EP0997562A2 - Gebundenes Gewebe und Verfahren zu dessen Herstellung - Google Patents

Gebundenes Gewebe und Verfahren zu dessen Herstellung Download PDF

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Publication number
EP0997562A2
EP0997562A2 EP99307017A EP99307017A EP0997562A2 EP 0997562 A2 EP0997562 A2 EP 0997562A2 EP 99307017 A EP99307017 A EP 99307017A EP 99307017 A EP99307017 A EP 99307017A EP 0997562 A2 EP0997562 A2 EP 0997562A2
Authority
EP
European Patent Office
Prior art keywords
woven product
thread
product according
threads
contact portions
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.)
Withdrawn
Application number
EP99307017A
Other languages
English (en)
French (fr)
Other versions
EP0997562A3 (de
Inventor
Gregor Hoy
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Don and Low Ltd
Original Assignee
Don and Low Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Don and Low Ltd filed Critical Don and Low Ltd
Publication of EP0997562A2 publication Critical patent/EP0997562A2/de
Publication of EP0997562A3 publication Critical patent/EP0997562A3/de
Withdrawn legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03J—AUXILIARY WEAVING APPARATUS; WEAVERS' TOOLS; SHUTTLES
    • D03J1/00—Auxiliary apparatus combined with or associated with looms
    • D03J1/06—Auxiliary apparatus combined with or associated with looms for treating fabric
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/50—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads
    • D03D15/587—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the properties of the yarns or threads adhesive; fusible
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D19/00—Gauze or leno-woven fabrics
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D9/00—Open-work fabrics
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2401/00—Physical properties
    • D10B2401/04—Heat-responsive characteristics
    • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2503/00—Domestic or personal
    • D10B2503/04—Floor or wall coverings; Carpets
    • D10B2503/041—Carpet backings
    • D10B2503/042—Primary backings for tufted carpets

Definitions

  • the present invention relates to an improved woven product, and to a method of manufacturing same.
  • Woven fabrics made from plastics material for use, for example, as a woven primary tufting substrate in the manufacture of carpets are known.
  • Such known fabrics suffer from a number of problems. For example, deformation of the substantially uniform fabric weave can occur if the fabric is stretched in the plane of the fabric. Further fabrics produced by weaving of flat rectangular cross section polypropylene tapes offer little resistance to penetration by a tufting needle. However, it has been found that at the point of entry the needle may cause tapes (e.g. warp tapes) to deflect.
  • a woven product comprising a plurality of first threads, and a plurality of second threads, wherein contact portions provided along each first thread contact respective contact portions provided along each second thread, wherein further each first thread is bonded to each second thread at the respective contact portions.
  • each contact portion of each first thread is bonded (fused) to each respective contact portion of each second thread by means of a thermal and/or pressure bonding process.
  • first and second opposing outer surfaces of each first thread are formed from a first material having a melting point and/or softening point lower than that of a second material from which the first and second outer surfaces of each second thread are formed.
  • first outer surface of each first thread is formed from a first material having a lower melting point and/or softening point than that of a second material from which the second outer surface of each second thread is formed, and further the first outer surface of each second thread is formed from a third material having a lower melting point and/or softening point than that of a fourth material from which the second outer surface of each first thread is formed.
  • the third material and the first material may be one and the same.
  • the fourth material and the second material may be one and the same.
  • the melting point of the first/third material may be between 20 and 50°C less than that of the second/fourth material, and preferably approximately 25°C less.
  • the melting point of the first/third material may be approximately 120°c.
  • the melting point of the second/fourth material may be approximately 160°c.
  • the first threads may comprise warp threads or weft threads.
  • the woven product may be in the form of a plain weave.
  • the woven product may be in the form of a leno weave including interweaved pairs of first threads.
  • each first thread comprises a core layer made of one material, and first and second opposing outer layers made of at least one other material, the/each other material having a melting point/softening point lower than that of the one material.
  • each second thread may be made from a further material, the further material having a higher melting point/softening point than the at least one other material(s).
  • the further material, and the one material may be one and the same.
  • each second thread may comprise a further core layer made from a further material, and further first and second opposing layers made of at least one further other material, the further material having a higher melting point/softening point than the at least one further other material.
  • the one material, and the further material may be one and the same, and further the at least one other material and the at least one further material may be one and the same.
  • the one material/further material may comprise polypropylene, e.g. a polypropylene homo-polymer, block co-polymer or ter-polymer.
  • the further material may comprise polypropylene, e.g. a polypropylene homo-polymer, block co-polymer or ter-polymer.
  • the at least one other material/one further other material may comprise ethylenepropylene, e.g. an ethylenepropylene random co-polymer, ethylenepropylene block co-polymer or ter-polymer.
  • the first and/or second threads may advantageously comprise flat rectangular cross-section tapes.
  • first layer/further first layer may comprise between 1% and 50% of the thickness of the tape.
  • the second layer/further second layer may comprise between 1% and 50% of the thickness of the tape.
  • Each tape may have an approximate thickness in the range 30 ⁇ m (Micron) to 300 ⁇ m (Micron).
  • each tape may have an approximate width in the range 0.5mm to 5mm.
  • the tape may have a width of approximately 1mm.
  • the tape may have a width of approximately 2.5mm.
  • Each tape may have a breaking load of approximately 400 to 450 mN/TEX.
  • first threads substantially equally spaced one from the other have a higher modulus than the remaining first threads.
  • first thread comprises a warp thread
  • every 50th to 60th warp thread (or alternatively the thread positioned at approximately every 5cm (centimetres))
  • comprises a higher modulus material that is a material having a higher breaking load and lower elongation, than the remaining warp threads.
  • the woven product may have a mesh size of between 0.1mm and 1.0mm.
  • the product may be used as a tufting substrate for use in the manufacture of carpets, or the like
  • the woven product may have a mesh size of between 3mm and 50mm.
  • the product may be used as an air permeable window, e.g. for use in a bag (plastic bag), or the like, e.g. intended for use in retaining perishable goods like fruit and/or vegetables.
  • the product may be used as a windbreak.
  • a carpet including a tufting substrate, the substrate comprising a woven product according to the first aspect.
  • a bag including an air permeable window, the window comprising a woven product according to the first aspect.
  • a method of manufacturing a woven product comprising the steps of:
  • the step of bonding includes the application of heat and/or pressure to the first and/or second threads.
  • the woven product 5a comprises a plurality of first threads 10a, and a plurality of second threads 15a, wherein contact portions 20a provided along each first thread 10a contact respective contact portions 25a provided along each second thread 15a, and wherein further each first thread 10a is bonded to each second thread 15a at the respective contact portions 20a, 25a.
  • Each contact portion 20a of each first thread 10a is bonded (fused) to each respective contact portion 25a of each second thread 15a by means of a thermal and/or pressure bonding process which will be described in greater detail hereinafter.
  • adjacent contact portions 20a of each first thread 10a are provided alternately on first and second opposing outer surfaces 30a, 35a of each first thread 10a. Further, adjacent contact portions 25a of each second thread 15a are provided alternately on first and second opposing outer surfaces 40a, 45a of each second thread 15a.
  • each first thread 10a is, in this embodiment, formed from a first material having a melting point and/or softening point lower than that of a second material from which the first and second outer surface 40a, 45a of each second thread 15a are formed. It will be appreciated, therefore, that the first threads 10a may be made wholly of the first material and the second threads 15a made wholly of the second material.
  • first outer surface 30a of each first thread 10a is formed from a first material having a lower melting point than that of a second material from which the second outer surface 45a of each second thread 15a is formed, and further the first outer surface 40a of each second thread 15 is formed from a third material having a lower melting point than that of a fourth material from which the second outer surface 35a of each first thread 10a is formed.
  • the third material and the first material may be one and the same, and further the fourth material and the second material may be one and the same.
  • the melting point of the first/third material is between 10 and 40°C less than that of the second/fourth material, and preferably approximately 25°C less. Further, the melting point of the first/third material is approximately 120°c, while the melting point of the second/fourth material is approximately 160°c.
  • first threads comprise warp threads.
  • first threads 10a may alternatively comprise weft thread.
  • the woven product 5a is in the form of a plain weave.
  • Each first thread 10a comprises a core layer 50a made of one material and first and second opposing outer layers 30a, 35a made of at least one other material, the/each other material having a melting point lower than that of the one material.
  • each second thread may be made from a further material, the further material having a higher melting point that the at least one other material(s).
  • the further material and the one material may be one and the same.
  • each second thread 15a may comprise a further core layer 55a made from a further material and further first and second opposing layers made of at least one further other material the further material having a higher melting point than the at least one further other material.
  • the one material and the further material may be one and the same, and further the at least one other material and the at least one further material may be one and the same.
  • the one material/further material comprises polypropylene, e.g. a polypropylene homo-polymer, block co-polymer or ter-polymer.
  • the further material comprises polypropylene, e.g. a polypropylene homo-polymer, block co-polymer or ter-polymer.
  • the at least one other material/one further other material comprises ethylenepropylene, e.g. an ethylenepropylene random co-polymer, ethylenepropolyne block co-polymer or ter-polymer.
  • the first and/or second threads 10a, 15 comprise planar tapes.
  • the first layer 30a /further first layer 40a comprises between 1% and 25% of the thickness of the tape.
  • the second layer 35a/further second layer 45a comprises between 2% and 25% of the thickness of the tape.
  • each tape has an approximate thickness in the range 30 ⁇ m to 300 ⁇ m, and each tape has an approximate width in the range 0.5mm to 5mm.
  • the tape advantageously has a width of approximately 1mm.
  • the second thread comprises a weft thread
  • the tape has a width of approximately 2.5mm.
  • each tape has a breaking load of approximately 400 to 450 mN/TEX.
  • the woven product 5a may have a mesh size of between 0.1mm and 1.0mm.
  • the product 5a may, therefore, be particularly suitable for use as a tufting substrate for use in the manufacture of carpets or the like, such as a carpet 60a as shown in Fig. 8 having tufts 65a.
  • first threads 10b comprise weft tapes made of a three-layer structure similar to that of Fig. 2, while the second tapes comprise warp tapes made of a single material having a higher melting point than that of the material from which the outer layers 30b, 35b of the weft tapes are made.
  • both first and second threads 10c, 15c are three layer bi-national threads similar to that of Fig. 2.
  • the woven product 5c is in the form of a leno weave including interleaved pairs of first (warp) threads 10c.
  • the mesh size of the woven product 5c may be, for example, between 3mm and 25mm.
  • the product 5c may, therefore, be particularly suitable for use as an air permeable article, e.g. for use as an air permeable window in a bag, such as a plastic (polythene) bag, e.g. for carrying of perishable goods such as fruit or vegetables.
  • a bag 70c incorporating in one side wall 75c thereof a breathable window 80c formed from the woven product 5c and retained on the wall 75c, e.g. by adhesive or plastic welding techniques.
  • the woven products 5a, 5b, 5c are manufactured by a method comprising the steps of:
  • the apparatus 100 may be used to form mono-layer (single material) threads by feeding material into a central inlet 105 and extruding such material through a central extrusion die outlet 110.
  • the apparatus 100 may further be used to form tri-layer (bi-component or two material) threads by feeding one material into the central inlet 105, and a second material into an outer inlet 115, and extruding the materials through the central extrusion die outlet 110 and an outer die outlet 120. In this way a three-layer bi-component tape as shown in Fig. 2 can be formed.
  • step (b) may be woven in accordance with step (b) by known weaving techniques, for example, using a loom 150, as shown in Fig. 6.
  • Fig. 7 shows a bonding process employing a 5mm wide calander 200.
  • the calander 200 comprises a first steel dowel 205 typically heated to around 170°C rotatable about a first longitudinal axis X, and a second polyamide dowel 210 which is normally unheated.
  • the woven product 5a, 5b, 5c is fed between the dowels 205, 210, in so doing heating and softening the product 5a, 5b, 5c and applying pressure thereto so as to activate bonding between adjacent contact portions 20a, 25a; 20b, 25b; 20c, 25c.
  • This step has been found to promote geometric stability and regular mesh size to the product 5a, 5b, 5c.
  • a mono-layer warp tape and bi-component tri-layer weft may be provided, or alternatively bi-component tri-layer warp tape and mono-layer weft tape, or alternatively also bi-component tri-layer warp and weft tapes.
  • warp threads positioned at regular intervals which have a higher modulus, that is a higher breaking load and lower elongation, than the remaining warp threads.
  • every 50th to 60th warp thread tape (or alternatively the tape positioned at approximately every 5cm (centimetres)), comprises a higher modulus material than the remaining warp threads.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)
  • Woven Fabrics (AREA)
EP99307017A 1998-09-04 1999-09-03 Gebundenes Gewebe und Verfahren zu dessen Herstellung Withdrawn EP0997562A3 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB9819288.3A GB9819288D0 (en) 1998-09-04 1998-09-04 Improvements in or relating to woven products
GB9819288 1998-09-04

Publications (2)

Publication Number Publication Date
EP0997562A2 true EP0997562A2 (de) 2000-05-03
EP0997562A3 EP0997562A3 (de) 2004-04-07

Family

ID=10838331

Family Applications (1)

Application Number Title Priority Date Filing Date
EP99307017A Withdrawn EP0997562A3 (de) 1998-09-04 1999-09-03 Gebundenes Gewebe und Verfahren zu dessen Herstellung

Country Status (2)

Country Link
EP (1) EP0997562A3 (de)
GB (1) GB9819288D0 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6902789B2 (en) * 2000-08-31 2005-06-07 Ohno Co. Ltd. Tufted carpet and backing fabric
US8784967B2 (en) 2009-10-09 2014-07-22 Volm Companies, Inc. Open mesh material and bags made therefrom
US20200283965A1 (en) * 2017-11-13 2020-09-10 Hugo de Vries Artificial turf mat and method for manufacture thereof

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH316308A (de) * 1955-10-14 1956-09-30 Schulthess Emil Verpackung für Hefegebäck
FR1127406A (fr) * 1954-12-21 1956-12-17 Papeteries Clement Chupin Pochette spécialement destinée aux produits ménagers
US3864195A (en) * 1972-01-27 1975-02-04 Henry G Patterson Stable synthetic carpet backing material
US4107371A (en) * 1977-10-25 1978-08-15 Johnson & Johnson Woven fabric that is relatively stiff in one direction and relatively flexible in the other
DE3120661A1 (de) * 1981-05-23 1982-12-16 Huesker Synthetic GmbH & Co, 4423 Gescher Gittergewebe, insbesondere zum bewehren von platten und schichten
US4406310A (en) * 1980-03-12 1983-09-27 Reader A M Secondary carpet backing fabrics
DE3835929A1 (de) * 1988-10-21 1990-04-26 Kirson Gmbh Verfahren zum gegenseitigen verbinden von gitter bildenden faeden
US4980227A (en) * 1987-06-03 1990-12-25 Diatex Co., Ltd. Netlike sheet and method for producing multilayer yarn for producing the same

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1127406A (fr) * 1954-12-21 1956-12-17 Papeteries Clement Chupin Pochette spécialement destinée aux produits ménagers
CH316308A (de) * 1955-10-14 1956-09-30 Schulthess Emil Verpackung für Hefegebäck
US3864195A (en) * 1972-01-27 1975-02-04 Henry G Patterson Stable synthetic carpet backing material
US4107371A (en) * 1977-10-25 1978-08-15 Johnson & Johnson Woven fabric that is relatively stiff in one direction and relatively flexible in the other
US4406310A (en) * 1980-03-12 1983-09-27 Reader A M Secondary carpet backing fabrics
DE3120661A1 (de) * 1981-05-23 1982-12-16 Huesker Synthetic GmbH & Co, 4423 Gescher Gittergewebe, insbesondere zum bewehren von platten und schichten
US4980227A (en) * 1987-06-03 1990-12-25 Diatex Co., Ltd. Netlike sheet and method for producing multilayer yarn for producing the same
DE3835929A1 (de) * 1988-10-21 1990-04-26 Kirson Gmbh Verfahren zum gegenseitigen verbinden von gitter bildenden faeden

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6902789B2 (en) * 2000-08-31 2005-06-07 Ohno Co. Ltd. Tufted carpet and backing fabric
US8784967B2 (en) 2009-10-09 2014-07-22 Volm Companies, Inc. Open mesh material and bags made therefrom
US9339986B2 (en) 2009-10-09 2016-05-17 Volm Companies, Inc. Open mesh material and bags made therefrom
US9573342B2 (en) 2009-10-09 2017-02-21 Volm Companies, Inc. Open-mesh bags and methods of production
US9630375B2 (en) 2009-10-09 2017-04-25 Volm Companies, Inc. Form, fill, and seal bags and method of production
US10934042B2 (en) 2009-10-09 2021-03-02 Volm Companies, Inc. Method of making form, fill, and seal bags
US20200283965A1 (en) * 2017-11-13 2020-09-10 Hugo de Vries Artificial turf mat and method for manufacture thereof

Also Published As

Publication number Publication date
EP0997562A3 (de) 2004-04-07
GB9819288D0 (en) 1998-10-28

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