Composite Carpet and Foam Laminate and Method

The method of this invention is particularly suitable for forming flexible or rigid foam laminates, including foam backed carpet laminates. Rigid foam laminates may be used in automotive applications for example for contoured wheel covers, interior paneling and the like.

Foam-fabric laminates are presently formed by adhesive bonding a foam sheet to the fabric or casting a foam sheet upon a carrier and applying the fabric, under pressure, after foaming and prior to complete curing. Generally, an adhesive is still required. Where the foam is applied in a fluid form to a porous fabric or substrate, such as carpeting, the foam bleeds through the fabric during blowing. The need therefore remains for a method of applying fluid foam directly to a porous substrate, eliminating the requirement for casting the foam prior to application to the substrate and bonding.

Another problem in the prior art has been to form a contoured rigid foam-fabric laminate without wrinkling the fabric. Where the foam sheet is cast prior to application of the fabric, wrinkles are formed in the fabric. One technique to reduce wrinkles has been to utilize stretcher frames, which would require stretching of the fabric prior to application of the foam layer. Finally, it has been found difficult to cut or trim the foam-fabric laminates of the prior art because of the flexibility of the fabric relative to the foam. These and other problems of the prior art have been solved by the method and foam laminate of the present invention.

One aspect of the method of forming a foam laminate of this invention concerns heating a substrate to eliminate the necessity of precasting a foam layer and the necessity of an adhesive bond between the foam and substrate, reducing the time, labor and apparatus for such operations. Additionally, this same method aspect forms a permanent, integral bond between the foam layer and substrate, reducing the chances of delamination. A further aspect of this invention includes forming a laminate of substrate and foam in a mold (a) to complete the foaming of the foam layer (b) to cure the foam and (c) to shape the laminate. A third aspect concerns the formation of a foam laminate with a skrim embedded within the foam layer. Each of these aspects may be practiced in combination or separately. For example, the first aspect is specifically and preferably for use with a porous substrate, and may or may not be used in combination with a skrim or a molding step. Further, the molding aspect does not require the heating step involved with the first aspect of the invention, nor the use of a skrim.

Thus, the method of this invention may be utilized with substantially any substrate, including relatively porous fabrics such as carpeting. Further, relatively rigid foams and substrates may be formed into permanently contoured shapes, without pre-forming either the foam or substrate layers. As described, the method of this invention also substantially eliminates the problem of wrinkling of the substrate, during forming. Finally, the preferred method of this invention results in a unique foam laminate, which may be easily formed and trimmed without special equipment.

The first aspect of the method of this invention includes the steps of heating the surface of the substrate, such as a porous fabric, to which the foam is to be applied, applying a layer of foaming plastic to the heated substrate surface and completing the foaming of the plastic layer and curing the foam and substrate into an integral homogeneous foam-substrate laminate. In the preferred method of this invention, a first layer of foaming plastic is applied to the heated substrate surface, providing a blow barrier at the foam-substrate interface. A second layer of foamable plastic may then be applied immediately over the first foam layer, permitting the building of the foam layer into a layer of substantial thickness. As described, the substrate may be a relatively porous fabric. For example, the foam may be applied directly to the backing of a carpet, providing an integral foam backing for the carpet. The substrate is preferably heated to at least 100.degree. F., but below the charring temperature of the substrate. The preferred foam in the method and laminate of this invention is a polyurethane foam, which may be a relatively rigid polyurethane foam, as described below.

Where the method of this invention is used to form a permanent contoured laminate, the plastic is preferably a relatively rigid polyurethane. The method of this aspect of the invention then includes forming the laminate, preferably under heat and pressure, in a contoured shape, preferably in a matched set die, or the like. The laminate is received in the die immediately after applying foam to a substrate, prior to complete foaming, wherein the foam is utilized as a forming media. The foaming plastic in the die aids in the forming of the contoured configuration of the laminate. Three method steps are then included in the forming die, including completion of the foaming, curing of the foam and shaping of the foam laminate. The resultant formed laminate is surprisingly free of folds and creases, which is believed to be caused by the compressive strength and pressure of the foam, wherein the strength of the foam and pressure offsets the tendency of the flexible substrate to wrinkle. As stated previously, this aspect of the invention may be practiced separately from heating the substrate to prevent foam bleed through, such as with an impervious substrate.

The substrate may also require trimming which has been a problem with the prior art primarily because of the difference in physical properties between the substrate and the foam layer. For example, when the foam is applied to a carpet, the carpet will tear during trimming and the foam will crack. This problem has also been solved by the improved foam laminate of this invention.

The preferred embodiment of the foam laminate includes the substrate, such as a napped carpet, a polyurethane foam layer permanently affixed to the substrate and a grid-like porous non-resilient skrim located within the polyurethane foam layer with the polyurethane foam continuous through the skrim and the skrim located between the substrate-polyurethane foam interface and the outer skin of the foam layer. The skrim is preferably flexible and non-resilient and permits the laminate to be easily trimmed without tearing of the substrate.

In the method of this aspect of the invention, the skrim is disposed over the face of the substrate which is to receive the foam layer and the substrate may be heated through the skrim, as by radiant heating. The foam layer is then sprayed or otherwise applied through the skrim, causing the skrim to "float" in the foam layer. Where two layers of foam are applied to the substrate, for example, the skrim will float at least one-third of the distance between the substrate and the exposed skin of the foam, preferably near the skin of the foam. The size of the skrim grid openings should therefore be selected to cause the skrim to float, as desired. Again, this aspect of the invention may be practiced with or without the steps of either heating the substrate or molding the laminate in a die.

Other advantages and meritorious features of the disclosed foam laminate and method of this invention will be more fully understood from the following description of the preferred embodiments and methods of this invention, the appended claims and the drawings, a brief description of which follows.

FIG. 1 illustrates a process line suitable for carrying out the separate aspects in the process of this invention;

FIG. 2 is a top perspective view of a skrim which may be utilized in the process and foam laminate of this invention;

FIG. 3 is a top perspective view of the foam laminate of this invention formed by the method disclosed in FIG. 1; and

FIG. 4 is a side cross-sectional view of the laminate shown in FIG. 3, in the direction of view arrows 4--4.

The process line 20 shown in FIG. 1 includes a heater station 22, a foam application station 24 and a forming station 26. The process illustrated in FIG. 1 applies a foam backing to a carpet section and forms the carpet section into a contoured shape, such as a self-supporting automotive interior wheel cover used in a stationwagon, fastback or the like. It will be understood however that the process of this invention may be utilized to form various types of laminates, as will be described more fully below.

In the process line shown in FIG. 1, carpeting 28 is continously fed from a roller 30 and skrim 34 is fed from roller 36, over the carpeting, to heater 40 of heater station 22. The heater may be a conventional radiant heater having a plurality of radiant heaters 42, heating the carpet backing prior to application of the foam. The heaters will also dry the carpet, removing entrained moisture which may be detrimental to the foam or laminate. The carpeting may be of any conventional design, including a napped side and a relatively smooth backing, either porous or non-porous.

Heating of the substrate, which in this case is a relatively porous carpet, eliminates the problem of the foam "bleeding" through the carpet upon application of the foam. When the foam contacts the heated carpet backing, it begins to foam immediately, forming a blow barrier and preventing the foam from bleeding through or penetrating the carpet. As described above, this has been a particularly difficult problem in the application of a foam layer directly upon a porous substrate, such as a carpet. When the carpet is heated, the foam expands upwardly or away from the carpet, providing a bridge without substantial penetration. Further, a mechanical interlock is provided between the porous substrate and the foam layer, providing excellent adhesion. Where the substrate is a carpet, the foam forms a tuft lock, actually improving the tuft retention of the carpet.

The preferred temperature to which the substrate is heated will depend upon the heat stability of the substrate and the particular foam utilized. In most applications, the temperature of the substrate should be at least 100.degree. F. and should preferably be greater than 120.degree. F. In the application of a polyurethane foam to a conventional carpet backing, the preferred temperature range is between about 120.degree.and 150.degree. F. The heated carpet and skrim is then received in the foam application station 24.

In the disclosed embodiment of the process line 20, foam is applied to the heated carpet backing by a reciprocating nozzle assembly 46. The nozzle assembly includes a drum 48 having an inlet pipe 50 receiving the constituents of the foamable plastic. In a conventional spray nozzle assembly, the constituents of the foam are mixed at the spray nozzle. The nozzles are reciprocated by a conventional linkage, including a power link 52 driveably connected to a drive shaft 54 and pivotally connected to a follower link 56. The follower 56 is pivotally connected to nozzle tube 58, which is pivotally connected to the drum at 60. Drive link 52 is thus rotated about drive shaft 54, pivotally reciprocating nozzle tube 58 from the position shown to the position shown in phantom shown in phantom at 59. The constituents of the foamable plastic are received through tube 50, mixed in drum 48 or previously mixed and sprayed on the heated carpet backing through nozzles 62. It will be understood that any suitable method may be used to apply the foam to the heated carpet backing, including casting with a metering knife, or the like. The preferred method however includes spraying the foamable plastic laterally or axially on the carpet because the thickness of the foam may be built-up by two or more passes of the disclosed reciprocating nozzle.

Where the foam is applied to a heated porous substrate by spraying through a reciprocating nozzle, the porous substrate is first impregnated with foam, forming a blow barrier and mechanical interlock as described above. In the second pass of the reciprocating nozzle, the foam is applied over the impregnated backing, building-up an intergral, homogeneous foam layer. The thickness of the first layer of foam applied to the substrate will primarily depend upon the porosity and temperature of the substrate, but will also depend upon the type of foam used. Where the foam is applied to a conventional carpet and is heated to between about 120.degree. and 150.degree. F., as described above, the foam may be applied in thickness of about one-quarter inch foamed thickness per pass of the reciprocating nozzle, forming foam layer 66 shown in FIG. 1.

The foam used in the method of this invention will depend upon the particular application of the composite laminate. A flexible polyurethane foam may be preferred for conventional carpet backing. A relatively rigid polyurethane foam having a density of about two pounds per cubic foot has been found suitable for the automative applications described above. One example of a suitable rigid polyurethane foam includes an isocyanate component comprising 90% polymeric isocyanate and 5 to 10% inert flame retarder and a resin or polyol component comprising 60 to 70% polyether polyol, 20 to 30% fluorocarbon 11-B (trichlorofluoromethane) and approximately 1% silicone surfactant and metal or acid salt catalysts. This foam composition may be purchased from Urechem Corporation. Other suitable rigid and flexible polyurethane foam compositions are disclosed in British Pat. No. 1,306,372 of the Union Carbide Corporation.

The composite laminate may then be cured by conventional means. Where a rigid polyurethane foam is utilized and the laminate is to be permanently formed into a contoured shape, the invention contemplates immediately inserting the laminate into a die, such as shown at forming station 26, a prior to complete foaming and curing of the foam. A cutting blade 68 is shown in FIG. 1, which cuts the laminate into sections suitable for receipt in the die. It is understood however that the carpet and skrim may be pre-cut into suitable sections, prior to receipt in the heating station 22 or the entire process may be continuous. It is also to be understood that the aspect of the invention concerned with forming th contoured shape in the die at station 26 does not necessarily require the heating step at station 22, for example, such as when an impervious substrate is used.

The die assembly shown in forming station 26 is a conventional matched set die assembly, including a lower platen or die 74 having conventional heat transfer coils 76 located within the die platen adjacent the interface between the lower platen 74 and the upper platen 78. The upper platen 78 is supported in the disclosed embodiment by frame 80 having conventional hydraulic rams 82 including pistons 84. Pressure is applied to the upper platen by extending piston rods 84 and the die is opened by retracting piston rods 84, as shown in phantom at 79.

As described above, the foam-carpet laminate is placed in the die as soon as the final foam layer is applied. The die opens immediately upon completion of the last pass of the reciprocating nozzle, the laminate is inserted and the die is closed.

Three steps are carried out in the forming die, including (1) completion of foaming, (2) curing of the foam and (3) shaping of the foam laminate. This method of the invention thus utilizes the foam as a forming media. Where the foaming is completed in the die, substantial pressures result and the pressure aids in the forming of the contoured configuration of the laminate. As described above, this is believed to be caused by the compression strength and pressure of the foam. The resultant contoured foam laminate is substantially free of folds and creases.

A suitable die for the method of this invention, as described, applied 8 to 10 pounds per square inch pressure. In the disclosed embodiment, the die is also heated by passing stem or other fluid medium through the heat transfer coil 76. The die may be heated to a temperature of about 150.degree. F. using conventional steam. It is understood that the method of forming of this invention may also be utilized to form foam laminates having relatively rigid impervious substrates. For example, contoured shapes may be formed using substrates such as coated asphalt impregnated craft or chip board, cardboard and the like. The foam will form a permanent bond to such materials in the method of this invention.

The method of this invention may also include a final trimming step, not shown, using a conventional trimmer blade, such as shown at 68 in FIG. 1. The foam laminate of this invention is particularly adapted to permit easy trimming, which is a problem in a foam laminate having a relatively resilient substrate, such as carpet. The utilization of a non-resilient skrim, retained in position within the foam layer, permits cutting of the laminate without tearing of the carpet. Further, a relatively rigid foam, such as a rigid polyurethane foam, will break easily when apart from the composite laminate of this invention, particularly under compressive stress. The utilization of a non-resilient skrim has solved this problem.

A suitable skrim for the foam laminate of this invention is shown at 34 in FIG. 2. The preferred skrim is formed of non-resilient polyester strands, such as the interwoven perpendicular strands 94 and 96 shown in FIG. 2. Skrim of this type are available commercially from various sources. In the method of this invention the skrim is received on top of the carpet backing as shown in FIG. 1 and the carpet backing is heated through the skrim. Finally, the foamable plastic is sprayed through the skrim in the foam application station 24, causing the skrim to "float" upwardly or away from the carpet backing as the foam expands. The size of the skrim grid openings should therefore be selected to cause the skrim to float, as desired. A skrim having perpendicular strands defining apertures of one-eighth to one-quarter inch, measured from cross-over points, has been found suitable for the foam laminate of this invention. In this embodiment, the skrim floats until it is located at least one-third of the distance between the carpet backing 100 and the skin 98 of the foam as shown in FIG. 4.

The foam laminate shown in FIGS. 3 and 4 has been formed by the method of this invention. The laminate 90 includes a contoured portion 96 formed in the forming station 26 of FIG. 1. As described above, the carpet portion 28 is formed free of folds, creases or the like and the foam portion 66 is permanently affixed to the back or reverse side of the carpet 100 and is homogeneous, although applied in plural passes of the reciprocating nozzle assembly 46. The contoured foam laminate is formed of a relatively rigid polyurethane, such as described above and will retain the contoured shape after repeated flexing. The foam alone is difficult to cut because it is subject to cracking or breaking and the carpet alone is more easily torn than cut. The foam laminate 90 however may be easily trimmed, primarily because of the non-resilient skrim.

Again, it will be understood that the improvements of the method of this invention may be used individually or in combination to produce foam laminates other than the foam laminate shown in FIG. 3 and 4. For example, a flexible foam may be applied to a carpet backing or other relatively porous fabric materials. Alternatively, an impervious substrate may be used in combination with a relatively rigid foam which is then formed into a permanently contoured shape as described above, this process not requiring the heating step since foam bleed through is not a problem. The skrim may not be required in certain applications, particularly where strength is not a factor or a non-resilient substrate is used.