CA1188072A

CA1188072A - Flat composite body, for use in textile applications as carpets, padding elements, floor or wall coverings

Info

Publication number: CA1188072A
Application number: CA000408033A
Authority: CA
Inventors: Gunter H. Tesch
Original assignee: Individual
Current assignee: Individual
Priority date: 1981-07-27
Filing date: 1982-07-26
Publication date: 1985-06-04
Also published as: EP0073919A2; JPS5823950A; ATE22127T1; EP0073919A3; EP0073919B1; DE3273189D1; JPH0235063B2

Abstract

ABSTRACT OF THE DISCLOSURE

A flat composite body (1) comprising a top layer (2) containing fibers or filaments and a support layer (3), which is at least passively needle-bondable, with the two layers (2, 3) including between them an internal layer of granular particles (6), for example sand and being needle bonded to each other through the internal layer. A composite body (1) of this configuration may be used as a self laying carpet or carpet tiles. By means of sand additions, an especially favorable sound attenutation is obtained. The high level capacity and poor thermal conductivity provide positive behavior in a fire.

Description

The in~ention concerns a flat composite body for textile applications as a carpet, padding element floor or wall covering or -the like with a top layer containing fibers or filaments and a support layer, and therebetween an inner layer of a granular filler and being joined through the inner layer.
In the case of a known composite body of the above-mentioned -type (DE-OS 23 44 835), two cover layers are sewed together through the granular filled layer. The filler particles must consist of a mass which as such has no defined form, so that it may be penetrated during the sewing process~ In this known com-posite body foams are used as the filler; they are characterized primarily by their light weight. The use of these known composite bodies is restricted by the properties of the fillers employed~
The sewing of this composite body is a complex process requiring the use of expensive sewing threads. If the thread is damaged, the seams may break, whereupon the coherence of the fillers between the seams is no longer assured.
Carpets are known further, wherein between a support layer and a top layer, loose fiber material from edge strips obtained during production is needle-bonded.
It is the object of the invention to provide a com-posite layer of -the aforementioned general type, permitting diverse applications unrestricted by the filler material.
This object is attained according to the invention by a composite body comprising a top layer containing fibers or filaments and a support layer, between these layers, is an inner layer comprising at least one nonreactive granular material having a hardness that makes it indestructable during needle-bonding and ~b wherein the top layer and support layer are needle-bonded through the inner layer. By the joining by needle-bonding of the two cover layers, an intermediate layer of granular particles, consisting of at least one mineral, nonreactive material is penetrated by a plur-ality of fibers or filaments, which retain the particles in their position. In this manner, the composite body is given its own co-herence, whereby in case of damage to fibers or filaments~ the needle bond is preserved in the undamaged locations, as the needle-bonded fibers or filaments are joined to each other. This also insures that the particles are lost only at the damaged location, as the rest of the bonded locations act as a lock. It is possible by these means to effect a uniform intermixiny of the particles with the fiber material and a dense arrangement of the latter, using a conventional needle bonding process, without expensive special measures. This is unattainable for example by the sewing of the cover layers as was previously done. The running of the granular particles in the composite body is completely prevented, and a closed spatial configuration of the composite body is obtained, which has varied applications as a flat textile structure. By the addition of heavy, granular particles, the flat structure is made heavier which has a very positive effect in numerous applications.
The granular particles used according to the invention, may be, especially if sand or gravel is involved, brittle and/or may have abrasive proper-ties, together wi-th a hardness that renders it indestructable during needle bon~ing. The particles thus have properties which by the nature of the material, actually would sugges~ not using a needle bonding technique. It has been surpris-ingly discovered however, that the top layer an1 the support layer may be needle-bonded with each other through the layer of granular particles by means of conventional needle bonding methods, i.e.
using needle bonding needles with counter hooks, for example conven-tional felting needles, without appreciable damage to the needles by wear or destruction. This is the result in part to the fact that the granular particles are present prior to needle bonding preferably displaceably with respect to each other and that therefore the particles impacted by needles are able to more laterally to escape the -2a-penetrating needle.
The composite body according to the invention may be advantageously used as a carpet, wherein for example, sand is present with a weight per unit area of 100-1000 g/m2. It is possible thereby to produce in an economical manner, a heavier carpet which compared to a liyhter carpet has better footfall attenuation and a higher degree of sound absorption.
The composite body according to the invention may also be used as a wall or floor covering o~ a di~ferent type, as a cover or as a padding element. In particular, in view of its weight, it is further suitable for use as a weiyhting band. While in most applications this composite body insert is present for example as a sheet, it is obvi~usly possible to join several, preferably two composite bodies together, for example as cus'nions, bags or hose.
In its simplest form the inner layer of the composite body consists exclusively of granular sand.
Thereby, for example, floor coverings may be produced, which may be used as sel~-sufficient heavy carpets, which adapt themselves to irregularitie3. In such an application, the weight per unit surface of the sand layer may amount to between 2 and 7 kg/m . Composite bodies of this type, may be cu-t advantageously as no seams are present and then be provided as roll of sh~ets or as carpet tile. When the composite body i5 divided into smaller sections, for example carpets of this type, granular particles will drop out in the immediate area of the cut edge only, as the individual particles are held, as explained hereinabove, by the holding fibers. This feature is obtained soley by the fact that the top layer and the cover layer which include the granular particles~ such as sand, bet~een themselves, are not sewn together as had been the practice heretofore~
but are needle-bonded. A layer denslty of this extent over the entire sur$ace of the composite body may be obtained only by needle bonding and is inconceivable in sewing. Carpets, and ln particular carpet tile produced in this manner are not necessarily adhesively bonded to the flo~r, as they lie flat by their own weight in close contact with the floor. Furthermore, if an inner layer of rock particles, such S a~ sand or the like, is used, binders, for example cement or the like, or synthetic resins may be added. If a carpet containing cement particles is placed on a wet surface, it may be bonded to it.
The ~ranular particles forming the filler can consist of cement, heavy spar or a light metal alloy, like aluminium hydroxide or the like. These materials inclusive the said sand or gravel improve the properties of the composite body in respect of its behavior against fire especially such a composite body can serve as a fire cut-off.
A composite body according to the invention may further be used advantageously as a wall covering, with the addition of for example cement or a synthetic resin, again being possible as a binder. To prevent the dropping for the wall of the composite body during the bonding process it may be tacked on ~uring the application by means of nails, tacks or the like. Such nails or tacks may be driven through the composite body without destroying it and may be removed after the bonding process is completed. By virtue of the elasticity of at least the top layer, the holes caused by the nails or the like, are closed automatically following the r~moval of the nails.
Since the composite body according to the invention may be cut into parts of different shapes, it is especially suitable for use as padding, for example for couches or chairs.
When sand is used as the granular particles in a composite body according to the invention, it displays positive propexties as a fire protection material, due to the high heat capacity and poor thermal conductivity of the sand. Textile wall coverings which already were provided in nonflammable forms, exhibit an even be-tter fire resistant behavior when filled with sand. A composite body according to the invention may thus be used for example as a so-called "iron curtain'l, which however, because of its textile like appearance, is optically more pleasing.
The granular particles/ may be present in particular when they consist of a binder such as cement, or the like, in the form of a powder. Granular particles of different materials may be present as mixtures. 4 ~8~

Preferablyl their gxain size is hetween 0.02 and 2 mm. The composite bodies may be produced with different weights and the resulting overall thickness; these are governed specifically by their intended application. If for example, sand is present in the form of granular particles, the total thickness may amount to approximately 4-5 mm, with a weight by unit area of the particle layer of 4 kg/m2, while a composite body in which the weight per unit area of the particle layer is approximate]y 12 kg/m2, has a total -thickness of approxi-mately 8-10 mm.
Depending on the total thickness of the composite body desired, the fibers or filaments forming the fleece, must have at least in the actively needle-bondable top layer an adequate length and are preferably 40-120 mm long so that they may extend through a sufficient thickness of the composite body from the -top layer into the support layer. These two layers are preferably needle bonded to each o-ther over the entire area of the composite body so that an adequate needle-bonding density may be obtained; -this may amount for example to 50-200 stitches/cm2. If necessary or desirable, the composite body may be needle-bonded both from the top layer and the suppor-t layer.
In a further embodiment, the suppor-t layer may consist of a material free of fibers, for example a foil or a sheet of syn-thetic plastic, so that different variants of the composite are possible. At least -the support layer may be provided with a reflect-ing layer, for example a me-tallic layer. But a sheet ofa fabric or a nonwoven material may also be used as the passively needle-bondable support layer.
In a preferred embodiment the support layer may have depressions filled with particles, the depressions beiny bowl like or elongated in shape. It is possible in this manner to obtain a particularly flexihle composite body that may be bent for example around the webs between the depressions, it is thus rollable in an especially advantageous manner. The cover layers may be needle bonded together in the locations free of --5a-depressionS and may be without bonding in the depressions.
Depending on the specific application, the holding fibers may penetrate the support layer provided with the depressions of different depths, i.e. the depth of insertion m~y be less than the height of the depressions, in which case the depressions are not perforated by the needles.
If, however, the latter is desirable, the depth of penetration may be greater, whereby the holding fibers possibly penetrate the bottom of the depressions also.
As an intermediate possibility, it is feasible to let the points of the needles penetrate the bottom of the depressions without pulling the holdin~ fibers all the way to the bottom.
By means of the holding fibers passing through I5 the sand layer and joining the top layer and the support layer, the individual sand grains are held @lastically between the cover layers, but the comp~site body may still be rolled up as suchr without the individual grains appreciably altering their position in ~he composite body.
If as the top layer for example, ball yarns of spherically wound fibers, such as described for example in EU-OS ~A 1) 0 013 4287 are used, an especially dense top layer is obtained, through which even powder particles cannot escape.
Further details and advantages of the invention will ~ecome apparent from the claims and the examples hereinaEter described with the aid of the drawing. In the drawing, partial areas of composite bodies according to the invention are shown schematically and enlar~ed, in cross sections.
Figure 1 shows a irst form of embodiment of a 1at composi~e body, wherein both the support layer and the top layer consist of fiber fleeces and the particles are uniformly distributed.
Figure 2 shows a second form of embo~1iment of the composite body, wherein the support layer is provided with bowl-like depressions in which the particles are %
located;
Pigure 3 shows a t~hird form of embodiment o~ the composite body, wherein the top layer consists of ball yarns separated from each other, and Figure 4 a fourth form of embodiment of the composite body, wherein the particles are arranged in strips in the composite body~
A composite body l here has a top layer 2, which in this case is actively needle-bondable and consists of a nonwoven fiber structure (Fig. 3). A support layer 3, which is at least passively needle-bondable, is held by means of holding fibers 4 taken from the top layer

2 in relation -to the latter. Between the top layer 2 and the support layer 3, a layer 5 of granular particles 6 is arranged. The two layers 2 and 3 are joined by needle bondina through the particle layer 5. Needle bonding may ~e effected by a needle bondiny process known in the technology of needle felting, such as described for example by Ro Krcma in "Handbook of Textile Composite Materials" (Deutscher Pachverlag, Frankfurt~Main, 1970, p. 198-202). In this technology most fre~uently elting needles with triangular shafts and lateral counter hooks directed toward the point are used. Other types of needles, such as fork needles and loop needles, are also employed.
The stitch bonding needles mentioned in the aforecited book may also be used for the bonding of the composite body 1. The felting needles seize upon their insertion into the top layer 2 individual fibers 4 or bundles of them and twist them into the support layer 3. For this purpose, the top layer 2 must be actively needle-bondable, i.e. it must be possible to grip fibers in this layer, while part of the fibers 4 remains anchored in the layer 2.
By means of the needle process not only -the top layer 2 and the support layer 3 are joined with each other, but also the granular particles of the layer 5 are prevented from shifting laterally by the numerous holding fiber~ 4 inserted in a distribution over the entire area of the composite body lo It is therefore possible to cut the composite body into arbitrary shapes, in particular sheets or tiles, without losing appreciable amounts of the particles fro~n the cut edge.
S The layer 5 of the granular particles 6 here consists of rock particles of a small grain size, for example of sand having a grain size by definition of 0.02-2 mm. Depending on tne application, larqer particles 6 may also be used. The advantayeous characteristics of these rock particles are the~r relatively great weight with respect to a given layer thickness, their relatively high heat capacity and particularly their inert behavior with respect to other substances.
As seen from the drawing, the support layer 3 may consist ofdi~ferent materials. The layer 3 must not split upon the insertionof the needles and must hold the inserted holding fibers 4, for example elastically by clamping or t~isting r i.e the support layer 3 must at least be passively needle bondahle.
For this purpose synthetic plastic sheet~ 7 of a soft, elastic material ~for example Fig. 2~, fiber layers or adequate density, which are urther densified and felted by the needle process itself f SO that they will retain the particles 6, together with adhesively bonded fiber composites, fleeces or spunbonds, are suitable. The support layer 3 may itsel be actively bondable, which makes it possible to needle-bond the composite body 1, as shown in -the right half of Fig.
4, additionally from the reverse side. It is further possible to provide under a synthetic plastic sheet or the like, as the support layer 3 another actively needle-bondable fiber layer and to needle bond the composite body from both sides. The support layer 3 may further have the configuration of a spring back, or have the spring back on its side acing the top layer 2.
The fiber layer, used either as the top layer or the support layer 3 may be predensified by separate needle bonding, it.may be bonded to a support layer such as for example a synthetic plastic sheet, a ~iber composite,or the like, in order to prevent the running of fine sand particles 6 and particularly of particles 13 of bindèrs (Fig. 3) prior to the needle bonding of the ~omposite l.
As fiber materlal for the fiber fLeece and also the ball yarns (Fig. 3), highly different textile fibers may be considered. Particularly suitable are na-tural fibers, such as for example cotton, wool, animal hair fibers, or synthetic fi~ers, or the like, or a mixture of them.
The form of embodiment according to Fig. l contain only distributed rock particles 6, such as finely grained sand, with said rock particles being present in a weight per unit surface of approximately lO0-l,000 g/m2.
According to this form of embodiment, an improved carpe~
may be obtained. The weight per unit area of a carpet of this type was heretofore 700-aoo g/m~ and this may be increased by about S0~ by the addition of approximately 400 g of finely grained sand per m2. By means of the incorporation of the sand particles 6 into these carpets, the hard/soft effect may be obtained in a relatively inexpensive manner thereby increasing the extent of footfall improvement and enhancing the degree of sound absorption. If to a carpet sand is added with a weight per unit area of 2 7 kg~m and needle bonded into it, the carpet in the form of a width and especially in the form of tiles is self-laying and there is no need for adhesive bonding.
A composite body according to Fig. l may also be used as a curtain, wherein it displays a particularly positive behavior in a fire. Because o~ the poor thermal conductivity and the high heat capacity of sand, present in a grain size of 1-2 mm and a weight per unit area of 0.5-2.5 kg/m2, the composite body may be employed as a protective fire curtain, for example a so-called "iron curtain", as used in theaters or as protective spark curtain. A~ sho~n in Fig. 2, the sheet 7 may be provided with depressions 8, obtained for example by _g_ deep-drawing in the hot plastic state. These depre~sions 8 have a bowl like configuration according to Fig. 2 but they may also be enlongated in shape, whereby they are parallel to each other and may be arranged offset in their position with each other. The depresslons 8 are opening toward the top layer 2 r SO that the particles 6 may be inserted in -the depressions. In the exa~ple of embodiment according to Fig. 2, the layer 5 of particles 6 is not coherent, but is divided into numerous portions. The needle s-titches may be distributed in a uniform density over the entire surface area of the composite 1, as shown in the case of the three left bowls of Fig~ 2, with the holding fibers 4 penetrating through the bottoms of the bowls. If the holding fibers 4 are inserted to a lesser depth7 as in a for~ of embodi-ment not shown, the holding fibers 4 are terminating ir.
the area of the depressions 8 in the bowls themselves, while the holding fibers penetrate the locations without depressions 9 of the synthetic plastic 7, whereby the top layer 2 is joined with the support layer consisting of the synthetic plastic sheet 7. The bonding of the composite body may be effected so that the points o the needles are still perforating the bottoms of the depressions 8, so that fluids may also enter the depressions 8 from the side of the support layer 3.
According to the representation in the right half of Fig.
2, the top layer 2 is connected with the synthetic plastic sheet 7 only in the area of the locations ~ free of depressions by the holding fihers 4O Even though the depressions 8 in the shape of bowls are rather rigid themselves, the composite body 1 has a relatively high flexibility, sinc~ the locations 9 without depreesions, representing the webs, are acting as hinges.
In the form of embodiment of the composite body 1 shown in Fig. 3, grains of sand 6 and smaller grains of binders activated by water, such as for example cement pow~er, are placed as the layer ~, onto a fiber structure serving as the support layer 3, upon which subsequently ball yarns of spherically wound fibers 14 are placed as the top layer. The three layers 2, 5 and 3 are needle-bonded from the top, with the holding fibers 4 being taken from the ball yarns S 14.
'rhis ball yarn layer 2 i5 particularly dense so that the partlcles 6 or 13 cannot drop out of the composite body and particles of dir-t falling on the co~posite cannot penetrate the top layer 2~ The form of embodiment of Fig. 3 is especially suitable as a carpet by virtue of its sur~ace structure. If the base upon which the carpet is placed is wetted, the holding fibers 4 in particular absorb the moisture and place it on contact with the binders, which in turn form a bond with the base.
In the form of embodiment of the composite body shown in Fig. 4, rows 11 or strips of granular particles 6,such as sand, are placed on an actively needle-bondable fiber layer as the support layer 3.
They form an interrupted intermediate layer 5, t~rough which needle bonding is effected. An actively needle-bondable fiber layer is placed on the rows 11 as the top layer 2 and the composite body needle bonded from the top. In the right half of Fig. 4 it is indicated that the composite body 1 rnay be bonded additionally from the bottom,i.eu the holding fibexs 4 are taken both rom the top layer 2 and the support layex 3. A
common feature of both embodiments is the fact that they form a kind of hinge at the locations 12 free of particles, whereby they may be easily bent or rolled even when several particles 6 are arranged transversely to the extent of the composite body, as shown in the left half of Fig~ 4.
The table hereinafter, grouped in lines according to grain size ranges of the particles 6, shows preferred size ranges for the weight of particles per unit area, fiber thickness, fleece weight per unit, needle thickness and sti~ch density~

~7;~

Grain Particle Fiber Fleece weight NeedleStitch Density diameter weight per per layer per thickne.ss ` unl~ are~unit area (m~) (kg/cm )(dtex) (g/m ) (gg)(~titchlcm2) 0.02-0.1 0.5-l<10 150 36 200-100 0.1 -1.0 1-55-20 150 30 120- 60

3-(30) 5-12(20)>20 350 17 30- 5 If a sheet 7 of synthetic plastic is used as the support layer, as in Fig. 2, the sheet thickness is between 30 and 200 ~m, with a thicXer shee~ being used for greater grain diameters.
An example for the preparation o a composite body 1, according to Fig. 1 is as follows:
The top layex 2 and the support layer 3 are made identically of the same material in the following manner. On a support sheet ~not shown in Fig. 1) of polyethylene of a thickness of 0.1 mm, a fiber mixture of 200 g/m2 of polye~ter fibers with a fiber titer of 3.3 and 17 dtex and a staple length of 90 mm, is placed. The ibers were needle-bonded with conventional felting needles with 45 stitches per cm . A fiber layer prebonded in this manner was placed with the fiber beards upward on the feeder table and a layer of washed quartz sand of ~ grain size of 0.5-0.75 mm sprinkled on it in an amount oE 7 kg/m2.
The layer was then covered with an identically prebonded fiber layer with the fiber beards downward. The entire composite body was then needle-bonded with conventional 25 gauge felting needles with 30 stitches per cm2. A
composite body with an approximate weight per unit of 7.4 kg per m2 was obtained.
An example for the preparation of a composite body 1 according to F~g. 2 is as follows:
A nubbed sheet 7 of polyethylene with cylindrical depres~ions (nuhs) of a diameter of 1 cm and a depth of 5 mm, 7,700 nubs per m2, was used as the support layer 3. The nubs were filled level with quartz sana and then co~ered with a layer of polypropylene fibers 17 dtex, a staple length of 90 mm, 200 g/m2. The composite body was needle bonded by ~eans of conventinal 25 gauge felting needles with 30 stitches per cm . A composite body 1 of an approximate weight per unit area of 1.8 kg per m was obtained. The nubs were perforated by the needles, but the sand was prevented from falling out.

Claims

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

1. A flat composite body for textile applications as carpets, padding elements, floor or wall coverings comprising a top layer containing fibers or filaments, and a support layer, with the two layers including between them an inner layer containing at least heavy, nonreactive granular filler material having a hardness that makes it indestructable during needle-bonding, and said top and support layers being joined together by needle-bonding.

2. A composite layer according to Claim 1, wherein the granular filler particles comprise rock particles, such as for example sand, gravel or the like, cement, heavy spar or a light metal alloy, like aluminium hydroxide or the like.

3. A composite body according to Claim 1 or 2, wherein the granular particles have a grain size of less than 4 mm, preferably between 0.02 and 2 mm.

4. A composite body according to Claim 1, wherein the granu-lar filler particles are present in a weight per unit area of 0.1-12 kg/m2.

5. A composite body according to Claim 2, wherein in addition to the nonreactive rock particles, further particles are provided.

6. A composite body according to Claim 5, wherein the other particles are binders selected from the group consisting of adhesives in the powder form.

7. A composite body according to Claim 1, wherein at least the top layer consists of a fleece.

8. A composite body according to Claim 7, wherein the fleece is prebonded.

9. A composite body according to Claim 1, wherein the fleece contains fibers with a staple length of 40-150 mm.

10. A composite body according to Claim 1, wherein the particles are secured against displacement in the direction of the plane of the top layer by means of the holding fibers or filaments produced by needle-bonding.

11. A composite body according to Claim 1, wherein at least the top layer is actively needle-bonded by means of holding fibers or filaments originating in said lower layer to the support layer through said granular inner layer.

12. A composite body according to Claim 1, wherein the support layer also consists of a fiber or filaments fleece.

13. A composite body according to Claim 12, wherein the com-posite body is needle-bonded both from the top layer and the support layer.

14. A composite body according to Claim 1, wherein the lower support layer consists of a nonwoven material.

15. A composite body according to Claim 1, wherein the lower support layer consists of a width of a fabric.

16. A composite body according to Claim 1, wherein the lower support layer consists of a material free of fibers or filaments.

17. A composite body according to Claim 16, wherein the lower support layer consists of a foil, in particular a preferably tough synthetic plastic.

18. A composite body according to Claim 1, wherein the lower support layer is provided with depressions.

19. A composite body according to Claim 18, wherein the depressions are elongated or in the shape of a bowl.

20. A composite body according to Claim 18 or 19, wherein the granular filler particles are arranged specifically only in the depressions.

21. A composite body according to Claim 18, wherein the holding fibers taken from the top layer penetrate the lower support layer at the locations without depressions.

22. A composite body according to Claim 21, wherein the depth of penetration of the holding fibers into the depressions is less than the height of said depressions.

23. A composite body according to Claim 21, wherein the holding fibers penetrate the lower layer in the areas of the depressions also.

24. A composite body according to Claim 1, which has a needle-bonding density of 50-200 stitches/cm2.

25. A composite body according to Claim 1, wherein a spring back is arranged on the lower support layer, at its side facing away from the top layer.

26. A composite body according to Claim 1, wherein the lower support layer has the configuration of a spring back.

27. A composite body according to Claim 1, which is treated with latex.

28. A composite body according to Claim 1, which is needle-bonded or adhesively bonded to a textile layer arranged on the top layer.

29. A carpet comprising the composite body of Claim 1 wherein the granular filler material consists of particles present with a weight per unit area of 100-1000 g/m2.