Alternate method for applying hot melt adhesives to carpet

Abstract

Described are methods of making a carpet by (a) providing a primary backing material having a front side and a back side, (b) tufting a yarn into the primary backing material to produce a carpet pile on the front side of the primary backing material and loops of the yarn on the back side of the primary backing material, (c) applying by slot coating a layer of a first melted coating composition onto the back side of the tufted primary backing material, (d) applying by slot coating a layer of a second melted coating composition onto the coating applied in step (c) thereby fixing the loops of the yarn to the primary backing material, and (e) applying and pressing a secondary backing onto the slot coated tackifying resin layers and pressing it to join the first and second tackifying resins and the primary backing and secondary backing and yarn loops together to form a carpet.

1 . A method of making a carpet comprising the steps of: 
 (a) providing a primary backing material having a front side and a back side,    (b) tufting a yarn into the primary backing material to produce a carpet pile on the front side of the primary backing material and loops of the yarn on the back side of the primary backing material,    (c) slot coating a layer of a first melted coating composition onto the back side of the tufted primary backing material,    (d) slot coating a layer of a second melted coating composition onto the coating applied in step (c) thereby fixing the loops of the yarn to the primary backing material, and    (e) applying and pressing a secondary backing onto the slot coated tackifying resin layers and pressing to join the first and second tackifying resins and the primary backing and secondary backing and yarn loops together to form a carpet.    
   
   
       2 . The method according to  claim 1  wherein the first coating composition comprises a tackifying resin and a hot melt adhesive resin.  
   
   
       3 . The method according to  claim 1  wherein between about 2 to about 12 ounces per square yard of the first coating composition is applied to the primary backing material.  
   
   
       4 . The method according to  claim 1  wherein the second coating composition comprises up to 80% by weight of a tackifying resin and a hot melt adhesive.  
   
   
       5 . The method according to  claim 1  wherein between about 5 to about 50 ounces per square yard of the second coating composition is applied to the primary backing.  
   
   
       6 . The method according to  claim 1  wherein between about 24 and about 50 ounces per square yard of the first and second coating compositions combined are applied to the primary backing.  
   
   
       7 . The method according to  claim 1  wherein the hot melt adhesive comprises a polyethylene, polypropylene, polyamide, polyvinyl chloride, ethylene vinyl acetate, polyester or copolymers thereof.  
   
   
       8 . The method according to  claim 1  wherein the second coating composition comprises an inorganic particulate filler.  
   
   
       9 . The method according to  claim 1  wherein the carpet is constructed entirely of recyclable polymer.  
   
   
       10 . A method of making a carpet comprising the steps of: 
 providing a primary backing material having a front side and a back side,    tufting a yarn into the primary backing material to produce a carpet pile on the front side of the primary backing material and loops of the yarn on the back side of the primary backing material, and thereafter    slot coating a layer of a melted adhesive composition onto the back side of the tufted primary backing material thereby fixing the loops of the yarn to the primary backing material.    
   
   
       11 . A method of making a carpet comprising yarn attached to a primary backing material and securing the yarn to the backing comprising applying to a back side of the primary backing material a slot coating of a melted adhesive composition thereon thereby flexibly securing the yarn to and retaining it in the primary backing material.