EP0009993A1 - Improvements relating to methods and apparatus for plastic coating sheet material - Google Patents

Improvements relating to methods and apparatus for plastic coating sheet material Download PDF

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Publication number
EP0009993A1
EP0009993A1 EP79302144A EP79302144A EP0009993A1 EP 0009993 A1 EP0009993 A1 EP 0009993A1 EP 79302144 A EP79302144 A EP 79302144A EP 79302144 A EP79302144 A EP 79302144A EP 0009993 A1 EP0009993 A1 EP 0009993A1
Authority
EP
European Patent Office
Prior art keywords
sheet
plastics material
plastics
machine
carpet
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Withdrawn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
EP79302144A
Other languages
German (de)
English (en)
French (fr)
Inventor
Ian David Slack
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.)
PLASTICISERS ENGINEERING Ltd
Original Assignee
PLASTICISERS ENGINEERING 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 PLASTICISERS ENGINEERING Ltd filed Critical PLASTICISERS ENGINEERING Ltd
Publication of EP0009993A1 publication Critical patent/EP0009993A1/en
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/0086—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique
    • D06N3/0088—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the application technique by directly applying the resin
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/04—Foam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/08—Treatments by energy or chemical effects using gas
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/12—Permeability or impermeability properties
    • D06N2209/121—Permeability to gases, adsorption
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/06—Characteristics of the backing in carpets, rugs, synthetic lawn
    • D06N2213/063—Porous back coating or pre-coat

Definitions

  • the present invention relates to a method and apparatus for applying a coating of a plastics material to a sheet-like material which is pervious to air.
  • sheet or film material can be plastic-coated by passing them underneath an extrusion die so that a film of molten plastic is spread over the surface of the material being coated. Immediately after the molten plastic-is applied, the material passes between a pair of nip rollers. Usually one roller is rubber-covered and the other is a metal roller which has water circulating therethrough to remove the heat from the plastic. The pressure of the nip rollers ensures a bonding.of the plastic on to the other material.
  • the aim of the present invention is to provide a method and apparatus which enables a plastics coating to be satisfactorily bonded to the back of a carpet without damaging the carpet or to any other sheet material which is pervious to air e.g. filter paper or a woven fabric.
  • a method of applying a coating of a plastics material to a sheet of material which is pervious to air comprising the steps of extruding molten plastics material onto the sheet of material and passing the material over suction means to thereby draw the plastics material ' against the material.
  • a machine for applying a coati. g of a plastics material to a sheet of material which is pervious to air comprising an extrusion die for dispensing molten plastics material onto the sheet of material as it passes therebeneath,. and suction means arranged beneath the path of the material for drawing the plastics material against the sheet of pervious material.
  • the suction means comprises a box, the top of which has a perforated metal grid with a polished surface, a vacuum fan being arranged to draw air through the grid into the box so that as the sheet material is passed over the box, air is drawn through the material.
  • the box with the material sliding over it is placed directly beneath the extrusion die from which the molten plastics material flows.
  • the film of plastics material is drawn onto the material by the air flow, the pressure drop beneath the plastic material causing atmospheric pressure to force the plastics material in to all the crevices and pores formed in the material.
  • the plastics coating can be any extrudable thermoplastic material or a mixture of such thermoplastic material with a filler such as chalk, talc, wood flour, etc. Further the plastic coating material with or without a filler may contain a foaming agent which is activated in the plastic extruder machine or in the die so that the plastics coating may have sponge-like properties. This latter plastic coating is especially suited for backing carpets.
  • the sheet of material is passed beneath the extrusion die at a slightly faster speed than that at which the plastic flows from the die, thereby stretching the plastics material to provide a more even layer and creating a degree of orientation i.e. aligning the polymer molecules to a certain extent to thus strengthen the coating.
  • This may be facilitated by having the extrusion head angled so that the extruded plastics emerges from the die at an angle to the plane of the sheet material, the orifice of the die being in close proximity to the leading edge of the vacuum box.
  • the material is preferably passed through a press nip with the plastics coating in contact with a water cooled roller to remove the heat from the plastic.
  • the plastics coating may be cooled by blowing a stream of air or gas onto the plastic surface. This latter alternative is especially suited to sponge backed carpet wherein the sponge would be flattened by a cooled press nip.
  • carpets backed according to the present invention can be vacuum formed to form, for example, motor"car carpets, door panels etc.
  • the carpet 1 is moved along a generally horizontal path in the direction oi arrow A with its pile side down.
  • the carpet passes through a first station comprising an extrusion die 2 and suction means 30
  • the suction means 3 comprises a vacuum box 4 which has a perforated uppermost wall 5 over which the carpet is drawn, the vacuum box 4 being connected to a suction pump 6.
  • the suction pump 6 may take the form of an extraction fan.
  • extrusion die 2 Directly above the suction means 3 is located extrusion die 2, the die 2 being arranged to dispense molten plastics material P onto the back of the carpet adjacent to the upstream end of perforated wall 5 taken in the direction of travel A.
  • the suction means 3 creates a low pressure region beneath the plastics material causing gravity and atmospheric pressure to force the plastics coating into the back of the carpet.
  • the plastic coating is preferably extruded at a slower speed than the speed at which the carpet passes the die 2, thereby stretching the plastics material and both providing a more even layer and creating a degree of orientation. This is facilitated by the die 2 being arranged so that the extruded plastics sheet is angled to the plane of the carpet at approximately 20 0 , the orifice of die 2 being in close proximity to the leading edge of the vacuum box 4. This preferred facility can be applied to the treatment of any other material within the scope of the present invention, with equal effect.
  • the carpet is passed through a second station comprising an adjustable, rubber-covered, nip roller 7, a water-cooled roller 8, and a guide roller 9.
  • the carpet 1 passes through the nip formed by rollers 7 and 8, and continues around water cooled roller 8 which removes heat from the plastics coating P; the carpet being guided around roller 8 by virtue of roller 9.
  • the pressure of this nip can be adjusted by varying the position of roller 7 by means of pneumatic ram 10.
  • the carpet is then passed to a collection station (not illustrated) where it is wound ready for storage and future use.
  • the plastic .coating is cooled by passing the carpet around a cooled roller, alternatively a stream or streams of cooling air or gas may be played onto the coating via, for example, nozzle 11 which is shown in dashed lines in the drawing.
  • This latter cooling method is especially suited to carpets or other sheet material, when coated with a sponge-like plastics layer as referred to herebelow, wherein the press nip and roller arrangement 7,8,9, would flatten the foam.
  • the plastics coating used in the present invention can be any extrudable thermoplastic material or a mixture of such thermoplastic material with a filler such as chalk, talc, wood flour etc. Further, the plastic coating material with or without filler may contain a foaming agent which is activated in the plastic extruder machine or in the die so that the plastic coating may have sponge-like propertieso
  • the present invention thus enables a plastic coating to be satisfactorily bonded to the back of a carpet without requiring any excessive pressure to be applied which might damage the carpet pile.
  • carpets can be subsequently vacuum formed to provide moulded motor car carpets or door panels. In such an event cooling of the plastics material coating can be delayed to obviate the necessity for reheating.
EP79302144A 1978-10-10 1979-10-09 Improvements relating to methods and apparatus for plastic coating sheet material Withdrawn EP0009993A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB3990978 1978-10-10
GB7839909 1978-10-10

Publications (1)

Publication Number Publication Date
EP0009993A1 true EP0009993A1 (en) 1980-04-16

Family

ID=10500216

Family Applications (1)

Application Number Title Priority Date Filing Date
EP79302144A Withdrawn EP0009993A1 (en) 1978-10-10 1979-10-09 Improvements relating to methods and apparatus for plastic coating sheet material

Country Status (7)

Country Link
EP (1) EP0009993A1 (es)
AR (1) AR218400A1 (es)
AU (1) AU5145479A (es)
BR (1) BR7906495A (es)
DK (1) DK424379A (es)
ES (1) ES484843A1 (es)
ZA (1) ZA795205B (es)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018233A1 (en) * 1979-04-24 1980-10-29 Plasticisers Engineering Limited Fire resistant carpets
EP0596457A2 (de) * 1992-11-03 1994-05-11 Hoechst Aktiengesellschaft Folienbeschichteter, recyclisierbarer Teppichboden
WO1998038374A2 (en) * 1997-02-28 1998-09-03 The Dow Chemical Company Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
WO1998038375A2 (en) * 1997-02-28 1998-09-03 Shaw Industries, Inc. Carpet, carpet backings and methods
US7910194B2 (en) 1997-02-28 2011-03-22 Columbia Insurance Company Homogenously branched ethylene polymer carpet backsizing compositions
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods
CN109640749A (zh) * 2016-04-14 2019-04-16 希金斯研究和发展有限责任公司 具有通用底布的地板覆盖件以及制造和回收方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1316765A (fr) * 1962-02-16 1963-02-01 British Cellophane Ltd Procédé pour l'application d'un enduit sur des bandes
US3418198A (en) * 1964-03-06 1968-12-24 Du Pont Non-roughening microporous laminate and process for producing the same
GB1194886A (en) * 1966-10-27 1970-06-17 Greenbank Engineering Company Improvements in the Production of Tufted or Pile Carpets
US3843760A (en) * 1972-04-04 1974-10-22 Riegel Textile Corp Channel cloth extrusion apparatus and process

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1316765A (fr) * 1962-02-16 1963-02-01 British Cellophane Ltd Procédé pour l'application d'un enduit sur des bandes
US3418198A (en) * 1964-03-06 1968-12-24 Du Pont Non-roughening microporous laminate and process for producing the same
GB1194886A (en) * 1966-10-27 1970-06-17 Greenbank Engineering Company Improvements in the Production of Tufted or Pile Carpets
US3843760A (en) * 1972-04-04 1974-10-22 Riegel Textile Corp Channel cloth extrusion apparatus and process

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018233A1 (en) * 1979-04-24 1980-10-29 Plasticisers Engineering Limited Fire resistant carpets
EP0596457A2 (de) * 1992-11-03 1994-05-11 Hoechst Aktiengesellschaft Folienbeschichteter, recyclisierbarer Teppichboden
EP0596457A3 (de) * 1992-11-03 1995-05-17 Hoechst Ag Folienbeschichteter, recyclisierbarer Teppichboden.
WO1998038374A2 (en) * 1997-02-28 1998-09-03 The Dow Chemical Company Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
WO1998038375A2 (en) * 1997-02-28 1998-09-03 Shaw Industries, Inc. Carpet, carpet backings and methods
WO1998038375A3 (en) * 1997-02-28 1998-12-03 Shaw Ind Inc Carpet, carpet backings and methods
WO1998038374A3 (en) * 1997-02-28 1998-12-10 Dow Chemical Co Carpet, carpet backing and method for making same using homogeneously branched ethylene polymer
US7910194B2 (en) 1997-02-28 2011-03-22 Columbia Insurance Company Homogenously branched ethylene polymer carpet backsizing compositions
US8283017B2 (en) 1997-02-28 2012-10-09 Columbia Insurance Company Carpet, carpet backings and methods
US8496769B2 (en) 1997-02-28 2013-07-30 Columbia Insurance Company Carpet, carpet backings and methods
US9051683B2 (en) 1997-02-28 2015-06-09 Columbia Insurance Company Carpet, carpet backings and methods
US9376769B2 (en) 1997-02-28 2016-06-28 Columbia Insurance Company Homogeneously branched ethylene polymer carpet backsizing compositions
CN109640749A (zh) * 2016-04-14 2019-04-16 希金斯研究和发展有限责任公司 具有通用底布的地板覆盖件以及制造和回收方法
EP3442380A4 (en) * 2016-04-14 2019-12-04 Higgins Research & Development LLC FLOORING WITH UNIVERSAL REINFORCEMENT AND METHOD OF MANUFACTURE AND REUSE

Also Published As

Publication number Publication date
ES484843A1 (es) 1980-10-01
AR218400A1 (es) 1980-05-30
AU5145479A (en) 1980-04-17
DK424379A (da) 1980-04-11
BR7906495A (pt) 1980-09-09
ZA795205B (en) 1980-09-24

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PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

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17P Request for examination filed
STAA Information on the status of an ep patent application or granted ep patent

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Withdrawal date: 19810105

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Inventor name: SLACK, IAN DAVID