Method for Coating Grey Goods for Carpeting Using a Broad Slotted Nozzle

Abstract

The invention relates to a method for coating grey goods for carpeting ( 1 ) comprising an upper layer ( 21 ) containing filaments, according to which a thermoplastic material ( 8 ) is applied to the upper layer ( 21 ) of the underside of the carpet, thus bonding the filaments in the grey goods ( 1 ). The invention also relates to a carpet comprising an upper layer of filaments, in which a thermoplastic material ( 8 ), which bonds the filaments in the carpet, is applied to the upper layer ( 21 ) of the underside of the carpet. In addition, the invention relates to a coating device for coating carpets comprising an upper layer ( 21 ) of filaments, said device being provided with transport elements for transporting the carpet ( 1 ) along the coating device. The device is also equipped with an applicator for applying the thermoplastic material ( 8 ) to the underside of the upper layer ( 21 ) of the grey goods that are transported past said applicator.

1 - 27 . (canceled)  
   
   
       28 . A method of making a carpet from a carpet article in a grey state using a slot nozzle applicator having an entry edge and a discharge slot having a pocket with a width, the carpet article including an upper layer having filaments and an underside, the method comprising: 
 transporting the carpet article in the grey state under the entry edge of the slot nozzle applicator,    bending over the filaments of the upper layer of the carpet article,    permitting the filaments to return to a standing position along the width of the pocket of the discharge slot, and    applying thermoplastic material from the discharge slot to the underside of the upper layer to bond the filaments to the carpet article.    
   
   
       29 . A method according to  claim 28 , wherein the upper layer comprises filaments joined in a non-ordered assembly or a laid assembly, and the thermoplastic material penetrates into at least one of (a) filaments at the underside of the carpet and (b) intermediate spaces between filaments.  
   
   
       30 . A method according to  claim 28 , in wherein the upper layer comprises a carrier material arranged in a plane of the carpet article and filament bunches are guided transversely through the carrier material.  
   
   
       31 . A method according to  claim 30 , wherein the thermoplastic material at least partially penetrates into portions of the filament bunches projecting from the carrier material at the underside of the carpet article and penetrates into intermediate spaces between the portions of the filament bunches.  
   
   
       32 . A method according to  claim 28 , further comprising: 
 heating the upper layer at the underside of the carpet article, and    applying thermoplastic material to the heated upper layer at the underside of the carpet article.    
   
   
       33 . A method according to  claim 28 , further comprising: 
 heating the thermoplastic material after applying the thermoplastic material to the upper layer.    
   
   
       34 . A method according to  claim 32 , wherein heating the upper layer further comprises using electromagnetic radiation,  
   
   
       35 . A method according to  claim 28 , wherein the thermoplastic material is a hot melt adhesive.  
   
   
       36 . A method according to  claim 28 , further comprising: 
 laminating a carpet backing onto the underside of the upper layer after applying the thermoplastic material.    
   
   
       37 - 45 . (canceled)  
   
   
       46 . A coating apparatus for coating carpet articles in a grey state, the carpet articles including an upper layer having filaments and an underside, the apparatus comprising: 
 transport elements for transporting the carpet articles in a transport direction along the coating apparatus,    a thermoplastic material applicator comprising a slot nozzle for applying a thermoplastic material to the underside of the upper layer of the carpet article in the grey state as the carpet article is transported past said thermoplastic material applicator,    said slot nozzle comprising: 
 a discharge slot,  
 an entry edge upstream of said discharge slot in said transport direction, and  
 at least one pocket downstream of said discharge slot and configured to open towards the carpet article  
   
   
   
       47 . A coating apparatus according to  claim 46 , further comprising a first heating element upstream of said thermoplastic material applicator in said transport direction.  
   
   
       48 . A coating apparatus according to  claim 46 , further comprising a second heating element downstream of said thermoplastic material applicator in said transport direction.  
   
   
       49 . A coating apparatus according to  claim 46 , wherein at least one of said first and second heating elements is an infrared radiating device.  
   
   
       50 . A coating apparatus according to  claim 46 , further comprising a coating roller disposed opposite said thermoplastic material applicator for supporting the carpet article.  
   
   
       51 . A method according to  claim 34 , wherein the electromagnetic radiation is infrared light.