Carpet molding process
View Patent ↗A carpet molding system includes a support structure having a receiving end and an output end. Two ovens and two receiving systems are coupled to the support structure. One receiving system receives an under-pad material through the receiving end and guides the under-pad material through one oven and through the output end. The other receiving system receives a carpet material through the receiving end and guides the carpet material through the other oven and through the output end.
1. A carpet molding system comprising:
a support structure comprising a receiving end and an output end;
a first receiving system coupled to said support structure and adapted to receive an under-pad material through said receiving end and guide said under-pad material through a first oven and through said output end;
a second receiving system coupled to said support structure and adapted to receive a carpet material through said receiving end and guide said carpet material through a second oven and through said output end;
a first heater coupled to said support structure, said first heater and a first space substantially adjacent to said first heater defining said first oven, said first oven receiving heat from both said first heater and a second heater such that both sides of said under-pad material are heated substantially simultaneously; and
said second heater coupled to said support structure and spaced apart from said first heater, said second heater and a second space substantially adjacent to said second heater defining said second oven.
2. A system as recited in claim 1 further comprising:
a molding device adapted to receive said carpet and said under-pad and mold the combination thereof.
3. A system as recited in claim 1 wherein said first receiving system and said second receiving system are adapted to guide said under-pad and said carpet together, thereby coupling said under-pad to said carpet.
4. A system as recited in claim 1 further comprising:
a manual feed into said receiving end for said under-pad and said carpet.
5. A system as recited in claim 1 further comprising:
an automated feed into said receiving end for said under-pad and said carpet.
6. A system as recited in claim 1 wherein said receiving end is positioned either linear to or at an angle from said output end.
7. A system as recited in claim 1 wherein said first receiving system and said second receiving system are adjustable.
8. A system as recited in claim 1 further comprising:
a coupler adapted to receive said under-pad from said first oven and said carpet from said second oven and couple said under-pad to said carpet.
9. A system as recited in claim 8 wherein said coupler is a directed feed area or a device adapted to apply pressure to said under-pad and said carpet, thereby coupling said under-pad to said carpet.
10. A system as recited in claim 1 wherein said first oven is further defined by said second heater and a third space substantially adjacent to said second heater.
11. A carpet molding system comprising:
a support structure comprising a receiving end and an output end;
a first oven coupled to said support structure between said receiving end and said output end comprises a first heater, said first oven receiving heat from both said first heater and a second heater such that both sides of an under-pad material are heated substantially simultaneously;
a second oven coupled to said support structure between said receiving end and said output end comprises said second heater;
a first receiving system coupled to said support structure and adapted to receive said under-pad material through said receiving end and guide said under-pad material through said first oven and through said output end;
a second receiving system coupled to said support structure and adapted to receive a carpet material through said receiving end and guide said carpet material through said second oven and through said output end;
a coupler adapted to receive said under-pad from said first oven and said carpet from said second oven and couple said under-pad to said carpet; and
a molding tool adapted to receive said under-pad and said carpet simultaneously and further adapted to mold said under-pad and said carpet.
12. A system as recited in claim 11 wherein said first receiving system and said second receiving system are adapted to guide said under-pad and said carpet together, thereby coupling said under-pad to said carpet.
13. A system as recited in claim 11 further comprising:
a manual feed into said receiving end for said under-pad and said carpet.
14. A system as recited in claim 11 further comprising:
an automated feed into said receiving end for said under-pad and said carpet.
15. A system as recited in claim 11 wherein said receiving end is positioned either linear to or at an angle from said output end.
16. A system as recited in claim 11 wherein said first receiving system and said second receiving system are adjustable.
17. A system as recited in claim 11 further comprising:
a coupler adapted to receive said under-pad from said first oven and said carpet from said second oven and couple said under-pad to said carpet.
18. A system as recited in claim 10 wherein said coupler is a directed feed area or a device adapted to apply pressure to said under-pad and said carpet, thereby coupling said under-pad to said carpet.