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
• • 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
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
  • D04H3/147—Composite yarns or filaments
• • 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
  • D06N7/0065—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 pile
• • 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
  • 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
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/02—Synthetic macromolecular fibres
  • D06N2201/0263—Polyamide fibres
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N2201/00—Chemical constitution of the fibres, threads or yarns
  • D06N2201/10—Conjugate fibres, e.g. core-sheath, side-by-side

Definitions

• the present invention pertains to a primary carpet backing and a tufted carpet backing.
• Primary carpet backings and tufted carpet backings are known.
• a known primary carpet backing consists of a nonwoven layer which consists of core/sheath bicomponent filaments with a polyester core and a polyamide sheath.
• tufted carpet backings are known which are obtained by tufting the primary carpet backing with pile yarns to form tufts. Such tufted primary carpet backings already exhibit a low thermal shrinkage, high breaking strength and high elongation at break.
• the object of the present invention is to provide a primary carpet backing which provides improved properties in a tufted carpet backing, in particular lower thermal shrinkage, higher breaking strength and higher elongation at break.
• a primary carpet backing comprising at least one nonwoven layer, wherein the at least one nonwoven layer comprises fibers which contact one another at contact zones, wherein the fibers comprise
• the primary carpet backing according to the invention as such exhibits a significantly higher thermal shrinkage than a known comparative primary carpet backing, a tufted carpet backing comprising pile yarns and the primary carpet backing according to the invention surprisingly exhibits
• the pile yarns of the tufted carpet backing and the first fiber forming polymer or the first component forming polymer both consist of a polyamide
• recycling of such a tufted backing is facilitated, because said polyamides can be depolymerized into their monomers, which in turn can be used - without a costly separation procedure to remove undesired monomers - to synthesize a new polyamide.
• the pile yarns of the tufted carpet backing and the first fiber forming polymer or the first component forming polymer consist of the same polyamide to further improve the efficiency of the depolymerization process.
• the nonwoven layer also called web
• technologies e.g. given in chapters 4 and 5 of "Nonwoven Fabrics", edited by W. Albrecht, H. Fuchs and W. Kittelman, Wiley-VCH Verlag GmbH & Co KGaA, ISBN 3-527-30406-1 .
• the primary carpet backing according to the invention comprises an embodiment i), wherein first fibers which have been manufactured from at least one polyamide as the first fiber forming polymer have been brought into contact with second fibers which have been manufactured from at least one bonding polymer as the second fiber forming polymer.
• first fibers and said second fibers contact one another at contact zones and the first fibers are melt bonded at their contact zones with the second fibers by a solidified melt of the at least one bonding polymer.
• the second fibers have been at least partially molten to obtain a melt of the at least one bonding polymer at said contact zones and said melt after solidification serves to melt bond first fibers and second fibers.
• the primary carpet backing according to the invention comprises an embodiment ii), wherein multicomponent fibers have been manufactured from at least one polyamide as the first component forming polymer and from at least one bonding polymer as the second component forming polymer. Said multicomponent fibers have been brought into contact with one another at contact zones during manufacturing of the nonwoven layer and have been melt bonded at their contact zones with one another by a solidified melt of the at least one bonding polymer. This means that at the contact zones of the multicomponent fibers the second component has been at least partially molten to obtain a melt of the at least one bonding polymer at said contact zones and said melt after solidification serves to melt bond the multicomponent fibers.
• the bonding polymer exhibits a melting temperature T m(bp) so that the bonding polymer can at least partially melt at the respective contact zones and after its solidification serves to melt bond the first fibers and second fibers in embodiment i) or the multicomponent fibers of embodiment ii).
• the polyamide does not need to have a melting temperature. Rather, for the polyamide it is sufficient that it remains stable during contact with the melt of the bonding polymer. However, if the polyamide exhibits a melting temperature T m(pa) , it is necessary that the relation T m(pa) > T m(bp) is fulfilled.
• the melting temperature T m(bp) of the bonding polymer ranges from 80 °C to 200 °C, especially preferred from 100 °C to 180 °C, however with the restriction that the relation T m(pa) > T m(bp) is fulfilled.
• the melting temperature T m(pa) of the polyamide ranges from 180 °C to 300 °C, especially preferred from 200 °C to 270 °C, however with the restriction that the relation T m(pa) > T m(bp) is fulfilled.
• the fibers may exhibit any cross-sectional shape.
• the cross-sectional shape of the fibers is round or elliptical.
• the cross-sectional shape of the fibers is triangular, rectangular or multilobal, like bilobal or trilobal. Selection of a certain cross-sectional shape for the fibers allows to fine-tune the bonding strength between said fibers.
• the polyamide is at least one synthetic thermoplastic homo-polyamide, at least one synthetic thermoplastic co-polyamide or a mixture thereof.
• thermoplastic homo-polyamide exhibits a recurring unit of formula (I) -[-NH-CO-(-CR 1 R 2 -) n ]- (I), wherein n is an integer ranging from 1 to 22, preferably from 3 to 12, and R 1 and R 2 independently from one another represent H or a linear alkyl group of formula -(-CH 2 ) x -CH 3 , wherein x is an integer ranging from 0 to 5, or of formula (II) -[-NH-(CR 3 R 4 -) m -NH-CO-(CR 5 R 6 -) p -CO-]- (II), wherein m and p are integers, and independently from one another range from 1 to 22, preferably from 3 to 12, R 3 and R 4 independently from one another represent H or a linear alkyl group of formula -(-CH 2 ) y -CH 3 wherein y is an integer ranging from 0 to
• R 1 preferably represents H, more preferably R 1 and R 2 both represent H so that the homo-polyamide is a linear polyamide.
• R 3 and/or R 5 preferably represents H, more preferably R 3 , R 4 , R 5 and R 6 all represent H so that the homo-polyamide is a linear polyamide.
• the homo-polyamide exhibiting a recurring unit of formula (I) may be obtained from the polycondensation of the respective aminocarboxylic acid.
• the homo-polyamide exhibiting a recurring unit of formula (II) may be obtained from the polycondensation of the respective diamine and dicarboxylic acid.
• the homo-polyamide is polyamide 6 (PA 6), polyamide 6.6, polyamide 4.6 (PA 4.6), polyamide 4.10 (PA 4.10), or polyamide 4.12 (PA 4.12), or any mixture thereof.
• the co-polyamide if compared with the homo-polyamide, additionally contains in its polymer chain a residue which is preferably obtained either from copolymerizing a further aminocarboxylic acid, a further diamine and/or a further dicarboxylic acid.
• the polyamide is an aliphatic polyamide.
• the polyamide may be a semi-aromatic polyamide, i.e. a polyamide having aliphatic and aromatic moieties in its polymer chain.
• the content of aromatic moieties in the semi-aromatic polyamide is limited to a value, at which the semi-aromatic polyamide is still thermoplastic.
• the bonding polymer is obtained by polymerization of an olefin which is an alkene having one terminal double bond so that the bonding polymer is an polyolefin which exhibits a recurring unit of formula (III) -[-CH 2 -CR 7 R 8 -]- (III), wherein R 7 and R 8 independently from one another represent H or CH 3 .
• the polyolefin exhibits a melt flow index ranging from 3 to 70 g/10 min, especially preferred from 5 to 40 g/10 min, in particular 10 to 30 g/10 min.
• the melt flow index is determined in accordance with ISO 1133 at 230°C/2.16 kg.
• the bonding polymer is obtained by polymerization of an alkene having one non-terminal double bond, for example 2-butene or 2-, 3- or 4-octene.
• the polarity of the polyolefin may be increased by reactive modification with a molecule such as maleic anhydride, acrylic acid, or an epoxy, to provide improved adhesion to the polyamide polymer of the first fiber forming polymer or of the first component forming polymer and/or to improve dye-ability of the polyolefin.
• a molecule such as maleic anhydride, acrylic acid, or an epoxy
• the bonding polymer is obtained by random-copolymerization of ethylene and propylene so that the bonding polymer is a random copolymer of ethylene and propylene.
• the bonding polymer is obtained by block-copolymerization of ethylene and propylene so that the bonding polymer is a block-copolymer of ethylene and propylene.
• fibers refers to both staple fibers and filaments.
• Staple fibers are fibers which have a specified, relatively short length in the range of 2 to 200 mm.
• Filaments are fibers having a length of more than 200 mm, preferably more than 500 mm, more preferably more than 1000 mm. Filaments may even be virtually endless, for example when formed by continuous extrusion and spinning of a filament through a spinning hole in a spinneret.
• the fibers of the primary carpet backing according to the invention are filaments to further improve the breaking strength and/or tear strength of the primary carpet backing and/or of the tufted carpet backing.
• the linear density of the fibers may vary, but preferably ranges from 1 to 25 dtex, more preferably 2 to 20 dtex, most preferably 5 to 15 dtex to further optimize the tufting behavior and/or to further improve breaking strength and elongation at break in the primary carpet backing and/or in the tufted carpet backing.
• the linear density of the fibers is expressed as dtex, which is the weight of a fiber per 10000 meter length.
• the primary carpet backing may comprise a mixture of fibers having different linear densities.
• the at least one nonwoven layer comprises the first fibers and the second fibers in a weight ratio W first fibers : W second fibers, and w first fibers : W second fibers ranges from 40 : 60 to 90 : 10, preferably from 50 : 50 to 90 : 10, especially preferred from 70 : 30 to 80 : 20.
• the at least one nonwoven comprises the multicomponent fibers, wherein the multicomponent fibers exhibit a weight ratio of the first component to the second component w first component : W second component , and w first component : w second component ranges from 40 : 60 to 90 :10, preferably from 50 : 50 to 90 : 10, especially preferred from 70 : 30 to 80 : 20.
• the multicomponent fibers are bicomponent fibers, wherein the bicomponent fibers are bicomponent filaments, wherein ⁇ ) the bicomponent filaments exhibit a core/sheath geometry, wherein the first component represents the core and the second component represents the sheath, or ⁇ ) the bicomponent filaments exhibit a side by side geometry, wherein the first component represents a side 1 and the second component represents a side 2, or ⁇ ) the bicomponent filaments exhibit an islands in the sea geometry wherein the first component represents the islands and the second component represents the sea. ⁇ ) the bicomponent filaments exhibit a segmented pie geometry of alternating segments of the first component and segments of the second component.
• the bicomponent filaments exhibit a core/sheath geometry, wherein the first component represents the core and the second component represents the sheath.
• the bicomponent filaments exhibit a core/sheath geometry, wherein the core consists of polyamide 6 (PA 6) or polyamide 6.6 (PA 6.6) and the sheath consists of polyethylene or polypropylene.
• a weight ratio of the core to the sheath w core : w sheath ranges from 40 : 60 to 90 : 10, preferably from 50 : 50 to 90 : 10, especially preferred from 70 : 30 to 80 : 20.
• the primary carpet backing according to the invention exhibits a significantly higher thermal shrinkage than a known comparative primary carpet backing.
• the tufted carpet backing comprising pile yarns and the primary carpet backing according to the invention surprisingly exhibits
• a tufted carpet backing comprising pile yarns and a primary carpet backing according to the invention is also part of the present invention.
• the pile yarns and the first fibers or the first component of the multicomponent fibers consists of an aliphatic polyamide.
• the pile yarns of the tufted carpet backing and the first fiber forming polymer or the first component forming polymer consist of the same polyamide to further improve the efficiency of the depolymerization process.
• the pile yarns consist of polyamide 6 (PA 6) or polyamide 6.6 (PA 6.6)
• the primary carpet backing consists of at least one non-woven layer which consists of bicomponent filaments exhibiting a core/sheath geometry, wherein the core consists of polyamide 6 (PA 6) or polyamide 6.6 (PA 6.6) and the sheath consists of polyethylene or polypropylene.
• Breaking strength and elongation at break of the primary carpet backing and the tufted carpet backing is determined according to DIN EN 29073-3 (August 1992) with a clamping distance of 200 mm, and a clamp speed of 200 mm/min.
• a primary carpet backing was prepared consisting of a nonwoven layer of fibers.
• the nonwoven layer of fibers was formed of bicomponent core-sheath filaments, which were spun and wound on bobbins in the form of multifilament yarns followed by the steps of unwinding the multifilament yarns and laying the (individual) filaments down on a conveyor belt as a web of filaments and thermally consolidating the web by through air bonding to form the nonwoven layer of fibers.
• the core component of the core-sheath filaments of the nonwoven layer of fibers represented 76 wt.% of the core-sheath filaments and consisted of polyamide-6 (PA6) having a melting temperature of 220°C, and the sheath component represented 24 wt.% of the core-sheath filaments and consisted of polypropylene having a melting temperature of 165°C and a Melt Flow Index of 25 g/10 min.
• the fibers were spun using a melt spinning installation using a bicomponent spinneret, a blow box, a spinning duo, a stretching duo and a winder.
• the yarns had a linear density of 1800 dtex and consisted of 124 individual filaments.
• the mechanical properties of the yarns were determined using a tensile tester according to DIN 885, with two modifications. The testing speed was set to 500 mm/min and the grip distance was set to 250 mm. The mechanical properties of the multifilament yarns are summarized in Table 1.
• the primary carpet backing had a weight of 100 g/m 2 .
• the mechanical properties of the primary carpet backing are summarized in Table 2 and Table 3, for the machine direction and cross machine direction, respectively.
• the primary carpet backing was supplied into a tufting machine and was tufted with a looppile construction using a tuft yarn consisting essentially of polyamide-6.
• the tuft construction used in all examples is summarized in Table 4.
• the primary carpet backing of example 2 was prepared according to example 1, but with one modification.
• the core component of the core-sheath filaments of the nonwoven layer of fibers represented 80 wt.% of the core-sheath filaments and consisted of polyamide-6 (PA6) having a melting temperature of 220°C
• the sheath component represented 20 wt.% of the core-sheath filaments and consisted of polypropylene having a melting temperature of 165°C and a Melt Flow Index of 11 g/10 min.
• PA6 polyamide-6
• the mechanical properties of the yarns are summarized in Table 1.
• a primary carpet backing was prepared consisting of a nonwoven layer of fibers.
• the nonwoven layer of fibers was formed of bicomponent core-sheath filaments, which were spun and wound on bobbins in the form of multifilament yarns followed by the step of unwinding the multifilament yarns and laying the (individual) filaments down on a conveyor belt as a web of filaments and thermally consolidating the web by through air bonding to form the nonwoven layer of fibers.
• the core component of the core-sheath filaments of the nonwoven layer of fibers represented 76 wt.% of the core-sheath filaments and consisted of polyethylene terephthalate (PET) having a melting temperature of 250°C, and the sheath component represented 24 wt.% of the core-sheath filaments and consisted of polyamide-6 (PA6) having a melting temperature of 220°C.
• PET polyethylene terephthalate
• PA6 polyamide-6
• the primary carpet backing had a weight of 100 g/m 2 .
• the primary carpet backing was supplied into the tufting machine and was tufted with a looppile construction using a tuft yarn consisting essentially of polyamide-6.
• the tuft construction used summarized in Table 4.
• the mechanical and thermal properties of the primary carpet backings of examples 1 and 2 and of the comparative example are summarized in Table 2 and Table 3, for the machine direction and cross machine direction, respectively.
• Table 2 Mechanical and thermal properties of the primary carpet backings in machine direction. MD Breaking strength EAB LASE 2 LASE 5 LASE 15 Thermal Shrinkage N/5cm % N/5cm N/5cm N/5cm %
• Table 3 Mechanical and thermal properties of the primary carpet backings in cross machine direction.
• Table 5 The mechanical and thermal properties of the tufted carpet backings in machine direction and in cross machine direction are summarized in Table 5 and Table 6, respectively.
• Table 5 Mechanical and thermal properties of the tufted carpet backings in machine direction. MD Breaking Strength EAB LASE 2 LASE 5 LASE 15 Thermal Shrinkage N/5cm % N/5cm N/5cm N/5cm % Example 1 523 71 12 33 118 1.50 Example 2 552 73 9 25 94 1.83 Comparative Example 369 38 19 72 186 2.25
• Table 6 Mechanical and thermal properties of the tufted carpet backings in cross machine direction.
• the examples show that the primary carpet backings according to the invention have lower mechanical properties, in particular lower breaking strength, lower elongation at break (EAB) and lower load at specific elongation of 2%, 5% and 15% (LASE values) as well as a higher thermal shrinkage than the comparative primary carpet backing.
• the tufted carpet backings comprising primary carpet backings according to the invention have higher breaking strength and higher elongation at break as well as a lower thermal shrinkage than the comparative tufted carpet backing.
• the tufted carpet backings comprising primary carpet backings according to the invention have comparable LASE values in cross machine direction as the comparative tufted carpet backing.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Carpets (AREA)
• Nonwoven Fabrics (AREA)

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Cited By (1)

Citations (5)

• 2014
  • 2014-12-02 EP EP14195815.7A patent/EP3009553A1/fr not_active Withdrawn

Patent Citations (5)

Non-Patent Citations (1)

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