Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
  • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/08—Melt spinning methods
  • D01D5/098—Melt spinning methods with simultaneous stretching
  • D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H13/00—Other non-woven fabrics
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/005—Synthetic yarns or filaments
  • D04H3/009—Condensation or reaction polymers
  • D04H3/011—Polyesters
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23979—Particular backing structure or composition
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
  • Y10T442/681—Spun-bonded nonwoven fabric

Definitions

• the invention relates to a high-strength lightweight tufted backing made of spunbonded non-woven, which comprises at least one ply of melt-spun synthetic filaments, which are bonded by means of high-energy water jets.
• a tufted backing based on a spunbonded non-woven fabric made of polypropylene is known.
• the filaments forming this tufted backing have a rough individual titer of more than 10 dtex and are drawn in segments in a special manner such that drawn longer segments having high crystallinity in the same thread are followed by less drawn, less crystalline segments having a slightly lower melting temperature. These are used in the composite as the binding component, which is activated during the subsequent thermal bonding using direct vapor.
• the length of the well-drawn crystalline segment is approximately 11 inches, and the length of the subsequent less drawn and less crystalline segment is approximately 1 inch.
• the weight proportion of the low-crystalline segments is consequently slightly higher than 8%.
• the special non-woven structure of such a tufted backing is rather unimportant for this analysis.
• tufted backings based on a spunbonded non-woven fabric made of polyester are known.
• coarse threads are used for producing the tufted backing, which is to say matrix threads made of polyethylene terephthalate having a titer of more than 10 dtex.
• matrix threads made of polyethylene terephthalate having a titer of more than 10 dtex.
• binding threads having a lower titer and made of a low-melting copolyester are spun. The weight proportion of these binding threads is approximately 20%.
• a tufted backing should be configured such that in the system comprising matrix threads and bonds the bonds between the threads are always weaker than the threads bound by them. In this way, it can be achieved that a tufted backing in the basic state has sufficiently high strength.
• a tufted backing in the basic state has sufficiently high strength.
• the threads can give way to the penetrating needles and form a “collar” around the tufted-in pile yarn. In this way, the strength and the resistance to tear propagation of the tufted base carpet are maintained at a high level, and hardly any damage is produced by the tufting process.
• the disadvantage of the above-mentioned tufted backing is that while it does not lose strength as a result of the tufting process, the initial modulus of the base carpet is low, thereby making the carpet not sufficiently dimensionally stable for the further processing steps.
• a high-strength lightweight tufted backing made of spunbonded non-woven, having at least one ply of melt-spun synthetic filaments bonded by means of high-energy water jets, that this backing comprises a small amount of a thermally activatable binding agent, which is applied onto the ply of melt-spun filaments in the form of at least one thin layer.
• the tufting process may result in excessive loosening of the weak bonds in the backing. Hence, this reduces the initial modulus of the base carpet so much that the base carpet during further processing is not sufficiently dimensionally stable. The result is the described deformation of the base carpet.
• a tufted backing according to the invention may be composed of one, or also several plies of spunbonded non-woven and binding agent. Other additional plies may also be provided, to the extent they neither interfere with the tufting process nor with further processing.
• the tufted backing according to the invention has a 3-ply structure, in which the middle ply comprises the binding agent and the outer plies the melt-spun synthetic filaments. Because hydroentangling is frequently carried out on both sides, this has the advantage that the binding agent is introduced into the non-woven fabric ply both from beneath and above.
• thermoplastic polymers are suited as binding agents, wherein such thermoplastic polymers are preferred, the melting temperatures of which are sufficiently lower than those of the spun-bonded non-woven filaments.
• the melting temperature should preferably be at least 10° C., in a particularly preferred embodiment at least 20° C. below the melting temperature of the spun-bonded non-woven filaments, so that they are not damaged during the thermal activation.
• the low-melting thermoplastic polymers also have a broad softening range. This has the advantage that the thermoplastic polymer used as the binding agent can be activated at lower temperatures than the effective melting point thereof. From a technological point of view, the binding agent does not necessarily have to be fully melted, but instead it suffices that it is sufficiently softened, thereby adhering to the filaments to be bound. In this way, during the activation phase the binding degree between the spun-bonded non-woven filaments and the binding agent can be adjusted.
• the low-melting thermoplastic polymer preferably substantially comprises a polyethylene, a copolymer having a substantial proportion of polyethylene, polypropylene, a copolymer having a substantial proportion of polypropylene, a copolyester, a polyamide and/or a copolyamide.
• the weight proportion of the low-melting polymer, relative to the total weight of the tufted backing, should not exceed 7%. If the proportion of the hot-melt adhesive is too high, the risk arises that the spunbonded non-woven fabric is thermally bonded too strongly. In any case, the bonds produced by the hot-melt adhesive would be stronger than those produced by the bound filament. During the tufting process, the filaments would then become significantly damaged and torn, and therefore the strength after tufting, in particular also the resistance to tear propagation, would be excessively impaired.
• the weight proportion is preferably between 1.5 and 5% by weight. With a weight proportion of less than 1.5% by weight, the reinforcement effect, in particular also with respect to the initial modulus, would not be sufficiently pronounced. In addition, due to the low quantity, also no sufficiently good distribution of the binding agent in the spunbonded non-woven cross-section would be achieved by the water jet treatment. However, even the use of smaller proportions of hot-melt adhesive are advantageous and should therefore be encompassed by the present invention.
• the low-melting polymer can be present, for example, in the form of fibers or fibrils.
• conjugate fibers can be used as the fibers, wherein the lower-melting component constitutes the thermally activatable binding agent.
• the present invention enables the use of filaments having a low titer for the spun-bonded non-woven filaments. Even with low basis weights, good strength and sufficient coverage is achieved.
• the fiber titer preferably ranges between 0.7 and 6 dtex. Fibers having a titer between 1 and 4 dtex have the special advantage that they ensure good surface coverage with average basis weights, however still have sufficient overall strength so that they are not damaged or torn during the tufting process by the penetration of the needles.
• a tufted backing according to the invention preferably includes filaments comprising polyester, particularly polyethylene terephthalate, and/or polyolefin, particularly polypropylene. These materials are particularly suited because they are produced from mass raw materials, which are available anywhere in sufficient quantities and sufficient quality. Both polyester and polypropylene are well-known in the production of fibers and non-woven fabrics for the durability thereof.
• a suitable method for producing a tufted backing according to the invention comprises the following steps:
• spunbonded non-wovens which is to say the spinning of synthetic filaments from different polymers, including polypropylene or polyester, and also the deposition thereof to form a random non-woven on a backing are state of the art.
• Large machines having widths of 5 m and more can be purchased from several companies. They can have one or more spinning systems (spin-die manifolds) and be adjusted to the desired output. Hydroentangling systems are also state of the art. Such machines as well can be provided by several manufacturers in large widths. The same applies to dryers and winders.
• the thermally activatable binding agent can be applied by different methods, such as by powder application, or also in the form of a dispersion.
• the binding agent is preferably applied in the form of fibers or fibrils using a melt-blown or air-laying method. These methods too are known and described in many places in literature.
• Melt-blown and air-laying methods have the particular advantage that they can be arbitrarily combined with spinning systems for the spunbonded non-woven filaments.
• hydroentangling should preferably be carried out such that a specific longitudinal strength of at least 4.3 N/5 cm per g/m 2 of the surface mass and an initial modulus, measured in the longitudinal direction as tension for 5% elongation, of at least 0.45 N/5 cm per g/m 2 surface mass can be achieved. In this way, sufficient strength of the tufted backing and sufficiently good distribution of the binding agent in the spunbonded non-woven ply are ensured.
• Activation as defined by the invention shall denote the creation of bonding sites using the binding agent, for example by melting a low-melting polymer used as the binding agent for deposition or adherence.
• Both the drying operation and the thermal treatment for activation are to be carried out at temperatures that are so low that damage to the spunbonded non-woven filaments, for example as a result of melting for deposition or adherence, is safely avoided.
• the drying operation and the thermal activation of the binding agent are preferably carried out in one step.
• different types of dryers may be used, such as tenters, belt driers, or surface driers, preferably however a drum dryer is suited.
• the drying temperature should preferably be approximately adjusted to the melting temperature of the low-melting polymer and optimized as a function of the results.
• the entire melting behavior of the binding agent must be taken into account.
• the tufted backing according to the invention is not only suited as primary, but also as secondary carpet backing. Due to the excellent mechanical properties thereof, a tufted backing according to the invention is in particular also suited for producing a three-dimensionally deformable carpet, in particular for automotive interior applications.
• the test machine for the production of spunbonded non-wovens had a width of 1200 mm. It included a spinneret, which extended across the entire width of the machine, two mutually opposed blow walls disposed parallel to the spinneret, and an extraction gap connecting thereto, which in the lower region expanded into a diffuser and formed a non-woven forming chamber.
• the spun filaments formed a uniform fabric, which is to say a spunbonded non-woven, on a collection belt suctioned downwardly in the non-woven forming region. Said non-woven was pressed together between two rolls and rolled up.
• the pre-bonded spunbonded non-woven was unrolled on a test machine for hydroentangling. With the help of an air-laying system, on the surface thereof a thin layer of short bonding fibers was applied, and the two-layer textile was subsequently treated with a plurality of high-energy water jets, thereby hydroentangled and bonded. At the same time, the binding agent was distributed in the textile. Thereafter, the bonded multi-layer non-woven was dried in a drum dryer, wherein in the end zone of the dryer the temperature was adjusted such that the bonding fibers were activated and brought about additional binding.
• a spunbonded non-woven was produced from polypropylene.
• a spinneret was used, which had 5479 spinning holes across the width described above.
• the raw material used was polypropylene granules from Exxon Mobile (Achieve PP3155), having an MFI of 36.
• the spinning temperature was 272° C.
• the extraction gap had a width of 25 mm.
• the filament titer was 2.1 dtex, measured based on the diameter in the spunbonded non-woven.
• the production speed was adjusted to 41 m/min.
• the resulting spunbonded non-woven had a basis weight of 78 g/m 2 .
• a layer of 3 g/m 2 comprising very short conjugate fibers in a shell/core configuration was applied with the aid of a device for non-woven formation under an air current, wherein the core was made of polypropylene and the shell of polyethylene.
• the weight ratio of the components was 50/50%.
• the spunbonded non-woven was subjected to the hydroentangling step.
• the bonding was carried out with the help of 6 manifolds, with alternately acted upon both sides.
• Manifold no. 1 2 3 4 5 6 Water pressure (bar) 20 50 50 50 150 150
• the short fibers were largely drawn into the spunbonded non-woven, so that they did not form a true surface layer.
• the spunbonded non-woven treated with water jets was dried in a drum dryer.
• the air temperature was adjusted to 123° C., so that the polyethylene melted easily and formed thermal bonds.
• the spunbonded non-woven bonded in this way had the following mechanical values for a basis weight of 80 g/m 2 :
• the specific strength in the longitudinal direction was 4.95 N/5 cm per g/m 2 and the specific secant modulus at 5% elongation was 0.56 N/5cm per g/m 2 .
• the bonded spunbonded non-woven was easy to tuft with conventional machine gauges.
• a machine gauge of 1/64 inch resulted in the tufted state in the following mechanical values:
• the non-woven was placed in the same machine for hydroentangling.
• a layer of 3 g/m 2 of the same short conjugate fibers (PP/PE 50/50) was placed on the surface of the pre-bonded spunbonded non-woven.
• the multi-layer material ran through the hydroentangling step using 6 manifolds, which were adjusted as follows:
• Manifold no. 1 2 3 4 5 6 Water pressure (bar) 20 50 80 80 200 200
• the short bonding fibers were largely drawn into the spunbonded non-woven, so that they did not form a true surface layer.
• the spunbonded non-woven treated with water jets was dried in a drum dryer.
• the air temperature was adjusted to 123° C., so that the polyethylene melted easily and formed thermal bonds.
• the spunbonded non-woven bonded in this way had the following mechanical values for a basis weight of 82 g/m 2 :
• the specific strength in the longitudinal direction was 4.82 N/5 cm per g/m 2 and the specific secant modulus at 5% elongation was 0.59 N/5 cm per g/m 2 .
• the bonded spunbonded non-woven was easy to tuft with different gauges.
• a machine setting of 1/64 inch resulted in the tufted state in the following mechanical values:
• the behavior of the tufted carpet was referred to as stable.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Mechanical Engineering (AREA)
• General Chemical & Material Sciences (AREA)
• Nonwoven Fabrics (AREA)
• Carpets (AREA)
• Automatic Embroidering For Embroidered Or Tufted Products (AREA)
• Laminated Bodies (AREA)
• Treatment Of Fiber Materials (AREA)

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• 2007
  • 2007-01-31 DE DE200750004553 patent/DE502007004553D1/de active Active
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