Method and apparatus for coating and bonding a secondary carpet backing
First Claim
1. A process for applying a layer of adhesive to a backing fabric, comprising the steps of:
- forming said adhesive into a layer on the surface of a rotating roller;
transporting successive portions of said backing fabric against said roller in a direction opposite to the direction of rotation of said roller to transfer said layer of adhesive from said roller to said backing fabric at a contact point; and
transporting said backing fabric nontangentially away from said roller at said contact point.
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Accused Products
Abstract
An improved method and apparatus for applying adhesive to a backing fabric, such as for adhesively laminating a secondary fabric backing to a carpet. The adhesive is formed into a layer of predetermined thickness on the surface of a rotating casting roller, and the backing fabric is conveyed along a path adjacent to the casting roller in a direction opposite to the direction of rotation of the casting roller. A press blade brings sucessive portions of the backing fabric into contact with a portion of the casting roller, and the adhesive layer on the casting roller is transferred to the backing fabric at an adhesive contact point. The backing fabric is then conveyed abruptly away from the casting roller at the adhesive contact point in a substantially radial direction. This abrupt lateral disengagement of the backing fabric from the casting roller prevents the backing fabric from being dragged through the oncoming layer of adhesive on the casting roller, and further prevents the cohesive interaction between the layer of adhesive on the casting roller and the deposited layer of adhesive on the back of the backing fabric which can pull adhesive off the backing fabric back onto the casting roller or vice-verse.
34 Citations
15 Claims
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1. A process for applying a layer of adhesive to a backing fabric, comprising the steps of:
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forming said adhesive into a layer on the surface of a rotating roller; transporting successive portions of said backing fabric against said roller in a direction opposite to the direction of rotation of said roller to transfer said layer of adhesive from said roller to said backing fabric at a contact point; and transporting said backing fabric nontangentially away from said roller at said contact point. - View Dependent Claims (2, 3)
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4. A process for forming a carpet product having a tufted primary backing fabric and a secondary backing fabric laminated to the back thereof, comprising the steps of:
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forming an adhesive into a layer on the surface of a rotating roller; transporting successive portions of said secondary backing fabric against said roller in a direction opposite to the direction of rotation of said roller to transfer said layer of adhesive from said roller to a first surface of said secondary backing fabric at a contact point; transporting said backing fabric nontangentially away from said roller at said contact point; and bringing the adhesive-coated first surface of said secondary backing fabric into intimate contact with the back of said tufted primary backing fabric to form a laminated carpet product. - View Dependent Claims (5, 6)
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7. A method of applying a layer of adhesive to a backing fabric, comprising the steps of:
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transporting said backing fabric along a path; depositing said adhesive onto the upper surface of a roller rotating in a direction opposite to the direction of movement of the backing fabric; forming said adhesive into a layer on the surface of said roller; pressing said backing fabric against a portion of said counterrotating roller to transfer said layer of adhesive from said roller to said backing fabric at an adhesive contact point; and transporting said backing fabric laterally away from said roller at said adhesive contact point.
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8. An apparatus for applying a layer of adhesive to a backing fabric, comprising:
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a rotating roller; means for forming said adhesive into a layer of controlled thickness on the surface of said rotating roller; means for transporting said backing fabric along a path adjacent to said rotating roller in a direction opposite to the direction of rotation of said rotating roller; means for pressing successive portions of said backing fabric against a portion of said rotating roller to transfer said layer of adhesive from said roller to said backing fabric at a transfer point; and means for transporting said backing fabric laterally away from said roller at said transfer point. - View Dependent Claims (9, 10, 11)
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12. An apparatus for manufacturing a carpet product having a tufted primary backing fabric and a secondary backing fabric laminated to the back of said primary backing fabric, comprising:
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a rotating roller; means for forming an adhesive into a layer of controlled thickness on the surface of said rotating roller; means for transporting said secondary backing fabric along a path adjacent to said rotating roller in a direction opposite to the direction of rotation of said rotating roller; means for pressing successive portions of said secondary backing fabric against a portion of said rotating roller to transfer said layer of adhesive from said roller to a first surface of said secondary backing fabric at a transfer point; means for transporting said secondary backing fabric nontangentially away from said roller at said transfer point; and means for intimately contacting said adhesive-coated first surface of said secondary backing fabric with the back of said tufted primary fabric backing to form a laminated carpet product. - View Dependent Claims (13, 14, 15)
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Specification