CN1522198A - 地板和/或墙壁的簇绒覆盖物 - Google Patents

地板和/或墙壁的簇绒覆盖物 Download PDF

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CN1522198A
CN1522198A CNA028133412A CN02813341A CN1522198A CN 1522198 A CN1522198 A CN 1522198A CN A028133412 A CNA028133412 A CN A028133412A CN 02813341 A CN02813341 A CN 02813341A CN 1522198 A CN1522198 A CN 1522198A
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primary backing
covering
wear surface
tufting
yarn
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CN1228187C (zh
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�޲��ء�D������ɭ
罗伯特·D·哈奇森
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Mohawk Brands Inc
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Mohawk Brands Inc
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Laminated Bodies (AREA)
  • Floor Finish (AREA)
  • Polyesters Or Polycarbonates (AREA)
  • Chemical And Physical Treatments For Wood And The Like (AREA)

Abstract

一种地板覆盖物，包括基底布，基底布具有贯穿基底布的簇绒纱线，形成了由簇绒纱线的回针针迹与基底布的非簇绒区域一起构成的磨损面部分，也形成暴露的磨损面。暴露的磨损面部分形成美观设计图案，由此以少的材料和低成本提供低而密集型的阔幅地毯或拼块地毯。最好，基底布由机织聚丙烯构成，第二层底布具有在基底布背面上其由树脂固定住的断损纱或起圈花线。由EVA、碳酸钙和树脂的复合物构成第二层底布，其上覆盖有机织稀松布。第二层底布可以由通过针织结合的合成纤维构成。此外，基底布可以由非纺织材料如尼龙和聚酯构成。

Description

地板和/或墙壁的簇绒覆盖物
技术领域
本发明涉及覆盖物，特别涉及簇绒阔幅地毯和/或拼块地毯，即组合地毯或平铺块(roll tile)，其中覆盖物的磨损面包括基底布的暴露图案部分和簇绒的回针针迹，它们具有互补的审美设计特征。
背景技术
常规覆盖物的一种形式是簇绒阔幅平铺地毯或拼块地毯，即组合地毯或平铺块，下面通常称之为地毯或覆盖物。术语地毯或覆盖物表示铺在地板、墙壁或天花板上的包围式地毯。特别是在商用设施中，地毯的主要内在缺点是，经过长时间使用后不能使地毯保持美观。例如，在商用设施以及家用设施中，铺在门口或频繁通行区域附近的地毯绒头迅速变粗糙且外观明显变差。另一个实例是供椅子、手推车和其它物体的轮子和/或轮脚频繁通过的许多场所中使用的常规地毯。在这种区域中，地毯的外观迅速变差。常规标准的地毯结构通常会以牺牲其它所需要的品质如脚感舒适或吸声并时常缺乏审美特性为代价。而且，为适应频繁使用和频繁通行区域而过分设计和过于安全的设计的地毯伴随的是在较少通行和使用区域中的过于安全的设计。例如，通过设计使用附加绒头的高密度地毯以适应频繁通行区域，不仅因地毯最昂贵部分即绒头的成本很高而实际提高了地毯的成本，而且废料处理问题十分严重。因此，需要提供一种地毯，它克服上述缺点，并以低成本获得赏心悦目的外观。
发明内容
根据本发明的优选实施例，由本发明构成的簇绒地毯的磨损面的载荷被部分地传递给通常由地毯绒头遮掩的基底布。簇绒地毯的基底布通常作为绒头的支承，而不是为了使地毯美观。在多数地毯中，基底布被绒头完全遮掩并且在地毯的审美设计中不起作用。但是在本发明的优选实施例中，提供一种簇绒地毯，其中簇绒的回针针迹和基底布的暴露部分都呈现为磨损面。也就是说，在所选择的地毯不连续区域中，簇绒的回针针迹和基底布部分都相应地暴露为磨损面的不连续部分。因此，基底布的暴露部分还与由暴露在基底布一侧上的簇绒的回针针迹构成的地毯磨损面的其它部分一起构成了地毯磨损面的审美部分。由于地毯磨损面的重要部分包括暴露的基底布，因此对基底布不仅有审美方面的考虑，而且使其具有紫外线稳定剂，从而减轻了太阳紫外线的破坏作用。
尽管可以使用其它结构的材料，如尼龙或聚酯，或其它聚烯烃如聚乙烯，但是根据本发明的基底布优选由机织聚丙烯扁丝(wovenpolypropylene tape yarn)或复丝纱线(multi-filament yarn)制成。还可以使用其它纱线形式或其它织物形式，包括经编、导纬(weftinsertion)，而且还可以使用非纺织或缝编(stitch-bonded)的形式。
因此地毯本身的特征在部分上在于，沿基底布的部分的磨损面的紧密且暴露的回针针迹和同样暴露为磨损面且没有任何簇绒纱线穿过的基底布部分。簇绒纱线仅用在地毯的部分上，并暴露基底布的其余部分(即非簇绒区域)作为磨损面的一部分，伴随而来的优点是，需要较少的表面绒头材料，降低了成本，和减少了在地毯使用寿命结束时的处理问题。此外，获得的地毯具有密集的低型表面，保持了其纺织品的审美，并使滚动通行如床、椅子、清洁设备和类似物在地毯上移动基本不会破坏地毯的外观。而且，该地毯比常规簇绒地毯更轻。
为了形成地毯，以常规方式在沿着基底布的选择区域对基底布进行簇绒处理。不沿地毯的磨损面形成割断毛圈或连续毛圈，而是将簇绒的基底布颠倒，使得簇绒的回针针迹形成磨损面部分。在现在包含断损纱或起圈花线的基底布的背面涂敷树脂，以将断损纱或起圈花线保持在基底布背面上。因此，在基底布背面的所有断损纱或起圈花线都由树脂包裹。接着将热熔合成物覆盖在树脂上。热熔物最好包括EVA、碳酸钙和树脂的混合物，一种在行业上称之为Unibond底布的混合物。此外，当热熔物还呈液体或塑性状态时，在熔融复合物上覆盖第二层底布，最好为机织聚丙烯稀松布。接着使地毯结构移动穿过冷却工作台，从而固化Unibond层。因此，机织聚丙烯稀松布构成了地毯的背面，接着例如通过粘结而铺设在地板面上。
可以采用通过针织结合的(needle-bonded)合成纤维底布代替由机织聚丙烯稀松布构成的第二层底布，将其覆盖在覆盖断损纱或起圈花线的树脂和Unibond层上。通过针织结合的合成纤维最好是尼龙和微量聚丙烯的混合物，优选地二者都是来自其它生产过程的适于再循环纤维。因此，使通过针织结合的尼龙和聚丙烯纤维均质化，并将其应用于用固定住断损纱或起圈花线的树脂浸透的基底布背面。当然，通过针织结合的尼龙和聚丙烯可以由原始尼龙和聚丙烯构成，而不含有任何废物成分，或者可以使用新的和废弃的尼龙和聚丙烯纤维的混合物。这种第二层底布形成密集而一致的衬垫织物，该织物使足底感觉舒适、控制传声并实现隔热。
作为另一可供选择的实施例，可以提供特别用于拼块地毯的非纺织基底布来代替机织聚丙烯基底布。该基底布可以由割断或开裂的混合在一起的尼龙和聚酯纤维混合物构成，使其在一对加热的辊之间穿过以形成扁平的合成结构。可以对合成片进行簇绒处理，并形成在尺寸上比机织聚丙烯更稳定的基底布。特别是当用于拼块地毯时，这确保了地毯的稳定性。虽然非纺织基底布可以与作为第二层底布的Unibond材料和机织聚丙烯稀松布或通过针织结合的合成纤维第二层底布一起使用，但是在阔幅地毯的制造中实际上不使用或不必使用非纺织底布。但是对于要求有高稳定性的拼块地毯，由尼龙和聚酯纤维的簇绒片构成的非纺织基底布可以具有第二层底布，包括PVC预覆层，用于包裹簇绒纤维并使簇绒纤维保持固定。可以添加含有更多PVC成分的主覆层和玻璃纤维稳定层以进一步增强稳定性。
在本发明的优选实施例中，提供一种覆盖在地板、墙壁或天花板表面的覆盖物，包括：在覆盖物一侧上部分暴露的基底布，用于形成覆盖物的磨损面的不连续磨损面部分；在基底布中沿基底布的其余部分形成簇绒的多根纱线，其在基底布的远离磨损面的背面上形成断损纱或起圈花线，沿磨损面的其余部分留下簇绒纱线的多个回针针剂并形成磨损面的其余部分；以及树脂，其沿基底布的背面固定割绒或毛圈绒头簇绒纱线；沿磨损面暴露的回针针迹和基底布部分形成彼此之间相区别的审美特征。
在本发明的另一优选实施例中提供一种覆盖在地板、墙或天花板表面的覆盖物，包括：机织基底布，在其一侧暴露有簇绒和非簇绒部分，用于形成覆盖物的磨损面的不连续磨损面部分；簇绒部分包括多根纱线，这些纱线在基底布中形成簇绒，并在远离磨损面的基底布背面上由断损纱或起圈花线形成，沿磨损面留下簇绒纱线的多个回针针迹，并构成部分磨损面；树脂，沿基底布的背面固定割绒或毛圈绒头簇绒纱线；非簇绒部分包括基底布的经纱和纬纱；基底布沿磨损面暴露的簇绒和非簇绒部分形成彼此之间相区别的审美特征。根据需要，可以在基底布的磨损面一侧上覆盖保护性覆层以延长抗磨寿命。
附图说明
图1是根据本发明优选实施例构成的覆盖物的横截面图；
图2和图3是类似于图1的本发明另一实施例的视图；
图4是表示根据本发明构成的一部分覆盖物的磨损面的透视图；
图5是另一种形式覆盖物的平面图。
具体实施例方式
下面参照附图，特别见图1，图中示出了根据本发明优选实施例构成的覆盖物10。覆盖物10包括机织聚丙烯基底布12，它是以常规方式使变形的(textured)或非变形的(untextured)连续长丝或细纱14穿过机织底布并沿基底布12的下侧形成起圈花线16来形成簇绒的。簇绒过程很常规，可以根据需要利用任何类型的纤维作为形成簇绒的纱线，例如聚酯、聚烯烃、聚乳酸或尼龙。此外，尽管所示的簇绒连续起圈花线16位于基底布12背面上，但是可以理解起圈花线16可以包括沿基底布12背面的割绒纱线。为亮丽起见，机织基底布还具有紫外线(UV)稳定剂以防止紫外线的降解作用。也就是说，基底布最好由具有UV稳定剂的机织聚丙烯构成，其中在挤出构成基底布的聚丙烯纱线时添加UV稳定剂。
沿基底布的背面施加树脂18，使树脂18覆盖、包裹和浸透毛圈16以将起圈花线固定住。接着在树脂覆盖的连续起圈花线16上施加Unibond底布或涂层。Unibond涂层20包括乙酸乙基乙烯酯(ethylvinylacetate)(EVA)、碳酸钙和树脂的混合物。Unibond涂层作为热熔合成物涂敷在树脂18上。在热熔合成物还处于液体或塑性状态时，将第二层底布最好是机织聚丙烯稀松布(scrim)22放置在Unibond涂层20上。接着将该地毯结构传递到冷却工作台上，以便固定和固化Unibond涂层，并确保将第二层底布22固定在地毯结构上。第二层底布22使覆盖物具有完整性和尺寸稳定性。
如图1所示，可以理解簇绒纱线14的回针针迹28通过基底布12露出并构成部分的磨损面。此外，每个回针针迹28形成紧密的簇绒，使得其基本连续地接触机织聚丙烯基底布12，以使其整个长度贯穿基底布12暴露在磨损面上。
下面参照图4和5，图中示出了两种不同形式的覆盖物结构，它们被看作是根据本发明的众多不同形式的覆盖物中的代表性覆盖物结构。本发明的主要方面在于使用基底布作为覆盖物的部分磨损面。在图4中，所示形式的覆盖物包括由簇绒纱线14形成沿对角线延伸的六角形图案。基底布12的部分24平露于覆盖物的耐磨面上并构成其部分的耐磨面。簇绒纱线14的回针针迹28构成覆盖物的磨损面的其它或剩余部分。因此，基底布12的非簇绒部分24和纱线14的簇绒部分，例如回针针迹28，沿覆盖物的磨损面构成了互补图案。在所述的实施例中，纱线14构成暴露为部分磨损面的基底布12六边形区域的边界。本实施例中的簇绒纱线14可以包括割绒或连续的起圈花线。由于基底布部分24暴露为覆盖物的部分磨损面，因此基底布受到紫外线照射。因此，构成基底布的纱线的纤维、薄膜纱或复丝(multi filament)，最好是聚丙烯，与UV稳定剂一起被挤出。这防止了由阳光引起的基底布的暴露部分的降解。
应该理解到图4中所示的覆盖物的图案，图中仅示出了暴露为部分磨损面的非簇绒基底布和暴露为部分磨损面的带回针针迹的簇绒基底布的西洋跳棋盘图案，可以以具有各种审美特性的多种不同形式和图案结构来实现本发明。例如，如图5所示，基底布12b包括具有成排的簇绒14b的簇绒图案，成排的簇绒14b被成排的非簇绒基底布相互分隔开，二者均暴露为地毯的磨损面。尽管可以通过使部分基底布形成簇绒而在基底布的其它部分不形成簇绒来获得多种不同图案，但是应该理解到最终结果是，使覆盖物的部分基底布暴露为部分磨损面，而含有用簇绒纱线的回针针迹在基底布中形成簇绒的纱线的基底布部分构成了其余的磨损面部分。非簇绒基底布部分由此与暴露的基底布的簇绒部分的回针针迹(backstitch)一起形成的了覆盖物的审美部分。因此，优选地在基底布形成过程中或随后通过染色而使其呈彩色，以便与优选地呈不同色彩的簇绒纱线合在一起而获得赏心悦目的审美外观。而且，鉴于基底布的非簇绒部分和簇绒部分的回针针迹都构成了不连续的磨损面部分，最好覆盖物磨损面的织构有显著差别。
本发明覆盖物的外观能够使用很长一段时间。不象在常规簇绒地毯中那样使频繁通行区域中暴露的直立毛圈持续受到磨损，本发明覆盖物的磨损面具有紧密挨靠着基底布的回针针迹。因此，形成了几乎不能移动的非常密集的毛圈。此外，由于具有这样的结构，因此保持了覆盖物的织物特性，如多色彩和不同的织物纹理。
覆盖物总的优点是，簇绒基底布的回针针迹与仔细设计的基底布部分一起呈现为地毯磨损面部分，它们各自具有构成覆盖物的审美设计要素的颜色、纹理和图案。紧密的回针针迹呈现为磨损面，并起引人注意和具有功能的双重作用。其次，回针针迹的作用是构成低绒头。伴随而来的优点是，覆盖物中需要较少材料的，降低了成本，减少了在产品使用寿命结束时的处理问题。第三，非常密集而且低外形的表面保持其织物审美特性的同时，便于滚转通行(rolling traffic)，在移动运输物中花费非常少的劳力并大大提高了滚转运输物以及覆盖物的寿命。此外，由于在其覆盖物中使用的材料减少了，因此实际节省了原材料成本。此外，容许覆盖物具有多种不同图案，因此形成了多种不同的颜色和纹理。
为了提供增强的衬垫效果，参照图2，图中示出了由连续起圈花线14形成簇绒的机织基底布12，其下面覆盖有树脂18，与图1中所示结构类似。但是在此结构中，通过针织结合的合成纤维主覆盖垫30衬在树脂覆层18的下面。通过针织结合的合成纤维成形垫30可以包括呈割绒混合物并与树脂混合的尼龙和聚丙烯。最好，可以由其它地毯生产过程的废材料来形成所有的、一点也没有的或部分短纤维。
下面参照图3，用非纺织基底布40代替机织聚丙烯基底布12，特别用于拼块地毯，即组合地毯。非纺织基底布优选地由尼龙和聚酯纤维混合物构成。将这些纤维缩减和混合在一起并使其在加热的辊之间穿过，从而压平所述的纤维并形成合成平片结构。聚酯纤维实质上使尼龙纤维彼此结合。接着可以采用短纱线或连续起圈花线14对该片材进行簇绒处理，从而形成尺寸极为稳定的基底布。
尽管可以使非纺织基底布具有作为第二层底布的Unibond材料和织造稀松布或者通过针织结合的合成纤维底布，但是对于阔幅毛毯不必使用非纺织底布。在模块毛毯中，最好在非纺织基底布上设置PVC底布。特别是，在簇绒起圈花线14上覆盖PVC预覆层42，以便沿非纺织基底布40下面固定住毛圈。接着，覆盖含有更多PVC的主覆层44和提供附加稳定性的玻璃纤维稳定层。
应该理解到，在所有上述结构中，覆盖物的磨损面包括暴露的非簇绒基底布和暴露的簇绒纱线的回针针迹，该绒纱线呈现从审美上来说是赏心悦目的由低而密集纤维构成的图案，其中暴露的非簇绒基底布构成了磨损面的部分审美设计要素。而且，应该理解到，以上述方式构成的织物，经过修改，就可以用作墙壁或天花板覆盖物。可以作这样的修改，用包含阻燃剂的混合物作为底布材料来代替上述Unibond底布。这些类型的底布在通常情况下是可得到的。在此情况下，不要求设第二层底布。
尽管结合目前被看作是最实用和优选的实施例对本发明进行了说明，但是应该理解本发明不限于公开的实施例，相反，本发明旨在覆盖由附加权利要求精神和范围限定的各种各样的改进和等同配置。

Claims (20)

1.一种用于地板、墙壁或天花板表面的覆盖物，包括：
基底布，部分暴露在覆盖物的一侧上，以便形成覆盖物的磨损面的不连续磨损面部分；
多根纱线，其在所述基底布中沿所述基底布其余部分形成簇绒，在所述基底布远离所述磨损面的背面上形成断损纱或起圈花线，沿所述的磨损面的其余部分留下簇绒纱线的多个回针针迹并形成所述磨损面的其余部分；以及
树脂，沿所述基底布的背面固定所述割绒或毛圈绒头簇绒纱线；
沿所述磨损面暴露的所述基底布部分和所述回针针迹形成彼此之间相区别的审美特征。
2.如权利要求1所述的覆盖物，其特征在于，所述基底布由具有紫外线稳定剂的机织材料构成。
3.如权利要求1所述的覆盖物，其特征在于，每个所述回针针迹在一对针刺眼之间沿着磨损面延伸，该磨损面沿基底布延伸并与基底布结合，基本上贯穿了所述针眼之间的回针针迹整个宽度。
4.如权利要求1所述的覆盖物，其特征在于，所述回针针迹和基底布部分具有不同色彩以产生不同审美效果。
5.如权利要求1所述的覆盖物，其特征在于，包括在所述树脂下面的EVA和碳酸钙层。
6.如权利要求5所述的覆盖物，其特征在于，包括第二层底布，所述第二层底布具有嵌入所述的EVA和碳酸钙层中的稀松布。
7.如权利要求6所述的覆盖物，其特征在于，所述稀松布包括机织聚丙烯。
8.如权利要求1所述的覆盖物，其特征在于，簇绒纱线具有连续毛圈绒头结构。
9.如权利要求1所述的覆盖物，其特征在于，簇绒纱线具有割断毛圈绒头结构。
10.如权利要求1所述的覆盖物，其特征在于，所述基底布由具有紫外线稳定剂的机织材料构成，所述回针针迹和基底布部分具有不同色彩以产生不同审美效果，EVA和碳酸钙层位于树脂下面，和第二层底布包括嵌入在EVA和碳酸钙层中的稀松布。
11.如权利要求10所述的覆盖物，其特征在于，所述稀松布包括机织聚丙烯，并且其中簇绒纱线具有连续毛圈结构。
12.如权利要求10所述的覆盖物，其特征在于，所述稀松布包括机织聚丙烯，并且其中簇绒纱线具有割断毛圈结构。
13.如权利要求1所述的覆盖物，其特征在于，包括铺设在所述树脂下面并通过所述树脂固定于所述基底布的的第二层底布，所述第二层底布包括通过针织结合的合成纤维底布。
14.如权利要求13所述的覆盖物，其特征在于，所述第二层底布包括由尼龙和聚丙烯构成的纤维。
15.如权利要求1所述的覆盖物，其特征在于，所述基底布包括由合成纤维构成的非纺织材料。
16.如权利要求15所述的覆盖物，其特征在于，所述非纺织纤维材料包括彼此结合的尼龙和聚酯。
17.如权利要求15所述的覆盖物，其特征在于，所述树脂包括聚氯乙烯预覆层和聚氯乙烯主覆层，其中预覆层用于固定断损纱或起圈花线，主覆层具有覆在预覆层下面的玻璃纤维稳定剂。
18.如权利要求1所述的覆盖物，其特征在于，覆盖物包括阔幅毛毯。
19.如权利要求1所述的覆盖物，其特征在于，覆盖物包括拼块地毯。
20.一种用于地板、墙或天花板表面的覆盖物，包括：
机织基底布，在其一侧暴露有簇绒和非簇绒部分，用于形成覆盖物的磨损面的不连续磨损面部分；
所述簇绒部分包括多根纱线，在所述基底布中形成簇绒，并在远离所述磨损面的所述基底布的背面上形成有断损纱或起圈花线，沿部分所述磨损面留下簇绒纱线的多个回针针迹，并构成部分所述磨损面；和
树脂，沿所述基底布的背面固定所述割绒或毛圈簇绒纱线；
所述非簇绒部分包括所述基底布的经纱和纬纱；
所述基底布沿所述磨损面暴露的簇绒和非簇绒部分形成彼此之间相区别的审美特征。
CNB028133412A 2001-05-02 2002-04-26 地板和/或墙壁的簇绒覆盖物 Expired - Fee Related CN1228187C (zh)

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