TWI403625B - Velournadelvliesstoff und seine verwendung - Google Patents

Abstract

A velour needle-punched non-woven fabric is disclosed, the velour needle punched non-woven fabric is made by producing a grouping layer from strengthened fleece on a brush-like stitch base, and needling the fleece on this stitch base. The fleece comprises a spun-bound nonwoven having filament, wherein the filament comprises multi-component filament. The multi-component filament has at least one component with a high melting point and at least one thermally activated component with a low melting point. The velour needle-punched non-woven fabric not only has excellent mechanical properties, but also has particular compatibility with environment and health. Therefore, it is not only suitable to be applied in the private field, but also especially suitable to be applied in the public domain as a serving of textiles.

Description

Velvet needle rolling non-woven fabric and its application

The present invention relates to a velvet needle-punched nonwoven fabric which is produced by laminating a possibly pre-consolidated batt on a brush-like stitch bottom layer and pinching the batt on the bottom layer.

German Patent No. DE 34 44 763 A1 teaches a device and a method for producing a Velour needle-punched nonwoven fabric in which a pre-needleed staple fiber (Stapelfaser, Staple Fiber) is drawn (Vlies, English). :fleece) The layer is applied to the bottom of a running brush base (Stichunterlage, Stitch substrate), and then needle-rolled on the side facing the bottom layer of the stitch to form a pole (Polausbildung). Since the needle-carryed fibers are carried by the needles into the bristles of the underlayer of the stitches in this method, the needle-punched non-woven fabric in this manner has a velvet appearance.

In order to increase the drafting strength of such a velvet needle-punched nonwoven fabric, a fiber floc (Vlies) under the intermediate layer of one layer is further mentioned in DE 44 09 771 [Vlies, English: fleece] The strength (Verzugsfestikeit) is higher than the other short fibers, in particular the textile flocs (especially the spinning flakes), to the bottom layer of the brush stitch, and this method is then carried out so that during pin rolling, the polar fibers ( Polfaser) is pulled through a layer with a large draft strength. Here, it is particularly important to note in this document that the weight per unit area of the intermediate sluice consisting of textile wadding is as small as possible, so that the effect of forming the poles of the intermediate layer is not impeded. On the other hand, the intermediate layer is composed of short fibers. The velvet needle-punched non-woven fabric is not rendered in the optical rendering image.

More and more velvet needle-punched nonwoven fabrics of the above type are used to coat the interior space of automobiles. The disadvantages are: the scratch-resistant strength required to achieve this application. The velvet needle-punched nonwoven fabric must be given a deep-drawing latex (Latex) binder of 200 to 300 grams per square meter. Latex binders are not only expensive, but they also contain volatile organic compounds (VOCs) that are scattered into the interior of the car (Fogging). This environmental discharge, health and quality awareness is generally increased, and this discharge into the interior space Phenomena (such as emissions into cars, building products or living spaces) are no longer acceptable.

The object of the present invention is to provide a velvet needle-punched nonwoven fabric, in particular for covering an internal space, which fully meets the high requirements for environmental and health compatibility and quality and which is characterized by excellent mechanical properties, such as high scratch resistance. Damage strength.

This object is achieved by using a velvet needle-punched nonwoven fabric of the first application of the patent scope. Patent Application No. 9 relates to a textile covering comprising a velvet needle-punched nonwoven fabric of the present invention. The 19th and 20th items of the patent application range are preferred applications for this covering. The scope of the patent application is a preferred design of the invention.

In the following, in the meaning of the present invention, "Filament" means an endless fiber. "Staple fibers" or "fibers" are used below to refer to fibers of limited length. A velvet needle-punched non-woven fabric is produced by arranging a possible pre-consolidated wadding on a brush-like stitch bottom layer and pinching the wadding on the bottom layer, wherein: The batt comprises a spun yarn having filaments, wherein the filament comprises a multicomponent filament having at least one high melting component and at least one thermally activated low melting component.

Unexpectedly, we have found that the use of the above-described type of velvet needle-rolled nonwoven fabric achieves a high scratch-resistant strength even without the use of additional chemical bonding agents. Latexanstrich (Latexanstrich) can be completely dispensed with when used in the interior space of a car to improve the scratch resistance of the velvet needle-punched nonwoven fabric. Therefore, the velvet nonwoven fabric of the present invention does not contain a fogging-active substance, and the odor-fed non-woven fabric of the present invention is sufficiently compatible with the health and environment of the present invention. The highest requirements for capacity and quality. In addition, the elimination of latex binders has significant cost advantages.

According to the invention, the velvet needle-punched nonwoven fabric comprises a spun yarn having filaments. The advantage of using a spun floc is not only to impart a certain strength to the textile fabric in a conventional manner, but also to make the spun yarn extremely inexpensive to manufacture. However, the spun floc is different from the short fiber floc and generally has a very smooth and small volume appearance (Erscheinungsbild). The filaments are almost all in one horizontal plane. These are all completely fluffy (Bausch, British: bulk) and velvet-like properties. Therefore, they may not be suitable for forming a velvet needle-punched nonwoven fabric at first glance. It is therefore mentioned in the above-mentioned DE 44 09 771 A1 that the weight per unit area of the spun yarn to be placed as a reinforcing layer has to be chosen to be small so that it does not appear in appearance.

Surprisingly, however, it has now been shown that even in the case of spinning fluffs, even at high basis weights, when pinching on the bottom layer of a brush pin, for example as described in DE 43 44 763 A1 A fluffy textile fabric with a velvety appearance. Even the fluffy repetitive phenomenon, which is important for velvet needle-rolled non-woven fabrics, can be achieved under load. Here, the needle-rolled spun yarn retains its well-known properties such as high draft strength, good deformability, high degree of stability, and scratch resistance.

If the heat is consolidated after the needle rolling, the re-relaxation ability, the draft strength and the measurement stability of the velvet nonwoven fabric of the present invention can be further improved.

The velvet needle-punched nonwoven fabric of the present invention can be produced by a method such as that described in the above-mentioned DE 34 44 763 A1. Special method variants (for example, they cause surface structuring of velvet nonwovens) are also known from the European patent EP 0 411 647 A1, hereby, for example, the use of fork needles (Gabelnadel) for each desired configuration ) and / or crown needle (Kronnadel). Correspondingly, single-stage or multi-stage methods are also mentioned, and these methods can also be applied to the velvet needle-punched nonwoven fabric of the present invention without limiting its generality.

According to the invention, the filament comprises a multicomponent filament having at least one high melting component and at least one thermally activated low melting component, and preferably a bicomponent filament. Two-component filaments are conventionally known which have a low melting point component composed of a low melting point polymer and a high melting point component composed of a high melting point polymer.

According to the present invention, the above heat-activatable low-melting component functions as a binder or a latex binder, but does not have the disadvantages of using the binder or other chemical binders, such as fogging, small recyclability, and the like. The melting point of the low-melting component is preferably from about 10 ° C to 20 ° C lower than the melting point of the melting point component, so that the latter does not break during heat activation.

The proportion of the two-component filament in the spinning floc should not be less than 5% (relative to the total basis weight of the velvet needle-punched non-woven fabric), otherwise the scratch resistance strength will be greatly deteriorated, and the ratio should be more than 15%.

The spun batt can be constructed in one layer or multi-layer, which can be composed of one or several kinds of filaments or mixed with short fibers. However, the proportion of short fibers should not exceed 75% (relative to velvet). The total basis weight of the needle-punched nonwoven fabric), because at a large value, the scratch resistance strength, tensile strength and shape stability are greatly reduced.

The staple fibers can also be designed in the form of multicomponent fibers (preferably bicomponent fibers), with the preferred embodiment being as described above.

The operation of mixing short fibers can be achieved on the one hand by injecting short fibers into the filament stream of the spun yarn. However, it is also possible to collect the short fibers on a spinning batt layer or to layer between the two spun flocculated layers, and to use the degree of needle rolling to cause the fibers to enter the spun batt layer. Furthermore, the two layers can be made separately and combined together in a subsequent step, for example, using a pin rolling step.

The operation of mixing the crimped staple fibers can further improve the fluffiness and the re-relaxation ability. This effect can also be achieved by using crimped endless filaments.

However, the addition of short fibers can also be used in an advantageous manner to achieve a reproducible and uniform coloring operation of the velvet needle-punched felt (Filz, Fell). Here only the short fibers are pigment carriers. The effect of adjusting the color is achieved by quantitative supply. This reproducible color adjustment operation can also be achieved by coloring the endless filaments in a continuous spinning process. However, staple fiber programs are generally much more flexible, so they can be converted faster to change color.

Several different fibers or filaments may be used in accordance with the present invention, which may be, for example, in composition or in the thickness of the fibers or filaments. The layers composed of different fibers and/or filaments can be in a stepped or gradient configuration. Thus, for example, it may be contemplated to form a diskret transition between layers having different fibers and/or filaments, or the filaments and/or fibers may continuously increase toward the surface. If such fibers or filaments comprise a low melting point heat-activatable binding polymer, an adhesion-producing layer can be formed in a simple manner. In a graded configuration, this bound polymer additionally causes consolidation and stabilization within the interior of the layer.

A textile covering (Auskleidung, lining) which comprises a velvet knitted nonwoven fabric of the present invention is particularly suitable for use in the field of articles because of its special mechanical stability and environmental health compatibility and high quality. Examples of these item areas are all of the target group categories, as well as those who are not in the personal field, such as offices, schools, banks, insurance, hotels, social and nursing areas, sports fields, especially in the automotive sector, ships, railways. Internal design.

In the field of this item, there is a very high demand for engineering quality. The textile covering of the present invention meets these requirements. Here, in particular, it is used in the field of automotive interior space coverings - in the interior of passenger and baggage compartments, as well as in carpet flooring, Bahneware and Fliese. However, such textile coverings can also be used for other applications, such as wallpapers, partitions, and the like. According to the above embodiments, it is of course also possible to use the textile covering of the present invention in the private sector, for example in the home field.

The textile covering of the present invention can also be designed, for example, in a fireproof, antistatic, or antimicrobial manner for the above applications.

The velvet needle-punched nonwoven fabric of the present invention or the textile covering of the present invention is not limited to the above specific application fields.

In particular, in the field of coverings for automotive interior spaces or in the field of carpet flooring, it is advantageous if the textile covering of the present invention is provided with a so-called "heavy layer" (Schwerschicht, heavy layer). Thick layers are used in the interior of the car. They are used for decoupling according to the mass spring principle (Masse-Feder-Prinzip). This thick layer is extruded or directly extruded onto the carpet using a layer of PE so that no additional adhesion agent is required. This thick layer is generally composed of CaCO ₃ and EVA. A decoupling agent such as a Cotton Shoddy or a foam may be applied thereto, but according to a preferred embodiment of the present invention, the thick layer may also be a non-woven fabric (especially in the form of a spunbonded nonwoven fabric). ) applied. In this way, not only is the implementation of the program simplified, but also many benefits can be derived from the point of view of recyclability, as will be explained below.

Further, according to another preferred embodiment, the covering of the present invention may be provided with a sound absorbing layer in a manner of being combined with the thick layer or in a separate manner. The sound absorbing layer can be formed in a conventional manner, for example, a so-called Cotton Shoddy having an intermediate layer (the intermediate layer restricts air permeability), or a microfiber floc may be used in combination with a Cotton Shoddy or needle non-woven fabric, or a knitted fabric can be utilized. It is formed by itself.

The above locations and/or layers are preferably joined to each other by a bonding layer which may be a conventional bonding agent. The term "environmental and health compatibility" and the economic point of view (simplified method implementation, less procedural steps) for the bonding layer can be similarly constructed using multicomponent filaments and/or fibers in accordance with a preferred embodiment of the invention. a layer composed of bicomponent filaments and/or fibers, or a single filament or fiber may be additionally or separately used as a bonding layer composed of a low melting point polymer (for example, a copolymer). . Chemical combinations which cause conventional fogging problems can also be completely dispensed with in the above embodiments.

For the purposes described in this application, the two-component filaments and/or fibers used in the preferred embodiment of the invention are in core/cabin form, side-to-side form, sea-island form and/or PIE (and Hollow PIE) filaments or fibers, bicomponent filaments or fibers with trilobal geometry or fibers or filaments from a spinning nozzle with a bone-shaped capillary geometry (in combination with dense parent polymers) Arrangement) causes the fiber or filament to be better locked in the non-woven fabric, thereby further increasing the tensile strength and scratch resistance of the material.

The toughness of the textile covering can also be adjusted in a simple manner via the ratio of multicomponent or bicomponent filaments and/or fibers. The higher the ratio, the tougher the material.

The low melting point component of the bicomponent filament or fiber is preferably (but generally not limited to the following examples) copolymerized PET (copolyester), CoPA (copolyamide), PA (polyamide), PP (polyethylene) Copolypropylene (CoPP), atactical (ataktisch) PP and/or PE (polyethylene), high melting point components are preferably PET (polyester), PA (polyamine), PLA (polyethyl lactone), PBT (polybutylene) and / or PP (polypropylene). This also applies to at least one low melting component or at least one high melting component of the multicomponent filaments and fibers used in the present invention.

According to another particularly preferred embodiment of the invention, all of the layers of filaments and/or fibers are constructed from the same polymer and/or derivatives thereof. The benefit of this is that it can be recovered relatively simply. The textile covering is preferably composed of polypropylene and/or its derivatives or from polyesters and/or derivatives thereof or from polyamines and/or derivatives thereof. Particularly in the case of textile coverings, the molded body is often punched out of the cloth, and the remaining waste of the stamping can be used for the production of filaments and/or staple fibers when the above materials are used.

Claims (19)

a velvet needle-punched non-woven fabric, which is produced by arranging a possible pre-consolidated floc on a brush-type stitch bottom layer and pinching the floc on the bottom layer, characterized in that The batt comprises a spun yarn having filaments, and the staple fibers blended in the batt are 75% of the total basis weight of the velvet needle-punched nonwoven fabric, wherein the filament comprises multi-component filaments, the multi-component The filament has at least one high melting point component and at least one heat-activatable low melting point component, and wherein the velvet needle-punched nonwoven fabric is a heat-bonded nonwoven fabric and the multi-component long fiber functions as a binder. The velvet needle-punched non-woven fabric of claim 1, wherein the multi-component filament comprises bicomponent filaments. For example, the velvet needle-punched nonwoven fabric of claim 1 or 2, wherein the ratio of the double-length filaments is more than 5% (relative to the total weight of the velvet needle-punched nonwoven fabric). For example, the velvet needle-punched non-woven fabric of claim 2, wherein: the two-component filament is designed as a core/cabin type, a side-to-side type, an island-in-the-sea type, a hollow piece and/or a pie-shaped filament method. The velvet needle-punched non-woven fabric of claim 2, wherein the low-melting component of the bicomponent filament comprises copolyester, copolyamide, polypropylene, copolypropylene, atactic polypropylene and/or polyethylene . The velvet needle-punched non-woven fabric of claim 2, wherein the high melting point component comprises polyester, polypropylene, polybutene, polyamine and / or polypropylene. A velvet needle-punched nonwoven fabric according to claim 1 or 2, wherein the staple fibers and/or filaments comprise crimped staple fibers and/or filaments. A textile covering comprising at least one layer constituting a velour surface, comprising a velvet needle-punched nonwoven fabric, characterized in that the velvet needle-punched nonwoven fabric is a velvet needle-punched nonwoven fabric of claim 1 of the patent application. A textile covering according to claim 8 wherein: a thick layer of polyethylene, calcium carbonate and ethylene vinyl acetate or non-woven fabric is provided on the back side surface of the textile covering material facing away from the velvet surface. A textile covering according to claim 9, wherein a sound absorbing layer is provided on a back side surface of the textile covering facing away from the velvet surface. A textile covering according to claim 8 wherein: a bonding layer is provided between the respective layers or all of the layers. The textile covering of claim 11, wherein the bonding layer comprises fibers and/or filaments of a low melting point polymer. The textile covering of claim 11, wherein the bonding layer comprises multicomponent fibers and/or filaments, fibers and/or filaments having at least one high melting component and at least one low melting component. A textile covering according to claim 12, wherein the multi-component or two-component fiber and/or filament low melting point polymer Or the low melting component comprises copolyester, copolyamine, polyamine, polypropylene, atactic polypropylene and/or polyethylene. The textile covering of claim 14, wherein the high melting point component comprises polyester, polyamine, polypropylene, polybutene and/or polypropylene. The textile covering of claim 11, wherein the multicomponent fiber and/or filament comprises bicomponent fibers and or filaments, wherein the bicomponent fiber or filament is designed as a core/shell, side pair Side-style, sea-in-the-sea hollow and/or pie-shaped filaments. A textile covering according to claim 9 wherein all of the filaments and/or fibers of the layer are composed of a single polymer and/or a derivative thereof. A textile covering according to item 8 of the patent application, which is used for covering a vehicle interior space. A use of a textile covering as claimed in claim 8 for carpet flooring.