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Carpet tile primary backing systems and methods

a technology of primary backing and carpet tiles, which is applied in the field of nonwoven fabric manufacturing, can solve the problems of tufts being susceptible to dislocation from the primary backing, and achieve the effects of enhancing tufting and securing characteristics, and enhancing strength and elasticity

Inactive Publication Date: 2011-10-27
JOHNS MANVILLE CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

Embodiments of the present invention encompass production methods for making a spunbond fabric that can be used as carpet tile primary backing. Exemplary products can include a spunbond fabric which is chemically bonded with a crosslinked emulsion latex binder system. The chemically bound spunbond provides enhanced strength and elasticity to attain the desired grip force for carpet tile backing application. Relatedly, carpet primary backing fabrics provided herein exhibit enhanced tufting and tuft securing characteristics.
Frequently, after the tufting process, but before the latex adhesive has been applied, the tufts are susceptible to dislodgment from the primary backing. It is desirable to reduce or minimize the amount of rework required between these steps to reinsert any tufts that were dislodged before the latex adhesive is applied.
Advantageously, unique emulsion latex binder compositions can be used during the backing production process to achieve carpet backing materials having improved performance properties. For example, production methods may entail treating a nonwoven web with an emulsion latex binder composition that includes an emulsion latex and a crosslinker. Such treated nonwoven webs exhibit useful characteristic profiles that include low insertion resistance, high gripping force, and high dimensional stability.

Problems solved by technology

Frequently, after the tufting process, but before the latex adhesive has been applied, the tufts are susceptible to dislodgment from the primary backing.

Method used

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  • Carpet tile primary backing systems and methods
  • Carpet tile primary backing systems and methods
  • Carpet tile primary backing systems and methods

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Embodiment Construction

Embodiments of the present invention encompass spunbonds and methods of their preparation that involve crosslinked binder systems. These techniques provide enhanced Quality Knee and Defect Peak values, or Tuft Grip parameters, while maintaining low Penetration Resistance and high dimensional stability.

Polyester or polyolefin spunbond can be manufactured by feeding a thermoplastic polymer into an extruder, feeding the extruded molten polymer through a spinneret to form continuous filaments, and laying down the extruded filaments on a moving conveyor belt to form a nonwoven web of randomly arranged continuous filaments. In the lay-down process, desired orientation can be imparted to the filaments by the rotation of the spinneret, introduction of controlled airstreams, or varying the speed of the conveyor belt. The individual entangled filaments in the nonwoven web can be bonded with an emulsion latex binder composition which can be dried and crosslinked in a heated oven.

Embodiments of...

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Abstract

Tuftable nonwoven fabric compositions and methods for their preparation are provided. Fabric compositions may include a nonwoven web of continuous filaments, and an emulsion latex binder composition having an emulsion latex and a crosslinker. Exemplary techniques for constructing a nonwoven composition include forming continuous filaments of thermoplastic polymer, placing the filaments on a moving belt to form a nonwoven web, and treating the web with an emulsion latex binder composition having an emulsion latex and a crosslinker.

Description

BACKGROUND OF THE INVENTIONEmbodiments of the present invention relate generally to methods of manufacturing nonwoven fabrics with emulsion latex binders, and in particular to methods of preparing primary carpet backing mats with binders that contain an emulsion latex and a crosslinker.A tufted carpet is generally manufactured by inserting reciprocating needles threaded with a face yarn through a primary backing material to form loops or tufts of yarn in the backing. The quality, appearance, and dimensional stability of tufted carpets depends in large part on the properties of the primary backing.Primary backings are usually produced from woven or nonwoven materials. Tufting into nonwoven materials is more difficult than tufting into woven materials. A woven fabric will open within the weave to accept the tufting needle and yarn and will then close around the tufted yarn after the needle has retracted. The closing property of woven fabrics provides a firm grip on the yarn in the ope...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D04H3/16D04H3/12
CPCD04H3/16D04H3/12Y10T442/60
Inventor NANDI, SOUVIK
Owner JOHNS MANVILLE CORP
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