Laminate structure suitable for carpet use and method of making

Abstract

Abstract A LAMINATE STRUCTURE, AS IN A CARPET, IN ONE FORM COMPRISES A NON-WOVEN HEAT SEALABLE FABRIC, HEAT SEALED ON ONE SIDE, LAMINATED WITH AN ADHESIVE TO A FACING LAYER OF HEAT SEALABLE FIBERS, APPLIED AS BY AN EMBOSSING ROLL WHICH CAN BE HEATED. THE NON-WOVEN FABRIC CAN BE A NEEDLE-PUNCHED ASSEMBLAGE OF A SCRIM AND FIBERS AND THE ASSEMBLAGE HEAT SEALED ON THAT SIDE OF THE SCRIM FROM WHICH THE NEEDLES HAVE EMERGED THUS TO LOCK THE FIBERS INTO THE SCRIM WHEN HEAT SEALING TO PROVIDE A FIBROUS, NON-HEAT SEALED PAD SIDE OF THE ASSEMBLAGE. THE ADHESIVE CAN BE A THERMALLY RESPONSIVE, I.E., A THERMOPLASTIC OR THERMOSETTING, FILM, POWDER OR MELT. THE ADHESIVE IN TACKY, FIBER RECEIVING CONDITION, AS AFTER BEING PASSED THROUGH A HEATING ZONE, IS PASSED TOGETHER WITH A FACE YARN WEB THROUGH AN EMBOSSING ZONE, THE EMBOSSING MEMBER OF WHICH CAN BE HEATED. IN A MODIFICATION A FURTHER BACKING CAN BE APPLIED TO THE NON-HEAT SEALED PAD SIDE. WHEN THE NONWOVEN FABRIC CAN BE READILY HEAT SEALED IT CAN BE PASSED DIRECTLY TOGETHER EITH THE FACE YARN TO A HEATED EMBOSSING ROLL OR PRESS AND THE TWO HEAT SEALED THERE TOGETHER WITHOUT USE OF ADHESIVE. LIKEWISE, THE SECOND BACKING CAN BE SO APPLIED.

Inventors

• 👤 F Stoller

Bibliographic Details