DE10357961B4 - Needle nonwoven covering and process for its production - Google Patents

Abstract

Needled flooring,
of which a surface (4) has a recess impressed after production of a substantially planar surface,
wherein a platelet-shaped insert (2) made of a non-textile material is inserted into the recess and terminates the upper side (8) of the insert (2) substantially flush with the surrounding surface (4).

Description

The The present invention relates to a needle-punched pad which For example, can be used as a floor covering, as well as on a Process for its preparation.

Needle nonwoven pads are known in the art. For example, in the European patent application EP 0 285 338 A2 a needled nonwoven fabric is described in which several different fiber materials are combined. Such a material is used for example as trunk lining application. The corresponding shaping is achieved by pressing under heat.

In the German utility model DE 200 17 838 U1 is a textile flooring made of woven goods, which has surface deposits that are glued into so-called 'Spiegelgründe'. The mirroring reasons are formed by the fact that the pile material of the woven goods is sometimes not lifted into the upper compartment. With regard to the shaping of the mirror surfaces or the surface inserts, however, there are restrictions imposed by the node structure formed by the pole material. The shape must be adapted to the size and orientation of the nodes.

From the DE 101 17 354 A1 is a sheet with a needle-fleece wear layer known. The needle-fleece wear layer has a surface for the visual enhancement of the product, the shape of which is structured in a relief-like manner. This surface is made by thermal embossing.

From the DE 22 44 670 A is a document plate made of needle felt for covering floors known. The document plate has a punched, in which a correspondingly shaped diecut is used from different types of needle felt material.

From the DE 20 34 089 A is a wiper made of needle felt known. The scraper has elongated impressions, are used in the stabilizing PVC webs. These webs are set back relative to the surface of the needle felt, so that dirt can accumulate in the recesses formed in this way.

Of the present invention is based on the object, technical measures to disposal to ask, with which the possibilities the surface design of needle-punched coverings be extended.

These The object is achieved by the Characteristics of the independent claims solved. The dependent claims form the central idea of the invention in a particularly advantageous Continue.

According to one The first aspect of the invention provides a needled nonwoven covering. its a surface one after the other by means of material displacing and / or material-removing, in particular molded mechanical means Well. These funds only work in a second Step on the surface of the needle felt.

"Subsequent" means in connection with the present invention that first in the usual, from the prior Technique known manner a needle felt with a substantially planar surface contour will be produced. The depression is not during the actual production of the needle felt produced. This two-tiered Process has the advantage that the liberties regarding the design the depression can be improved, since this step according to the invention regardless of the actual production of the needle felt is.

"Essentially plane surface contour "is in turn like this to understand that macroscopically, that is, on a scale beyond the inherent surface roughness A needle fleece goes out, the surface appears flat. The depression also has dimensions that exceed those dimensions goes clearly.

In this recess is a platelet-shaped insert, which consists of a Non-textile material is inserted. At the surface can For example, it is the top of a needle-punched floor covering act.

Especially For example, the coating may have a plurality of depressions, for example arranged with each other in a certain geometric pattern are. When using an embossing roller can doing so in a simple manufacturing technology, a grid-shaped pattern be formed, extending in the longitudinal direction the needle-punched sheet is repeated according to the circumference of the roller. By embossing The depression can also be arbitrarily complex contours of the depression realize.

A principal restriction in the choice of the shape of the recess (in plan view) through the needle-punch material is not given. It can So for example, round or annular peripheral shapes are selected.

Advantageously, the contour of the recess is substantially filled by the insert. Furthermore advantageously closes the top of the insert in Substantially flush with the surrounding contour of the pavement. In this way, a visually clearly structured appearance of the needle felt cover is made possible. Potentially disturbing or even dangerous elevations, for example in the form of protruding corners or edges, can thereby be ruled out.

The However, the upper side of the insert can also with respect to the surrounding surface - at least partially - set back be. The surface In this case, therefore, the mission has a somewhat lower value Level as the surrounding needle-punched surface. At a corresponding Flooring therefore results in this case, that the top of the Use something is lower than the surface of the surrounding needlepunch material. Thereby is enabled that even in the case of occurrence and associated depression of the surrounding needled nonwoven material is a formation of a potentially disruptive or dangerous projection or the like can be avoided by the use.

The Deepening can for example have a depth of about 1 to 6 mm, preferably about 1 to 3 mm. The diameter (in plan view) can eg in the size range from 0.1 to 20 cm. The size ranges mentioned are, according to experience, particularly special good for the illustrated technique. They are production-wise advantageous and enable an overall positive visual appearance of the coating.

Farther Advantageous is the use of an adhesive bond in the recess held. For example, the insert directly into the recess be glued. This makes a technically comparatively easy to be realized solution represents.

alternative or additionally can further advantageously the fixation of the insert in the depression using done by barbs. For example, appropriate, outward and barbs pointing upwards in the area of the lower outer edge of the insert be molded or otherwise attached.

to Preparation of the compound can be used in this case in the case Depression are pressed. When loosening then hook the barbs in the surrounding needle fleece material. In this way, the production is a simple and safe Connection possible.

Advantageous The insert is made of metal, cork, porcelain, wood or plastic. The metal may be, for example, metal in silver, Trade gold or other colors. The materials mentioned can be used with the needled fleece material well matched and harmoniously combined become. this makes possible altogether a refinement of the basic commodity.

Of the Insert can be made in one piece be educated. But it can also be designed in several parts, with also the possibility of a Compound of different materials is given. This will be the design options once again significantly expanded. For example, the lower Area of use made of a material that is itself for the Training barbs is suitable, so for example plastic, while the upper area of another material, for example wood or of different materials, such as wood and porcelain consists. The different joining techniques of the possible Materials are known as such from the prior art.

Advantageous is the recess in the needle-felt cover with the aid of a roller pressed. The pressing is carried out under appropriate pressure and back pressure. For example, the depression can be pressed in by means of a cold roller be. It is also possible, a heated roller for this to use.

to impressing The depression is suitable for a stamping calender. Here too can additional heat be used advantageously.

A another possibility the preparation of the recess consists in a trituration of needle felt fibers under pressure. Advantageously, this can be done under a simultaneous Rotational movement done.

By appropriately sized heat input, For example, in the form of appropriate heating of the roller or of the embossing calender can be achieved that the needle felt fibers at least at embossing partially melt. It is advantageous when the recess is melted Having needled nonwoven fibers, because a particularly good fixation the deposits allows becomes.

The heat can be advantageously controlled in particular so that the Fibrous fibers of the needle felt melt and at least partially stick together. In this way, a substantially smooth surface of the Well, in particular a smooth surface of the bottom of the depression, formed which, in addition to a good fixation of the insert a special good adhesion for the adhesive bond of the insert allowed.

A smooth surface of the recess is also advantageous when using barbs for fixing the insert. A smooth surface is provided in this case, especially in the field of NEN barb connection for stabilizing the connection advantageous, for example, in the region of the lower edge of the recess.

It is possible, too, to use an adhesive that alters the fibers such that a sticky solid surface, especially soil surface the depression is created, which is particularly good for connecting with suitable for use.

According to one Another aspect of the invention is a floor covering is provided which from a needle punch according to the above Representations exists.

According to one Still another aspect of the invention is a method of manufacture a needle-punched covering, comprising the following steps: subsequent Molding at least one depression into a substantially planar one surface contour a needle felt material and paste an insert in this depression. The use consists of a non-textile material, preferably made of metal, cork, porcelain, wood or plastic.

The Deepening can, for example, by pressing, stamping, punching, Cutting or peeling with the help of a roller, an embossing calender or a knife be formed. This can be done a simultaneous heat. The heat supply can be controlled so that the fibers of the needle-punched material at least partially melt and form a smooth surface.

The For example, fixation of the insert in the recess can be done using an adhesive bond and / or using barbs, which are attached to the insert. The barbs can, for example, in the area the lower edge of the insert to be firmly connected to the insert, so that they can make the connection in the neighboring Drill needle felt area and get caught there.

Further Features, advantages and properties are now based on a detailed description of an embodiment and reference to the figure attached Drawings explained become. It shows:

1 a schematic representation of a cross section through a needle felt according to the invention,

2 a schematic representation of a section of a plan view of a needle-fleece pad sheet according to the invention, and

3 a schematic representation of a cross section through a needle-felt according to the invention according to another embodiment.

1 shows in schematic form in cross-section a section of a needle-cloth covering according to the invention 1 with a surface 4 and a bottom 5 , In the case of a floor covering thus represents the surface 4 the visible tread.

The needle felt cover 1 has a depression with a bottom 3 and sidewalls 7 on. The recess may, for example, have a depth of about 2 mm. In this recess is a platelet-shaped insert 2 inserted. The use 2 is through an adhesive layer 6 with the ground 3 firmly connected to the recess.

The use 2 For example, it is made of metal in silver, gold or other color or cork, porcelain or plastic.

The use 2 closes with its top 8th essentially flush with the surface 4 of the surrounding needled nonwoven material. However, it is also possible that the top 8th of the insert 2 something is formed offset into the depression. This can be avoided when pressing down the surface of the needle-punched nonwoven material that the insert 2 surrounds, disturbing edges or the like through the insert 2 be formed.

Furthermore, the top is 8th of the insert 2 in the 1 evenly displayed. However, this is only to be understood as an example. In general, the top can 8th be uneven trained; For example, the upper edges 10 of the insert 2 be rounded or the top 8th have a total of convex and / or concave form elements.

The use 2 can continue with its side walls 9 essentially flush with the side walls 7 complete the recess. In the 1 is between the sidewalls 7 the recess and the side walls 9 of the insert 2 a certain gap recognizable. However, this is only intended to serve as a clear illustration. According to the invention, therefore, the use 2 with its side walls 9 along with the side walls 7 the depression essentially come to a positive conclusion.

Both the side walls 7 Well, as well as sidewalls 9 of the insert 2 are in the 1 shown vertically. Again, this is only an example. In general, said walls may be provided differently oriented. You can unlike that presentation of the 1 also have a non-uniform surface. For example, the side walls 7 the recess have an upwardly diverging shape. The side walls 9 of the insert 2 can in this case either also divergent upwards, so that, for example, in turn, a positive connection is given, or else - to achieve a special effect - run at least partially different.

Overall, therefore, the shape of the insert 2 be provided substantially congruent to the shape of the recess.

However, facing the sidewalls, it is also possible for there to be a space between the sidewalls 9 of the insert 2 and the side walls 7 the depression is formed. This also makes it possible to form a special optical effect or additional effect.

Overall, therefore, with regard to the shaping of depression on the one hand and use 2 On the other hand given innumerable variations. The above representations are only to be understood as examples here. The relevant possibilities arise for the expert in many ways and are therefore not exhaustive listed here.

The surface of the soil 3 the recess is advantageously substantially smooth, whereby a particularly good adhesive connection is made possible.

The smooth surface of the soil 3 The recess is formed by needle-fleece fibers which are embossed with the supply of heat. The heat input is controlled in such a way that the needle-fleece fibers melt and stick at least partially during the embossing process.

A smooth surface of the recess allows for improved overall fixation of the insert 2 , A smooth surface of the soil 3 The recess also allows a particularly good surface adhesive bond.

Of course, the adhesive bond does not have to be on the floor 6 be limited. It can generally be at least partially on the sidewalls 7 the depression and the corresponding adjacent parts of the insert 2 extend.

Regarding the fixation of the insert 2 in the recess is also generally given and depending on the materials used, the alternative possibility that the use 2 is held without separate addition of adhesive and only by using the adhesive force of the melted needle felt fibers in the recess. For this purpose, the heat supply is controlled accordingly. The insert can be inserted correspondingly quickly after the heating of the needled nonwoven fibers or substantially at the same time with this.

2 shows in schematic form a detail of a plan view of a web of a needle-felt cover according to the invention 1 , You can see several inserts 2 . 2 ' , By the thick arrow, the longitudinal direction of the corresponding path is indicated. The limits 12 thus represent the lateral track boundaries.

The stakes 2 . 2 ' are arranged in such a geometric grid pattern that results in a repetition in the longitudinal direction. When using an embossing roll that extends substantially the entire width of the web, a pattern repeating itself is formed. The repetition length is predetermined by the scope of the roller used. Of course, it is not necessary that the stakes - as in the 2 illustrated for the sake of clarity - each extending along a line transverse to the web direction.

Furthermore, it is again emphasized in this context that the contour of the inserts 2 thanks to the embossing process can be freely selected in principle. For example, circles, triangles, annular shapes, etc. can be selected.

Finally, it should be mentioned that the 2 is a schematic representation and the size ratios, in particular between the inserts 2 . 2 ' and the web width are not to scale.

In 3 is another embodiment of a needle felt cover according to the invention 1 shown schematically. According to this embodiment, the insert 2 designed so that its top 8th in the inserted state is lower than the surface 4 of the surrounding needled nonwoven material.

For fixing the insert 2 is provided according to this embodiment, that in the region of the lower edge of the insert 2 barb 11 attached, for example, are formed.

For fixation is the use 2 pressed into the recess. After releasing the pressure then drill due to the elasticity of the needle felt material 1 the tips of the barbs 11 into the surrounding needlepunch material 1 and get caught up there. In this way, a connection is created that is simple to manufacture and in terms of fixation of the insert 2 safe and durable.

In the area where the barbs get caught, is the surface 7 the depression smooth. This can be realized by appropriate heat supply: By controlling the heat supply, the fibers of the needle-punched nonwoven material 1 be brought in this area for melting and gluing. Thus, a smooth and comparatively solid surface 7 formed, in which the barbs find correspondingly good and solid support.

The needled nonwoven covering according to the invention can be produced, for example, as follows:
In a surface of the raw material - in the sense of a needle felt cover 1 without depressions - at least one recess is first formed, for example embossed. Subsequently, a platelet-shaped insert is inserted into the depression 2 , which consists of a non-textile material inserted.

Advantageously, the use 2 be fixed by an adhesive bond in the recess. This is easy to implement in terms of production technology and enables a secure and long-lasting connection. For this, for example, on the floor 3 the recess an adhesive layer 6 and on this the use 2 be applied.

alternative or additionally a fixation of the insert can be done by barbs.

The Pressing the depression can advantageously by means of a cold or heated roller under appropriate pressure and back pressure respectively.

To the inculcate For example, a so-called embossing calender is suitable. Again, this is an additional heat possible.

The heat If necessary, by heating the appropriate parts of the Roller or the embossing calender respectively.

Optionally, the heat input can be controlled such that the fibers of the needle-punched nonwoven melt at least partially by the press-fit or embossing process. Furthermore, the heat supply can be controlled so that the fibers of the needle felt at least partially stick together. This makes it possible to form the surface of the recess substantially smooth, whereby a particularly good fixation of the insert is made possible. Furthermore, allows a smooth surface of the soil 3 the recess a particularly good adhesion of the deposit 2 ,

Alternatively or additionally, it is possible to use an adhesive which alters the needle-punched fibers such that a stickable solid surface of the recess, in particular in the region of the bottom 3 , arises.

Depending on the material of the insert and the needle fleece cover 1 can the use 2 be fixed in the recess by an adhesive bond using only the adhesive force of melted needle-punched fibers. In this case, therefore, can be dispensed with the use of a separate adhesive. This can be the use 2 For example, be introduced at a time in the depression to which the melted needled nonwoven fibers are not yet dried, so preferably in a single step, which follows immediately and in a timely manner to the pressing or impressing the depression under heat.

Alternatively to the two-step process described above (i) insert wells - (ii) insert 2 Insert 'is a one-step process possible in which the use 2 first at the desired location on the needle felt cover 1 is applied - optionally with an adhesive interlayer - and then in one operation under pressure and optionally heat to the desired end position in the needle felt cover 1 pressed or stamped.

With The illustrated technique is made possible by a needle-punched pad to refine by combining with other materials. To this Way can be created a needle felt covering, which is essential higher Value mediated.

The Shaping the recesses or inserts is not a matter of principle restrictions inferior by the needle fleece material. This in particular represents an advantage over corresponding web goods, in which a three-dimensional design only very limited can be created by appropriate choice of nodes.

1

Needled flooring

2

commitment

3

ground the depression

4

Surface of the Needled covering

5

bottom of the needle felt cover

6

adhesive layer

7

Side wall the depression

8th

top of the insert

9

Side wall of the insert

10

the top edge of the insert

11

barb

Claims (20)

Needle felt covering, whose one surface ( 4 ) after the production of a substantially planar surface subsequently embossed recess, wherein in the recess a platelet-shaped insert ( 2 ) is inserted from a non-textile material and the top ( 8th ) of the mission ( 2 ) substantially flush with the surrounding surface ( 4 ) completes. Needle-non-woven pad according to claim 1, characterized in that the contour of the recess substantially from the insert ( 2 ) is filled out. Needle felt covering according to claim 1 or 2, characterized characterized in that the recess has a depth of about 1 to 6 mm, in particular 1 to 3 mm. Needle nonwoven covering according to one of the preceding claims, characterized characterized in that the recess has a diameter of the order of magnitude from about 0.1 to 20 cm. Needle nonwoven covering according to one of the preceding claims, characterized in that the insert ( 2 ) by an adhesive connection ( 6 ) is held in the recess. Needle nonwoven covering according to one of the preceding claims, characterized in that the insert ( 2 ) is held in the recess by means of barbs. Needle nonwoven covering according to one of the preceding claims, characterized in that the insert ( 2 ) consists of metal, cork, porcelain or wood. Needle nonwoven covering according to one of the preceding claims in that the recess is melted needle-punched fibers having. Needle nonwoven covering according to one of the preceding claims, characterized in that the depression has a surface ( 3 ) has bonded from heat-bonded needle-punched fibers. Needle nonwoven covering according to one of the preceding claims, characterized characterized in that the recess is a substantially smooth surface having. Needle nonwoven covering according to one of the preceding claims, characterized characterized in that the surface the recess consists of needle-punched fibers, which are treated with an adhesive. Process for producing a needle-punched nonwoven covering, comprising the following steps: - production of a needle-punched nonwoven covering with a substantially planar surface contour, - subsequent embossing of at least one depression in the substantially planar surface ( 4 ) of the needle-punch material ( 1 ), - Inserting an insert ( 2 ), which consists of a non-textile material, so that the top ( 8th ) of the mission ( 2 ) substantially flush with the surrounding surface ( 4 ) completes. Method according to claim 12, characterized in that that the recess under heat imprinted becomes. Method according to claim 12 or 13, characterized that the depression using a cold or heated roller or a stamping calender is formed. Method according to one of claims 12 to 14, characterized that the recess by trituration of fibers of the needle-punched material under Pressure is formed. Method according to one of claims 12 to 15, characterized in that the insert ( 2 ) using an adhesive bond ( 6 ) is fixed in the recess. Method according to one of claims 12 to 16, characterized in that the insert ( 2 ) is fixed in the depression by means of barbs. Method according to one of claims 12 to 19, characterized that needled nonwoven fibers are melted in the area of the depression. Method according to one of claims 12 to 18, characterized that needled nonwoven fibers in the region of the recess bonded under heat become. Method according to one of claims 12 to 19, characterized that needle felt fibers are treated in the area of the recess with an adhesive become.