EP0073919B1 - Use of a laminated flat article as textile material - Google Patents

Abstract

1. The use as a textile material of a laminated flat article with an upper layer (2) containing fibres or filaments, with an inner layer (5) of granular particles (6) of at least one non-reactive mineral material and with a supporting layer (3), the upper layer (2) and the supporting layer (3) being needled together through the inner layer (5).

Description

The invention relates to the use of a flat laminate with an upper layer containing fibers or filaments.

In the case of a laminate body known from NL-A-7 212 202, two cover layers are needled to one another through a granular filler layer. The filler particles must consist of a mass which as such has no defined shape so that it can be penetrated when needling. In this known laminate synthetic foams are used as advantageous fillers, which are characterized in particular by their light weight. The use of these known laminates is limited to the properties of the fillers used.

Carpets are also known in which loose fiber material is needle-punched from edge strips produced during production between a base layer and an upper layer.

The invention has for its object to provide a flat laminate for textile applications, which is heavier than the known laminates and which should allow a versatile, unrestricted use by the filler.

The priority European patent application number 82106 681 8 (publication number 0071 212) is intended to protect a mat-shaped layer body with a cover layer made of a fiber and filament fleece, an underlay layer and a particle layer made of granular particles arranged between these layers, in which the particles pass through individual or tufts of holding fibers are held, which are needled distributed over the surface of the laminated body through the particle layer and connect the cover layer and the underlayer to one another. The particles consist of mineral, inert material, in particular of inert rock particles, such as. B. sand, gravel or the like, and have a hardness that makes them indestructible when needling. In addition to these particles made of at least one mineral, inert material, further particles may be present.

It has now been found that, in order to achieve this object, such a laminate to be protected by European patent application number 82106 681 8 (publication number 0 071 212) can be used for textile purposes.

The granular particles used according to the invention can be brittle and / or also have abrasive properties and a hardness which makes them indestructible when needling, in particular if they are sand or gravel. The particles therefore have properties that speak against needling. However, it has surprisingly been found that the top layer and the backing layer with conventional needling techniques, i. i.e., by means of needling needles with barbs, e.g. B. usual Fiiznadeln without significant damage, for. B. wear or destruction of the same, can be needled through the layer of granular particles. This is partly due to the fact that the granular particles are preferably displaceable relative to one another prior to needling and that particles hit by needles can laterally evade.

The laminate used according to the invention can advantageously be used as a carpet, with z. B. sand with a basis weight of 100 to 1,000 g / m ² is present. As a result, a heavier carpet can be produced in an inexpensive manner, which has a better impact sound improvement measure and a higher sound absorption level than a lighter carpet.

The laminated body used according to the invention can also be used as other wall or floor covering, as a support, and also as a cushion element. In particular due to its weight, it is also suitable in stripes as a weight band. While in most applications this laminate insert, e.g. B. is present as a web, of course, several, preferably 2 laminates together, z. B. connected as a pillow, sack or hose.

In its simplest form, the inner layer of the laminate consists exclusively of granular sand. This allows z. B. Flooring can be made that can be used as self-laying, heavy carpets, this carpet hugs bumps. As a self-laying carpet, the basis weight of the sand layer can be between 2 and 7 kg / m ² . Such laminate can now advantageously be cut and then z. B. as a roll or carpet tile. When dividing the laminate into smaller sections, such as. B. these tiles, granular particles fall out only in the direct area of the cut edge, since the individual particles are held individually by the introduced holding fibers, as explained above. Such a possibility is only opened by the fact that the top layer and the top layer, including the granular particles, such as sand, are not sewn together, but are instead needled together. Such a layer density over the entire surface of the laminated body can only be produced when needling. A carpet web and in particular carpet tile produced in this way need not be glued to the floor, since it comes to rest on the floor due to its own weight. In addition, if an inner layer of rock particles, such as sand or the like, is used, binders such as e.g. B. cement or the like or synthetic resins. Then becomes a carpet mixed with cement particles placed on a damp surface so that it can set.

The granular, the filler-forming particles can also be cement, heavy spar or a light metal, such as. B. aluminum hydroxide or the like. These materials, including the sand or gravel mentioned above, improve the properties of the laminate in relation to its behavior in the event of fire, in particular such a laminate acts as a fire barrier.

The inner layer of a laminate used as a wall covering can also be used here as a binder, for. B. cement or a synthetic resin can be supplied. So that the laminated body does not fall down again beforehand during the setting on the wall, it can be attached to the wall with nails, pens or the like during attachment. Such rodents or pins can be driven through the laminate without destroying it and removed again after the setting process has been completed. Due to the elasticity, at least of the upper layer, the holes formed during nailing or the like close automatically after the nail is pulled out.

The fact that this laminated body used according to the invention can be cut into differently shaped parts makes it particularly suitable for use as upholstery, for. B. for sofas or armchairs.

When using sand as a granular particle in such a laminate, it shows positive properties in fire protection due to the large heat capacity and the poor thermal conductivity of the sand. Textile wall hangings, which up to now could only be supplied as flame retardant, now show even better behavior when they are filled with sand. Such a laminate can therefore also be used as a so-called “iron curtain”, which, however, is optically more appealing due to its textile design.

The granular particles can also be in the form of a powder, particularly if they are binders such as cement or the like. Granular particles of different materials can be mixed. The grain diameter is preferably between 0.02 and 2 mm. These laminated bodies can be produced with different weights and resulting total thicknesses, which are also based in particular on the specific application. Is z. B. sand as granular particles, the total thickness can be about 4 to 5 mm with a basis weight of the particle layer of 4 kg / m ² , while a laminate in which the basis weight of the particle layer is about 12 kg / m ² , a total thickness of has about 8 to 10 mm.

Depending on the desired total thickness of the laminate, the fibers or threads from which a nonwoven is formed have sufficient length at least for the actively needlable top layer and are preferably 40 to 120 mm in length so that they pass through a sufficient thickness of the laminate can extend from the top layer into the base layer. These two layers are preferably needled together over the entire surface of the laminated body, so that a sufficient needling density can be achieved, which, for. B. is 50 to 200 punctures / cm ² . If necessary or desired, the laminated body can be needled both from the top layer and from the support layer.

In a further embodiment, the support layer made of a fiber-free material, for. B. consist of a plastic film, so that this further variants of the laminated body can be made possible. At least the base layer can then, for. B. with a reflective layer, e.g. B. a metal layer, provided or equipped. However, a fabric sheet or a nonwoven fabric can also be used as a passively needled carrier layer.

In a preferred embodiment, the support layer may have depressions filled with the particles, which, for. B. are well-shaped or elongated. This makes it possible, for. B. a particularly flexible to obtain the webs between the recesses bendable laminate, which can be wound up in a particularly advantageous manner. The cover layers can be needled to one another at the recess-free locations and present without needles at the recesses. Depending on the specific application, the holding fibers can engage at different depths in the carrier layer provided with depressions, i. H. on the one hand, the penetration depth can be smaller than the height of the depressions, in which case they would not be perforated by the needles. If this is desired, however, the penetration depth can also be chosen to be larger, in which case the retaining fibers may also penetrate the bottom of the depressions. As an intermediate possibility, it is also envisaged to let the needle tips perforate the bottom of the depressions, but not to pull the holding fibers down to the bottom.

Due to the holding fibers penetrating the sand layer, which connect the top layer and the base layer with each other, the individual grains of sand are held elastically between the cover layers, the laminated body as such can still be rolled up without the individual grains changing their position in the laminated body.

Is used as an upper layer z. B. ball yarns from spherically wound fibers such as z. B. are described in EP-A-0013428, so when needling a particularly dense top layer is obtained, through which particularly powdery particles cannot escape.

In a special form of use of the laminated body, it is needled or glued to a further textile layer arranged on the upper layer.

Further details and advantages of the invention emerge from the subclaims and from the exemplary embodiments described below with reference to the drawing. In the drawing are Portions of the laminated body according to the invention are shown schematically and enlarged in section.

• Figur 1 eine erste Ausführungsform eines Schichtkörpers, bei dem sowohl die Trageschicht, als auch die Oberschicht aus einem Faservlies besteht und die Partikel gleichmäßig flächig verteilt sind ;
• Figur 2 eine zweite Ausführungsform des Schichtkörpers, bei dem die Trageschicht mit näpfchenartigen Vertiefungen versehen ist, in der sich die Partikel befinden ;
• Figur 3 eine dritte Ausführungsform des Schichtkörpers, bei der die Oberschicht aus voneinander abgegrenzten Kugelgarnen 14 besteht, und
• Figur 4 eine vierte Ausführungsform des Schichtkörpers, bei der die Partikel streifenförmig in dem Schichtkörper angeordnet sind.

It shows :

• Figure 1 shows a first embodiment of a laminated body, in which both the support layer and the top layer consists of a nonwoven fabric and the particles are evenly distributed;
• Figure 2 shows a second embodiment of the laminated body, in which the support layer is provided with cup-like depressions in which the particles are located;
• 3 shows a third embodiment of the laminated body, in which the upper layer consists of spherical yarns 14 which are delimited from one another, and
• Figure 4 shows a fourth embodiment of the laminate, in which the particles are arranged in strips in the laminate.

A laminated body 1 here has an upper layer 2, which can be actively needled here and consists of a nonwoven fabric or of fibers spherically wound as ball yarns 14 (FIG. 3). A support layer 3, which can be at least passively needled, is held relative to the upper layer 2 by holding fibers 4 removed from the upper layer 2. A layer 5 made of granular particles 6 is arranged between the top layer 2 and the support layer 3. The two layers 2 and 3 are needled together through the particle layer 5. The needling can be done according to a needle method known in needle felting technology, as described, for. B. by R. Krcma in the "Handbook of Textile Composites" (Deutscher Fachverlag, Frankfurt am Main, 1970, pages 198-202). In this technology, felting needles with a triangular needle shaft and lateral barbs directed towards the tip are most commonly used for needling. Other shapes, such as fork needles and loop needles, are also common. The sewing needles mentioned in the aforementioned book can also be used accordingly for the needling of the laminated body 1. When piercing the upper layer 2, the felting needles grasp individual or tufts of fibers 4 from this upper layer and interweave them with the base layer 3. The upper layer 2 must be actively needled for this purpose, i. H. it should be possible to detect fibers from this layer, a portion of these fibers 4 still being anchored in layer 2.

The needling process not only connects the top layer 2 and the base layer 3 to one another, it also prevents the granular particles 6 of the layer 5 from laterally shifting due to the holding fibers 4 which are distributed throughout the entire surface of the layer body 1. This makes it possible to cut the laminated body into any shape, in particular sheets or tiles, without the particles dropping out of the cut edge in substantial quantities.

The layer 5 of granular particles 6 here consists of rock particles of small grain size, e.g. B. from sand, which by definition has a grain size of 0.02 to 2 mm. Depending on the intended use, larger particles 6 can also be used. Advantageous features of these rock particles are their relatively large weight in relation to a certain layer thickness, their relatively high heat capacity and in particular their inert behavior towards other substances.

As can be seen from the drawing, the support layer 3 can consist of different materials. This base layer 3 should not splinter when the needles are pierced, and the pierced holding fibers 4, e.g. B. elastic, hold tight, e.g. B. by clamping or interlacing, d. that is, the base layer 3 should be at least passively needled.

There are z. B. plastic films 7 made of soft elastic material (compare, for example, Figure 2), fiber layers in sufficient density, which are further compressed and matted by the needle process itself, so that they retain the particles 6, and adhesively bonded fiber composites, nonwovens or Spunbonds. The support layer 3 can itself be actively needled, which allows the layered body 1 to be additionally needled from the opposite side, as shown in the right half of FIG. It is also possible to provide a further actively needled fiber layer under a plastic film or the like as the base layer 3 and to needle the laminated body 1 from both sides. The support layer 3 can itself be designed as a spring back or, which is not shown, have a spring back on its side facing away from the top layer 2.

The fiber layer, be it as a top layer 2 or as a base layer 3, can be pre-compressed by separate needling, it can be on a carrier layer such. B. a plastic film, a fiber composite or the like. Needled to facilitate handling during manufacture and / or to the leakage of fine sand particles 6 and in particular of binder particles 13 (see FIG. 3) before needling the laminated body 1 to prevent.

A wide variety of textile fibers can be used as the fiber material for the nonwoven fabric and also for the ball yarns 14 (FIG. 3). Natural fibers, such as B. cotton, wool, animal hair fibers. Like., Or synthetic fibers or a mixture thereof.

The embodiment according to FIG. 1 has only distributed rock particles 6 such as fine-grained sand, these rock particles having a basis weight of approximately 100 to 1,000 g / m ² . According to this embodiment, z. B. improve a carpet. Until now, a carpet designed in this way had a basis weight of 700 to 800 g / m ² , but by adding about 400 g of fine-grained sand per m ^2, its weight can be increased by around 50%. By embedding the sand particles 6 in this carpet, the hard / soft effect is obtained in a relatively inexpensive manner, as a result of which the impact sound improvement measure and the sound absorption level can be increased. If sand with a basis weight of 2 to 7 kg / m ^{2 is} added to a carpet and needled in it, this carpet is a web, but especially as a carpet tile, self-laying and does not need to be glued on.

A laminated body 1 according to the embodiment according to FIG. 1 can, however, also be used as a curtain, with the added sand particles 6 showing particularly positive behavior in the event of fire. Due to the poor thermal conductivity and the high heat capacity of the sand, which then z. B. with a grain size of 1 to 2 mm and a weight per unit area of 0.5 to 2.5 kg / m ² , this laminate can be used as a fire protection partition curtain, e.g. B. as a so-called «iron curtain •, z. B. can be used in theaters or as a spark protection curtain.

As particularly shown in Figure 2, this film 7 can be provided with depressions 8 which, for. B. can be achieved by deep drawing in the hot plastic state. According to FIG. 2, these depressions 8 are of cup-like design. However, these depressions can also be elongated, in which case they come to lie parallel to each other and z. B. can be arranged offset in their position. The depressions 8 open towards the top layer 2, so that the particles 6 can be introduced into these depressions. In the exemplary embodiment according to FIG. 2, the layer 5 of particles 6 is therefore not contiguous, but rather divided into numerous portions. The needle punctures can be evenly distributed over the entire surface of the laminated body 1, as is shown in the three left wells 8 in FIG. 2, where the holding fibers 4 also reach through the bases of the wells 8. If the retaining fibers 4 were needled less deeply, as corresponds to an embodiment that is not shown, these retaining fibers end in the wells themselves in the region of the depressions 8, while the retaining fibers penetrate the recess-free locations 9 of the plastic film 7, as a result of which the top layer 2 with the is formed as a plastic film 7 support layer. In this case, the needling of the laminated body can be carried out in such a way that the needle tips still perforate the bottom of the depressions 8, so that fluids can also flow into the depressions 8 from the side of the support layer 3. According to the illustration in the right half of FIG. 2, the top layer 2 is connected to the plastic film 7 only in the region of the recess-free points 9 by means of holding fibers 4. Although the well-shaped recesses 8 themselves are quite stiff, the laminated body 1 has a relatively high degree of flexibility, since the recess-free points 9 acting as webs act like a hinge.

In the embodiment of the laminated body 1 shown in FIG. 3, grains of sand 6 and smaller binders which can be activated with water, such as e.g. B. cement powder, deposited as layer 5, on which ball yarns 14 made of spherically wound fibers are then deposited as an upper layer. These three layers 2, 5 and 3 are then needled from above, the holding fibers 4 being removed from the ball yarns 14.

This ball yarn top layer 2 is particularly dense, so that neither the particles 6 or 13 can fall out of the layer body 1, nor dirt particles falling onto the layer body from outside can penetrate through this top layer 2. The embodiment according to FIG. 3 is particularly suitable as a carpet due to its surface structure. By moistening the surface on which this carpet is to be placed, the holding fibers 4 in particular suck in the moisture and bring it into contact with the binders, which then also set in relation to the surface.

In the embodiment of the laminated body 1 shown in FIG. 4, 3 rows 11 or strips of granular particles 6, such as sand, are deposited on an actively needlable fiber layer as the base layer. These form an interrupted intermediate layer 5, through which needling is carried out. On these rows 11 of particles 6, an actively needled fiber layer is deposited as a cover layer 2 and the layered body 1 is needled from above. In the right half of this figure 4 it is shown that this laminate 1 can also be needled from below, i. that is, the holding fibers 4 are taken from both the top layer 2 and the support layer 3. Both designs now have in common that they form a kind of hinge at the particle-free locations 12, which means that even if several particles 6 are arranged transversely to the extent of the laminated body, as shown in the left half of FIG. 4, it is still bend slightly and let roll.

The following table, which is broken down by grain size range of the particles 6, shows the preferred size ranges to be used for the particle weight per unit area, the fiber thickness, the fleece weight per fiber layer per unit area, the needle thickness and the stitch density.

If a plastic film 7 is used as the base layer 3, as in the case of FIG. 2, the film thickness is between 30 and 200 μm, a thicker film should also be used with a larger grain diameter.

• Die Oberschicht 2 und die Trageschicht 3 wurden identisch aus dem gleichen Material auf folgende Weise hergestellt. Auf eine Trägerfolie (in Fig. 1 nicht dargestellt) aus Polyäthylen von 0,1 mm Dicke wurde ein Fasergemisch von 200 g/m² von Polyester-Fasern mit einem Fasertiter von 3,3 und 17 dtex und einer Stapellänge von 90 mm abgelegt. Die Fasern wurden mit der Folie mittels konventioneller Filznadeln mit 45 Stichen pro cm² vorvernadelt. Eine solche vorvernadelte Faserschicht wurde mit den Faserbärten nach oben gerichtet auf den Zuführtisch der Nadelmaschine gelegt, dann darauf eine Schicht von gewaschenem Quarzsand der Korngröße 0,5 bis 0,75 mm in einer Menge von 7 kg/m² gestreut. Die Schicht wurde sodann mit einer identischen vorvernadelten Faserschicht mit den Faserbärten nach unten gerichtet, zugedeckt. Der ganze Schichtkörper wurde mit konventionellen 25 - gauge Filznadeln und mit 30 Stichen pro cm² vernadelt. Es entstand ein Schichtkörper von zirka 7,4 kg/m² Flächengewicht.

Example for the production of a laminated body 1, according to FIG. 1:

• The top layer 2 and the base layer 3 were produced identically from the same material in the following way. A fiber mixture of 200 g / m ² of polyester fibers with a fiber titer of 3.3 and 17 dtex and a stack length of 90 mm was placed on a carrier film (not shown in FIG. 1) made of polyethylene 0.1 mm thick. The fibers were pre-needled with the film using conventional felting needles with 45 stitches per cm ² . Such a pre-needled fiber layer was placed with the fiber beards facing upwards on the feed table of the needle machine, then a layer of washed quartz sand with a grain size of 0.5 to 0.75 mm was sprinkled in an amount of 7 kg / m ² . The layer was then covered with an identical pre-needled fiber layer with the fiber whiskers facing downwards. The entire laminate was needled with conventional 25-gauge felting needles and with 30 stitches per cm ² . The result was a laminate with a surface weight of approximately 7.4 kg / m ² .

• Als Trageschicht 3 wurde eine Noppenfolie 7 aus Polyäthylen mit zylinderischen Vertiefungen (Noppen) von 1 cm Durchmesser und 5 mm Tiefe, 7 700 Noppen pro m² verwendet. Die Noppen wurden mit Quarzsand gestrichen gefüllt, dann mit einer Schicht von Polypropylen-Fasern 17 dtex, Stappellänge 90 mm, 200 g/m² zugedeckt. Der Schichtkörper wurde mit konventionellen 25 - gauge Filznadeln mit 30 Stichen pro cm² vernadelt. Es entstand ein Schichtkörper 1 von zirka 1,8 kg/m² Flächengewicht. Die Noppen waren durch die Nadeleinstiche perforiert worden. Der Sand konnte jedoch nicht herausfallen.

Example for the production of a laminated body 1, according to FIG. 2:

• A pimpled film 7 made of polyethylene with cylindrical recesses (pimples) of 1 cm diameter and 5 mm depth, 7 700 pimples per m ^{2 was} used as the base layer 3. The knobs were filled with quartz sand, then covered with a layer of polypropylene fibers 17 dtex, staple length 90 mm, 200 g / m ² . The laminate was needled with conventional 25-gauge felting needles with 30 stitches per cm ² . The result was a laminate 1 of approximately 1.8 kg / m ² basis weight. The knobs had been perforated by the needle punctures. However, the sand could not fall out.

Claims (15)

1. The use as a textile material of a laminated flat article with an upper layer (2) containing fibres or filaments, with an inner layer (5) of granular particles (6) of at least one non-reactive mineral material and with a supporting layer (3), the upper layer (2) and the supporting layer (3) being needled together through the inner layer (5).

2. Use according to claim 1, characterised in that the granular particles (6) are particles of stony material, such as for example sand, gravel or the like, cement, pearl white or a light metal such as aluminium hydroxide or the like.

3. Use according to claim 1 or 2, characterised in that the particles (6) are present with a weight per unit surface of 0.1 to 12 kg/m².

4. Use according to one of claims 1 to 3, further particles being present in addition to the granular particles of at least one non-reactive mineral material, characterised in that the further particles (13) are of a binder such as cement, powdered adhesive or the like.

5. Use according to one of the foregoing claims that a resilient backing is arranged on that face of the lower supporting layer (3) which faces away from the upper layer (2).

6. Use according to one of claims 1 to 4 that the lower supporting layer (3) is formed as a resilient backing.

7. Use according to one of the foregoing claims characterised in that the laminated article is treated with latex.

8. Use according to one of the foregoing claims that the laminated article is needled or stuck to a further textile layer applied to the upper layer (2).

9. Use according to one of the foregoing claims as a floor covering.

10. Use according to one of claims 1 to 8 as a wall covering.

11. Use according to claim 9 or 10 as a carpet, the granular particles being present with.a density per unit area of 100 to 1 000 g.

12. Use according to one of claims 1 to 3 as a curtain or hanging.

13. Use according to one of claims 1 to 3 as an upholstery covering for seats, sofas or the like.

14. Use according to one of claims 1 to 11 as separate carpet tiles.

15. Use according to one of claims 1 to 4 in the form of strips as weighting or ballast strips.

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