Process for manufacturing flooring using recycled materials

Details Process for manufacturing flooring using recycled materials Process for manufacturing flooring using recycled materials

B - Operations, Transporting

32

B

B32B 37/00 (2006.01) B32B 27/12 (2006.01) D04H 3/02 (2006.01) D04H 13/00 (2006.01) D05C 17/00 (2006.01) D06N 7/00 (2006.01)

Patent

CA 2413796

A continuous carpet (10) or other flooring manufacturing process that accommodates use of a variety of materials including recycled PVC from used carpet and carpet manufacturing waste. The continuous process forms backing (12) and is capable of feeding the backing into a lamination stage for bonding with the face cloth (14). By providing a continuous process whereby the backing layer, upon formation, can be immediately laminated to the face cloth, manufacturing time and associated costs are reduced. Moreover, formation of the backing layer as a process separate from the lamination thereby protecting the face cloth from unnecessary heat and pressure and enhancing the many types of material, including recycled and waste materials, especially used carpet and used carpet by products. Use of these cheaper materials reduces both the manufacturing costs by products. Use of these cheaper materials reduces both the manufacturing costs of the flooring and the amount of landfill waste and associated environmental concerns.

L'invention concerne un procédé continu de fabrication de tapis (10) ou d'un autre revêtement de sol permettant d'utiliser une variété de matériaux, notamment du PVC recyclé provenant de tapis usés et de déchets de fabrication de tapis. Le procédé continu permet de former un endos (12) et de fournir cet endos à un étage de stratification afin de le relier à un tissu d'endroit (14). Ce procédé continu permet de réduire la durée de fabrication et les coûts associés du fait que couche d'endos, lors de sa fabrication, est immédiatement stratifiée avec le tissu d'endroit. De plus, la formation de la couche d'endos à l'aide d'un procédé séparé du procédé de stratification permet de protéger le tissu d'endroit contre une chaleur et une pression excessives, et d'améliorer les nombreux types de matériau, notamment les matériaux de recyclage ou de déchet provenant en particulier de tapis usés et de sous-produits de tapis usés. L'utilisation de ces matériaux bon marché réduit à la fois les coûts de fabrication d'un revêtement de sol, la quantité de déchets de décharge et les préoccupations environnementales associées.

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