IE43904B1 - Covering for floor or wall - Google Patents

Description

The present invention relates to a covering material, a process for the production of such a covering material and an apparatus for effecting the said process. The material may be used as a floor or wall covering or as a furnishing fabric.

More specifically, the invention relates to a covering material of the non-woven type and comprising at least one layer of parallel juxtaposed textile threads, as well as a supporting layer to which the textile threads are individually fixed.

Hitherto the textile threads have been fixed to the supporting layer by means of an adhesive, or a Malimo-type tack or stitch using a sewing thread for fixing the textile threads to the supporting layer.

When the textile threads are adhesively bonded to the supporting layer, the diameter of the said threads cannot be very large because the bonded portion of the thread must be large relative to the unbonded surface of the thread and at the same time must be sufficiently small that the textile threads are not rigidified to too great extent by the hardened adhesive, so that they retain-on the visible face of the covering their textile feel and appearance. It has been found that these requirements can only be satisfied by using very thin threads so that the scope of application of the known coverings of this type is limited to 3 3 0/3 - 3 vertical panels and walls. Moreover, the adhesive used in these coverings is often a thermoplastic film which is attached to a sheet of paper, which film is heated to its softening temperature before applying a layer of textile threads thereto by pressure, and which film looses its pliability relatively quickly and becomes rigid so that the threads can easily be pulled out, whereby the covering deteriorates in a short time. During the manufacture of such a known covering, it is necessary to ensure that the textile threads are located in the same plane and come into contact with the supporting layer covered with the thermoplastic film because any textile thread located outside the thread layer plane cannot be fixed to its support. When large threads are used there is a danger of their being flattened during their application to the film, and also of their being bonded, over a portion of the periphery thereof which is inadequate for preventing their premature pulling out. Analogous difficulties occur with twisted threads, layered threads and any other socalled fancy thread.

Attempts have already been made to obviate these disadvantages by using for the fixing of large threads fine tacking or stitching threads inserted by means of a Malimo-type loom in such a way as to surround the visible side of the periphery of the threads and fix the said threads to the supporting layer. To the extent that the large threads are all of the same colour, the tacking thread can also be of the same colour so that the appearance of the covering is not impaired by the said tacking thread. However, the aesthetic, appearance is impaired when the large threads are of different colours and are different in colour from the tacking thread colour. Quite apart from this disadvantage of an aesthetic nature, a covering of this known type cannot withstand intensive wear because the fine tacking thread is relatively weak and the large threads can be removed from their supporting layer when no longer held in place by the tacking thread. Moreover, the weakness of the tacking thread prevents any usage of this type of covering as a floor covering.

To obviate this disadvantage, it has been proposed to cover the layer of large threads and the tacking threads with a plastics protective layer. However, this means that the covering no longer has the basic textile characteristics such as a soft and pliable feel which are absolutely necessary in a textile floor and/or wall covering.

A covering embodying the present invention retains its textile characteristics whilst having a great resistance to wear and fraying. It also permits the use of fancy threads.

According to the present invention, a covering material of the non-woven type comprising a layer of parallel juxtaposed textile threads, each formed from a plurality of twisted fibres, superimposed on a supporting layer to which the said textile threads are individually fixed by fixing some fibres of each textile thread to the supporting layer by needling.

In a floor or wall covering embodying the present invention the textile threads are fixed to their supporting layer throughout their lengths without the fixing fibres being visible or exposed to any wear. The large threads retain their puffed-out appearance, especially if the needling is of low density, Moreover, superimposed threads are fixed without difficulty to the supporting layer. It has been found that in conjunction with the supporting layer the fixing fibres prevent the other fibres, which are twisted about the thread axis, from unwinding and opening in such a way that the wear and abrasion resistance of the covering is greatly increased. This is due to the fact that the invention advantageously combines the strength characteristics of a textile thread due both to the torsion and the adhesion of the fibres relative to one another, - 5 and to the tangling of the fibres due to needling, as well as to the locking of the twisted fibres by the needled fibres whilst ensuring the fixing of the threads to the supporting layer at numerous points. In view of these characteristics a covering embodying the invention can be used as a floor covering and for a given wear resistance requires less textile material than other textile coverings such as needled carpets or velvet carpets.

In order that the invention may be better understood examples of covering materials embodying the invention and of processes and apparatus for making them will now be described with reference to the accompanying drawings, in which :Figure 1 is a perspective view of a first embodiment of a floor and/or wall covering according to the invention; Figure 2 is a perspective view of a second embodiment of a covering according to the invention; Figure 3 is a longitudinal section of the embodiment of Figure 1; Figure 4 is a schematic side view of the installation embodying the invention: Figure 5 is a plan view of the installation according to Figure 4.

The floor and/or wall covering comprises a layer 1 of textile threads and a supporting layer 2, to which is fixed each textile thread 3 of the said layer 1. The thickness of the supporting layer 2 can be larger or smaller than the thickness of layer 1 whose threads 3 are preferably large threads with a diameter of a few millimetres.

The external configuration of these threads may differ and as an example 4 designates a twisted fibre thread,5 a burled thread in which wide portions 5a and narrow portions 43904 . - 6 5b alternate, and 6 a braided thread formed from several thin threads.

The basic threads used within the scope of the present invention all comprise a plurality of synthetic or natural fibres 7 (Figure 3) which are approximately parallel to one another and which are twisted about the thread axis. The threads 3 to 6 are fixed to the supporting layer 2 by means of certain fibres 8 of each thread 3 to 6, the said fibres 8 being at least partly embedded in the supporting layer 2 by means of a needling operation. It uaa been found lhat a needling dens;.uy of ICS stii-hea/dm of covering surface is adequate for a good fixing of threads 3 to S to their supporting layer. Good results have been obtained with needling densities between 30 and 600 2 stitches/dm .

Obviously these values vary as a function of the type and length of the fibres forming threads 3 to 6. Moreover, the needling density limit must not be exceeded because beyond this limit the threads are destroyed. In Figure 1 reference numeral 9 designates a thread which partly overlies the adjacent threads in the layer 1 but which is nevertheless adequately fixed to the supporting layer 2 by means of fibres 8 which pass between the adjacent threads in the layer 1.

A portion of each connecting fibre 8 remains in the structure of the threads 3 to 6 but an end of each fibre passes into or through the supporting layer 2 and is embedded therein by a conventional needling operation.

The supporting layer 2 can comprise a strip of paper ) or non-woven fibrous material, obtained by the wet method with continuous threads arranged in layers and needled to one another, a polypropylene or polyester film, a cloth or a knitted fabric. In the example shown in Figures 1 to 3 the ends 8a of the connecting fibres 8 project from the i supporting layer 2 on the side opposite to that of the 4380/2 - 7 layer of threads 1 and are embedded in a thermoplastic coating 10 applied in the fluid state to the back of supporting layer 2 (Figures 1 and 3). Threads 3 to 6 forming the layer of threads 1 can all have the same diameter or can be of a different diameter; groups of threads of one diameter can alternate witn groups of threads of a different diameter.

It is also possible to form the layer of threads from groups of threads of different types and configurations. The type of threads 3 to 6 used is adapted to the intended use of the floor and/or wall covering. They can be fibres of wool, cotton, sisal, coir or synthetic fibres. Thus, for example, sisal fibres can be transformed into threads, cords or braids which will then be used to form the layer of threads for plaiting.

Even if in the embodiment of Figure 1 threads 3 to 6 of layer 1 are arranged parallel to the longitudinal direction of the supporting layer 2 of the floor of wall covering, it is also possible to arrange them in the first layer or in the second layer of threads 11 (Fig. 2) so as to be transverse to the longitudinal direction of the said layer 2. The second layer of threads 11 is not necessarily continuous but can be discontinuous and vary in its width. The threads 12 of the second layer 11 are parallel to one another and are fixed by needling at least to the threads 3 of the first layer of threads 1 and preferably also to the supporting layer 2. In order to facilitate the fitting of the second layer of threads, called transverse layer 11, an assembly of the thread layer and supporting layer is advantageously formed as shown in Figure 1 wherein the threads are parallel to the longitudinal direction of the supporting layer which in this particular case preferably comprises an extremely thin transparent film or strip constituting a provisional supporting strip. The film width then determines the width of the different £ «3> 904 > portions Ila, lib of the second layer of threads 11. In place of a thermoplastic film it is also possible to use a thin non-woven fibrous material strip e.g. obtained by the wet method from fibres whose composition is analogous or identical to that of the large threads of the layer of textile threads 11. Instead of arranging portions Ila, lib of the.second layer of threads 11 transversely relative to threads 3 of the first layer of threads 1, they can be placed on the latter in such a way that the threads 12 grouped into several columns are parallel to the threads 3 of the first layer and thus form raised columns of varying widths. Other arrangements Of the threads are obviously possible.

Figures 4 and 5 schematically show an embodiment Of the installation for the manufacture of the textile floor and/or wall covering. The threads 3 which form the layer of threads 1 or 11 are stored in the form of spools 14 mounted on a spool support 15 and pass between the teeth 16 of a comb 17 before passing below a guiding roller 18.

A supporting layer 2 coming from a supply roll on a roller 19 passes with the layer of threads' 1 or 11 above a further guiding roller 20 before following, together with the layer of threads 1 or 11,. a path.leading through the working area 21a of a needling machine 21, the working area being defined by the anvil plate 22 and the head 23 (vertically movable in reciprocating manner in accordance with the double arrow F) of the said needling machine 21. The needles ate on the side of the path facing the layer of threads. Obviously the needling machine 21 is of conventional design except that the number of needles 24 per cm of the working area, is less than is conventional.

The needles 24 are preferably of the forked type and have a smooth shank. The gap between the two branches of the needle fork is relatively small so that the number of fibres seized and driven through the supporting layer 2 39 0 4 - 9 per active stroke of the needle is small. The covering which comprises a supporting layer 2 and a layer of threads I fixed to the said layer 2 on leaving the needling machine 21 is spooled onto a storage roll 25. Prior to this spooling operation the covering can obviously be provided with a coating 10 on the back of the supporting layer (see Figure 3).

The second layer of threads 11 can be placed on the first layer of threads 1 in several ways, but advanta10 geously the second layer of threads 11 is initially produced with an installation such as that known in Figures 4 and 5 and is fixed provisionally and preferably by needling to a very thin supporting strip such as a thermoplastic film or a non-woven fibrous strip obtained by the wet method and whose fibres have a composition identical with or similar to that of the threads 12 of the second layer 11. The threads 12 are positioned parallel to the longitudinal direction of the provisional supporting strip of the second layer of threads 11 and can then be either arranged parallel or transverse relative to threads 3 to 6 of the first layer 1 for producing the covering. If it is decided to position the threads 12 of the second layer II parallel to those of the first layer 1, one of several rolls of the second layer-supporting strip assembly is positioned above the first layer 1 and the supply roll 19 as shown by dotted lines in Figure 4 and designated by reference number 26; a return roller 27 brings the said assembly into contact with the first layer 1. The threads 12 of the second layer 11 can be collected together into several groups which are spaced in the transverse direction of the first layer 1 in such a way as to form on the latter groups of columns or raised threads relative to those of the first layer 1. If it is desired to arrange the threads 12 of the second layer of threads 11 transver35 sely to those of the first layer 1, one or several rolls - 10 28 (Figure 5) of the second layer-supporting strip assembly are provided preferably upstream of the needling machine 21 and on one side of the conveying path of the supporting layer 2. Adjacent to the said conveying path of the assembly of the first layer 1 and the supporting layer 2, namely between the latter path and the roller or rollers 28, is a cutting device 29, and on the other side of the said conveying path is a traction device schematically shown at 30 and permitting the removal from roller 28 of a new portion of the second layer after previously cutting a length substantially equal to the width of the first layer 1. The different portions of the second layer 11 with threads 12 arranged transversely to those of the first layer 1 can be placed on the first layer 1 either in contigous manner or in such a way as to leave gaps between the forward travel direction of the first layer in the direction Of the needling machine 21. In the case where a second layer of threads 11 has to be needled to the supporting layer simultaneously with the first layer of threads, the stroke height of the needling machine head 23 is regulated so that the lower end of the needles 24 can pass through the assembly comprising first and second layers of threads and the supporting layer.

Obviously the embodiments described hereinbefore can be modified within the scope of the invention as defined by the attached claims. Thus, it is possible to use as threads (for forming at least partly the layer of threads) chenilles, which are well-known in the manufacture of thick pile carpets. It is known that these chenilles are obtained from a preparatory fabric formed from warp threads serving as chenille binding threads and weft threads serving as velvet or wool threads. The weft threads, for example large woollen threads of the said preparatory fabric, are then cut between each binding warp, whereby the rows of thus formed weft threads are called chenilles. Depending 2 9 q g on whether the V-shaped weft thread strands are folded or not, so-called flat or so-called round chenilles are obtained. These chenilles are needled to the supporting layer preferably only in the binding area of the weft thread strands with the binding warp threads. Moreover, it is possible, for example, to use a shrinkable textile fabric as the supporting layer, e.g. a cotton fabric, and then subject the same to a shrinking treatment after having fixed tnerefco by needling the threads of the layer of threads. This further secures the fibres embedded in the supporting layer by needling and increases their resistance to pulling out. In addition, the use of the covering is not limited to floors and/or walls and can, for example, be used for furnishing fabrics.

Claims (15)

1. A covering material of the non-woven type comprising a layer of parallel juxtaposed textile threads, each formed from a plurality of twisted fibres, superimposed on a supporting layer to which the said textile threads are individually fixed by fixing some fibres of each textile thread to the supporting layer by needling.

2. A covering material in accordance with claim 1, comprising a second layer of parallel juxtaposed textile threads superimposed on and at least partly covering the first layer of threads, the threads of the second layer being individually fixed either to the first layer of threads or to the supporting layer by fixing some fibres of each thread of the second layer to the said first layer of threads or to the supporting layer by needling.

3. A covering material according to claim 1 or 2, wherein the threads of the layer or layers of threads have different diameters and are grouped so that threads of one diameter alternate with groups of threads of different diameters. 4.3© θ' 1 4 3904 - 13

4. A covering material according to claim 1, 2 or 3 wherein the threads of the layer or layers of threads comprise groups of threads of different types.

5. A covering material according to any one of the preceding claims, wherein the threads of the layer or layers of threads comprise threads of different configurations.

6. A covering material according to claim 2, wherein the threads of the second layer of threads are arranged on the first layer of threads in spaced groups.

7. A covering material according to claim 2, wherein the threads of the second layer of threads extend parallel to those of the first layer of threads.

8. A covering material according to claim 2, wherein the threads of the second layer of threads extend transversely to those of the first layer of threads.

9. A covering material according to claim 2, wherein the threads of the second layer of threads are fixed to a provisional supporting strip.

10. A covering material according to any one of the preceding claims, wherein the ends of the needled fibres of the threads of the layer or layers of threads are embedded in a coating applied to the back of the supporting layer. Ji.

11. A process for manufacturing a covering material according to any one of the preceding claims, wherein the supporting layer comprises a shrinkable textile fabric which is shrunk after fixing the threads of the layer or layers of threads thereto by needling.

12. An apparatus for the manufacture of a covering material according to claim 1, comprising means for supporting a roll of strip material constituting the supporting layer of the covering, means for supporting spools of textile threads, each formed from a plurality of twisted fibres, for forming a layer of parallel juxtaposed threads, a guiding roller for receiving the threads from the spools and the supporting layer from the roll of strip material, a comb in the path of the threads from the spools in their passage to the guiding roller, a needling machine, and means for defining a path movement for the layer of threads superimposed on the supporting layer from the guiding roller through the needling machine, the needling machine having needles on the side of the said path of movement facing the layer of the threads, mounted for reciprocating motion to advance into and be withdrawn from the said layers to fix fibres of the textile threads to the supporting layer.

13. A covering material of the non-woven type substantially as described hereinbefore' with reference to the drawings.

14. A process for manufacturing a covering material of the non-woven type substantially as described hereinbefore with reference to the drawings.

15. An installation for the manufacture or Aa covering material of the non-woven type substantially as described hereinbefore with reference ho the drawings.