HOT FILM LAMINATION (VACUUM ASSISTED) FOR CARPET BACKING APPLICATIONS
A process for laminating a substrate, where the process may include: disposing at least one a thermoplastic film on a porous substrate; heat softening the at least one thermoplastic film; conjoining the at least one thermoplastic film and the porous substrate to form a laminated substrate; and cooling the laminated substrate; wherein the conjoining comprises suctioning the thermoplastic film into the porous substrate. An apparatus for laminating a substrate, where the apparatus may include: a system for disposing a thermoplastic film on a tufted substrate; a heater for heat softening the thermoplastic film; and a vacuum for suctioning the thermoplastic film into the tufted substrate.
1 . A process for laminating a substrate, the process comprising
disposing at least one thermoplastic film on a porous substrate;
heat softening the at least one thermoplastic film;
conjoining the at least one thermoplastic film and the porous substrate to form a laminated substrate; and
cooling the laminated substrate;
wherein the conjoining comprises suctioning the thermoplastic film into the porous substrate.
2 . The process of claim 1 , further comprising adhering a second substrate to the thermoplastic film.
3 . The process of claim 2 , wherein the second substrate comprises at least one of a film, a foam, a modifiable film, and a crosslinkable foam.
4 . The process of claim 2 , wherein the second substrate is at least 1 mm thick.
5 . The process of claim 3 , wherein the foam comprises at least one of a high density foam and a multilayer foam.
6 . The process of claim 1 , wherein the conjoining further comprises roller pressing.
7 . The process of claim 1 , wherein the heat softening comprises at least one of infrared heating, microwave heating, convective heating, conductive heating, radiant heating, and radio frequency heating.
8 . The process of claim 1 , wherein the heat softening is prior to the disposing.
9 . The process of claim 1 , wherein the cooling comprises suctioning the thermoplastic film into the tufted substrate.
10 . The process of claim 1 , wherein the thermoplastic film comprises an ethylene-based homopolymer, copolymer, interpolymer, or multi-block interpolymer, a propylene-based homopolymer, copolymer, interpolymer, or multi-block interpolymer, or combinations thereof.
11 . The process of claim 1 , wherein the thermoplastic film comprises at least two layers.
12 . The process of claim 11 , wherein the at least two layers are modifiable film layers.
13 . The process of claim 1 , wherein the thermoplastic film comprises a modifiable film.
14 . The process of claim 13 , wherein the modifiable film comprises an expandable film, the process further comprising expanding the expandable film.
15 . The process of claim 1 , wherein the tufted substrate comprises at least one of carpet and artificial turf.
16 . The process of claim 15 , wherein the laminated carpet or artificial turf has a tuft lock of at least 2 kg.
17 . The process of claim 1 , further comprising applying an aqueous dispersion layer between the tufted substrate and the thermoplastic film.
18 . The process of claim 17 , wherein the aqueous dispersion layer comprises:
a thermoplastic resin; and
water;
wherein the aqueous dispersion has an average volume diameter particle size from about 0.3 to about 8.0 microns
19 . The process of claim 18 , wherein the aqueous dispersion further comprises a dispersion stabilizing agent.
20 . The process of claim 18 , wherein the thermoplastic resin comprises an ethylene-based homopolymer, copolymer, interpolymer, or multi-block interpolymer, a propylene-based homopolymer, copolymer, interpolymer, or multi-block interpolymer, or combinations thereof.
21 . The process of claim 18 , wherein the aqueous dispersion further comprises at least one of an ethylene vinyl acetate copolymer, a styrene-butadiene copolymer, and an epoxy, an acrylic polymer, a urethane polymer, or monomers therefore,
22 . Carpet manufactured according to the process of claim 1 .
23 . Artificial turf manufactured according to the process of claim 1 .
24 . An apparatus for laminating a substrate, the apparatus comprising:
a system for disposing a thermoplastic film on a tufted substrate;
a heater for heat softening the thermoplastic film; and
a vacuum for suctioning the thermoplastic film into the tufted substrate.
25 . The apparatus of claim 24 , further comprising a system for disposing a second substrate on the thermoplastic film.
26 . The apparatus of claim 24 , further comprising a cooler for cooling the softened thermoplastic film.
27 . The apparatus of claim 26 , wherein the cooler further comprises a vacuum for suctioning the thermoplastic film into the tufted substrate during cooling.