Claims
- 1. A process for manufacturing substantially 100% nylon 6 carpet comprising:a) making an unbound carpet having a face side which is displayed when the carpet is installed and a back by inserting nylon 6 face yarn into a nylon 6 support means; and b) melting nylon 6 to form molten nylon 6; c) binding the face yarn to the support means by providing the molten nylon 6 at points where the face yarn and the support means contact each other, and then allowing the molten nylon 6 to cool, thereby forming a substantially 100% nylon bound carpet.
- 2. The process of claim 1 wherein said inserting is by weaving the face yarn into the support.
- 3. The process of claim 1 wherein said inserting is by tufting the face yarn into the support means.
- 4. The process of claim 1 wherein said binding is by presenting molten nylon 6 film to the back of said carpet.
- 5. The process of claim 4 wherein the film is extruded on the back of the carpet.
- 6. The process of claim 4 wherein the film is a preformed film and is heated at least to the stick point of nylon 6 after combining the carpet and the film.
- 7. The process of claim 6 wherein the film is heated by a calendar roll which is maintained at a temperature sufficient to cause the nylon 6 to stick.
- 8. The process of claim 6 wherein the film is heated by a direct flame source.
- 9. The process of claim 6 wherein the film is heated by infra-red radiation.
- 10. The process of claim 1 wherein said binding is by heating to the melting point of nylon 6, a nylon 6 powder supplied to the back of the carpet.
- 11. The process of claim 10 wherein said beating is by a direct flame source.
- 12. The process of claim 10 wherein said heating is by infrared radiation.
- 13. The process of claim 1 wherein said binding is by solution coating the back of the carpet with a solution containing nylon 6 and a liquid including at least one solvent for nylon 6.
- 14. The process of claim 13 further comprising sending the solution coated carpet to a heat exchanger where the liquid is removed.
- 15. The process of claim 1 further comprising:c) backing the bound carpet with sufficient nylon 6 coating, film or powder to bind the face yarn into the support means and provide dimensional stability for the carpet.
Parent Case Info
This is a divisional of application(s) Ser. No. 08/289,163 filed on Aug. 11, 1994, now U.S. Pat. No. 5,464,677, which was a continuation of July 753,478, filed Aug. 30, 1991 now U.S. Pat. No. 5,370,757.
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Continuations (1)
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Number |
Date |
Country |
Parent |
07/753478 |
Aug 1991 |
US |
Child |
08/289163 |
|
US |