EP1026311A2 - Tapis recyclable et son procédé de fabrication - Google Patents
Tapis recyclable et son procédé de fabrication Download PDFInfo
- Publication number
- EP1026311A2 EP1026311A2 EP00830024A EP00830024A EP1026311A2 EP 1026311 A2 EP1026311 A2 EP 1026311A2 EP 00830024 A EP00830024 A EP 00830024A EP 00830024 A EP00830024 A EP 00830024A EP 1026311 A2 EP1026311 A2 EP 1026311A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- floor covering
- vinyl
- covering material
- fiber
- process 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.)
- Withdrawn
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 9
- 238000000034 method Methods 0.000 claims abstract description 27
- 230000008569 process Effects 0.000 claims abstract description 26
- 239000000463 material Substances 0.000 claims abstract description 21
- 239000011230 binding agent Substances 0.000 claims abstract description 19
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims abstract description 19
- 229920005989 resin Polymers 0.000 claims abstract description 17
- 239000011347 resin Substances 0.000 claims abstract description 17
- 229920002554 vinyl polymer Polymers 0.000 claims abstract description 16
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 12
- 229920002994 synthetic fiber Polymers 0.000 claims abstract description 10
- 239000004753 textile Substances 0.000 claims abstract description 10
- 239000007900 aqueous suspension Substances 0.000 claims abstract description 9
- 239000012209 synthetic fiber Substances 0.000 claims abstract description 9
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 3
- 229920002689 polyvinyl acetate Polymers 0.000 claims abstract 3
- 239000011118 polyvinyl acetate Substances 0.000 claims abstract 3
- 239000002904 solvent Substances 0.000 claims abstract 3
- 239000000835 fiber Substances 0.000 claims description 22
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 10
- 239000000945 filler Substances 0.000 claims description 10
- 229920001577 copolymer Polymers 0.000 claims description 8
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 6
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 6
- 150000001875 compounds Chemical class 0.000 claims description 6
- 150000002148 esters Chemical class 0.000 claims description 6
- 125000005395 methacrylic acid group Chemical group 0.000 claims description 6
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical group [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 5
- 229910021502 aluminium hydroxide Inorganic materials 0.000 claims description 5
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 5
- 239000007864 aqueous solution Substances 0.000 claims description 4
- 238000009960 carding Methods 0.000 claims description 4
- 239000002562 thickening agent Substances 0.000 claims description 4
- JAHNSTQSQJOJLO-UHFFFAOYSA-N 2-(3-fluorophenyl)-1h-imidazole Chemical compound FC1=CC=CC(C=2NC=CN=2)=C1 JAHNSTQSQJOJLO-UHFFFAOYSA-N 0.000 claims description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 3
- 239000005977 Ethylene Substances 0.000 claims description 3
- 230000007062 hydrolysis Effects 0.000 claims description 3
- 238000006460 hydrolysis reaction Methods 0.000 claims description 3
- LVHBHZANLOWSRM-UHFFFAOYSA-N methylenebutanedioic acid Natural products OC(=O)CC(=C)C(O)=O LVHBHZANLOWSRM-UHFFFAOYSA-N 0.000 claims description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 3
- 235000019422 polyvinyl alcohol Nutrition 0.000 claims description 3
- 239000011265 semifinished product Substances 0.000 claims description 3
- 229920001567 vinyl ester resin Polymers 0.000 claims description 3
- NIQCNGHVCWTJSM-UHFFFAOYSA-N Dimethyl phthalate Chemical group COC(=O)C1=CC=CC=C1C(=O)OC NIQCNGHVCWTJSM-UHFFFAOYSA-N 0.000 claims description 2
- 229920002821 Modacrylic Polymers 0.000 claims description 2
- 229920000728 polyester Polymers 0.000 claims description 2
- OAXIABLJUFVKAX-MKWAYWHRSA-N (z)-4-butoxy-4-oxobut-2-enoic acid;ethenyl acetate Chemical compound CC(=O)OC=C.CCCCOC(=O)\C=C/C(O)=O OAXIABLJUFVKAX-MKWAYWHRSA-N 0.000 claims 1
- 238000010438 heat treatment Methods 0.000 claims 1
- 229920006163 vinyl copolymer Polymers 0.000 claims 1
- 229920000642 polymer Polymers 0.000 abstract 1
- 239000000047 product Substances 0.000 description 8
- 238000009408 flooring Methods 0.000 description 7
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 239000003063 flame retardant Substances 0.000 description 5
- 239000003637 basic solution Substances 0.000 description 3
- 239000004816 latex Substances 0.000 description 3
- 229920000126 latex Polymers 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 238000001035 drying Methods 0.000 description 2
- -1 e.g. Substances 0.000 description 2
- 229920006395 saturated elastomer Polymers 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 1
- 241000124033 Salix Species 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- WPYMKLBDIGXBTP-UHFFFAOYSA-N benzoic acid group Chemical group C(C1=CC=CC=C1)(=O)O WPYMKLBDIGXBTP-UHFFFAOYSA-N 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- UTOVMEACOLCUCK-PLNGDYQASA-N butyl maleate Chemical compound CCCCOC(=O)\C=C/C(O)=O UTOVMEACOLCUCK-PLNGDYQASA-N 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000002209 hydrophobic effect Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000010687 lubricating oil Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000020477 pH reduction Effects 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229920003048 styrene butadiene rubber Polymers 0.000 description 1
- 239000000725 suspension Substances 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/435—Polyesters
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
- D04H1/488—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with bonding agents
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
-
- 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
- D06N7/0068—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 the primary backing or the fibrous top layer
-
- 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
-
- 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
- D06N2201/0245—Acrylic resin 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
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
- D06N2201/0254—Polyolefin 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
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/041—Polyacrylic
-
- 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
- D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06N2203/045—Vinyl (co)polymers
-
- 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
- D06N2209/00—Properties of the materials
- D06N2209/12—Permeability or impermeability properties
- D06N2209/126—Permeability to liquids, absorption
- D06N2209/128—Non-permeable
-
- 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
- D06N2211/066—Floor coverings
Definitions
- the present invention relates to a process for the manufacture of a textile flooring material, in particular a recyclable wall-to-wall carpeting.
- the invention further relates to the textile flooring material manufactured according to said process. More specifically, the invention relates to those textile flooring materials that are subject to an intensive use over a short period of time, for instance during a fair show, and are destined to be removed after use.
- textile flooring materials for these types of use are manufactured using synthetic materials, essentially for their cost-effectiveness, and include a needlepunched base layer made of a synthetic fiber, mainly polyolefine fiber and in particular polypropilene fiber, held together by a layer of binding resin applied onto a face thereof.
- binding resin an aqueous solution (latex) of a styrene-butadiene copolymer is used as binding resin.
- the solution contains various additives and fillers, e.g., calcium carbonate and aluminium hydroxide, in order to increase its consistence and fire retardant properties, thickening agents for controlling its fluidity, etc.
- the latex can be applied with a spreader roller drafting from a latex collection tank, or with another likewise technique, and then the latex-saturated semifinished product is heated in order to evaporate the water and dry the binder.
- the fitting of this type of carpet is implemented by means of a two-sided tape, that also enables an easy removal of the carpet after use.
- An object of the present invention is to provide a process for the manufacture of a textile flooring material which is able to be recycled after use by means of a treatment that entails no damage to the fiber, thus allowing the reclaiming of at least the latter and the reintroduction thereof into the manufacture cycle.
- a particular object of the present invention is to provide an after-use recyclable carpet.
- the process according to the invention is conventionally based on the use of synthetic fibers received as bales that undergo a preliminary treatment indicated with 1, i.e., a processing through a machine 2 called "bale-breaker" for homogenising the batch by grading it according to the colour and to the fiber type (denier, length, crimp, composition).
- a first rough opening of the fiber staples, compacted by the stationing thereof inside the bales, is implemented in a carding willow 3, and then lubricating oil is added to the partly-opened fibers to let them slide into a so-called oiling cell 4.
- the fiber compound thus obtained, or “mix” is then sent to the next manufacture step of a raw fiber panel, or felt, indicated with 5. At this stage, the fiber compound is repeatedly aired inside storage chambers 6 to which it is recirculated with a suitable device called "mill” 7.
- the compound thus homogenised is sent to a carding machine 8 comprising: a feeder 9 receiving the fiber from chambers 6 and laying it homogeneously, in the shape of a mat on the conveyor of the apparatus: a carding machine 10 formed by a series of toothed cylinders of various diameters providing the fiber paralleling and the laying of the same onto a conveyor belt as a light and homogeneous card web: a lap roller 11 receives the card web and lays it as a multilayer onto a conveyor belt that feeds a needlepunching apparatus 12.
- Needlepunching is carried out in a series of knitters which, by means of the action of a plurality of needles, moving orthogonally to the fiber mat feed in a reciprocating swift motion, that seize the fibers and drag it through the fiber mass, binding and compacting therebetween.
- the semifinished product resembles a felt and is sent to the subsequent finishing process.
- a binder in a aqueous suspension contained in a collection tank 13 is applied onto the back of the felt with a spreader roller 14 drafting therefrom.
- the binder-saturated felt is passed through a hot air circulation drying apparatus 15 wherein layer water is removed by evaporation, yielding a flexible layer strengthened onto the back of the felt.
- the finished product is delivered to a packaging unit 16.
- the binder is a water-resistant vinyl resin having hydrolizable functionalities sufficient to be dissolved in a strongly basic solution when heated.
- a vinyl resin having such qualities comprises a vinyl acetate homopolymer or a copolymer of vinyl acetate with at least one of the following compounds:
- the aqueous suspension of the binder, or binding bath, contained in the collection tank 13 and applied onto the felt back, in a practical embodiment consists of an inert filler made of aluminium hydroxide or calcium carbonate, a thickening agent and water.
- the average percent composition by weight of the binding bath is the following: vinyl resin 20-40% inert filler 40-70% thickening agents 1- 5% water 5-35%
- a plastifier is further provided, preferably a molecular phtalic, isophtalic, benzoic or phosphoric plastifier, e.g. a dimethylphtalate or the like.
- the plastifier can constitute from 0 to 40% of the binding bath, depending on the product softness required.
- the binding resin is the commercial product VINAVIL 19 WM, and the inert filler is aluminium hydroxide, 27% and 54% b/w respectively.
- the inert filler is aluminium hydroxide, 27% and 54% b/w respectively.
- a fire-retardant product is obtained.
- calcium carbonate can be used when fire retardant properties are not a prerequisite.
- the binder density is regulated in order to have an applied quantity comprised from 400 to 1000 g/m 2 (wet basis).
- the carpet manufactured with the process according to the invention is made of a layer of needlepunche non-woven fabric of a synthetic fiber, and of a layer of a resinous binder applied onto a face thereof.
- the binder layer can be entirely dissolved in a strongly basic solution, e.g. a 5-30% NaOH solution, a property that is advantageously exploited in the reclaiming process of the used carpet, as is described in a corresponding patent application filed on the same date by the same applicant.
- the carpet according to the invention is first separated from possible two-sided tape and coarse dust residues, and then is scoured with a strongly basic solution, e.g., with a 15% NaOH caustic bath. Under such conditions the binder layer is completely dissolved and the fiber can be reclaimed and recycled.
- the solution containing the binder and the inert filler in suspension can be reclaimed as well by acidification with a separation of the water that can be returned to the process water circuit, and of a precipitate made of the binder admixed to the filler that can be reused to form binders for other covering materials.
- the preferred synthetic fiber type is polypropylene, both for the cost-effectiveness and for the hydrophobic, acid- and light-resistance characteristics thereof.
- a certain percentage of fire-retardant modacrylic and/or polyester fiber can be advantageously added thereto, in a ratio comprised from 10 to 50%.
- the final unit weight of the product is comprised from about 400 to 900 g/m 2 .
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Mechanical Engineering (AREA)
- Dispersion Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Laminated Bodies (AREA)
- Carpets (AREA)
- Detergent Compositions (AREA)
- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
ITFI990019 | 1999-02-01 | ||
IT1999FI000019A IT1310002B1 (it) | 1999-02-01 | 1999-02-01 | Procedimento per la produzione di moquette riciclabile e moquettecosi' ottenuta |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1026311A2 true EP1026311A2 (fr) | 2000-08-09 |
EP1026311A3 EP1026311A3 (fr) | 2003-04-09 |
Family
ID=11352781
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP00830024A Withdrawn EP1026311A3 (fr) | 1999-02-01 | 2000-01-18 | Tapis recyclable et son procédé de fabrication |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP1026311A3 (fr) |
IT (1) | IT1310002B1 (fr) |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7622408B2 (en) | 2003-07-01 | 2009-11-24 | Dzs, Llc | Fabric-faced composites and methods for making same |
CN103243569A (zh) * | 2013-05-22 | 2013-08-14 | 南通鑫平制衣有限公司 | 一种耐碱性纺织面料 |
ITUA20164689A1 (it) * | 2016-06-27 | 2017-12-27 | Alma Spa | Moquette funzionalizzata e metodo per la sua realizzazione |
CN111472091A (zh) * | 2020-05-07 | 2020-07-31 | 江苏伟创力新材料有限公司 | 一种立体构造的面膜无纺布及其制作方法 |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH01272855A (ja) * | 1988-04-20 | 1989-10-31 | San Chem Kk | ニードルパンチカーペットおよび製造方法 |
BE1005056A3 (fr) * | 1991-07-03 | 1993-04-06 | Yves Farber | Procede et installation de fabrication de feutre. |
JPH05148751A (ja) * | 1991-11-25 | 1993-06-15 | Kotobukiya Furonte Kk | 自動車用ニードルカーペツトの製造方法 |
JPH08238162A (ja) * | 1995-03-07 | 1996-09-17 | Toa Boshoku Kk | ニードルパンチカーペットやタフトカーペットのリサイクル方法 |
EP0765960A2 (fr) * | 1995-09-26 | 1997-04-02 | Basf Aktiengesellschaft | Procédé pour la production de matériaux composites non-tissés réutilisables |
-
1999
- 1999-02-01 IT IT1999FI000019A patent/IT1310002B1/it active
-
2000
- 2000-01-18 EP EP00830024A patent/EP1026311A3/fr not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH01272855A (ja) * | 1988-04-20 | 1989-10-31 | San Chem Kk | ニードルパンチカーペットおよび製造方法 |
BE1005056A3 (fr) * | 1991-07-03 | 1993-04-06 | Yves Farber | Procede et installation de fabrication de feutre. |
JPH05148751A (ja) * | 1991-11-25 | 1993-06-15 | Kotobukiya Furonte Kk | 自動車用ニードルカーペツトの製造方法 |
JPH08238162A (ja) * | 1995-03-07 | 1996-09-17 | Toa Boshoku Kk | ニードルパンチカーペットやタフトカーペットのリサイクル方法 |
EP0765960A2 (fr) * | 1995-09-26 | 1997-04-02 | Basf Aktiengesellschaft | Procédé pour la production de matériaux composites non-tissés réutilisables |
Non-Patent Citations (3)
Title |
---|
PATENT ABSTRACTS OF JAPAN vol. 014, no. 037 (C-680), 24 January 1990 (1990-01-24) & JP 01 272855 A (SAN CHEM KK), 31 October 1989 (1989-10-31) * |
PATENT ABSTRACTS OF JAPAN vol. 017, no. 540 (C-1115), 29 September 1993 (1993-09-29) & JP 05 148751 A (KOTOBUKIYA FURONTE KK), 15 June 1993 (1993-06-15) * |
PATENT ABSTRACTS OF JAPAN vol. 1997, no. 01, 31 January 1997 (1997-01-31) & JP 08 238162 A (TOA BOSHOKU KK), 17 September 1996 (1996-09-17) * |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7622408B2 (en) | 2003-07-01 | 2009-11-24 | Dzs, Llc | Fabric-faced composites and methods for making same |
CN103243569A (zh) * | 2013-05-22 | 2013-08-14 | 南通鑫平制衣有限公司 | 一种耐碱性纺织面料 |
ITUA20164689A1 (it) * | 2016-06-27 | 2017-12-27 | Alma Spa | Moquette funzionalizzata e metodo per la sua realizzazione |
EP3263762A1 (fr) * | 2016-06-27 | 2018-01-03 | Alma Spa | Tapis fonctionnalisé et son procédé de fabrication |
CN111472091A (zh) * | 2020-05-07 | 2020-07-31 | 江苏伟创力新材料有限公司 | 一种立体构造的面膜无纺布及其制作方法 |
Also Published As
Publication number | Publication date |
---|---|
EP1026311A3 (fr) | 2003-04-09 |
ITFI990019A0 (it) | 1999-02-01 |
IT1310002B1 (it) | 2002-02-05 |
ITFI990019A1 (it) | 2000-08-01 |
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