NO752674L - - Google Patents

Description

New, woven textile.

This<*>invention relates generally to woven textile fabrics made from synthetic materials. The materials can be used to replace burlap, jute and other natural fiber materials in the manufacture of primary and secondary coverings and in the manufacture of sacks, bags, wrapping bales, wall coverings, curtains etc.

In the area of carpet production in the textile arts, several patents have been published which illustrate the attempts of previous professionals to produce a substance that can be used for synthetic, primary and secondary coverings for carpets.

U.S. Patent No. 3,542,632 shows that a synthetic primary or secondary coating can be made by weaving the fabric using polyolefin tapes as both warp and fill, and then lightly or heavily fibrillating the entire fabric. Although the resulting highly fibrillated material does have acceptable adhesion when used as a secondary coating, it actually has no strength. Example 8 below shows the results obtained by following the instructions in U.S. Patent No. 3,542,632.

U.S. Patent No. 3,283,788 discloses a method for weaving thermoplastic fabrics in which a strongly oriented sheet of thermoplastic material is torn up by. mechanical treatment such as painting, rubbing, brushing and vibrating into a cloth of split fibers which is fed over several U-shaped fingers which are pushed up through the foil to form a warp subject. Filling yarn is fed through the subject to give a woven structure. The products of U.S. Patent No. 3,283,788, when used as secondary carpet coverings, have unknown adhesive quality, and due to the mechanical processing of the fabric to form the warp, it has questionable strength characteristics, particularly in the direction of the warp. In addition, the use of expensive fiber-cleaved foil material would result in an expensive product.

U.S. Patent 3,549,470 includes an olefinic primary or secondary coating fabric woven from foamed, hot-melt-diluted fibrillated olefin yarn in the warp and/or filling. The adhesion characteristics of the material have not been determined and the strength of the material has not been measured.

U.S. patent no. 3 317 366 discloses a primary covering fabric woven from polyester tape in the warp and spun polyester yarn in the filling. The polyester material is rather expensive and nothing is mentioned about strength or adhesion qualities •. Furthermore, no fibrillated material is indicated and therefore a secondary coating material with acceptable adhesion when laminated to a primary loose coating surface is neither considered nor contemplated by the patent seeker.

In its broadest aspect, the present invention relates to a woven fabric with synthetic warp and filling material, where at least one of the materials has been strongly fibrillated. In another aspect, this invention relates to a synthetic woven carpet covering fabric with synthetic warp and filling material, where at least one of the materials has been highly fibrillated. In another aspect, the present invention relates to a synthetic woven fabric useful as a coating in a carpet fabric and the like with as one of its warp and filling materials a substantially unfibrillated or unfibrillated band and a highly fibrillated band as the second material. In yet another aspect, this invention relates to a synthetic primary or secondary covering for carpets and the like, comprising polyolefin tapes as warp or filler, and highly fibrillated polyolefin tapes as the second fabric, characterized by a delamination strength greater than 3.4 kg when laminated to a fabric- structured surface, such as a plain carpet fabric. In a further aspect, the invention relates to a carpet structure comprising a base material or primary coating, material surfaces such as a fleece surface attached to the base material and a woven secondary

in

coating laminated to the surface of the base material, where the secondary coating consists of polyolefin tapes as the warp or filling component and highly fibrillated polyolefin tapes as the filling or warp component, where the delamination strength of the secondary coating is greater than 3.4 kg, the tensile strength of the fabric in the highly fibrillated direction of the material is greater than 11.3 kg and of the other material greater than 13.6 kg.

Another aspect of the invention relates to a method of making a synthetic fabric which can be used as a primary or secondary carpet covering consisting of woven synthetic ribbon warp or filling material and a highly fibrillated filling or warp material in the fabric described above, and treating the fabric by brushing and/or stitching to raise the fibril ends of the fibrillated warp or filling above the surface of the fabric and then laminating it into a pile fabric as described above for use as a secondary coating.

In the manufacture of fluffy quality fabrics such as carpets

and the like, a surface is attached to a substance that can be referred to as the base material or the primary coating, such as by weaving, knotting or needle-stitching a staple fiber into it. An adhesive, often rubber latex or so-called hot melts, is applied so the back and a secondary coating called the secondary coating are laminated to this. Until recently, the secondary coating in quality loose fabrics, especially carpet fabrics, was almost exclusively a jute fabric. However, this natural material is now available in small supplies and attempts have been made to produce synthetic secondary coverings to replace those hitherto made of jute. The criteria for a usable material is that it should not only behave like a jute fabric with regard to adhesion and fabric strength, but perhaps most importantly, it should be cheap like jute.

In terms of price and strength, polyolefins in particular are particularly attractive among synthetic materials and also have their well-known resistance to chemicals, water, mildew, etc. However, the use of polyolefins is not exclusively successful, mainly because of their poor adhesion qualities and because polyolefin materials treated for improved adhesion have no fabric strength or have an unacceptable aesthetic appearance.

The present invention is based on the discovery that a widely applicable fabric can be produced, which is woven from synthetic components and which has a combination of good strength, where it is needed, appearance and the jute fabric's low costs and good adhesion where it is used as a synthetic secondary coating for loose objects such as carpets and the like.

The fabric is preferably woven on a conventional loom using synthetic ribbons either as warp or filling materials and highly fibrillated material as the other components. Other forms of weaving, e.g. diagonal weave, broken diagonal weave, satin, "basket", etc. can all be used to advantage and may sometimes be preferred if it is desired to have more or less fibrillated material visible on one side of the fabric. In general, almost any form of weaving within the textile industry can be used with ordinary technical knowledge in the implementation of the invention. In the following description, all fabrics are flat-woven as this is the most common form of weaving that is widely used and is the most long-lasting, strong, firm and the most dimensionally stable method for joining the warp and fill components in one fabric.

When the fabric is intended to be used as a secondary coating, it is usually woven so that it has an open structure to facilitate the application of the adhesives that are normally used to attach the coating to loose fabrics or carpet structures. In this connection the weave may be one with from 10 to 30 tape ends per .x inch (warp) or tips (fill) of about 500 to lOOO denier and from about 8 to 12 highly fibrillated tape tips (fill) or ends per. inch (warp) of around 800 to 2800 denier. Usable secondary coating is achieved when the fabric has 12 tape warp ends per empty and 9 strongly fibrillated filling tips (12 x 9), as well as when the fabric has 14 - 15 ribbon warp ends per empty and about 9 strongly fibrillated filling tips (14 x 9). Usable primary coatings are achieved when the fabric has from 10 to 30 warp ends per empty and from about 6 to 12 strongly fibrillated filling tips. The weaving characteristics are not critical and, as mentioned above, to be considered within the field of expertise and will depend on the characteristics desired for the resulting fabric in its final use.

As previously indicated, the described substance can also be produced

so that the tape warps are the highly fibrillated constituents and the filling materials are tapes, and the number of warp ends and filling tips change accordingly so that the number of highly fibrillated constituents remains approximately the same.

The term "ribbon" as used herein means that the constituents or components of the warp and/or fill weave of the fabric preferably have a flat appearance and are generally rectangular in cross-section. For the purposes of the present invention, a "tape", "tape-yarn" or component etc. as used in this description includes, in addition to what is indicated above, laces, rudder, foils or strips of synthetic resin material either with a rectangular cross-section or not. Thus, other cross-sectional shapes, round, oval, the so-called "dumb bell" and combinations of these shapes can be used. Multifilament ribbons are also within this scope whether they are held together by adhesives or are loosely united in a continuous bundle to form a warp or filling component of the fabric and either fibrillated or not. Included here are other terms such as narrow films, cords, ribbons, fibres, threads, yarns and yarn elements, whether they are single-stranded constructions or multi-stranded and whose cross-section can vary from round to rectangular, even or non-even, or symmetrical or asymmetrical.

Ribbon or ribbon yarn can be made by cutting a film or

when released from certain openings depending on their shape and form. In each process, the tape material is oriented, usually by drawing. Final band dimensions are determined by the amount or degree of orientation and the original dimensions

ner of the bands for the orientation.

Strongly fibrillated components or bands mean a product or fiber that is structured with many fibers or fibrils. which has a lower denier than the original product. The fibrils may or may not be interconnected, depending on the method of fibrillation of the band. The ribbon can be shaped as a flower- or net-like structure consisting of one or more more or less parallel extended basic structures (backbones) or stem-like fine fibrils connected with even finer fibrils. This structure can be obtained by any well-known method, e.g. the rotating staple roll consisting of separate rows of staples arranged on the periphery of the roll over which the tape is drawn at a speed somewhat less than the surface speed of the roll, thereby forming laterally spaced, longitudinally extended perforations or openings placed in a separate, parallel offset relationship in the tape and the openings are so arranged that stretching the strip or band in a lateral direction shows the web-like structure. In a variant of this device, the roller consists of peripherally arranged rows of serrated saw blades which rotate relative to the moving band to form the staggered openings or perforations and the fibrils along the longitudinal direction of the band. The fibrillated strip can also be produced by an embossing method where a furrowed or embossed roll rotates against another roll, and the strip is lined between them. The embossed band is then oriented. The orientation causes breakage in the thinner sections resulting in a fibrillated band. U.S. Patent No. 3,369,435 illustrates a rotary pin roll technique that can be adapted to the production of highly fibrillated ribbons.

As used hereinafter, highly fibrillated refers to products with fine ground-structure fibrils or stalks connected by even finer fibrils resembling a flor or web-like structure in which the connecting fibrils have a denier of less than 250, varying from about 3 to 250, where the average the denier ranges from about 12 to 150. A preferred highly fibrillated tape is one having the above-described flor or net-like structure with interconnecting fibrils having a denier range from about 3 to 235 with an average denier of from 12 to 125. a particularly preferred highly fibrillated ribbon is one in which the fibrils have a denier of 3 to about 235 with an average denier of 12 to 150, and the majority of the fibrils have a denier of less than 60, and at least 30% of the fibrils in the network have an average denier from 12 to around 35.

While previous work suggested that 60 denier was an upper limit with respect to the degree of fibrillation, it has been found that deniers as high as 250 can be advantageously used to produce usable fabrics.

Preferred tapes used are from 0.01 mm to 0.11 mm thick and 0.76 mm to 5.08 mm wide, more preferably from approx. 0.025 to approx. 0.08 mm thick and 1.2 to 3.8 mm wide. A particularly preferred band is approx. 0.04 to 0.08 mm thick and from approx. 1.5 to approx. 2.54 mm wide, and can have smooth or uneven surfaces. A preferred fabric is woven in a plain weave for ease and on a regular double-stitched loom using the above bands in the warp and the highly fibrillated bands in the fill. Some of the warp yarns can be folded during weaving which advantageously helps to maintain the strength of the fabric while producing a more open weave structure with spaces that facilitate the passage of latex adhesives normally used in the carpet industry. Folding of the tape yarn during weaving is, although advantageous, not necessary for the successful implementation of the invention.

The highly fibrillated yarn is obtained by various devices in any conventional manner. For fibrillation, the film can be from approx. 0.01 mm to approx. 0.076 mm thick, more often from approx. 0.01 mm to approx. 0.05 mm thick and of almost any desired width. It has been found easy to cut a wide film of these thicknesses into strips of approx. 0.625 am's to approx. 2.5 cm<1>s wide and then-fibrillate them. It has also been advantageous to matt the film or tape for fibrillation by running the film over a rotating sandpaper-covered roll.

The following description illustrates a further advantage achieved by the present invention, which is that the fabric can be produced with warp filling components from a single extruded film. In this case the film is cut into strips of approximate width which can then be used as desired. E.g. the extruded film can be cut into one or more wide films and each of these films further cut into ribbons of the desired width depending on their use as ribbon components or fibrillated components in the fabric. Thus, both components can be produced from a single extruder from the same material source and in a continuous, uninterrupted process. Alternatively, the tapes of different widths can be produced on a single slicer having its cutting elements suitably positioned to cut the film into tapes of the desired width, after which the tapes are oriented, matted, if desired, and separated as a consequence of whether they are to be fibrillated or used directly in the weaving of the fabric.

A preferred method of making highly fibrillated ribbon yarn utilizes the above film slitting technique to form ribbons of suitable dimensions which are then oriented, then conveyed over a rotating roll equipped with staples on the surface at specified angles. The belt is perforated with a monster of openings determined by the pin positions, the angles for the pins and the belt speed in relation to the roll's peripheral speed. The result is the flor or network of fine fibers or fibrils which are connected in longitudinally extended branches, bands, basic structures or channels as described above. A particularly desirable staple roll is one that has parallel multiple rows of staples, up to 90 or more, arranged around the periphery of the roll, and the staples in each row are spaced apart from corresponding staples in every other row to create a monster of repeating staple positions. several times over the entire roll surface. The pins are angled towards the added tape to facilitate the tearing of the pins from the fibrillated tape. As mentioned above, the roller rotates at a speed somewhat faster than the belt, moving therewith with a ratio of roller to belt speed of over 1.0 to approx. 2.5 times depending on the extent and type of desired fibrillated network. After

that the ribbon is fibrillated, it is twisted onto a package to be used as filling or warp components in the woven fabric. A fibrillation method or technique using the pin roll that has been useful is described in detail in Example A herein.

in

In addition, synthetic materials can be produced which have flammability-reducing properties and are used as tapes in the present materials by mixing them with one or more flame retardant additives. The polyamides generally have good non-flammability properties. Other extruded new ion substances f are, f . e.g. modified phenylene oxide based resins having excellent non-flammable properties are available and can be used herein. Brominated polyester is available as a non-combustible material and can be used as well as polyester compounded with halogenated hydrocarbons. Many additives, both organic and inorganic, are known and can be used to prepare non-flammable polyesters and polyolefins. E.g. these synthetic substances can be combined with chlorinated paraffins, either alone or in combination with antimony oxide. Combinations of halogenated organic compounds and antimony oxide are also well known, as are perchloropentacyclodecane and related products. New bromine-substituted aromatics and mixed halogen-substituted aliphatics have recently been introduced and can also be used with polyolefins, polypropylene in particular. Other additives which may be used include, but are not limited to, inorganic compounds such as tri-hydrated alumina, and antimony oxide dispersions. The benefits of a non-combustible carpeting are obvious - safe, non-combustible carpeting can be applied to the area and room where non-combustible materials are needed according to today's regulations, building codes, and state and federal statutes.

A useful method for determining fibril density is one that is based on direct observation and measurement of a selected number of fibrils from the fibrillated constituent. In this method, the f±ril specimens are placed in a plastic matrix and cut to give cross-sections. The specimens are viewed through a microscope, the fibril width and thickness are determined by direct measurement and the denier is calculated. Alternatively, photomicrograms are made of the fibrils, and the fibril width and thickness are measured from there and the denier is calculated.

To ensure the achievement of a reasonably representative fibril-denier profile, from 30 to over 100 or more observations should be made.

Another method for determining the fibril denier, also based on direct observation, uses a Shadowgraph with a 10-fold graduated measuring lens. The specimens are mounted and viewed on circular steel bars with a smooth surface. Observations of fibril lengths and thicknesses and denier calculations are made in setups of up to 30 fibrils.

Fibril denier can also be determined by vibroscope as described in ASTM Designation D-1577, "Linear Density of Textile Fibers", method A vibroscope method. This method is based on a determination of the fundamental resonant frequency of transverse vibration in a fiber (or fibril) which is measured and used primarily to measure denier in symmetrical fibers. The fibrils of interest herein, obtained by fibrillation of a ribbon, are asymmetric and variations in resonance frequency can be observed depending on the position of the fibrils in the apparatus. It can therefore be difficult to obtain measurements using the vibroscope method.

Once the fabric has been woven from ribbon in one direction (warp or filling) and strongly fibrillated yarn in the other direction, it can be used directly. If the fabric is to be used for secondary carpet covering, further treatment is preferred to release some of the fibrils from the felt or network and raise the fibril ends over the surface of the fabric. In a preferred embodiment of such further processing, the woven fabric is brushed. A brush device is a rotating brush with relatively stiff bristles that rotates in a device against the fabric surface. Some good results have been found with a nylon bristle brush that moves at a speed of 18.3 m to 23.9 m per minute and has a penetration depth of 0.15 cm to 0.32 cm into the fabric. .

The best results were found with a brushing or napping machine manufactured by Woonsocket Napping Machinery Co., Inc. of Woonsocket, Rhode Island, which is a double-acting, multiple cloth roll machine. The fabric is run through the rollers at a speed of 23.9 m per minute. The machine is equipped with loklede rolls (up to 36) consisting of exposed metal wires and motlo rolls with a similar cover but which are turned opposite to the lokled wires. The cloth threads appear in vertical projection as in the open letter L with chisel-like points that penetrate the fabric to a depth of from 0.15 cm to 0.39 cm, preferably approx. 0.3 2 cm to loosen and raise the strongly fibrillated band-fibril ends above the fabric surface. In another embodiment of finishing or further manufacturing, the woven fabric is first penetrated by needles with barbs. These needles are positioned so that the non-fibrillated bands are relatively untouched, while most of the fibrillated components are touched. The arrangement is such that the non-fibrillated components remain unfibrillated or essentially unfibrillated. A weak effect such as a little cleavage can be seen on the ufi glazed components by this finishing. However, this effect is desirably minimal and the band remains substantially unfibrillated. The effect is again to loosen the fibrils in the fibrillated components from the warp or network and raise the ends above the surface of the fabric. As indicated in both modifications of finishing, the fibrils are at least partially detached from the warp or network and then the fibril ends are raised above the surface. In yet another embodiment, after weaving, the fabric is first subjected to the penetration of needles with barbs as described above, and then brushed or piled, either with a rotary brush with nylon bristles or a clothes roll piler. It has been found that the combination of these finishing steps results in a secondary carpet coating with excellent delamination strength, high retention of strength and good dimensional stability with fibrils with deniers as high as 250.

Barbed needle penetration means that the fabric is subjected to an array of needles mounted in parallel rows on a needle table which are moved up and down to cause the needles to penetrate the fabric. The fabric is fed under the needle table at a predetermined speed of from 6.1 m to approx. 12.2 m per minute, and the needles go up and down at around 350 to approx. 800 strokes per minute, preferably from approx. 400 to approx. 750 beats per minute. As indicated, the needles are placed on the board in parallel rows and in a sufficient number to penetrate the fabric at speeds from approx. 16 to approx. 48 penetrations per cm 2 fabric, preferably approx. 24 to approx.

43 penetrations per cm 2.

A particularly preferred needle is a so-called "pinched barbed" needle manufactured and supplied by Foster Needle Com., Minitowoc, Wisconsin, under the designation "PB-30" and characterized by the standard needle number 15 x 18 x 32 x 3.0 or 3, 5. The last number is well-known to the person skilled in the art. This particular needle is one that has two rows of barbs in each row on the needle shaft, and the rows are opposed by 180° and each barb in one row is offset a short distance from the corresponding barb in the opposite row.

As stated above, the needles are attached to the up and down needle table. They are placed in rows with the hooks pointing in the direction of movement of the fabric (i.e. parallel to the warp components of the fabric if the filling components are fibrillated components). With this orientation and selection of the needles with regard to the fabric, damage to the warp yarn is minimized while maximum lifting of the fibril ends is achieved. The needles are set so that they penetrate down to a depth of approx. 0.93cm to approx. 1.4 cm. This deepened together with from 33 to 46 penetrations per cm 2 has given satisfactory results, and the best results have been obtained in the needle depth range from 0.93 cm to 1.17 cm. A particularly preferred combination is 1.1 cm's depth with 4 2 through workouts per

2

cm.

As previously mentioned in this description, a fabric finished by needling can be further improved by further finishing with brushing or ratining to increase the hairiness and adhesion of the surface when used as a secondary coating.

A further embodiment of this invention is contemplated within its scope where the highly fibrillated tape itself is treated prior to weaving to loosen some or most of the fibrils

in

from the warp or network and raise the ends from the tape body. E.g. can the highly fibrillated ribbon for recovery

during movement is brought into contact with a cloth brush or roller with wires as described above and which will cause the fibrils to loosen and raise the ends from the moving belt body. The treated fibrillated ribbon is then collected on packs

and transported to the loom for weaving into textile fabric. Other means of treating the highly fibrillated band to make the fibril ends stand up are air or sandblasting directed at the moving band, contact of the band with emery or sandpaper, and jabbing.

Delamination strength is determined by attaching a secondary coating to a fabric surface, loose fabric or soft carpet fabric using a commercial rubber latex compound with 73% solids and measuring the strength in kg required to tear the secondary coating from the soft carpet fabrics on a strip 7.5 cm wide at a speed of 30 cm per minute. This test is standard throughout the carpet industry and a value less than 3.4 kg is considered unacceptable.

In addition to good adhesiveness, the woven fabric produced in this description has a sufficiently high tensile strength. The tensile strength or, as used in the following, "Grab Strength", which is described in ASTM Designation D-1684-64, can be defined as the maximum weight that can be applied in tension or pull to a test piece of fabric 10 x 15 cm in each of the warp and filling directions at a speed of 30 cm per minute in the lengthwise (15 cm) direction of the rips, and the fabric is held with 2.5 cm's notches, 7.5 cm apart, and the length direction is warped in one case and filled in the other. The maximum strength in kg at break is measured and designated as the breaking strength or kg at break. In some cases, the percentage elongation is measured at the same time and can be noted.

Acceptable fabrics should have "Grab Strength" over 13.6 kg in the warp and 11.3 kg in the fill, preferably over 18 kg in the warp and 13.6 kg in the fill. The materials produced in accordance with this have tensile strength or Grab Strength above these values

in both directions.

The invention is further illustrated by the following examples, and it should be noted that although polypropylene is used here, comparable results can be achieved with other synthetic, thermoplastic materials, including polyamide, polyester, and other polyolefins as well as mixtures of these.

Example A

This example illustrates a preferred process for fibrillated ribbon.

A polypropylene film approximately 50 cm wide and 0.06-0.08 mm thick was extruded through a screw extruder, where the heating zones from the feed end to the outlet of the extruder varied continuously from 204-243°C. After leaving the extruder, the film was hot-stretched in air for cooling in a 26°C water bath. The film was cut into equally wide strips and oriented by feeding through increasingly hotter zones from 121-154°C for a total orientation of 6.3-1.0. The strips were cured at 154°C and matted by passing them over rotating sandpaper-covered rollers.

The matted ribbons were then fibrillated by contact with a needle roller at an angle close to 40°. The tapes that came onto the needle roll were under tension and left the roll at about half of their initial stretch. The needles were arranged around the roll edge in 90 rows with over 12 needles per needle. cm in each row and placed at an angle less than perpendicular to the surface of the roll. The needles were alternately shifted from row to row down a distance of less than 0.002 cm and repeated several times around the roll. The ratio of roller speed to belt speed was 1.2:1 to 1.5:1.

The thus fibre-reinforced tape was wound on gaskets by a tying machine. Some of the fibrillated band was twisted to 0.5-1.5 Z TPI and the remaining bands were slowly recovered. Both bands were rewound on a rewinding machine. After the winding, the packs were transported to looms for weaving into fabrics such as twisted or extracted warp or filling yarn with polypropylene tape.

The fibrillated ribbons produced above had a denier of approximately 2300, a tensile strength of over 4.5 kg (ribbon yarn density 2.0 g per denier). and little shrinkage (less than 1.5% tested at 132°C for 15 minutes). The fibrillation was visibly characterized by lateral expansion of part of the band to give multiple, longitudinally extended basic structures, branches, stalks or bands with a laterally placed interconnecting net j

of fine fibers or fibrils.

Example 1

Several bands of highly fibrillated 2200 denier polypropylene were

produced, fibrillated to varying degrees of fineness at varying needle roll speeds according to example A. The highly fibrillated bands were designated Fibrillated Band no. 1, Fibrillated Band no. 2 and Fibrillated Band no. 3 - fine, medium and coarsely fibrillated respectively.

Fibrillated Band No. 1: speed ratio - 1.45:1

Fibrillated Band No. 2: speed ratio - 1.31:1

Fibrillated Ribbon No. 3: velocity ratio - 1.21:i.

The fibrillated ribbons were wound up on roller packs and transferred to the loom for weaving into fabrics. Some of the packings of Fibrillated Band No. 1 were extracted^the rest of Fibrillated Band No. 1 and Fibrillated Band No. 2 and 3 were twisted 0.8-1.5

Z TPI.

All of the fibrillated tapes provided the felting and appearance of burlap. The deniers of the fibrils, where the fibrils gave the bands their hairiness, were determined by microscopic examination of fibril cross-sections. The deniers are presented below together with an analysis of their distribution in the investigated fibrillated band.

Example 2

Fabric samples were woven in canvas binding with Fibrillated Ribbon No. 1 from Example 1 and designated A, B, C and D as follows: Sample A: 4.8 unfibrillated 1000 denier polypropylene ribbon warp component sender per cm, and 3.6 extracted filling tips of Fibrillated Band no. 1 from example 1.

Sample B: Same construction as sample A above, except that the Fibrillated Tape no. 1 from example 1 was twisted 0.32-0.4 Z twists per cm (TPI).

Sample C: Extracted. Fibrillated Ribbon no. 1 from example 1 warp component transmitter per cmbg 3.6 recovered Fibrillated Bands No. 1 from Example 1 filler tips.

Sample D: 4 Fibrillated Ribbons No. 1 from Example 1 twisted 0.32-0.4 Z TPI warp component transmitter per cm and 3.6 recovered Fibrillated Band No. 1 from example 1 filler tips.

The fabric samples were all directly brushed onto a fabric roll ratiner supplied by Woonsocket Napping Machine Co., Inc., Woonsocket, Rhode Island, and laminated to a bare pile carpet fabric with

a commercial latex laminating compound with 73% solids content. Three delamination tests, consisting of pulling a 7.5 cm strip of fabric from the bare carpet at 30 cm per minute, was conducted with each sample, and 3"Grab Strength" tests as described in ASTM regulation D-1684-64 were also conducted. The average results of three tests of each sample are given below:

Example 3

A fabric was prepared as in Example 2 using 1000 denier unfibrillated polypropylene tape as the warp component, 4.8 ends per skein. cm, around 2.54 mm wide and 0.04-0.05 mm thick and approximately 9 tips with 2100 denier strongly fibrillated polypropylene tape as filling component. The filler components were needle roller fibrillated generally according to Example A and had fibrils in the range of 4-31 by Vibroscope measurements of 50 randomly selected fibrils with an average denier of 22.99. The fibrillated components felt twisted 1.5 Z TPI. The fabric was post-treated by brushing with the fabric roll ratiner in example 2.

The fabric was then laminated to a bare carpet fabric with the latex laminating compound from Examples 2 and 3 delamination and Grap Strength tests were also carried out as in Example 2. The average results of these tests are given below-

under :

This example illustrates a fabric in which the highly fibrillated yarn is of a much lower average denier and, despite the twisting, a delamination strength of over 3.4 kg was achieved and the fabric strength was maintained.

From the preceding example, it appears that finishing by brushing with a fabric roll ratiner is an effective means of raising the fibril ends from the fibrillated constituents and providing fabrics with delamination strengths of 3.4 kg and higher. It can also be seen from samples C and D that adhesion is achieved when both components of the material are strongly fibrillated. Twisting has little, if any, effect on adhesion. Samples A and B indicate some adverse effect on adhesiveness; however, all samples are acceptable. Strength in both fill and warp direction is maintained in all samples and is considerably higher compared to previously known fabrics

(see example 8 for comparison with previously known substances).

Example 4

Several fabric samples were woven using Fibrillated Tape No. 1 from Example 1 as filler components. The warp components were 1000 denier polypropylene tape 1.65-2.03 mm wide and 0.04-0.05 mm thick; the fabric constructions were all close to 12 x 9. After weaving, the samples were subjected to finishing: some for both stitching and brushing, some for stitching alone and others for brushing alone. *A11 brushing was carried out with rotating nylon bristles rotating at 22.5 m per minute which penetrated to a depth of 0.15-0.23 cm in the fabric. The fibril densities after the above-mentioned treatments were determined from measurements by microscopic examination of the fibril cross-sections. The lamination and grab strength tests were also carried out.

Stitching was carried out under varying conditions with 18 x 15 x 32 x 3.5 spindle pitch Foster Type PB-30 needles oriented for stitching down into the fabric to a depth of 1.1 cm. The fabric was brushed (samples A-C) after stitching. A fabric (sample D) was stitched, without brushing as shown below: Sample A: Needle table speed 700 strokes per minute (s/m); fabric speed 7.2 m per minute (m/min.); needle penetration speed 42.4 penetrations per cm 2; brushing as described above.

Sample B: Needle table speed 550 s/m, fabric speed 7.2 m/min; reaching a bed penetration rate of 33.3 cm 2;• brushing as described above.

Test C: Needle table speed 400 s/m; fabric speed 7.2 m/min; needle penetration density 24 penetrations per cm 2; brushing as described above.

Test D: Needle table speed 700 s/m; fabric speed 7.2 m/min; needle penetration density 42.4 penetrations per cm 2; no brushing'.

A further sample, designated sample E, was run, in which the fabric after weaving was brushed only with a nylon bristle roller under the above conditions.

An unstitched and unbrushed fabric with fibrillated band No. 1 from example 1 as filling component was run as a control.

The results from the sample consisting of fibril denier measurements

are set out in Table I below:

From the preceding example, it appears that a number of after-treatments are effective in producing substances with delamination strengths above 3.4 kg. It is particularly noted that sample A with a delamination strength of 7.24 kg can be compared with the adhesive quality for jute fabrics and spun polyester fillers, as shown in Table I. For this reason, sample A is a particularly representative embodiment of the invention. Secondary fabric coverings can therefore be produced with adhesive strengths up to 7.24 kg, filling component strengths well over 13.6 kg and warp component strengths over 29<*>.5 kg.

Example 5

Example 4 was repeated using Fibrillated Band No. 2

from example 1. The conditions for samples A, B, C, D and E

from example 4 was repeated for the corresponding sample in this example. The control substance was prepared using Fibrillated Ribbon No. 2 from Example 1 as filler components; it was unplucked and unbrushed. The results from the test are listed in table II below:

Example 6

Example 4 was repeated using Fibrillated Band No. 3 from Example 1. The conditions for samples A, B, C, D and E from Example 4 were repeated for the corresponding sample in this example. The control substance was prepared using Fibrillated Band No. 3 from Example 1 as filler components; it was unplucked and unbrushed. The results from the tests are listed in Table III below: Examples 4, 5 and 6 show that many finishing methods can be used to provide substances with acceptable adhesiveness. They further show that the post-treatment can overcome the effect of high fibril density. As previously stated, tackiness tends to be a function of denier; in general, the finer the fibril (lower denier), the greater the adhesiveness. The results obtained in examples 15-17 show that the delamination strength increases with increasing stitching from 400 blows per minute/24 penetrations per cm 2 to 700 strokes per minute/42.2 penetrations per cm 2* - a result consistent with the fact that increased stitching loosens more fibrils from the web or network and raises more fibril ends above the plane of the fabric. Samples C and D in example 6 show in table III that although stitching at a density of 400 s/m-24 penetrations per cm 2 produces a delamination strength of 3.1 kg for a fabric whose filling component has an average denier of 70.6, produces a stitch density of 700 s/m-42.2p per cm a delamination strength of 4.2 kg for a fabric whose filler component has an average denier of 75.4.

In examples 4-6, all brushing was done with a rotating brush with relatively stiff plastic bristles. The results obtained with such brushing as the only finishing treatment were not acceptable. However, Examples 2 and 3 show acceptable fabrics that were produced when finishing was done with a metal wire rolling fabric brush.

Example 7

A woven synthetic fabric was produced using 1000 denier polypropylene ribbons as warp constituents. The tape dimensions were 2.8 mm wide and 0.04-0.05 mm thick. The ribbons were run through a special weaving spoon on the loom which folded some of the ribbons longitudinally and thereby brought them apart, so that when weaving with strongly fibrillated ribbons as filling components, up to 50% air space was present in the weaving spoon. The fabric had a canvas weave construction with ribbon warp ends per cm and 9 filling tips (really 11.7 x 10.3 warp for filling).

The fill components were 2000 denier polypropylene tapes that were highly fibrillated by needle roll, generally according to Example A above, for they were woven into the fabric with fibrils having a denier from 5-60 by vibroscope measurements of 50 randomly selected fibrils with an average denier of 25, 26. The fibrillated ribbon was given a 1.5 Z-twist per inch (1.5 Z TPI) and wound up on a gasket for weaving on a loom. The fabric thus woven was subjected to finishing by pointed needles which detached the fibrils from the web or network and raised their ends above the surface. The fabric surface was found to have an increased number of fibrils and was found to have a very hairy or shaggy appearance, aesthetically similar to woven burlap. A final hand brushing was given to the fabric to further raise the fibril ends above the surface of the fabric.

The fabric thus treated was then laminated with a commercial latex laminating compound of 73% solids content to a plain carpet fabric consisting of a pile face piled to a tightly woven synthetic ribbon woven fabric or primary coating and a layer of the salmon applied to the underside to lock in the piles. After lamination and curing of the latex, the fabric was exposed to

a delamination or bond strength test. This proy consists of tearing away a 7.5 cm strip of the coating at a speed of 30 cm per second. minute, while the required force is measured. The results obtained in this exam are presented below. The "Grab Strength" tests described in ASTM regulation D-1682-64 were also carried out. Delamination strength (kg): 3.35,

(average of 3 samples, varying from 3.1-3.5)

Example 8

This example illustrates an attempt to repeat the content

of the U.S. patent 3,542,632 and consequently sample the content of the patent, whereby various woven fabrics were produced and fibrillated by pointed needles as described in U.S. Pat. patent 3,542,632. Each substance was prepared for the fibrillation in accordance with the following description and the patent's preparation. j

Fabric: Loosely woven polypropylene ribbon oriented (5-6 times)

in a canvas weave of 12 x 8 construction with spaces between the yarns and dimensionally stabilized by heat treatment.

Warp: Polypropylene tape formed by extrusion through a rectangular outlet head, 0.05-0.06 mm thick, 0.30-0.20 mm wide, 4.8 ends per cm.

Filling: Polypropylene tape formed by extrusion through a rectangular opening, 2.54 mm wide x 0.05 mm thick, 8 tips.

The material samples were designated alphabetically as follows:

Samples A, B, C, D and E, and each was fibrillated with pointed needles, the particular needle being selected essentially from the same as shown in Figure 4A of the U.S. patent No. 3,542,632. The degree of fibrillation from sample A to sample E was varied; fibrillation of sample A was the least strong and fibrillation of sample E was strongest. The degree was correlated with a scale of needle penetrations per cm<2> as indicated below. The data show that the fabric strength decreases with increasing fibrillation.

This example illustrates an advantage of this invention.

A defect in the secondary carpet coating manufactured at the U.S

patent no. 3.54 2.632 as appears from the preceding example

pel is that fibrillation strong enough to provide acceptance

table adhesiveness of a primary carpet covering which, measured by the delamination strength, significantly weakens the fabric, so that the tensile strength in the filling direction drops from 26.7 kg to 6.3 kg; the tensile strength in the warp direction drops from 44.8 kg to 11.1 kg.

It appears that the tensile strength of fibrillated material produced by the method of U.S. patent 3.54 2.63 2, which has acceptable adhesion to a bare carpet, is a 1/4 of what it was for fibrillation.

The present invention is characterized by the ease, applicability and efficiency of the production, which provides a textile with acceptable adhesiveness without sacrificing strength.

Example 9

A fabric was made with tan 1000 denier polypropylene webbing as the warp component and brown 2000 denier high fibrillated polypropylene webbing twisted 1.50 TPI as the fill component; the filler component was supplied by Hercules Company, Wilmington, Delaware. The fabric was woven in a plain weave construction, 4.8 warp ends per cm and 3.6 filler tips. Some of the warp components were folded using a special weft spoon on the loom. The fill component was around 2000 denier and highly fibrillated. The fibril rill denier by vibroscope measurement of 50 randomly selected fibrils ranged from about 7-31 with an average denier of about 21.06. The fabric was subjected to finishing with pointed needles followed by hand brushing. It was laminated to a bare carpet and gave the following lamination and "Grab Strength" results when measured:

Examples 10-13

Different coating sample fabrics were woven from different materials to compare the delamination strengths of fabrics

with fibrillated components. Each sample consisted approximately of a 14 x 9 weave construction, the warp in each sample was 1000 denier

polypropylene tape, 1.91-2.55 mm wide with some folding in the weave of a loom with 14.4 openings between the loom threads or

teeth per empty. A warping per spoon tooth with an air opening of 49.6% in the tissue spoon. The filling ingredients were as follows:

Example 10

Tan colored 2100 denier, 1.5 Z TPI high fibrillated polypropylene tape supplied by Hercules Company, as in Example 1 with the same fibril denier.

Example 11

Tan 2100 denier, 1.5 Z TPI heavily fibrillated with needle roller according to Example A, polypropylene tape, fibril denier by vibroscope measurement of 50 randomly selected fibrils ranging from 4-31 with an average denier of 22.99.

Example. 12

Naturally dyed 2400 denier, coarsely fibrillated polypropylene ribbon' (visually measured) supplied from a private source, fibril denier and fibrillation method unknown.

Example 13

Tan colored 2.25 g/l spun polyester, twisted 3.5 Z TPI yarn supplied by the Whitaker Company.

After weaving, the fabrics were subjected to finishing to

raise the fibrils above the fabric plane according to the procedure in example 7. The fabrics were then laminated to a bare carpet and assessed with regard to adhesiveness. The results are set out in Table 4 below. A 13 x 10 jute fabric was evaluated as a comparison.

It should be noted that although spun polyester fill produces excellent adhesion, the material is quite expensive and unless more material is used, it is likely that the fabric will become sloppy, i.e. has poor dimensional stability which adds to the already high costs.

Another advantage apart from relative material costs

which follows the invention is that the manufacturer can work with tape alone in both warp and filling components. This'means that he can<*>extrude and split the film into ribbons. Some of the bands can be used as warp components in the fabric suitable for a secondary coating, while other of the bands can be fibrillated to provide fill components. It is immediately understood that the present invention provides a significant reduction in material and equipment investment; assuming a fibrillator, you do not need to add single-stranded, multi-stranded yarns or spun yarns to the mineral list. Furthermore, spinning nozzles, cutting tools and other equipment needed in the production of these yarns can be dispensed with.

Example 14

A 15 x 9 (approximate) plain weave construction fabric was made from 1000 denier, beige polypropylene tape 1.91-2.54 mm wide in the warp and 1100 denier flat tape fill yarn, 2.54 mm wide. The woven fabric was then fibrillated after weaving by stabbing the entire surface and then mated for lamination into a bare carpet as with the fabric in Examples 10-13 and then subjected to delamination testing as in these examples with the following results: Delamination strength kg/7.5 cm strip-1.68 kg.

Example 15

This example illustrates the relationship between the degree of fibrillation, adhesiveness and tensile strength. Various fabrics were produced with an approximate 12 x 9 construction: the warp components were polypropylene tapes as in the previous examples and the fill components were fibrillated polypropylene tapes. The degree of fibrillation is reflected in table V below by the denier of the fibrils - the finer the fibrils (lower denier), the greater the degree of fibrillation. The denier is determined in this example using a Goko Co. (Japan) Shadowgraph with a 10x latitude graduated objective lens. The specimens were placed and observed on round steel rods with a smooth surface. Observations of fibril lengths and thicknesses and denier calculations were performed and reported for collections of 10 and 30 fibrils.

After the weaving of each fabric, they were finished by stitching using a 15 x 18 x 32 x 3.5 gauge PB-30 (point needle) needles from Foster Needle Co., Manitowoc, Wisconsin. The fabric was run at a speed of 7.2 m/min, the penetration depth of the needles was 0.94-1.1 cm with a needle speed of 700 strokes per minute and a needle penetration rate or density of 42.4 penetrations per cm^. It generally appears that when the fibril denier becomes higher (i.e. coarser) the adhesiveness decreases. It also appears that fibrillated bands with individual fibrils up to 250 denier and average denier as high as 122 can provide secondary coatings with delamination strengths above 3.4 kg.

Example 16

In this example, different substances were considered for use

as a secondary coating, in which one of the components consisted of polypropylene with a flame-retardant additive. The fabrics were all approximately 12 x 9 construction, the warp components were white colored 1000 denier polypropylene webbing with flame retardant incorporated therein. These components were from about 1.8-2.2 mm wide and from 0.05-0.08 mm thick. The flame retardant material was a halogenated antimony oxide additive supplied in concentrated form from Monmouth Plastic Company under their trade name PP 3. The material was mixed with the polypropylene resin in a mixer or dropped in a ratio of 8 to 10:1 polypropylene to retardant. The filler components were white colored, highly fibrillated ribbons prepared by the method described in Example A above.

The fabrics were post-treated by stitching and brushing and delamination and "grab strength" tests were carried out. The results of 3 fabric samples, designated A, B and C together with an unstitched sample worn as a control are given below in table VI.

Example 17

In this example, two substances A and B were produced, in which highly fibrillated polypropylene ribbons according to example A and Fibrillated Ribbon No. 1 from example 1 were used as warp components. The fabrics were approximately 9 x 13 constructions. The filler components were polypropylene unfibrillated 1000 denier webs 16.5-17.8 mm wide and 0.4-0.5 mm thick. The fabrics were finished by stitching and brushing for lamination into a plain pile carpet. In one fabric, designated sample A, the fibrillated ribbon was twisted for weaving and in another, sample B, the fibrillated component was extracted. Delamination and "Grab Strength" tests were carried out and the results are listed below in Table VII. The degree of twisting is also stated where necessary (table VII). From this example it appears that an acceptable secondary coating can be produced, in which the warp component is the highly fibrillated component. Furthermore, when the fibrillated material is slightly twisted, a slight decrease in delamination strength is produced.

Example 18

This example illustrates the proposition that a plurality of fibrillation techniques are possible to provide highly fibrillated synthetic tapes which, when woven into fabrics, exhibit delamination strengths in excess of 3.4 kg.

A fabric was woven with polypropylene tapes as warp components as in previous examples and highly fibrillated polypropylene tapes as fill components were prepared as in Example A except that the tapes were run over a roll with 34 metal saw blades placed around the periphery. Each blade had 9.5 fibrillation teeth per cm and the roll to film speed ratio was 2.05:1. The fabric had an approximately 12 x 9 construction and was laminated to a plain pile carpet. Delamination and "Grab Strength" tests were carried out (the latter only on filler components) with the following results:

Example 19

This example illustrates another finishing technique that can be used to produce secondary coatings with delamination strength greater than 3.4 kg.

A fabric, approximately 12 x 9 construction, woven from unfibrillated, 1000 denier, polypropylene ribbons, 1.6 mm wide and 0.04 mm thick as the warp constituents and highly fibrillated, spun 2400 denier ribbons as the fill constituents, was coated with a latex avier or adhesive in an amount of about 2% by weight of the fabric and heat treated in a plant oven to dry the coating. The fabric was then finished with a peau de péche or coating forming machine supplied by Parks-Woolson Machine Co., Inc., Springfield, Vermont, consisting of one or more rotating rolls coated with an abrasive such as emery cloth. The resulting fabric was then laminated into a plain carpet fabric and subjected to delamination and "Grab Strength" tests with the following average results from 3 passed tests:

The above described and exemplified fabric is a woven fabric of a synthetic polymer, preferably polyolefin and especially polypropylene yarn which provides a synthetic substitute for jute fabrics. The fabrics according to the invention have an appearance very similar to jute fabric or burlap and a strikingly similar grip and handling feel. The fabrics possess the same hairy or furry surface and exhibit comparable acceptable adhesive properties when laminating into a bare carpet. When used as a coating in a carpet structure, the fabric adds strength to the finished carpet and appears to have the appearance of a jute coated fabric or carpet, while retaining the benefits and attributes of the synthetic materials from which it is made.

The fabric according to the invention is also useful for bags and sacks as a sack yarn substitute and overcomes the problems of previous synthetic yarn fabrics for this use by using a fibrillated yarn in the warp or filling of the fabric which provides high friction between them and the smoother ribbon yarns, thereby stabilizing the fabric so that it can easily contain large quantities even of loose materials.

The fabric is characterized by finely divided fibrils with low denier in the filling or the warp yarns. It has been found that by fibrillating to produce fibrils with deniers in designated areas, fewer fibrils may be required in the fabric for adhesive strength compared to prior fabrics similar to those prepared and described in previously cited U.S. Pat. patent No. 3,542,632. Previous fabrics that are fibrillated after weaving as in the U.S. patent No. 3,542,632, have been found to be unusable as carpet secondary coatings because, when fibrillated strongly enough for acceptable bond strengths, they do not retain sufficient stability or fabric strength to be acceptable in the carpet industry. On the contrary, the present invention provides the desired<*>fibrous, furry or hairy appearance with acceptable adhesiveness, with high retention strength and good aesthetics, and some higher denier fibrils may be present and still provide acceptable adhesiveness. The fabric fulfills its role adequately as a secondary coating and additionally strengthens the finished carpet and gives it good dimensional stability and manageability.

Claims (60)

1. A synthetic woven textile usable as a secondary carpet covering consisting of warp and filling components, where at least one of said components consists of highly fibrillated synthetic tape, characterized in that the textile has a tensile strength greater than 11.3 kg in the fibrillated tape's direction and 13.6 kg in the other direction and a delamination strength greater than 3.4 kg. 2. A synthetic woven textile according to claim 1, characterized in that the warp components consist of unfibrillated bands and the filling components consist of strongly fibrillated bands. 3. A synthetic woven textile according to claim 1, characterized in that both the warp and filling components consist of highly fibrillated bands. 4. A synthetic woven textile according to claim 1, characterized in that the fibrils of the strongly fibrillated tape components are in the range from 3-235 denier. 5. A synthetic woven textile according to claim 1, characterized in that the fibrils from the highly fibrillated components are in the range from 4-200 denier. 6. A synthetic woven textile according to claim 1, characterized in that the fibrils of the strongly fibrillated band components have an average denier below 150. 7. A synthetic woven textile according to claim 1, characterized in that the fibrils of the highly fibrillated . the components have an average denier from around 12-125. 8. One. synthetic woven textile according to claim 1, characterized in that the fibrils of the strongly fibrillated components have an average denier of from 15-100. 9. A synthetic woven textile according to claim 4, characterized in that most of the fibrils have a denier of less than 60. 10. A synthetic woven textile according to claim 9, characterized in that most of the fibrils with a denier of less than 60 are from around 12-35 denier. 11. A synthetic woven textile according to claim 1, characterized in that the plastic for the warp and filling components is selected independently from the group consisting of polyamide, polyester, polyolefin and mixtures thereof. 12. A synthetic woven textile according to claim 1, characterized in that the warp and filling components are both polyolefin. 13. A synthetic woven textile according to claim 1, characterized in that the warp and filling components are both polypropylene. 14. A synthetic woven textile according to claim 1, characterized in that at least one of said warp and filling components is flame retardant polypropylene. 15. A synthetic woven textile which can be used as a carpet covering, characterized in that it consists of synthetic ribbon warp components which are from 0.01-0.1 mm thick and highly fibrillated synthetic ribbons as the filling component, the fibrils in said fibrillated ribbon has an average denier of around 12-150 denier, and the textile has a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the fill direction. 16. A synthetic woven textile according to claim 15, characterized in that the warp components and filling components are polyolefin. 17. A synthetic woven textile according to claim 15, characterized in that the warp components and filling components are polypropylene. 18. A synthetic woven textile usable as a secondary carpet covering woven from polyamide, polyester, polyolefin or mixtures thereof, characterized in that the warp tape components are from 0.01-0.1 mm thick and from 0.76-3 mm wide and the highly fibrillated fill components whose fibrils are from about 3-235 denier with an average denier of from 12-150, said textile having a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the fill direction and a delamination strength greater than 3.4 kg. 19. A carpet structure characterized in that it consists of a primary covering containing a pile surface attached to it and a secondary covering glued to the underside of this primary covering, the secondary covering consisting of a synthetic fabric 'woven from polyamide, polyester, polyolefin or mixtures thereof, and further consists of warp tape components, these tapes being 0.01-0.1 mm thick and from 0.76-3 mm wide and highly fibrillated filling components whose fibrils have an average denier of from around 12-150, and said secondary coating is characterized by a tensile strength of over 13.6 kg in the filling direction and a delamination strength greater than 3.4 kg. 20. A carpet structure according to claim 19, characterized in that the primary covering is a synthetic fabric woven from polyamide, polyester, polyolefin or mixtures thereof, including warp tape components from 0.01-0.1 mm thick and from 0.76-3 mm wide and strongly fibrillated filling components. 21. A woven synthetic textile usable as a carpet covering, characterized by warp components and filling components, and these warp and filling components comprise unfibrillated synthetic tape from 0.01-0.1 mm thick, as this plastic consists of polyolefin , polyamide, polyester or mixtures thereof, the other of these warp and filling components. consists of strongly fibrillated synthetic tape, the plastic consists of polyolefin, polyamide, polyester and mixtures thereof, and the fibrils are from 3-235 denier and have an average denier of around 12-150, as the material is characterized by a tensile strength greater than 13, 6 kg in the band direction and greater than 11.3 kg in the fibrillated band direction. 22. A woven synthetic textile according to claim 21, characterized in that the plastic in both the warp and filling components consists of polyolefin. 23. A woven synthetic textile according to claim 21, characterized in that the plastic in both the warp and filling components consists of polypropylene. 24. A synthetic woven secondary covering, characterized in that it consists of warp components and filling components, where one of these warp and filling components mainly consists of unfibrillated synthetic tape and the other of these warp and fill components consist of highly fibrillated synthetic tape, the coating is characterized by a stretch-| strength greater than 11.3 kg in the fibrillated tape direction and 13.6 kg in the other direction, and a delamination strength greater than 3.4 kg. 25. A synthetic woven secondary coating according to claim 24, characterized in that the plastic comprises polyolefin, polyamide, polyester or a mixture thereof, and that the fibrils in this fibrillated band have an average denier of from around 12-150. 26. A synthetic woven secondary coating according to claim 24, characterized in that the warp components comprise substantially unfibrillated bands and the filling components comprise highly fibrillated bands. 27. A woven synthetic secondary coating, characterized in that it consists of warp components and filling components, where one of these warp and filling components consists of synthetic tape from 0.01-0.1 mm thick, this synthetic material is selected from the group consisting of polyolefin, polyamide, polyester and mixtures thereof, the other of these warp and fill components consists of highly fibrillated synthetic tape, the plastic is selected from the group consisting of polyolefin, polyamide, polyester and mixtures thereof, the fibrils are from 3 -235 denier and has an average denier of from around 12-150, the secondary coating is characterized by a strength greater than 13.6 kg in the band direction and greater than 11.3 kg in the fibrillated band direction and a delamination strength -greater than 3.4 kg. 28. A synthetic woven secondary coating, characterized in that it consists of warp and filling components, where at least one of these components comprises highly fibrillated synthetic tape, the synthetic material is selected from the group consisting of polyolefin, polyamide, polyester and mixtures thereof, the fibrils of this highly fibrillated tape are from 3-235 denier and have an average denier of from about 12-150, the coating is characterized by a tensile strength greater than 11.3 kg in the fibrillated tape direction and a delamination strength greater than 3.4 kg. j 29. A synthetic woven secondary-r coating according to claim 28, characterized in that both the warp and fill components consist of strongly fibrillated tape. 30. A woven polyolefin secondary coating, characterized in that it consists of warp components and filling components, one of these warp and filling components consists of polyolefin tape from 0.01-0.1 mm thick, the other of these warp and the filling components consist of highly fibrillated poly-olefin tape, the fibrils in this tape are from 3-235 denier and have an average denier of around 12-150, the coating is characterized by a tensile strength greater than 13.6 kg in the tape direction and greater than 11.3 kg in the fibrillated band direction and a delamination strength greater than 3.4 kg. 31. A woven polypropylene secondary coating, characterized in that it consists of polypropylene tape warp components which are from 0.01-0.1 mm thick and strongly fibrillated polypropylene tape as a filling component, the fibrils in this fibrillated tape are from 3-235 denier with an average denier of from 12-150, the coating is characterized by a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the filling direction and a delamination strength greater than 3.4 kg. 32. A woven polypropylene secondary carpet covering, characterized in that it consists of strip polypropylene warp components from 0.01-0.1 mm thick, and from 1.9 to around 3 mm wide and highly fibrillated polypropylene filling components whose fibrils are from 4 -200 denier with an average denier of around 15-100, this secondary coating is characterized by a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the fill direction and a delamination strength greater than 3.4 kg. 33. A carpet structure characterized in that it consists of a) a primary — coating containing a sooty surface attached thereto, <:> °g b) a secondary coating attached to the underside of this primary coating, the secondary coating consists of a woven polypropylene fabric which further consists of i) polypropylene warp components which are from 0.01-0.1 mm thick and from 1.3-3 mm wide and, ii) highly fibrillated polypropylene fillers with fibrils from 3-235 denier and with an average denier from 12 to about 150; this secondary coating is characterized by a tensile strength of over 13.6 kg in the filling direction and a delamination strength greater than 3.4 kg. 34. A method for producing a synthetic secondary carpet covering, characterized by interweaving synthetic warp tape components 0.01-0.1 mm thick and strongly fibrillated filling components with fibrils from around 3-235 denier and with an average denier from around 12-150, this plastic is in each case independently selected from polyamide, polyester and polyolefin, this coating has a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the filling direction. 35. A method according to claim 34, characterized in that the resulting coating is further processed to raise the ends above the fabric's surface. 36. A method according to claim 35, characterized in that the coating is brushed to raise the fibril ends over the surface of the fabric. 37. A method according to claim 36, characterized in that the coating is brushed with a cloth keratinizer to raise the fibril ends. 38.. A method according to claim 35, characterized in that the coating is easily penetrated with pointed needles to raise the fibril ends. in i IN 39. A method according to claim 35, characterized in that the resulting coating is first lightly penetrated mainly only in the filler components by pointed needles and then brushed. 40. A method for producing a synthetic secondary carpet covering, characterized in that it consists of a) weaving polypropylene warp components from 0.01-0.1 mm thick and highly fibrillated polypropylene filling components with fibrils from about 4-205 denier and with an average denier of from about 15-100 into a fabric, and b) then further treatment of this fabric to raise the fibril ends over the fabric surface, the resulting fabric is characterized by a tensile strength greater than 13.6 kg in the warp direction and greater than 11.3 kg in the fill direction and a delamination strength greater than 3.4 kg. 41. A synthetic woven secondary coating according to claim 24, characterized in that the fibrils in the fibrillated components are from 3-235 denier with an average denier of from 12-150. 42. A synthetic woven secondary coating according to claim 24, characterized in that the fibrils in the fibrillated components have an average denier of from around 15-100.. nine 43. A synthetic woven secondary coating according to claim 24, characterized in that the fibrils in the fibrillated components are from 4-200 denier with an average denier of from around 15-100. 44. A synthetic woven secondary coating according to claim 24, characterized in that the fibrils in the fibrillated components are from 3-235, where most of these fibrils have a denier of less than 60. 45. A synthetic woven secondary coating according to claim 44, characterized in that at least 40% of the fibrils in the fibrillated components are less than 35 denier. 46. A method for finishing a woven fabric, wherein the fabric is woven from synthetic warp tape components and highly fibrillated filling components to raise the fibril ends of these fibrillated components above the top of this fabric flat, characterized by the fact that this textile is pierced with pointed needles. 4 7. A method for finishing a woven textile according to claim 46, characterized in that the needles go up and down to penetrate the textile. 48. A method for finishing a woven textile according to claim 47, characterized in that the needles penetrate the textile to a depth of from 0.93 cm to around 1.17 cm. 49. A method for finishing a woven textile according to claim 46, characterized in that the textile is pierced while it moves from around 6 to around 12 m per minute. 50. A method for finishing a woven textile according to claim 47, characterized in that the needles penetrate the textile from around 16-48 penetrations 2 per cm textile. 51. A method for finishing a woven textile according to claim 47, characterized in that the needles go up and down from around 350 to around 800 strokes per minute. 52. A method for finishing a woven textile according to claim 46, characterized in that the needles are arranged in rows in an up and down needle table with the tips parallel to the unfibrillated components. in I I 53. A method for finishing a woven textile according to claim 46, characterized in that the pointed needles have a pair of rows of points 180° to each other on the shafts. 54. A method for finishing a woven textile according to claim 53, characterized in that each row has two tips, each tip in a row is offset from the corresponding tip in the next row. <*> 55. A method for finishing a woven textile according to claim 53, characterized in that the needles are pinched tip No. 15 x 18 x 32 x 3.0 or 3.5. 56. A method for finishing woven textile where the textile is woven from polyolefin tape warp components and highly fibrillated filling components to raise the fibril ends of these fibrillated components above the fabric surface, characterized in that the textile is pierced by the pricking needles, these needles going up and down from around 350-800 strokes per minute to penetrate the textile to a depth of 0.93 cm to about 1.17 cm and from about 16-48 penetrations per cm^ textile. 57. A method for finishing a textile according to claim 56, characterized in that the warp and filling components are polypropylene. . 58. A method for finishing a woven textile according to claim 56, characterized in that the needles go up and down in a needle table. 59. A method for finishing a woven textile according to claim 58, characterized in that the needles are arranged in rows in the needle table with the tips parallel to the unfibrillated components. 60. A method for finishing a woven textile according to claim 56, characterized in that the needles have a pair of ■• tips, which stand 180° to each other on their shafts.