Carpet backing using rubbers

1. LATEX CARPET BACKING
Presented By,
Vishal K.P.

2. Introduction
• A carpet is a textile floor covering typically consisting of
an upper layer of pile attached to a backing.
• Two types: Woven and Non-woven/Tufted.
• Advantages of applying latex as carpet backing:
o improved anchorage of the pile
o improved anti-slip characteristics
o prevention and permanent folds and creases

3. Tufted carpets
• The piles are embedded in a primary fabric backing.
• Fiber tips were treated with a rubber latex compound which would
solidify to a flexible backing.
• The pile fibers between this new backing and the original fabric
backing were then cut when the latex had solidified.

4. Methods of application of latex
compounds to carpet backs
• The Lick-Roll method
• Knife-over blanket spreading
• Spraying

5. The Lick-Roll Method
•The carpet is pulled through the assembly by means of a variable-
speed driven roller.
•After brushing and steaming the carpet, the back of the carpet is coated
by means of a lick roller which revolves in a bath of the latex compound.
•A doctor blade is used to control the final thickness of the coating.
•The backing is then dried and vulcanized by passing through a hot-air
oven.

6. Knife-Over Blanket Spreading
•Similar to the lick-roll method.
•Differs in that this method uses a spreader instead of a lick roll.
•The latex is spread uniformly using a spreader unit.
•The backing is then dried and vulcanized by passing through a hot-air
oven.
DRYING OVEN
BRUSH
DOCTOR BLADE
HAUL OFF

7. Spraying
•A spray gun situated above the carpet back reciprocates in a direction
perpendicular to that in which the carpet moves.
•The motion of the spray gun is optimized in such a way that uniform
coverage is obtained.
• The backing is then dried and vulcanized by passing through a hot-air
oven.
HAUL OFF
DRYING OVEN

8. Formulations-Conventional Carpets

9. Formulation-Justification
• The cheapest compounds contain large amounts of substances
such as starch, glue or gelatin, together with large amounts of a
cheap filler such as whiting.
• Only a small proportion of the compound is rubber as latex.
• The 75% N.R latex is produced by evaporation process and is
preserved using KOH.
• The function of the rubber is to improve the permanence and
pile-anchoring characteristics of the blend.
• The amount of water added depend upon whether application is by
lick-roller or by spreading.
• Vulcanization at 120°C for 5 minutes.

10. Formulation-Tufted Carpets

11. Formulation-Justification
• The large addition of glue and starch as in case of conventional
carpets is replaced by cheapening fillers like whiting.
• 60% ammonia preserved N.R. latex is used.
• Sodium oleyl-p-anisidinesulphonate - Colloidal stabilizer.
• ZMBT & ZDC – Accelerators
• ZnO – Activator
• Phenolic antioxidant (non-staining)
• Ground whiting – Cheapening filler.
• Vulcanizing agent – Sulphur
• Vulcanization at 120°C for 5 minutes.

12. REFERENCE
1) Polymer Latices-Science and Technology:Second edition:Volume
3: Applications of latices: D. C. Blackley
2) Polymer Latices-Science and Technology:Second edition
Volume 2: Types of latices:D. C. Blackley

13. THANK YOU