US3669819A - Carpet material - Google Patents

Carpet material Download PDF

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Publication number
US3669819A
US3669819A US29931A US3669819DA US3669819A US 3669819 A US3669819 A US 3669819A US 29931 A US29931 A US 29931A US 3669819D A US3669819D A US 3669819DA US 3669819 A US3669819 A US 3669819A
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United States
Prior art keywords
fleece
fibers
carpet
needled
binder
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
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US29931A
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English (en)
Inventor
Dieter Bischoff
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Carl Freudenberg KG
Original Assignee
Carl Freudenberg KG
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Filing date
Publication date
Application filed by Carl Freudenberg KG filed Critical Carl Freudenberg KG
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Publication of US3669819A publication Critical patent/US3669819A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0005—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface
    • D06N7/0039—Floor covering on textile basis comprising a fibrous substrate being coated with at least one layer of a polymer on the top surface characterised by the physical or chemical aspects of the layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • 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

Definitions

  • the invention relates to a novel carpeting or other such floor covering material.
  • Another object of the invention is imparting resistance to bacteria and fungi in a way resulting in substantial advantages.
  • a carpet material which comprises a non-woven matting needled one or more times and which is impregnated as such, e.g. to approximately /3 of its depth (i.e. height, measured from the floor side of the fleece) with a binding agent.
  • the fibers are bonded by the binder.
  • FIG. 1 is a schematic showing of a needled fleece
  • FIG. 2 is a schematic showing of the fleece with binder applied thereto.
  • the needled web of non-woven material that is formed has a structure such as the one schematically indicated in 3,669,819 Patented June 13, 1972 "ice FIG. 1 of the annexed drawing.
  • the fibers 1 lie substantially horizontally, i.e. parallel to the suface of the thin web.
  • some of the fibers which originally were lying parallel are set generally vertically or perpendicular to their original orientation.
  • These needled fibers 2 thus form loops 3 on the surface of the mat, while on the opposite surface the free ends 4 of the loops protrude.
  • the invention provides that the needled mat is impregnated from the loop side with a binding agent 5, e.g. a high-percentage, latex foam.
  • a binding agent e.g. a high-percentage, latex foam.
  • the loop side i.e. the side harboring loops 3, forms the lower or floor side of the carpet; the free fiber ends 4, are disposed at or adjacent the tread side or upper side of the carpet.
  • the foam impregnation process is known from US. Pats. Nos. 2,338,960, 2,719,795, 2,719,802, 2,719,803, and 2,719,806.
  • the needled matting is passed through the gap between two rolls and at the same time foam is introduced into the fleece by the rolls.
  • the foam 5 is made to penetrate only to a limited depth, e.g. about two thirds of the depth of the needled mat.
  • the preferred binding agent is a self-vulcanizing styrene-butadiene-latex. In this case it is suflicient to dry the mat briefly at C. after the foam impregnation. If a non-self-vulcanizing binding agent is used, the mat has to be heated for a longer period at higher temperatures in order to bring about a complete vulcanization or setting of the binding agent.
  • the dried material is laid on the fioor in such a manner that the binding agent-free side having the open, projecting extremities 4 of the needled fibers 2 serves as the tread, or walked on, surface. If one pulls at the two extremities, the fibers cannot be pulled out, because on the back they are firmly anchored in the fabric by a loop and the binder.
  • Such a carpet is also substantially softer to walk on than one manufactured merely according to FIG. 1, in which the loop side serves as the tread surface and in which a binding agent, if any, is uniformly distributed in the matting.
  • a special optical effect can also be achieved by clipping the protruding free fiber ends.
  • An apparatus that serves for shearing sheep can be used for the purpose.
  • the back of this carpeting can also be cemented to a stiffening support such as cork and/or asphalt.
  • a stiffening support such as cork and/or asphalt.
  • the material can be marketed then in the form of tiles of a size of, for example, 30 x 30 cm.
  • edges formerly had visible seams between them when laid, in the new material the edges are not visible, since the binding agent-free pile surface of the one tile merges with the pile of the adjacent one.
  • the carpeting manufactured according to the invention proves to be especially advantageous because it can be used without the supporting fabric otherwise commonly used in needled felt sheet materials. Furthermore, it has a plush-like appearance and feel over its entire surface, which is to be attributed to the fact that the tread surface itself, as previously mentioned, is practically free of binding agent.
  • bactericidal and/ or fungicidal agent included in the binding agent a bactericidal and/ or fungicidal agent. Since the binder is not present at or adjacent the tread surface, the tendency for soil to adhere to the mat is not adversely affected by the binder.
  • fungicidal and/or bactericidal agent for the practical manufacture of these bacteria-resistant floor coverings, it is sufficient to add small quantities of a fungicidal and/or bactericidal agent to the binding agent.
  • the action of the bactericidal or fungicidal agents is not adversely affected either by the binding agent or by the treatment at elevated temperature that follows.
  • the fibers can be dyed.
  • the penetration of the binder can be Va- A the depth of the carpet; it is preferably about
  • the length of the fibers can be 40-100 mm., preferably 60-80 mm.; the denier can be 6-40, preferably 6-47.
  • the Weight of the fleece or mate can be 200-1200, preferably 250-800, without binder, and 300-700, preferably 330-880, with binder, the weight units being g./m.
  • a non-woven matting is prepared having a weight of 450 g./m. This matting is needled, and then impregnated with a 50%? butadiene-styrene latex by the foam-impregnating method. To 100 g. of this latex 12.7 g. of additive mixture is added. Thisadditive mixture consists of Parts by weight Sulfur 0.2 Zinc oxide 5.0 Thiuram 3.0 Anti-aging agent MB 1.0 Vultamol surfactant dispersing agent 0.5 Water 15.0
  • the matting is impregnated to a wet absorption becan be brought about by adding only 0.01 part by weight of the Sanitized agent to the above-mentioned additive mixture.
  • the bactericidal and fungicidal agents are elfective even though, e.g. only two-thirds of the carpet depth is impregnated, i.e., the impregnation does not extend as far as the surface of the carpeting. Were the impregnating material to extend to the surface, it would detract from the appearance and increase the soiling susceptability of the carpet.
  • Carpet consisting essentially of a needle non-woven fleece having a floor side and a tread side, substantially horizontallyextending fibers forming the body of the fleece, and, securing the fibers of the body of the fleece together, generally vertically extending needled fibers having looped sections on the floor side of the fleece and free fiber ends adjacent the tread side thereof, the floor side and the tread side being distinguished from each other in that the floor side harbors said looped sections and is impregnated with a cured, self-vulcanizing latex foam binder extending from said floor side upwardly to about two-thirds of the height of the fleece securing fibers of the fleece together and forming a backing for the carpet, while the tread sied is substantially free of binder and has said fiber ends disposed therein and adjacent thereto.
  • carpet according to claim 1 wherein said binder has admixed therewith an effective amount of a bactericidal agent, and wherein the portion of the fleece which is substantially free of binder is also substantially free of said agent.
  • carpet according to claim 1 wherein said binder has admixed therewith an effective amount of a fungicidal agent, and wherein the portion of the fleece which is substantially free of binder is also substantially free of said agent.
  • carpet according to claim 2 the fibers consisting essentially of polypropylene.
  • carpet according to claim 3 the fibers consisting essentially of polypropylene.
  • Col. 3, line 26, reads "300-700" and should be --30o-17oo--.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
US29931A 1969-05-07 1970-04-20 Carpet material Expired - Lifetime US3669819A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CH704269 1969-05-07

Publications (1)

Publication Number Publication Date
US3669819A true US3669819A (en) 1972-06-13

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ID=4319016

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Application Number Title Priority Date Filing Date
US29931A Expired - Lifetime US3669819A (en) 1969-05-07 1970-04-20 Carpet material

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US (1) US3669819A (enrdf_load_html_response)
JP (1) JPS4921529B1 (enrdf_load_html_response)
DE (1) DE2009182A1 (enrdf_load_html_response)
ES (1) ES183795Y (enrdf_load_html_response)
GB (1) GB1312311A (enrdf_load_html_response)
NL (1) NL7003196A (enrdf_load_html_response)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3836422A (en) * 1971-01-16 1974-09-17 Freudenberg C Antistatic fabrics
US4032383A (en) * 1975-11-04 1977-06-28 Mcdonnell Douglas Corporation Fiber insertion device for continuous 3d foaming machine and method
US5254386A (en) * 1991-05-10 1993-10-19 Church & Dwight Co., Inc. Deodorized carpets and process for producing same

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8915662D0 (en) * 1989-07-07 1989-08-23 Walters Ian D Surface covering material

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3836422A (en) * 1971-01-16 1974-09-17 Freudenberg C Antistatic fabrics
US4032383A (en) * 1975-11-04 1977-06-28 Mcdonnell Douglas Corporation Fiber insertion device for continuous 3d foaming machine and method
US5254386A (en) * 1991-05-10 1993-10-19 Church & Dwight Co., Inc. Deodorized carpets and process for producing same

Also Published As

Publication number Publication date
ES183795Y (es) 1975-06-16
JPS4921529B1 (enrdf_load_html_response) 1974-06-01
GB1312311A (en) 1973-04-04
DE2009182A1 (enrdf_load_html_response) 1970-11-19
ES183795U (es) 1973-08-01
NL7003196A (enrdf_load_html_response) 1970-11-10

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