METHOD FOR MANUFACTURING A CARPET OR A RUG AND A CARPET OR RUG OBTAINED THEREBY

Abstract

Method for manufacturing a carpet or a rug, comprising the following steps: the step (S1-S2) of providing a primary backing (1), being a woven or non-woven layer comprising filaments (2) of polyethyleneterephthalate and copolymer of polyethyleneterephthalate, the coPET having a lower melting temperature than the PET and wherein said PET is available in said primary backing (1) in a higher amount than said coPET; the step of providing a glue layer (11) consisting for 50% or more out of coPET; the step of tufting yarn at least into said primary backing (1); the step of activating said glue layer (11) at least for partially fixing said yarn (12) on said primary backing (1). The invention also concerns carpets (16) and rugs that are obtained or obtainable by means of such method.

Claims

1-30. (canceled)

31. Method for manufacturing a carpet or a rug, wherein the method comprises at least the following steps: the step of providing a primary backing; the step of providing a glue layer; the step of tufting yarn at least into said primary backing; the step of activating said glue layer at least for partially fixing said yarn on said primary backing; characterized in that said primary backing is a woven or non-woven layer comprising, filaments comprising polyethylene terephthalate (PET); said glue layer is a layer comprising copolymer comprising polyethylene terephthalate (coPET) wherein the coPET has a lower melting temperature than the PET.

32. Method according to claim 31, characterized in that said glue layer is a woven or non-woven layer comprising filaments comprising coPET.

33. Method according to claim 32, characterized in that said filaments in said glue layer at least comprise bicomponent filaments comprising PET and coPET.

34. Method according to claim 31, characterized in that the primary backing comprises PET filaments and coPET filaments

35. Method according to claim 31, characterized in that said glue layer is at least provided as a powder comprising said coPET.

36. Method according to claim 31, characterized in that said glue layer is at least provided as a liquid comprising said coPET.

37. Method according to claim 31, characterized in that said coPET is available in said glue layer in an amount of at least 20 weight percent.

38. Method according to claim 31, characterized in that said glue layer is applied to the primary backing after said primary backing has been tufted.

39. Method according to claim 31, characterized in that said glue layer is applied to the primary backing before said primary backing is tufted, wherein the step of tufting comprises tufting yarn into at least said primary backing and said glue layer.

40. Method according to claim 31, characterized in that said step of activating said glue layer is at least executed with heat and/or pressure.

41. Method according to claim 31, wherein the method comprises the further step of joining a secondary backing layer to the combination of the primary backing and the glue layer.

42. Method according to claim 41, wherein said secondary backing layer is a nonwoven or foam layer with internal cavities from PET, coPET or combinations of PET and coPET.

43. Method according to claim 41, characterized in that the secondary backing is joined to the primary backing by the glue layer and a second glue layer, the second glue layer comprising powdery or liquid PET, coPET or a combination of PET and coPET.

44. Method according to claim 31, characterized in that said primary backing is a woven or non-woven layer comprising continuous filaments of polyethylene terephthalate (PET)

45. Method according to claim 31, characterized in that said primary backing is a woven or non-woven layer comprising filaments of polyethylene terephthalate (PET) and copolymer of polyethylene terephthalate (coPET), wherein the coPET has a lower melting temperature than the PET and wherein said PET is available in said primary backing in a higher amount than said coPET.

46. Method according to claim 31, characterized in that said glue layer is a layer comprising at least 15% of coPET.

47. Method according to claim 31, characterized in that said yarn is a yarn based on PET.

48. Method according to claim 31, characterized in that said filaments in said primary backing comprise at least bicomponent filaments.

49. Method according to claim 48, characterized in that said bicomponent filaments are of the sheath/core type, wherein the core is PET, while the sheath is coPET.

50. Method according to claim 31, characterized in that the primary backing comprises PET filaments and coPET filaments

51. Method according to claim 31, characterized in that said PET is available in said primary backing in an amount of at least 60 weight percent.

52. Method according to claim 31, characterized in that said primary backing is a non-woven layer provided by means of spunbonding technology, meltblowing, carding and/or needling.

53. A carpet or rug comprising a primary backing being a woven or non-woven layer comprising filaments comprising polyethylene terephthalate (PET), anchored to each other by means of masses of copolymer of polyethylene terephthalate (coPET); a tufted pile tufted on said primary backing, said pile being present at a first side of the primary backing; and, a glue layer present at the second side of the primary backing, said glue layer resulting from a coPET matrix further comprising filaments comprising PET embedded in said coPET matrix.

54. A carpet or rug according to claim 53 further comprising: a secondary backing layer which is present at the side of the glue layer opposite to the side of the glue layer which is contacting the primary backing.

Description

[0130] With the intention of better showing the characteristics according to the invention, in the following, as examples without limitative character, some embodiments are described, with reference to the accompanying drawings, wherein:

[0131] FIG. 1 schematically illustrates the step of providing a primary backing or a glue layer in a method in accordance with amongst others the first aspect of the invention;

[0132] FIGS. 2 and 3 are photographs taken with a microscope showing the filaments of the glue layer in a cross-section according to lines II-II of FIG. 1 for two different compositions of bicomponent filaments;

[0133] FIGS. 4 and 5 are photographs taken with a larger magnification of the glue layers of FIGS. 2 and 3 respectively;

[0134] FIG. 6 in a larger view illustrates the technique of through air bonding as a variant for the area indicated with F6 in FIG. 1;

[0135] FIG. 7 represents a tufted primary backing;

[0136] FIG. 8 schematically illustrates the step of providing the glue layer on the tufted primary backing of FIG. 7;

[0137] FIGS. 9 and 10 on a larger scale show cross-sections according to the lines IX-IX, and X-X respectively in FIG. 8;

[0138] FIGS. 11 to 13 in a view similar to that of FIG. 10 represent variants;

[0139] FIG. 14 in a view similar to that of FIG. 8 represents a variant; and

[0140] FIG. 15 on a larger scale shows a view on the area indicated with F15 in FIG. 14.

[0141] The present invention will be described with respect to particular embodiments. It is to be noticed that the term comprising, used in the claims, should not be interpreted as being restricted to the means listed thereafter; it does not exclude other elements or steps. It is thus to be interpreted as specifying the presence of the stated features, steps or components as referred to, but does not preclude the presence or addition of one or more other features, steps or components, or groups thereof. Thus, the scope of the expression a device comprising means A and B should not be limited to devices consisting only of components A and B. It means that with respect to the present invention, the only relevant components of the device are A and B.

[0142] Throughout this specification, reference to one embodiment or an embodiment are made. Such references indicate that a particular feature, described in relation to the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment, though they could. Furthermore, the particular features or characteristics of different aspects of the invention may be combined in any suitable manner, such as in one or more embodiments, as would be apparent to one of ordinary skill in the art.

[0143] When reference is made to a percentage (%), unless otherwise indicated this percentage refers to weight percentage, i.e. the weight of the component itself over the total weight of the composition in which the component is present.

[0144] Unless otherwise indicated, the term amount refers to the amount in weight.

[0145] FIG. 1 illustrates an exemplary step S1 of providing a primary backing 1. In this case the primary backing 1 is a non-woven layer comprising continuous filaments 2, provided by spunbonding technology. In this case the filaments 2 are bicomponent filaments. Two extruders 3, each for one of the components of the filaments, are fed with respective polymer chips through respective inlets 4. Filaments 2 are formed by extrusion and drawing through a spinning die 5. The filaments 2 are laid on a moving screen or belt 6 to form a web. The web may, like in the example, optionally be subjected to a bonding step S2 e.g. by calender bonding. In calender bonding the web of loose filaments 2 is passed through the nip 7 of a set of rollers 8, of which preferably at least one is heated. One or more of the rollers 8 may optionally be patterned.

[0146] FIG. 2 shows that, as afore stated, bicomponent filaments 2 of the sheath 9/core 10 type may be produced, in this case illustrated for the glue layer 11. These filaments are obtained through a process similar as that illustrated in FIG. 1. The core 9 consists of a first polymer, and the sheath 10 consists of a lower melting second polymer, wherein the first polymer, preferably PET, is available in said glue layer in an amount of 50 wt % or less, while said second polymer, preferably coPET, is available in an amount of 50 wt % or more. In accordance with a preferred embodiment of the first aspect of the invention the core 9 consists of PET, while the sheath 10 consists of coPET. A concentric configuration is used with a ratio PET/coPET of about 50/50. The illustrated glue layer is uncompacted and unbounded.

[0147] FIG. 3 shows bicomponent filaments 2 of an alternative glue layer. In accordance with a preferred embodiment of the first aspect of the invention the core 9 consists of PET, while the sheath 10 consists of coPET. A concentric configuration is used with a ratio PET/coPET of about 20/80. The glue layer 11 is uncompacted and unbounded. The glue layer 11 of FIG. 3 exhibits higher loft than the glue layer 11 of FIG. 2. The loft is at least partially to be attributed to the differential shrinking of the material of the sheath 10 and core 9 of the filaments 2. FIG. 3 shows some fusing between the filaments 2, which is due to the filaments 2 touching as they move due to shrinking.

[0148] FIG. 4 illustrates the glue layer 11 of FIG. 2 at a larger scale, and FIG. 5 illustrates the glue layer 11 of FIG. 3 at a larger scale.

[0149] The filaments 2 of the glue layer 11 are of a lower dpf size than the filaments 2 of the primary backing 1. The filaments 2 of the illustrated glue layer 11 have a size smaller than 5 dpf, while the filaments 2 of the primary backing 1 preferably have a size larger than 6 or larger than 8 dpf. The surface weight of the primary backing 1 is above 100 grams per square meter. The surface weight of the glue layer 11 is above 85 grams per square meter.

[0150] FIG. 6 illustrates through air bonding as an alternative technology for the calender bonding of FIG. 1. This technology involves passing hot air through the unbonded web in order to heat and at least partially melt the second polymer or coPET. In the through air bonding process the applied pressure is minimum and almost no compaction of the web is obtained.

[0151] FIG. 7 shows the primary backing 1 after the step of tufting yarn 12. As indicated with the line 13 the loops 14 of the yarn 12 are preferably cut to create the piles 15 of the carpet 16. The yarn 12 is preferably a PET yarn that may be obtained from recycled material, e.g. from PET bottles.

[0152] FIG. 8 schematically illustrate how the glue layer 11 can be provided on the back 17 of the tufted primary backing 1. The whole 18 can then be fused, wherein the glue layer 11 is activated for at least partially fixing the yarn 12 or piles 15 on said primary backing 1. The fusing operation is in the example executed in a rotary thermal lamination device 19. The primary backing 1 and the glue layer 11 are lead over a heated drum 20. Pressure P is applied to the whole by means of the conveyor 21. Alternatively, but not illustrated here, one or more nip rolls could be used as well for creating the pressure P.

[0153] FIGS. 9 and 10 respectively show the carpet 16 before and after activation of the glue layer 11.

[0154] FIGS. 11 and 12 show alternative embodiments wherein the yarn 12 is tufted into both the primary backing 1 and the glue layer 11. In the case of FIG. 11 the glue layer 11 is applied underneath or at the back 17 of the primary backing 1. In FIG. 12, the glue layer 11 is applied on top of the primary backing 1, namely at the side of the carpet 16 which will be facing up in use.

[0155] FIG. 13 shows a further example wherein a second glue layer 11B has been applied to the embodiment of FIG. 12, such that the primary backing 1 at both flat sides thereof is flanked by a glue layer 11A-11B. The tufting operation has been carried out on the assembly of the primary backing 1 and the first glue layer 11A. The second glue layer 11B has been applied after the tufting operation, in the same or similar way as was the case for FIGS. 9 and 10. It is clear that a similar embodiment could be reached by tufting in all three of the primary backing 1, the first glue layer 11A and the second glue layer 11B.

[0156] According to a special embodiment, not represented here, a sandwich is made of, from top to bottom, a first primary backing, a glue layer, and a second primary backing, wherein the sandwich is tufted. Preferably the second primary backing is of a lower surface weight than the first primary backing. For example, the first primary backing may have a weight of 100 grams per square meter or higher, while the second primary backing has a weight of between 40 and 85 grams per square meter. It is clear that for the composition of the primary backings and the glue layer the compositions disclosed earlier may be used. Preferably, the primary backings are non-woven layers of continuous bicomponent filaments having a ratio PET/coPET of more than 50 percent, for example about 80/20. The glue layer is preferably a non-woven layer of continuous bicomponent filaments having a ratio PET/coPET of less than 50 percent, for example about 20/80.

[0157] FIG. 14 illustrates a method in accordance with amongst others the third independent aspect of the invention, wherein the glue layer 11B is provided in powder form. As illustrated here the powder 22 may be distributed on the bottom of the tufted substrate, e.g. on the bottom side or back of the tufted primary backing 1. The distribution may be executed by means of a scattering or strewing apparatus 23. As schematically illustrated in FIG. 15, the powder 22 is dropped from a reservoir 24 on a patterned roller 25, from which it is released by gravity and/or vibration and/or rubbing e.g. with a brush 26.

[0158] As explained in the introduction the powder 22 may be a mixture of glue powder, e.g. coPET powder, and filler material, e.g. sand or chalk, or may comprise granulate formed from both glue and filler material. According to an alternative a plurality of powder depositing operations may be performed, for example at least one with glue and at least one with filler material.

[0159] In the particular case illustrated in FIG. 15, the powder 22 is applied as a second glue layer 11B on the back of a tufted substrate comprising both a primary backing 1 and a first glue layer 11A. It is however clear that any glue layer 11 may be applied by means of powder deposition.

[0160] It is further clear that any of the glue layers 11 may comprise filler material. Preferably only the glue layers 11 that are not tufted comprise filler materials.

[0161] The present invention is in no way limited to the above described embodiments, but such methods, carpets and rugs may be realized according to several variants without leaving the scope of the invention.

[0162] The invention further relates to the following methods and carpets as defined by the below numbered paragraphs.

[0163] 1.A method for manufacturing a carpet or a rug, wherein the method comprises at least the following steps: [0164] the step (S1-S2) of providing a primary backing (1); [0165] the step of providing a glue layer (11); [0166] the step of tufting yarn (12) at least into said primary backing (1); [0167] the step of activating said glue layer (11) at least for partially fixing said yarn (12) on said primary backing (1);

[0168] characterized in that [0169] said primary backing (1) is a woven or non-woven layer comprising, filaments (2) comprising polyethylene terephthalate (PET); [0170] said glue layer (11) is a layer comprising copolymer comprising polyethylene terephthalate (coPET) wherein the coPET has a lower melting temperature than the PET.

[0171] 2.A method according to paragraph 1 above, characterized in that said primary backing (1) is a woven or non-woven layer comprising continuous filaments (2) of polyethylene terephthalate (PET).

[0172] 3.A method according to paragraph 1 or 2 above, characterized in that said primary backing (1) is a woven or non-woven layer comprising filaments (2) of polyethylene terephthalate (PET) and copolymer of polyethylene terephthalate (coPET), wherein the coPET has a lower melting temperature than the PET and wherein said PET is available in said primary backing (1) in a higher amount than said coPET.

[0173] 4.A method according to any one of the paragraphs 1 to 3, characterized in that said glue layer (11) is a layer comprising at least 15% of coPET.

[0174] 5.A method according to any of the paragraphs 1 to 4, characterized in that said yarn (12) is a yarn based on PET.

[0175] 6.A method according to any of the paragraphs 1 to 5 above, characterized in that said filaments (2) in said primary backing (1) at least comprise bicomponent filaments (2).

[0176] 7.A method according to paragraph 6 above, characterized in that said bicomponent filaments (2) are of the sheath/core type,

[0177] 8.A method according to paragraph 7 above, characterized in that the core (9) is PET, while the sheath (10) is coPET.

[0178] 9.A method according to any of the paragraphs 1 to 5 above, characterized in that the primary backing comprises PET filaments and coPET filaments

[0179] 10.A method according to any of the paragraphs 1 to 9 above, characterized in that said PET is available in said primary backing in an amount of at least 60 weight percent.

[0180] 11.A method according to any of the paragraphs 1 to 8 above, characterized in that the primary backing is of 100% PET.

[0181] 12.A method according to any of the paragraphs 1 to 11 above, characterized in that said primary backing (1) is a non-woven layer.

[0182] 13.A method according to paragraph 12 above, characterized in that said primary backing (1) is provided by means of spunbonding technology, meltblowing, carding and/or needling.

[0183] 14.A method according to any of the paragraphs 1 to 13 above, characterized in that said glue layer (11) is a woven or non-woven layer comprising filaments (2) comprising coPET.

[0184] 15.A method according to paragraph 14 above, characterized in that said filaments (2) in said glue layer (11) at least comprise bicomponent filaments (2) comprising PET and coPET.

[0185] 16.A method according to any of the paragraphs 1 to 14 above, characterized in that the primary backing comprises PET filaments and coPET filaments

[0186] 17.A method according to any of the paragraphs 1 to 11 above, characterized in that said glue layer (11) is at least provided as a powder (22) comprising said coPET.

[0187] 18.A method according to any of the paragraphs 1 to 11 above, characterized in that said glue layer (11) is at least provided as a liquid comprising said coPET.

[0188] 19.A method according to paragraph 18 above, characterized in that the liquid is molten coPET.

[0189] 20.A method according to any of the paragraphs 1 to 19 above, characterized in that said coPET is available in said glue layer (11) in an amount of at least 20 weight percent.

[0190] 21.A method according to any of the paragraphs 1 to 20 above, characterized in that said glue layer (11) is applied to the primary backing (1) after the relevant part of said primary backing (1) has been tufted.

[0191] 22.A method according to any of the paragraphs 1 to 20 above, characterized in that said glue layer (11) is applied to the primary backing (1) before the relevant part of said primary backing (1) is tufted, wherein the step of tufting comprises tufting yarn (12) into at least said primary backing (1) and said glue layer (11).

[0192] 23.A method according to any of the paragraphs 1 to 22 above, characterized in that said step of activation said glue layer (11) is at least executed with heat and/or pressure,

[0193] 24.A method according to paragraph 23 above, characterized in that said step of activation said glue layer (11) is at least executed by means of calender bonding or by means of a rotary thermal lamination device (19).

[0194] 25.A method according to any one of the paragraphs 1 to 24 above, wherein the method comprises the further step of joining a secondary backing layer to the combination of the primary backing and the glue layer.

[0195] 26.A method according to paragraph 25 above, wherein said secondary backing layer is an layer with internal cavities from PET, coPET or combinations of PET and coPET.

[0196] 27.A method according to paragraph 25 or 26 above, wherein said secondary backing layer is a nonwoven or a foam layer.

[0197] 28.A method according to any one of the paragraphs 25 to 27 above, characterized in that the secondary backing is joined to the primary backing by means of the glue layer or using a second glue layer, the secondary glue layer comprising or consisting of powdery or liquid PET, coPET or a combination of PET and coPET.

[0198] 29.A carpet or rug comprising [0199] a primary backing being a woven or non-woven layer comprising filaments comprising polyethylene terephthalate (PET), anchored to each other by means of masses of copolymer of polyethylene terephthalate (coPET); [0200] a tufted pile tufted on said primary backing, said pile being present at a first side of the primary backing; [0201] a glue layer present at the second side of the primary backing, said glue layer resulting from a coPET matrix further comprising filaments comprising PET embedded in said coPET matrix; [0202] optionally a secondary backing layer which is present at the side of the glue layer opposite to the side of the glue layer which is contacting the primary backing.