Process of thermal transfer using hot melt adhesive lamination for forming a carpet backing and finished carpet or tile product

Abstract

A method for binding a greige carpet and a secondary backing material using a hot melt adhesive is disclosed. A heated application roll may be provided and the secondary backing material may be contacted with the hot melt adhesive and greige carpet and pressed against the heated application roll.

Description

[0001] This application claims priority to provisional application Ser. No. 60 / 614,966, filed Oct. 4, 2004, entitled, “Process of Thermal Transfer Using Hot Melt Adhesive Lamination for Forming a Carpet Backing and Finished Carpet or Tile Product,” Ser. No. ______ attorney docket No. 62136.000032, the disclosure of which is incorporated by reference herein in its entirety.FIELD OF THE INVENTION [0002] Embodiments of the invention relate generally to finishing systems for tufted primary backing carpets and more specifically to systems that bind greige carpet and secondary backing material using hot melt adhesives. DESCRIPTION OF RELATED ART [0003] The primary component of conventional broadloom carpet products such as carpet tiles is tufted “greige” carpet. Greige carpet generally comprises fiber tufts looped around a primary backing fabric. Primary backing fabrics may be woven, nonwoven, or spun bonded natural or synthetic materials. The tufted loops of fiber may be left intact or s...

AI Technical Summary

Benefits of technology

[0021] It therefore would be desirable to bind a greige carpet with a secondary backing material using a hot melt adhesive in a single-pass process that provides for excellent penetration of the hot melt adhesive into the yarn fiber tufts of the greige carpet while minimizing shrinkage and general deterioration of the greige carpet. It also would be desirable to provide a process of making a secondary backing material the provides improved fire retardancy for the carpet material, and preferably so that the carpet materials pass a Class 1 fire rating.

Problems solved by technology

However, such an adhesive often does not have adequate mechanical strength to impart dimensional stability to the greige carpet.

Higher process temperatures may cause the greige carpet to shrink and may damage the primary backing material and fiber tufts, resulting in a loss of finished carpet and increased manufacturing costs.

The dichotomy between low viscosity and low application temperature sometimes makes application of hot melt adhesives difficult.

Nipping at pressures, however, may result in distortion of the carpet because of the flattening of the fiber tufts at the face side of the carpet.

However, heated lamination rolls are often sullied by loose fibers that adhere to the roll, therefore necessitating shut down for cleaning.

Forming a multi-layered hot melt adhesive, however, may introduce additional complexity and cost into the manufacturing process.

Again, pre-forming an adhesive layer may introduce additional complexity and cost in the manufacturing process.

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