JPH04245954A - Pile fabrics joined by latex adhesive agent and method for connecting yarn - Google Patents

Abstract

PURPOSE: To obtain a latex adhesive-bonded pile fabric having good bundle- bonding, and improved pilling and fuzzing properties. CONSTITUTION: This pile fabric is constituted of a liquid-permeable base layer, and piles formed by a yarn adjacent to the base layer and not tufted through the base layer but bent. The yarn is bonded to the base layer by means of supplying a latex adhesive on the back surface of the base layer and compulsorily making the adhesive to pass the base layer.

Description

[Detailed description of the invention]

0001

FIELD OF THE INVENTION This invention relates to pile fabrics. More specifically, the present invention relates to latex adhesive bonded pile fabrics and latex adhesive bonded carpet tiles.

[0002] Pile fabrics such as carpets are produced by weaving,
It can be manufactured in several ways such as tufting, needling or gluing. In each method, the pile must be affixed to the base or support layer in some way. The invention relates, in one aspect, to a manufacturing method, in particular in which the pile is adhered to a base layer by means of a latex adhesive. Such fabrics are variously referred to herein as latex adhesive bonded pile fabrics or latex adhesive bonded carpets.

0003

BACKGROUND OF THE INVENTION A method of applying a preformed base layer with a layer of adhesive and then pressing the yarn of the pile growth into the adhesive to adhere the pile growth to the base layer. Many methods of manufacturing bonded pile fabrics are known.

Previous commercial techniques for making adhesive fabrics relied on the use of polyvinyl chloride (PVC) plastisol formulations. The use of other adhesive formulations, such as hot melt and latex adhesive systems, is considered to be disadvantageous in processing. According to that technique, before positioning the pile-forming yarns relative to the base layer,
Apply polyvinyl chloride plastisol to the base layer. The pile yarn is then placed in contact with the base layer and the plastisol can be melted or hardened, typically by heating. Difficulties arise when attempting to use other adhesives, such as hot melt adhesives, in place of PVC plastisol in this process. That is,
For example, with hot melt adhesives, the equipment used to position the yarns typically becomes coated with adhesive and requires frequent interruptions of the equipment for cleaning, which is referred to as Needless to say, it is considered commercially unattractive.

Thus, although PVC plastisol is the adhesive of choice in the production of bonded pile fabrics, there are disadvantages associated with the use of PVC plastisol in the production of such fabrics. That is, the PVC plastisol may not penetrate into the yarn bundle to the desired extent to achieve complete adhesion of all the pile yarn fibers of the pile yarn bundle to the pile fabric structure. Other typical disadvantages associated with using PVC plastisols as adhesives in the manufacture of bonded pile fabrics are detailed in U.S. Reissue Patent RE 31,826 to Machell (assignee Milliken Research Corporation). It is being

Another disadvantage typically associated with the prior art for producing bonded or non-tufted pile fabrics, ie, fabrics in which the pile yarns are simply glued to the backing rather than being tufted to it, is that the adhesive , is applied to the base layer on the side of the base layer facing the pile yarn, and the base layer is generally such that the adhesive does not flow through it and may penetrate somewhat into the base layer but remain substantially on its surface. The point is that it has a structure that makes it difficult to understand. Therefore, if a backing layer, for example a hard backing, is to be applied to the back side of a pile fabric, as is desired for the manufacture of carpet tiles, the base layer must be adhered directly to the backing layer or An additional step is required to apply the adhesive. In either case, a number of distinct layers result in the final product: pile layers, adhesive layers, base layers, other adhesive layers and hard backing layers. Such a structure is
It is inherently disadvantageous in processing and expensive to manufacture.

Machell's US Reissue Patent RE 31,
No. 826 provides a bonded pile fabric in which the adhesion of the pile-forming yarns to the base layer can be achieved with a hot melt adhesive. There, a hot melt adhesive is applied to a liquid permeable layer from the back of the base layer, forcing it to pass through the base layer, and the one-step adhesive layer is a means for adhering the pile yarn to the base layer. A method and apparatus are disclosed that can provide both a backing layer and a means for integrally securing the backing layer to the base layer. The resulting product is less complex, less expensive to manufacture, and there are fewer distinct, distinct layers in the final product that could cause unwanted separation.

[0008] In contrast to traditional adhesive carpet tiles,
Tiles backed with water-based adhesives are generally easier to cut during manufacturing and installation. Latex adhesive-based products also typically have a relatively soft texture and are therefore easier to handle than conventional products.

From a manufacturing standpoint, hot melt adhesives:
It is typically applied at temperatures within the range of about 300 to 400 degrees Fahrenheit. These are difficult to handle in hot conditions;
The equipment used to apply this adhesive needs to be heated, which is dangerous and a waste of energy. Latex adhesives, on the other hand, can be applied at room temperature, which greatly facilitates manufacturing operations, especially in terms of safety and cost.

Furthermore, because latex adhesives typically contain significant water-based components, in contrast to conventional adhesives used to make adhesive carpet tiles, they can be applied at much lower viscosities and provide the desired It greatly facilitates the desired yarn bundle penetration to achieve the tuft bonding and minimizes fuzz and other undesirable properties in the final product. Furthermore, latex adhesives can be stored for long periods of time without deterioration and without the need for heating before use.

[0011]

The pile fabric of the present invention comprises a liquid-permeable base layer, a pile formation, preferably in a folded manner, adjacent to the base layer but not tufted thereto. The pile forming yarn is a latex adhesive bonded fabric that is adhered to the base layer with a latex adhesive. Preferably, the latex adhesive is applied to the back of the base layer and forced into contact with the pile-forming yarns through the base layer. However, latex adhesives
It should also be understood that this can be applied to the entire surface of the backing prior to contacting the yarns, or to the folded yarns prior to contacting the backing layer.

[0012] The pile-forming configuration is particularly suitable for the so-called I
- tufted configurations, e.g. non-folded configurations, U-tufted configurations,
and loop pile configurations. Regarding the folded pile formation mode, which is a preferred embodiment, the intention is to:
A pile yarn configuration, such as a cut pile configuration, in which the yarn has at least one fold in its portion, generally where it is closest to the base layer. Other folded configurations contemplated are loop pile configurations in which the pile yarn remains uncut in the form of a substantially continuous folded yarn in the final product. Various pile configurations in unfolded and folded configurations
Described in the attached drawings. According to a most preferred embodiment, the pile yarn is cut to form a folded cut pile product.

According to the method and apparatus of the present invention, the pile-forming yarns are positioned in a pile-forming manner adjacent one side of the liquid permeable base layer. Thereafter, a latex adhesive is applied to the base layer from the opposite side of the base layer and adjacent to the pile-forming yarns. In the next step of the process, the latex adhesive is forced into the base layer and brought into bond-forming contact with the pile-forming yarns, either simultaneously with its application or in a separate step, and the adhesive is then heated to a temperature of about 200 to about 400 degrees Fahrenheit. The pile-forming yarn is cured by heating for about 60 to 500 seconds, thereby adhering the pile-forming yarn to the base layer. The device has means for applying the adhesive and forcing it into the base layer.

In a preferred embodiment of the invention, two successive liquid-permeable base layers are positioned within the passageway in substantially parallel relation to each other with a predetermined spacing;
At least one continuous pile-forming yarn is positioned by a folder blade against an opposing surface of the base layer relative to the base layer when they enter or proximate the passage. applying latex to the back of the base layer, forcing the latex adhesive into the base layer such that the latex adhesive is in contact with the pile-forming yarn; Methods and apparatus are provided for curing an agent to adhere the pile-forming yarn to the base layer. This step of the method provides an additional action, i.e., bonding the individual pile-forming yarns together, typically at or near the portion of the yarn closest to the base layer, thereby improving the woven pile product. This achieves the effect of imparting improved performance. The base layers can then be separated from each other to produce two continuous latex adhesive bonded products. Typically, this separation can be accomplished by a stationary or movable knife blade positioned between the base layers and cutting the pile yarn along the entire width of the combined base layers.

The yarn used to form the pile may be any fiber known to be useful in hot melt bonded fabrics such as carpets, such as nylon, acrylic, polyester, wool, cotton, and rayon. can be made.

A variety of latex adhesives used as carpet backing adhesives for multiple yarns are provided in connection with the present invention. Examples include styrene butadiene (SBR), acrylic acid derivatives, vinyl acetate, vinyl acrylate, aqueous urethanes and the like. SBR emulsions are preferred.

The SBR latex emulsion is prepared in a well-known manner, for example by polymerizing the respective monomers in an appropriate form in an aqueous medium containing an emulsifier and a peroxide catalyst. Emulsion stabilizers such as anionic surfactants are usually added during the polymerization step. Although the SBR latex is typically resistant to binary copolymers of styrene and butadiene, copolymers composed of three or four monomers are useful in the present invention. The preferred latices in the carpet adhesive industry are carboxylated styrene-butadiene polymers with fairly high styrene content.

The emulsion usually contains about 50% water by weight, but may contain more or less water, for example from about 40 to about 60%. Excess water is added to impart the desired workability of the adhesive mixture.

Other additives commonly used in carpet backing adhesives such as fillers, thickeners, antioxidants, antifreeze components, fungicides, corrosion inhibitors and pigments are included in the carpet of the present invention. Present in lining adhesive. Each additive is carefully selected to be compatible with the initial components of the mixture and not to impair the functionality of the other additives.

The carpet backing adhesive of the present invention is applied to carpet by techniques commonly used in the industry. Kiss roll, spreading, and spraying techniques are described in "High Polymer Lattice" (Applied Science, Publisher 1966). Kiss roll application involves pulling the carpet under tension through an assembly roll, brushing and steaming the carpet backing, pressurizing the backside with a kiss roll in which the adhesive is transported from a bath of adhesive in which the kiss roll is rotated, and creating an adhesive coating. The process consists of passing the backside of the carpet through a doctor blade to control the adhesive thickness, and then curing the adhesive with a heater.

Suitable liquid permeable base layers for use in the products and methods of the invention include woven, knitted, nonwoven mats, scrims, felt materials or flexible porous materials.

After applying the latex adhesive, the composite is transferred to a curing oven where the latex adhesive is cured and the water is removed. Previously, it was believed that large amounts of water could be removed from adhesives during the manufacture of bonded floor covering products. Quite the contrary, however, it has been found that when large amounts of moisture are actually transferred to the yarn, the liquid water is converted to steam in the curing oven, bulking up the yarn by not evacuating said steam through an exhaust fan beforehand. Therefore, the presence of moisture in the latex adhesive is a detriment rather than a benefit in terms of the properties of the final floor covering product.

The latex adhesive bonded pile fabrics of the present invention are desirably provided as floor covering products, particularly carpet tiles, for which some of a wide variety of suitable, resilient backing layers are applied as fabrics. This is desirable. Such carpet tiles are considered within the scope of this invention. The backing layer may be made of, for example, ethylene/vinyl acetate copolymer, atactic polyethylene,
It is formed from suitable thermoplastic or thermoset materials such as asphalt, hydrocarbon resins, waxes, polyvinyl chloride compounds, and mixtures including synthetic and natural rubbers.

Previously, the use of latex adhesives in bonded carpet tiles had been abandoned because resilient backing layers, polyvinyl chloride, ethylene vinyl acetate as well as hot melt backing materials were compatible with latex adhesives. This is because it was believed that they were not compatible. However, quite the contrary, it is possible in addition to ensuring that sufficient adhesive is present in the yarns due to the need to further achieve desirable yarn bundle penetration by choosing an appropriate combination of latex adhesive composition, resilient backing layer composition. By providing the greatest chemical bond possible, latex adhesives have been found to be compatible with a wide variety of resilient backing layers. By doing so, voids are removed from between and around the yarn bundles due to chemical adhesion of the second backing material to the preformed structure.

The backing layer is provided with at least a hard and stable membrane, such as woven or non-woven glass fibers, to which the pile layers are bonded by a separate hot melt adhesive. After the reinforcing material is applied to the backing, it is cut by suitable cutting means and made carpet tight by any number of techniques well known in the art.

The resulting carpet tile product is not only printed, but also subjected to textile process operations at relatively high temperatures that do not impair the physical properties of the product. The carpet tile is suitable for use as a floor covering in the home and/or for commercial use in an office environment where the tile is subjected to substantially high stress conditions (e.g. car traffic). The tiles typically have a dense pile and do not require adhesives for installation. The carpet tiles have excellent dimensional stability with essentially no curling, slipping, bending, stretching or wrinkling. Moreover, the carpet tile has low smoke and low fuzz properties.

The invention will be better understood from the drawings and accompanying description. However, various changes may be made without departing from the scope or spirit of the invention, which is defined solely by the appended claims.

In FIG. 1, carpet yarn 10 is fed from a yarn source (not shown) past and around guide rolls 12, 14 and down to a vertical guide 16. The base layer 17 is transferred from the roll 18 to the guide 16.
supplied to positions in between. When the yarn 10 is inserted between the vertical guides 16, the folding blades 20, 2
The yarns 10 are zigzag within one or the other of the base layer sheets 17 as carpet backing, with alternating displacement of 2 and 2 moving downwards. Bladelets 24, 26 fixed on the pivot assist in folding the yarn. The folding blades 20, 22 are fixed to connecting rods 28, 30, respectively. Connecting rods 28, 30 are pivotally connected to pivot shafts 36, 38 through appropriate links (not shown). The shaft 36
, 38 are oscillated by a oscillating crank arm mechanism (not shown).

The blade 20 is out of phase with the blade 22 so that when the blade 22 swings inward as shown in FIG. 1, the blade 20 swings outward and vice versa; It should be noted that the yarn is in a zigzag configuration between the carpet base layers 17 which are liquid permeable (through which the applied adhesive passes).

[0030] The yarns form the carpet base layer 17.
After being made into a zigzag form during the process, the latex adhesive 80 contained in the bath 88 is forced through the liquid permeable carpet base layer 17 by rotation of the applicator roll 84 and comes into contact with the carpet yarn 10. .

After the latex adhesive is applied to the carpet base layer 17 and forced through the carpet layer into contact with the carpet yarn, the latex adhesive is converted into a solid phase by heating means 90; A bond between the carpet yarn 10 and the carpet base layer 17 is formed. The heating means 90 is an infrared heater 9 that heats the latex adhesive and thereby hardens the latex adhesive.
2 is installed. The yarn 10 is then cut by a cutting blade 98, typically in the middle of the base layer 17, providing two carpet sheets at the same time.

FIG. 2 is a modification of the example latex adhesive applicator means 78 shown in FIG. The bath 100 is located below the applicator roll 84, which rotates in the direction of fabric travel. The coating ratio of the latex is 1
Controlled by 02. FIG. 3 is yet another example and shows a reservoir 103 located on the side wall of the applicator roll 84. The latex application rate is 10 with a doctor roll.
5.

FIG. 4 shows a variant in which the latex adhesive is contained in a reservoir bounded on one side by the base layer 17 and on the other side by the doctor blade 104. The adhesive 80 is contacted with the carpet backing and the tip 106 of the doctor blade 104
is forced through.

FIG. 5 illustrates another example of the invention in which the latex adhesive is contained in a tank 108. Application of the adhesive to the base layer 17 is accomplished by introducing the adhesive out of the tank 108 through a pump 110 into a manifold 112. The adhesive is applied to the carpet backing 1.
7 and is forced through the opening 114 of the manifold 112 under pressure conditions sufficient to contact the carpet yarn 10.

FIG. 6 illustrates the spray application of latex adhesive by spray applicator 107. After latex application, the latex is forced through the carpet backing 17 and into contact with the carpet yarn 10 by permeator rolls 109 .

FIG. 7 is a diagram illustrating an example of the present invention, showing the I-tassel outline of the pile yarn. The latex adhesive 80 is shown as a continuous layer in the relatively open-fold base layer 17, and the adhesive permeable pile is embedded in the base. Lining layer 150 is glass fiber
Made of thermoplastic material with 151 stabilizing layers,
It is shown that it is bonded to the pile fabric by a thermoplastic material. Figures 8, 9 and 10 illustrate several folded profiles of piles formed from preferred yarns. Identical numbers refer to components similar to those in FIG. FIG. 8 shows the folded cut pile outline. FIG. 9 shows the loop pile outline. FIG. 10 shows another folded pile profile on the surface where the folding site of the yarn gives rise to the appearance of a looped pile, but where the loops are not connected to each other at their base position. This profile provides an essentially looped pile product while offering yarn saving benefits, such as the so-called I-tassel profile.

FIG. 11 is a photomicrograph (20x magnification) of the tassel bonding by the flat method in Example I. The tassels are pulled out of latex adhesive and representative surfaces are cut at the base to show adhesive penetration. It can be observed that the latex adhesive exhibits excellent permeability in contact with all the fibers of the yarn bundle.

FIG. 12 is a conventional yarn, with the bonded product photographed and cut in a manner similar to FIG. The adhesive is penetrated only through the surface layer leaving a large number of separated yarns causing undesirable fuzzing and pilling.

[0039]

EXAMPLES The present invention will be further understood by reference to examples which are not to be construed as unduly limiting the invention. EXAMPLE I An example in which the adhesive applicator means is shown in FIG. 6, the apparatus essentially as shown in FIG. use In these base layers there is placed a pile made of dyed nylon 6,6, spun yarn 2.00/2 yarn. The yarn has a structure of approximately 8 folds per inch by 9 fibers per inch (ab
out 8 folds per inch by 9e
nds perinch construction)
It is folded. The latex adhesive mixture (a 50% aqueous mixture of styrene butadiene supplied by Reachhold Chemical) was approximately 50 oz. /s
q. It is applied at a rate of yd. The latex adhesive mixture also contains 1 part filler to 100 parts polymer.
Filler is included at the 50 part level. The viscosity of the latex adhesive is approximately 3,000 centipoise, providing optimal yarn penetration and maximum surface area to form chemical bonds to the tie coat. The adhesive is then heated with an infrared heater (3 outputs with a 50% output transformer).
Cured with the use of 100% 18-inch low antibody feed). The generated moisture is exhausted by an exhaust fan (not shown). The carpet is then cooled and cut lengthwise into strips.

Filled Atactec polyurethane (weight: approximately 50 ozs./sq. yd) was cast onto a non-woven glass mat as a preform backing layer, then cut into strips and laminated to the carpet bonded with latex adhesive. and about 20 oz. on the backing layer. /sq. yd
Casting filled Atactec polyurethane,
Immediately thereafter, the carpet is pressed into the molten material in a conventional manner. The resulting product is cooled, cut into carpet tiles and subjected to other processes such as printing, steam treatment, water washing,
Drying is done properly. EXAMPLE II In this example, the carpet tile properties of tuft bonding, pilling, and fuzzing were measured for carpet tiles made as described in Example I, and further comparisons were made essentially in U.S. Pat.
Similar properties are measured for polyvinyl chloride bonded tiles produced by the apparatus described in, 1999, 1999, 1996. The PVC is 55ozs. /
sq. yd (100% solids). Tassel binding is measured by ASTM Standard Test Measurement D1335, pin ring and fuzz by the industry conventional test DuPont Random Pilling and Fuzz Test. The latter test results are rated 1 with 1 being poor and 5 being excellent.
Measured on a scale of ~5. The results are shown in the table below.

[0041]
table
Tassel connection Pin ring and fluff Example I
8lbs. 4
．． 0 Example II
4.5lbs. 3.0 The results shown in the table above show that the products of the invention have improved tassel bonding properties, less than 50% of the weight added to the adhesive mixture. The product has good handling and good yarn coverage because yarn bending occurs during the latex curing process and at the same time water is excluded.

[Brief explanation of the drawing]

FIG. 1 is a front view of the device.

FIG. 2 shows an example for forcing latex adhesive through a base layer.

FIG. 3 shows another example for forcing latex adhesive through a base layer.

FIG. 4 shows another example for forcing latex adhesive through a base layer.

FIG. 5 shows another example for forcing latex adhesive through a base layer.

FIG. 6 shows another example for forcing latex adhesive through a base layer.

FIG. 7 is a diagram illustrating a pile formation form applied to the hot-melt adhesive-bonded pile fabric of the present invention.

FIG. 8 is a diagram illustrating another pile formation configuration provided to the hot-melt adhesive bonded pile fabric of the present invention.

FIG. 9 is a diagram illustrating yet another form of pile formation provided to the hot-melt adhesive bonded pile fabric of the present invention.

FIG. 10 is a diagram illustrating yet another form of pile formation provided to the hot-melt adhesive bonded pile fabric of the present invention.

FIG. 11 is a photograph showing a base of pile yarn bonded to a base layer by a latex adhesive mixture of the present invention.

FIG. 12 is a photograph showing a base of pile yarn bonded to a base layer by conventional methods.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 10... Carpet yarn, 16... Guide, 17... Base layer, 20, 22... Folding blade, 80... Latex adhesive, 84... Applicator roll, 90... Heating means, 15
0... Lining layer, 151... Glass fiber.

Claims (7)

[Claims] 1. A pile formed of a liquid permeable base layer and yarns adjacent to the base layer without tasseling through the base layer, and the yarns are coated with a latex adhesive on the back side of the base layer. latex adhesive bonded pile fabric, further bonded to said base layer by means of applying said adhesive and forcing said adhesive through said base and into contact with said yarns. 2. The latex adhesive bonded pile fabric of claim 1 further comprising a thermoplastic backing layer bonded to said back side of said base layer. 3. Feeding first and second successive liquid permeable base layers to a guide across which the base layers are spaced apart from each other in parallel relationship; and wherein the base layer is fed through the guide. during which a continuous pile of yarn is folded by a folding blade against opposing surfaces of the base layer to impart a jittery and folded configuration to the yarn without tucking the yarn through the base layer; forcing a latex adhesive through the backside of each of said base layers to contact said yarn after said yarn has been folded between said base layers; drying the adhesive by passing the yarn through a heater while contacting the yarn by passing it between the layers; and drying the yarn between the first and second base layers after drying the latex adhesive. cutting to form two continuous bonded pile fabrics. 4. Yarn to a base layer according to claim 3, characterized in that the guide positions the base layer vertically, and the latex adhesive is applied to the base layer at a position below the guide. How to combine. 5. The method of bonding yarn to a base layer as claimed in claim 4, wherein the heater is positioned vertically below the latex adhesive application location. 6. The method of claim 3, wherein the latex adhesive is forced through the first and second base layers at the same time. 7. The base of claim 5, wherein the base layer is not vertically supported on a back surface applied such that the base layer is provided between a latex adhesive application location and a heater. How to join yarns into layers.