Method for Manufacturing a Carpet Product, and a Product Obtainable Using This Method

Abstract

A method for manufacturing carpet product includes providing a first sheet having a front surface and a back surface, providing polyester yarns having a weight of at least 2500 Dtex and a twist level of at least 100 tpm, forming a pile on the front surface of first sheet by stitching the yarns through the first sheet, the yarns having a free end that forms the said pile and a locked end present at the back surface of the first sheet, thereby forming an intermediate product, processing the intermediate product by feeding it along a body having a heated surface, the back surface being contacted with the said heated surface, and then cooling the molten part of the polyester to solidify this molten part of the polyester.

1 . A method for manufacturing a carpet product comprising:
 providing a first sheet having a front surface and a back surface,   providing one or more polyester yarns having a weight of at least 2500 Dtex and a twist level of at least 100 tpm,   forming a pile on the front surface of the first sheet by stitching the one or more yarns through the first sheet, the one or more yarns having a free end that forms the pile and a locked end present at the back surface of the first sheet, thereby forming an intermediate product,   processing the intermediate product by feeding the intermediate product along a body having a heated surface, the back surface being contacted with the said heated surface, to melt at least a part of the polyester of the locked end of the one or more yarns,   cooling the molten part of the polyester to solidify this molten part of the polyester, thereby connecting the locked end of the one or more yarns to the first sheet and forming the carpet product.   
     
     
         2 . The method according to  claim 1 , wherein the one or more polyester yarns have a weight of at least 2800 Dtex and a twist level of at least 120 tpm. 
     
     
         3 . The method according to  claim 1 , wherein the one or more polyester yarns have a weight of at least 3000 Dtex and a twist level of at least 150 tpm. 
     
     
         4 . The method according to  claim 1 , wherein the first sheet is a polyester sheet. 
     
     
         5 . The method according to  claim 1 , wherein the polyester comprises PET (polyethylene terephtalate) and/or PTT (polytrimethylene terephthalate). 
     
     
         6 . The method according to  claim 1 , wherein the polyester of the yarns has an intrinsic viscosity above 0.8 dl/g. 
     
     
         7 . The method according to  claim 1 , wherein the one or more yarns are multi-ply yarns. 
     
     
         8 . The method according to  claim 1 , wherein the one or more yarns are each composed of multiple filaments having a weight of between 2 and 40 dpf. 
     
     
         9 . The method according to  claim 8 , wherein the filament weight is between 5 and 20. 
     
     
         10 . The method according to  claim 1 , wherein the one or more polyester yarns have a weight of at least 3500 Dtex. 
     
     
         11 . The method according to  claim 1 , wherein in the step of processing the intermediate product by feeding the intermediate product along a body having a heated surface, the intermediate product has a relative speed with respect to the heated surface of the body. 
     
     
         12 . The method according to  claim 1 , wherein the method comprises connecting a second sheet to the carpet product, using an adhesive applied between the processed back surface of the first sheet and the second sheet. 
     
     
         13 . The method according to  claim 12 , wherein the adhesive is a hot melt adhesive. 
     
     
         14 . The method according to  claim 13 , wherein the adhesive is a polyester hot melt adhesive. 
     
     
         15 . The method according to  claim 12 , wherein the second sheet is a fibrous sheet. 
     
     
         16 . The method according to  claim 12 , wherein the second sheet is a polyester sheet. 
     
     
         17 . A carpet product comprising a first sheet having a front surface and a back surface and one or more polyester yarns stitched through the first sheet, forming a pile on the front surface of the sheet, which yarns have a weight of at least 2500 Dtex and a twist level of at least 100 tpm, wherein at least a part of the polyester of the locked end of the one or more yarns is molten, spread over the back surface of the sheet and solidified.