DE2527582A1 - Composite floor- or wall-cover - contg non-woven hydrophobic top layer, hydrophilic intermediate- and hydrophobic bottom layer - Google Patents

Abstract

Impregnated composite material, contg. >=1 cover-layer of non-woven fabric needle with >=1 bottom-layer of non-woven- and/or woven fabric, consists of a non-woven fabric top layer esp. of water-repellent fibres and a lower stratum of esp. water-repellent fibres, with an intermediate pre-bonded non-woven fabric, esp. of hydrophilic fibres, e.g. cellulose fibres. Material has improved opaqueness and higher strength and tread-resistance. Absorbency of intermediate layer improves printing.

Description

Composite material, in particular for floor or wall coverings.

The present invention relates to an impregnated composite, in particular for floor coverings, with at least one non-woven cover layer and at least a further nonwoven and / or woven or knitted layer as a lower layer, which with each other are needled; The invention also relates to a method of production such a composite.

It is already known to use in the manufacture of composites at least one top layer and a lower layer of synthetic fiber waste for to use the underlayer; because such, generally colored synthetic fiber waste are cheap, the manufacturing price can be reduced.

However, in order to show through or bleed through the color of the brightly colored To prevent synthetic fibers of the lower layer by the cover fleece layer as much as possible, Such a composite must generally have a relatively thick nonwoven facing layer are manufactured, whereby the manufacturing costs are still relatively high are.

There are also known composites for floor coverings in which a fleece layer is needled with another fleece layer. The one through the needling The combined layers are further solidified by impregnation with a binder (saturated or impregnated on one side). This is done by for a better shelf life Impregnation of the floor covering with the plastic binder is necessary first the textile character of the covering surface changes. Even will through the impregnation, the elasticity originally inherent in the fibers the binder is noticeably suppressed.

As a result, such a floor covering is, for example, much stiffer as a merely woven, needled or otherwise manufactured floor covering, which has no plastic impregnation.

It is an object of the present invention to provide a composite of To create the type mentioned at the beginning, in which the above-mentioned disadvantages are avoided are. In particular, the invention aims to provide a composite which on the one hand, an improved opacity, particularly good in the case of a floor covering mechanical properties, especially with regard to walking, as well as high resistance to treading having; on the other hand, the composite according to the invention should also be produced cheaply can be.

The composite according to the invention of the type mentioned is characterized in that between the non-woven cover layer of preferably hydrophobic Fibers and the lower layer of preferably hydrophobic fibers a pre-bonded Fleece as an intermediate layer, preferably made of hydrophilic fibers, for example cellulose fibers, is provided. Under a pre-bonded fleece there is one after any known nonwoven bonding processes - such as fusing or gluing - and not understood fleece bound by mere needling; for example, a corrugated fleece can also be used or paper, especially long-fiber paper, for the intermediate layer be used.

The composite according to the invention can thereby preferably be hagetellt that first the lower layer, the pre-bonded intermediate layer and the non-woven cover layer are connected to each other by needles, after which the composite material treated or impregnated with aqueous synthetic resin dispersions or solutions and finally - is squeezed off - for example by passing it through between two rollers.

If the intermediate layer is made of hydrophilic synthetic fibers, can have a high concentration of the binding agent or impregnating agent in the intermediate layer also obtained after squeezing the composite; on the other hand remains when using hydrophobic synthetic fibers for the outer fleece layers, little binding agent or impregnating agents in these fleece layers. This allows a regarding inspection elastic and soft flooring can be obtained, but still a high has mechanical strength and, in particular, high resistance to treading. as hydrophobic fibers are particularly suitable synthetic fibers made of polyamide, polyester, Polyacrylic or polyolefins. For the production of the underlayer it is useful used cheap synthetic fiber waste.

The intermediate layer made from a pre-bonded fleece, for example from Cellulose fibers, especially rayon fibers, or else - for example for use of the composite according to the invention as wall covering - also made of polyamide fibers, prevents the color of the synthetic fiber waste from showing through, which can be used for the manufacture of the underlayer as the fibers not so when the three layers or plies are needled despite the same level of consolidation need to be deeply needled7; for this it is essential that the intermediate layer fleece impregnated or otherwise consolidated or pre-bonded, since then the fibers of the intermediate fleece practically remain in the horizontal position during the needling process and practically no fibers of this intermediate fleece are drawn into the lower layer will. It is therefore possible to provide a relatively thin top or cover fleece layer. This makes the production costs of such a composite considerable reduced, since the - relatively thin - intermediate layer, for example, made of cellulose fibers is already cheap from the material or from the production, while the production the lower layer due to the possibility of using synthetic fiber waste is cheaper.

The non-woven cover layer is generally white or, for example, uni-colored - printed; It is therefore advantageous if the intermediate layer is made of white fibers or but consists of fibers dyed according to the non-woven cover layer, so that the strength the non-woven cover layer can be further reduced. During the printing process, the intermediate layer acts if it is made of hydrophilic fibers, it is also absorbent and thus increases the security in complicated printing processes, for example with one on top of the other Colours. The intermediate layer fleece also enables concentrated storage of chemicals just below the surface and favors the moisture balance of the top layer or step surface, due to the hydrophilic fiber (antistatic property).

The composite of the present invention can further be used if so desired will be refined on its surface by embossing, etc., the embossing can for example be applied cold or hot by calendering; however, it can can also be embossed in the HF field. It is also possible by training in layers to provide any color patterns for the non-woven cover layer, for example by streaky ones or the like. Formation of the cover fleece layer.

In the formation of the composite material according to the invention as a wall covering material allows the fleece intermediate layer, which is then preferably made of polyamide fiber is, an extremely thin top or cover fleece layer, for example also made of polyamide fibers. The intermediate layer made of polyamide fibers can be used during the printing process be printed through the cover fleece layer with the same authenticity.

The following examples serve to further illustrate the invention, but without this being restricted to this.

Example 1 1: A cover fleece or tread layer made of white polyamide fibers with 300 to 350 g / m2 is made with an underlayer of colored polyester fiber waste with 300 to 350 g / m2 with a white cellulose fleece of 50 g / m2 in between by Needles connected. The composite material thus obtained is then coated with an acrylic resin dispersion Impregnated as a binder on both sides and squeezed between two rollers, whereby a high concentration of the binder in the hydrophilic cellulose fleece intermediate layer and with it a good binding of the needled fibers and also an intimate anchoring of the fibers of the nonwoven layer introduced into the intermediate layer in the 7th eye of the needling is obtained. Compared to comparable 7-layer composites for floor coverings a weight saving of approx. 100 g / m2 in the - expensive - white Top layer achieved, although the color of the lower layer is not on the surface hits through.

e i s p i e 1 1 In a manner similar to Example 1, a composite from a cover fleece layer made of white polyamide fibers with 250 g / m², an intermediate layer from a pre-bonded white cellular wool fleece with 100 gim and from a lower layer made of colored acrylic fiber regenerated with 350 g / m². This composite too has good strength and a textile surface, but, though Even less material is used for the white top layer, a strike through the color of the underlayer is prevented.

Just like the composite according to Example 1, this composite can can then be printed.

B e i s v e 3 3: A melé-gold colored cover fleece made of polyami @@ asern with 250 g / m2, a melé-gold colored Cellulose fleece intermediate layer with 100 g / m2 and a bottom layer of colored polyester fibers (new disposal) with 350 g / m2 needled; the composite obtained is impregnated and squeezed, after which the impregnating agent or binding agent is crosslinked. Here, too, there is an optical strike through of the colored fiber material of the lower layer to the surface prevents and a uniform Melé-gold-colored tint of the surface of the floor covering or composite material obtain.

B e i s p i e 1 4: For the production of composite materials for wall coverings different cover layers of nylon fibers in the range from 160 to 200 g / m², 7 to 15 denier, with a full bath-impregnated longitudinal fleece in between from nylon fibers with 50 g / m 4 to 7 den, with an underlayer of white or colored Polyester fibers (original or regenerated) with 200 g / m2, 6 to 12 den, through needles connected and then solidified by impregnation. The composites obtained showed a good opacity despite the thin cover fleece layer.

EXAMPLE 1 5: In a manner similar to Example 4, composites are made Manufactured for wall coverings, however, for the intermediate layer or separating layer a pre-bonded cellulose fleece, again with 50 g / m2, is used. Here too inter alia, a through n the coloring of the underlayer to the surface is effectively prevented.

Example 1 6: similar to example 4 and 5, a composite material is used made of a polyamide cover layer with 200 g / m2 and an underlayer made of colored Polyester fibers with 200 g / m2, but with a separating layer of three layers of 16 g-tissue paper as an intermediate layer. In addition to showing good opacity This composite also has a surface with a textile character and a good one Strength.

Claims (4)

P a t e n t a n s p r ü c h e e Impregnated composite, especially for floor coverings, where at least one cover fleece layer with at least one further fleece and / or fabric or knitted layer is needled as a lower layer, characterized in that between the top layer of preferably hydrophobic fibers and the bottom layer preferably hydrophobic fibers, a pre-bonded fleece as an intermediate layer, preferably made of hydrophilic fibers, for example cellulose fibers, is provided. 2. Composite according to claim 1, characterized in that the intermediate layer consists of white fibers. 3. Composite according to claim 1, characterized in that the intermediate layer consists of fibers dyed according to the non-woven cover layer. 4. A method for producing a composite according to claim 1, characterized in that initially the underlayer, the intermediate layer and the Cover fleece layer are connected to each other by needles, after which the so obtained Composite treated with an impregnating agent or binding agent and finally is squeezed, with a higher Concentration of the impregnating agent or binder in the intermediate layer than in the top layer and in the lower layer is brought about.