CA1165988A - Non-woven textile material - Google Patents
Non-woven textile materialInfo
- Publication number
- CA1165988A CA1165988A CA000391811A CA391811A CA1165988A CA 1165988 A CA1165988 A CA 1165988A CA 000391811 A CA000391811 A CA 000391811A CA 391811 A CA391811 A CA 391811A CA 1165988 A CA1165988 A CA 1165988A
- Authority
- CA
- Canada
- Prior art keywords
- balls
- textile material
- fibers
- carrier layer
- needle
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H13/00—Other non-woven fabrics
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
- A61F13/00—Bandages or dressings; Absorbent pads
- A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
- A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
- A61F13/539—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers
- A61F2013/53966—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium characterised by the connection of the absorbent layers with each other or with the outer layers by needling, sewing, blow-needling
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
- Paper (AREA)
- Laminated Bodies (AREA)
- Manufacturing Of Multi-Layer Textile Fabrics (AREA)
Abstract
A nonwoven textile material having an upper layer of fiber-containing balls, and wherein the balls have a diameter of at least 6 millimeters, and therebelow a fiber-containing carrier layer containing connecting fibers connecting the balls to the carrier layer, includes a plurality of substantially actively needle-unprocessable fibers or yarns fastened to one another included in the balls, so that the balls are only passively connected to the connecting fibers of the carrier layer.
Description
- ~ 3 ~5~88 The invention relates to a nonwoven te~tile material having an upper layer of fiber-containing balls, the balls having a diameter of at least 6 millimeters, and therebelow a fiber-containing carrier layer containing connecting fibers connecting the balls to the carrier layer.
Textile structures of the aforedescribed type are already known, for example from EP Pub]ication No. 13.428-Al, or EP Publication No. 13.427-Al, which use ball yarns from spherically intertwined fibers, which are, however, intertwined loosely at a needle-processing density. In order to be cohesive, they must therefore be actively needle-processed, in other words must be connected to connecting fibers having their origin in the ball yarns. The active needle-processing capability of the ball yarns is furthermore also used to fasten the ball yarns to the carrier layer, and the needle-processing fibers are needle-processed as connecting fibers into the carrier layer. As a result of this active needle-processing the ball yarns are, however, more or less compressed, which is further reinforced during dense needle-processing. This in turn leads to a flattened or felt-like formed structure, so that any pattern desired to be formed by the ball yarns, particularly an embossment pattern, is impaired and does not lead to the desired appearance. Only if an actively needle-processable carrier layer is used, then the passively needle-processable ball yarns, which have, however, been firmed up by the active needle-processing, can be needle-processed from the side of the carrier layer. This does not, however, obviate the aforedescribed disadvantages of known flat -' .
~!
,1 . . ' 9 8 ~
structvres, so that these flat structures do not meet all require-ments of the user, nor are they suitable for further processing.
It is therefore an object of the presen~ invention to devise an unwoven textile structure of the aforedescribed kind without the disadvantages of known structures, in which the fiber-containing balls are disposed on the ~pper side and remain in unchanged round shape, while still being connected with an adequate firmness to the carrier layer in such a manner that a clearly structural appearance, for example an embossed structure, can be achieved without being impaired by the method of connecting the balls to the carrier layer.
This object is attained for te~tile structures of the aforedescribed kind, according to the present invention, by the fiber-containing balls comprisin~ substantially actively needle-unprocessable and spherically intermingled, fibers or yarns fastened to one another, and as the result of these fibers or yarns being actively needle-unprocessable, being only passively connected to the carrier layer by means of connecting Fibers hàving their origin in the carrier layer.
` 20 The balls are preferably connected to the carrier layer by a needle process, wherein fibers of the carrier layer are gripped, for example, by means of barbed needles and passed as holding ~ibers into the balls, so that the balls are passively needle-processed to the carrier layer. This passive attachment of the balls to the carrier layer, or implementation of the holding fibers can, however, also be accomplished by other known methods, for example Mali processes. The term "actively needle-, . ~
Textile structures of the aforedescribed type are already known, for example from EP Pub]ication No. 13.428-Al, or EP Publication No. 13.427-Al, which use ball yarns from spherically intertwined fibers, which are, however, intertwined loosely at a needle-processing density. In order to be cohesive, they must therefore be actively needle-processed, in other words must be connected to connecting fibers having their origin in the ball yarns. The active needle-processing capability of the ball yarns is furthermore also used to fasten the ball yarns to the carrier layer, and the needle-processing fibers are needle-processed as connecting fibers into the carrier layer. As a result of this active needle-processing the ball yarns are, however, more or less compressed, which is further reinforced during dense needle-processing. This in turn leads to a flattened or felt-like formed structure, so that any pattern desired to be formed by the ball yarns, particularly an embossment pattern, is impaired and does not lead to the desired appearance. Only if an actively needle-processable carrier layer is used, then the passively needle-processable ball yarns, which have, however, been firmed up by the active needle-processing, can be needle-processed from the side of the carrier layer. This does not, however, obviate the aforedescribed disadvantages of known flat -' .
~!
,1 . . ' 9 8 ~
structvres, so that these flat structures do not meet all require-ments of the user, nor are they suitable for further processing.
It is therefore an object of the presen~ invention to devise an unwoven textile structure of the aforedescribed kind without the disadvantages of known structures, in which the fiber-containing balls are disposed on the ~pper side and remain in unchanged round shape, while still being connected with an adequate firmness to the carrier layer in such a manner that a clearly structural appearance, for example an embossed structure, can be achieved without being impaired by the method of connecting the balls to the carrier layer.
This object is attained for te~tile structures of the aforedescribed kind, according to the present invention, by the fiber-containing balls comprisin~ substantially actively needle-unprocessable and spherically intermingled, fibers or yarns fastened to one another, and as the result of these fibers or yarns being actively needle-unprocessable, being only passively connected to the carrier layer by means of connecting Fibers hàving their origin in the carrier layer.
` 20 The balls are preferably connected to the carrier layer by a needle process, wherein fibers of the carrier layer are gripped, for example, by means of barbed needles and passed as holding ~ibers into the balls, so that the balls are passively needle-processed to the carrier layer. This passive attachment of the balls to the carrier layer, or implementation of the holding fibers can, however, also be accomplished by other known methods, for example Mali processes. The term "actively needle-, . ~
-2-9 ~ 8 processed" will be understood to mean tha-t the fibers of the fiber layer may be moved in a needle-process relative to other fibers in the layer, for example may be withdrawn therefrom, or may be intertwined with one another, in other words, they can actively perform some function. They can also be passed to a layer bordering the fiber layer, so that the bordering layer is connected with the fiber layer. The term "passively-needle-processed", or "passively attached" will be understood to mean, however, that in a similarly fiber-containing material layer there will be found fibers from another fiber-containing layer acting as holding fibers, but where these fibers are not used in this material layer substantially for any active purpose, but remain passive therein. Reference is made to the Stanley Swiss ~3~,20~
Patent No. ~g~ , published August 31, 1970, in this connection.
The balls disposed on the upper side of the textile structure, according to the present invention, are therefore `~ located on an actively needle-processed carrier layer, fibers o~ which, for example only portions of such fibers, have merely penetrated the balls as holding fibers, so that the balls are passively connected to the carrier layer by the active partici-pation of the carrier layer fibers. The fibers or yarns fastened to one another are held, for example, in a manner substantially similar as the fiber connection in a spun yarn, and are therefore substantially actively needle-unprocessable.
The balls are thereby pref~rably firmed up within themselves, and therefore have a cohesiveness even during use of the textile ~ 3 --,~, structure, which results in an adequate and desired firm connection to the carrier layer, so that, for example, an attachmert to the carrier layer by active needle-processing is not only not required, but is substantially disadvantageous, if not impossible. The attachment to the carrier layer, for example by needle-processing, can be carriea out in an advantageous manner only passively from the carrier layer side. The balls are then disposed, for example, on the carrier layer without being impaired in their shape by the method of attachment and retain their unchanged round shape, for example an unchanged circular cross-section, so that a clearly embossed structure with respec~ to the base, namely the carrier layer, can be obtained. Thus an appearance with a clearly embossed structure can be obtained, which differs, for example, clearly from that of the initially described known textile flat structures, which have a felt-like appearance as a result of the active needle-processing of the ball yarns in order to give these ball yarns an adequate firmness.
The holding or connecting fibers advantageously merely 20 penetrate the balls without being visible from the exterior, for example they penetrate, at most, up to a surface of the balls facing away from the carrier layer or through only part of the thickness of the balls, for example through half their thickness~
This results, for example, in the upper side of the textile structure being free or substantially free from any holding or connecting fibers projecting therefrom, so that, for example, they are not subjected to any wear or tear and cannot be damaged 9 g ~
during the use of the textile structure. The ball yarns may thereby remain firm without in any way being changed. For example, the incisions made by the needles as a result of the passive needle-processing are made into the carrier layer, and therefore appear on the lower side of the textile s-tructure without being visible on the upper side of the structure by an observer. The balls are therefore merely processed from the actively needle-processable carrier layer by a so-called "blind stitch technique", namely an invisible technique, so that they cannot, for example, be impaired by use. According to the invention, the balls are therefore attached to the carrier layer without any risk of their being destroyed or their appearance impaired, because their fibers are not used for attachment to the carrier layer.
In another preferred version, parts of the holding fibers or connecting fibers are bent back on themselves, for example, the end portion within the balls~ namely in a direction toward the carrier layer. This bend may take the shape of a barb, may be in the shape of an inverted V, or may have the form of a loop. As a result of this backward bend, the holding or connecting fibers can be hooked with one end onto the fibers or yarns of the balls, and therefore firmly anchored thereto; with their other ends these holding fibers or connecting fibers will be disposed, however, in the carrier layer, where in the case of the loop-like bend both ends of the respective holding fiber or connecting fiber can be anchored in the carrier layer.
The plurality of balls therefore represent a finite 1 3 ~8~
structure having a thickness of at least 6 millimeters which thickness can be up to 50 millimeters, so that each ball, as viewed in cross-section, can be penetrated along several locations by the holding fibers or connecting fibers at high uniformity, so that the balls can be attached to the carrier layer with adequate firmness. Consequently it is possible, for example, without impairing or substantially changing the shape of the balls, to obtain a high needle-processing density and therefore passive compacting, which, for example, increases the firmness and uniformity of the attachment of the balls to the carrier layer. Dependent upon, for example, the balls, the desired covering or the desired or required firmness, the balls may be needle-processed from the carrier layer at a needle-density of, for example 20 to 200 incisions per square centimeter. As a result of the thickness of the ball yarns being greater than 6 millimeters, textile structures having a weight in the range of, for example, .5 kilograms per square meter to 8 kilograms per square meter, can be obtained.
In a textile structure according to the invention a thick product can be obtained with a single layer of balls, in which the bal]s clearly form an embossed structure, and can, for example, be clearly visible in three dimensions and discerned as standing out from the base, namely from the carrier layer.
Therefore preparation of a preliminary sample can be avoided.
The balls can, on the contrary, for example, be individually placed in a desired pattern on the carrier layer, for example close to one another, or at spacings from one another, which not ~ 1 ~59~8 only facilitates their attachment to the carrier layer, but permits a variety of patterns and structures or variations thereof. By, for example, a strip-like arrangement of the balls a web-like or tuft-like character can be obtained.
During bending of the textile structure in a direction toward the carrier layer there may appear longitudinal gaps between rows of balls, without, for example, the at-tachment of the balls to the carrier layer being impaired thereby. Thus the textile structure has a pliability which canno-t, for example, be obtained in a needle-processed felt or a known felt-like textile structure of the aforedescribed EP publications, so that properties similar to, for example, those of tufted carpets are obtained.
These yarns, fibers or threads o~ the balls can be closely intertwined to obtain the required firmness, can be glued to one another, can be bound to one another by foamed material, or can be felted. They may be felt-like lumps or burl-like structures, as are obtained, Eor example, in a spinning process. The fibers are thereby prevented from being withdrawn from the fiber connection of the balls, for example by active needle-processing, or at least their relative movement can be made more difficult or limited. The fibers or threads are therefore blocked, for example, in such a manner that they at least do not slide with respect to one another, and therefore do not move sufficiently with the needle during needle-processing and cannot be withdrawn. If it is attempted to actively process the so firmed up fibers or yarns, they would, for example, ~ ~ &598~
either be stamped out, or tear, or the needles may even break.
The balls may therefore be merely penetrated by the holding or connecting fibers, without the fibers of the balls or the yarns having taXen part in any way actively during attachment to the carrier layer. In one version the fibers or yarns of the balls may have a density of from .1 grams per cubic centimeter to .25 grams per cubic centimeter, so that a compact ball formation with an advantageous attachment of the fibers or yarns is obtained.
In view of the holding fibers or connecting fibers which have penetrated the balls, according to the present invention, and which may be present in the balls either under tension or loosely, there is avoided, for example, a compression of the balls or a flattened product, which does occur, for example, with needle-processing from above, particularly at the high needle-processing density employed in known flat textile structures.
The balls may also be ball yarns of spherically inter-twined fibers or threads, or may have a round shape, for example a cylindrical or oval form. They may have properties similar to one another or different from one another as far as size, color, shape, type of fiber or the like is concerned; the fibers or threads of the balls or the ball yarns may be natural fibers or synthetic fibers or a mixture thereof, and the fibers may also be filaments. The fibers or threads of the ball yarns may have a length of from 40 millimeters to 5 meters. In a ball-shaped form the balls may have a diameter of about 6 millimeters to 25 millimeters, and in longitudinal or cylindrical form, for example may have a thickness of from, for example, 4 millimeters .
to 15 millimeters.
Further properties of the ball yarns, which may be advantageous for the textile structure, according to the present invention, are described in the previously mentioned EP publica-tions, and reference should be had thereto. The inventive attachment can therefore be combined in an advantageous manner, for example, with the properties of the ball yarns, so that the textile structure according to the invention may, for example, retain the properties of the ball yarns as employed according to the invention in an unimpaired or unchanged manner on the upper side of the carrier layer.
The textile structure may have the form of a strip or segments, for example a layer, or a piece good, and can be used for a floor covering, a wall covering, for decorative purposes, for a furniture covering, or as clothing material, or as a cover.
The manufacture of the textile structure, according to the invention, requires, for example, that the needle-processing of the holding ~ibers or connecting ~ibers from the carrier layer be aimed therethrou~h to the balls. This is preEerably accomplished by means of needles, which permit both gripping and release of the holding fibers or connecting fibers by means of barbs or recesses in the needles during withdrawal of the needles from the balls, so that the connecting fibers may be disposed within the balls preferably with their ends bent backwards on ` themselves. The needle-processing can be accomplished, for example, with so-called close-barb needles (for example informa-tion leaflet FOIA, Singer Felt Needles). Here, for example, th~
5 9 ~ 8 spacings from barb to barb, namely the barbed hook, as well as, for example, the stitch penetration depth and/or stitch density, are relevant to decide whether single fibers or bundles, for example, are to be gripped by the barbed hook, and to what depth and at what spacings the connecting fibers must be positioned in the balls or, for example, bent in the shape of a loop. sy, for example, appropriate arrangements of the needles in the needle board, and the position of the ball yarns, for example, leaving spaces between the balls, the balls can be needle-processed in a desired manner so that in an aimed fashion the connecting fibers merely penetrate the balls.
The carrier layer may contain natural fibers or synthetic fibers, or consist of such fibers or threads, and may, for example, be a fiber binding material. Starting from the carrier layer, for example, it is possible to start with a fiber fleece or from a fiber layer, ~or example from parallel fibers or threads or from fibers or threads which are crossed with one another. A supporting layer may be cLisposed on the side of the carrier layer facing away from the balls, for example, a cover-ing layer as conventionally used for floor coverings on the backside of the carrier layer, for example a spring carrier layer, or a layer of binding means, and this support may be attached by needle-processing or gluing, so as to implement the textile material according to the demands placed thereon, and also to secure the connecting fibers on the lower side.
In textile structures according to the present invention, it is therefore possible in a surprising manner to ~ ~ 6598~
combine properties of balls, for example ball yarns composed of spherically intertwined fibers, with the passlve attachment of the balls to the carrier layer, and to obtain in particular a product of unchanged properties, particularly as it applies -to the shape of the balls on the upper side of the layer, which can be obtained by a single layer of adjacently positioned balls on the carrier layer. The balls may be treated with binding means, which can be inserted from the side of the carrier layer and penetrate thereinto, namely by so-called slop padding or impregnating.
Further objects and advantages of the invention will be set forth in part in the following specification, and in part will be obvious therefrom without being specifically referred to.
For a full understanding of the nature and object of the invention, reference should be had to the following detailed description, taken in connection with the accompanying drawings in which:
Figure 1 is a fragmentary perspective view, partly in section, showing a portion o a nonwoven textile material; and Figure 2 is an elevational view, party in section, of a modified unwoven textile material.
In carrying out the invention it will be seen that the unwoven textile material, according to Figure 1, is for example a floor covering 1, for example a carpet, and includes an unwoven carrier layer 2, composed of fabric material 3, on which are disposed relatively thick balls 4, which have a thickness D
of at least 6 millimeters. The carrier layer 2 is actively 9 8 ~
needle-processed with the balls 4, namely the balls 4 are connected to the carrier layer 2 by holding fibers or connecting fibers 5, having their origin in the carrier layer 2, the balls 4 thus being passively needle-processed to the carrier layer 2.
The holding fibers or connecting fibers 5 merely penetrate the balls 4 substantially up to a surface 6 of the balls ~, or sections of the surface 6, which face away from the carrier layer 2. Within the portion 7 of the connecting fibers 5, which have merely penetrated the balls ~, the connecting fibers 5 can therefore be hooked into the fibers 8 of the balls 4 and be connected thereto. The portions 7 of the connecting fibers 5 may be hooked end-portions 9, or a fiber loop 10, which has ends 11 remaining in the carrier layer 2, which depends on the staple length of the fiber material 3 of the carrier layer 2, or on the fiber portion present on the needle at the time of needle-processing. For clarity's sake the fiber portions 7 or 10 which are bent back on themselves have been shown to be more clivergent than is the case in practice, namely in practice the fiber end portions are less divergent: and closer to one another 2Q than shown in the drawings.
The balls 4 are ball yarns, in which the ~ibers 8 are spherically intermingled, as has been described, for example, in the previously mentioned EP publications. The fibers 8 are, however, spherically intertwined at a density of, for example, .1 to .25 grams per cubic centimeter, so that they are to all intents and purposes fastened to one another and are therefore substantially actively needle-unprocessable. On the lower side 59~
12 oE the carrier layer 2, and consequently of the floor covering 1, there can be found incisions 13, which have arisen during needle~processing oE the carrier layer 2 with the ball yarns 4, and which are invisible from the upper side 14 of the floor covering 1. As a result of the passive needle-processing from the carrier layer 2, the balls 4 are therefore not flattened, retaining their full original thickness D, and as a result of the connecting fibers 5, which have merely penetrated the balls 4 without passing completely through them, the upper side 14 of the covering 1 is free of any connecting fibers 5.
The balls 4 are connected to the carrier layer 2 by means of the connecting fibers 5 with an adequate firmness, because they have been needle-processed at a variety of needle-processing locations along the incisions 13. During the process ; o:E manufacture, the balls 4 may be individually placed under the carrier layer 2 and following passive needle-processing may be disposed there without being additionally connected to one another, so that the floor covering ]., for example, transversely to the longitudinal direction L, may be bent, leaving longitudinal spaces between the balls 4, and is therefore flexible in a direction transverse to the longitudinal direction.
In the nonwoven textile material 15 shown in Figure 2, which again may be a floor covering, there is disposed a carrier layer 16, onto which there are fastened ball yarns 17 of spherically intertwined fibers 18 by means of connecting fibers 19 having their origin in the carrier layer 16. The fibers 18 have again a density in the range of .1 grams per cubic ~` .
' 1 1 ~5988 centimeter to .25 grams per cubic centimeter, ~here they are, to all intents and purposes, fastened to one another, and therefore substantially actively needle-unprocessable, so that the ball yarns 17 are again passively needle-processed by the connecting fibers 19. By means of a portion 20 bent back on itself, the connecting fibers 19 again merely penetrate the ball yarns 17, namely into half the thickness D of the ball yarns 17, and are anchored to the fibers 18 of the ball yarns 17. On the lower side of the textile structure 15 there is provided a covering layer 21, which protects the connecting fibers 19 having their origin in the carrier layer 16.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
Patent No. ~g~ , published August 31, 1970, in this connection.
The balls disposed on the upper side of the textile structure, according to the present invention, are therefore `~ located on an actively needle-processed carrier layer, fibers o~ which, for example only portions of such fibers, have merely penetrated the balls as holding fibers, so that the balls are passively connected to the carrier layer by the active partici-pation of the carrier layer fibers. The fibers or yarns fastened to one another are held, for example, in a manner substantially similar as the fiber connection in a spun yarn, and are therefore substantially actively needle-unprocessable.
The balls are thereby pref~rably firmed up within themselves, and therefore have a cohesiveness even during use of the textile ~ 3 --,~, structure, which results in an adequate and desired firm connection to the carrier layer, so that, for example, an attachmert to the carrier layer by active needle-processing is not only not required, but is substantially disadvantageous, if not impossible. The attachment to the carrier layer, for example by needle-processing, can be carriea out in an advantageous manner only passively from the carrier layer side. The balls are then disposed, for example, on the carrier layer without being impaired in their shape by the method of attachment and retain their unchanged round shape, for example an unchanged circular cross-section, so that a clearly embossed structure with respec~ to the base, namely the carrier layer, can be obtained. Thus an appearance with a clearly embossed structure can be obtained, which differs, for example, clearly from that of the initially described known textile flat structures, which have a felt-like appearance as a result of the active needle-processing of the ball yarns in order to give these ball yarns an adequate firmness.
The holding or connecting fibers advantageously merely 20 penetrate the balls without being visible from the exterior, for example they penetrate, at most, up to a surface of the balls facing away from the carrier layer or through only part of the thickness of the balls, for example through half their thickness~
This results, for example, in the upper side of the textile structure being free or substantially free from any holding or connecting fibers projecting therefrom, so that, for example, they are not subjected to any wear or tear and cannot be damaged 9 g ~
during the use of the textile structure. The ball yarns may thereby remain firm without in any way being changed. For example, the incisions made by the needles as a result of the passive needle-processing are made into the carrier layer, and therefore appear on the lower side of the textile s-tructure without being visible on the upper side of the structure by an observer. The balls are therefore merely processed from the actively needle-processable carrier layer by a so-called "blind stitch technique", namely an invisible technique, so that they cannot, for example, be impaired by use. According to the invention, the balls are therefore attached to the carrier layer without any risk of their being destroyed or their appearance impaired, because their fibers are not used for attachment to the carrier layer.
In another preferred version, parts of the holding fibers or connecting fibers are bent back on themselves, for example, the end portion within the balls~ namely in a direction toward the carrier layer. This bend may take the shape of a barb, may be in the shape of an inverted V, or may have the form of a loop. As a result of this backward bend, the holding or connecting fibers can be hooked with one end onto the fibers or yarns of the balls, and therefore firmly anchored thereto; with their other ends these holding fibers or connecting fibers will be disposed, however, in the carrier layer, where in the case of the loop-like bend both ends of the respective holding fiber or connecting fiber can be anchored in the carrier layer.
The plurality of balls therefore represent a finite 1 3 ~8~
structure having a thickness of at least 6 millimeters which thickness can be up to 50 millimeters, so that each ball, as viewed in cross-section, can be penetrated along several locations by the holding fibers or connecting fibers at high uniformity, so that the balls can be attached to the carrier layer with adequate firmness. Consequently it is possible, for example, without impairing or substantially changing the shape of the balls, to obtain a high needle-processing density and therefore passive compacting, which, for example, increases the firmness and uniformity of the attachment of the balls to the carrier layer. Dependent upon, for example, the balls, the desired covering or the desired or required firmness, the balls may be needle-processed from the carrier layer at a needle-density of, for example 20 to 200 incisions per square centimeter. As a result of the thickness of the ball yarns being greater than 6 millimeters, textile structures having a weight in the range of, for example, .5 kilograms per square meter to 8 kilograms per square meter, can be obtained.
In a textile structure according to the invention a thick product can be obtained with a single layer of balls, in which the bal]s clearly form an embossed structure, and can, for example, be clearly visible in three dimensions and discerned as standing out from the base, namely from the carrier layer.
Therefore preparation of a preliminary sample can be avoided.
The balls can, on the contrary, for example, be individually placed in a desired pattern on the carrier layer, for example close to one another, or at spacings from one another, which not ~ 1 ~59~8 only facilitates their attachment to the carrier layer, but permits a variety of patterns and structures or variations thereof. By, for example, a strip-like arrangement of the balls a web-like or tuft-like character can be obtained.
During bending of the textile structure in a direction toward the carrier layer there may appear longitudinal gaps between rows of balls, without, for example, the at-tachment of the balls to the carrier layer being impaired thereby. Thus the textile structure has a pliability which canno-t, for example, be obtained in a needle-processed felt or a known felt-like textile structure of the aforedescribed EP publications, so that properties similar to, for example, those of tufted carpets are obtained.
These yarns, fibers or threads o~ the balls can be closely intertwined to obtain the required firmness, can be glued to one another, can be bound to one another by foamed material, or can be felted. They may be felt-like lumps or burl-like structures, as are obtained, Eor example, in a spinning process. The fibers are thereby prevented from being withdrawn from the fiber connection of the balls, for example by active needle-processing, or at least their relative movement can be made more difficult or limited. The fibers or threads are therefore blocked, for example, in such a manner that they at least do not slide with respect to one another, and therefore do not move sufficiently with the needle during needle-processing and cannot be withdrawn. If it is attempted to actively process the so firmed up fibers or yarns, they would, for example, ~ ~ &598~
either be stamped out, or tear, or the needles may even break.
The balls may therefore be merely penetrated by the holding or connecting fibers, without the fibers of the balls or the yarns having taXen part in any way actively during attachment to the carrier layer. In one version the fibers or yarns of the balls may have a density of from .1 grams per cubic centimeter to .25 grams per cubic centimeter, so that a compact ball formation with an advantageous attachment of the fibers or yarns is obtained.
In view of the holding fibers or connecting fibers which have penetrated the balls, according to the present invention, and which may be present in the balls either under tension or loosely, there is avoided, for example, a compression of the balls or a flattened product, which does occur, for example, with needle-processing from above, particularly at the high needle-processing density employed in known flat textile structures.
The balls may also be ball yarns of spherically inter-twined fibers or threads, or may have a round shape, for example a cylindrical or oval form. They may have properties similar to one another or different from one another as far as size, color, shape, type of fiber or the like is concerned; the fibers or threads of the balls or the ball yarns may be natural fibers or synthetic fibers or a mixture thereof, and the fibers may also be filaments. The fibers or threads of the ball yarns may have a length of from 40 millimeters to 5 meters. In a ball-shaped form the balls may have a diameter of about 6 millimeters to 25 millimeters, and in longitudinal or cylindrical form, for example may have a thickness of from, for example, 4 millimeters .
to 15 millimeters.
Further properties of the ball yarns, which may be advantageous for the textile structure, according to the present invention, are described in the previously mentioned EP publica-tions, and reference should be had thereto. The inventive attachment can therefore be combined in an advantageous manner, for example, with the properties of the ball yarns, so that the textile structure according to the invention may, for example, retain the properties of the ball yarns as employed according to the invention in an unimpaired or unchanged manner on the upper side of the carrier layer.
The textile structure may have the form of a strip or segments, for example a layer, or a piece good, and can be used for a floor covering, a wall covering, for decorative purposes, for a furniture covering, or as clothing material, or as a cover.
The manufacture of the textile structure, according to the invention, requires, for example, that the needle-processing of the holding ~ibers or connecting ~ibers from the carrier layer be aimed therethrou~h to the balls. This is preEerably accomplished by means of needles, which permit both gripping and release of the holding fibers or connecting fibers by means of barbs or recesses in the needles during withdrawal of the needles from the balls, so that the connecting fibers may be disposed within the balls preferably with their ends bent backwards on ` themselves. The needle-processing can be accomplished, for example, with so-called close-barb needles (for example informa-tion leaflet FOIA, Singer Felt Needles). Here, for example, th~
5 9 ~ 8 spacings from barb to barb, namely the barbed hook, as well as, for example, the stitch penetration depth and/or stitch density, are relevant to decide whether single fibers or bundles, for example, are to be gripped by the barbed hook, and to what depth and at what spacings the connecting fibers must be positioned in the balls or, for example, bent in the shape of a loop. sy, for example, appropriate arrangements of the needles in the needle board, and the position of the ball yarns, for example, leaving spaces between the balls, the balls can be needle-processed in a desired manner so that in an aimed fashion the connecting fibers merely penetrate the balls.
The carrier layer may contain natural fibers or synthetic fibers, or consist of such fibers or threads, and may, for example, be a fiber binding material. Starting from the carrier layer, for example, it is possible to start with a fiber fleece or from a fiber layer, ~or example from parallel fibers or threads or from fibers or threads which are crossed with one another. A supporting layer may be cLisposed on the side of the carrier layer facing away from the balls, for example, a cover-ing layer as conventionally used for floor coverings on the backside of the carrier layer, for example a spring carrier layer, or a layer of binding means, and this support may be attached by needle-processing or gluing, so as to implement the textile material according to the demands placed thereon, and also to secure the connecting fibers on the lower side.
In textile structures according to the present invention, it is therefore possible in a surprising manner to ~ ~ 6598~
combine properties of balls, for example ball yarns composed of spherically intertwined fibers, with the passlve attachment of the balls to the carrier layer, and to obtain in particular a product of unchanged properties, particularly as it applies -to the shape of the balls on the upper side of the layer, which can be obtained by a single layer of adjacently positioned balls on the carrier layer. The balls may be treated with binding means, which can be inserted from the side of the carrier layer and penetrate thereinto, namely by so-called slop padding or impregnating.
Further objects and advantages of the invention will be set forth in part in the following specification, and in part will be obvious therefrom without being specifically referred to.
For a full understanding of the nature and object of the invention, reference should be had to the following detailed description, taken in connection with the accompanying drawings in which:
Figure 1 is a fragmentary perspective view, partly in section, showing a portion o a nonwoven textile material; and Figure 2 is an elevational view, party in section, of a modified unwoven textile material.
In carrying out the invention it will be seen that the unwoven textile material, according to Figure 1, is for example a floor covering 1, for example a carpet, and includes an unwoven carrier layer 2, composed of fabric material 3, on which are disposed relatively thick balls 4, which have a thickness D
of at least 6 millimeters. The carrier layer 2 is actively 9 8 ~
needle-processed with the balls 4, namely the balls 4 are connected to the carrier layer 2 by holding fibers or connecting fibers 5, having their origin in the carrier layer 2, the balls 4 thus being passively needle-processed to the carrier layer 2.
The holding fibers or connecting fibers 5 merely penetrate the balls 4 substantially up to a surface 6 of the balls ~, or sections of the surface 6, which face away from the carrier layer 2. Within the portion 7 of the connecting fibers 5, which have merely penetrated the balls ~, the connecting fibers 5 can therefore be hooked into the fibers 8 of the balls 4 and be connected thereto. The portions 7 of the connecting fibers 5 may be hooked end-portions 9, or a fiber loop 10, which has ends 11 remaining in the carrier layer 2, which depends on the staple length of the fiber material 3 of the carrier layer 2, or on the fiber portion present on the needle at the time of needle-processing. For clarity's sake the fiber portions 7 or 10 which are bent back on themselves have been shown to be more clivergent than is the case in practice, namely in practice the fiber end portions are less divergent: and closer to one another 2Q than shown in the drawings.
The balls 4 are ball yarns, in which the ~ibers 8 are spherically intermingled, as has been described, for example, in the previously mentioned EP publications. The fibers 8 are, however, spherically intertwined at a density of, for example, .1 to .25 grams per cubic centimeter, so that they are to all intents and purposes fastened to one another and are therefore substantially actively needle-unprocessable. On the lower side 59~
12 oE the carrier layer 2, and consequently of the floor covering 1, there can be found incisions 13, which have arisen during needle~processing oE the carrier layer 2 with the ball yarns 4, and which are invisible from the upper side 14 of the floor covering 1. As a result of the passive needle-processing from the carrier layer 2, the balls 4 are therefore not flattened, retaining their full original thickness D, and as a result of the connecting fibers 5, which have merely penetrated the balls 4 without passing completely through them, the upper side 14 of the covering 1 is free of any connecting fibers 5.
The balls 4 are connected to the carrier layer 2 by means of the connecting fibers 5 with an adequate firmness, because they have been needle-processed at a variety of needle-processing locations along the incisions 13. During the process ; o:E manufacture, the balls 4 may be individually placed under the carrier layer 2 and following passive needle-processing may be disposed there without being additionally connected to one another, so that the floor covering ]., for example, transversely to the longitudinal direction L, may be bent, leaving longitudinal spaces between the balls 4, and is therefore flexible in a direction transverse to the longitudinal direction.
In the nonwoven textile material 15 shown in Figure 2, which again may be a floor covering, there is disposed a carrier layer 16, onto which there are fastened ball yarns 17 of spherically intertwined fibers 18 by means of connecting fibers 19 having their origin in the carrier layer 16. The fibers 18 have again a density in the range of .1 grams per cubic ~` .
' 1 1 ~5988 centimeter to .25 grams per cubic centimeter, ~here they are, to all intents and purposes, fastened to one another, and therefore substantially actively needle-unprocessable, so that the ball yarns 17 are again passively needle-processed by the connecting fibers 19. By means of a portion 20 bent back on itself, the connecting fibers 19 again merely penetrate the ball yarns 17, namely into half the thickness D of the ball yarns 17, and are anchored to the fibers 18 of the ball yarns 17. On the lower side of the textile structure 15 there is provided a covering layer 21, which protects the connecting fibers 19 having their origin in the carrier layer 16.
I wish it to be understood that I do not desire to be limited to the exact details of construction shown and described, for obvious modifications will occur to a person skilled in the art.
Claims (20)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A nonwoven textile material comprising an upper layer of fiber-containing balls, the balls having a diameter of at least 6 millimeters, and therebelow a fiber-containing carrier layer, the fiber-containing balls being connected to said carrier layer by connecting fibers having their origins in the carrier layer, each ball including a plurality of substantially actively needle-unprocessable and spherically intermingled fibers or yarns fastened to one another, said balls are only passively connected to said connecting fibers.
2. The textile material as claimed in claim 1, wherein said connecting fibers penetrate said balls up to at most a surface of a respective ball facing away from said carrier layer, so as to remain invisible.
3. The textile material as claimed in claim 2 wherein said connecting fibers pass only through a portion of respective of said balls.
4. The textile material as claimed in claim 1, wherein a portion of said connecting fibers are bent back on themselves within a corresponding ball.
5. The textile material as claimed in claim 4 wherein said connecting fibers are bent in the shape of a loop.
6. A textile material as claimed in claim 4, wherein said connecting fibers are bent in the shape of a hook.
7. A textile material as claimed in claim 1, wherein said balls are passively needle-processed to said carrier layer.
8. The textile material as claimed in claim 1, wherein said fibers or yarns of said balls are fastened to one another by at least one of: tight intertwining, pressing, gluing, bonding, binding with foam material, or felting, thereby being actively needle-unprocessable.
9. The textile material as claimed in claim 1, wherein said fibers or yarns of the balls have a density ranging from about 0.1 grams per cubic centimeter to about 0.25 grams per cubic centimeter.
10. The textile material as claimed in claim 1, wherein said balls each have a thickness up to about 50 millimeters.
11. The textile material as claimed in claim 1, wherein said balls are spherical-shaped.
12. The textile material as claimed in claim 1, wherein said balls are substantially shaped in the form of a longitudinal cylinder.
13. The textile material as claimed in claim 1, wherein said balls have a predetermined size, color, shape, and fibrous composition.
14. The textile material as claimed in claim 13, wherein said balls differ from one another in at least one of said size, shape, color, or fibrous composition.
15. The textile material as claimed in claim 13, wherein said balls are similar to one another in at least one of said size, shape, color, or fibrous composition.
16. The textile material as claimed in claim 1, wherein the length of said spherically intermingled fibers or yarns is within the range of 40 millimeters to 5 meters.
17. The textile material as claimed in claim 1, wherein said carrier layer is needle-processed to said balls at a needle-processing density from about 20 to about 200 stitches per square centimeter.
18. The textile material as claimed in claim 1, wherein the weight of said material ranges from 0.5 kilograms per square meter to about 8 kilograms per square meter.
19. The textile material as claimed in claim 1, wherein said carrier is actively needle-processed by its own connecting fibers to itself and to said balls.
20. The textile material as claimed in claim 1, wherein the position assumed by each ball with respect to a neighboring ball remains substantially unchanged.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CH908680 | 1980-12-10 | ||
| CH9086/80-9 | 1980-12-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1165988A true CA1165988A (en) | 1984-04-24 |
Family
ID=4348169
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000391811A Expired CA1165988A (en) | 1980-12-10 | 1981-12-09 | Non-woven textile material |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP0053701B1 (en) |
| JP (1) | JPS57123044A (en) |
| AT (1) | ATE12269T1 (en) |
| CA (1) | CA1165988A (en) |
| DE (1) | DE3169433D1 (en) |
| ZA (1) | ZA818541B (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE4244252C2 (en) * | 1992-12-27 | 1998-07-16 | Guenter Tesch | Textile floor covering with spherical fiber aggregates consisting of spherically entangled, textile fibers and process for its production |
| DE10132103C1 (en) * | 2001-07-03 | 2003-04-30 | Filzfabrik Fulda Gmbh | Process for the production of a patterned textile fabric |
| CN114392058B (en) * | 2022-01-17 | 2022-12-06 | 贵州卡布婴童用品有限责任公司 | Nursing type dry and comfortable paper diaper |
Family Cites Families (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2299473A1 (en) * | 1975-02-03 | 1976-08-27 | Sommer Exploit | FLOOR AND / OR WALL COATING |
| DE2966997D1 (en) * | 1979-01-09 | 1984-06-20 | Breveteam Sa | Spherical fibrous aggregate |
-
1981
- 1981-10-26 AT AT81108905T patent/ATE12269T1/en not_active IP Right Cessation
- 1981-10-26 DE DE8181108905T patent/DE3169433D1/en not_active Expired
- 1981-10-26 EP EP81108905A patent/EP0053701B1/en not_active Expired
- 1981-12-09 JP JP56198331A patent/JPS57123044A/en active Pending
- 1981-12-09 CA CA000391811A patent/CA1165988A/en not_active Expired
- 1981-12-09 ZA ZA818541A patent/ZA818541B/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| DE3169433D1 (en) | 1985-04-25 |
| EP0053701B1 (en) | 1985-03-20 |
| ZA818541B (en) | 1982-12-29 |
| JPS57123044A (en) | 1982-07-31 |
| ATE12269T1 (en) | 1985-04-15 |
| EP0053701A1 (en) | 1982-06-16 |
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