EP0084446A2 - Tapis et procédé pour fabriquer du tapis - Google Patents

Tapis et procédé pour fabriquer du tapis Download PDF

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Publication number
EP0084446A2
EP0084446A2 EP83300200A EP83300200A EP0084446A2 EP 0084446 A2 EP0084446 A2 EP 0084446A2 EP 83300200 A EP83300200 A EP 83300200A EP 83300200 A EP83300200 A EP 83300200A EP 0084446 A2 EP0084446 A2 EP 0084446A2
Authority
EP
European Patent Office
Prior art keywords
sheets
face
stack
carpeting
fibres
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP83300200A
Other languages
German (de)
English (en)
Other versions
EP0084446A3 (fr
Inventor
Duncan Stewart
William Henry Bowyer
Anthony Kenneth Green
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fulmer Research Institute Ltd
Original Assignee
Fulmer Research Institute Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fulmer Research Institute Ltd filed Critical Fulmer Research Institute Ltd
Publication of EP0084446A2 publication Critical patent/EP0084446A2/fr
Publication of EP0084446A3 publication Critical patent/EP0084446A3/fr
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics

Definitions

  • THE PRESENT INVENTION relates to carpeting and to the manufacture of carpeting, and in particular relates to the manufacture of carpet tiles, although it must be appreciated that methods in accordance with the invention may be utilised for manufacturing articles other than carpet tiles.
  • carpet tiles are widely utilised, particularly in areas where carpeting is subject to heavy wear.
  • the present inversion seeks to provide a process for the manufacture of carpeting which will reduce or eliminate some or all of the abovt described disadvantages of the currently utilised production methods.
  • a method of manufacturing carpeting comprising the steps of forming a body of material from a stack of sheets of non-woven material, said body having at least one end face, compressing the body in at least one direction which lies in the plane of said end face at least in the region of said end face, and bonding together the.material of the body at said end face.
  • the method also comprises the further step of separating the bonded end face and a portion of unbonded material secured to the bonded end face, from the remainder of the body of material.
  • said material has thermoplastic properties, or incorporating a material having thermoplastics properties, said bonding step being effected by heating the said end face.
  • said bonding may be effected by coating the exposed face with adhesive and permitting or causing the adhesive to cure.
  • the method comprises the step of applying a backing material to said bonded fibres.
  • Said sheets may comprise polymeric film, which may be pre-treated to cause them to fibrilate when they are brushed or mechanically deformed.
  • said sheets may comprise sheets formed by a paper-making technique.
  • said sheets are treated or printed or incorporate coloured fibres so that the resultant carpeting is patterned and/or textured.
  • the invention also relates to carpeting whenever manufactured by a method as described above.
  • a body of fibrous material is assembled from a stack of separate sheets of non-woven fibrous material.
  • the body is compressed in at least one direction.
  • the fibrous material is initially supplied in the form of sheets of rectangular shape, and each sheet 1 has at least a substantial proportion of the fibres therein aligned with the longitudinal axis 2 of this sheet.
  • the sheets may be of many possible forms, as will be described hereinafter in greater detail. However, in this embodiment of the invention the sheets are formed of a material that has some thermoplastic properties.
  • FIG. 2 Illustrated in Figure 2 is a compressing apparatus comprising a substantially "U" shaped former 3 and a plunger 4 adapted to be received within the former 3.
  • the plunger is provided with means (not shown) for driving the plunger downwardly in the direction illustrated by the arrow 5. It can be seen that the stack of sheets 1 is located in position within the hollow interior defined by the "U" shaped former 3 and then the plunger 4 is driven downwardly, thus providing a stack of sheets compressed in one direction, the stack of sheets having a substantially square exposed end face.
  • FIG 3 a heated platen 5 is applied to the exposed end face of the stack of sheets. Since the sheets have, as described above, some thermoplastic properties, the sheets become fused together, and the fused portion of the material 6 forming the sheets is clearly visible in Figure 4, which shows the situation that exists when the heated platen has been removed. It can be seen that there is a slight recess defined between the fused material 6 and the ends of the former 3 and plunger 4.
  • a molten backing material has been inserted into the depression and has been permitted to cool.
  • the molten backing material may comprise limestone filled bitumen, although it is to be appreciated that a filled thermoplastic backing, such as a filled plastisol, or filled molten PVC could be utilised.
  • the backing material 7 cools, within the recess, and partially solidifies.
  • the stack, together with the cooled backing material is then pushed partially from the recess and plunger by a platen 8 which is illustrated as pushing upwardly in Figure 6.
  • a backing scrim 9 may be applied to the partly solid bitumen or thermoplastic backing 7.
  • any required product identification is printed onto the backing, by printing members 10 although it is to be appreciated that a pre-printed backing sheet may be utilised if desired.
  • the protruding part of the stack is then cut off either by utilising a mechanical cutter, such as, for example, a continuous abrasive belt cutter, or by utilising a high pressure fluid jet cutter or a laser cutter.
  • the stack is cut flush with the end faces of the trough 3 and plunger 4.
  • the part of the stack that is cut off is, of course, the part of the stack associated with the backing member, and this part of the stack then constitutes a square section of carpet, as shown in Figure 9.
  • the cut surface is then brushed to produce a required pile surface, and it is to be appreciated that fibres and binder removed during the process may be stored for reuse in the manufacture of the sheets 1 utilised as the first step of the process.
  • the finished carpet tile will be checked for quality control and will then be packed for delivery.
  • the above described bitumen material will shrink on cooling, and also the compressed sheets will relax after being cut from the rest of the stack, since the stack is under considerable pressure. This will ensure that the carpet tile 11, as shown in Figure 10, will have at least two opposed outwardly inclined side edges in the region of the pile. Thus, when tiles of this type are laid the outwardly inclined edges of the pile will serve to disguised joins between adjacent tiles, and will tend to prevent the above described recesses or valleys forming between adjacent tiles when the tiles have been laid. It is to be appreciated that the above described process provides tiles that have primarily two opposed outwardly inclined edges. However, if two perpendicular compressional forces are applied to the stack, the tile may have four outwardly inclined side edges. This can be achieved by utilising sheets that are slightly wider than the distance between the side walls of the "U" shaped former 3, or can be achieved by utilising an "L" shaped former and two plungers.
  • the stacks may be inserted in the former 3, and the former can then be located on a "carousel" type machine.
  • the stack within the former will then be compressed by the plunger 4 and wil move through sequential work stations where the various process steps described above will be performed.
  • the former in the condition illustrated in Figure 8, will be returned to the first operational station where the platen 5 is introduced to the exposed ends of the sheets contained within the former. The process will be repeated until the supply of sheets within the former is totally exhausted. A fresh stack of sheets will then be inserted in position.
  • the sheets 1 may comprise a stack of sheets of polymeric film. Some, or all of the polymeric films could be pre-textured to increase the body of the carpet, or alternatively the films could have different degrees of cross linking of the polymer, so that the films would respond differently to a subsequent heat treatment. Hence texturing could be introduced into certain areas of the resultant carpet tiles. Alternatively the polymer films could have different degrees of cross linking that respond to radiation by a high energy electron beam. An electron beam could then be provided to generate patterns in the carpet tiles by "writing" with the beam in a predetermined configuration.
  • the polymeric films could be coloured, and precoloured polymeric films could be stacked in a predetermined order to provide a desired design for each carpet tile. Of course, provided that the polymeric films are appropriately printed there will be no problems with registration.
  • the sheets 1 can be prepared by the use of a technique closely relating to a paper-making technique.
  • the fibres would, during the paper making process, be substantially aligned with the longitudinal axis of the sheets, and it will be appreciated that by following this route it would be possible to produce sheets including cellulose fibres, viscose fibres or thermoplastic fibres. It is envisaged that it may be possible to incorporate animal hairs in sheets formed by such a process. Self-coloured fibres could be utilised when forming the fibrous sheets or the fibrous sheets could, after being manufactured, be pattern-colour printed. Again, in this way, pattern variations can be introduced into tile surface by appropriate stacking of appropriately printed coloured sheets.
  • sheets made by a paper-making-type process as described above and polymeric films may both be utilised in forming a stack of sheets to be utilised in a process in accordance with the invention.
  • the heated platen 5 was utilised to fuse the exposed ends of the sheets with the primary function of fusing or bonding the sheets together.
  • the exposed ends of the sheets may be fused by using a flame, or may be coated with an adhesive which may be a heat-curing or a radiation-curing adhesive. In such cases heat, or radiation, would be applied to the adhesive to cause the adhesive to cure.
  • any other form of adhesive could be utilised, as may be appropriate.
  • a process in accordance with the invention may operate on a substantially continuous basis. It is envisaged that, in such a process, a plurality of reels of sheet will be provided, and the ends of the reels will be withdrawn and stacked to form a substantially continuous stack corresponding to the stack illustrated in Figure 1. The stack will then be introduced to a continuous processing machine, and as the processing machine draws the stack through the machine, so further portions of the respective sheets will unwind from the reels.
  • the apparatus will include means capable of compressing the stack in at least one direction transverse to the direction of advance of the stack, the means being such that the stack can be advanced under pressure, and the exposed end of the stack can be treated to bond together the elements comprising the stack, to apply a backing material, if desired, and to cut the thus-formed carpet tile from the rest of the stack.
  • a plurality of separate lockable frames may be utilised to engage and advance the stock, a frame advancing to the front face of the stack being removed and replaced at the rear of the stacks.
  • two or morc compressing endless belts (similar to conveyor belts, but pressed firmly into contact with the edges of the stack to compress and advance the stack) may be used.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Carpets (AREA)
  • Floor Finish (AREA)
EP83300200A 1982-01-18 1983-01-14 Tapis et procédé pour fabriquer du tapis Withdrawn EP0084446A3 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8201329 1982-01-18
GB8201329 1982-01-18

Publications (2)

Publication Number Publication Date
EP0084446A2 true EP0084446A2 (fr) 1983-07-27
EP0084446A3 EP0084446A3 (fr) 1983-08-24

Family

ID=10527689

Family Applications (1)

Application Number Title Priority Date Filing Date
EP83300200A Withdrawn EP0084446A3 (fr) 1982-01-18 1983-01-14 Tapis et procédé pour fabriquer du tapis

Country Status (2)

Country Link
EP (1) EP0084446A3 (fr)
WO (1) WO1983002467A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5392708A (en) * 1992-08-28 1995-02-28 Textilma Ag Method and apparatus for handling a packet of pieces cut from a band

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH377773A (de) * 1961-08-10 1964-02-14 Schneiter Siegenthaler & Co Filzteppich und Verfahren zu seiner Herstellung
US3334006A (en) * 1963-01-22 1967-08-01 Du Pont Bonded pile article and process for the production thereof
BE634458A (fr) * 1963-06-27
US3359147A (en) * 1963-12-30 1967-12-19 Paul E Miller Non-woven patterned pile making method and apparatus
FR1411087A (fr) * 1964-07-15 1965-09-17 Elektrochem Fab Kempen Rhein Fabrication de moquettes de velours à partir de nappes de carde
BE754751A (fr) * 1969-08-13 1971-02-12 Monsanto Co Materiaux non tisses comportant des poils, et procedes et appareils pour les fabriquer
US3740080A (en) * 1971-11-10 1973-06-19 Gen Motors Corp Cushioned hook for a push-pull type vehicle coupling

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5392708A (en) * 1992-08-28 1995-02-28 Textilma Ag Method and apparatus for handling a packet of pieces cut from a band
BE1008355A3 (fr) * 1992-08-28 1996-04-02 Textilma Ag Procede et installation pour traitement d'un paquet de sections de bandes.

Also Published As

Publication number Publication date
EP0084446A3 (fr) 1983-08-24
WO1983002467A1 (fr) 1983-07-21

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Inventor name: GREEN, ANTHONY KENNETH

Inventor name: STEWART, DUNCAN

Inventor name: BOWYER, WILLIAM HENRY