CS207470B1 - primary backing of tufted carpets and method of manufacturing said backing - Google Patents

Abstract

A fabric of thermoplastic yarns, which is capable of being lined with loop pile (terry pile), is superposed with a ply of thermoplastic fibres, and the combination is passed into a heated calender, without needling. The fibres of the ply become bonded to the fabric and to each other. The backing thus obtained is particularly suitable for manufacturing fine-gauge loop-pile (terry-pile) carpets. <IMAGE>

Description

(54) Primary substrate for sewn-on carpets and a method of making the substrate

The invention relates to a primary substrate for sewn-on carpets and to a process for the manufacture thereof.

The sewn rug has at least two parts. The first part is the primary backing and the second part is the sewn hair loops, which usually pass through and are the primary backing. carried. In a sewn-pile carpet, the hair loops either cut or not cut out from one side thereof and are usually connected by loops on the other side, or on the floor side.

Sewing fine pitch hair loops means sowing using approximately 10 or more tufting needles per inch in the weft direction. Fine pitches are usually in the range of about 1/10 "to about 1/20", with a weft direction of 1/10 "equivalent to 10 tufts per inch and 1/20" equivalent to 20 tufts per inch. The pile height, titers, and number of stitches per inch in the warp direction vary from one type of carpet to another such that an exhaustive assignment for fine pitch tufting cannot be made. Usually, when sewing with fine pitch, the hair heights range from 3mm. up to about 15 mm; hair loop titers in the range of 75 tex to about 250 tex, but titers to about 300 tex are also known, and the number of stitches per inch in the warp direction is in the range of about 8 to about 20. The finer. the spacing becomes smaller and the shorter the length of the hair, the discontinuities that result from the deflection of the needle or the deflection of the strip become very marked.

Bases based on woven belts or woven ribbon yarns have been described in U.S. Pat. No. 3,110,905, which relates to a tufted pile fabric, consisting of a synthetic backing material of uniform plastic thickness, woven from uniform strands through which a series of pile protrusions penetrate. Such bases include multifilament weft fibers and improve the primary backing so that it is applicable to fine pitch pitch carpets. However. there are still many petett problems due to lack of hair uniformity. The stability of the tufted base is not usually sufficient to prevent bending and slipping when dyeing or applying a foamed substrate. It should be noted that the deformation of the color image in the fine-pitched tufted carpets usually has a more critical, unfavorable impact on the aesthetic appearance of the tufted carpets than other sewn-pile carpets.

It should also be noted that attempts to sta207470 bleach the woven base by deposition. Adhesives, in order to overcome the above problems, often have an adverse effect on the ghastly plot and hence have not generally met with success.

Initiation of the use of a synthetic primary substrate is also described in U.S. Pat. No. 3,359,934, which relates to a tufted pile fabric consisting of a primary backing woven from warp and weft yarns and a series of pile yarns sewn into the backing to form hair loops above the substrate, and tie loops below the substrate. The weft yarns here are made of synthetic plastic yarns of generally flat cross-section, and each weft yarn consists of a plurality of longitudinally extending continuous filaments and means for holding the filaments together in a bundle and allowing them to: without breaking the weft yarn, it is separated when subjected to a quilting needle, so that the pile yarns are firmly anchored in this primary substrate.

When using synthetic materials, the availability of primary, general, but especially polyolefin-based substrates, such as polypropylene and polyethylene resins, etc. has become a problem. • The reason for this problem is that the base is not color-compatible with the pile fibers, i.e., if it does not accept the same dyes as the pile fibers, the base will be light and will reduce the overall desired light reflectance. The carpet will also not have the desired uniform coloration and a clear pattern after deep coloring of the pattern. For the following considerations, both of these undesirable properties of a base which is not compatible with the hair loops in terms of dye will be referred to as "screening problems". Of the many ways that 'have been tried for. To solve the translucency problem, only the needling of a compatible fiber in terms of dye with hair loops has been met with greater commercial success. . % to form a thin subsurface fiber layer that optically covers said base. A method of needling a base is described in U.S. Pat. No. 3,605,666, which relates to a method for producing a tufted and dyed carpet, with a tensile strength in both longitudinal and transverse directions, and a yarn that can be dyed using a particular dyeing system. Staple fibers are selected which can be dyed using this system. Then, a layer of such fibers is needle punched onto one side of the scrim to form a thin backing layer of fibers which is supported by the scrim and effectively clearly covers one surface of the scrim. Then, the yarn is pulled through the scrim and backsheet to form loops protruding above the backsheet, wherein the scrim provides virtually all dimensional stability to the tufted product. The dyeing system is then used to simultaneously color the backsheet of the tufted layer.

The primary substrate formed by this needle bonding process will be referred to as the primary FLW substrate in the following description (FLWs are the initial letters of the Fiber Lock Weawe). Attention is drawn to the fact that the reason for using different types of fiber for the base and for train loops is dictated by commercial considerations, since the colored white loops are usually far more expensive than the material used to form the backing layer of the primary substrate.

However, both production and performance of the primary FLW substrate are associated with various disadvantages. These drawbacks are: 1. production rates for the needling process are largely unaffected by: - reducing fiber titers, increasing web or web weights, and increasing the number of needles per length unit, with considerable needling associated with needles; 2. part of the effective covering capability of the needle fibers is lost because some of the needled fibers protrude to the back of the base; 3. some webs tend to break through the primary FLW (fiber breakdown) substrate, which has adverse effects on the performance and appearance of the finished carpet; 4. Although the greater hiding power for a certain weight of a web of pigmented dye or dye-compatible fibers is obtained by using fibers with an even finer wiped or increasingly low cross-sectional area, in practice the cross-sectional area of the fibers in the needling process is limited the finer the fiber, the slower the needle bonding process; 5. blockage of sewn hair is reduced in the primary backing that was needled prior to tufting; 6. The overall tensile strength of the tufted primary substrate is reduced by needle bonding.

It is therefore an object of the invention in some of its embodiments to provide a primary backing for fine pitch pitch sewn carpets so as to overcome the aforementioned sewing problems. with fine pitch.

It is a further object of the present invention to provide such a product and a method for its manufacture that are suitable for the primary substrate of sewn pile carpets and remove the limitations imposed by the primary FLW carpet substrates and their method of manufacture. ‘.

It is a further object of the present invention to provide a product suitable as a primary substrate for sewn-on carpets and using substantially less dyed, pigmented or dyed subsurface or cobweb fibers than a primary FLW substrate to achieve the same degree of optical coverage or masking factor.

It is a further object of the present invention to provide such a primary substrate for sewn-pile carpets in which the subsurface fibers have both a greater adhesion and a lower tendency to break through the fibers than the primary FLW substrate.

It is also an object of the invention that the primary substrate for the pile-sewed carpet has a greater overall tensile strength after tufting or dyeing than that of the FLW substrate. '

Other purposes and advantages of the invention will be apparent from the detailed description thereof.

According to the invention, the primary substrate for the sewn-on carpet comprises a woven, non-woven or knitted thermoplastic base and a web or web having at least 3 g per square meter, the web comprising 5% by weight to 100% by weight of the first fibrous component. and is 95% by weight, up to 0.0% w / w, of the second fiber component that is attached to the first fiber component, wherein both the first and second fiber components have a titer of 1.2 dtex and a fiber length at least 5 mm.

Preferably, the second fibrous component has a melting point above the heat of melting of the first fibrous component.

According to a preferred embodiment of the invention, the base consists of a fabric in which, at least in the weft direction, it is multifilament yarn with a multifilament fiber titer in the range of 200 to 1500 dtex and an elemental fiber titre in the range of 2 to 20 dtex. yarn titer ranging from 200 to-1500- dtex.

The weight of the web per square meter is 5 to 50 g, preferably less than 25 g.

In another embodiment, the base is made of a polyolefin selected from the group consisting of one or more 1-olefins of up to 8 carbon atoms.

The process for the production of a primary substrate according to the invention depends on the invention in that a nonwoven fabric is formed on a woven, non-woven or knitted thermoplastic base by being able to be tufted, comprising 5 to 100% by weight, first fiber component and 95 to 0%. 0% by weight of a second fibrous component, of which the first fibrous component is heat-adjustable with a base and has a titre of at least 1.2 dtex and a fiber length of at least 5 mm, and the second fibrous component is not heat-adjustable with a base and has a titre of 1.2 dtex and a fiber length of at least 5 mm, and that it is applied by heat and pressure to form a stable bond between the web fibers as well as between the web and the base.

^: Preferably, the woven base made of a thermoplastic flat strips. The multifilament fiber is preferably inserted in the woven thermoplastic base in the weft direction.

In the following description, the term "heat-fusible or heat-fusible" refers to the ability to form a bond under the influence of both heat and pressure. The web or web usually consists of a mixture of two fiber components: the first component, which may at least in part be colored, dyable, -pigmented or the like, is heat-sealable to said base at a temperature equal to or a lower melting point or melting point of the base and which is preferably also lower and expediently lies at least 2.8 ° C below the melting point of the second fiber component of the mixture; a second fibrous component, which is preferably at least partially dye-compatible with the sewn! fiber loops to be formed later to complete the sewn-haired carpet. The second fibrous component may also be at least in part a colored or pigmented fiber which is not itself fusible or heat-sealable to said base. The first fibrous component either provides attachment of the second fibrous component in the web to said base or / and, in the absence of the second fibrous component, provides color coverage of the base.

Methods for producing a dyeable fiber such as a polyolefin fiber by incorporating a dye-receiving additive are disclosed in U.S. Pat. Nos. 3,819,758, 3,834,870, 3,820,949 and 3,926,553.

According to US Pat. No. 3,319,758, it has been found that polyamides, polyamidoesters or polyesters so treated that substantially no free carboxyl group remains in the molecules, for example by reaction of a polymer molecule with a primary or secondary monoamine and / or a monocarboxylic acid either during the process. the basic reaction by which the polymer is formed or ₍ used) and used as improved dye receptors in a polyolefin, for example polypropylene, greatly improves the dye receptivity and dye retention in the polyolefin.

According to US Pat. No. 3,834,870, the centenary of acid-dyed polypropylene yarns is improved by applying a water-insoluble fatty acid ester to the yarn surface after dyeing.

US Pat. No. 3,820,949 discloses -o. a method and article obtained from differential dyeing of the composite material by forming at least two fibers from the same spinable polymer composition having different concentrations of the same promoter; carpets, and the composite material are dyed piece by piece to produce different shades of the same color by contact with a suitable dye.

US Pat. No. 3,926,553 relates to a method for selectively controlling the degree of dyeability of shaped articles made of fiber-forming materials, a polyolefin, and a small amount of an alkyl amine-containing polymer. arylalkylamine; said process either by treating the shaped articles with a weakly acidic anionic surfactant to enhance colorability, or by treating the shaped articles with a strongly acidic anionic surfactant to prevent colorability.

Methods for treating pigmented fibers such as pigmented polyolefin fibers are well known in the art.

It should be noted that usually only the base itself will be able to accept the sewn pile, the weight of the square meter of fiber web attached to the base preferably being as small as possible and still giving the dimensional stability required in subsequent carpet production steps as well as sufficient coverage to avoid major translucency problems. Usually, the fiber web will not be tufted unless attached to the base. A base which, in itself, is not capable of being tufted, must acquire this ability when a fiber web or band is attached thereto.

Typically, the adhesion will be the greater the weight percent of the bonding fibers based on the total weight of the web. The titre and length of the fibers inside the web are limited in part by the cloudiness problem, which term describes the unevenness of the card web, as is known in the carding art. Fiber sections substantially larger than 150 mm may be used: provided that titers of sufficient size are used. When the liter of fiber approaches 1.2 dtex and its length is constantly increasing above 150 millimeters, the cloudiness becomes an increasing problem.

The weights of the web are generally advantageous, as low as possible, although they achieve sufficient dimensional stability, as well as coverage and to eliminate the major translucent problems. Usually, at least 3 g of cobweb per square meter is required. The mass of cobwebs or Typically, the nonwoven webs per square meter are found to be in the range of about 3 to 70 grams, and preferably in the range of 5 to 50 grams.

The range of grams in the weight of the web per square meter is about 33 to about 135 grams for a FLW commercial substrate. Obviously, the weight of the web needed to achieve a certain level of coverage depends in part on the depth of color derived from the dye or pigment used in the fibers present in the web. Due to the increased coverage achievable by the invention compared to the FLW substrate, particular advantages are achieved due to the use of fleece weights and / or fleece weights. cobwebs less than about 25 grams per square meter.

Said second fiber component consists of fibers which are not heat-sealable to the base, so that only the bonds between the first fiber component and the second fiber component can be formed.

In general, any base, woven, nonwoven or knitted, capable of tufting the pile and to which heat-meltable thermoplastic fibers can be attached by heat and pressure. Examples of useful thermoplastic substrates according to the invention are generally polyolefins, polyamides, polyesters, vinyl and acrylates.

Woven bases having fibers of preferably a flat and rectangular cross-section with a titer of 200 to 1500 dtex in both the warp and the weft of 10 to 30 per inch in the warp and 5 to 30 per inch in the weft are particularly useful. Examples of such woven bases are described in U.S. Pat. No. 3,110,905. In fine pitch pile carpets, such woven bases preferably use multifilament yarns having elemental fibers having a titre of between 2 to 18 dtex with a circular or multilobal cross section. The multifilament yarn has: approximately 10 to 20 twists per meter with the advantage of production. It has been found that fine pitch tuftability can usually be improved by thermally fusing the fiber layer to the base, and thus using the invention, a particularly useful primary substrate for fine pitch pile carpets can be made.

One way to apply heat and pressure is to use a nip formed between two rollers rotating in opposite directions. The cylinder in contact with the side of the base which is covered by the fibrous web is heated to a temperature sufficient to induce heat build-up between the first fibrous component, i.e., the heat-meltable fibrous component, and between the substrate, and if a second fibrous component is present. to form a bond between the first fibrous component and the second fibrous component without the second fibrous component being substantially softened; said temperature being below the melting point of the second fiber component and is preferably at least 2.8 ^° C lower. For example, when polyamide-6 fibers and a fiber and a base of polypropylene or another polymer obtained from one or more 1-olefins having up to 8 carbon atoms or the like are used, this temperature is in the range of about 160 to &gt; 200 ° C, which is the range for the melting point of polypropylene. The other of the counter-rotating cylinders is in contact with the uncovered base straddle and is heated to a temperature in the range of about 0 to 160 ° C, and the linear pressure <in this compression can be up to 350 kp per centimeter length. The linear velocity of said base in the machine direction through this pressing is in the range of up to 60 meters per minute.

Both straight and domed cylinders can be used to produce said compression.

In a first arrangement, a smooth steel or chrome coated roller contacts the side of the base which is covered with a fibrous web or web, and an exposed embossed roller provided with elevations or a smooth roller having a flexible or deformable surface contacts the exposed side of the base. An example of such a deformable surface is a cotton-covered surface. In this first embodiment, the pressures are preferably in the range of Ы about 180 kp / cm to about 300 kp / cm. If the pressure is well below 180 kp / cm, the fibrous irony does not adhere well to the base, but at a pressure well above 350 kp / cm, the base may be po207470

Škozen. In the second embodiment, the embossing roller is in contact with one side of the base covered with a web or web and the opposite Istrian is in contact with either a smooth steel roller or a roller having a deformable surface, for example a cotton paper surface. In a second embodiment, the pressures are preferably in the range of about 20 kp / cm to about 180 kp / cm. At a pressure considerably less than 20 ips / cm, the fiber web does not adhere well to the substrate, but at a pressure considerably higher than &gt; 180 kp / cm, the substrate may be adversely affected. Typically, the number of protrusions on the embossing roll in both arrangements is in the range of about 20 to 80 protuberances / cm 2, and preferably about 30 to 50 protuberances / cm 2, giving an effective relief area of about 10-50% and preferably 20 to 40% of the primary underlying surface.

In general, the greater the number of protuberances / cm ² in the second arrangement, the higher the adhesion of the web or web will be, with all other factors such as the web or web web weight, the linear pressure and the temperature of the calender rollers. the linear velocity of the foundation in the machine direction are kept constant. For the optimum height of the protrusions, the effect of the different heights on the wear rates of the protrusions, as will be apparent to one skilled in the calendering art, should be considered. If rollers with a non-deformable surface, for example chrome-coated rollers, are used against the embossing roll, the calendered webs, even with decreasing projection heights, tend to adhere to the embossing calendering roll rather than being easily separated from it during processing. However, when a deformable roll is used, for example a roll coated with cotton paper, the tendency to adhere to a considerable degree will be greatly reduced in that it does not interfere with processing. Wadding paper is a woven or nonwoven cotton fabric that is covered by a calender roll to achieve a deformable surface.

The temperature of the calender rollers will depend in part on the specific heat and thermal conductivity of the web, or on the web, and on its surface area per m2, as well as on the speed of movement of the base through the printing point in the machine direction. If the web is heavier, higher temperatures and slower speeds are generally preferred. In general, higher temperatures tend to allow a higher base speed in the machine direction.

It is important to note, however, that although the speed of the needle thread is largely influenced by the fiber titers and / or the weights of the web, neither the fiber titer and / or the weight of the web have a significant effect on the calendering rate.

Other heating methods useful in connection with the pressure to achieve the web or web connection to the base are infrared radiation, ultrasonic, magnetic and dielectric heating of suitable coatings and / or fiber components.

The primary substrates produced by the above-described processes have excellent tuftability at a pile weight in the range of 150-2000 grams per square meter and a height in the range of 3-30 m. In addition, the rate of formation of the primary substrate of the present invention is generally faster, and where a fleece or web of fine titer fibers is used, it is considerably faster than the rate of formation of the primary FLW substrate.

It has been found that the sold base and given sewn hair loop is a sewing block for the primary substrate according to the invention - considerably greater than a sewing block achievable on the primary substrate - FLW.

It has been found that only half the weight of the dye-compatible fibers in the web or web is required to achieve the same covering agent with dye-compatible fibers in the primary substrate of the present invention in comparison with the primary FLW substrate.

The web is formed on said base by conventional means for forming a web, such as a conventional carding machine, which can apply the web in one direction or a web-randomly oriented web formed by lamination in a movable conveyor assembly.

The notion of forming a web-based material is fed into a calender which is at a temperature which is largely dependent on the melting point of the heat-curable fiber contained in said web or web. This - temperature - will normally - be less than about 300 ° C and must be precisely - controlled to prevent the web from tending to wrap - around the heated rollers. Low melting point materials can be calendered between rollers having a temperature of about 150 ° C. The calender pressure will preferably be adjusted to allow linear pressures of up to about 350 kp / cm. Problems arising from the build-up of static electricity can be avoided by treating the web with moisture during processing and / or by maintaining a moisture content of about 60% at the outlet.

Example 1

A method of forming a primary substrate according to the invention.

20 g / m ² web or web, composed of 30% w / w polypropylene fibers of 3.1 dtex, 60 mm long and matt finish up to 70% by weight of '3.5 dtex' polyamide fibers, - with a length of 60 mm and with a matt finish, it was created in a carding line consisting of a bale spreader and a front tinder, a material transport fan, a hopper control, a vibration chute, a compact carder and a edge-removing device. Intrinsic viscosity measured with a viscometer, at a concentration range between 1 g and 62.5 mg

Per 100 ml of polyamide fiber solvent at 20 ° C was 57 ml / g in m-cresol and 35 ml / g in 901% formic acid. The flow of molten polypropylene was 13 g / 10 min at 190 ° C and at an energy of 2.16 kp. The web consisting of these fibers was conveyed to the upper press point of a three-roll multipurpose calender from where the web is distributed into a woven for pollen 2400.

i Woven polypropylene · 2400 is a smooth fabric Ό 9 threads per centimeter in the warp and 4 threads per centimeter in the weft. The warp yarn titer is 525 denier and the weft yarn titer is 1050 denier. The upper roller of the calender is provided with a protruding pattern and the middle roller is a smooth steel roller. The cylinders are heated by a flow of hot oil at controlled pressure and in this case the upper cylinder has a temperature of 195 ° C and the lower cylinder has a temperature of 130 ° C. The composite structure was extruded at a pressure of 80 daN / cm and processed at a speed of 14 m / min.

Example 2

PPleniness.

The adhesion test of the fibrous web to the base gave a value of 3N compared to that of the fibrous web in the primary substrate FLD, which gave a value close to 2N.

A modified version of the test involves sticking an adhesive tape onto the sample, which is then rolled twice with a metal cylinder (weighing 4.2 kg and a 'larger' width than the sample. The sample is cut at each edge to have a width The web with the adhesive paper on the top side is separated from the base fabric, the base fabric is then clamped in a rigid jaw, and a laminate consisting of a web and adhesive paper is clamped in the movable jaw of the tensile strength tester. it detects the force required to pull both parts apart by pulling.

Example 1 a d 3

Blockage and tuftability.

Tufting was performed on a 10 m long and 1 m wide section of the substrate made as described above. The loop pile has a double fiber having a titer of 1260 dtex 'made of 100% nylon 6 and a height of 6.35 µm and a pitch of 4 mm at a pile weight of approximately 520 g / m 2. Visual observation revealed two techniques, making independent observations, that susceptibility is excellent.

The sewing blockage was measured on a tester comprising a slip loop and a loop for uncut loops, measured for the primary FLW substrate and for the substrate made according to Example 1 of the method of forming the primary substrate of the invention. In each primary substrate ^{: the} same hair yarn as above was sewn under the same conditions. In the case of the tufted primary substrate FLW, a value of 85 cN was found and in the case of the tufted primary substrate according to the invention a value of 140 cN.

Example 4

Tensile Strength of the Sewn Pile Carpet Made with the Substrate of the Invention.

Two samples of the primary substrate of the species as in Example 1 were both processed to. a primary substrate by the method of Example 1 'and needling to form a primary FLW substrate. Then, on each sample, two different teething operations were successively used. One operation was, with eight stitches per inch (3.2 stitches per cm 3 and the other with

6.5 stitches per inch (2.7 stitches per cm). The hair loops had a pitch of 4.5 mm inches and were double polyamide-6 yarns of 42-60 denier. Tufted carpet. the hair was then stained with hasp dye before determining the tensile strength in the warp and weft directions. The table below shows the results in decanewtons, daN:

Pol Bac (Reg. FLW

TM) 2400 upon completion of sewing the article of the invention upon completion of sewing direction

(warp 100 ALIGN! 42 40 * 50 46 escape 7'6 56 26 * 64 29 (warp 100 ALIGN! 42 42 ** 50 48 Escape 76 56 24 ** 64 27 Mar:

* tufted 6.5 stitches per inch, ** tufted with 8 stitches per inch.

Example 5

Pigmented polypropylenes used in the primary substrate of the invention.

parts of polypropylene Amoco 5013 · for 1 ddl wt. % of carbon black in polypropylene D 1937, blended and extruded in the molten state and oriented into fibers having a titre of 3.1 dtex.

A fibrous web of 25 parts of the above pigmented polypropylene to 75 parts of the above unpigmented polypropylene fiber, each having a titre of 3.1 dtex and a length of 60 mm, was formed on the above mentioned woven polypropylene

2400 and fused according to an example for a process for producing a primary substrate of the invention.

The results were satisfactory.

Example 6

Dyestuffable polypropylene used in the primary substrate of the invention.

A fiber made of a compound containing 2% by weight, poly- [1,3-di- (4-piperidyl) propane diapamine, based on Amoco 5013 polypropylene weight, was used in the same manner as the pigmented polypropylene in the previous examples.

At primary. The substrate was tufted and stained by immersion in an aqueous solution containing 0.5% w / w as the only dye. Terasil Blue BGL (C.I. Disperse Blue 73), 2% by weight, wetting agent and a sufficient amount of moleic acid to achieve a pH = 5 at a 50: 1 liquid ratio.

The carpet was placed in a bath at 50 ° C. The bath was heated to boiling point and held there for one hour. The carpet was then rinsed and fixed in an aqueous 2% wetting agent for 15 minutes at 50 ° C.

The results were satisfactory.

Example 7

Primary substrate using fiber weight ratios.

Primary substrate. for tufted pile carpets was produced by the method of Example 1 to form a primary substrate of the invention and the results are compiled in the following table:

base weight fleece weight weight ratio g / m ² g / m ² polyamide-6 polypropylene

48 20 May 7 3 110 20 May 7 3 250 20 May 7 3 600 20 May 7 3 110 20 May 9 5 1 110 20 May 7 3 110 20 May 5 5 110 20 May 3 7 110 20 May 1 9 110 20 May 0 10 110 8 7 3 110 12 7 3 110 16 7 3 110 20 May 7 3 110 25 7 3 110 30 7 3 110 40 7 3 110 50 7 3 110 20 May 7 3

Example

Primer especially suitable for carpets with fine-pitch pile.

A 25 g / m2 heat-meltable web is applied to both sides of a smooth-woven base in two successive calendering operations as in Example 1. The plain fabric has 10.2 threads per centimeter in the warp and 4.3 threads per centimeter in the weft. The warp and weft yarns are both multifilament polypropylene yarns of 500 dtex titer, each elementary fiber having a titre of approximately 5 dtex, a round cross-section, and a factory twist of approximately 15 twists per meter. The web consists of 100% by weight of the thermofusible polypropylene fiber mentioned in Example 6 with a titre of 3.1 dtex and a length of 60 mm.

The connection between said fleece and the base is formed at the compression point of two counter-rotating rollers. One of the two rolls in contact with the non-woven side is a chrome-coated stainless steel cylinder having a temperature of 185 ° C, and the other roller is a cotton-coated steel cylinder having a temperature of 25 ° C. Cotton paper consists of 75% cotton, 15% flax and 10% wool, is 120 mm thick and has a Shore hardness of 70.

A finely pitched 5/64 inch (1.4 mm) tufted pile carpet can be sewn into the finished primary substrate for the tufted tufted carpet having a pitch of 1260 denier.

The aesthetic appearance of a carpet with a tufted fine pitch pile and a layer of heat-meltable nonwoven attached thereto is · compared to a carpet made without. the fleece has the following advantages:

1. both the pile height and the pile density are more even; 2. translucent problems are substantially reduced.

The above examples serve only to illustrate the invention, which is not limited thereto.

Claims (9)

SUBJECT OF THE INVENTION 1. Primary .podklad for tufted carpet, characterized in that it comprises a woven, nonwoven or knitted base and thermoplastic net, eventually. Irouno having a weight per square meter of at least 3 g, wherein the web comprises about 5 / _about hm.ot . up to 100 why. by weight, the first fiber component being heat-bonded to the base and 95% by weight, up to 0.0% by weight, of a second fiber component which is bonded to the first fiber component, wherein both the first and second fiber components have a titer of 1.2 dtex; A fiber length of at least 5 millimeters. 2. The primary substrate of claim 1 wherein the second fiber component has a melting point above the melting point of the first fiber component. 3. The primary substrate for carpets according to claim 1, characterized in that the base consists of a fabric in which, at least in the weft direction, the multifilament yarn has a multifilament fiber titre in the range of 200 to 1500 dtex and an elemental fiber titre in the range of 2 to 20 dtex. wherein in the warp direction the yarn has a titer in the range of 200 to 1500 dtex. 4. The primary substrate of claim 1 wherein the weight of the web per square meter is 5 to 50 g. 5. The primary substrate of claim 4, wherein the weight of the web per square meter is less than 25 g. 6. The primary substrate of claim 1, wherein the substrate is made of a polyolefin selected from the group consisting of one or more 1-olefins up to δ carbon atoms. 7. A method for producing a sewn-pile mat according to any one of claims 1 to 6, characterized in that a nonwoven fabric comprising 5 to 100% by weight of a first fibrous component and 95 to 0 is formed on a woven, non-woven or knitted thermoplastic tuft base. 0% by weight of a second fibrous component, of which the first fibrous component is heat-adjustable with a base and has a titre of at least 1.2 dtex and a fiber length of at least 5 mm, and the second fibrous component is not heat-adjustable with a base and a titer of at least 1.2 dtex and a fiber length of at least 5 mm, and that heat and pressure are applied to form a stable bond between the nonwoven fibers as well as between the web and the base. 8. The method of claim 7, wherein the woven thermoplastic base is made of flat strips. 9. Method according to claim 7, characterized in that a multifilament fiber is inserted into the woven thermoplastic base in the weft direction.