NO760344L - - Google Patents

Description

"Coating for floors and walls".

The present invention relates to a coating for

floor and/or walls, as well as a method and an installation or device for producing this coating.

The invention is more particularly directed to a

floor and/or wall covering of a non-woven type, comprising at least one layer or cover of parallel textile threads lying next to each other as well as a base layer to which the individual of the many textile threads are attached.

Until now, the textile threads have either been attached using a suitable glue or binder, or a sewing thread with a Malimo seam or stitch has been used to attach the textile threads to the base layer.

When the textile threads are glued to the base layer, the diameter of the threads cannot be particularly large, as the glue-coated part must both be relatively large in relation to the non-glue-coated surface, but at the same time it must be so small that the textile threads do not become too stiff from the hardened glue , so that the textile feel and appearance is maintained on the visible side of the covering. It has been found that this double requirement can only be fulfilled by very thin threads, so that the area of application of the known coating of this type is limited to vertical panels or walls. Moreover, the glue used for these coatings is a thermoplastic film which is one with a paper tap, which is heated to the softening temperature before the textile thread layer is applied under pressure and which loses its flexibility relatively quickly, and the threads soon become stiff in such a way that they can easily be pulled out, whereby the coating deteriorates in a short time. During the production of this known coating, it is absolutely necessary that the textile threads are placed in the same plane and can come into contact with the base layer which has an adhesive film applied, since textile threads that lie outside the thread plane will not be able to be attached to the base layer. When thick threads are used, there is a possibility that they will be flattened when they are applied to the adhesive layer and that they will be provided with glue over a part of the periphery which is insufficient to prevent the threads from being pulled out. Analogous difficulties arise with twisted threads, coated threads and with all the so-called artificial threads.

Attempts have already been made to avoid these problems or disadvantages by using thin basting or staple threads to fasten thick threads by means of a Malimo stitch in such a way that they surround the visible side of the periphery of the threads and fasten the threads of the base layer. To the extent that the thick threads have the same colour, the booklet thread can also have the same colour, so that the appearance of the coating is not impaired by said booklet thread. However, the aesthetic appearance is degraded if the thick threads have different colors and become very different from the color of the booklet thread. Quite apart from this disadvantage of an aesthetic nature, coatings of this known type cannot withstand strong wear due to the fact that the thin staple thread is relatively weak, so that the thick threads can be removed from their proper place when they are no longer held in place by the staple threads. The weakness of the staple threads will also be an obstacle to this type of covering as a floor covering.

To counter these disadvantages, it has been proposed to cover the thicker thread layer and the booklet threads with a protective plastic layer. However, this means that the coating no longer has the original textile character, so that it is soft to the touch, as this is absolutely necessary for a textile floor and/or wall covering.

The present invention proposes to eliminate all the above-mentioned disadvantages and provides a coating of the above-mentioned type, which completely retains the text U character while at the same time having great resistance to wear and fraying and enabling the use of differently colored threads.

This is achieved according to the invention by means of floor and/or wall coverings of the non-woven type which comprise at least one layer of parallel and adjacent textile threads as well as a base layer as the individual textile threads, produced from a series of more or less twisted fibers , is attached to, characterized in that a small part of the fibers in each textile thread is attached to the base layer by needle stitching with a density that does not destroy the continuity and the inventive appearance of each textile thread.

Because of this precaution, all the textile threads will be attached to the base layer along the entire contact surface with it without the fixing agent being visible or exposed to wear. The thick threads retain their elasticity and swollen shape because the not-so-tight needlework hardly modifies their structure. The adjacent threads are also attached without difficulty to the base layer. It has been found

that when the fibers are attached to the base layer, the attachment fibers will prevent . that other fibers which are more or less screw-wound about the thread axis are wound up and loosened, so that the wear and rubbing resistance of the coating increases significantly. This is largely due to the fact that the invention advantageously combines the strength properties of a textile thread both with regard to torsion and adhesion of the fibers in relation to each other and to the entanglement of the fibers resulting from the needle stitching, at the same time that the twisted fibers are locked by the needle twisted fibers which ensures that the threads are attached to the base layer at several points. Because of these properties, the covering according to the invention can be used as a floor covering, and at the same time, for a given wear resistance, less textile material is needed than for other textile coverings, such as needle felt, velvet carpets, etc.

A production process according to the invention comprises at least one layer of adjacent textile threads and a base layer being put together and introduced into a needle-stitching machine where the threads in the textile thread layer are attached to the base layer at a relatively low needle-stitching density.

The device for carrying out the manufacturing process comprises at least a spool holder with several spools of thread which are used to lay a layer of threads lying next to each other, a comb guide for the different threads, a bearing roll for a web which forms the base layer for the thread layer, a needle stitch machine which is placed downstream of the cam guide and optionally one or more return and guide cylinders or rollers for the thread layer and/or base layer, the cylinders or rollers being positioned upstream of the introduction to the needle stitching machine.

In the following, the invention will be described in connection with preferred embodiments shown in the drawings

where:

Fig. 1 is a perspective view of a first embodiment of the floor and/or wall covering according to the invention. Fig. 2 is a perspective view of another embodiment of the coating according to the invention. Fig. 3 is a longitudinal section through the coating in fig. 1. Fig. 4 is an elevation of a device according to the invention and

fig. 5 is a plan view of the device in fig. 4..

The floor and/or wall covering mainly comprises a layer or a path of textile threads 1 and a vase layer 2 to which each of the textile threads is attached. The thickness of the base layer 2 can be greater or less than the thickness of the layer 1 with threads 3 which are preferably thick threads with a diameter of a few millimeters. These threads can have a different external shape and, as an example, 4 indicates a twisted thread, 5 a knotted thread with alternating thick parts 5a and thin parts 5b and 6 indicate a braided or twisted thread consisting of several thinner threads.

All the main threads used according to the invention comprise a number of synthetic or natural fibers 7 which are approximately parallel and which are twisted to a more or less pronounced degree about the thread axes. The threads 3 to 6 are attached to the base layer 2 by means of some fibers 8 in each of the threads 3 to 6, these attachment fibers 8 being at least partially inserted into the base layer 2 by means of a needle-stitching operation with low density. It has been found that a stitch density of twice 84 stitches per dm 2 of the coating surface is sufficient to attach the threads 3 to 6 completely securely to the base layer. Good results have been achieved with stitch densities between 30 and 600 per DM 2.

These values obviously vary as a function of the thread type and the length of the fibers in the threads 3 to 6. Moreover, this stitch density limit must not be exceeded because the threads can then be destroyed. In fig. 1, the reference number 9 indicates a wire that is partially in the wrong position, but despite this, this wire 9, which is significantly higher than the wire layer 1, is suitably attached to the base layer 2 by means of the fastening fibers 8 which connect this wire to the base layer via the wire layer 1.

One end of the fastening fibers 8 remains largely embedded in the structure of the threads 3 to 6, while the other end of these is led into or through the base layer 2 in which they are embedded by a conventional needling operation.

The base layer 2 can consist of a paper web or non-woven fabric produced by the wet method, a non-woven fabric with continuously laid needle-stitch threads, a propylene or polyester film, a cloth, a knitted textile fabric or the like. The ends 8a of the fastening fibers 8 protrude from the base layer 2 on the opposite side of the fiber thread layer 1 and can be enclosed in, for example, a thermoplastic coating 10 which is applied in liquid form to the back of the base layer 2 (fig. 1 and 3). The threads 3 to 6 in the thread layer 1 can all have the same diameter or different diameters, where thread groups with one diameter and thread groups with a different diameter are alternately laid.

It is also possible to combine the wire layer 1 with wire groups of different types and designs. The type of threads 3 to 6 used must be suitable for use in floor and/or wall coverings. The fibers can be made of wool, cotton, sisal, bast or synthetic fibers etc. Sisal fibers can, for example, be transformed into threads, twisted or braided cords which are then assembled into the thread cover layer 1.

Although the threads 3 to 6 in layer 1 in the embodiment in fig. 1 are arranged parallel to the longitudinal direction of the base layer I in the floor and/or wall covering, it is also possible to arrange the first wire layer 1 and the second wire layer 11 so that they are perpendicular to the longitudinal direction of the base layer 2. The second wire layer II does not necessarily have to be continuous, but it can be discontinuous and the width can vary. The threads 12 in the second layer 11 are parallel and are attached by needle stitching at least to the threads 3 in the first thread layer 1 and preferably also to the base layer 2. To facilitate the assembly of the second thread layer, which is called the transverse layer 11, the assembly of a wire layer and a base layer preferably designed as shown in fig. 1 where the threads are parallel to the longitudinal direction of the base layer, which in this particular case preferably consists of an extremely transparent film or web which forms a preliminary base web. The film width will then determine the width of the different parts 11a, 11b, in the second wire layer 11. Instead of a thermoplastic film, it is also possible to use a thin non-woven fabric, e.g. produced by the wet method from fibers whose composition is analogous or identical to that of the thick threads in the textile thread layer 11. Instead of arranging the parts 11a, 11b in the second thread layer 11 transversely 1 in relation to the threads 3 in the first thread layer 1, they can also in reality placed on the latter layer in such a way that the threads 12, grouped in several columns or groups of varying widths. It is obvious that it is impossible to prescribe other wire arrangements in the second layer 11 in relation to the first layer 1 without interfering with the scope of the present invention.

Fig. 4 and 5 schematically show an embodiment of a device for producing a textile floor and/or wall covering. The threads 3 that form the thread layer 1 or the thread layer 11 are stored on spools 14 mounted on a spool stand 15 and pass between the tines 16 in a comb guide 17 before they pass under a guide roller 18 which places the thread layer 1 or 11 on the base layer 2. The base layer

2 comes from a storage roll 19 and passes in the same way as the wire layer 1 over another guide roll 20 before it, together with the wire layer 1 or 11, enters the working area 21a of a needle-stitching machine 21 which consists of a quilt plate 22 and the vertically movable head 2 3 ( as indicated by arrow F) on the needle stitching machine 21. The needle stitching machine 21 is obviously of conventional design with the exception that the number of needles of 24 per cm in the working area is relatively low. The needles 24 are preferably of the fork-shaped type and have a smooth stem. The gap between the two branches in the fork-shaped needle is relatively small, so that the number of fibers that are gripped and driven into the base layer per active needle stroke becomes relatively small. The coating consisting of a base layer 2 and a thread layer 1 attached to the layer 2 as they leave the needle stitch machine 21 is wound up on

a bearing roll 25. Before this winding operation, the coating can of course be provided with a coating 10 on the back of the base layer 2 (fig. 1 and 3).

The second wire layer 11 can be arranged on the first wire layer 1 in many different ways. But the second wire layer 11 is preferably first produced on a device such as the one in fig.

4 and 5 shown and is attached temporarily, preferably by stitching to

a very thin base strip, such as a thermoplastic film or a non-woven fabric web produced by the wet method and whose fibers have an analogous or identical composition to the threads 12 in the second layer 11. The threads 12 are laid parallel to the longitudinal direction of the auxiliary base strip for the second thread layer 11 and can then arranged either parallel to or directly across the threads 3

to 6 in the first layer 1 during the production of the coating. If it is decided that the threads 12 in the second layer 11 are to be placed parallel to the threads in the first layer 1, one or more rollers for the base strip for the second layer are placed above the first layer on a bearing roll as in fig. 4 is shown in dotted lines and given the reference number 26, and a deflection roller 27 brings the second layer 11 into contact with the first layer 1. The threads 12 in the second layer 11 can be gathered together in several groups spaced from each other in the transverse direction for the first layer 1 in such a way that the latter groups or columns are higher than the threads in the first layer 1. If it is desired to arrange the threads 12 in the second layer 11 directly across the threads in the first layer 1, it is arranged one or more rolls 28 with base strip and applied second thread layer, preferably upstream of or in front of the needle stitching machine 21 on one side of the feed path for the base layer 2. Between the feed path for the first thread layer 1 and the base layer 2 or between the feed path and a roll or rolls 27 provided with a cutting device 29, and on the other side of said feed path there is provided a pulling device, schematically shown at 30, which enables the withdrawal of a new part of the second layer after it has first been cut off to a length which essentially corresponds to the width of the first layer 1. The different parts of the second layer 11 with threads 12 are arranged across the first thread layer 1, either continuously or so that the gaps are formed between

these in the advance direction of the first layer in the direction towards the needle stitch machine 21. In the event that the second thread layer is to be needle stitched to the base layer at the same time as the first thread layer, the stroke length of the needle stitch machine head 2 3 is regulated so that the lower end of the needles 24 can pass through the assembly of the first and second thread layers as well as the base layer.

The production process for the coating can be understood from the explanation given above, so that a further detailed description is unnecessary.

The embodiments described above can of course be modified without deviating from the idea of the invention as defined in the appended patent claims. It is thus possible that when forming at least part of the thread layer, frayed threads are used which are well known in the production of thick layer carpets. It is known that these pile carpets are produced from a pre-processed textile web which, firstly, is composed of warp threads which serve to bind the pile threads together and, secondly, islet threads which consist of velvet or wool threads. The islet threads can, for example, be thick wool threads in the processed textile web which are then cut off between each warp thread, and such rows of islet threads formed in such a way are often referred to as "floss threads". Depending on whether the V-shaped islet threads are folded or not, so-called flat or round threads are obtained. These floss threads are preferably only stuck with needles to the base layer in the bonding area between the ice threads and the connecting warp threads. It is also possible to use, for example, a shrinkable textile fabric as a base layer, e.g. a cotton fabric, and then subject this to a shrink treatment after the thread layer has been attached to this by stitching with needles. Thereby, the fibers will be further securely attached after the needling, as the resistance to pulling them out is increased. The area of application for the coating is not limited to floors and/or walls either. It can e.g. used as furniture fabrics.

Claims (17)

1. Floor and/or wall covering of the non-woven type which comprises at least one layer of parallel textile threads lying next to each other as well as a base layer as the individual textile threads, made from a series of more or less twisted fibres, is attached to, characterized in that a small part of the fibers in each textile thread (3) is attached to the base layer (2) by needle stitching with a density that does not destroy the continuity and original appearance of each textile thread. 2.G wolf and/or wall covering according to claim 1, characterized in that the threads (3) in the thread layer (1) have different diameters and are grouped in such a way that threads in a thread group with one diameter are laid alternately with thread groups with other diameters. 3. Floor and/or wall covering according to one of claims 1 or 2, characterized in that the threads in the thread layer comprise thread groups of different types. 4. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the thread layer comprise threads of different shapes. 5. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the textile threads at least partially consist of floss threads, whose cut threads, formed by islet threads, are needle-stitched to the base layer in the bonding area, where the floss threads form the warp. 6. Floor and/or wall covering according to one or more of the preceding claims, characterized in that it consists of two wire layers, that the second layer at least partially covers the first wire layer and that the wires in the second wire layer are connected with the base layer by means of binding fibers from the threads, which are inserted into the base layer by needle stitching. 7. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the second thread layer are arranged on the first in groups that are spaced apart. 8. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the second thread layer extend parallel to the threads in the first thread layer. 9. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the second thread layer extend across the threads in the first thread layer. 10. Floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the second thread layer are attached to a temporary base strip. 11.G floor and/or wall coating according to one or more of the preceding claims, characterized in that the ends of the fibers in the wire layer or layers, after being stitched through the base layer, are embedded in a coating that is applied to the back of the base layer. 12. Method for producing a floor and/or wall covering according to one or more of the preceding claims, characterized in that the threads in the thread layer are attached to the base layer by a needle-stitching operation with low stitch density. 13. Method according to claim 12, characterized in that the base layer consists of a shrinkable textile fabric which is given a shrink treatment after the threads have first been attached to this by needle stitching. 14. Device for producing a floor and/or wall covering according to one or more of the preceding claims, characterized in that it comprises a supply roll for a strip which forms the base layer for a wire layer, a needle-stitching machine and optionally one or more - and guide cylinders or rollers. for the wire layer and/or the base layer, where the cylinders or rollers are arranged upstream of the introduction to the needle-stitching machine and that the device additionally comprises at least one spool stand whose different thread spools serve to lay the layer in parallel separate threads as well as a guide card or comb for the different threads in the layer, where the card or comb is arranged upstream of the needle stitching machine and the supply roll for the base strip. 15. Wall and/or floor covering essentially as described above with reference to the accompanying drawings. 16. Procedure for producing a floor and/or wall covering essentially as described above with reference to the accompanying drawings. 17. Device for producing a floor and/or wall covering essentially as described above with reference to the accompanying drawings.