DE1619204A1 - Pile textile and process for its manufacture - Google Patents

Description

P "" 6 * 9 204.4-43 DA-5b'7

Description of the patent application

of the company

COUITAUIDS LIMITED, 18, Hanover Square, London W 1 / England

Pile textile and process for manufacturing it

Common indoor floor coverings range from. hard floor coverings such as stone slabs or wooden parts to soft coverings such as carpets and carpets. Hard floor coverings usually have the advantage of being exceptional Durability. However, they are often not as elastic as carpets and usually do not show such good results thermal insulation. A floor covering that has the excellent and desirable properties in itself would therefore be ideal a hard flooring and. combined in a carpet that at the same time has a pleasant appearance and is cheap and easy to manufacture.

It is known to apply an adhesive, e.g. a rubber latex, to the rear surface of a pile part,

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Lagetextil

in order to anchor the pile yarns with ä. & m löiterlagei in this layer. However, this material differs from the pile fabric according to the invention in that the fibers which form the pile are not bonded to one another.

The Flortextil invention is namely characterized in that the pile fibers having at least 5 wt. -4> resin, particularly with 15 wt .- ^ to 100 wt .- ^ resin based on the weight of the Flortextils, are bonded to each other. The pile textiles according to the invention can of course also be covered on their back with an adhesive in the usual way, if this is desired.

The method for producing the novel Flortextilien is that the pile fibers are impregnated with a .Florgewebes at least 5 wt. -I> resin, in particular with 15 to 100 wt .- $ resin based on the weight of the Flortextils and the adjacent Flox 'binds the fibers that carry the resin together. The pile textiles can be floor coverings with a structure in the manner of tufted carpets or woven carpets, which have cut or uncut fibers. However, for economic reasons it is preferable that the fibers have a short pile and a high density of tufts. Numerous fibers of natural or synthetic origin in the pile textiles, in the pile

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and used in the underlay fabric. Examples are Wool, viscose rayon, polyamide and acrylic fibers and blends of this. The fibers should of course be at the temperature waiting unaffected, in which the relevant Resin is hardened in the heat.

The resins which are used for the process of the invention are polymeric materials which adhere to one another bind lying pile fibers to which they are applied «The bonding can be done with or without a hardening treatment, which normally requires the application of heat makes to further polymerization or crosslinking of the resin. Of course, if high temperatures are used at the same stage in the process they should not be so high as to damage the pile fibers. which are connected together or the underlying textile harmful affect.

The resin is preferably applied to the pile fibers in a liquid Form undiluted or as a solution, suspension or emulsion applied in a liquid medium such as water. Many suitable Resins are commercially available in the form of 30 to 50 weight percentages Emulsions in water are available that can be further diluted. The impregnation in liquid form can be easily by spraying, tapping, dipping or foaming

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accomplish an application roller. When the resin is applied as a solution, suspension or emulsion, that will liquid medium is then removed, for example by evaporation. Another application method is the resin Applied in molten form and then cooled.

The pile fabric can also be treated with materials other than the resin before or after the impregnation step, provided that this does not prevent the binding effect of the resin. The impregnation can be carried out in more than one stage if so desired. If , however, a catalyst is used to catalyze the polymerization or crosslinking of the resin, it is usually applied to the Plortextile at the same time as the impregnation of the resin. In another method of applying the resin to the pile fibers, the resin is formed in situ by reaction between two or more components after they have been applied to the fibers separately or, preferably, shortly after they have been mixed. One resin that can easily be applied in this way is a polyurethane resin, (also known as a polyisocyanate. Another method of impregnating the pile fibers is to apply the resin as a powder, which is then melted to bind the fibers.

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The resins used should preferably be deformable so far that the pliability property is not completely eliminated from the pile fabrics in the course of the process will. It has been shown that self-crosslinking Acrylic resins, especially those which contain a major proportion of units that differ from an acrylic ester derive and which contain minor proportions of units that differ from substituted acrylic acids and / or substituted AlkyIo! Acrylamide derive for the purposes of the present Process are particularly suitable. Examples of other suitable resins are polyvinyl alcohol and polyvinyl chloride. Other resins that can be used are elastomeric, natural, or synthetic resins. Additionally For example, the resin may conveniently be an insolubilized protein such as insolubilized gelatin. Applying a insolubilized protein is easily accomplished by impregnating the pile fabric with a protein and a hardening agent for the protein such as formaldehyde, a humectant to prevent it from becoming too severe Hardening of the protein and becoming too brittle is also preferably used.

The amount of resin used in relation to weight of the pile fabric depends on the special properties, that are desired in the end product. Although it is required

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is to use at least 5 wt .- $ resin based on the weight of the pile fabric, can also up to. $ 100> and even more resin can be used. In general, it can be said that the high Kengen resin used in floor coverings for industrial purposes and the improvement in the wear properties achieved for this purpose by increasing the resin content, especially the retention of the appearance, the resistance of the pliability and the durability of the floor coverings, outweighs the loss of grip and initial appearance. Normally, the resin amount in the range will be from about 15 to 100 wt .- $ W for industrial use. For purposes of use, at. for whom particularly high durability is not so important and good handle or good processability and appearance are desired, e.g. for residential purposes, the pile textiles are usually 5 to 40 wt .- ^, preferably 15 to 40 wt .- $, based on the Impregnated pile fabric weight.

The degree of bonding of adjacent pile fibers is influenced by the amount of resin applied. In general it can be said that the greater the degree of attachment, the greater the degree of attachment the product is more durable, but with an increasing degree of binding, the similarity of the product to a unbound carpet, decreasing. If larger amounts of resin -

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are used, it has been shown that contiguous Pile tufts can be connected to one another. The drying Also affects the degree of adhesion of adjacent pile tufts · It has been shown to be slow drying it enables a larger amount of resin to be used without too much loss of appearance due to pile tuft adhesion.

When the resin is applied to the pile fabric in liquid form In addition to the resin, other materials such as fillers, e.g. white clay or thermoplastic, can be present in the liquid Powders, dyes or pigments, · emollients, anti-wear agents, flame retardants or germicides may be present. If a filler is used, its amount will normally be in the area of e.g. 5% by weight, based on the fabric of the pile textile.

The appearance and the physical properties of the floor coverings according to the invention can optionally be changed considerably by inerting on the pile components, applies particulate materials and resins. The impregnation of the pile fabric with the resin can be carried out are applied before, after or at the same time as the particulate material in order to bond the pile fibers lying next to one another and the adhesion or sticking of the partial

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to effect cheniform material on the pile fibers. However, it is preferred that the particulate material on the pile fabric together with the resin, or less desirably prior to the application of the resin and not first is applied after the resin has been applied. The particles can adhere more strongly to the pile fibers after the preferred sequence of application.

The term "particulate material" includes particles which are preferably generally spherical in shape with the average maximum dimension in the range from about 0.25 to about 1.5 mm. Usually all particles are essentially the same size, but is this is not essential. If the particles are in a range of different diameters, the larger one should Proportion of the particles are preferably in the size range given above. The particulate material can be natural It can be of synthetic origin, e.g. sand, or it can be of synthetic origin, e.g. glass beads. Furthermore, this can Material can be any color desired, or it can be colorless. When the particulate material is reflective e.g. if there are glass beads or other small spheres, the products show a certain degree of reflection, which is unexpected in a pile textile. If, as usual,

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the particulate material is inorganic and hard the floors are very durable and show in general. increased fire resistance compared to similar ones Products »without the particulate material.

The amount of particulate material and resin can vary widely according to the properties of the impregnating agents and the treated pile fabric. Generally from about 2 to about 10 weight percent particulate matter Material with at least about 25% resin, preferably about 50 to 100 # resin, based on the weight of the pile fabric used.

The pile textile can also have other aspects besides the actual pile itself and the underlying textile. A resilient layer, for example made of foamed rubber or polyurethane foam, can be provided that

one of the two surfaces of the underground fabric or both adheres. The impregnated pile textiles can also be made before or subjected to mechanical treatments at the same time as binding by the resin, such treatment consists in the fact that the textile is zv / ischen. Heated calender rolls is guided to compress the pile and the To bind fibers at the same time .. The basic advantage of Flooring according to the invention is that they are cheaper

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can be produced in comparison to a large number of other floor coverings and that they are nevertheless extreme are permanent. Although they have the property of great durability, the resin-bonded ones keep Pile textiles according to the invention to a surprising extent the advantageous properties of the usual non-bonded carpets, especially the very * desirable property of thermal insulation and resilience. In addition, the floor coverings make no noise when walking.

The product according to the invention is essentially a floor covering, however, despite the use of the term "flooring", it is possible to use the resin-impregnated pile fabrics to be used anywhere other than on the floor. Especially they can be used as decorative wall coverings and if the products have been made waterproof by using a larger percentage of resin, they can also be used outdoors for decorative purposes, e.g. as wall or roof cladding materials. if the products of the invention for their main intended purpose Purpose, i.e. as floor coverings, they can be adapted or adapted in the usual way for carpets. be laid, or they can be adapted or laid in a similar way as is usual for slabs,

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by gluing the lower surfaces, the resin-impregnated pile textiles with a solid "base", e.g. made of wood or concrete. On the other hand, areas of the material, usually in the form of squares, can be glued in the same way are joined together like surfaces of a thin block Materials, e.g. hardboard or plywood, to produce laminated panels that are applied in the normal way or can be relocated.

The invention is illustrated by the following examples, in which percentages relate to the weight of the pile textile relate:

example 1

A pile fabric was made by a viscose rayon yarn was tufted through a jute fabric underground,

the tuft density was approximately 8 tufts per cm.

The tufted textile was impregnated with 25% of an approximately 40% strength by weight emulsion of a self-crosslinking acrylic resin. Thus the amount of resin applied was 10% by weight of the textile.

After drying the impregnated textile at 105-110 ° C The hardening of the resin was made by the textile

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sent through an oven at a temperature of 140-150 ° C. was with a residence time of about 3 minutes. The treated carpet could withstand wear tests much better survive as a sample of the same carpet that has not been resin treated.

Example 2

A rake carpet with a pile consisting of a mixture of viscose rayon and oellulose acetate fibers with a pile height of about 0.5 cm was treated with a self-crosslinking acrylic emulsion until 5 ^c /> pests were deposited on the carpet. After drying at 105 to 110 ° in an oven, the resin was cured by placing the impregnated textile between 2 heated plates at a temperature of 150 ° C. for 3 minutes. The pile height decreased to approximately 40 % during curing. In wear tests, the treated carpet performed particularly well compared to the branded product that was not treated according to the invention.

Example 3

A sample of the rake carpet described in Example 2 was impregnated with a self-crosslinking acrylic acrylic ion so that 94 % resin was applied to the carpet.

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The impregnated carpet was dried in an oven at 105 to 110 ° C, followed by curing of the resin in a heated oven at a temperature of 130 ° O iai ? half an hour. The pile tufts were bonded together in the carpet, which exhibited excellent durability, although the compliance was retained.

Example 4

The resin used in Example 5 was applied to a carpet with a pile containing the same sewn quantities of polyacrylic film staple fibers 15 denier at 6.3 cm fiber height and viscose rayon fibers 8 denier at 6.3 cm pile height. The carpet had a cut pile with a _{height of 9} 1/2 inches, which was formed from twisted yarn. The amount of emulsion applied to the carpet was such that after drying, $ 18 resin was deposited on it.

The drying of the carpet and the hardening of the fabric were carried out under the conditions described in Example 3. Side-by-side pile tufts were tied together in a carpet, which gave it excellent durability.

Example 5

The procedure of Example 4 "wuA-d © · repeated with the ab»

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softening that the impregnated carpet at 45 ° G slowly dried in an oven with no air circulation. In the product were those within the Pile tufts of adjacent fibers tied together, but adjacent tufts were not together related »This resulted in a carpet, its appearance was similar to an untreated carpet, but still had improved durability.

Example 6

A Markentuftteppich with a pile yarn comprising a mixture of viscose rayon and cellulose acetate, and the pile height was 0.5 cm approximately, was impregnated with a self-crosslinking acrylic resin emulsion so strong that 50 i> solids aif the carpet were deposited. The resin emulsion contained 50 grams of glass beads with an average diameter of about 0.75 µm per 100 grams of emulsion.

Impregnated carpet was tumbled to distribute the beads between the pile drifts, followed by drying the impregnated carpet at 105 to 110 ° G in an oven, while curing the resin by heating the carpet in an oven at about 150 for about 3 minutes ° G took place.

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In wear tests, the treated carpet showed opposite untreated marl products have very favorable properties. In addition, the flame resistance of the carpet was considerably increased.

Example 7

A carpet sample with a mesh pile made of viscose rayon yarn and with a weight of 0.95 kg / m 2 was impregnated by Sprayed with an aqueous emulsion of a terpolymer of butadiene, styrene and vinyl pyridine, so that 23.9 $ des elastomeric resin was deposited on the carpet.

The impregnated carpet was dried in an oven at 40 ° C; it was not necessary to use a higher temperature to obtain a non-sticky product. In the carpet adjacent pile fibers were bonded together and the material showed very favorable properties in the course of the durability tests against an untreated sample of the same carpet.

Example 8

The procedure of Example 7 was repeated except that as impregnating agent is an aqueous emulsion of a Gopolymeren was used "the 50 fo · styrene contained were 2O abgeiagort ₉ 5% resin on the carpet. . ■ '- 1.5 -

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The impregnated carpet was dried at 90 ° C and was then a non-tacky product with excellent durability compared to an untreated sample of the carpet. ,

Claims

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Claims (1)

1819204 Pat en t a η s ρ r ü c h e 1. Pile textile, thereby g e tea η η ζ e i c h net that the pile fibers with at least 5 wt .- $ resin, in particular with 15! to 10O GrewV- ^ resin, based on the wind of the Plortextile are bound to each other » 2. Covering according to claim i, characterized geke η η ζ eic " _: -h η et that the resin is an acrylic resin or an elastöraergs Resin is. ^: . ; ·. ■ "■ ...- ■■,. ^: ; - '" ■ _: 3. Covering according to claim 1 or 2, characterized in that g e Ic- e η η ze I h η e t that there is a susätslieh in the fluorine fibers particulate material, in particular glass beads or, grass beads are bound, 4. Covering according to claim 3> thereby ge k e η η ζ e 1 c h '■ -net that the parts hen jrörmige material makes up about 2 to about 10 S@w.- ^ of the f-lortextils. . - · ■ ·. \ Process for the production of a ■ Plortextils "." Häoh. "Claims bi @ 4s thereby g efc en / n ζ e ie h _ae t _P ; d © S. Man. the pile fibers, a pile textile with at least 5 wt .- # Resin, in particular with 15 to 100 wt. ~ $ Hara ,, related on the weight of the pile textile, impregnated and the Adjacent pile fibers, which carry the hara, binds together. Si method according to claim 5 »characterized in that the resin is applied to the pile fibers as a solution, suspension or emulsion of the resin in a liquid medium. 7. The method according to claim 5 or 6, characterized in that g e k e η η. draw t. that an acrylic resin or an elastomeric Hara is used as the resin. 8 «, method according to claim 5 to 7, characterized in that one prior to the mutual gluing the adjacent pile fibers that make up the resin and carry the particulate material, etchingly a particulate Material, especially glass beads on the impregnated pile textile. 9 · Method according to claim 8, characterized in that: gek-.e-nnzeich net that about 2 to 10% by weight of particulate material, weighed on the weight of the pile fabric, on the Pile textile applies. - 18 - BATH 18192O k 10. Terfehreii to. Ms claim 5 9, characterized ge ken η ζ eic h net that a mechanical treatment exposing the impregnated Moctextil before or simultaneously with the binding of the Harsses. - 19 -