Field of the Invention

The present invention relates to the production method of carpet tiles used in many areas including living spaces, workplaces, and industrial areas.

In particular, the present invention relates to a production method which enables the production of carpet tiles with high abrasion resistance in the desired thickness and weight by patterning circular knitting, raschel knitting, woven fabrics consisting of polyester or polyester yarn mixture, non-woven (non-woven, waterjet, etc.) fabrics produced from polyester and polyester blended fibers by joining said fabric with PVC, polyurethane, acrylic or latex materials.

State of the Art

Carpet tile is a type of carpet with a high-quality base, which is joined together in desired sizes and shapes and creates an aesthetic appearance with its design. Carpet tiles generally have many fields of use including living spaces, workplaces, and industrial areas.

In the state of the art, polyamide or polypropylene yarn is traditionally used on the surface in the production of carpet tiles. Carpet tiles are produced by using bitumen and PVC layers in the lower layers. Carpet tiles are generally used in two distinct types as curl pile and cut pile. Curl pile carpet is a type of carpet consisting of uncut pile curls. In cut pile carpet tile production, cut pile carpet tile is produced by cutting the curl pile carpet tile and cutting the curls. In said carpet tile production method, polyamide or polypropylene threads forming the pile are sewn in the form of curls on a substrate consisting of materials such as latex and bitumen in the form of a film. Thereafter, PVC plastisol is applied to the lower surface of the substrate and is dried in the ovens. If cut pile tile is produced, cut pile tile is produced by cutting the curls. Subsequently, produced carpet tile material is cut into the desired dimensions, packed, and packaged. However, there are no unlimited colour/pattern possibilities in the production of carpet tiles produced with the traditional method, and the production costs are high. Therefore, a method that can be produced in the desired pattern and colour with lower cost is needed in the state of the art.

As a result of the aforementioned issues and the limited supply of available solutions, it became necessary to make an improvement in the relevant technical field.

Aim of the Invention

The present invention is related to a production method of carpet tile which eliminates the abovementioned disadvantages and brings new advantages to the relevant technical field.

The main aim of the present invention is to enable the production of carpet tiles with more affordable costs with high abrasion resistance in the desired thickness and weight by patterning circular knitting, raschel knitting, woven fabrics consisting of polyester or polyester yarn mixture, non-woven (non-woven, waterjet, etc.) fabrics produced from polyester and polyester blended fibers by joining said fabric with PVC, polyurethane, acrylic or latex materials.

The aim of the invention is to make the desired carpet tile pattern to polyester and polyester mixed fabrics or polyester and polyester mixed non-woven fabrics produced by knitting or weaving method, with different printing methods such as digital printing, transfer printing or rotation printing. Another aim of the invention is to provide easy and high-speed application of patterns and colours that are difficult to reach in traditional carpet tiles.

Detailed Description of the Invention

In this detailed description, the preferred alternatives of the inventive production method of carpet tile are described only for clarifying the subject manner such that no limiting effect is created.

The present invention relates to the production method of carpet tiles used in many areas including living spaces, workplaces, and industrial areas.

The process steps of the inventive production method of the carpet tile are as follows; a1) Laminating the film material of different thicknesses and weights, produced with PVC, polyurethane, acrylic or latex, by the coating method or the plastering method or the calendaring method or the lamination method on circular knitting, raschel knitting, woven fabrics consisting of polyester or polyester yarn mixture, nonwoven (non-woven, waterjet etc.) patterned fabric produced from polyester and polyester blend fibers. a2) Laminating the film material of different thicknesses and weights, produced with PVC, polyurethane, acrylic or latex, by the coating method or the plastering method or the calendaring method or the lamination method on circular knitting, raschel knitting, woven fabrics consisting of polyester or polyester yarn mixture, nonwoven (non-woven, waterjet etc.) unpatterned fabric produced from polyester and polyester blend fibers. Direct printing or transfer printing on the semi-finished product obtained from the unpatterned fabric, or applying the pattern process directly to the fabric surface by rotation printing method, b) Wrapping the patterned product as a coil and packaging the carpet tiles obtained by cutting the coiled product into desired shapes and sizes with laser cutting or press die cutting.

In the coating method mentioned in the (a1) or (a2) process steps;

It can be applied with PVC, polyurethane, acrylic or latex materials on the carrier paper. These materials are plastered in the form of foam or directly on the transfer paper with the help of a blade in the desired weights. Plastering can be done by using more than one blade according to the product features. The material is dried in the oven at the appropriate temperature after each plastering process. In the last plastering blade, before the material enters the oven, patterned or unpatterned fabric is laminated on wet dough and then dried in the oven at the appropriate temperature, semi-product is obtained in the desired thickness and weight.

In the plastering method mentioned in the (a1) or (a2) process steps;

Patterned or unpatterned fabric is attached to the machine and the non-printed side of the fabric is plastered with PVC, polyurethane, acrylic or latex materials in the desired weight and thickness by methods such as blade, rotation head, cylinder. In the plastering process, the plastering process can be applied either in the form of foam or directly. After the plastering process, the desired thickness is adjusted during drying in the oven and the drying process is carried out and semi-product is obtained in desired thickness and weight.

In the calendaring method mentioned in the (a1) or (a2) process steps;

PVC is turned into a film in the desired weight with the help of hot rollers by applying heat treatment to the PVC material. The PVC, which has been turned into a film, is laminated on a patterned or unpatterned fabric with the help of printing rollers while it is hot and is wound in coils at the end of the line. The semi-product obtained is subjected to heat in the desired state by passing through an external machine and the desired thickness can be adjusted by inflating PVC.

In the lamination method mentioned in the (a1) or (a2) process steps;

Materials in the film form with various thicknesses and weights, produced with PVC, polyurethane, acrylic or latex, are combined with various lamination methods on patterned or unpatterned fabrics and semi-finished products are obtained.

If the process step (a2) of the above-mentioned methods is applied; the semi-product is then patterned by direct printing, transfer printing or rotation printing.

After (a1) or (a2), process (b) is applied.

In the inventive carpet tile production method, features such as non-flammability, easy cleaning, antibacterial and antistatic can be optionally added. Apart from these, a visuality and texture that is closer to standard carpet tiles can be obtained by applying physical pressure with various methods to optionally give the carpet tile a visual feature, and by adding dimension and depth to the product.