METHOD FOR PRODUCING 100 % RECYCLABLE CARPETS FROM A SINGLE RESIN OR POLYMER HAVING BACKING AND SECONDARY LAMINATION BY THERMOFUSING LAMINAE MADE OF THE SAME POLYMER WITH OR WITHOUT FOAM INSULATOR AND THERMOMOLDED IN A SINGLE OPERATION AND PRODUCT THUS OBTAINED

摘要

The invention concerns a thermomoldable carpet having a 100 % recyclable insulator made of a single polymer laminated onto a secondary substrate by thermofusion based on infrared units. Recycled low-denier-per-filament fibers made of the same polymer or resin as that of the surface or primary base of the carpet are used as means for mechanical backing. Said fibers must not necessarily have a different molecular weight or a different fusion point. The fibers form a bonded-pile or fabric and are applied by simple superimposition and tied when the threads are inserted during the tufting process of the carpet. The fibers may also form a non-woven. Secondary lamina layers and the same polymer or resin used for the other elements already applied to the carpet are laminated onto the non-woven, one of said layers being a foam insulator. All components have one common denominator, namely the thermoplastic resin, which makes them 100 % recyclable. No other method such as precipitation or the like is needed for the selection of the polymers. In order to manufacture a recyclable thermomoldable carpet, the front and rear sides of the carpet are protected during the manufacturing process by performing wetting and by applying a cooling process using sprinklers and tools with water re-circulation and chambers in which cold air is applied.