GB2160790A - Improvements in the manufacture of carpet underlays - Google Patents
Improvements in the manufacture of carpet underlays Download PDFInfo
- Publication number
- GB2160790A GB2160790A GB8416261A GB8416261A GB2160790A GB 2160790 A GB2160790 A GB 2160790A GB 8416261 A GB8416261 A GB 8416261A GB 8416261 A GB8416261 A GB 8416261A GB 2160790 A GB2160790 A GB 2160790A
- Authority
- GB
- United Kingdom
- Prior art keywords
- doctor blade
- foamed rubber
- latex
- layer
- foamed
- 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.)
- Granted
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 229920001971 elastomer Polymers 0.000 claims abstract description 26
- 229920000126 latex Polymers 0.000 claims description 18
- 239000004816 latex Substances 0.000 claims description 16
- 239000000463 material Substances 0.000 claims description 14
- 239000006260 foam Substances 0.000 claims description 12
- 238000000034 method Methods 0.000 claims description 10
- 238000003892 spreading Methods 0.000 claims description 6
- 230000015572 biosynthetic process Effects 0.000 claims description 4
- 238000007373 indentation Methods 0.000 claims description 4
- 150000001875 compounds Chemical class 0.000 claims description 2
- 230000003111 delayed effect Effects 0.000 claims description 2
- 238000000151 deposition Methods 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims description 2
- 229920001821 foam rubber Polymers 0.000 claims description 2
- 239000003349 gelling agent Substances 0.000 claims description 2
- 230000005484 gravity Effects 0.000 claims description 2
- 239000004615 ingredient Substances 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 230000009974 thixotropic effect Effects 0.000 claims description 2
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
- B05D1/40—Distributing applied liquids or other fluent materials by members moving relatively to surface
- B05D1/42—Distributing applied liquids or other fluent materials by members moving relatively to surface by non-rotary members
-
- 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
- D06N7/0073—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 applied as an aqueous dispersion or latex
-
- 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
- D06N7/0086—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 characterised by the cushion backing, e.g. foamed polyurethane
-
- 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
- D06N7/0089—Underlays
-
- 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
- D06N2203/00—Macromolecular materials of the coating layers
- D06N2203/02—Natural macromolecular compounds or derivatives thereof
-
- 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
- D06N2205/00—Condition, form or state of the materials
- D06N2205/20—Cured materials, e.g. vulcanised, cross-linked
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Carpets (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
Abstract
A carpet underlay is formed by applying a layer of foamed rubber to a backing surface and controlling the thickness of the layer by a doctor blade having teeth or projections spaced along its operative edge while imparting in a direction normal to the surface reciprocating movements between the blade and layer whereby areas of foamed rubber each bounded by grooves are formed.
Description
SPECIFICATION
Improvements in the Manufacture of Carpet
Underlays
This invention relates to the manufacture of carpet underlays incorporating a layer of foamed rubber and its object is the formation on the surface of the rubber of distinctive patterns which enhance the appearance of the product and improve its performance.
Normally the layer of foamed rubber is formed by aerating suitably compounded latex, which may be natural, synthetic, or a mixture of both, and spreading it on a backing material separate from the carpet, or on the reverse side of the carpet itself. The thickness of this layer is controlled by a doctor blade set at a fixed distance, usually about 7mm, from thesurface on which the foamed latex is deposited. The doctor blade is set at an angle to the backing surface and the foamed rubber is fed onto the surface just in front of the blade which controls and forms an even layer of the foamed rubber as it is carried by the backing surface past the blade This blade may be provided with projections or teeth uniformly spaced along its edge.Such projection may be about 3--5mm wide and may penetrate the foam to the depth of 3-4mm, that is approximately 50%, so forming on the surface of the foam a pattern of longitudinal grooves. A wavy appearance can be produced by moving the doctor blade backwards and forwards along its length. The pattern can be varied by varying the speed of this movement.
According to the present invention, a carpet underlay is formed by applying a layer of foamed rubber onto backing material and controlling the thickness of the layer by the action of a doctor blade having teeth or projections spaced along its operative edge while imparting in a direction normal to the layer reciprocating movements between the blade and layer whereby areas of foamed rubber each bounded by grooves of controlled depth are formed. Advantageously, these reciprocating movements take place at intervals for brief periods and may be such that the tips of the teeth or projections completely penetrate the depth of the foam at predetermined points. Therefore, the movements may be arranged to result in the formation on the surface of the foam of a pattern of squares, rectangles or parallelograms, with deep indentations at all corners.This results in an attractive appearance and tends to improve the grip of the foamed rubber surface.
This additional movement towards and away from the backing sheet may be produced by any conventional means applied to the backing material, or doctor blade or both such as cams, pneumatic actuators, solenoids, or a combination of such means. The spread foam is dried and processed in the usual manner, depending on the type of material used. It may incorporate heat, or delayed gelling agents, although the invention is primarily intended to be used without such ingredients. The pattern does not collapse under the action of gravity partly because foamed latex exhibits slightly thixotropic properties, and partly because the air content renders the foam very light.
In one specific example, the doctor blade has projections 2cms apart distributed along its edge.
Thus, as the doctor blade traverses the foamed latex, grooves 2cms apart and about 3mm deep, i.e.
about half the depth of the foamed material, are formed. However, at predetermined intervals, the latex is raised for a brief period to form transverse grooves while the projections penetrate the latex to the backing material. Thus, squares or rectangles are formed with deep indentations at the corners.
The dimensions of the rectangles in the direction of the travel over the mass of latex past the doctor blade depends on the duration of the intervals between the up and down movements of the latex.
These intervals can be varied to produce a predetermined pattern.
1. A method of manufacturing a carpet underlay comprising depositing foamed rubber latex compound on a surface of a sheet of backing material or of the reverse side of the carpet itself, effecting relative movement between said surface and a doctor blade extending transversely over said surface whereby the doctor blade is caused to spread the latex foam over the surface, further imparting relative reciprocating movements between said surface and said doctor blade, said reciprocating movements having a component normal to said surface for forming a pattern in the foamed rubber during the spreading thereof on the surface, and then drying and vulcanising the deposit thus formed.
2. A method according to claim 1, in which a doctor blade having teeth or projections spaced along its operative edge is used whereby areas of foamed rubber each bounded by grooves of controlled depth are formed.
3. A method according to claim 1 or claim 2, in which the reciprocating movements are effected at intervals of comparatively brief periods during the spreading of the foamed rubber on said surface.
4. A method according to claims 2 and 3, in which the tips of the teeth or projections are caused completely to penetrate the depth of the foamed rubber at predetermined points.
5. A method substantially as hereinbefore described in the accompanying specific example.
6. A carpet underlay when made by a method according to any one of the preceding claims.
**WARNING** end of DESC field may overlap start of CLMS **.
Claims (6)
1. A method of manufacturing a carpet underlay comprising depositing foamed rubber latex compound on a surface of a sheet of backing material or of the reverse side of the carpet itself, effecting relative movement between said surface and a doctor blade extending transversely over said surface whereby the doctor blade is caused to spread the latex foam over the surface, further imparting relative reciprocating movements between said surface and said doctor blade, said reciprocating movements having a component normal to said surface for forming a pattern in the foamed rubber during the spreading thereof on the surface, and then drying and vulcanising the deposit thus formed.
2. A method according to claim 1, in which a doctor blade having teeth or projections spaced along its operative edge is used whereby areas of foamed rubber each bounded by grooves of controlled depth are formed.
3. A method according to claim 1 or claim 2, in which the reciprocating movements are effected at intervals of comparatively brief periods during the spreading of the foamed rubber on said surface.
4. A method according to claims 2 and 3, in which the tips of the teeth or projections are caused completely to penetrate the depth of the foamed rubber at predetermined points.
5. A method substantially as hereinbefore described in the accompanying specific example.
6. A carpet underlay when made by a method according to any one of the preceding claims.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8416261A GB2160790B (en) | 1984-06-26 | 1984-06-26 | Improvements in the manufacture of carpet underlays |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB8416261A GB2160790B (en) | 1984-06-26 | 1984-06-26 | Improvements in the manufacture of carpet underlays |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8416261D0 GB8416261D0 (en) | 1984-08-01 |
| GB2160790A true GB2160790A (en) | 1986-01-02 |
| GB2160790B GB2160790B (en) | 1987-04-29 |
Family
ID=10563003
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8416261A Expired GB2160790B (en) | 1984-06-26 | 1984-06-26 | Improvements in the manufacture of carpet underlays |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2160790B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| RU2305606C1 (en) * | 2006-02-22 | 2007-09-10 | Федеральное государственное образовательное учреждение высшего профессионального образования "Орловский государственный аграрный университет" (ФГОУ ВПО Орел ГАУ) | Article surface for deposition preparation method |
-
1984
- 1984-06-26 GB GB8416261A patent/GB2160790B/en not_active Expired
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| RU2305606C1 (en) * | 2006-02-22 | 2007-09-10 | Федеральное государственное образовательное учреждение высшего профессионального образования "Орловский государственный аграрный университет" (ФГОУ ВПО Орел ГАУ) | Article surface for deposition preparation method |
Also Published As
| Publication number | Publication date |
|---|---|
| GB8416261D0 (en) | 1984-08-01 |
| GB2160790B (en) | 1987-04-29 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |