DE102008010091A1 - Consolidating textile material containing compressed fibers, e.g. carpet backing, by applying low viscosity molten thermoplastic melt adhesive to penetrate into fibers by capillary action - Google Patents

Abstract

A method for consolidating textile material containing compressed fibers (e.g. in bundle or thread form) by applying molten thermoplastic melt adhesive (A) to one side of the material is carried out using an adhesive (A) which penetrates into the compressed fibers by capillary action due to its low viscosity at the predetermined processing temperature. An independent claim is included for apparatus for carrying out the process, in which a heat treating device and/or a cooling section (14) is located immediately downstream of the device (5) for applying (A) to one side of the textile material (1).

Description

The The invention relates to a method and a device for carrying out of the process for the consolidation of textile material according to the preamble the method or device claim.

at The production of a carpet in the tufting process will be the Flor forming fibers introduced into a carrier layer, the tufts or pile loops on the back of the carpet must be fixed afterwards. To it is known to coat the back with latex material. Furthermore, it is known to fixation, anchoring the tufts on Apply a plastic to the back of the carpet. Also it is possible to use another layer as second back to attach to the back. A method for back coating a carpet is known from 10 2005 060 450 Al.

From the WO 99/35327 is a multilayer carpet back construction known. In one of the layers, heat-expandable microspheres are incorporated in a thermoplastic material.

task The present invention is a method and a corresponding Device to develop further.

Solved This object is achieved by the features of the method or device claim. advantageous Further developments of the invention will become apparent from the dependent claims.

According to the Invention is envisaged that a hot melt adhesive is used, in the processing state, such a low viscosity has, so that this only by the capillary action in the preferably in bundles or at least partially compacted present Fiber material penetrate at least a portion of the textile material can. Preferably, the viscosity of the molten thermoplastic hot melt adhesive lower than 5 Pas. The hot melt adhesive is thus brought to a temperature at which this to the Penetration provided in the fiber material viscosity having. Depending on the type of fiber (density of the filament bundle, the yarn or thread type) is now by thermal post-processing of the applied hot glue the temperature curve of the glue controlled so that this completely into the fiber bundles, the threads of the tissue can penetrate. The thermal post-processing can by appropriate control of a belt furnace (setting the individual heating zone sections), by radiant heaters or combinations be influenced by it.

The Invention is preferred for solidifying pile loops in one Carpet back applicable. It can be done as well Woven carpets or other fabrics but also compressed nonwovens and composite composites with the invention Refine adhesive bond or solidify. By selecting the properties of the adhesive depending on the fiber material With the invention a variety of applications can be realized.

So it is possible, for a fabric consisting of weft and warp yarns of different fiber material a glue to use at the intended temperature in the one fiber type penetrates, but not in the other or only superficially surrounds.

When Hot melt adhesive can be a liquid to process plastic used, which liquefies to processing temperature is applied. Also is a powder applied Plastic usable, the order by heat input is liquefied and so in the fiber bundles, the densified fiber areas penetrates.

According to one preferred embodiment of the invention is further provided that the hot melt adhesive via a nozzle, over the entire width of the material or the carpet back extends, is applied in the molten state.

Furthermore, it is advantageous that the application takes place with a basis weight between 50 and 500 g per m ² .

Advantageous is further that the nozzle via an exit slit so that the glue application over the Width of this nozzle is done.

Advantageous is further that the exit slit an exit slit thickness (Distance of the lips of the exit slit) between 0.2 and 2 mm having.

Farther is advantageous that the textile material and preferably the Carpet back or the woven carpet before applying the hot melt adhesive is warmed up.

Prefers the hot melt application takes place in an area in which the textile material or the carpet fixed by a tenter is encouraged. It can be provided that the fixation by the clamping frame in direct connection to the hot melt application he follows.

When further education measure is provided that before solidifying of the melted thermoplastic hot melt adhesive on the textile Material or the carpet back another layer in Form of a fabric, a fleece or a second back applied becomes.

in this connection it is advantageous if for solidification of the textile material or the carpet is a hot melt adhesive is used, the Properties optimally to the desired solidification effect are adjusted. The penetration into the fiber bundles Selected hot melt temperature in conjunction with the as described above thermal treatment causes so the fastest possible penetration of the adhesive into the structure. For the order of another shift or second back Now another glue is used whose function is fixing the further layer or the second back is. This more glue can therefore a much higher viscosity have, since these only penetrated the first of the adhesive To wet threads or pile loops, but not in this must penetrate.

The Equipment of a carpet by means of a second back offers the possibility that on the second back and the first still molten thermoplastic Hot melt adhesive is a mixture of another thermoplastic Hot melt adhesive and heat-expandable gas-filled microspheres is applied. These Microspheres are foamed directly by another heat treatment and cooled together.

When Device according to the invention is provided that to the device for the hot melt application a Device for heating and / or cooling at least the back of the textile material or the carpet followed. Does the textile material or the back of a carpet after the hot melt application still a heat treatment, so the time is extended in which by heating in a low-viscosity Condition staggered hot melt in the fiber material of the threads or the pile loops can penetrate.

The textile material or the carpet is preferably by means of a Tenter frame promoted by the oven and / or the cooling section. This measure is particularly advantageous if by a subsequent to the hot melt adhesive application Heat treatment or by the adhesive itself shrink of the textile material or the carpet is to be expected.

When Particularly advantageous, the invention, when the device for hot melt application in the area of the guide of the textile material or the carpet arranged by the tensioning rams is or the material or the carpet immediately after taken over to the hot melt application of the clamping frame becomes.

Of Further, the explanation of embodiments takes place based on the drawings.

1 shows a first embodiment of the invention, wherein a processed in a previous, not shown Einfärbestation carpet 1 via a drying drum 2 is guided with a round clamping frame. About a slot nozzle is on the back of the carpet 1 applied to a designated temperature heated thermoplastic (hot melt adhesive). The slot nozzle is assigned to an area in which the carpet 1 is conveyed vertically upwards. The hotmelt adhesive has such a low viscosity at the appropriately selected processing temperature that it can penetrate into the fibers of the pile loops by virtue of the capillary action.

Immediately following the hot melt application, the carpet becomes 1 after a deflection through a cooling section 14 promoted. The transport of the carpet 1 through the cooling section 14 takes place either via a circulating belt or, if by the effect of temperature of the hot melt application 5 a shrinking of the carpet 1 can not be ruled out, by means of a tenter 17 , Depending on the air flow permeability of the carpet 1 cooling takes place by means of blown air and / or air sucked through the carpet material.

After the cooling section 14 goes through the carpet of the carpet 1 a goods store 15 with several movably mounted pulleys, before the carpet 1 on a winder 16 is recorded.

In the embodiment according to 2 becomes the carpet 1 as previously described via a drying drum 2 guided with round clamping frame. Via a slot die, the hot melt application is applied to the back of the carpet 1 , One on a roll 8th Provided secondary backing is via one of the slot nozzle 5 Subordinate pressure roller 9 on the back of the carpet covered with hot-melt adhesive 1 applied and by the pressure of the pressure roller 9 ironed on this. The carpet covered with the second back 1 is a circulating belt or a tenter through a belt furnace 6 with subsequent cooling section 14 promoted. In the belt furnace 6 as in within the cooling section 14 takes the heat applying or cooling the carpet-Zweitrückenverbundes by blowing or blowing air. In the belt furnace, a heat treatment can be carried out by means of infrared radiators.

As in the embodiment according to 1 goes through the carpet of the carpet 1 a goods store 15 with several movably mounted pulleys before the carpet 1 on a winder 16 is recorded.

at 3 becomes one on a roll 3 rolled up carpet 1 provided. The carpet 1 thus has ambient temperature. By means of infrared heating is the back of the carpet 1 preheated. In the uphill conveyor area of the carpet 1 are consecutive two slit nozzles 5 . 7 arranged, are preferably applied by the two different viscous hot melt adhesive on the back of the carpet. Preferably, by means of the slot nozzle 5 the application of a low-viscosity hot-melt adhesive, which is able to penetrate due to its low viscosity at the processing temperature in the fibers of the pile loops. About the second slot nozzle 7 a higher viscosity hot melt adhesive is applied, which serves as one on a roll 8th provided and via a pressure roller 9 on the back of the carpet 1 to fix applied second backs. Then, go through carpet 1 with applied second back on a circulating band 17 or a tenter frame a belt furnace 6 and a cooling section 14 ,

The execution after 4 also goes from one on a roll 3 provided carpet 1 off, the ambient temperature has. The back of the carpet 1 is by means of infrared heating 4 preheated, over a slit nozzle arranged in the upward part of the carpet conveyor 5 a hot melt application takes place in a temperature range which gives the hot melt adhesive such a low viscosity that it penetrates into the fiber material of the pile loops by the capillary action.

About a circulating band 17 or fixed by a tenter the carpet passes through 1 with the back-applied hot melt adhesive a belt furnace 6 , By this heat application too fast cooling of the applied enamel adhesive is prevented, this has a greater exposure time to penetrate into the fibers of the pile loops.

A further preferably higher-viscosity hot melt adhesive is applied over a slot nozzle arranged downstream of the belt furnace, in order to directly impinge on a roll 8th provided second back over a pressure roller 9 on the back of the carpet 1 hang up. Before the carpet 1 together with applied second back over the goods storage 15 the winder 16 is fed, the carpet runs 1 still over a cooling line 14 ,

The embodiment of the invention according to 5 corresponds to the 4 , Here, however, following the application of the second back on the pressure roller 9 via a litter order 10 thermally expandable microspheres applied to the outside of the secondary backing. By means of infrared heating 12 become the unexpanded microspheres 11 expanded - the outside of the second back experiences by these expanded microspheres 13 a damping layer, which also gives a slip resistance.

The 6a) -C) show a fiber bundle 18 with a glue application according to the prior art. The bundle of fibers 18 gets from the side of the glue application (from the top) with a lot of glue 19 applied. The glue 19 encloses - depending on the order quantity - the fiber bundle 18 either completely ( 6c) ) or only partially ( 6b) ). By the property of the glue used 19 as well as the nature of the order, however, this encloses the fiber bundle 18 only externally - according to the schematic diagram of 6b) and 6c) are only the outer fibers 18 fixed. Is done over the glue 19 a fixation with bspw. another layer of material, so transferred just in a partial enclosure of the outer fibers 18 ( 6b) ) the forces unfavorably on the Gesamtfaserverbund (the thread). The inner fibers are not glued and can easily be released from the composite.

According to the invention it is provided that an adhesive 20 is used, due to its viscous properties in conjunction with the intended processing in the composite of fibers 18 (the fiber bundle) penetrates. According to the order dosage (slot nozzle 5 . 7 ) as well as the thermal loading after the adhesive application - controlling of belt furnace 6 , Cooling section 14 as well as others in the following 1 - 5 not shown facilities - arise in the 7a) - 7c) principally illustrated situations. According to 7a) a relatively small amount of glue was chosen, the glue 20 is completely in the bundle of fibers 18 (similar to impregnation) penetrated. The fiber bundle 18 (the thread) thus essentially retains its original structure on the outer surface but is penetrated by the adhesive 20 strengthened and stiffened inside. As a result, a significantly increased tensile and abrasion resistance can be achieved.

According to 7b) the amount of glue in the dosage is chosen so that the glue 20 the fiber bundle 18 also in a small layer thickness on the outer surface surrounds. This results in addition to a reinforcement and stiffening a kind of protective layer around the complete bundle 18 , The outer structure of the fiber bundle 18 (of the thread) is retained, which z. B. with regard to appropriate steps in the further processing may be required.

A very high adhesive application results in a complete encapsulation of the fiber bundle 18 , This is basically in 7c) shown. This complete encapsulation of the fiber bundle 18 thus provides an optimal prerequisite for bonding the fiber bundle 18 z. B. with another layer (secondary backing).

The 8a) C) show, in principle, three phases of the adhesive application according to the invention. 8a) returns the situation right after the glue application. According to the thermal aftertreatment (eg belt furnace, infrared radiator) the adhesive penetrates 20 from the order side into the fiber composite 18 one ( 8b) ), until finally the completely penetrated situation according to 8c) is reached. The amount of adhesive application, the application temperature, the processing speed and the type and strength of the thermal post-processing are adapted to the properties of the adhesive and the type of fibers, the fiber composite, the thread.

9a) , b) and c) each show a pole loop 21 in a carrier layer 22 a carpet. To consolidate the carpet back 22 becomes an adhesive 20 applied, with too little adhesive amount ( 9a) ) only an internal solidification of the fibers 18 the pole loops 21 results. An adhesion of the pile loops 21 to the carrier layer 22 takes place only to a very small extent. 9b) shows the ideal situation that can be achieved by the method according to the invention. The fiber composite of the pole loop 21 is completely soaked, at the same time is the pole loop 21 with the carrier layer 22 (the back of the carpet) glued. If the adhesive application is too high, the applied adhesive penetrates 20 also the carrier layer 22 to the visible side, which in particular can lead to a visual impairment.

The 10 shows a cross section through a fiber bundle 18 , which in the manner described above of hot melt adhesive 20 is permeated. By order of a second glue 23 , as indicated in particular by the 3 - 5 has been described, thus creating the basis for the order of a second back 24 , what in 11 is shown. For fixing the second back 24 can be such a glue 23 whose properties are optimally adapted to this task.

The 12 and 13 show a further application of the method according to the invention. A fabric consisting of weft and warp threads is shown in principle 25 a woven or woven carpet. The adhesive application penetrates the adhesive into the warp and weft threads (the fiber bundles of the respective threads), resulting in impregnation and solidification of the fabric ( 12 ). By order of another glue 13 can thus further solidify the tissue 25 be achieved. The order of the further cement 23 can also serve to apply another layer (fabric, nonwoven fabric).

In order to estimate how quickly an adhesive of given viscosity (at the processing temperature) penetrates into the fiber bundles, the threads of the fabric, the physical relationship can be used for the rise height resulting from the capillary forces as well as the suction speed. The following applies:

Of the Capillary radius r is the radius of the actual resulting Capillary between the fibers in a fiber bundle, in a thread.

The required for complete penetration Time is thus at a lower viscosity adhesive smaller than a higher viscosity adhesive. The thermal treatment (exposure time) of a fast in the Fiber bundles, the filaments penetrating hot melt adhesive is thus lower than with a higher viscosity adhesive. Accordingly, the processing line is to be dimensioned. The Suitability of a fiber bundle or a tissue for an impregnation with the appropriate adhesives can be determined by a simple quick test. For this dives you enter the tissue or fiber bundle in water and determined after one minute, the height of the water in the tissue or Fiber bundles. If this is more than 3 mm, is the fiber bundle or fabric for impregnation suitable according to the invention.

14 shows the dependence of the viscosity of three different thermoplastic hot melt adhesives SK ₁ , SK ₂ and SK ₃ on the temperature. The viscosity range below 5 Pas, which is relevant according to the present invention, is highlighted dark.

SK ₁ is a very low-viscosity hot-melt adhesive which has a very low viscosity in the region of the processing temperature and has a good penetration behavior, but remains very soft even at normal temperature, ie in the cured state, and therefore does not give stable solidification.

SK ₂ is a hot-melt adhesive which has a viscosity of less than 5 Pas in the region of the processing temperature but has sufficient hardness in the cured state for stable solidification.

SK ₃ is an ideal hot melt adhesive for applying, fixing a second layer, a second back. Due to its high viscosity even in the processing temperature range of the hotmelt adhesive SK ₂ , this penetrates only very slightly through the fabric of a carpet backsheet, so that disturbing phenomena on the visible side of the carpet can be ruled out. Therefore, the careful selection of a suitable hot-melt adhesive and the corresponding adjustment of the processing parameters are always required to fulfill a specific task.

1

carpet

2

dryer drum (with round clamping frame)

3

Roll (unwinder carpet 1 )

4

infrared heating

5

slot

6

belt furnace

7

slot

8th

role (Unwinder second back)

9

pressure roller

10

scattered order (Microspheres)

11

microspheres (not expanded)

12

infrared heating

13

microspheres (Expanded)

14

cooling section

15

goods storage

16

winders

17

Conveyor / tenter (Chain)

18

Fiber / fiber bundle / filament

19

Glue

20

Glue

21

pile loop

22

Backing / backing

23

Glue

24

secondary backing

25

tissue

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• WO 99/35327 [0003]

Claims (29)

Process for the consolidation of textile material, which compressed fibers in the form of fiber bundles, threads or the like, wherein on one side of the textile material a melted thermoplastic hot melt adhesive is applied, characterized by, the use of a hot melt adhesive, at the intended processing temperature due to its low Viscosity by capillary action in the compacted Fibers or the fiber bundles penetrated into it. Method according to claim 1, characterized in that that with the hot melt adhesive solidification of a carpet backing he follows. Method according to claim 1 or 2, characterized that with the hot melt adhesive a solidification of a tissue takes place. Method according to claim 1, 2 or 3, characterized that the viscosity of the molten thermoplastic Hot melt adhesive is less than 5 Pas. Method according to claim 1, characterized in that that the hot melt adhesive over a nozzle that is over the whole width of the web-like product extends, in the molten one Condition is applied. Method according to claim 1, characterized in that that the hot melt adhesive is applied in powder form. A method according to claim 6 or 7, characterized in that the order takes place with a basis weight between 50 and 500 g per m ² . Method according to claim 5, characterized in that that the nozzle has an exit slit and this a distance between 0.2 and 2 mm to the back of the carpet having. Method according to claim 1, characterized in that that warmed up the goods before applying the hot melt adhesive becomes. Method according to claim 1, characterized in that that the goods after the application of the hot melt adhesive a temperature treatment experiences. Method according to claim 10, characterized in that that the temperature treatment is carried out by infrared radiators. Method according to claim 10, characterized in that that the temperature treatment in a belt dryer or flat tensioning frame he follows. Method according to claim 10, characterized in that that this temperature treatment in a drum dryer or round clamping frame he follows. Method according to claim 1, characterized in that that before solidification of the molten thermoplastic hot melt adhesive another layer is applied. Method according to claim 1, characterized in that that after application of the first hot melt adhesive another adhesive is applied to fix another layer. Method according to claim 1, characterized that fiber bundles or tissues are used in which the height of rise of water in the fiber bundles or the tissue is at least 3 mm within the first minute. Method according to claim 14, characterized in that that on the second layer and the first still molten thermoplastic hot melt a mixture of another thermoplastic hot melt adhesive and by heat expandable gas-filled microspheres is applied. A method according to claim 17, characterized in that these microspheres directly through foamed up a further heat treatment and then cooled together. Apparatus for carrying out the method according to claim 1, comprising means for applying a hot-melt adhesive to a side of a textile material comprising compressed fibers in the form of fiber bundles, threads or the like, characterized by the device ( 5 ) for the application of hot melt adhesive is immediately a means for heat treatment ( 6 ) and / or a cooling line ( 14 ). Apparatus according to claim 19, characterized by the means for heat treatment ( 6 ) and / or the cooling section ( 14 ) is assigned a clamping frame. Device according to claim 19, characterized by the device ( 5 ) for the application of hot melt adhesive is arranged in an area in which the goods ( 1 ) in a tentering frame ( 17 ) is held. Device according to claim 20, characterized by the device ( 5 ) for the application of hot melt adhesive is directly the tenter ( 17 ). Device according to one of claims 19-22, characterized by the device ( 5 ) for the application of hot melt adhesive is another application device ( 7 ) assigned to the order of an adhesive with a different viscosity. Device according to one of claims 19-23, characterized by the device ( 5 ) for the application of hot melt adhesive is a device for heating the goods ( 1 ), preferably an infrared heating ( 4 ) upstream. Device according to one of Claims 19-24, characterized by the device ( 5 ) for the application of hot melt adhesive is a device for applying another layer ( 8th ). Apparatus according to claim 25, characterized by the means for applying the further layer ( 8th ) is a facility ( 7 ) arranged to order another hot melt adhesive. Device according to claim 25 or 26, characterized by, between the device ( 5 ) for the application of hot melt adhesive and the device for applying the further layer ( 8th ) is a furnace ( 6 ) arranged. Device according to at least claim 25, characterized by the device for applying a second layer ( 8th ) is a facility ( 10 ) for the application of thermally activated microspheres ( 11 ). Device according to claim 28, characterized by the device ( 10 ) for the application of thermally activated microspheres ( 11 ) is a device for heating the back of the goods ( 1 ), preferably an infrared heating ( 12 ).