limits the speed of production. In addition, the ovens used to dry latex are very expensive, costing several hundred thousand dollars in excess of one million dollars. Not only are the ovens the capital intensive equipment parts, but they also consume energy in operation. The above-described method for making carpets also requires expensive applicators and other associated equipment for the handling, storage and application of the latex binder to the primary base of the carpet with tassels. Depending on the procedure particularly used, additional equipment may be required for latex application to the secondary base as well. The operation and maintenance of this equipment is labor intensive and expensive.
The environmental disadvantages associated with the use of traditional latex are generally double. First, the use of that, hinders the recyclability of used carpets and even products of fragments that are generated in the manufacturing process, such as rimmed carpets, because the latex in general can not be remelted; latex causes adhesion in molds and other recycling devices. Latex releases unpleasant odors when heated and latex requires excessive mechanical energy to be able to be applied to the recycled product that contains the latex. With the decreasing availability and increase in the cost of landfills for these fragments, the carpet industry has experienced the need to find other alternatives for use for these manufacturing fragments.
Actually, the production of recyclability with respect to manufacturing fragments only, is a problem series without considering the fact that the front yarns in the bases of the carpet, typically used, are made of all thermoplastic materials. Once these components are contaminated with the latex filler (which includes a very significant component of inorganic filler eg calcium carbonate), these are difficult to recirculate economically and because of the aforementioned technical problems. In addition, although the carpet industry has done an admirable line work in motion, its operations are reduced to waste materials and recirculated to the extent possible, regardless of the fact of manufacturing life that even the most efficient carpet produced generates fragments that are equivalentte to approximately 0.5 -1% of your commercial production. In the US, this corresponds to roughly the order of 10,000,000 square yards or 30 to 40,000,000 pounds annually of production fragments. When the problem of removing used carpets is factored into the availability of recyclability, you can see that this is the main competition for the carpet industry.
The other environmental problem refers to the use of latex compositions and is related to the speculation that the compositions can generate certain volatile organic compounds (VOCs). These VOCs can contribute to the call (building sickness syndrome). See "Is carpet hazardous to our healt?" Carpet & Ruy Industry, October 1990. VOC emissions during the manufacture of the carpet have also led some manufacturers to add special air handling and ventilation equipment, which again contributes to the cost of carpet manufacturing.
It is an additional disadvantage of traditional latex in the manufacture of carpets, is its weight. A latex composition is typically spread by mixing it in large amounts of inorganic materials, in particular ground lime. This increases the weight of the carpet significantly. In the transportation of carpets from factories to their distribution centers, to places where they are sold at retail, or in export, the cost of transportation is typically based on weight. According to the above, a reduction in the weight of the carpet is highly desirable. In addition, the high level of inorganic filler not only contributes to the weight of the carpet, but also results in a stiffness that can be a disadvantage in certain applications, such as a recreational vehicle and truck conversion applications where the carpet it must conform to the contour of the vehicle floor.
According to the above, there has been a great need in the industry to find an inexpensive, inexpensive replacement for the latexes traditionally used in carpet construction, while, independently of this, provide the desired physical properties to the final carpet that are achieved with these latex. According to this, for many years carpet manufacturers have tried to develop a new solution for the preparation of carpets with tassels that eliminates or at least reduces the amount of latex used.
The previous technique:Efforts to replace traditional latex compositions in carpet constructions with tassels can be described as belonging to one of two general classes. In one class, molten adhesives have been applied in place of the latex composition. In the other class, the adhesive binder material has been provided in solid form, for example, as a powder or a meltable fiber intermixed with the base and then subsequently melted and fused in a heating step.
A typical solution comprising the application of the adhesive binder in molten form employs the use of a hot melt adhesive. The application of a hot-melt adhesive is generally carried out by passing the lower surface of the primary base with tassels onto an applicator roll placed in a tank containing the hot melt composition in a molten state. A scalpel is ordinarily employed to control the amount of adhesive that is transferred from the applicator roll to the bottom or bottom surface of the structure. After application of the hot melt composition to the lower surface of the primary base with tassels and before cooling, the secondary base, if desired, is brought into contact with the lower surface and then the resulting structure is it passes through heated nip rollers and subsequently cools.
By the use of hot melt adhesives, the need to dry the composition after application is eliminated. In addition, when a secondary base material is desired, it can be applied directly after the hot melt composition is applied.
Various hot-melt adhesives and processes using the hot-melt adhesive have been proposed for use in carpet lamination, for example, the U.S.A. No. 3'551,231, granted on December 29, 1970 to Smedberg, patent E.U.A. No. 3 '583, 936 granted on June 8, 1971 to Sthal and US Patent E.U.A. No. 3,684,600, issued August 15, 1972 to Smedberg, each discloses the use of certain hot-melt adhesives for carpet lamination with tassels. The thermoplastic resins are identified in each patent as useful components in the hot melt adhesive composition. Hot-melt adhesives have not proven to be a cost-effective solution to the needs of the carpet industry, however, because of their cost, the required application rate is generally high and in some cases because the adhesive that melts in hot itself, presents some of the same environmental productions present with the use of latex.
Another solution comprises the application of a molten adhesive to the primary base with tassels is an extrusion or lamination coating. See, for example, British patent no. 971,958. In this process, an extruded sheet of molten binder material, which may be a thermoplastic polyolefin polymer, is applied to the back of the primary base with tassels. The extruded sheet is obtained by feeding raw material to an extruder and extruding the raw material at relatively high temperatures to form a thin sheet through a die at a sufficiently high temperature to integrally melt the extruded sheet to the primary base with tassels and if you want, to a secondary base. A recent example of the extrusion lamination / extrusion lamination solution is found in U.S. Pat. No. 5 * 240,530, granted on August 31, 1993 to Fink. However, extrusion lamination and extrusion lamination have not achieved widespread acceptance in the industry for several reasons, including the high capital costs and technical competencies associated with installation and operation of a fairly wide extrusion coater (12 * or larger), the high application rates and the relatively slow line speeds that can be achieved and the high percentage of waste that results when a change in style is introduced in the manufacturing operation.
With respect to this latter point, for example, a single carpet manufacturing operation is common for producing multiple grades and weights of carpets; Each type of carpet may require a different degree of adhesive. Changing the rate of application of the adhesive that is being supplied by an extruder, can not be easy "on the fly" nor can a proper application regime be kept uniform at start-up without experiencing any waste.
In the other class of the prior art, the adhesive binder material is provided in a solid form and then subsequently melted and fused in a heating step. A solution of this nature is described in U.S. Pat. Nü 4 * 844,765 granted on July 4, 1989 and commonly ceded from Reith. Reith describes proportionally to the adhesive in the form of a film, preferably a film composed of two adhesive compositions with a different viscosity. Although Reith solves some of the problems in the industry, it has several drawbacks. For example, as shown in the Reith examples, the adhesive composition is applied to a combined weight of 1 Ib. per square yard approximately, in order to meet the minimum specifications of the FHA (Federal Housing Authority) for delamination resistance and tassel bonding.
In addition, Reith provides two separate films of different viscosities (or one composed of two different films) in order to achieve acceptable carpet properties and improve the results obtained when using simple films. The handling of adhesive films also requires the use of expensive release paper separators. All these factors contribute to the high cost of the Reith solution that has not found any commercial application in the market.
Another solution of this same category is described in the patent E.U.A. no. 4 * 439,476, granted on March 27, 1984 to Guild. Guild supplies the adhesive material in the form of a polyamide raw material fiber with a low melting point. In particular, Guild apparently first distributes the loose fiber on a primary basis and then sews with needles the fibers in and through the primary base. Guild states that by melting the fibers, the tassels of the carpet are secured in the primary base (although numerical data from the tassel union are not provided). Guild is silent about the resistance to fraying of carpets produced according to his method and does not teach the use of pressure in the manufacture of carpets. In addition, Guild does not teach or suggest the importance of providing an adhesive coating on the bottom of, as opposed to below, the tassel seams. However, Guild offers a solution that eliminates some of the problems in the technique, such as the use of latex and the need for a drying operation. However, the disadvantages of the Guild solution are split in at least three. First, Guild does not seem to provide a carpet that has resistance to fraying. Secondly, the polyamide fiber with low melting point mentioned and preferred by Guild is very expensive, with an approximate cost of $ 8.50 per Ib. Third, Guild requires distributing the fibers on the primary base and then sewing the fibers through the primary base. Indeed, Guild repeatedly refers to the need to sew the fusible fibers so that they extend continuously through the primary base, in order to form fibrous layers on either side of the primary base. The sewing operation, of course, adds an additional cost to the carpet. As far as the applicant is aware, no carpet has been commercially produced or made available that uses Wild's solution.
Yet another solution has been described by theCompany Hoechst Celanese Corporation of Salisbury, NorthCarolina, in a brochure entitled "All Polyester Carpet System: Environmental and Performance Aspects" presented by L.G. Stockman et al in the International Durable Needlepunch Conference on April 20, 1994 (previously summarized in "The Carpet Recycling Newsletter") Vol., No. 7, September 1993. See also European patent application no. 0 568 916 Al, published on November 10, 1993. According to this report, the carpet can be constructed using a primary base of polyester felt with tassels along with a secondary polyester base, each base containing a certain percentage of fiber heterollenada with a low melting sheath (bonded fibers) intimately mixed with non-bonded fiber comprising the carpet bases. The bases are then sewn together and thermally treated. This solution is certainly a positive step in the direction of providing the market with an all-recyclable polyester carpet, but the physical properties described for carpets made using this solution are modest.; none had a tassel union in excess of 5.7 lbs. and the resistance to the unraveling of a carpet with pile hair made by this method is open to speculation. In addition and perhaps more significant this solution requires the installation of fiber mixer equipment and also sewing lines in the carpet manufacturing process. This will be a substantial investment for the carpet industry, which is unlikely to be done. In addition, this solution needs the use of fibers with two exotic components are expensive. In addition, this solution uses a non-woven primary base and a secondary non-woven base, which are heavier than the woven polypropylene base typically used in the industry. In general, non-woven backing bases lack the strength and dimensional stability of the woven backing bases and therefore, it is to be expected that the carpet will find only limited application.
An additional solution to possibly solve the problems faced by the carpet industry, has been proposed by a Danish machine manufacturer, Carcpenn A / S, in cooperation with a German company Knobel GmBH. Campen / Knobel propose the use of a dispersion system in which thermoplastic polymers in powder form, such as ethylene-vinyl acetate (EVA), polyethylene and polypropylene, are applied to the back side of a primary carpet base with tassels. The base with the powder deposited on it, then is passed through a tunnel with infra-red rays to melt the powders and presumably secure the tassels.
However, Campbel / Knobel states that if it is required to secure a special fiber then a traditional filler pre-cover can be applied. In fact, applicants think that the dispersion coating solution, in commercial practice, always or almost always involves the use of a latex pre-coat. In addition, the Campen / Knobel solution requires the purchase of new equipment by the carpet manufacturer and will make obsolete the existing equipment typically found in carpet mills. In addition, powder coatings tend to be expensive and for this and additional reasons on an economic basis, as well as perhaps performance, the technology of powder coating technology (DPS) has been slow to make significant paths in manufacturing operations. commercial carpets, except for carpets for cars in Europe.
The invention of the applicants solves the problems of the carpet industry that have eluded the solutions of the prior art.
THE INVENTIONThe present invention provides a carpet with tassels comprising front yarns with gauze hair, at least one base fabric backing and an adhesive binder practically without inorganic materials and latex, the front yarns of gauze hair having a binding of tassels of at least 4 lbs.and a resistance to unraveling in the scale of 1 or better. In another embodiment, the invention provides a tassel carpet comprising cut pile yarns, at least one backing base fabric and an adhesive binder with virtually no inorganic materials and latex where the adhesive binder is provided in the form of a Adhesive fabric and cut pile yarns have a tassel binder of at least three and preferably at least 4 lbs. In still another embodiment, the invention provides an improved carpet base comprising a support fabric operatively connected to an adhesive fabric. In still another embodiment, the invention provides a method for manufacturing a carpet with tassels, comprising: tasseling a primary base fabric with yarn for the front; contacting the primary base fabric with tassels with an adhesive fabric; melt the adhesive fabric; and apply force to the melted adhesive fabric while in contact with the primary base with tassels.
Description of the invention:Briefly there are three aspects of the present invention. One aspect of the present invention is a new carpet with tassels comprising front yarns, at least one base fabric (i.e., at least one primary base fabric) and an adhesive binder (preferably provided in the form of a fabric) which is practically free that is to say, is without inorganic materials and latex, such as those found in traditional binder compositions used in the prior art. In addition, the new tassel carpet provides a tassel binder of at least three and preferably at least four pounds in the construction of the cutting hair and at least four pounds in the gauze hair construction, which are generally accepted as minimum industrial standards. The minimum standards required to satisfy the FHA home guide were previously 4 lbs. although recently they were lowered to 3 lbs for cutting hair construction, although they are 6.25 lbs. vine construction of gaza hair.
This higher standard for the construction of gauze hair is also reached and exceeded by means of the present invention. In a gauze pile construction, the inventive mat has an unraveling regime (as will be more fully explained below) of 1 or 0 '. Another aspect of the present invention relates to a new improved carpet base comprising a support fabric that is operatively connected (i.e., fastened) to an adhesive fabric. The base can be either a base for primary or secondary carpet. In the event that the base is intended for use as a primary base, preferably the adhesive fabric is disposed on the stitched surface (ie, the side that has no hair) of the primary base with tassels between the seams of the tassels and the woven support fabric. In the case of a secondary base, it is intended that the adhesive fabric be juxtaposed with the primary base with tassels, in order to contact the stitched surface of the primary base. A third aspect of the present invention is a new process for manufacturing a carpet with tassels comprising the steps of: tasseling a primary base fabric with front yarn; contacting a primary base fabric with tassels (which optionally may have, although it is not required that they have, an adhesive web operatively connected to the hairless side of the base before putting the tassels) with an adhesive web; melt the adhesive fabric; and then apply force to the melted adhesive fabric while in contact with the primary base with tassels. Alternatively, the process can also be conducted by inverting the first and second steps so that the primary base fabric first comes into contact with an adhesive web and then the combined primary base and adhesive web are provided with tassels; preferably the additional adhesive fabric is contacted with the compound product with tassels before the melting step.
More particularly, with respect to the new tassel carpet of the present invention, it is preferred that the adhesive binder comprises at least one thermoplastic resin. Because the vast majority of carpets with tassels are manufactured with thermoplastic facing yarns and thermoplastic primary and secondary bases, the use of a thermoplastic adhesive binder significantly promotes the recyclability of the used carpet, as well as the recyclability of the lint . In current practice, the thermoplastic used as the adhesive binder can be selected from a wide range of materials, as long as the thermoplastic has a melting point that is at least 20 βC approximately less than the melting point of the thermoplastic. Thermoplastic used in the primary and secondary bases of the carpet with tassels and while not being too viscous at processing temperatures that does not flow around the tassels and provides binding. For example, when the primary base is made, as is often the case of a crystalline propylene homopolymer with a typical melting point determined by differential scanning colorimetry (DSC) of about 165SC, the adhesive binder may be a linear low polyethylene. density, which has a melting point of about 40SC less than, the propylene homopolymer. Other suitable resins include randomized propylene copolymers, metallocene polymers, syndiotactic polypropylene, low melting point polyamides, polyesters, ethylene copolymers (including, for example, copolymers of ethylene-methyl acrylate and ethylene-vinyl acetate), Low density polyethylene and high density polyethylene. At present, applicants prefer linear low density polyethylene because of its melting characteristics and operating properties, such as, fraying resistance and agglutination of tassels that impact the final carpet product and also because of its relatively low cost . Two low density polyethylenes, particularly linear ones which are preferred by the solicitors, are provided by Dow Chemical Co. and sold under their trademarks Aspun 6807 and Aspun 6831.
Other preferred resins include blends of linear low density polyethylenes such as Aspun 6806 and metallosogenic polyethylene and blends of linear low density polyethylenes, with low density polyethylenes, such asRexene 2080 provided by Rexene Corporation.
Another preferred feature of the adhesive binder is that it has a relatively high melt index or a melt flow rate in order to facilitate good wetting and encapsulation of the tassels. In the case of linear low density polyethylenes, a melt index (determined by ASTM D-1238) above 30 gms is preferred. for 10 min. (at 1902C) A melt index above 60 gms for 10 min (at 190 aC) is more preferred.
For convenience in the application and in order to maintain a consistent and uniform amount of adhesive throughout the carpet, the adhesive binder will be supplied, in accordance with an embodiment of the invention in the form of a fabric. In that form, the adhesive binder can be supplied in weights less than 12 ounces per square yard, while still providing good to excellent physical properties of the final carpet. Preferably, weights below 9 ounces per square yard and more preferably below 6 ounces per square yard are used as long as acceptable carpet properties are maintained.
A more preferred form of fabric for providing the adhesive binder is a non-woven fabric. Traditionally non-woven fabrics are cheaper than woven fabrics, so they are advantageously employed in the present invention, especially when they are of sufficient uniformity to achieve uniform binding (and because of the strength of the adhesive fabric before use on the carpet). which is not critical to this use as long as it can be handled). In this regard, applicants prefer continuous filament non-woven fabrics, such as those described in US Pat. no. 5 * 173,356, issued December 22, 1992 to Eaton et al. (which is incorporated here as a reference). The fabrics produced according to the Eaton patene, have a basic uniform weight and particularly consistent. Uniformity is important because it allows the carpet manufacturer to reduce the total weight (and costs) of the final carpet, minimizing the amount of adhesive binder that should be used. These fabrics can also be used, and are preferably used, in a calendered condition that makes them more easily meltable. Examples of these fabrics are those sold by Amoco Fabrics and Fibers Company as RFX (MR) fabric.
Another particularly advantageous feature of the fabrics produced according to the Eaton et al. Patent is that they can be handled "as they are" without the need for any additional mechanical consolidation, chemical binders or thermal embossing. Accordingly, because these additional operations are eliminated, these fabrics can be produced economically on a basis that allows the present invention to have a competitive cost with the traditional latex solution in carpet manufacturing. However, it will be understood that although self-adhesive fabrics are preferred, the adhesive web can also be supplied in any convenient way, such as, for example, a spunbond fabric, blown melt or needle-punched non-woven fabric, the latter being made from stapled fibers, continuous filaments or both. Fabrics that are agglutinated by spinning and their manufacture are described, for example, in the patent E.U.A. no. 3 * 502,763, granted on March 24, 1970 as Cari Freudenberg Kommandigesellschaft Auf Actien; Blow-melt fabrics have been described in, for example, in US Pat. no. 3 * 972,759, granted on August 3, 1976 to Exxon Corporation.
If the carpet with tassels is going to be built of dissimilar thermoplastics, for example, nylon front yarns and primary and secondary polypropylene bases, may be desirable in order to assist the recyclability of the used carpet and any lint that is generated, include in the adhesive binder composition a compatibility agent for the different resins. Alternatively, the compatibility agent can be included in any of the component parts of the carpet, perhaps adding separately during the manufacture of the carpet, as, for example, by applying it to a base cloth before or after the provision of tassels. by using a cylinder or by spraying or can be added separately during recirculation operations. Compatibilizers can also serve to reduce the total viscosity of the thermoplastic adhesive, and increase wetting of the front yarns by the adhesive, by any agent that does not interfere with the melting of the adhesive binder or the flow of the adhesive binder in the molten state within the adhesive. The tassels of the carpet is acceptable. Applicants have found functionalized polyolefin compatibilizers that are satisfactory for use with polypropylene bases and nylon front yarns. One of those compatibilized is a malleable random polypropylene copolymer having a melt flow rate of 850 to 230SC and sold as Fusabond MZ-278D by E.l. DuPont de Bemours &; Company Also suitable is a malleable polyethylene wax sold by Eastman Chemicals, Inc. as "C-18", or ethylene-acrylic acid copolymers containing from 3 to 20% acrylic acid, provided by Exxon Chemicals.
Another aspect of the present invention relates to improved carpet bases. More particularly, the carpet bases may comprise a traditional primary or secondary base fabric (either woven or non-woven), although a woven fabric is preferred because of its higher weight strength ratio and because it helps to manufacture rugs resistant to fraying), to which an adhesive fabric of the above-mentioned type has been operatively connected, for example, by knit joints, thermal calendering, or needle stitching (or any other method known to those skilled in the art). Traditional primary and secondary bases form support fabrics that can be used in the common carpet manufacturing operation to carry the adhesive fabric through tiling, washing, dyeing and drying operations (in the case of primary carpet bases) ). Such support fabrics are well known in the art and may include, for example, fabrics made of splittable yarns as described in US Pat. no. 3 * 359,934, issued December 26, 1967 to Schwart et al. In the case of a secondary base material, the support fabric can be used to bring the adhesive fabric to the primary base material with tassels using an apparatus traditionally associated with the latex application. The secondary base, with the adhesive web, can then be attached using that equipment on the primary base material with tassels (which may also optionally have, in accordance with one aspect of this invention, an adhesive web) immediately prior to transporting the structure. composed through the traditional latex drying oven.
In the case that both primary and secondary bases are provided with adhesive cloth, any weight of adhesive cloth which is effective to provide the necessary binding of tassels and other performance properties required by carpet may be used, whereas the total weight of The adhesive fabric does not become so large as to interfere with the carpet construction. In general, it is preferred that the total weight of the adhesive webs be equal to, or less than, 12 ounces per square yard approximately to minimize weight and cost. More preferably, the total weight of the adhesive web is 9 ounces or less to further reduce costs and increase processing speeds. Total weights below even 6 ounces per square yard have also shown that they result in carpets that have a good tassel joint and other good performance characteristics. However, it will be appreciated by those who have the benefit of this exposure that although certain performance advantages and properties can be obtained by providing some of the adhesives as an adhesive web in each of the primary and secondary fabrics, that for reasons to improve the operations or to simplify the manufacturing process, it is not essential that the adhesive fabric is on both secondary and primary bases or, indeed, that the same adhesive fabric be used on both bases. For example, depending on the application and properties of the carpet desired, a low viscosity adhesive can be used to make the adhesive fabric of the primary base to improve its fraying resistance and an adhesive of different viscosity and higher strength can be used to improve the union of the tassels. However, whenever a secondary base is used, applicants have preferred to use at least one adhesive web on the secondary base with a weight of at least 1.5 ounces per square yard approximately to provide good delamination resistance and dimensional stability to the carpet. . In addition, the preferred weight for the adhesive fabric will depend on factors such as the type of front yarn (e.g., nylon or polypropylene) its denier and the seam pattern on the primary base.
A preferred woven support fabric for primary base that is used, is a polyolefin fabric woven with threads of a practically rectangular section, for example, slot film threads, in square or rectangular spinning, to form a flat fabric of essentially uniform thickness. The uniform thickness of the base and the almost rectangular section of the base yarns, facilitate the formation of tassels of the base, because the friction is reduced during the penetration of the needle and the surfaces with arc wires capable of deflecting the edges are absent. needles with tassels. One of those bases having threads of practically rectangular section in a one-to-one fabric, has been described in the U.S. patent. no. 3 * 110,905 granted on November 19, 1963 to Rhodes, which is hereby incorporated by reference. More preferably, woven fabrics of polypropylene, polyester yarns or a polypropylene-polyester blend having a substantially rectangular section are used.
A preferred support fabric when the base is to be used as a secondary base, is a woven base having threads of practically rectangular section in the weft and in the warp or warp with spun weft threads. The woven bases of the last construction, have been used advantageously as secondary bases when a latex binder has been used, due to the aggregate capacity of the spun yarns to interact with the latex, not supporting the complexity and added cost of manufacturing a Fabric of two different types of thread. However, in the case of the present invention, because the latex has been supplanted in the manufacturing process by the use of an adhesive fabric, the need for secondary bases having spun yarns has been reduced, still providing an additional advantage. to the carpet manufacturer.
Again, the preferred materials for use in the manufacture of the support fabric are polypropylene, polyester or a mixture of polypropylene and polyester. The characteristics of the secondary base may also vary with the styles of the carpet as is known, but for purposes of the present invention, a secondary base having a more open fabric is preferred, because this aids in the transfer of heat during melting. and cooling of the adhesive fabric. The support fabric, as well as the adhesive fabric, may have special characteristics in batches, either to one or the other or to both incorporating or applying various treatments of dyes, additives, modifiers or surface treatments to improve the flame or flame resistance. stains, reduce static charge, impart color and other purposes. However, it will be understood that the use of those materials in typical proportions are within the scope and spirit of the present invention. Therefore, when we refer to adhesive binders or adhesive webs that are "substantially free of inorganic materials and latex", we do not intend to exclude from the scope of the invention adhesives to which those additives have been incorporated.
According to the method of this invention, a carpet can be manufactured by providing tassels with a fabric d = primary base with front yarns (preferably a front or face-thermoplastic yarn), followed by the contact of the primary base fabric with tassels with an adhesive fabric, which does not necessarily need to be attached either to the primary base or to the secondary base before contact with the primary base with tassels, the adhesive fabric is melted and the adhesive fabric is pressed while it is melted into the primary base with tassels. Alternatively, the primary base fabric can be first connected to the adhesive fabric and then put the tassel to the primary base and adhesive fabric combined. It will readily be appreciated by those skilled in the art that in the context of the traditional latex method, for manufacturing carpets, the adhesive web can be conveniently supplied for contact with the primary base with tassels while providing the secondary base. Therefore, the same "wedding" roll or cylinder used to combine the secondary base with the primary base with tassels, can also be used to contact the primary base with tassels with the adhesive fabric, as well as with the secondary base. if it is going to be used.
The structure of the composite carpet can then be heated conveniently to melt the adhesive fabric by any of several conventional techniques. For example, the composite structure can be fed onto a hot drum laminator comprising a hot drum, followed by the application of pressure to the composite structure, by the use of a set of pressure rolls. Typically, the bases contact the drum, so that the secondary base is in contact with the drum, thereby preventing potential damage to the front or face yarns due to prolonged contact with the heated surface of the drum. . Conventional drying ovens of the type used in latex processes, can also be used, with the base fabrics and adhesive-s being passed through with a rotating branch frame or on rollers or other similar devices. After the exit of the latex oven, the secondary and primary bases with tassels can be pressed into the melted adhesive fabric, again by means of the use of pressure rollers. As will be understood by those familiar with this technique who have the benefits of this exposure, it is advantageous to press the melted adhesive web while the adhesive is in the molten state because this helps to achieve a good bonding of the tassels and especially good fraying resistance in the final carpet product. The cooling of the carpet structure can be carried out by any suitable means, for example, simply by passing the carpet structure to an area at room temperature or preferably to a cooling box or against quenching rollers to ensure the configuration . When line speeds are desired, for example greater than 40 'per min., Then the use of that cooling box or hardening rollers is recommended. A branch to minimize and control the shrinkage during these steps is also desirable. Applicants believe that line speeds of the carpet manufactured with the fusible adhesives of this invention can be at least as high as those of carpets made with latex adhesives filled in conventional forced air ovens.
It will be appreciated that an essential aspect of the present invention is the use and application of force to help press the molten adhesive into the primary trim and when a secondary is used, fuse the secondary base to the mat. Although the precise lower and upper limits of the applied pressure will depend on numerous factors, such as the nature and material used for the front yarn, (in general, nylon is more elastic than polypropylene, for example) the viscosity of the adhesive composition used in the adhesive fabric, the temperature of the ovens, the residence time in the ovens and the weight of the adhesive fabric; Applicants have found that a higher force is generally better than a low force, so that the crushing of the front wires is reduced to a minimum. In general, a minimum force of approximately 10 lbs. per linear inch, it is required to cut pile carpets, while a minimum of 20 lbs, preferably 40 lbs, and more preferably 80 lbs. per linear inch, it is required to produce gauze pile carpets that have acceptable tassel bonding properties and fray resistance. In general, it is more difficult to achieve both, high tassel joint and good fray resistance instead of just a high tassel joint only and in gauze pile carpets the fraying resistance is a critical property required to maintain a good appearance of the carpet. Therefore, in general, greater forces are used in this invention, in the construction of gauze pile carpets than in carpets with cut pile. It has also been found that, again in general, pressures in excess of 300 lbs have to be avoided. per linear inch that result when attaching and crushing the front wires.
The following examples are intended to illustrate the invention, but should not be considered as limiting the scope of the invention.
E J E M P L O SA series of carpets with tassels was manufactured using various thermoplastic adhesives primarily in the form of cloth. For each of the following examples, the materials used, the manufacturing equipment, the manufacturing procedures and the test methods are all as indicated below, unless an exception is noted for a specific example.
Primary baae materials with tassels: Thirteen styles of primary base materials with tassels were used and identified as NY-1 to NY-10, PP-1 and PP-2 and PET-1. The primary base materials with tassels were made according to the following specifications, it being understood that in examples employing an adhesive fabric below the primary base material the latter was provided with tassels with the adhesive fabric disposed on the sewn surface of the base between the woven polypropylene support fabric and the tassels. The base carpet materials of support fabric, PolyBac (mr) and FL (mr), are each available from the Amoco Fabrics and Fiber Company of Atlanta, Georgia.
NY-1 Nylon 6 face or face yarns; Chiffon hair construction, 1/8 gauge, straight stitch, tassels on polypropylene woven material PolyBac style2205. Thread style: bulky continuous filament; denier: 2750. Hair height: 0.25", hair weight 17.5 ounces / square yard (osy).
NY-2 Nylon 6 front threads; Gauze hair construction, 1/8 gauge, straight seam; embossed on a FLW style woven polypropylene carpet base material 4005 that has a 1.5 os shearing layer and a 50/50 blend of polypropylene and nylon 6 strand fiber on the hair side of the support fabric . Thread style: fluffy continuous filament; denier 2750. Hair height: 0.25", hair weight: 17.8 inches.
NY-3 nylon 6 front threads; trimmed hair construction, 3/8 gauge; embossed on FLAT woven polypropylene backing material style 4005. Yarn style: 1100/2 wiring, hot consolidated yarn four turns per inch.
Hair height 1/2"; hair weight: 7 osy.
NY-4 nylon 6.6 threads; trimmed hair construction, 3/8 gauge; embossed on a woven polypropylene carpet base material, FLW style4005. Wire style: 1100/2 wiring, hot bonded yarn four turns per inch. Hair height: 1/2", hair height: 12 osy.
NY-5 nylon 6.6 threads; trimmed hair construction, 1/4 gauge with a stitched seam; embossed on a woven polypropylene carpet material, FLW style 4005. Yarn style: 1100/2 wired, hot consolidated yarn four turns per square inch. Hair height 72", hair weight: 20 osy.
NY-6 Nylon 6.6 front wire; trimmed hair construction, 1/8 gauge, straight seam, bordered on a PolyBac woven polypropylene base material style 2205. Yarn style: 1100/2 wired, hot-bonded yarn four turns per inch. Hair height: 5/8", hair weight: 50 osy.
NY-7 nylon 6.6 front yarns, trimmed hair construction, 5/32 gauge, with a straight stitch, bordered on a PolyBac woven Polypropylene carpet base material; yarn style: yarn spun from filament fiber; 3.0 / 2 (cotton count / layer); wiring and hot consolidation; 5.5 vueeltas per inch. Hair height 1/2"; height of hair: 24 osy.
NY-8 6 nylon front yarns, 5/32 gauge, trimmed hair construction, with a stitched seam stitched over a PolyBac 22-5 woven polypropylene carpet base material. Yarn style: bulky continuous filament, wired, filled and hot bonded, 4 turns per inch, denier 1400/2. Hair height 5/8", hair weight 38 osy.
NY-9 6 nylon front yarns, gauzy pile construction, 1/10 gauge with a straight constura, bordered on a PolyBac woven polypropylene carpet base material Style 2205. Yarn style: bulky continuous filament; denier 2800. Hair height 0.18", hair weight: 24 osy.
NY-10 6-gauge nylon threads, gauzy pile construction, 1/10 gauge, with a straight seam, bordered on a PolyBac woven polypropylene carpet base material style 2205. Thread style: bulky thread filament : denier 2800. Hair height: 0.18", hair weight 24 osy.
PP-1 Polypropylene front wires; gauze hair construction, 1/10 caliber, boring on a woven polypropylene carpet base material, PolyBac style2205. Denier de hilo 3500. Hair height: 0.25", hair weight: 25 osy.
PP-2 Polypropylene front yarn; gauze hair construction, 1/8 gauge with a straight stitch, bordered on PolyBac woven polypropylene base material style 2205. Yarn style: bulky continuous filament; denier de hilo 2750. Hair height: 0.24", hair weight: 11.3 osy.
PET-1 Polyester forehead yarn, trimmed hair construction, 1/8 gauge with a stitching seam, bordered on PolyBac 2205 woven poly-pylene base material. Yarn style: spun yarn from graded fiber; 3.8 / 2 (cotton count / layer); 5.5 turns per inch; wired, filled and consolidated in hot. Height the hair: 1/2". Hair weight: 40 osy.
Adhesive fabric materials; The adhesive webs used in the following examples were made following the teachings of the US patent. no. 5 * 173,356 with the polymers identified in the following. The adhesive fabrics, each had between 0.5 and 1.5 osy per layer:6806 Low density linear polyethylene (LLDPE), sold as Aspun 6806 by Dow Chemical Co.6831 LLDPE, sold as Aspun 6831 by Dow Chemical Co.2220 Ethylene-methyl acrylate copolymer resin, sold as Chevron SP 2220, offered for sale by Chevron Chemical Co.2080 Low density polyethylene, sold as Rexene 2080 by Rexene Corporation, Dallas, TX.
Mixture 1. Mixture 90/10 by weight, of 6806 copolymer / randomly assembled polypropylene sold as Fusabond MZ-278D by E.l.DuPont.
Mixture 2. Mixture 90/10, by weight of a 6806 wax / pooled polyethylene (a "C-18" resin from Eastman Chemicals).
Mix 3. Blend 80/20, by weight of 6806 / C-18.
Adhesive fiber materials;K115 Fiber cut from low melting polyamide from EMS Grilon, Ine; Sumter. SC. Fiber length: 80mm; denier 11; fusion temperature 115ßC.2080-S A staple fiber spun from Rexene 2080, a low density polyethylene resin supplied by RexeneCorporation, Dallas, TX. Fiber length: 4.5", denier: 6. The melting index of Rexene 2080 was 100 g / 10 min at 190 aC.6811A A spun cut fiber of Aspun 6811A, a linear low density polyethylene resin supplied by Dow Chemical; fiber length: 4.5"; denier: 6. The Aspun 6811A melt index was 35 g / 10 min at 190 aC.
Secondary base support fabrics;3870 Woven polypropylene fabric from Amoco Fabrics and FibersCo., Atlanta, GA. which has a number of weft yarns per inch of fabric of 16 x 5, a nominal weight of 2.1 osy, ribbons of rectangular section such as warp yarns and threads spun with a denier of 1800 as fill yarns. Natural color.3865 A woven polypropylene fabric identical to the 3870 fabric, except that the color was light jute instead of natural.
R-921 A woven polypropylene gauze fabric having a number of weft threads per inch of fabric of 16 x 15, a nominal weight of 1.6 osy, ribbons of rectangular section, with a denier of 450 as warp threads and toothed belts with a 1050 denier as filling yarns.
Equipment; The equipment used in examples 1-15 and 23 was the oven and calender described in the following:Oven - HIX Corporation (Pittsburgh KS) moving in the infra-red band, model 4819.
Calandria - Laboratory Hot Melt, type 500, with two rollers heated in oil, manufactured by Ernst Benz AG, Rumlang, Switzerland.
Examples 16-22 were made using the carpet laminator described below:Carpet laminator - laboratory carpet laminator with a width of 1.2 meters. produced by Villars AG in Muenchwilen, Switzerland with advance frame, a 2.3 meter heating zone with infra-red heaters, a calender and a pick-up roller. The laminator had a moving metal band to transport the carpet through the heating zone.
Test procedures; The tassel joint was determined in accordance with ASTM D 1335. The unraveling was determined using the "Sailboat" roller test, a common test (although not a universal standard) employed by the carpet industry. More specifically, a cylindrical steel roller with a diameter of 2"and a width of 3" and weighing 2 Ib with a trademark Sailboat tape (the hook portion), which is available from U.S. Sailing Company, is covered. A., Inc. of Manchester, NJ. The unraveling was determined by passing the roller 20 times (10 in each direction) on a section of the carpet with hair in gauze. The unraveling of the carpet was then observed and graded according to the following scale of unraveling resistance: 0 (nothing) - unraveling 1 (very low) - light unraveling 2 (low) - moderate unraveling 3 (medium) - considerable unraveling 4 (high) - severe frayingCarpets that did not show or showed a slight fraying (from 0 to 1) were judged acceptable. See US patent no. 3 * 684,600, column 4, Chapter II, 71-75, for a scale of similar rank.
Example 1 A wide piece 12"wide by 18" long from a primary base with tassels (NY-1) was placed with the hair side down on a metal strip outside the infrared oven. The primary base with tassels had 3 osy non-woven adhesive fabric of 6806 between the bottom side of the base and the tassels. A 6806 (6 osy) non-woven fabric fluff was placed on top of the primary base with tassels, followed by a 3870 ActionBac secondary base piece. A 2 'by 2' piece of heavy duty cloth weighing 2 so many of wool (approximately) 2 'by 4") was placed in the upper part of the set.The temperature button of the oven was set to 300 * F. When starting the rolling process, the assembly moved quickly in the hot section of the oven. It remained there for 3.5 min., During which time the adhesive fabric melted. A temperature band on the back side of the sample indicated a surface temperature of 289 * F. At the end of that period, the assembly was quickly removed from the oven. The resistant fabric was then quickly removed and the assembly was passed through the heated calender at 10 feet / min. The rollers were heated to 100 * C. The force applied by the rollers to the sample was 138 Ib. per linear inch. The hot consolidated carpet sample was passed a second time through the hot rolls and then cooled under a heavy flat sheet. After it was cooled, the sample was subjected to the Velero roller test. No fraying was detected. The sample was also tested for binding of tassels. The union of tassels was 9.5 Ib.
Examples 2 to 18 These examples were carried out in the same manner as Example 1, except that the primary base was varied with tassels, the heating time and type, amount and placement of adhesive material, as indicated in Table I. All samples had tassel unions of 6 Ib. or greater and the unraveling regime was either "very low" or "none", as also summarized in Table I. In examples 9-11, the cut fiber of K115 was sewn into the primary base using a loom of cross winding and needles Say it. When the K115 fiber was placed between the primary and secondary bases with tassels (examples 10 and 11), it was sprayed by hand and rearranged until a uniform distribution was obtained. In Examples 17-18 the adhesive fiber material 2080-S and 6811-A, respectively, was first formed into a non-woven fabric by stapling and needle stitching. The non-woven adhesive web with the resulting needle, with the basic weights indicated in Table 1, was then attached to a primary base without tassels and then provided with tassels to a secondary backing support fabric. The non-woven adhesive fabric was also fastened with needles, carpet samples were made by placing the secondary fabric composed above the primary with tassels with the adhesive fabrics of each in relation to each other. The general procedure for heating and applying a gripping force with the rollers described in Example 1 was employed using the conditions indicated in Table I.
Comparative Examples A and B Example A: A piece of carpet 12"wide by 18" long was made with the primary base with tassels NY-1, 6806 and with a secondary base ActionBac style 3870 in the same way as in the Example 1, except that the gripping force of the rolls applied to the hot set was less than 10 Ib per linear inch. The cooled sample had a tassel joint of 9.7 lb., but the unraveling in the Velero roller test was"medium". This experiment showed that the application of the pressure to the mat set with melted adhesive was essential to obtain an acceptable level of fraying resistance.
Example B A carpet sample 12"wide or 18" long was manufactured in the same manner as in Example 3, except that the gripping force of the rollers was less than 10 Ib per linear inch. The cold sample was tested to know the tassel joint and the unraveling resistance. The tassel union was 4.7 Ib. and the unraveling regime was high.
Ia - J ---_ IAdhesive quantity Adhesive type Example ßox-a Ba-ji-. About ñ- -2 About Lue-cza Time Tune Union RegimePrimary primary school primary secondary second warming calender flbl frayed iosy} lo-ü íosy) (osy) (osy) ímin)) ípli) A NY-1 3 6 6806 6806 3.5 < 10 9.7 Medium1 N? -1 3 6 6806 6806 3.5 138 9.5 nothing2 NY-1 0 11 - 6806 4 275 8.3 very lowB NY-1 6 3 6806 6806 3.5 < 10 4.7 high3 N? -l 6 3 6806 6806 3.5 92 9.1 nothing4 NY-1 3 6 6806 mix 1 3 229 7.4 very lowNY-1 3 6 6806 mix 1 3.5 229 7.4 nothing6 NY-1 3 6 6806 mix 1 4 229 8.0 nothing7 NY-1 3 8 6806 mix 2 4 275 9.8 nothing8 NY-1 3 6 6806 mix 3 3.5 229 8.7 nothing9 NY-1 3 6 K115 6806 3.5 229 7.9 nothingNY-1 5 3 K115 kll5 3.5 229 17.0 very low11 NY-1 3 6 K115 kll5 3.5 229 9.0 very low12 PP-1 0 9 - 6806 3.5 138 7.7 very low13 NY-1 3 3 6806 6806 3.0 138 8.3 very low14 NY-1 3 6 2080 6806 3.5 183 8.6 nothingNY-1 3 6 2220 6806 3.5 183 8.5 very low16 PP-2 1.5 4.5 6806 6806 3.0 * 25 12.2 very low17 NY-1 3 6 2080-S 2080- 3.5 92 7.5 very low18 NY-1 3 6 6811A 6811A 3.75 92 11.2 very lowperature of the oven set to 28? 'FExamples 19-21 A 30"wide band of front yarn is provided with tassels through a woven primary base having 3 osy of a non-woven adhesive fabric made of 6831 resin punched with needles for the seam surface (it is say the hairless side of the base.) A ribbon 36"wide 6-osy non-woven adhesive fabric 6831 was attached to a secondary ActionBac 3870 base and sewn lightly on the underside of the primary base with tassels, the entire assembly was wound on a cylinder and placed On the forward side of the Villars carpet rolling machine, the assembly was passed with the hair side down through the laminator at a speed of 0.5 m / min.The adhesive fabric melts when it passes under the heaters. Surface of the back side or carpet backing after it passed through 2m heaters was 128 'C. As soon as the carpet came out of the heater areas, was passed through a calender, where a grip force of 59 Ib per lineal inch was applied to consolidate the whole. Then the carpet was rolled over a cold roll and wound on a cylinder. A section of the finished carpet was removed to test the bonding and fray resistance. The tassel union was 10.9 Ib and the unraveling regime was "very low". Examples 20 and 21 were made according to the general procedure of Example 19, except for the variations indicated in Table II. These examples also illustrate the construction of gas-filled carpets in accordance with the present invention.
Table TTExample No. Tassel Temperature Force velocity Nlp primary ('Ci 1inea calandria Trowel Union Side surface regime (m / min) Adhesive fabric fPll) -U-tLL unraveled19 NY-1 128 0.5 3 osy 6831 low 59 10.9 Very low primary and 6 osy of 6831 on secondary 20 NY-1 121 0.6 3 osy of 2080 59 8.5 Very low low primary and 6 osy of 6806 on secondary 21 NY-2 126 0.5 3 osy 6806 low 59 12.0 Very low primary and 6 osy of 6831 over secondaryExamples 22-25 A product composed of a 40"wide roll of a primary base with NY-3, 4 osy tassels and a non-woven non-woven fabric 6831 and ActionBac 3870, were lightly sewn together and rolled The assembly was placed on the forward side of the Villars laminator and then fed through the laminator at a speed of 0.9 m / min.The heaters were adjusted so that the surface temperature of the lower side of the set was 126 * C at the end of the second heating zone.A calender gripping force of 45 Ib per linear inch was applied to the assembly, then cooled and collected on a cylinder. The finished carpet The tassel bond strength was 4.3 lb. Examples 23-25 were made following the general procedure of Example 22, except for the variations noted in Table III.
Table IIITemperature ('O surface Adhesive cloth Nip strength Example Tassel side line attached to calender Tassel bond -------- primary back (m / min) Sec -'nder'a (pli) (Ib)22 NY-3 126 0.9 4 osy 6831 45 4.3 23 NY-4 128 0.9 6 osy 6806 44 4.9 24 NY-6 133 0.7 6 osy 6806 44 5.3 25 NY-6 130 (est) 0.7 8 osy 6806 44 7.1 L?EXAMPLE 30 A primary base with tassels with a width of 152"(NY-9) was contacted with a 4.5-os composite material and a 6806 non-woven adhesive web sewn to a secondary 3870-style base support fabric. Then the combined fabrics were placed in contact with the surface of an oil-heated, rotary drum with a diameter of 14. The secondary base support fabric of the carpet set was again brought against the drum and the non-woven adhesive fabric. was placed between the secondary base and the back side of the primary base with tassels, the oil in the drum was preheated to 340 * F and the speed of rotation of the edge of the drum was 20 ft / min. of carpet was moved over the surface of the rotating drum by an arc of 340 *, was passed over a rotating roller and a series of infrared heaters that kept the back of the carpet at 260 * F until it was passed through a pair of r Chrome-plated steel grip irons. The rollers applied a grip strength of 22 Ib per linear inch to the carpet. After the carpet passed through the gripping rollers, it was transferred to a laying frame and rolled onto a cylinder. The tassel binding was measured on the alformbra. The tassel union was 5.8 Ib on the portion of cut hair and 9.9 Ib on the gauze pile poricón.
EXAMPLE 31 The general procedure of Example 1 was repeated, except that the secondary base R-921 was replaced by the secondary base 3870. The carpet set was composed of a primary base with NY-1 tassels with 3 osy of a non-stick adhesive fabric. woven 6806 fastened, a 6 osy band of a 6806 non-woven adhesive fabric and the secondary base support R-921 fabric. The assembly was heated for 3.5 min at an oven temperature set at 300 * C. At the end of that period, it was passed immediately through a calender that applied a grip force of 92 Ib per linear inch. The final carpet was tested to know its physical properties. The tassel joint was 9.5 Ib and the unraveling regimen in the Sailboat roll test was "very low." The delamination resistance measured in accordance with ASTM D-3676 was 10.5 lb / in. The resistance was significantly above the requirement. FHA minimum of 2.5 lb / inch.
Examples 32 and 33 Example 32 illustrates a process in which a non-woven fabric without support is sewn to the underside of the carpet before melting.
In example 32, the primary base with NY-10 tassels was placed with the hair side down on a needle loom. A 6-osy fluff of 6806 non-woven adhesive fabric was placed on top of the primary base with tassels and sewn on the back side of the yarns of the hair using a needle density of 1200 penetrations per inch, a depth of 12 mm needle and one needle type F-20-6-22-3.5-NK / 15X18X36X3RB manufactured by Foster Needle Co. Manitowoc, Wl. The NY-10 needle-punched compound and the non-woven fabric were placed with the hair side down on a band in the infrared oven of Example 1, an additional non-woven adhesive fabric 6806 of 3 os was placed in the of the assembly, followed by a piece of a secondary base 3870. After the procedure of example 1, the whole assembly was heated for 3.75 min at an oven temperature set at 300 * F and then immediately passed through the rollers of the calandria that applied a grip strength of 92 Ib per linear inch. The final carpet was stolen for tassel binding and frayed resistance. The tassel joint was 9.1 Ib and the unraveling regime in the Velero roller test was "very low".
In Example 33, the procedure of Example 32 was repeated, except that the non-woven adhesive web was not punctured with the needles on the back side of the pile yarns. A total of 6806 nonwoven adhesive fabric of 9 osy was used. The carpet of that experiment had a tassel union of 7.6 Ib and a fraying regime from "very low" to "none".
Both examples 32 and 33 resulted in carpets that meet the criteria for fraying resistance. However, the tassel joint in Example 32 was slightly higher than Example 33.
Table- IVAdhesive Quantity Adhesive Type Low Sqbre Low About Force Time Uni? NExample Primary Primary Secondary Secondary Warming Calandria Tassel Na-. primary (osy) (osy) íosyl (osy) (min)) (li) LU? l26 NY-5 0 6 - 6806 3.0 92 4.327 NY-7 0 7.6 - 6806 3.25 92 4.328 NY-8 1.5 4.5 6806 6806 3.5 75 5.229 PET-1 0 6 - 6806 2.5 25 4.8