EP0508287B1 - Tufted carpet - Google Patents

Tufted carpet Download PDF

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Publication number
EP0508287B1
EP0508287B1 EP92105586A EP92105586A EP0508287B1 EP 0508287 B1 EP0508287 B1 EP 0508287B1 EP 92105586 A EP92105586 A EP 92105586A EP 92105586 A EP92105586 A EP 92105586A EP 0508287 B1 EP0508287 B1 EP 0508287B1
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EP
European Patent Office
Prior art keywords
tufting
carpet
polyamide
base
carpet according
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP92105586A
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German (de)
French (fr)
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EP0508287A1 (en
Inventor
Karl-Heinz Erren
Regina Grewe
Robert Heidhues
Frank Hoeppner
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Norddeutsche Faserwerke GmbH
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Norddeutsche Faserwerke GmbH
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Application filed by Norddeutsche Faserwerke GmbH filed Critical Norddeutsche Faserwerke GmbH
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04G—MAKING NETS BY KNOTTING OF FILAMENTARY MATERIAL; MAKING KNOTTED CARPETS OR TAPESTRIES; KNOTTING NOT OTHERWISE PROVIDED FOR
    • D04G3/00—Making knotted carpets or tapestries
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0076—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/065—Polyamides
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/06—Melt
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2205/00—Condition, form or state of the materials
    • D06N2205/10—Particulate form, e.g. powder, granule
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2213/00—Others characteristics
    • D06N2213/02—All layers being of the same kind of material, e.g. all layers being of polyolefins, all layers being of polyesters
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23986—With coating, impregnation, or bond
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Definitions

  • the invention relates to a tufted carpet and its use as a floor and wall covering.
  • Carpets are tufted, woven, knotted and needled from man-made fibers, wool, hair yarn, silk and cotton. Tufting is the dominant production technology in relation to the factory-made carpet, whereby mainly synthetic fibers and in particular polyamide filament yarns and spun fiber yarns are used.
  • the factory-made tufted carpet which can be used both as a floor and as a wall covering, offers not only comfort but also considerable advantages with regard to insulation and thereby favors the heat balance in buildings.
  • the tufting carpet constructions which are common today consist mainly of three components, namely the tufting base, the pile material and the carpet back (see documents DE-A-1685159 and EP-A-0030126). Different materials are used for these components, which differ fundamentally chemically and cannot be processed together, e.g. B. polypropylene, polyamide, polyurethane, polyvinyl chloride and jute. Combinations of polypropylene as the base fabric, polyamide as the pile material and polyurethane as the back coating predominate.
  • the tufting base is made of fabrics that mainly consist of polypropylene or spunbonded fabrics made of polyester or polypropylene. Jute fabrics are rarely used.
  • the carpet backing has several functions.
  • a pre-coat of rubber or self-adhesive latex is applied to the tufted carpet to strengthen the knobs.
  • a second back mainly made of polyester fabric, is often glued on and the carpet laid in this way.
  • partially filled foams based on latex or polyurethane are usually applied to increase comfort.
  • the tufting carpets constructed in the manner described represent a major garbage or waste disposal problem after use, since they occur in large quantities (large volume and weight) and practically do not weather or only weather very slowly. A separation into the individual components and a reuse of these components is extremely difficult or almost impossible and has therefore been avoided for purely economic reasons. With waste disposal problems increasing, there is an urgent need for tufted carpets that can be easily disposed of or recycled after use.
  • the object of the invention is to create a tufted carpet which, after use, can be easily removed or preferably reused (recyclable).
  • a tufted carpet which comprises a tufting base, a pile material and a carpet back and is characterized in that it consists essentially exclusively of polyamide 6.
  • the invention further relates to the use of the carpet according to the invention as a floor and wall covering.
  • the tufting base of the tufting carpet according to the invention consists of a woven fabric, knitted fabric, fleece or a stretched film made of polyamide 6.
  • Laying rail 2 (fringe) 100-011 Stitches / cm 20th division E 28
  • a knitted fabric in this version results in a stable web without rolling edges and is solid in itself with sufficient longitudinal and width expansion. Due to the high offset in laying rail 1, the chosen laying prevents the filament from being broken if the filaments are damaged by the tufting needles.
  • the knitted fabric leads to a stretchable tufted carpet, which can be stabilized by the following back consolidation, but still has the necessary stretchability of 3 to 7% for tensioning.
  • the knitted fabric has a high resistance to displacement, so that problems, e.g. Cracking of the carpet on the needle bar due to low resistance to displacement can be avoided.
  • the yarns used for the knitwear are in the titer range from 20 dtex to 200 dtex. Yarns with a titer of 44 dtex or 67 dtex have proven to be particularly suitable.
  • the filament yarns show a shrinkage of about 14%, which can be triggered by heating (fixing). If the pole is tufted before fixation, the shrinkage causes the surface to become denser and thus an increase in the quality of the tufted carpet. On the other hand, it is advantageous to tuft on a coarser machine division and to achieve a product surface like a tufting machine with a finer division due to the triggered shrinkage.
  • a tufted fabric (1/10 "pitch, 8 mm pole, 45 stitches / 10 cm) using the warp knit fabric described above shrinks by 25% from 1270 g / m 2 to 1600 g / m 2. If such Shrink effects are undesirable fixed and thus stabilized knitwear of the same construction can be used as a tufting base.
  • the plain weave is preferred in order to achieve uniform stability in warp and weft.
  • the thread density in warp and weft depends on the thread size used. Yarns in the fineness range of 200 to 4000 dtex are primarily suitable. Typical thread densities for a thread size of 300 dtex are 8 to 14 threads / cm in the warp, for a thread size of 1100 dtex 5 to 10 threads / cm in the weft.
  • the resistance to displacement and diagonal stability of the coarse fabrics can be improved by applying a fleece.
  • the extensibility is at a low level due to the strong force absorption due to the binding, so that the lower stretch range of 3% must be selected for tensioning.
  • textured yarns that is, polyamide yarns with higher elasticity, can be used to create carpets with higher elongation, which can be made to measure according to the needs of the use.
  • a nonwoven as a carpet base shows a uniform strength in all directions with an extensibility which can be set by the consolidation, but has a lower strength than other basic goods.
  • Nonwovens with a weight of 90 to 200 g / m 2 and preferably 110 to 150 g / m 2 and a strength in the longitudinal direction of 130 to 170 N / 5 cm and preferably 140 to 160 N / 5 cm and a strength in are particularly suitable Transverse direction from 100 to 150 N / 5 cm and preferably 110 to 140 N / 5 cm.
  • Secondarily spun yarn, endless stretch-textured filament yarn or any other yarn made of polyamide 6 in the usual way is used as pile or pile material in the usual way.
  • the yarn which is mainly in the titer range from 800 dtex to 4000 dtex, can be normal textured or additionally fixed or rotated and fixed.
  • the pimples are solidified by gluing with a polyamide film or with polyamide hot-melt adhesive powder or a loosened polyamide mass.
  • the polyamide film or the polyamide powder must be heated to flow or a dissolved polyamide mass must be applied in liquid form in order to solidify the knobs properly.
  • a copolyamide which has a reduced melting point is advantageously used, but the highest possible proportion of polyamide 6, in particular copolyamides with a polyamide 6 content of at least 80% by weight and preferably at least 90% by weight, is selected.
  • the minor component introduced is of minor importance in relation to the total weight of the material used and is therefore not disruptive for recycling by depolymerization and the recovery of the starting component caprolactam.
  • Copolyamides suitable for this purpose are commercially available hotmelt adhesives which are available both in film form and in powder form.
  • the degree of solidification can be controlled by the type of copolymer, the thickness of the film or the amount of powder, depending on the application and consumption. Coatings of 30 to 90 g / m 2 and preferably 40 to 70 g / m 2 are typical. At the same time, the degree of consolidation determines the stretchability of the carpet for the bracing, especially when knitted fabric is used as the carpet base.
  • a textile surface made of polyamide 6, for example a woven fabric, a fleece or a knitted fabric, can be applied at the same time as a second backing for additional stabilization of the carpet.
  • the carpet construction according to the invention is with or without a separate insulation layer without gluing laid by stretching over needle bars. The insulation layer can then be taken up again after use and can be recycled separately. In this way, the carpet that is laid remains recyclable.

Abstract

The invention relates to a tufted carpet which comprises a tufting material, a pile material and a carpet backing and essentially exclusively comprises nylon 6. The use of a chemically uniform material in all components of the tufted carpet allows the entire carpet to be recycled for recovery of the monomer starting material without separation into the individual components being necessary, which has hitherto prevented the recycling of tufted carpets and has resulted in considerable waste disposal problems.

Description

Die Erfindung betrifft einen Tufting-Teppich sowie dessen Verwendung als Boden- und Wandbelag.The invention relates to a tufted carpet and its use as a floor and wall covering.

Teppiche werden aus Chemiefasern, Wolle, Haargarn, Seide und Baumwolle getuftet, gewebt, geknüpft und genadelt. Tufting ist bezogen auf die fabrikmäßig hergestellte Teppichfläche die dominierende Produktionstechnik, wobei überwiegend Chemiefasern und insbesondere Polyamid-Filamentgarne und -Spinnfasergarne zum Einsatz kommen. Der fabrikmäßig gefertigte Tufting-Teppich, der sowohl als Boden- als auch als Wandbelag verwendet werden kann, bietet neben Komfort erhebliche Vorzüge hinsichtlich Isolierung und begünstigt dadurch den Wärmehaushalt in Gebäuden.Carpets are tufted, woven, knotted and needled from man-made fibers, wool, hair yarn, silk and cotton. Tufting is the dominant production technology in relation to the factory-made carpet, whereby mainly synthetic fibers and in particular polyamide filament yarns and spun fiber yarns are used. The factory-made tufted carpet, which can be used both as a floor and as a wall covering, offers not only comfort but also considerable advantages with regard to insulation and thereby favors the heat balance in buildings.

Die heute üblichen Tufting-Teppichkonstruktionen bestehen überwiegend aus drei Komponenten, nämlich dem Tuftinggrund, dem Polmaterial und dem Teppichrücken (siehe Dokumente DE-A-1685159 und EP-A-0030126). Für diese Komponenten werden unterschiedliche Materialien verwendet, die sich chemisch grundsätzlich unterscheiden und nicht miteinander aufbereitungsfähig sind, z. B. Polypropylen, Polyamid, Polyurethan, Polyvinylchlorid und Jute. Kombinationen von Polypropylen als Grundgewebe, Polyamid als Polmaterial und Polyurethan als Rückenbeschichtung überwiegen.The tufting carpet constructions which are common today consist mainly of three components, namely the tufting base, the pile material and the carpet back (see documents DE-A-1685159 and EP-A-0030126). Different materials are used for these components, which differ fundamentally chemically and cannot be processed together, e.g. B. polypropylene, polyamide, polyurethane, polyvinyl chloride and jute. Combinations of polypropylene as the base fabric, polyamide as the pile material and polyurethane as the back coating predominate.

Bei dem Tuftinggrund handelt es sich um Gewebe, die überwiegend aus Polypropylen bestehen, oder um Spinnvliese aus Polyester oder Polypropylen. Seltener kommen Jutegewebe zum Einsatz.The tufting base is made of fabrics that mainly consist of polypropylene or spunbonded fabrics made of polyester or polypropylene. Jute fabrics are rarely used.

Das Polmaterial besteht überwiegend aus aus Polyamid hergestellten Spinnfasern, die sekundär versponnen und dann nachgetuftet werden, oder aus Polyamiden, die im Ein- oder Mehrstufenprozeß zu einem endlosen Garn extrudiert, gestreckt und texturiert worden sind (BCF-Garne = bulked continuous filament).The pile material consists predominantly of staple fibers made of polyamide, which are spun secondarily and then re-tufted, or of polyamides, which have been extruded, stretched and textured into a continuous yarn in a single or multi-stage process (BCF yarns = bulked continuous filament).

Dem Teppichrücken kommen mehrere Funktionen zu. Auf den getufteten Teppich wird zur Verfestigung der Noppen ein Vorstrich aus Kautschuk oder SB-Latex aufgebracht. Bei Tufting-Teppichen für Objekte wird häufig ein Zweitrücken vorwiegend aus Polyestergewebe aufgeklebt und der Teppich so verlegt. Für den Einsatz im Wohnbereich werden üblicherweise teils gefüllte Schäume auf der Basis von Latex oder Polyurethan zur Komforterhöhung aufgebracht.The carpet backing has several functions. A pre-coat of rubber or self-adhesive latex is applied to the tufted carpet to strengthen the knobs. In the case of tufted carpets for objects, a second back, mainly made of polyester fabric, is often glued on and the carpet laid in this way. For use in living areas, partially filled foams based on latex or polyurethane are usually applied to increase comfort.

Die in der beschriebenen Weise aufgebauten Tufting-Teppiche stellen nach beendetem Gebrauch ein großes Müll- bzw. Abfallbeseitigungsproblem dar, da sie in großen Mengen (großes Volumen und großes Gewicht) anfallen und praktisch nicht bzw. nur äußerst langsam verwittern. Auch eine Auftrennung in die einzelnen Komponenten und eine Wiederverwendung dieser Komponenten ist äußerst schwierig bzw. nahezu unmöglich und ist deshalb bisher schon aus rein wirtschaftlichen Gründen unterblieben. Angesichts der immer größer werdenden Abfallbeseitigungsprobleme besteht deshalb ein dringendes Bedürfnis nach Tufting-Teppichen, die nach Gebrauch leicht beseitigt oder wiederverwertet werden können.The tufting carpets constructed in the manner described represent a major garbage or waste disposal problem after use, since they occur in large quantities (large volume and weight) and practically do not weather or only weather very slowly. A separation into the individual components and a reuse of these components is extremely difficult or almost impossible and has therefore been avoided for purely economic reasons. With waste disposal problems increasing, there is an urgent need for tufted carpets that can be easily disposed of or recycled after use.

Dementsprechend liegt der Erfindung die Aufgabe zugrunde, einen Tufting-Teppich zu schaffen, der nach erfolgtem Gebrauch in einfacher Weise beseitigbar bzw. vorzugsweise wiederverwertbar (recycling-fähig) ist.Accordingly, the object of the invention is to create a tufted carpet which, after use, can be easily removed or preferably reused (recyclable).

Zur Lösung dieser Aufgabe wird ein Tufting-Teppich vorgeschlagen, der einen Tuftinggrund, ein Polmaterial und einen Teppichrücken umfaßt und dadurch gekennzeichnet ist, daß er im wesentlichen ausschließlich aus Polyamid 6 besteht.To solve this problem, a tufted carpet is proposed which comprises a tufting base, a pile material and a carpet back and is characterized in that it consists essentially exclusively of polyamide 6.

Gegenstand der Erfindung ist ferner die Verwendung des erfindungsgemäßen Teppichs als Boden- und Wandbelag.The invention further relates to the use of the carpet according to the invention as a floor and wall covering.

Bevorzugte Ausführungsformen der Erfindung und mit der Erfindung erzielbare Vorteile ergeben sich aus der nachfolgenden Beschreibung und den Unteransprüchen.Preferred embodiments of the invention and advantages achievable with the invention result from the following description and the subclaims.

Es hat sich überraschend gezeigt, daß die Herstellung von Tufting-Teppichen aus im wesentlichen einem chemisch einheitlichen Material (abgesehen von üblichen Hilfsstoffen wie Farbstoffen, Antistatika usw.) möglich ist, wenn das Material für die verschiedenen Komponenten hinsichtlich der erforderlichen Eigenschaften sorgfältig ausgewählt wird. Durch die Verwendung eines chemisch einheitlichen Materials in allen Komponenten des Tufting-Teppichs ist es bei der Aufarbeitung und Wiederverwertung von gebrauchtem Teppich nicht mehr erforderlich, die Komponenten und deren Bestandteile voneinander zu trennen. Vielmehr kann der Teppich insgesamt dem Recycling zur Rückgewinnung des monomeren Ausgangsmaterials unterworfen werden. Polyamid 6 kann nämlich durch einfache Depolymerisation in das monomere Ausgangsprodukt Caprolactam zurückgeführt werden.It has surprisingly been found that the production of tufted carpets from essentially a chemically uniform material (apart from conventional auxiliaries such as dyes, antistatic agents, etc.) is possible if the material for the various components is carefully selected with regard to the properties required. By using a chemically uniform material in all components of the tufted carpet, it is no longer necessary to separate the components and their components from one another when refurbishing and recycling used carpets. Rather, the carpet as a whole can be subjected to recycling in order to recover the monomeric starting material. This is because polyamide 6 can be recycled into the monomeric starting product caprolactam by simple depolymerization.

Der Tuftinggrund des erfindungsgemäßen Tufting-Teppichs besteht aus einem Gewebe, Gewirke, Vlies oder einer gestreckten Folie aus Polyamid 6. Bei Einsatz einer durch Kettwirktechnik hergestellten textilen Fläche - Kettgewirke - sollte die Wirkware vorwiegend mit folgender Legung erstellt werden: Legeschiene 1 (Samt) 102 - 454 Legeschiene 2 (Franse) 100 - 011 Maschen/cm 20 Teilung E 28 The tufting base of the tufting carpet according to the invention consists of a woven fabric, knitted fabric, fleece or a stretched film made of polyamide 6. When using a textile surface produced by warp-knitting technology - warp-knitted fabrics - the knitted fabric should primarily be created with the following laying: Laying rail 1 (velvet) 102-454 Laying rail 2 (fringe) 100-011 Stitches / cm 20th division E 28

Eine Wirkware in dieser Ausführung ergibt eine stabile Warenbahn ohne rollende Kanten und ist bei ausreichender Längs- und Breitendehnung in sich fest. Die gewählte Legung verhindert durch den hohen Versatz in Legeschiene 1 bei einem eventuellen Beschädigen von Filamenten durch die Tuftingnadeln ein Auftrennen der Gesamtkonstruktion.A knitted fabric in this version results in a stable web without rolling edges and is solid in itself with sufficient longitudinal and width expansion. Due to the high offset in laying rail 1, the chosen laying prevents the filament from being broken if the filaments are damaged by the tufting needles.

Die Wirkware führt zu einem dehnbaren Tufting-Teppich, der durch die folgende Rückenverfestigung stabilisiert werden kann, aber noch über die notwendige Dehnbarkeit von 3 bis 7% zum Verspannen verfügt. Darüber hinaus weist die Wirkware eine hohe Verschiebefestigkeit auf, so daß Probleme, z.B. Reißen des Teppichs an der Nadelleiste durch niedrige Verschiebefestigkeit, vermieden werden.The knitted fabric leads to a stretchable tufted carpet, which can be stabilized by the following back consolidation, but still has the necessary stretchability of 3 to 7% for tensioning. In addition, the knitted fabric has a high resistance to displacement, so that problems, e.g. Cracking of the carpet on the needle bar due to low resistance to displacement can be avoided.

Die für die Wirkware verwendeten Garne, vorwiegend Filamentgarne, liegen im Titerbereich von 20 dtex bis 200 dtex. Als besonders geeignet haben sich Garne mit einem Titer von 44 dtex oder 67 dtex erwiesen. Die Filamentgarne zeigen einen Schrumpf von etwa 14%, der durch Erhitzen (Fixieren) ausgelöst werden kann. Wird der Pol vor der Fixierung aufgetuftet, erreicht man durch das Auslösen des Schrumpfes eine Verdichtung der Oberfläche und damit eine Qualitätssteigerung des Tufting-Teppichs. Andererseits kann man vorteilhaft auf einer gröberen Maschinenteilung tuften und durch den ausgelösten Schrumpf eine Warenoberfläche wie von einer Tuftingmaschine mit feinerer Teilung erzielen. Beispielsweise schrumpft eine Tufting-Ware (1/10"-Teilung, 8 mm Pol, 45 Stiche/10 cm) unter Verwendung der oben beschriebenen Kettwirkware als Trägermaterial von 1270 g/m2 um 25% auf 1600 g/m2. Wenn derartige Schrumpfeffeke unerwünscht sind, kann eine ausfixierte und damit stabilisierte Wirkware gleicher Konstruktion als Tuftinggrund eingesetzt werden.The yarns used for the knitwear, mainly filament yarns, are in the titer range from 20 dtex to 200 dtex. Yarns with a titer of 44 dtex or 67 dtex have proven to be particularly suitable. The filament yarns show a shrinkage of about 14%, which can be triggered by heating (fixing). If the pole is tufted before fixation, the shrinkage causes the surface to become denser and thus an increase in the quality of the tufted carpet. On the other hand, it is advantageous to tuft on a coarser machine division and to achieve a product surface like a tufting machine with a finer division due to the triggered shrinkage. For example, a tufted fabric (1/10 "pitch, 8 mm pole, 45 stitches / 10 cm) using the warp knit fabric described above shrinks by 25% from 1270 g / m 2 to 1600 g / m 2. If such Shrink effects are undesirable fixed and thus stabilized knitwear of the same construction can be used as a tufting base.

Im Falle einer Webware als Tuftinggrund wird die Leinwandbindung bevorzugt, um gleichmäßige Stabilität in Kette und Schuß zu erreichen. Die Fadendichte in Kette und Schuß ist abhängig von der eingesetzten Garnstärke. Geeignet sind vorwiegend Garne im Feinheitsbereich von 200 bis 4000 dtex. Typische Fadendichten bei einer Garnstärke von 300 dtex sind 8 bis 14 Fäden/cm in der Kette, bei einer Garnstärke von 1100 dtex 5 bis 10 Fäden/cm im Schuß. Die Verschiebefestigkeit und Diagonalstabilität der groben Gewebe kann durch ein aufgebrachtes Vlies verbessert werden. Bei der Webware liegt die Dehnbarkeit wegen der bindungsbedingt starken Kraftaufnahme auf einem niedrigen Niveau, so daß der untere Dehnungsbereich von 3% zum Spannen gewählt werden muß.In the case of a woven fabric as the tufting base, the plain weave is preferred in order to achieve uniform stability in warp and weft. The thread density in warp and weft depends on the thread size used. Yarns in the fineness range of 200 to 4000 dtex are primarily suitable. Typical thread densities for a thread size of 300 dtex are 8 to 14 threads / cm in the warp, for a thread size of 1100 dtex 5 to 10 threads / cm in the weft. The resistance to displacement and diagonal stability of the coarse fabrics can be improved by applying a fleece. In the case of the woven goods, the extensibility is at a low level due to the strong force absorption due to the binding, so that the lower stretch range of 3% must be selected for tensioning.

Aber auch hier lassen sich durch texturierte Garne, also solche Polyamid-Garne mit höherer Elastizität, Teppiche mit höherer Dehnung erstellen, die auf die Bedürfnisse der Verwendung nach Maß gefertigt werden können.But here too, textured yarns, that is, polyamide yarns with higher elasticity, can be used to create carpets with higher elongation, which can be made to measure according to the needs of the use.

Ein Vlies als Teppichgrund zeigt eine gleichmäßige Festigkeit in allen Richtungen bei einer durch die Verfestigung einstellbaren Dehnbarkeit, aber gegenüber anderen Grund-Waren erniedrigter Festigkeit. Geeignet sind insbesondere Vliese mit einem Gewicht von 90 bis 200 g/m2 und vorzugsweise 110 bis 150 g/m2 sowie einer Festigkeit in Längsrichtung von 130 bis 170 N/5 cm und vorzugsweise 140 bis 160 N/5 cm und einer Festigkeit in Querrichtung von 100 bis 150 N/5 cm und vorzugsweise 110 bis 140 N/5 cm.A nonwoven as a carpet base shows a uniform strength in all directions with an extensibility which can be set by the consolidation, but has a lower strength than other basic goods. Nonwovens with a weight of 90 to 200 g / m 2 and preferably 110 to 150 g / m 2 and a strength in the longitudinal direction of 130 to 170 N / 5 cm and preferably 140 to 160 N / 5 cm and a strength in are particularly suitable Transverse direction from 100 to 150 N / 5 cm and preferably 110 to 140 N / 5 cm.

Als Pol- oder Flormaterial werden in üblicher Weise aus Spinnfasern sekundär gesponnenes Garn, endloses streck-texturiertes Filamentgarn oder ein anderes wie auch immer hergestelltes Garn ausschließlich aus Polyamid 6 verwendet. Das Garn, das vorwiegend im Titerbereich von 800 dtex bis 4000 dtex liegt, kann normal texturiert oder zusätzlich fixiert oder gedreht und fixiert eingesetzt werden.Secondarily spun yarn, endless stretch-textured filament yarn or any other yarn made of polyamide 6 in the usual way is used as pile or pile material in the usual way. The yarn, which is mainly in the titer range from 800 dtex to 4000 dtex, can be normal textured or additionally fixed or rotated and fixed.

Die Verfestigung der Polnoppen erfolgt durch Verkleben mit einer Polyamidfolie oder mit Polyamid-Schmelzklebepulver oder einer angelösten Polyamidmasse.The pimples are solidified by gluing with a polyamide film or with polyamide hot-melt adhesive powder or a loosened polyamide mass.

Zur Verfestigung der Noppen muß die Polyamidfolie oder das Polyamidpulver bis zum Fließen erhitzt werden oder eine angelöste Polyamidmasse flüssig aufgebracht werden, um die Noppen einwandfrei zu verfestigen. Vorteilhaft verwendet man ein Copolyamid, das sich durch einen verringerten Schmelzpunkt auszeichnet, wählt jedoch den höchstmöglichen Anteil an Polyamid 6, insbesondere Copolyamide mit einem Gehalt an Polyamid 6 von mindestens 80 Gew.% und vorzugsweise mindestens 90 Gew.%. Die dabei in geringstem Maße eingebrachte Hilfskomponente ist bezogen auf das Gesamtgewicht des eingesetzten Materials von untergeordneter Bedeutung und daher für das Recycling durch Depolymerisation und der damit angestrebten Rückgewinnung der Ausgangskomponente Caprolactam nicht störend. Für diesen Zweck geeignete Copolyamide sind handelsübliche Schmelzklebstoffe, die sowohl in Folienform als auch in Pulverform erhältlich sind.To solidify the knobs, the polyamide film or the polyamide powder must be heated to flow or a dissolved polyamide mass must be applied in liquid form in order to solidify the knobs properly. A copolyamide which has a reduced melting point is advantageously used, but the highest possible proportion of polyamide 6, in particular copolyamides with a polyamide 6 content of at least 80% by weight and preferably at least 90% by weight, is selected. The minor component introduced is of minor importance in relation to the total weight of the material used and is therefore not disruptive for recycling by depolymerization and the recovery of the starting component caprolactam. Copolyamides suitable for this purpose are commercially available hotmelt adhesives which are available both in film form and in powder form.

Der Grad der Verfestigung kann sowohl durch die Art des Copolymers als auch die Stärke der Folie oder die Menge des Pulvers anwendungs- und verbrauchsgerecht gesteuert werden. Typisch sind Auflagen von 30 bis 90 g/m2 und vorzugsweise 40 bis 70 g/m2. Gleichzeitig wird durch den Grad der Verfestigung die Dehnbarkeit des Teppichs für die Verspannung, insbesondere bei Einsatz von Wirkware als Teppichgrund, vorgegeben.The degree of solidification can be controlled by the type of copolymer, the thickness of the film or the amount of powder, depending on the application and consumption. Coatings of 30 to 90 g / m 2 and preferably 40 to 70 g / m 2 are typical. At the same time, the degree of consolidation determines the stretchability of the carpet for the bracing, especially when knitted fabric is used as the carpet base.

Bei der Verfestigung der Noppen kann gleichzeitig eine textile Fläche aus Polyamid 6, z.B. eine Webware, ein Vlies oder eine Wirkware, als Zweitrücken zur zusätzlichen Stabilisierung des Teppichs aufgebracht werden. Die erfindungsgemäße Teppichkonstruktion wird mit oder ohne separate Dämmschicht ohne Verkleben durch Spannen über Nadelleisten verlegt. Die Dämmschicht ist dann selbst nach beendetem Gebrauch wieder aufnehmbar und kann getrennt wiederverwertet werden. Auf diese Weise bleibt der verlegte Teppich recycling-fähig.When the knobs are solidified, a textile surface made of polyamide 6, for example a woven fabric, a fleece or a knitted fabric, can be applied at the same time as a second backing for additional stabilization of the carpet. The carpet construction according to the invention is with or without a separate insulation layer without gluing laid by stretching over needle bars. The insulation layer can then be taken up again after use and can be recycled separately. In this way, the carpet that is laid remains recyclable.

Beispiel 1example 1

Beispiel einer Konstruktion eines textilen Fußbodenbelags hergestellt nach dem Tuftingverfahren: Tuftinggrund: Kettwirkware aus Polyamid 6 Maschinen-Feinheit: 28 E Legeschiene 1: Material dtex 44 Bindung: Samt 102 - 454 Legeschiene 2: Material dtex 44 Bindung: Franse 100 - 011 Maschen/cm: 20 Gewicht g/m2: 90 Pol: Polyamid 6 - Teppichgarn Type: dtex 1250 f 68 x 2,215 T/m, S-Draht fixiert, antistatisch Tuften: Maschinenteilung: 1/10" Polhöhe (mm): 8 Stichzahl/10 cm, roh: 46 Poleinsatzgewicht roh (g/m2): 1270 Poleinsatzgewicht nach Färbung, ungeschoren (g/m,2): 1604 Verfestigung: Copolyamid-Folie (optischer Schmelzpunkt DIN 53 376 B 110 bis 115°C) - Gewicht 40 g/m2 Verfestigung: 115 - 122°C Example of a construction of a textile floor covering manufactured using the tufting process: Tufting reason: Warp knitted fabric made of polyamide 6 Machine fineness: 28 E. Laying rail 1: Material dtex 44 Binding: Velvet 102-454 Laying rail 2: Material dtex 44 Binding: Fringe 100-011 Stitches / cm: 20th Weight g / m 2 : 90 Pole: Polyamide 6 - carpet yarn Type: dtex 1250 f 68 x 2.215 T / m, S-wire fixed, antistatic Tufting: Machine division: 1/10 " Pole height (mm): 8th Number of stitches / 10 cm, raw: 46 Pole weight raw (g / m 2 ): 1270 Pole weight after coloring, unsheared (g / m, 2 ): 1604 Consolidation: Copolyamide film (optical melting point DIN 53 376 B 110 to 115 ° C) - weight 40 g / m 2 Consolidation: 115-122 ° C

Beispiel 2Example 2

Beispiel einer Konstruktion eines textilen Fußbodenbelags hergestellt nach dem Tuftingverfahren mit Zweitrücken:

Tuftinggrund:
analog Beispiel 1
Pol:
analog Beispiel 1
Tuften:
analog Beispiel 1
Verfestigung:
Copolyamid-Folie (Schmelzbereich wie in Beispiel 1) - 40 g/m2 - und Kettwirkware analog Tuftinggrund werden auf die Tuftingkonstruktion aufkaschiert (Temperatur 115-122°C)
Example of a construction of a textile floor covering manufactured according to the tufting process with two backs:
Tufting reason:
analogous to example 1
Pole:
analogous to example 1
Tufting:
analogous to example 1
Consolidation:
Copolyamide film (melting range as in Example 1) - 40 g / m 2 - and warp knitted fabrics analogous to the tufting base are laminated onto the tufting construction (temperature 115-122 ° C)

Claims (11)

  1. Tufting carpet which comprises a tufting base, a pile material and a carpet back, characterised in that it is made almost exclusively from polyamide 6.
  2. Tufting carpet according to claim 1, characterised in that the tufting base is knitwear.
  3. Tufting carpet according to claim 2, characterised in that the tufting base consists of yarns in the denier range from 20 dtex to 200 dtex.
  4. Tufting carpet according to claim 2 or 3, characterised in that the tufting base consists of filament yarn.
  5. Tufting carpet according to one of claims 2 to 4, characterised in that the tufting base is knitwear which has been produced with the following lay: Guide bar 1 (velvet) 102-454 Guide bar 2 (thread) 100-011 Stitches/cm 20 Pitch E 28.
  6. Tufting carpet according to claim 1, characterised in that the tufting base is a woven product.
  7. Tufting carpet according to claim 6, characterised in that the tufting base consists of yarns in the fineness range from 200 to 4000 dtex and the weave is linen cloth weave.
  8. Tufting carpet according to claim 1, characterised in that the tufting base is a fleece.
  9. Tufting carpet according to one of claims 1 to 8, characterised in that the carpet back consists of a film, a melt adhesive powder or a dissolved-on melt consisting of polyamide 6 or a copolyamide with a polyamide 6 content of at least 80% and is glued to the pile nap.
  10. Use of the tufting carpet according to one of claims 1 to 9 as a floor and wall covering.
  11. Use according to claim 10, characterised in that the floor or wall covering is laid by tensioning.
EP92105586A 1991-04-09 1992-04-01 Tufted carpet Expired - Lifetime EP0508287B1 (en)

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