EP1961851B1 - Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung - Google Patents

Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung Download PDF

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Publication number
EP1961851B1
EP1961851B1 EP20080002082 EP08002082A EP1961851B1 EP 1961851 B1 EP1961851 B1 EP 1961851B1 EP 20080002082 EP20080002082 EP 20080002082 EP 08002082 A EP08002082 A EP 08002082A EP 1961851 B1 EP1961851 B1 EP 1961851B1
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EP
European Patent Office
Prior art keywords
process according
fibres
tufted
polymeric component
fibers
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.)
Not-in-force
Application number
EP20080002082
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German (de)
English (en)
French (fr)
Other versions
EP1961851A1 (de
Inventor
Norbert Goffing
Engelbert Löcher
Ararad Emirze
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.)
Carl Freudenberg KG
Original Assignee
Carl Freudenberg KG
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Filing date
Publication date
Application filed by Carl Freudenberg KG filed Critical Carl Freudenberg KG
Publication of EP1961851A1 publication Critical patent/EP1961851A1/de
Application granted granted Critical
Publication of EP1961851B1 publication Critical patent/EP1961851B1/de
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • 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
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • 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
    • D05C17/023—Tufted products characterised by the base fabric
    • 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
    • Y10T428/23943—Flock surface
    • 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

Definitions

  • the invention relates to a method for producing a tufted product, in particular to a tufted carpet top layer produced thereafter, and to the use of such a tufted product, in particular of such a tufted carpet top layer.
  • Tuftteppichs the so-called tufting or tufting, that is a technique for producing three-dimensional surfaces, used, which works on the principle of a sewing machine.
  • Tuft needles bring a tufted yarn into a basic material, the so-called tufts.
  • the tuft needles mounted on a needle bar are arranged in the width of the base material, for example a nonwoven fabric, and at the same time pierce through the base material.
  • the introduced tuft yarn is held on the underside of the base material by grippers, so-called loopers. This creates loops or loops, so-called knobs, which form the visible side (upper layer) in the finished carpet.
  • Velorsteppich which is used especially in the automotive interior with a share of more than 95%.
  • Non-woven fabrics made of thermoplastic polymers such as, for example, polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are produced by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these consolidation processes, are often used as tufts are bound.
  • thermoplastic polymers such as, for example, polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are produced by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these consolidation processes, are often used as tufts are bound.
  • the known conventional tufts with round fibers used as Tuftschreiben therefore satisfy the different requirements for a particularly good adhesion of the tufted tufted tufts in Tuftschreiben and a flawless Tuftstory in the carpet top layer is not always satisfactory.
  • the document GB 854,335 A describes a method of making a pile fabric having a patterned pile which includes the formation of a base fabric and the pile yarn fuse to provide pile of fibers extending from one side of the base fabric and using synthetic polymer fibers for certain portions of the pile which were previously defined as filaments or fibers, and wherein for certain parts of the pile synthetic polymer fibers are used, which are determined only after the formation in twisted yarns.
  • the base or back fabric consists of a fabric, in particular a woven burlap.
  • the document US 4,617,218 A discloses a method for producing a tufted carpet having a tightly curled appearance of a Persian lamb, comprising the steps of: a) knitting, knotting or knitting an outer carpet yarn composed of continuous filaments or spun staple fibers of a thermoplastic synthetic resin; b) heating the fabric to a temperature at which bends and kinks are produced in the yarn; c) cooling the tissue to room temperature; d) unwinding and unwinding the yarn under tension to re-straighten; e) tufting the yarn as an external yarn into a first backing material and forming a cut pile carpet; f) coating the bottom of the carpet with a heat-setting adhesive, g) heating the coated carpet.
  • the first backing material is preferably made of woven polypropylene and the second backing is woven jute.
  • the document US 3,788,364 A describes tufted pile fabrics and their backs.
  • the back thereby represents a fabric of polyolefin warp yarns and weft yarns, wherein the warp yarns are formed from flat ribbon monofilaments having a substantially rectangular cross section and at close intervals and wherein the weft yarn has a relatively round cross section and substantially (further) Extra-spaced distances.
  • the pitch index as the product of the yarn width and the number of yarns in inches is 1.3 to 1.6 for the warp yarns and 0.15 to 0.45 for the weft yarns, whereby the tufting penetrates the warp yarns by a relatively large proportion of tufted yarns and the weft yarns from a relatively small proportion of tufting yarns.
  • the document GB 816.185 A discloses a method of producing crimped yarns wherein a yarn is tufted into a backing material to obtain a tufted pile fabric which is subjected to a treatment of said pile fabric in which loops are set / sewn into the tufted yarn and wherein the set yarn returns is removed or pulled from the backing material.
  • the backing material is preferably a fabric.
  • the invention has the object of an alternative, possible to provide a simple and economical process for producing a tufted product, in particular a tufted carpet topcoat, with improved nap-sticking properties.
  • the carpet top layer produced by the process is intended to be used in particular in the automotive interior or in the object sector.
  • object area is meant that the carpet is designed especially for heavily to extremely stressed areas, especially in offices, hotels, airports and / or hospitals.
  • splittable fibers in the back of the tufts in the form of a nonwoven or nonwoven fabric are used which splice on tufting at or in the region of the puncture site of the tufts back.
  • Fibers are understood here to mean staple fibers or continuous fibers, so-called filaments.
  • the fibers may also be combined into nonwovens, in particular nonwoven webs, the nonwoven fabric.
  • the tufts backs are locally felted at the puncture site by the separation or disintegration of the spliceable fibers into single filaments or segments, thereby increasing the specific fiber surface in this area of the tufts back and thereby also the static friction and sliding friction between the fibers of the tuft and the back of the tuft is increased.
  • the type of fibers used thus allows the formation of particularly stable Tuftgarnsch secured or nubs and the formation of a particularly flawless Tuftstoryes in the carpet.
  • spliceable fibers are used in a proportion of 10 to 100 wt.%.
  • a mixture of spliceable and non-splittable fibers is used.
  • the ratio of spliceable and non-splittable fibers can be adjusted depending on the carpet or tuft specification.
  • the proportion of spliceable fibers is preferably equal to or less than 50% by weight.
  • the proportion of spliceable fibers is preferably equal to or greater than 75% by weight.
  • At least two mutually incompatible (incompatible) polymer components are used as spliceable fibers.
  • At least one polymer component preferably has a lower one Weight fraction as the other (s) polymer component (s).
  • At least one polymer component has a weight fraction of equal to or less than 20% by weight, preferably equal to or less than 10% by weight, particularly preferably equal to or less than 5% by weight, very particularly preferably up to 3 wt .-%, based on the total weight of the fibers.
  • the production costs for the tufted products, in particular for the tufted carpet top layer can be reduced.
  • Another cost saving potential is that because of the improved nub adhesion, one can reduce the amount of fixative or precoat that is commonly used in the carpet industry for final fixation of the carpet yarn.
  • fixative or precursors such as to latex compounds, odors and emissions can be reduced, especially in confined spaces such as in the passenger compartment of an automobile.
  • undesirable properties of a component such as a low temperature or flame resistance, can be reduced by using only a minimal amount of this component. Also, the significant reduction of a polymer content can improve the recyclability.
  • the desired properties of the tuft products, in particular the tufted carpet top layer can be precisely controlled.
  • a polymer component having a lower melting temperature is used as the polymer component with a lower proportion by weight.
  • At least one polymer component preferably a polymer component with a lower weight fraction than the other (n) polymer component (s), used as adhesive or binder component, wherein the melting temperature of this polymer component at least 10 ° C, preferably at least 20 ° C, below the melting temperature the other polymer component (s).
  • the properties of the tufted product produced therefrom, in particular the tufted carpet top layer can be influenced, in particular its degree or degree of solidification or softness can be adjusted.
  • the non-splittable fibers are selected from mono-, bi-, multi-polymer component fibers and / or blends of such fibers.
  • the fibers are furthermore preferably selected from thermoplastic polymers, in particular from polyesters, preferably polyethylene terephthalate (PET), from polyolefins, preferably polyethylene (PE) and / or polypropylene (PP), from polylactates and / or from polyamides (PA), preferably polyamide 6.6 (PA6.6) and / or copolymers derived therefrom.
  • PET polyethylene terephthalate
  • PA polyamide 6.6
  • PA6.6 polyamide 6.6
  • combinations of incompatible (incompatible) polymer components are selected, preferably combinations of polyethylene terephthalate (PET) and polypropylene (PP), polyethylene terephthalate (PET) and polyamide (PA), preferably polyamide 6 or polyamide 6.6, and / or polypropylene (PP) and polyethylene (PE).
  • incompatible polymer components preferably combinations of polyethylene terephthalate (PET) and polypropylene (PP), polyethylene terephthalate (PET) and polyamide (PA), preferably polyamide 6 or polyamide 6.6, and / or polypropylene (PP) and polyethylene (PE).
  • the fibers selected are those which advantageously have a titre in the range from 5 to 20 dtex, preferably from 5 to 12 dtex.
  • fibers are selected which preferably have round or non-round cross-sectional shapes.
  • Non-round cross-sectional shapes lead to increased fiber-to-fiber friction compared to round fibers and thus result in improved pimple adhesion due to better adhesion to one another.
  • the selected fibers are further preferably solid or hollow.
  • the fibers are used in the form of a spunbonded fabric or a spunbonded nonwoven fabric as tufa backs.
  • the carpet top layer is preferably subjected to a heat treatment after tufting. As a result, the knobbed adhesion of the carpet top layer is further improved.
  • the tufted products produced according to the invention are preferably used in the automotive interior and / or in the object sector, in particular in offices, hotels, airports and / or hospitals.
  • the scanning electron micrographs allow images of the fiber / nonwoven cross sections and the surface structure with the corresponding magnifications.
  • the SEM images were taken with a low pressure scanning electron microscope JEOL JSM-6480LV under an acceleration voltage of 20 kV.
  • spliceable fibers in particular in the form of a nonwoven fabric, are used as tufts for the production of the tufted product, in particular the tufted carpet top layer.
  • a nonwoven fabric having spliceable fibers at a content of 100% by weight is prepared as follows.
  • PET polyethylene terephthalate
  • PP polypropylene
  • the spun filaments have a linear density of 9.5 dtex with strength values of 29 mN / dtex and elongation values of 135% (DIN 53812 and DIN 53816).
  • the fabric produced in this way is preconsolidated by calendering, wherein a smooth and a roughened roll with the surface temperatures of 100 ° C are used and wherein the cylinder pressure is 16 bar.
  • the fabric is finally solidified in an air dryer at an air temperature of 225 ° C.
  • an aqueous polydimethylsiloxane emulsion as textile auxiliaries (Avivage) is applied, wherein the solids concentration is 5 wt .-% and the wet pickup is 7% (0.35 wt.% Avivage based on the Vilesstoffong).
  • the drying of the nonwoven fabric finished with Avivage takes place in an air dryer at an air temperature of 100 ° C.
  • a nonwoven fabric having a weight of 115 g / m 2 which comprises splittable fibers.
  • FIG. 1 shows that between the PET and the PP segments of the spun spliceable PET / PP Pieturan despite the low proportion by weight of the polypropylene (PP) is a very good, that is a clear segmentation.
  • PP polypropylene
  • FIG. 2 shows that after solidification of the segmented PET / PP prepregs, there is already a slight pre-splicing of the spun spliceable PET / PP ply fibers of the nonwoven fabric by the thermal consolidation step.
  • the distance between the tufting needles which bring the Tuftgarn in the back of the tufts, here in the nonwoven tufts, in fractions of an inch. 1/10 ° thus means 10 needles per 2.54 cm, ie a distance of 2.54 mm between the tufting needles.
  • the distance of the stitches along the length of the tuft back is called the stitch length.
  • the number of stitches is given per 10 centimeters. It also determines the number of loops or nubs.
  • Other tuft pitches such as 6/32 ", 1/8", 5/64 ", 1/16" or 1/22 "can also be used to make the top carpets.
  • the tufted yarn used is a commercial PA6 BCF 1300 dtex f128, which stands for bulked continuous filament, in particular for a textured nylon yarn continuous yarn having a denier of 1300 dtex and 128 individual filaments. Other common tuft games can also be used.
  • the tufted yarn is held in place by grippers, so that loops or nubs on the top of the tufa back arise.
  • a loop pile carpet top layer is created.
  • a cut pile carpet top layer or so-called velor carpet top layer is created.
  • FIGS. 4 . 6 and 7 show the surface of a tufted carpet top layer produced according to the invention, that is to say here a tufted non-woven fabric with spliced PET / PP pief fibers after extraction of the tuft yarn in order to obtain a free area for the SEM images.
  • FIGS. 3 and 5 show in comparison to the surface of a conventional tufted carpet top layer, that is, a tufted conventional standard nonwoven fabric (Lutradur ® LDT 53 12) with separated spun PET and PP monofilaments after pulling out the Tuftgarns, in order to obtain a free area for the SEM photographs.
  • the Tuft discipline correspond exactly to the same conditions to which the nonwoven fabric was exposed with spliceable PET / PP Pietician.
  • FIGS. 6 and 7 also show, due to the splicing in the region of the puncture site, the so-called Tuftloch Scheme, pushed out PP fiber parts, which lead to a further increase in the specific fiber surface.
  • the dimpled adhesion depends on the stiction between the fibers of the tuft back, in this case the nonwoven fabric, and the Tuftgarns is due to the smaller contracted Tuftlöcher and the increased specific fiber surface in the tufted nonwoven fabric with spliced fibers, that is, the invention prepared carpet top layer, a in Compared to the tufted conventional standard nonwoven fabric to expect improved pimple adhesion.
  • the untufted tufts back that is, the nonwoven fabric with the spliceable fibers or the non-spliceable fibers attached to a train-elongation device (Zwick) is clamped on a special holder, is engraved from the back with a Einzelte Kunststoffnadel (Groz Beckert).
  • the yarn which was also used for tufting (PA6 BCF 1300 dtex 128f, yarn length 400 mm), is then threaded into the needle, pulled through the back of the tufts and fixed parabolically to the back of the tufts on a very fine-resolution load cell.
  • N spec nonwoven fabric with spliced PET / PP ply fibers: 0.99 N m 2 / g
  • the measurement results confirm that the nubbly adhesion of the tufted nonwoven fabric with the spliced fibers, that is to say that of the carpet top layer produced according to the invention, is improved compared to the tufted conventional standard nonwoven fabric.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Carpets (AREA)
  • Manufacturing Of Multi-Layer Textile Fabrics (AREA)
EP20080002082 2007-02-12 2008-02-05 Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung Not-in-force EP1961851B1 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE200710006760 DE102007006760B3 (de) 2007-02-12 2007-02-12 Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung

Publications (2)

Publication Number Publication Date
EP1961851A1 EP1961851A1 (de) 2008-08-27
EP1961851B1 true EP1961851B1 (de) 2010-04-07

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EP20080002082 Not-in-force EP1961851B1 (de) 2007-02-12 2008-02-05 Verfahren zur Herstellung eines Tuftprodukts, Tuftprodukt und dessen Verwendung

Country Status (9)

Country Link
US (1) US7892622B2 (ko)
EP (1) EP1961851B1 (ko)
KR (1) KR100987893B1 (ko)
AR (1) AR065296A1 (ko)
AT (1) ATE463601T1 (ko)
AU (1) AU2008200672B2 (ko)
BR (1) BRPI0801645A2 (ko)
DE (2) DE102007006760B3 (ko)
TW (1) TWI394879B (ko)

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WO2008113004A1 (en) * 2007-03-14 2008-09-18 Futuris Automotive Interiors (Us), Inc. Low mass acoustically enhanced floor carpet system
ES2467340T3 (es) * 2009-05-18 2014-06-12 Autoneum Management Ag Moquetas de pelo insertado para aplicaciones en automoción
US20110177283A1 (en) * 2010-01-18 2011-07-21 Futuris Automotive Interiors (Us), Inc. PET Carpet With Additive
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US20080220199A1 (en) 2008-09-11
AR065296A1 (es) 2009-05-27
AU2008200672A1 (en) 2008-08-28
KR100987893B1 (ko) 2010-10-13
TW200912079A (en) 2009-03-16
ATE463601T1 (de) 2010-04-15
TWI394879B (zh) 2013-05-01
BRPI0801645A2 (pt) 2008-11-11
KR20080075458A (ko) 2008-08-18
US7892622B2 (en) 2011-02-22
DE502008000497D1 (de) 2010-05-20
DE102007006760B3 (de) 2008-08-21
EP1961851A1 (de) 2008-08-27
AU2008200672B2 (en) 2010-04-01

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