DE2011335A1 - Pile fabric - Google Patents

Description

Dr. F. Zumsteln sen. - Dr. E. Assmann Dr. R. Koenigsbergor - Dipl. Phys. R. Holzhauer

Dr. F. Zumstein jun. Patent attorneys

8 Munich 2, Bräuhausstraße 4 / III

Case 12533/69

S.A. COTEXMA N.V., Kuurne (Kortrijk) / Belgium

Pile fabric

The present invention relates to new pile fabrics and a Process for their manufacture.

Many suggestions have been made in recent years that relate to the manufacture of non-woven pile fabrics, wherein needle procedures in particular were used. For example, a pile fabric has been proposed in which tufts of fibers on a fibrous layer are attached and which normally consist of stick out of this layer. The fibrous layer can be desired cn ta I have a rubber base layer, especially if it is to be used as carpet material. However generally create the tufts of fibers in these pile fabrics not a dense pile to ensure that the fibers are sufficiently resistant to wear and tear are. As a result of this, and as a result of repeated wear and tear, the tufts of fibers are flattened and the fabric will lose its pile effect.

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BATH

According to a further known proposal, a fiber layer is needled through a carrier fabric, whereby the needled Tufts of threads form that protrude from the carrier fabric. The tufts are then in a substantially fixed perpendicular position to the carrier fabric, which is then peeled off from the fiber layer. Fixing the tufts of fibers can be accomplished by heat treatment or by appropriate chemical treatment. However, suffers this method has the disadvantage that the fibers often have different lengths and are often not fixed firmly enough. Farther If the pile fabric is used as a carpet material, the tufts of fibers tend to be deformed during use and to be ripped out of the tissue.

According to another known proposal, a composition is comprising layers of fibers located on and between woven fabrics, needled using a needle with barbs and with one of the woven fabrics after-. is deducted in the following.

It has also been proposed to produce pile fabric by passing a fiber material through a waxy or plastic film needles and then the film is heated in order to cement the resulting tufts of fibers together.

The present invention is based on the discovery that new pile fabrics with good wear qualities can be made in a needle-punching process using a peelable layer of, for example, felt to ensure that the fibers which make up the pile of the resulting fabric are essentially are mounted perpendicular to the thread layer to be _t and wherein the fibers in the produced pile fabric firmly in a base layer fixed.

According to one embodiment of the present invention, a pile fabric is provided which comprises a layer of fibrous material

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and a base layer bonded thereto, the fibers from the layer of fiber material being needled through the base layer and extending substantially perpendicularly the surface of the base layer from the layer of fiber material starting extend, thereby forming a pile will.

According to the present invention there is also provided a method of making pile fabrics, thereby characterized in that 1) a structure is needled which comprises a) a layer of fiber material, b) a base layer and c) comprises a peelable layer adjacent the base layer, whereby fibers from the layer of fibrous material in the base layer and the strippable layer are needled with a substantial number of the needled fibers being the strippable Penetrate layer; 2) the needled structure of a treatment submits, which serves to pull the needled fibers into attach the base layer and bond the layer of fiber material to the base layer, and 3) the peelable Separating the layer from the base layer to produce a pile fabric, in which the needled fibers protrude essentially perpendicularly from the surface of the base layer.

The layer of fibrous material can be made of any desired natural or synthetic fibers, such as polyamide or acrylic or polypropylene fibers, which if desired be crimped and / or colored can. -

• It should be noted that, during step 1) of the invention Process is always the first step of the process, stages 2) and 3) are interchangeable in order, although it is generally preferred that stage 2) to be carried out before step 3).

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However, if necessary, the needled fibers can be placed can also be effected in the absence of a layer e.g. the peelable layer can be formed by brushing on attached to a cylinder, e.g. on a floating ge * - stored support plate of a device for needling, the floating support plate in the form of a cylinder is formed (which generally has a high density and is made of metal), the peripheral thereof Surface carries a plurality of brushes that essentially cover this surface. The height of the brush pile is generally greater than the depth to which the needles penetrate during the needling process.

The mentioned base layers and removable layers are advantageously composed of a felt material, if desired through a cloth or another woven fabric Material, e.g. made of synthetic fibers or strands of polyethylene or polypropylene, can be reinforced. The above-mentioned cloth or other woven material can be used, if desired instead of the felt material can be used as the base layer, especially if a pile fabric in the form of a velvety Material is desired. The cloth or the like woven material used in the base layer is preferable woven relatively tightly to prevent the needled apart from pushing apart Prevent fibers from becoming ranks.

Alternatively, the base layer used in the method of the present invention may comprise a loosely woven cloth that is placed in front of the Contact with the fiber material layer was needled.

In order to facilitate the removal of the peelable layer from the base layer in the method according to the invention, the peelable layer, preferably in the form of a pile-like material, in particular as a permanent, tightly tufted material, and is preferably made of relatively soft fibers. built as if made of polyolefin fibers. On the other hand, the upper

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surface of the peelable layer .with adjacent to the base coat a suitable lubricant be impregnated, for ^example: to facilitate a Seif.enemul.sidn or diluted detergent to the separation of said surface of the base layer. ·.

That used in the base layer and / or peelable layer (s) Cloth or similar woven material can, if desired, be covered by a layer of synthetic plastic or Foam material to be replaced.

The as peelable layers and / or base layers in the Felt materials used in the method according to the invention can be largely impregnated or on one odex on both sides be coated with natural or synthetic latices or other binding materials. The felt materials can be the same or different and their physical and / or chemical properties differ. Similarly, the base layer and the fiber layer can die show the same or a different color to form a pattern on the final pile fabric.

The cloth or similar woven material that makes up the base layer reinforced, preferably at or near the surface of this layer adjacent to the fiber layer. However, the cloth or similar woven material that the strippable layer is reinforced, preferably attached at or on the surface of this layer, that of the base layer removed to avoid unnecessary damage to the Reinforce-G2n Cloth se v.'ähxenG des Mauel — Voiyäiiys ixi ueii ·. tjj-XXniiLuMj ^^^ ii ^ Btiri Procedure to avoid. .

According to the method of the invention, the laminated composition subjected to a treatment, after needling, to set the needled fibers in the base layer. These Treatment can be effected in any conventional manner, e.g. by applying an adhesive or potentially adhesive

009839/152 2

BAD ORiGiNAL ^;

benden back cover layer on the fiber layer. D / .ese back cover layer can be applied, for example, with the aid of a doctor blade or an applicator roller or by spraying on the top composition on the fiber layer. Binders or adhesives that can be used in the backsheet natural or synthetic rubber latex optionally filled with fillers and thermoplastic synthetic Resins such as soft polyvinyl acetate, polyvinyl chloride plastisols etc. and other binders commonly used in finishing textiles. The binder can be applied together with a humectant if desired.

After applying the backing layer, the resulting composition can e.g. be passed through a pair of nip rollers, to facilitate penetration of the adhesive component of the backsheet into the composition and to provide a to ensure a tight fit of the needled fibers of the composition. The needled fibers can finally go through e.g. Heat treating the composition including the backsheet. This heat treatment can be carried out by putting the composition through a drying oven leads, the drying being effected e.g. by infrared radiation.

To create pile fabrics that have a sufficiently dense pile, can, if desired, the needling in the method according to the invention repeated until a pile of the desired density is obtained.

In this case, the initially needled laminated composition becomes preferably introduced into a closed circuit so that they are periodically needle punched with the laminated composition conveniently being passed around the backing plate of the device, which is used for the needle operation. These repeated needling operations are generally applied to the laminated assembly.

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Setting applied before the needled composition is treated is used to set the fibers, however, if desired, the needled composition can be temporary or permanent be tightened after each needle operation. After the last needling process, the resulting composition finally bound and the peelable layer removed. E.g. it can be peeled off the composition, and the deep-needled side of the felt on the base can then be added a binder that is used to bind the piece of fabric finished, coated or sprayed.

Generally, if more than one needle operation is performed Apply a new layer of fibrous material to the existing layer or layers of fibrous material before each needling operation Material applied. The fiber layers can be identical or different. E.g. consecutive Layers of fiber material of different colors and / or Fibers are used to create a pattern on the resulting pile fabrics.

The needle board structure for each needling process is advantageously adapted to ensure that needle no structures in the pile of the fabrics according to the invention are visible. This can be achieved by appropriately adjusting the feed rate per cycle of each needle operation.

The height of the pile in the fabrics produced according to the invention is generally at least in the range of 4 to 12 mm. Relief effects on the resulting pile fabrics can can be achieved by changing the barb penetration the fiber layer into the peelable layer.

With regard to the needle operation, the term "barb penetration" is used used herein to mean the depth of the first barb of the needles display, measured below the surface

009839/1522 - **> ■ ·: .--

the backing plate of the device for needling. The barb penetration in the method according to the invention preferably does not exceed the thickness which is formed by the peelable Layer and the base layer in order to avoid difficulty in separating the former layer.

The backing plate of the device used for needling, which is used in the method according to the invention, can conveniently a grooved backing board containing rows of grooves, such as in the "burr tufting" process uses v / ird. The position of the needles in the needle board of the needle device depends on the arrangement the rows of grooves in the base plate.

The peelable layer that is removed, e.g., peeled off, from the needled composition in the present invention Process can generally be reused in a subsequent operation as a preliminary one Layer or as a base layer, e.g. in a continuous process, with the preliminary layer in a closed Is circulated and thereby used in a plurality of needle operations. After removing the preliminary Layer, the pile fabric produced can be cut and trimmed and wound onto a roll for storage will etc.

According to a further object of the present invention, a modification of the method according to the invention is provided, which consists in 1) needling a structure which is a) a layer of pre-sewn felt or loosely woven Fabric and b) a peelable layer whereby fibers from the felt or loosely woven cloth into the peelable Layer to be needled; 2) subjecting the needled composition to a treatment intended to remove the needled To attach fibers in the first mentioned layer, and 3) peel the peelable layer from the first mentioned layer, to form a pile fabric.

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On the other hand, according to a further modification of the inventive method, the fiber layer to be replaced _for d, the base layer by a conventional layer of a material provided with threads and wherein one then carries out the inventive method using the resulting • composition. The threads of the threaded material are needled or tufted through a base layer of felt or cloth into the strippable layer and then coated, the strippable layer subsequently being removed, resulting in a cloth with a surface of loops.

If the pile fabrics according to the invention are to be used as carpet materials, they are preferably with a or several base layers of a relatively heavy base material, e.g. rubber, to provide a solid and to create a robust base for the material.

In general, the Florgev.-ebe according to the invention as Carpet materials or as fabrics for covering walls, for upholstery or for furnishing fabrics. These fabrics have a soft, springy pile, and yet are quite resistant to wear and tear. if If materials of relatively low density are used, the resulting pile fabric becomes a velvety material resemble.

For a better understanding of the present invention will be certain preferred embodiments of the method according to the invention are described with reference to the accompanying drawings, wherein:

1 and 4 to 6 show preferred embodiments of the method according to the invention,

Fig. 2 shows a cross section of a pile fabric according to the invention and, *

009 8 3 9 / Ί 5 2 2

FIG. 3 shows a cross-section of a deep-needled felt used in the method illustrated in FIG. 4.

With respect to the method shown in Fig. 1, a base layer 2, which is reinforced by a cloth 4, and a peelable layer 1, reinforced by a cloth 3, created with a layer of a fiber material 5. The laminated Composition is needled in a device for needling 6, and a coating 7 is subsequently applied to the back applied to the fiber layer of the needled composition. The backing coat is then dried by the composition is passed through a drying oven 8 to fix the needled fibers and the preliminary layer is pulled off and wound on a spool 9, while the resulting pile fabric 11 is on a separate roll 10 for the Storage is wound up. Fig. 2 shows a cross section of the pile fabric obtained. Referring to FIG. 4, a deep-needled felt 12 initially produced, as shown in Fig. 3, by needling a fiber layer 13 with a reinforcing Cloth 14 and is then brought into contact with a peelable layer 15, upon which the laminated composition in a device 16 for needling. The method is then carried out as shown in FIG.

As shown in Fig. 5, a cloth layer 18 and a fine peelable layer 19 of felt is provided with a layer of fibrous material 17, and the laminated composition is made needled in a needle device. The sewn composition is then covered with a top coat with the aid of a spray device 20 and passed through two nip rollers 21. The method is then carried out further, as explained in FIG.

In FIG. 6, the method of FIG. 1 is carried out using an endless felt belt 23 as a peelable layer.

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BATH

- li -

The following examples further illustrate the invention.

example 1

A fiber layer of crimped 22 dtex 60 mm fibers of dyed, fresh 100 g / m ² polyamide 66 is applied to an endless feed cloth with the help of a carding device and then a camel back folder, whereupon two needle-punched mushrooms lie crimped 17-dtex approx. 80 mm fibers of 300 g / m tear nylon are formed; these felts, which can be colored in the same or a little different color from the first-mentioned layer, are provided with a

2
pre-stabilized 80 g / m polypropylene cloth Reinforced and bonded with 7 to 10 % of a self-crosslinking elastic acrylic latex. The layer of felt that is adjacent to the feeder sheet is hereinafter referred to as the "peelable felt layer", while the layer of felt that is adjacent to the fiber layer is referred to as the "base felt layer" The feed sheet is applied while the base felt layer is applied to the peelable layer with the reinforcing sheet facing up.

fr

This layer composition is used in a needling process subjected to a classic needle device with a barb penetration depth of 2 mm with closely spaced barb needles the needle size 32 (normal gauge), which contains 2400 needles per right, whereby the feed is 3.3 mm, who darcn

the composition has 72 stitches per cm.

The needled laminated composition then becomes second and subjected to third needling operations after applying the second and third fiber layers to the. first mentioned fiber layer.

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6ADORIGfNAL

The three fiber layers, which make a total of 300 g / m 2, contain fibers that pass through the base layer into the peelable Penetrate felt layer and are oriented essentially perpendicular to the fiber layers. The reinforced laminated composition is applied to the outer fiber layer with a clay-filled vulcanized natural latex on a doctor blade coating machine coated to have an undercoat

2
a dry weight of 750 g / m. Penetration of the latex into the composition during dipping is controlled to ensure that the latex penetrates to the reinforcing cloth of the base felt layer and, if desired, a little further. The cover is dried and vulcanized to secure a firm bond at the base of all tufts of fibers and to provide improved bonding of the base felt layer to the reinforcing fabric and to hold the needled fibers substantially perpendicular to the reinforcing fabric of the base felt layer.

If desired, a foamed natural latex composition can

2
Tung in an amount of 600 g / m 2 can be applied to the underlayer cover and pressed in in the shape of a weapon, whereby this cover gives the carpet an anti-slip effect.

To allow easy removal of the removable felt layer after To secure the application of the backing, a soapy solution is applied evenly to the surface of the peelable felt layer distributed.

After standing for 2 to 3 minutes, the peelable Layer of film lightly between two rollers of the base layer removed, creating a dense material similar to Wilton carpets. While the peelable Layer is wound on a drum, becomes the carpet material trimmed and wound on a drum. This carpet material has a total weight of 2030 g / m and

2
comprises 300 g / m fiber tufts at a height of 6 mm, a base layer

2
of 380 g / m with a thickness of 3 mm and a back side

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ρ
layer of 1350 g / m.

Example 2 '

A deep-needled felt 12, as shown in Fig. 3,

which is composed of a layer that weighs 400 g / m: and consists of dyed, torn, lightly crimped acxyl fibers of 15 denier + 80 mm, is made with a needle device with even barbed needles of 'size 32

on a 80 g / m polypropylene sheet 14 with a barb penetration depth of 9 mm needled. The "needled composition." is then on a peelable felt layer 15γ as described in example!., turned over and a needle operation (16) subjected to the same execution as in Example 1, with the exception that the feed per pass is reduced to 2 mm will. The laminated composition obtained is coated with a pure acrylic emulsion in an amount equal to Corresponds to 200 g / m. After drying and removing the preliminary felt layer will be the edges of the resulting "acrylic pile fabric." circumcised. This pile fabric is soft and light

2
(680 g / m) and can be used, for example, as a material for upholstering chairs. The peelable felt layer can be reused for the same purpose in a subsequent operation.

Example 3

The procedure as described in Example 2 is repeated with the exception that a layer of dyed garnetted, lightly crimped polyamide 6 fibers of 17 dtex - ~ s J ~ ci pr \ __ T ^ ---.- *,. «Ν-, ..-—, α ^ .4- ... 4 w ^ q ^«>. 4 · />1; 1η ^ J / ^ v- C ~ K ■? >-V> 4- ιγαπ

Mill ι π ο IC> vy Mill ι .ln-iiii.Jtr: Wt ^ J- w ι ·) jm.i. wv i »- vt t.» ! 1 »-3 ** - vr_a_ J ^. ti. . v * \ - a, »^» - »*. * - ν- λ * » - »on

Acrylic fibers. After the first needling process, another

2
Layer of 200 g / m 2 of the same fibers applied to the composition obtained and in a similar one. As described in Example 2, needled. A back coating of butadiene-styrene latex with fillers with a

2
Dry weight of 1200 g / m is applied to the last needled layer, followed by the application of a jute

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SAD ORIGINAL

2
fabric that weighs 255 g / m to give the pile fabric dimensional stability.

The peelable felt layer is then peeled off and wound onto a drum for reuse if necessary. The carpet material is then trimmed. If the garnetted fibers used are not of the same length, the pile fabric can advantageously be sheared.

Example 4

A layer 17, as shown in Fig. 5, composed of colored 10 dtex acrylic staple fibers of 40 mm length and one

Composed weight of 80 g / m and which had been produced by laying down by means of air flow, is colored on

2 twisted cotton fabric 18 of 80 g / m applied to the a peelable acrylic-bonded felt layer 19 rests made of multicolored 12-denier polypropylene crimped fibers of 80 mm

2
Length and a weight of 300 g / m, and is needled onto a polyethylene film 0.07 mm thick. The composition is then needled with a size 36 barbed needles at a feed of 4 mm and a barb penetration depth of 1 mm. The needled surface of the composition is then sprayed with a soft crosslinking acrylic binder (in an amount equivalent to 30 g / m 2) containing a humectant, and the sprayed composition is passed between two squeegees 21 and then dried by infrared heaters. Another fabric of the same fiber is placed on the coated surface of the ^ usamnipr) <5 <= f7, and needled again with the same device, but with a different feed, in order to avoid patterns on the needle board. ι

Another spray treatment with the same amount of the spray composition is applied, dried and cured as described above. The peelable felt layer 19 is then * ^J (using an "airlaid doffing card")

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8AD ORIGINAL

withdrawn and, if desired, reused for the same purpose in a further operation. The pile fabric obtained is trimmed and is in the form of a velvety material that is used as a material for wall coverings, for covering
Mobein or can be used for upholstery. .

0 0 9839/1 52 ^ 2. ;

Claims (1)

Claims Pile fabric, characterized in that there is a layer of fiber material and a base layer bonded to it , wherein the fibers are needled from the layer of fiber material through the base layer and extend substantially perpendicularly from the surface of the base layer that is not adjacent to the fiber layer adjoins, creating a pile. 2.) pile fabric according to claim 1, characterized in that the base layer is composed of a felt material. 3.) pile fabric according to claim 2, characterized in that the felt material is woven by a cloth or another Material is reinforced. 4.) pile fabric according to claim 3, characterized in that the felt material is woven by a cloth or another Material is reinforced, which is located adjacent to the layer of fiber material. 5.) pile fabric according to claim 1, characterized in that the base layer is composed of a cloth or other woven material. 6.) pile fabric according to claim 3 to 5, characterized in that the cloth or the other woven material made of synthetic Fibers or strands is formed. 7.) pile fabric according to claim 6, characterized in that the cloth or the other woven material made of polyethylene or Polypropylene fibers or strands is formed. 009839/1522 8.) pile fabric according to one of the preceding claims, characterized characterized in that the layer of fiber material consists of polyamide, acrylic or polypropylene fibers. 9.) pile fabric according to one of the preceding claims, characterized characterized in that at least one further layer of fiber material is bonded on the side of the layer of fiber material which faces away from the base layer is, with fibers of this further layer of fiber material also through the base layer and the adjacent Layer of fiber material are needled and essentially extend perpendicularly from the surface of the base layer, thereby forming a pile. 10 ·) pile fabric according to one of the preceding claims, characterized characterized in that the fibers of the fiber layer or fiber layers in the base layer are bound with the aid a thermoplastic resin. 11.) pile fabric according to one of the preceding claims, characterized characterized in that it comprises a backing layer bonded to the surface of the layer of fibrous material facing away from the base layer. 12.) pile fabric according to claim 11, characterized in that the back layer is made of natural or synthetic rubber. 13.) pile fabric according to one of the preceding claims,., Characterized marked * that the height of the pile from the base layer is about 4 to 12 mm. •. 14) A process for the production of pile fabrics, characterized in that) a structure, needling 1 a) one layer of fiber material, b) a base layer, and c) a peelable layer adjacent to the base layer, 00983 9/15 22 BAOORiGINAL whereby fibers are needled from the layer of fiber material into the base layer and the peelable layer, whereby a substantial number of the needled fibers penetrate the peelable layer; 2) the needled structure subjected to a treatment that serves to fix the needled fibers in the base layer, and this Bonding layer of fiber material to the base layer and 3) peeling off the peelable layer from the base layer, to create a pile fabric, the needled fibers emerge essentially vertically from the surface of the base layer. 15.) The method according to claim 14, characterized in that the base layer is one of the claims 2 to 7 defined is. 16.) The method according to claim 14, characterized in that the base layer is a pre-needled loosely woven cloth. 17.) The method according to claim 14 to 16, characterized in that that the layer of fibrous material is as defined in claim 8. 18.) The method according to claim 14 to 17, characterized in that that the peelable layer consists of a felt material. 19.) Method according to claim 18, characterized in that the felt material is covered by a cloth or another woven material is reinforced. 20.) Method according to claim 19, characterized in that the felt material is covered by a cloth or another woven material that is attached to or near the surface of the strippable layer remote from the base layer is. 009839/1522 ■ * '20 Π 335 21.) Method according to claim 14 to 17, characterized in that that the peelable layer of the laminated composition consists of a cloth or other woven material. 22.) Method according to one of claims 19 to 21, characterized in that that the cloth or other woven material of the peelable layer of synthetic fibers or Strands. 23.) The method according to claim 22, characterized in that the Cloth or other woven material made of polyethylene or Consists of polypropylene fibers or strands. 24.) Method according to one of claims 14 to 17, characterized in that that the peelable layer of the laminated composition is formed by brushing on a Cylinders are attached, the strippable layer being separated from the base layer before the fibers are in the Base layer binds. 25 ·) Method according to claim 24, characterized in that the peelable layer is formed by the floating support plate of a device for needling or through a grooved backing plate of a device for needling. 26.) The method according to any one of claims 14 to 25, characterized in that that the treatment of the needled laminated composition acts to bind the needled fibers is achieved by applying an adhesive or potentially adhesive backing layer to the layer of fiber material, if desired accompanied by a subsequent hit Treatment of the applied backing layer in order to bind the needled fibers. 27.) Statute of limitations according to claim 26, characterized in that the treatment of the needled laminated composition 0 0 9 8 3 9/1522 201133 is effected by one on the layer of fiber material applies a back cover layer made of a natural or synthetic rubber latex, soft polyvinyl acetate or a polyvinyl chloride plastisol. 28.) The method according to claim 26, characterized in that the back cover layer is applied by spraying. 29.) The method according to any one of claims 14 to 28, characterized in that the resulting pile fabric at least
is subjected to a further needle operation, each operation consisting in that the side of the resulting pile fabric, iie away from the pile, is contacted with a further layer of fiber material, the resulting composition is needled in order to increase the density of the pile
increase, and subjecting the needled composition to a treatment designed to keep the needled fibers in the
To bind base fabric permanently or temporarily. 30.) Modification of the method according to claim 14, characterized in that 1) needling a structure made up of a) a layer of pre-needled felt or loosely woven cloth and b) consists of a peelable layer, whereby fibers from the felt or the loosely woven cloth into the peelable layer needling; 2) subjecting the needled composition to a treatment intended to remove the needled fibers in the first mentioned. Layer to bond, and 3) peel off the peelable layer from the first-mentioned layer to a Form pile fabric. 31.) Method according to one of claims 14 to 30, characterized in that that a backing layer is applied and connected to the side of the resulting pile fabric, facing away from the pile. 32.) pile fabric, produced by a method according to the claims 14 to 31. 009839/1522