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Process of laminating carpet to elastomeric backing
| Details |
Inventors: Reuben, Harold;
Assignee: The Akro Corporation (Canton, OH)
Primary Examiner: McCamish; Marion E.
Assistant Examiner:
Attorney, Agent or Firm:
A method of laminating a curable elastomeric backing section to a pile carpet section, for example, for automobile floor mats, utilizing a compressive molding process to laminate the curable elastomeric backing to the carpet. Cooling the pile of the carpet protects the carpet from becoming substantially permanently deformed during molding despite the compressive molding pressure. While the carpet pile is being cooled, sufficient heat is applied to the elastomeric backing to cure the backing. The back face of the carpet is bonded to the elastomeric backing during the compressive molding process. |
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DETAILED DESCRIPTION What is claimed is: 1.
A method of laminating a curable elastomeric backing section having a first surface and a second surface to a heat deformable pile carpet section having a first surface, a second surface, and a carpet pile adjacent to the second surface of the carpet section, comprising: contacting the second surface of the curable elastomeric backing section to the first surface of the pile carpet section, placing the curable elastomeric backing section and pile carpet section under a compressive molding pressure of at least 50 psi applied to the first surface of the curable elastomeric backing section and the second surface of the pile carpet section, crushing the carpet pile while the curable elastomeric backing section and pile carpet section are under the compressive molding pressure, embedding a portion of the first surface of the pile carpet section in the second surface of the curable elastomeric backing section, heating the curable elastomeric backing section to set the elastomeric backing simultaneously while the pile carpet section and the curable elastomeric backing section are under the compressive molding pressure, cooling the pile carpet section to maintain the carpet pile below a temperature at which the carpet pile becomes substantially permanently deformed under the applied molding pressure so as to maintain the resiliency of the carpet pile upon release of the compressive molding pressure, the cooling being conducted simultaneously while the carpet and backing are under pressure, and maintaining the heating of the curable elastomeric backing section until the elastomeric backing is set.
2.
A process as claimed in claim 1 wherein the compressive molding pressure is selected from the range of about 50 psi to about 250 psi, the curable elastomeric backing section is heated to a temperature within the range of about 250.
degree.
F.
to about 400.
degree.
F.
, the pile carpet section is cooled to a temperature less than about 100.
degree.
F.
, and the heating of the curable elastomeric backing section is maintained for a period of time selected from the range of about one minute to about twenty minutes
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