CA1176826A

CA1176826A - Non-woven floor covering

Info

Publication number: CA1176826A
Application number: CA000391812A
Authority: CA
Inventors: Gunter Tesch
Original assignee: Breveteam SA
Current assignee: Breveteam SA
Priority date: 1980-12-10
Filing date: 1981-12-09
Publication date: 1984-10-30
Also published as: ATE19532T1; ES262264Y; DK154306C; EP0053700B1; EP0053700A1; DE3174520D1; AU7821081A; DK525381A; ES262264U; JPS57122814A; DK154306B; ZA818540B

Abstract

Abstract of the Disclosure In a non-woven floor covering having an upper layer including fiber material, and therebelow a fiber-containing carrier layer containing connecting fibers interconnecting the layers, a plurality of individual fibrous strands are included in the upper layer; the strands are relatively thick in comparison to the thickness of the connecting fibers, and the connecting fibers penetrate the strands at least partially, so that the strands are passively-connected to the carrier layer.

Description

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This invention relates to non-woven textile materials, and, more particularly, to non-woven floor coverings.
Non-woven floor coverings are known from, for example, German pat~nt

2,604,098, in which at least one layer of parallel textile yarns disposed adjacent to one another are needle-processed to a supporting layer through fibers having their origin in these yarns. As the needle-processing is accom-plished by fibers of the yarns, namely from the upper side of the floor covering, only a small proportion of the fibers of each yarn is needle-processed to the covering layer at an insufficient density, in view of the risk of destroying the twisted yarns, and consequently impairing their appearance. This results, in turn, in an insufficiently rigid connection of the layer of threads to the supporting layer for many purposes, which, in the event the fibers, which have their origins in the yarns, are damaged, can lead during use of the floor covering to a separation of the layer of yarns, and consequently result in the destruction of the upper side of the floor covering. If it is desired to accomplish the needle-processing at a greater density based on this known process, then this may at most lead to a plane felt-like textile material, where manufacture of individual yarns is not economically worthwhile, even if a structured appearance can be obtained thereby. The known floor coverings do not meet therefore the demands posed thereon, and are limited to yarns ; which permit a low needle-processing density, and therefore the floor coverings are of relatively small thickness. Any attempt to add additional layers above the first layer of yarns leads in known floor coverings only to the formation of an additional pattern.
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From German patent 1,7~9,~3, it is also known to manufacture non-woven carpets from two layers of yarns crossing one another at a strength of, for example, 20 ktex, which are fastened to one another by needle-processing, ~' 1~6~2~i ancl may also be needle~proce~sed to a carrier. The crossed layer of the yarns is needle~processed from the yarn side, namely the yarns are actively needle-processed w~th a carrier layer, and there are always required two layers of yarns, so that the layers of yarns are pressed to one another again also as a result of the needle processing.
Floor coverings are also known, for example, from the Belgian patent 700,540, dated December 27, 1967 of "Centre International Pour L'Economie et la Technologie, en Abrege "I.C.E.T.", in which yarns or rovings are needle-processed from the fiber fleece side, which must, however, be always brought together in the form of a prefabricated layer with the fiber fleece.
The known coverings therefore require prior formation of the yarn la~er or rovings at a desired pattern, which is, for example, expensive in the case of any change of patterns, and particularly does not permit any individual patterns.
The fibers from the fiber fleece are particularly needle-processed, however, through the yarn layer or rovings, so that these protrude from the upper sur-face of the floor covering, and project therefrom with their free ends in the layer of yarns or rovings. They are thereby subjected not only to wear and tear, but also the rigidity of connection of the layer of yarns or rovings on the fiber fleece is endangered, as the layer can easily become loose due to wear of needle-processed fibers, and can therefore become separated from the fiber fleece.
It is therefore a principal object of the invention to devise a non-woven floor covering of the aforedescribed type without the disadvantages of known coverings, which shows on its upper side a clearly structured appear-ance, for example, a handwoven appearance, as a result of the fiber material, and whose fiber materi~al can be fastened at an adequate rigidity to the carrier layer in such a manner that, for e~ample, an embossed structure can be accom-plished without any problems by the manner of the attachment of the fiber 1~7~i~26 matcrial.
This object is attained for a floor covering of the aforedescribed mamler by individual relatively thick strands being passively needle-proc~sed onto the carrier layer only by connecting fibers from the carrier layer which at least partially penetrate the strands.
The strands disposed on the upper side of the floor covering are therefore located, for example, on the actively acting carrier layer, and a portion of the fibers of the carrier layer has merely passed into the strands as connecting fibers so as to connect the strands to the carrier layer. This leaves the upper side of the floor covering substantially free from any connect-ing fibers projecting therefrom. As a result of the active participation of the fibers of the carrier layer in the aforedescribed attachment, the strands are only passively fastened to the carrier layer.
The relatively thick strands, can, according to the invention, be fastened to the carrier layer without there occurring any risk of their being destroyed or their appearance impaired, as their fibers are not utilized for attachment to the carrier layer. In view of the thickness of the strands, the connecting fibers may pass therethrough at several locationsl as viewed in cross-section, so that the strands are fastened to the carrier layer at an adequate rigidity. Thus it is possible to achieve, for example, a high density of the connecting fibers and therefore passive compacting, so that, for ex-ample a desired high firmness, and moreover, uniformity of the attachment can be obtained.
Strands having a thickness of at least 5 mm., but also of 20 mm., can be used or processed, which, as a result of their considerable thickness, can be entered by means of connecting fibers at a plurality of locations, as viewed in cross-section, and can therefore be attached to the carrier layer at a high uniformity. The strands may have a fineness between 10 ktex to 100 ktex.

117682~i The connecting fibers may pass through only a portion of the thickness of the strands, for exa~ple through half their thi:ckness, or may pass tfirough the en1ire thickness o the strands, 6ut at most up to a surface portion of the st~ands facing away from the carrier layer.
Tfie strands are preferably fastened to the carrier layer by a con-ventional needle process, ~here, for example fiaers of the carrier layer are gripped by means, for example, of barbed needles and merely introduced into the strands as needle-processing fibers, namely connecting fibers, so that the strands are passively needle-processed to the carrier layer. For the afore-described passive attachment also other processes such as Mali processes, can ae used. Here the carrier layer is preferably needle-processed to the strands by connecting fibers emanating from the carrier layer, In what follows the term "actively processed" will be understood to mean that fibers from a fiber layer may be moved, or withdrawn from the layer by a needle process with respect to other layers, and twisted therewith, in other words may acti~ely accomplish some object. These fibers may also be introduced into another layer border~ng the fibrous layers, so that this other layer is connected with the fibrous layer.
The term "passively needle-processed" or "passively attached" will be understood to mean, however, that in a fiber-containing material layer there can be found fibers from other fiber-containing layers or layer serving as connecting fibers, but where the fibers of the material layer are not substan-tially utilized for any active purposes, but remain passive. See, for example, Swiss patent 43~,2n6, of Brevetex S.A., dated December 15, 1967.
In view of the passive attachment of the strands to the carrier layer, prefe~ly by ~assive needle-processing, the needles may, for example, 2~i be inserted through the bottom part of the carrier layer and pass into the covering thereafter, so that they are not visible to an observer viewing the upper side of the covering. The strands may therefore be needle-processed from an actively needle-processable carrier layer by a so called "blind stitch technique"J namely, invisible technique, so that) for example, they are not influenced by any wear, and the upper side of the floor covering is not, for example, damaged or changed by severe wear.
In dependence of the types of the strands, the desired covering, or the desired or required firmness, the strands may be needle-processed from the carrier layer side at a needle-processing density between 20 to 200 stitches per cm. . As a result of the thickness of the strands, for example, 5 mm. it is, for example, not only possible to obtain a high needle processing density, but it is also possible to obtain floor coverings having a weight, for example, in a range from .5 kg. per square meter to 8 kg. per square meter.
In the covering, according to the present invention, it is prefer-ably possible to obtain a thick product using only a single layer of the strands, where the strands are clearly visible as an embossed structure and can, for example, be clearly recognized as a three-dimensional formation, separate and apart from the carrier layer. Preparation, for example, of a preliminary pattern is avoided. On the contrary, the strands may be fastened singly, for example in a desired pattern, onto the carrier layer, which makes it possible to obtain a multiplicity of patterns or structures or variations of the same.
The strands are preferably not connected to one another, so that they may split from one another during bending of the floor covering in a direction towards the carrier layer without, for example, impairing their attachment to the carrier layer. The floor covering therefore has a pliability which cannot, for example, be obtained in a needle-processed felt, so that for example, properties ~17682~
similar to tufted or woven carpets can be obtained. In view of the passively penetrating connecting fibers, according to the invention, which may be fastened to the strands under tension or loosely, there is also avoided any compression of the strands, and therefore a resulting compressed and flat product, which may, for example arise during needle-processing from above, particularly at a high needle processing density.
The strands may have an arbitrary form of shape, for example they may have a circular or substantially circular, ellipsoid, rectangular, quadratic or triangular cross-section. The strands may include natural fibers or synthetic fibers, fiber reinforced plastics or fibers or yarns adhering or glued to one another, or consisting of such fibers or yarns. The strands may be disposed parallel or substantially parallel to one another. The strands may also have different respective diameters, and groups of strands having the same diameter can be mixed with groups of strands having a different diameter.
These strands may have the shape of a band or yarn, for example, can be coarse formations and preferably have a cohesion of their own. The strands may also be constructed in a manner as is described, for example, in South African patent No. 81/8542, published and granted on November 24, 1982, and entitled "Fiber Strands and Method for Manufacture Thereof", the construction and method being therefore not further described here in detail. The strands may also be spun by imparting a rotation thereto, or contain fibers which sur-round, for example, a core, such as a fiberous core. They may be wound around the core in the form of a cylindrical mantle, or helically. In the case of non-twisted strands, namely strands having nontwisted fibers, the attachment to the carrier layer may be accomplished by a surrounding yarn or a binding yarn, or through the~previously mentioned adhesion of fibers or yarns to one another such as, for example, by means of a glue; the surrounding or binding yarns can ~17~26 be inserted by way of the carrier layer and can pass therefrom to the strands, and treated, for example, by so called slop padding, or impregnation.
In one version of the invention the strands may be surrounded by a visible binding yarn having a diameter smaller than that of the strands up to a number of 200 coils per square meter, and thus give the appearance of a chain thread imitation. It is to be noted that, for example, in known hand-woven carpets, chains made of yarn are clearly visible, compared to, for example a coarse woolen yarn or loose wool, and represent a quality feature of the carpet. In the floor covering, according to the invention, the floor covering can in a completely surprising manner appear like a handwoven floor covering as a result of the binding yarn, having the appearance of a floor covering using chains in handwoven carpets, without such chains actually being present. Thus the appearance of the needle-processed floor covering can be avoided, and rather the appearance of a handwoven floor covering can be obtained.
In another version of the invention, binding threads may be wound around respective strands in such a manner as to result in a plurality of constrictions in a corresponding strand, so as to give the appearance of a tufting loop imitation. The binding thread is wound around the strand during the manufacture thereof so as to be under tension; this makes it possible for the binding thread to be displaced interiorly within the strand, and apparently surrounded by the strand in a manner appearing to pass through its longitudinal axis. On viewing such a strand the binding thread appears extended along the longitudinal direction, and appears to actually be surrounded by the strand.
The binding thread or surrounding thread is therefore, for example, no longer recognizable as such, and the fibers of the strands may plastically expand, for example in a loop form, so that an embossment structure results. The binding thread may have a fineness from 100 to 8000 dtex, and the tension 1~7~8Z6 applied to the binding thread during manufacture of the~strand is preferably below the tearing force required to tear the binding thread. At a fineness of, for example 4000 dtex, this tension is preferably less than 20 kg.
Reference is again made to the aforecited South African patent No.
81/8542 for other versions of the invention.
Parts of the connecting fibers which have penetrated the strands are bent back on themselves within the strands, namely in a direction towards the carrier layer. They may be bent into the shape of a hook, for example a barbed hook, may be n-shaped, may be shaped in the form of an inverted V, or may be loop-shaped. As a result of parts of the connecting fibers being bent back on themselves the resulting hooks or the like can be hooked to the fibers of the strands, and therefore be securely connected thereto. The strands are therefore firmly connected to the carrier layer by the other ends of the connecting fibers, which are located in the carrier layer, where, for example, in the case of a loop each end of a connecting fiber can be anchored within the carrier layer.
The manufacture of the floor covering, according to the invention, requires that the connecting fibers of the carrier layer be needled to the strands with a good aim. This is preferably accomplished by means of needles which permit the gripping of the connecting fibers by means of hooks or recesses in the needles, where the connecting fibers are, for example, formed with loops, so that the needles can grip the loops, but also release the connecting fibers, when the needles are withdrawn from the strands, so that the connecting fibers are thereby bent back on themselves within the strands. Needle-processing can be accomplished with so called close-barbed needles (for example see information leaflet FOlA, SINGER* Felting Needles). Here, for example, the spacings from barb to barb, the type of barb, as well as, for example, the penetrating stitch * Trade Mark ~76~3Z~

depth and/or stitch density influence the fact whether individual fibers or bundles of fibers are to be gripped by a barb, and to what depth and at what spacing these must be positioned in the strands, and how the connecting fibers are to be bent back on themselves within the strand, for example, in the form of a loop. The type of bending the connecting fibers back on themselves, or formation of a loop is, for example, also depedndent on the staple length of the fiber material in the carrier layer. By, for example, appropriate arrangement of the needles in the needle board and the position of the strands, for example, positioned adjacent to one another, but leaving spaces between respective strands, the strands can be needle-processed in a desired manner, so that the connecting fibers will be aimed to merely penetrate the strands.
The carrier layer may contain natural or synthetic fibers, or con-sist thereof, and may be non-woven, for example a fiber fleece, a fiber connect-ing material, or only a fiber layer. On the side of the carrier layer facing away from the strands there may be disposed a support layer, for example a covering layer customary for the back of floor coverings, for example a springy layer, which is then needle-processed or glued to the covering layer, so as to tailor the floor covering to the demands made thereon. The floor covering may be also a flat structure, for example in the shape of longitudinal strips, in the form of a piece good, of a sheet or slab-formed.
Further objects and advantages of the invention will be set forth part in the following specification, and in part will be obvious therefrom without being specifically referred to, the same being realized and attained as pointed out in the claims hereof.
For a fuller understanding of the nature and objects of the inven-tion, reference should be had to the following detailed description, taken in connection with the accomplnying drawings in which:

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Figure 1 is a perspective view of a floor covering according to the invention in part section;
Figure 2 is an elevation view of the floor covering in section along the line II-II of Figure l;
Figure 3 is a perspective view of a floor covering of another ver-sion of the invention in part section;
Figure 4 (third sheet of drawings) is a photograph of the upper side of another version of the floor covering; and Figure 5 is an elevation view of a portion of the strand of the floor covering of Figure 4 shown in a stretched state.
Referring now to the drawings, and in particular to Figures 1 and 2, a non-woven floor covering 1, for example, a carpet, includes a carrier layer 2 composed of a fiber material 3, and a plurality of substantially parallel disposed fiber-containing thick strands 4, which have a thickness D (as seen in Figure 2) of at least 5 mm. The fiber material of the strands 4 is prefer-ably twisted, so that each strand 4 is cohesive. The carrier layer 2 is actively needle-processed with the strands 4, namely the strands 4 are connected through connecting fibers 5~ contained in the carrier layer 2 to the carrier layer 2, and thus are passively needle-processed therewith. The connecting fibers S merely penetrate the strands 4, and as seen in the right portion of Figure 2, penetrate the strands 4 at most up to a surface 6, or a portion of the surface 6 of the strands 4, which faces away from the carrier layer 2. As is illustrated in the version on the left portion of Figure 2, the connecting fibers 5 may penetrate only a portion of the thickness D of the strands 4, and can therefore extend through half the thickness D, or less than half the thick-ness D of each strand. The penetration depth of the connecting fibers 5 is, for example, dependent on the needle-processing conditions and/or the staple ~.~ 7~i~Z~

length of the fiber material of the carrier layer 2. A portion 7 of the connecting fiber 5 which have penetrated into the strand 4 is bent back on it-self, and can therefore be hooked onto the fibers or fiber material of the strand 4, and therefore be connected thereto. The portion 7 of the connecting fibers 5 may be an end portion 8 of the connecting fibers 5 or a loop 9, which with its two free ends can remain in the carrier layer 2. This depends on the length, for example, the staple length of the fiber material 3 or the fiber portion of the connecting fibers 5 being gripped by the needles during needle-processing. For the sake of clarity the portions 7 of the connecting fibers 7 or the free ends 10 of the connecting fibers 5 remaining in the carrier layer have been shown to be more divergent than is the case in practice; in practice they converge at a narrower angle, in other words, the free ends are disposed more tightly next to one another. On the lower side 11 of the carrier layer 2, and consequently of the floor covering 1, there will be seen incisions 12 which result during needle-processing of the carrier layer 2 to the strands 4, and which are invisible from the upper side 13 of the covering layer 1. As a result of the needle-processing having been carried out from the bottom side of the carrier layer 2, and due to the connecting fibers 5 merely having pene-trated the strands 4 fro~ below, the upper side 13 of the floor covering 1 therefore remains free of any connecting fibers 5.
The strands 4 adhere to the carrier layer 2 through the connecting fibers 5 at an adequate strength, as the needle process~ng has accomplished at a multiplicity of needle processing locations according to the incisions 12.
During the process of manufacture the strands 4 may be disposed individually on the carrier layer 2 and may remain unconnected to one another in a direction transverse to their longitudinal direction, so that the floor covering 1 remains completely bendable and flexible in a direction transverse to the longitudinal ~,~.76~Z6 direction L leaving spaces between the strands 4.
In the floor covering 14, according to Figure 3, non-twisted strands 15 are also passively needle-processed through connecting fibers 16 onto a carrier layer 17, the connecting fibers 16 having their origin in the fibrous material 18 of the carrier layer 17. The actively needle-processed carrier layer 17 is therefore connected to the strands 15. The connecting fibers 16 have penetrated again into the strands 15 at most up to a surface 19 thereof, which faces away from the carrier layer 13, without thefiber material 20 of the strands 15 in any way having been used for the needle process. This results in turn in the floor covering 14 being free on its upper side 21, or substan-tially free from any connecting fibers 16 projecting therefrom. To the lower side 22 of the carrier layer 17 there is connected a covering layer 23. The strands 15 consisting of non-twisted fiber material 21 are surrounded or wound around by a binding thread 24, so that each has its own cohesiveness.
Figure 4 shows a top side 25 of a floor covering 26, including strands 27 which, not visible, but as has been described in the versions illus-trated in Figures 1 and 2, are passively needle-processed through a fibrous carrier layer, and wherein connecting fibers of the carrier layer merely penetrate the strands 27 and are therefore passively needle processed thereto.
The strands 27 are composed of nontwisted fiber material 28 and a binding thread 30 is wound therearound in such a fashion that the strands 27 are drawn together along the longitudinal direction and have constrictions 29; this makes it appear that the binding thread passes near or through the center of the strand as it is not visible. As can be seen, the floor covering gives the appearance of a tufting loop imitation.
Figure 5 shows one of the strands 27 pulled apart along a longi-tudinal direction E, so that the respective entwining of the binding thread 30 1~768Z6 and the strands 27 can be recognized. On releasing the tension, the binding thread 30 under tension constricts the strand 27 in such a manner that, for example its constricted portions appear in a pearl-like manner, as if strung along a string ~Figure 4). The strand 27 therefore is elastic along its longi-tudinal direction E, its elasticity being dependent upon the tension applied to the binding thread 30 during manufacture of the strands 27, and the resulting apparent excessive twist thereof.
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.

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Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. In a nonwoven floor covering having an upper layer and therebelow a fiber-containing carrier layer containing connecting fibers interconnecting said layers, in combination, a plurality of individual strands composed of fiber material, comprised in said upper layer, each strand being relatively thick in comparison to the thickness of each connecting fiber and having a thickness of at least five millimeters, and said strands being disposed substantially parallel and adjacent to one another, said connecting fibers penetrating said strands at least partially, whereby said strands are passively connected to said carrier layer.

2. A floor covering as claimed in claim 1, wherein said strands are passively needle-processed by said connecting fibers passing through said strands from below.

3. A floor covering as claimed in claim 1, wherein said fiber material of said strands is twisted.

4. A floor covering as claimed in claim 1, wherein said fiber material of said strands is non-twisted.

5. A floor covering as claimed in claim 1, wherein parts of said connecting fibers are bent back on themselves within said strands.

6. A floor covering as claimed in claim 5, wherein said parts are bent in the shape of a hook.

7. A fiber covering as claimed in claim 5, wherein said parts are bent in the shape of a loop.

8. A floor covering as claimed in claim 1, wherein said strands have each a thickness of at least 20 millimeters.

9. A floor covering as claimed in claim 1, wherein said connecting fibers penetrate into said strands from below so as to remain invisible.

10. A floor covering as claimed in claim 9, wherein said connecting fibers penetrate said strands no further than a respective surface thereof facing away from said carrier layer.

11. A floor covering as claimed in claim 1, wherein each strand has a cross-section of arbitrary shape.

12. A floor covering as claimed in claim 1, wherein each strand has a round cross-section.

13. A floor covering as claimed in claim 1, wherein each strand has a substantially square cross-section.

14. A floor covering as claimed in claim 1, wherein each strand has a substantially triangular cross-section.

15. A floor covering as claimed in claim 1, wherein said strands are twisted.

16. A floor covering as claimed in claim 1, wherein each strand is visibly surrounded by a thread having a considerably smaller cross-section than the surrounded strand, thereby creating the impression of an imitation chain thread.

17. A floor covering as claimed in claim l, wherein said strands include fibers, and a core surrounded by said internally disposed fibers.

18. A floor covering as claimed in claim 15, wherein said fibers surround said core helically.

19. A floor covering as claimed in claim 17, wherein said fibers surround said core in the form of a cylindrical mantle.

20. A floor covering as claimed in claim 1, further comprising a binding thread wound around respective strands in such a manner as to result in a plurality of constrictions in a corresponding strand, thereby giving the appearance of a tufting loop imitation.

21. A floor covering as claimed in claim 1, wherein some of the said strands have a cross-section differing from that of other strands.

22. A floor covering as claimed in claim l, wherein said carrier layer is needle-processed to said strands at a needle-processing density of up to about 200 stitches per square centimeter.

23. A floor covering as claimed in claim 1, wherein said strands include natural fibers.

24. A floor covering as claimed in claim l, wherein said strands include synthetic fibers.

25. A floor covering as claimed in claim 1, wherein said strands include fiber-reinforced plastics.

26. A floor covering as claimed in claim 1, wherein said strands include fibers adhering to one another.

27. A floor covering as claimed in claim 1, wherein said strands include yarns adhering to one another.

28. A floor covering as claimed in claim 1, wherein the weight of the floor covering is within the range from about 0.5 kilograms per square meter to about 8 kilograms per square meter.

29. A floor covering as claimed in claim 1, wherein said strands are unconnected to one another in a direction transverse to their longitudinal direction.

30. A floor covering as claimed in claim 1, wherein said carrier layer is actively needle-processed within itself by its own connecting fibers.

31. A floor covering as claimed in claim 1, wherein said connecting fibers, as viewed in a cross-section of the strand, pass at least partially therethrough at a plurality of locations.