RU2418894C1 - Needle-punched non-woven velour and its usage - Google Patents

Abstract

FIELD: textile, paper. ^ SUBSTANCE: velour needle-punched nonwoven fabric is produced by laying of fabric, which may not be previously fastened together, onto a brush-like sewing base and needle-punching of nonwoven material on this base. Nonwoven fabric according to this invention differs by the fact that the nonwoven material includes a spinneret nonwoven material with threads, which include multicomponent threads, having at least one high-melting component and at least one thermally activated soft component. ^ EFFECT: proper mechanical properties and harmlessness for environment and safety, which makes it possible for use as textile lining in residential houses and especially in commercial objects.

Description

FIELD OF TECHNOLOGY

The invention relates to a velor needle-punched non-woven fabric, which is obtained by laying an optionally pre-cured fabric on a brush-like base and needle-punched fabric on this basis. In addition, the invention relates to preferred uses of a velor needle-punched non-woven fabric.

KNOWN LEVEL OF TECHNOLOGY

DE 3444763 A1 describes a device and method for producing a velor needle-punched non-woven fabric, according to which a staple fiber fabric after preliminary needle piercing is placed on a rotating brush-like sewing base, and then a pile is made with a needle on the side facing the sewing base. Since in this method the fibers captured by the needles are pulled into the brush of the sewing base, the non-woven fabric thus bonded acquires a velor-like appearance.

In order to increase the resistance to distortion of this velor needle-punched non-woven fabric, DE 4409771 A1 proposes to lay a staple fiber fabric on a brush-like sewing base with an insert of a layer having a higher resistance to distortion than a staple fiber fabric, in particular with an insert spunbond nonwoven material, and then implement the method so that at the needle-piercing stage, the fibers of the pile are pulled through a formation having a higher resistance to warping. In this case, care must be taken to ensure that the bulk of the intermediate layer of spunbond nonwoven material is as small as possible so as not to impair the formation of lint through the intermediate layer and, on the other hand, so that the intermediate layer is not visible on the appearance of the velor needle-punched non-woven fabric from staple fibers.

The needle-punched non-woven velor webs of this type are increasingly being used for car interiors. One of the drawbacks in this regard is that in order to achieve the wear resistance required for this use, 200-300 g / m ² latex binder with the ability to deep ^draw must be added to the velor needle-punched non-woven fabric. Latex binder is not only very expensive, it also contains volatile organic compounds (VOCs), which are released into the interior of cars (fog formation). Given the generally growing awareness of environmental, health and quality issues, these discharges into the interior spaces, for example, automobiles, construction products, or the interior spaces of living spaces are no longer acceptable.

SUMMARY OF THE INVENTION

The aim of the present invention is to provide a velor needle-punched non-woven fabric, especially for interior cladding, which meets high expectations in terms of environmental and medical compatibility and quality and at the same time has very high mechanical properties, such as high wear resistance, for example.

This goal is achieved by a velor needle-punched non-woven fabric according to paragraph 1 of the claims. Paragraph 9 of the claims relates to textile upholstery containing the proposed velor needle-punched non-woven fabric. Claims 19 and 20 relate to preferred uses of textile upholstery. The dependent claims relate to preferred embodiments of the present invention.

In the following description, for the purposes of the present invention, the term “filaments” means continuous fibers. The terms “fibers” or “staple fibers” should, on the contrary, be understood as meaning fibers of finite length.

It is proposed, in relation to a velor needle-punched non-woven fabric obtained by laying an optionally pre-cured fabric on a brush-like sewing base and needle-punched fabric on this basis, that the fabric contains spunbond non-woven material containing yarns containing multicomponent yarns having at least one high melting component and at least one thermally activated low melting component.

It was unexpectedly found that the velor needle-punched non-woven fabric of the type described above provides very high wear resistance even without the use of an additional chemical binder. The latex coating, usually applied to the back of a velor needle-punched non-woven fabric used in car interiors to increase its resistance to wear, does not need to be used at all. Thus, the proposed velor needle-punched non-woven fabric does not contain active substances that form a fog. When using the proposed velor needle-punched non-woven fabric, harmful emissions of volatile hydrocarbons associated with the known latex coating are completely excluded. Thus, the proposed velor needle-punched non-woven fabric meets the highest expectations in terms of environmental and medical compatibility and quality. Moreover, the exclusion of a latex binder additionally leads to significant economic benefits.

In accordance with the present invention, a velor needle-punched non-woven fabric comprises a spunbond non-woven material containing threads. The use of spunbond non-woven material has a greater advantage than simply giving the textile fabric a certain strength in the usual way. Spunbond nonwoven materials are also very economical in their production. However, spunbond non-woven materials - unlike staple fiber webs - usually have a very smooth appearance with small lumps. Threads lie almost exclusively in the horizontal plane. These materials do not have the characteristics of velor and are not fluffy. Therefore, at first glance, they do not seem suitable for the formation of a velor needle-punched fabric. Accordingly, DE 4409771 A1, described at the beginning, clearly states that the bulk of the spunbond nonwoven material inserted as a reinforcing layer must be kept so low that it is not visible.

However, as it now unexpectedly turned out, even spunbond non-woven materials, even with high base weights, if needle-punched on a brush-like sewing base, as described in DE 4344763 A1, for example, provide a fluffy textile fabric having a velor-like appearance. Even the property of restoring fluffiness after applying a load, which is important for velor needle-punched non-woven fabrics, is achieved. In this case, the needle-punched spunbond nonwoven material retains its well-known good properties, such as high resistance to distortion, very good formability, high dimensional stability and wear resistance.

The properties of the proposed velor needle-punched non-woven fabric in terms of recovery, resistance to warping and dimensional stability can be further improved if the proposed velor needle-punched non-woven fabric after needle-piercing is further subjected to heat curing.

The proposed velor needle-punched non-woven fabric can be obtained by the method described, for example, in the aforementioned document DE 3444763 A1. Specific process options leading to surface structuring of a velor needle-punched non-woven fabric, for example, are further known from EP 0411647 A1. Depending on the desired structuring, for example, fork and / or crown needles are used. Accordingly, single or multi-stage methods are described. These methods are applicable to the proposed velor needle-punched non-woven fabric without limiting versatility.

In accordance with the present invention, the filaments comprise multicomponent filaments having at least one high melting component and at least one thermally activated low melting component, preferably bicomponent filaments. Two-component yarns are well known. They contain a low melting component containing a low melting polymer and a high melting component containing a high melting polymer.

The aforementioned thermally activated low melting component assumes, in accordance with the present invention, the function of a binder or latex binder, however, without the drawbacks associated with the use of this binder or any other chemical binder, such as fogging, poor recyclability use, etc. The melting point of the low melting component should be about 10-20 ° C lower than the melting point of the higher melting component so that the latter does not collapse during thermal activation.

The proportion of bicomponent filaments in a spunbond nonwoven material should be at least 5% (based on the total bulk of the velor needle-punched nonwoven fabric), since otherwise the wear resistance will decrease too much. This proportion is preferably above 15%.

Spunbond nonwoven material may have a single or multilayer structure. It may consist of one or more types of threads. Perhaps the mixing of staple fibers. However, in this case, the proportion of staple fibers should not exceed 75% of the total bulk of the velor needle-punched non-woven fabric, since at higher values, tensile strength and shape stability, as well as wear resistance, are significantly reduced.

Similarly, staple fibers can be formed from multicomponent, preferably bicomponent, fibers; in this case, with respect to the preferred polymers used, the above remarks apply.

One way to mix staple fibers is to introduce staple fibers into the spun filament yarn thread. It is possible, however, to staple the fibers onto a layer of spunbond nonwoven material or between two layers of spunbond nonwoven material and introduce these fibers into layers of spunbond nonwoven material through a needle-piercing operation. In addition, these two layers can be made separately and can only be joined together in a subsequent step, for example, through a needle-piercing step.

By mixing crimped staple fibers, fluffiness and fluffiness recovery can be further improved. This effect can be achieved by using crimped continuous threads.

However, the addition of staple fibers can also be advantageously used to achieve reproducible and uniform coloration of the velor needle-punched coating. In this coloration, staple fibers are the only carriers of color. Color is controlled by the quantity added. Such reproducible coloring can also be achieved by pigmenting continuous filaments in a continuous spinning operation. However, the dyeing operation using staple fibers is usually much more flexible and therefore faster for color changes.

In accordance with the present invention, several different fibers or threads can be used. Differences may lie, for example, in the composition or even in the thickness of the fibers or threads. The layers of different fibers and / or threads may have a step or gradient-like design. For example, it is possible to form discrete transitions between layers having different fibers and / or filaments, or, alternatively, to continuously enrich one kind of filaments or fibers in the direction of one of the surfaces. If such a fiber or yarn contains a low melting thermally activated polymer binder, in this simple way you can create a layer that is an adhesion promoter. In a gradient-like structure, such a polymer binder further leads to curing and stabilization within the layer.

Textile upholstery containing the proposed velor needle-punched non-woven fabric has special mechanical stability, as well as environmental and medical compatibility and quality and, therefore, is very suitable for applications in the commercial sector. This sector includes all target groups, including those that are not related to the private sector, for example, institutions, schools, banks, insurance companies, hotels, the social sector and the health sector, sports facilities, in particular also interior decoration in the automotive, shipbuilding and railway sectors transport, etc.

The commercial sector makes very high demands in terms of technical quality. The proposed textile upholstery meets these requirements. In this case, preference is given to applications in the car interior cladding sector - not only the passenger compartment, but also the trunk or luggage compartment, as well as carpet flooring, not only as a continuous sheet material, but also in the form of tiles. But there are other possible applications for this textile upholstery, for example, as wall upholstery, wall separation, etc. From the foregoing, it is clear that the proposed textile upholstery can, of course, be used in the private sector, for example, in the housing sector.

In addition, the proposed textile upholstery can be processed for the above applications to impart flame retardant, antistatic or antimicrobial properties, for example.

The possible uses of the proposed velor needle-punched non-woven fabric or the proposed textile upholstery, of course, are not limited to the above specific applications.

Especially for applications in automobile interior facing or in carpet flooring, it may be advantageous to carry out the proposed textile upholstery with a so-called heavy layer. The use of heavy seams in the car interior cladding sector is known per se. They provide spring-loaded separation. The heavy layer is extruded either by means of a polyethylene layer with heat supply, or directly onto the mat and after that does not require any additional adhesion promoter. A heavy formation typically consists of CaCO ₃ and a copolymer of ethylene and vinyl acetate. A separator, for example, cotton Shoddy or foam, is applied on top. In one preferred embodiment of the invention, the heavy formation may, however, be applied in the form of a non-woven fabric, especially in the form of a spunbond non-woven material. This not only simplifies the process control, but can also bring advantages in terms of recyclability for recycling, which is described in more detail below.

In addition, in one preferred embodiment of the invention, the proposed upholstery may have a sound-absorbing layer, either in combination with a heavy layer, or separately. The sound-absorbing layer can be carried out in the usual way using a cotton Shoddy with a layer that limits air permeability, or else using a microfiber cloth in combination with a cotton Shoddy or needle-punched cloth, or using the needle-punched cloth itself.

The above pile and / or layers are preferably connected by means of tie layers. For binders, traditional binders can be used. From the point of view of environmental and medical compatibility, as well as from an economic point of view (simplified process control, fewer operations), layers of multicomponent filaments and / or fibers, preferably bicomponent fibers, are similarly used in these bonding layers in one particularly preferred embodiment of the invention threads and / or fibers. In the bonding layer, monofilament or monofilament, which consists of a low melting polymer, for example, a copolymer, can also be additionally or exclusively used. Using these last mentioned embodiments, chemical binders that can lead to the familiar problem of fogging can then be completely eliminated.

In one preferred embodiment of the invention, for the uses described herein, as bicomponent filaments and / or fibers, filaments or fibers are used, such as a core type with a sheath, type Side-By-Side, type Island-In-The- Sea (island in the sea) and / or PIE type (pie) (including Hollow PIE type (hollow cake)). Bicomponent filaments or fibers with three-blade geometry, or fibers or filaments from die heads having capillary geometry in the form of dumbbells (= concentrated arrangement of binder and polymer matrix), lead to better fixation of fibers or filaments in a non-woven fabric and, therefore, even higher tensile strength and even higher wear resistance for the material.

The proportion of multicomponent or bicomponent filaments and / or fibers is one of the simplest ways to set / adjust the stiffness of textile upholstery. The higher this fraction, the harder the material becomes.

The low melting component of the bicomponent filaments or fibers preferably contains, without loss of versatility, CoPET (copolyester), CoPA (copolyamide), PA (polyamide), PP (polypropylene), polypropylene copolymer (CoPP), atactic PP and / or PE (polyethylene), and the high melting component preferably contains PET (polyester), PA (polyamide), PLA (polylactide), PBT (polybutylene) and / or PP (polypropylene). The same applies to at least one low-melting component and, accordingly, at least one high-melting component of bicomponent filaments and fibers used in accordance with the invention.

In another particularly preferred embodiment of the invention, the threads and / or fibers of all layers and / or layers consist of the same polymer and / or its derivatives. The advantage of this is its suitability for easier recycling. Preferably, the textile upholstery consists of polypropylene and / or its derivatives or polyester and / or its derivatives or polyamide and / or its derivatives. Especially in the case of textile linings, curly products are often carved from a continuous sheet material. The waste after cutting can be reused for the production of yarns and / or staple fibers, if the above materials are used.

Claims (20)

1. Velor needle-punched non-woven fabric obtained by laying an optionally pre-cured fabric on a brush-like sewing base and needle-punched fabric on this basis, characterized in that the fabric contains a spunbond non-woven material containing threads containing multicomponent threads having at least one high melting point a component and at least one thermally activated low melting component. 2. Velor needle-punched non-woven fabric according to claim 1, characterized in that the multicomponent threads contain two-component threads. 3. The velor needle-punched non-woven fabric according to claim 2, characterized in that the proportion of two-component yarns exceeds 5% and preferably exceeds 15% based on the total weight of the velor needle-punched non-woven fabric. 4. Velor needle-punched non-woven fabric according to claim 2, characterized in that the two-component yarns are made as a core type with a sheath, type Side-By-Side (side by side), type Island-In-The-Sea (island in the sea) and / or type PIE (pie) (including type Hollow PIE (hollow cake)). 5. Velor needle-punched non-woven fabric according to claim 2, characterized in that the low-melting component of the two-component yarns contains CoPET (copolyester), CoPA (copolyamide), PA (polyamide), PP (polypropylene), CoPP (polypropylene copolymer), atactic PP (polypropylene) ) and / or PE (polyethylene). 6. Velor needle-punched non-woven fabric according to claim 5, characterized in that the high-melting component contains PET (polyester), PLA (polylactide), PBT (polybutylene), PA (polyamide) and / or PP (polypropylene). 7. Velor needle-punched non-woven fabric according to claim 1, characterized in that the spunbond non-woven material contains up to 75% staple fibers of the total basis weight. 8. Velor needle-punched non-woven fabric according to any one of claims 1 to 7, characterized in that the fibers and / or threads contain twisted fibers and / or threads. 9. Textile upholstery, in particular for interior cladding in the commercial and residential sector, containing at least one layer consisting of a velor needle-punched non-woven fabric and forming a velor surface, characterized by a velor needle-punched non-woven fabric according to any one of claims 1 to 8 . 10. The textile upholstery according to claim 9, characterized in that the textile upholstery has on its rear surface, i.e. on the surface opposite the velor surface, a heavy layer. 11. The textile upholstery according to claim 9, characterized in that the textile upholstery has on its rear surface, i.e. on the surface opposite the velor surface, a sound-absorbing layer. 12. The textile upholstery according to claim 9, characterized in that there are adhesive layers provided between some or all of the layers and / or layers. 13. The textile upholstery according to claim 12, characterized in that the bonding layers contain fibers and / or filaments consisting of a low melting polymer. 14. Textile upholstery according to claim 12, characterized in that the binder layers contain multicomponent, preferably bicomponent, fibers and / or threads having at least one high melting component and at least one low melting component. 15. Textile upholstery according to any one of paragraphs.13 and 14, characterized in that the low-melting polymer or component of multicomponent or bicomponent fibers and / or threads contains CoRET (copolyester), CoRA (copolyamide), PA (polyamide), PP (polypropylene), atactic PP (polypropylene) and / or PE (polyethylene). 16. The textile upholstery of claim 15, wherein the high melting component comprises PET (polyester), PA (polyamide), PLA (polylactide), PBT (polybutylene) and / or PP (polypropylene). 17. The textile upholstery according to claim 14, characterized in that the bicomponent fibers and / or threads are made as a core type with a sheath, type Side-By-Side (side by side), type Island-In-The-Sea (island in sea) and / or PIE type (pie) (including Hollow PIE type (hollow cake)). 18. Textile upholstery according to claim 9, characterized in that the threads and / or fibers of all layers and / or layers consist of the same polymer and / or its derivatives. 19. The use of textile upholstery according to any one of paragraphs.9-18 for lining the interiors of cars, such as a passenger compartment or luggage compartment. 20. The use of textile upholstery according to any one of paragraphs.9-18 for carpet flooring.