EP0603774B1 - Carpet-interlayer consisting of a nonwoven - Google Patents

Abstract

The invention relates to a mat fabric (2) produced on the basis of a nonwoven (1). In order to provide a novel mat fabric of this type, the invention proposes using fibrous constituents which consist predominantly of synthetic material and which are partly thermoplastic and low-melting and partly higher-melting, cohesion being achieved by melting on the low-melting thermoplastic fibre fractions (4). <IMAGE>

Description

The invention relates to a manufactured on the basis of a nonwoven Mat goods.

Mat products of this type are known. BE-A-9 100 631 describes the Production of a felt from individualized individual fibers.

The object of the present invention is to provide a novel, Mat goods made on the basis of a fleece are available to deliver.

This problem is solved by the one specified in claim 1 Invention.

The subclaims represent advantageous developments represents.

As a result of this design is a novel, based a mat made of a fleece, which a high flexibility, due to the confusion of low and high-melting components. The mat goods consists mainly of fibrous plastic components, some of them thermoplastic and low melting and some are more melting. By melting the low-melting thermoplastic fiber is a Cohesion of the fibrous components is given. As a high-melting Fiber components are preferred polyamide fibers used, which have a melting point of about 220 ° C. The latter is significantly higher than that of thermoplastic and low-melting fiber components. Be here Polyolefins such as polypropylene, polyethylene or the like is preferred. Using heat the loosely spread out or laid out in the form of a mat Fibers will melt the low-melting thermoplastic fiber components such as polypethylene or polypropylene, resulting in arrest between the low-melting and the higher-melting ones Components leads. The temperature during the The effect of heat corresponds approximately to the melting point the low-melting fiber content, i.e. approx. 120-l70 ° C. Here, the rigidity and inherent load-bearing capacity the mat goods are affected. For example, increased this increases with the proportion of low-melting thermoplastic fiber parts within the mat or even with prolonged exposure to heat, whereby also the lower-lying, low-melting fiber parts melted will. The mat goods can also share of polyester fiber material and proportions of styrene butadiene, Styrene acrylate or ethylene vinyl acetate. It proves to be particularly advantageous that the melted areas networked island-like or island-like are arranged. This is a network Support structure of the mat given, the narrowness of the Mesh and thus the rigidity and the self-bearing capacity the mat goods depending on the quantity ratio between low and high melting parts and depending on the duration of the heat application stands. It is preferred that the melted areas only to be arranged lying on the surface. This means, that the melted on the surface of the mat Areas of cohesion of the fiber parts achieve and thus form a stabilizing "outer skin". The high-melting parts and those caused by the heat non-melted low-melting parts stick to each other through their confusion and on the other hand, by fusing the melted Areas with the low melting parts. In a preferred embodiment, that the melted areas lie on the surface are arranged on one side. The mat fabric thus shows only a stabilizing "outer skin" on one side on. It also proves to be particularly advantageous that the mat fabric produced as a fleece is set to be conductive is, for example, by proportions of carbon fibers or metallized conductive fibers (the latter again preferably based on polyamide).

The invention also relates to a method for the production a mat product made on the basis of a fleece, for example a mat product of the previously described Embodiment. In this context focused on being a predominantly plastic fiber existing carpet, which is preferably made of a pole material based on preferably polyamide 6.6, preferably from a carrier material made of polypropylene nonwoven or polypropylene ribbon fabric, more preferably from a pre-coat of styrene-butadiene, ethylene vinyl acetate, Styrene acrylate or the like preferably from a laminating adhesive based on Polyolefins such as polyethylene and polypropylene and more preferably from a backing layer Based on polyolefins, preferably made of polypropylene or The like exists, torn into fibrous components becomes, if necessary, a needled, fleece is laid and this fleece at least on the surface Heat is applied so that the low-melting melt the thermoplastic parts. There is one Heat required, which is the polyolefinic Components, but not the fibrous parts based of polyamide in particular melts. For example Polyamide a melting point of 220 ° C, the used In contrast, polyolefins already soften and melt at 120-170 ° C. This will make the surface of the fleece arranged low-melting fiber parts melted, creating a point-like bond of the components arranged in confusion on the surface of the fleece is achieved. The melted areas can, as already described, island-like or island-like be networked. To improve To achieve adhesion of the components to one another preferred that the mat goods compact after melting becomes. This also increases stability the mat product achieved. It is advantageous to use the mat compress after melting between press chill rolls. Finally, it is provided that the fleece on a Carrier web is laid, at least until the success Melting of low-melting thermoplastic parts follows. Manageability is achieved in this way despite one only due to the confusion of the individual components given cohesion of the fiber components the effect of heat.

The invention also relates to carpeting, especially with a pile layer of pile threads, one Backing layer made of fiber or ribbon material consists of polyolefins or polyester, and a back coating, the pile threads possibly over the Back coating firmly attached to the backing are and from a comparatively high temperature resistant Plastic, especially polyamide 6 or 6.6. This is based on the fact that an intermediate layer consists of a mat, the mat fibrous components consisting predominantly of plastic, some of them thermoplastic and low melting and are partially higher melting, has a Cohesion by melting the low-melting thermoplastic fiber content is achieved, preferably produced in a process in which a Carpeting consisting mainly of plastic fibers is torn out to fibrous constituents if necessary needled fleece is placed and this Fleece is subjected to heat at least on the surface, such that low-melting thermoplastic components melt. Those in the previous embodiments The mat goods described can be used as underlay mats (Underlay) can be used for tensioned carpets or used as an intermediate layer in a carpet will. It can be provided that the mat is covered on the underside by a layer of fabric. Finally, it can advantageously be provided that the mat goods are laminated with an intermediate layer is, in particular by melting the low-melting thermoplastic parts. This can be done here be that the melting of the low-melting thermoplastic parts of the fleece both the cohesion between the fibrous components of the mat as well as form the adhesion to an intermediate layer. This can be done in one operation, provided that the components of the mat to be provided Rug made of high temperature resistant thermoplastic Shares exist.

Figur 1

eine schematische Darstellung einer auf Basis eines Vlieses hergestellten Mattenware in stark vergrößerter Draufsicht,

Figur 2

den Schnitt gemäß der Linie II-II in Figur 1,

Figur 3

eine stark vergrößerte Ausschnittsdarstellung der Figur 1 im Bereich von inselartig angeordneten aufgeschmolzenen Bereichen niedrigschmelzender thermoplastischer Faseranteile,

Figur 4

eine schematische Darstellung einer Vorrichtung zur Herstellung einer auf Basis eines Vlieses hergestellten Mattenware und

Figur 5

einen schematischen, teilweise aufgetrennt dargestellten Teppichboden, welcher mit einer aus einer Mattenware gemäß Figur 1 bestehenden Zwischenschicht versehen ist.

The invention is further explained below with reference to the accompanying drawing, which, however, only represents exemplary embodiments. Here shows:

Figure 1

1 shows a schematic representation of a mat product produced on the basis of a fleece in a greatly enlarged top view,

Figure 2

the section along the line II-II in Figure 1,

Figure 3

1 in the region of melted regions of low-melting thermoplastic fiber parts arranged in island-like fashion,

Figure 4

is a schematic representation of a device for producing a mat made on the basis of a nonwoven and

Figure 5

a schematic, partially separated carpet, which is provided with an intermediate layer consisting of a mat according to Figure 1.

It is shown and described first with reference to FIG 1, a mat product produced on the basis of a fleece 1 2, which is predominantly made of plastic fibrous Components 3 has. These fibrous components 3 are a mixture of thermoplastic low melting Fiber parts 4 and higher melting fiber parts 5. The low-melting fiber portions 4 exist, for example made of polyolefins such as polyethylene, polypropylene or the like. As a high temperature resistant fiber 5 parts preferably those made of polyamide 6 or polyamide 6.6. used. The fiber parts 4 and 5 are arranged in a tangled position, with a cohesion of the fiber parts 4 and 5 is given, which by on one surface 2 'or Mat fabric 2 distributed areas 7 of melted low-melting fiber portions 4 reinforced is. As can be seen in particular from FIG. 3, the higher melting polyamide fibers 5 interconnected by the low-melting fiber parts 4, the partially envelope-like, as in reference number 6, for example shown, the polyamide fibers 5 glue. There are also larger clusters, as indicated by the reference number 8 explains the thermoplastic components. There are fiber groups 8 which are due to longer polyamide fibers 5 connected to other fiber groups 8 ' are. This further results on the surface 2 'of the mat 2 melted areas 9 in the form of adhesive dots. Through these island-like glue dots is an improved cohesion of the fiber shares within the mat product 2 achieved. Depending on the frequency of the low-melting fiber portions 4 can use these glue dots 9 also merge into one another. So it is given a support structure, the melted from low-melting fiber components 4 existing adhesive points 9 partially the higher melting fiber portions 5 enclose. These in turn form due to the confusion a cohesion with each other. As can be seen from FIG. 2, are only those located near the surface 2 ' low-melting fiber parts 4 to glue points 9 merged. The low-melting fiber components 4, which is distant from the surface 2 ', i.e. arranged in the middle or on the opposite side are not melted and fit into the Confusion. Due to the island-like or island-like cross-linked bonding of the fiber parts 4 and 5 and the Confusion of the fibrous parts is a flexibility of Given mat material 2.

In addition, the mat fabric has 2 conductive substances on. These can be made of carbon fibers, for example 26 or made of metallized conductive fibers (the latter in turn preferably based on polyamide). FIG. 4 shows a device 10 for producing a shown on the basis of a fleece 1 mat fabric 2. For this purpose fibrous constituents 11, which consist of a ripped open, consisting mainly of plastic fibers Carpeting can be obtained in a first Device 12 to a loose, only by the confusion of the individual fiber parts 4 and 5 held together Fleece, for example by means of a slide device 13, shaped and on a carrier web 14 in the form of a circumferential Endless belt laid. That only through the Tangle of the fibrous components 3 molded fleece is provided with the reference number 15 in FIG. That on the fleece lying on the carrier web 14 now passes underneath a reflow device 16 in which the surface 2 'of the mat fabric 2 arranged low-melting Fiber portions 4 are melted and thus a form a stabilizing "outer skin". In the further course of transport after the melting device has been undermined 16 in the direction of the arrow x is the mat material of press chill rolls 18 acted upon and compressed.

Figure 5 shows an example of using one of these manufactured mat material 2. The latter serves as Intermediate layer 19 of a carpet 20. This carpet 20, which is shown schematically in FIG. 5, has pile threads 21, which form a pile layer, made of polyamide 6 or polyamide 6.6. These pile threads 21 are in a carrier material 22 needled. The carrier material 22 can be a fleece or ribbon fabric made of polypropylene. A first solidification of the pile threads 21 with the carrier material 22 is achieved by a so-called primer 23, the is shown here as an exaggerated layer. In the In reality, the primer coating is very thin. The primer consists of copolymers of e.g. Styrene acrylate, Styrene butadiene, ethylene vinyl acetate and others. The carrier material 22 with those in it - maybe because of the primer 23 - needled and solidified pile threads 21 is by means of a lamination 24, which is also made here For reasons of demonstration shown as an exaggeratedly thick layer is formed with the intermediate layer 19 Mat fabric 2 connected. However, this connection can also by melting the low-melting thermoplastic Fiber portions 4 of the mat fabric 2 take place. Underside the mat is covered by a fabric layer 25. The latter can be based on a fabric, for example Be polypropylene.

The mat goods 2 shown and described can, however also as an independent product in the sense of a mat (Underlay) can be used for tensioned carpets.

The in the above description, the drawing and Features of the invention disclosed in the claims can both individually and in any combination for the Realization of the invention may be of importance. All disclosed Features are essential to the invention.

Claims (14)

1. Mat product based on a bonded-fibre fabric which has fibrous constituents consisting of plastic, some of which are thermoplastic and have low melting point and some of which have higher melting point, characterised in that fibres (5) of higher melting point are adhered to form fibre groups (8, 8') by partial melting of the thermoplastic constituents, wherein the fibre groups (8, 8') are joined by longer fibres (5).
2. Mat product according to claim 1, characterised in that the molten regions (9) are arranged like islands.
3. Mat product according to one or more of the preceding claims, characterised in that the molten regions (9) are arranged to be cross-linked like islands.
4. Mat product according to one or more of the preceding claims, characterised in that the molten regions (9) are arranged to lie on the surface (2').
5. Mat product according to one or more of the preceding claims, characterised in that the molten regions (9) are arranged to lie on one side of the surface (2').
6. Mat product according to one or more of the preceding claims, characterised in that the bonded-fibre fabric (1) is made to be conductive, for example by portions of carbon fibres (26) or metal-coated fibres.
7. Process for producing a mat product, particularly according to claim 1, characterised in that carpeting consisting predominantly of plastic fibres, having thermoplastic and low melting point constituents and some higher melting point constituents is torn apart to form fibrous constituents (11), from which an optionally needled bonded-fibre fabric (15) is laid, in that at least one surface (2') of the bonded-fibre fabric (15) is exposed to heat such that low melting point, thermoplastic portions adhere by melting fibres (15) of higher melting point to form fibre groups (8, 8'), wherein the fibre groups (8, 8') are joined by longer fibres (5).
8. Process according to claim 7, characterised in that carpeting consisting predominantly of plastic fibres having a polar material based on polyamide 6 or polyamide 6.6, having a support material of a polypropylene bonded-fibre fabric or polypropylene tape fabric, having a primary coating of copolymers based on ethylene vinyl acetate, styrene-butadiene or styrene-acrylate, having a laminating adhesive and having a backing layer based on polyolefins, such as polypropylene or the like, is torn apart and the low melting point, thermoplastic portions are melted by heat exposure of the bonded-fibre fabric laid therefrom.
9. Process for producing a mat product (2) according to claim 7 or 8, characterised in that the mat product (2) is compacted after melting.
10. Process for producing a mat product (2) according to one or more of claims 7 to 9, characterised in that the mat product (2) is compressed after melting by pressing cooling rollers (18).
11. Process for producing a mat product (2) according to one or more of claims 7 to 10, characterised in that the bonded-fibre fabric (1) is laid on a support web (14) which runs with it at least until melting of low melting point, thermoplastic portions (4) is completed.
12. Carpeting (20) having polar threads (21) forming a pile layer, having a support layer (22) and a backing coating, wherein the polar threads (21) are firmly joined to the support layer optionally via the backing coating, characterised by an intermediate layer (19) of a mat product (2) according to claims 1 - 13, produced particularly by a process according to claims 7 - 11.
13. Carpeting according to claim 12, characterised in that the mat product (2) is covered on the under side by a fabric layer (25).
14. Carpeting according to one or more of claims 12 - 13, characterised in that the mat product (2) is bonded to the fabric layer (25) and/or the backing coating or the support layer (22) by melting its low melting point, thermoplastic portions (4).

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