RO126483A2 - Needle-punched non-woven velour and use thereof - Google Patents

Abstract

The invention relates to a needle-punched velour-type material, meant to be used in particular for lining the internal walls in commercial buildings or dwelling houses. According to the invention, the material comprises a non-woven fabric tape with filaments, reinforced by chemical spinning, where the filaments comprise multi-component filaments including at least one high-melting component and at least one thermally-active low melting component.

Description

The invention relates to a velvet non-woven material obtained by interlacing with needles, which is achieved by placing an optionally preconsolidated nonwoven fabric on a brush-like substrate and interweaving the non-woven fabric on this substrate. The invention also relates to the preferred uses of velvet nonwovens obtained by interlacing with needles.

State of the art

From DE 34 44 763 A1 there is known a device and a method for producing a non-woven velvet obtained by interlacing with needles, in which a short fiber non-woven made by pre-interlacing with needles is located on a peripheral seam-like substrate and is then interspersed with needles on the side facing the sewing substrate, forming a loose structure. whereas by this method the fibers seized by the needles are interwoven into the brushes of the sewing substrate, the nonwoven interwoven in this way acquires a velvet appearance.

In order to increase the tensile strength of such non-woven velvet reinforced with needles, DE 44 09 771 A1 also proposes placing a non-woven short fiber web on a brush-like sewing substrate, interspersing a layer that has a higher resistance to stretching than the non-woven strip of short fibers, especially one non-woven, which is consolidated with chemical spinning, and then the method is continued so that during the operation of intercourse with the needles the soft fibers are drawn through the layer which has the highest tensile strength. According to the document, special attention should be paid in particular to the fact that the basic weight of the intermediate layer made of non-reinforced fabrics at chemical spinning is reduced, so that on the one hand the formation of a plush is not damaged by the intermediate layer and on the other hand, the intermediate layer does not interfere with the visual appearance of the nonwoven velvet obtained by intersecting with needles, made of short fibers.

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The velvet fabrics obtained by interlacing with needles, of the type described above, are increasingly used for the upholstery of the interior spaces of the vehicles. The disadvantage is that 200 to 300 g / m ² of latex binder that can be deeply embossed must be added to the velvet nonwoven material obtained by intersecting with needles to obtain the abrasion resistance required for this application. Latex binders are not only extremely expensive, but also contain volatile organic compounds (VOCs) that have emissions inside the vehicle (wetting). Given the growing awareness of issues related to environment, health and quality, such emissions in interior spaces, for example, in vehicles, construction products or interior living spaces are no longer acceptable.

Description of the invention

The problem that the invention aims to solve is that of producing a non-woven velvet material obtained by interlacing with needles, used in particular for the lining of interior spaces, which meets the high requirements regarding compatibility with the environment, health and quality and which at the same time characterized by good mechanical properties, such as high abrasion resistance.

This problem is solved with a nonwoven velvet material obtained by needle interlocking according to claim 1. Claim 9 relates to a textile lining comprising a nonwoven velvet material obtained by interlacing with needles according to the invention. Claims 19 and 20 show preferred uses of the textile lining. Subordinate claims refer to advantageous embodiments of the invention.

In the following, within the meaning of the present invention, filaments are continuous fibers. On the other hand, short fibers or fibers must mean fibers with a finite length.

According to the invention, in a velvet non-woven material obtained by needle spacing, which is produced by placing an optional preconsolidated nonwoven material on a brush-type sewing substrate and the needle spacing on this sewing substrate, the non-woven material is provided to it comprises a filament nonwoven, reinforced by chemical spinning, wherein the filaments comprise multi-component filaments, with at least one

CVI O 1 C - O 02 42 - ni -08 20 <8 high melting point component and at least one thermally activated component with low melting point.

Surprisingly, it has been found that in a velvet non-woven material obtained by intersecting with needles, of the type described above, a very high abrasion resistance can be obtained, even without the use of an additional chemical binder. the latex coating that is applied to the back of the non-woven material for interior applications of vehicles to increase the abrasion resistance of a velvet non-woven material obtained by intersecting with the needles can be completely removed. A non-woven velvet material obtained by interlacing with needles, according to the invention, is thus devoid of active substances in relation to emissions. The emission of volatile hydrocarbons from the known latex shell is completely avoided with the non-woven material obtained by interlacing with needles according to the invention. The non-woven velvet material obtained through the needle interconnection thus meets the maximum requirements regarding compatibility with health and the environment as well as with quality. The elimination of the latex coating has a considerable cost advantage.

According to the invention, the velvet non-woven material obtained by needle interconnection comprises a non-woven filament material, reinforced by chemical spinning. The use of a non-woven material reinforced with chemical spinning has the advantage that it offers a textile surface structure with a certain level of stability in a known way. Non-woven materials reinforced with chemical spinning can, in addition, be produced very cost-effectively. Unlike non-woven short fiber materials, non-woven materials reinforced with chemical spinning are characterized by a very smooth appearance, not very bulky. The filaments are almost exclusively laid horizontally. The materials are completely devoid of fluffy appearance and velvet features. Therefore, at first glance, they do not seem suitable for the formation of a non-woven material obtained by intersecting with needles. DE 44 09 771 A1, described at the beginning, also expressly mentions that the basic weight of the non-woven reinforced chemical filament introduced as a reinforcing layer must be selected sufficiently low so that it is not visually apparent.

Surprisingly, however, it has been found that even with non-woven fabrics reinforced with high basic weight chemical spinning during needling with needles on a brush-like sewing substrate, as described in DE 43 44 763 A1, a

0 ~ 2 Ο 1 0 - Ο Ο 2 4 2 - Ο I -08 '2008 fluffy surface structure that has a velvet appearance. The fluffy appearance can be achieved even after the application of a pregnancy, which is important for non-woven velvet obtained through intercourse with needles. The non-woven fabrics reinforced with chemical spinning maintain their well-known properties, such as high tensile strength, very good deformation, high dimensional stability and abrasion resistance.

The resilience, the tensile strength and the dimensional stability of a nonwoven velvet material obtained by interlacing with needles according to the invention can be further increased if it is thermally reinforced after interlacing with needles.

A non-woven velvet obtained by intersecting with needles, according to the invention, can be produced by a method such as that described in DE 34 44 763 A1 mentioned above. Various variants of the method, which result in a structuring of the surfaces of a nonwoven velor obtained by needle interlacing, for example, are known from EP 0 411 647 A1. In these, for example, needles in the form of a fork and / or crown are used, depending on the type of structure desired. Accordingly, one-step or multi-step methods are described. These methods can also be used for a non-woven velvet material obtained by intersecting with needles, according to the invention, without limiting the generality.

According to the invention, the filaments comprise multi-component filaments, with at least one high melting point component and at least one thermally activated component with a low melting point component, preferably two-component filaments. Two-component filaments are known per se. They comprise a component with a low melting point made of low melting polymer and a component with a high melting point made of high melting polymer.

According to the invention, the thermally activable component mentioned above, with a low melting point, has the function of a binder agent, or a latex binder, without the disadvantages associated with the use of this binder, respectively of another chemical binder, such as emissions, low recyclability and the like. The melting point for a component with a low melting point should preferably be about 1 ° C to 20 ° C below the point (X - 2 01 0 - Ο Ο 2 4 2 - Ο 1 Ό8 * 2008 of the melting of the component with the higher melting point to ensure that it is not destroyed during thermal activation.

The portion of two-component filaments in the non-woven fabric reinforced with chemical spinning should be 5% (in relation to the total basic weight of the non-woven material obtained through the needle interconnection), because otherwise the abrasion resistance would deteriorate drastically. It is preferred that the portion exceeds 15%.

The non-woven material reinforced with chemical spinning may comprise one or more layers. It can be made from one or more types of filaments. It can also be designed to mix short fibers. The short fiber portion, however, should not exceed 75% relative to the total base weight of the velvet nonwoven material, obtained by interlacing with needles, as higher values greatly reduce abrasion resistance, tensile strength and dimensional stability.

Short fibers can also be made from multi-component fibers, preferably two-component fibers, in which the above explanations refer to polymers used preferably.

The mixing of the short fibers can be done so that the short fibers are injected into the stream of non-woven fabrics consolidated by chemical spinning. However, it is also possible to place the short fibers on a non-woven layer reinforced with chemical spinning or between two layers of non-woven fabric reinforced with chemical spinning and insert the fibers into the non-woven layers reinforced with chemical spinning by means of the needle-spacing process. In addition, both layers may be produced separately and be combined at a later stage, for example, with the help of the needle interphase.

By mixing the wrinkled short fibers, the fluffy character and the ability to return the powder can be further improved. This effect can also be achieved by using continuous wrinkled filaments.

In addition, the short fibers can advantageously be used to achieve the reproducible and homogeneous coloring of the velvet nonwovens obtained by intersecting with needles. Short fibers are then the only carriers of color. The color is adjusted by dosing <> - 2010-00242-Ο | 08- 2008 to the dye. Ο such reproducible color adjustment can also be achieved by dyeing the continuous filaments in a continuous spinning process. The process of short fibers, however, is generally considerably more flexible and as a result color changes can be implemented faster.

According to the invention, a lot of fibers, respectively different filaments, can be used. The differences may be, for example, a composition or also the thickness of the fiber respectively of the filament. A stepwise or gradient configuration of layers containing different fibers and / or filaments may even be provided. For example, the formation of discrete transitions between layers containing different fibers and / or filaments or a continuous enrichment of a type of filament or fiber to one of the surfaces can be conceived. If such a fiber or filament comprises a thermally activated binder polymer with a low melting point, an adhesive layer may thus be formed. In the case of a gradient-like configuration, such a binder polymer additionally contributes to the consolidation and stabilization of the interior of the layer.

Due to its special mechanical stability, compatibility with health, environment and quality, a textile lining comprises a non-woven velvet obtained by interlacing with needles, according to the invention, is particularly suitable for applications in the public domain. This field covers all the target groups that cannot be associated with the private domain, such as offices, schools, banks, insurance companies, hotels, medical and social care sectors, sports facilities, especially interior decorations in the motor vehicle sector, in the industry. shipbuilding, railway industry, etc.

in the public domain, there are numerous extremely high technical quality requirements. These requirements are met by the textile lining according to the invention. Applications in the field of interior lining of vehicles, both inside the passenger compartment and the lining of the trunk, as well as carpets, both as footage and in the form of pieces, are preferable. However, other applications can be designed for such a textile lining, for example for wall lining, for separating walls and the like. Due to the above explanations, it is obvious that this textile lining according to the invention can also be used in the private sector, for example in the residential field.

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Ο The textile lining according to the invention, for example can also be provided with flame retardant, antistatic or antimicrobial properties for the above applications.

The possibilities of use for a non-woven velvet obtained by interlacing with needles, according to the invention, and / or of a textile lining according to the invention are not limited to the specific fields of application mentioned above.

In particular for applications in the interior of the linings for the interior spaces of vehicles or in the area of floor coverings, it may be advantageous if this textile lining according to the invention is provided with a heavy layer. The use of heavy layers is known in the field of interior linings of motor vehicles. They serve the purposes of decoupling according to the table-spring principle. The heavy layer is either extruded from the PE layer when heat is provided or directly on the carpet and in this case does not require any binder. The heavy layer is usually made of CaCC> 3 and EVA. This applies a decoupling layer, for example lower quality cotton, or a foam. According to a preferred embodiment of the invention, the heavy layer may also be applied in the form of a non-woven fabric, in particular a non-woven fabric reinforced with chemical spinning. This simplifies not only the method but is also associated with other benefits including the recyclability aspect.

In addition, according to another preferred example, a liner according to another preferred embodiment may be provided with a noise-absorbing layer, either combined with the heavy layer or alone. The noise damping layer may be formed in a manner known as lower quality cotton with an intermediate layer, which limits air permeability, or may be formed by a microfibre nonwoven in combination with lower quality cotton or a non-woven fabric obtained through the needle intercourse, or through a non-woven fabric obtained through the needle interception, itself.

The layers described above are preferably linked to each other by means of the binding layers. For binders, conventional binders can be used. as regards the compatibility aspect with the environment, health and also for economic reasons (simplified method, fewer process steps), according to a particularly preferred embodiment of the invention, these binding layers may also <-2010 -00242-0 1 08- 2008

contains layers of filaments and / or fibers with multiple components, preferably filaments and / or two-strand fibers. In addition, it is also possible to use monofilaments or fibers, either supplementary or single, containing a low melting point polymer, such as a copolymer, for the binding layer. Chemical bonding agents that may result in a known emission problem, can be completely eliminated in these last embodiments.

For the uses described in the present application, according to a preferred embodiment of the invention, two-component filaments or fibers, sheath / core fibers, adjacent filaments, isolated filaments and / or PIE filaments (or bare PIE filaments) can be used as filaments and / or bicomponent fibers. the interior). Two-component filaments or fibers with trilobal geometry or fibers or filaments from spinning nozzles with round capillary geometry (= concentrated arrangement of matrix polymers or binding polymers) result in improved anchoring of fibers or filaments in non-woven material and thus improve resistance to stretching and abrasion resistance.

The percentage of filaments or fibers can also be used to easily adjust the rigidity of the textile lining. The higher this percentage, the more rigid the material.

The low melting point component of two-component filaments or fibers preferably comprises, without limitation the generality, CoPET (copolyester), CoPA (copoliamide), PA (polyamide), PP (polypropylene), copolypropylene (CoPP), PP and / or PE ( Atactic polyethylene), the high melting point component preferably comprises PET (polyester), PA (polyamide), PLA (polylactide), PBT (polybutylene) and / or PP (polypropylene). The same applies also for at least one component with low melting point, respectively at least one component with high melting point of filaments and fibers with many components used according to the invention.

According to another preferred embodiment of the invention, the filaments and / or fibers of all layers are made of the same polymer and / or derivatives thereof. This has the advantage of simpler recyclability. It is preferable if the textile lining is made of polypropylene and / or derivatives thereof or polyester and / or derivatives thereof, or polyamide and / or derivatives thereof. especially for the linings λ-2 Ο 1 Ο - Ο Ο 2 4 2 - Ο ί 08- 2008

textiles, the parts formed are frequently cut from the footage. If the above materials are used, the residues resulting from the cutting can be reused for the production of filaments and / or short fibers.

Claims (20)

1. Velor nonwoven material obtained by needle spacing, produced by placing an optionally preconsolidated nonwoven fabric on a brush seam substrate and interweaving this nonwoven fabric on this substrate, characterized in that the nonwoven comprises a nonwoven reinforced with chemical spinning comprising filaments, wherein the filaments comprise filaments with many components having at least one component with high melting point and at least one thermally activable component with low melting point. 2. Velor nonwoven material obtained by interchanging with needles according to claim 1, characterized in that the multi-component filaments comprise two-component filaments. 3. Velor nonwoven material obtained by interchanging with needles according to claim 1 or 2, characterized in that the proportion of two-component filaments is greater than 5% and preferably greater than 15% relative to the total weight of the velvet material obtained by intersecting with needles. 4. Velor nonwoven material obtained by intersecting with needles according to claim 2 or 3, characterized in that the two-component filaments are configured as core filaments, adjacent filaments, insulated filaments and / or PIE filaments (including hollow PIE filaments inside). 5. Non-woven velvet material obtained by interchanging with needles according to any one of claims 2 to 4, characterized in that the low melting point component of the two-component filaments comprises CoPET, CoPA, PA, PP, CoPP, PP and / or PE atactic. 6. Velor nonwoven material obtained by interchanging with needles according to any one of claims 2 to 5, characterized in that the high melting point component comprises PET, PLA, PBT, PA and / or PP. 7. Velor nonwoven material obtained by interlacing with needles, according to any one of claims 1 to 6, characterized in that the non-woven fabric reinforced with chemical spinning contains up to 75% of the total basic weight of the short fibers. 8. Non-woven velvet material obtained by interlacing with needles according to any one of claims 1 to 7, characterized in that the fibers and / or filaments comprise fibers and / or wrinkled filaments. (λ-1 r c - O O 2 4 2 - Ol '0 / - 2808 / 9. Textile lining, in particular for lining interiors in commercial and residential buildings, comprising at least one layer composed of non-woven velvet material obtained through needles and forming a velvet surface, characterized by a non-woven velvet material obtained by interest needles according to any one of claims 1 to 8. 10. The textile lining according to claim 9, characterized in that said textile lining has a heavy layer on its rear surface, that is, the surface that is removed from the velvet surface. 11. The textile lining according to claim 9 or 10, characterized in that the textile lining has a noise insulation layer on the rear surface, ie the surface which is removed from the velvet surface. 12. The textile lining according to any one of claims 9 to 11, characterized in that the bonding layers are provided between the distinct thicknesses or all the thicknesses and / or the layers. The textile lining according to claim 12, characterized in that the bonding layers comprise fibers and / or filaments composed of low melting polymer. The textile lining according to claim 12, characterized in that the bonding layers comprise several components, preferably two components, fibers and / or filaments having at least one component with a high melting point and at least one component with a melting point. low melting. The textile lining according to any one of claims 13 to 15, characterized in that the low melting point polymer, respectively the component of multicomponent or bicomponent fibers and / or filaments comprises CoPET, CoPA, PA, PP, PP and / or PE atactic . 16. The textile lining according to claim 15 or 16, characterized in that the high melting point component comprises PET, PA, PLA, PBT and / or PP. 17. The textile lining according to any one of claims 12 to 16, characterized in that the two-component fibers and / or filaments are configured as sheath-core filaments, side-by-side filaments, insulated filaments and / or PIE filaments (even filaments) PIE empty inside). 18. The textile lining according to any one of claims 10 to 17, characterized in that the filaments and / or fibers of all thicknesses and / or layers consist of one and the same polymer and / or derivatives thereof. (V- 2 Ο 1 0-00242-0 1 08- 2008 19. The use of a textile lining according to any one of claims 1 to 18 for the upholstery of motor vehicle interiors, such as passenger compartments or trunk. 20. Use of a textile lining according to any one of claims 1 to 18 for carpeting.