WO2008064637A1

WO2008064637A1 - Method and device for producing web material having a fluffy surface, and web material produced accordingly

Info

Publication number: WO2008064637A1
Application number: PCT/DE2007/002025
Authority: WO
Inventors: Ullrich MÜNSTERMANN; Erwin Glawion; Manfred Aulbach; Markus Nienhaus
Original assignee: Fleissner Gmbh
Priority date: 2006-12-01
Filing date: 2007-11-09
Publication date: 2008-06-05

Abstract

The invention relates to a method and a device for producing web material for tufting carpets, pile carpets and/or plush material having a fluffy surface (16), by means of a napping unit (20), wherein the web material (10) is formed by at least one carrier layer, or by a carrier layer (12) and a further non-woven material, which is punctiformly (6) connected to the carrier layer (12) and forms a composite layer (5), on the back (12.1) of which only loosely held gassed cotton yarns are incorporated in the form of pile loops (13.1). The object of the invention is to achieve improved incorporation of the yarns, or of the individual filaments of the yarns, into the carrier layer. For this purpose, according to the invention the pile loops (13.1) incorporated into the composite layer (5) are treated by means of hydrodynamic needle-punching, or a mechanical napping unit, such that pile loops (13.2) that are prominent and/or at least partially close-fitting on the back of the web material (10) are at least partially napped, opened, or split into their individual filaments, and that an adhesive (17) is applied to the at least partially napped back of the pile loops.

Description

Method and device for producing a web material with a fluffy upper side and correspondingly produced webs

The invention relates to a method and apparatus for producing a web material for tufted carpets, pile carpets and / or plush fabric with a fluffy top, wherein the web is formed at least from a carrier layer or a carrier layer and another nonwoven, the points with the carrier layer is connected and forms a composite layer, on the back only loosely held pile yarns are introduced in the form of pile loops.

It is already known to produce carpeting or Auslegeware (DE 19506845 A1), wherein the carpet is provided with a filament having wear layer or a pole (tufts) and a hereby connected in particular by tufts support layer, wherein the support layer by a melting and cooling process is connected to the wear layer for Polfixierung and filament binding and for this purpose originally fusible and cured components in the region of the support layer are present.

Furthermore, it is known (EP 1081263) to use a method for the continuous stabilization of a pile fabric such as pile carpet, tufted carpet, plush fabric, wherein the front or visible side of the sheet-like product may not be changed in its structure and quality and has a back side, which is still unstable at first. In this back so the florbildenden fibers must still be anchored, in this primary carrier of a spunbond of synthetic fibers (primarily polyester fibers), a woven or knitted fabric attached to the pile fibers z. B. tufted and then for anchoring tion in the primary carrier only loosely held pile fibers of the backs of the web material with a backing layer securing the pile fibers (melt fiber fleece) is provided. Check content

In order for the carpets to have the required mechanical durability, it is necessary to incorporate the pile material so as to achieve the technological strength and durability properties. This can be done for example by a latex precoat (the currently generally customary way), with which at first a sufficient binding of the pile layer in the outreach is achieved. Subsequently, in order to achieve the desired performance properties, in particular to improve the comfort of walking, usually a secondary backing, for example a fleece, a fabric or a foam back is applied. However, the latex primer proves to be extremely polluting in both the manufacture and disposal of the carpets. Furthermore, the back of the carpet can be connected to a textile secondary backing by mechanical needling, which can lead to impairment of the top, so that the finished carpet no longer meets the quality requirements. Another option is to "glue" the secondary backing together with the latex primer.

Still, it is a problem to achieve an intensive connection of the fibers of a second back with the carrier layer waiving a latex precursor.

Based on the type mentioned above, the invention has for its object to achieve an improvement of the integration of the yarns or the individual filaments of Game in the carrier layer.

This is achieved by the fact that the introduced into the composite layer pole loops are treated by means of a hydrodynamic needling such that the protruding on the back of the web and / or at least partially adjacent pile loops are at least partially roughened, opened or split into their individual filaments, and that an adhesive is applied to the at least partially roughened back side of the pile loops.

The advantageous composite structure of the web material and the fixation of the pile loops with the aid of a liquid or liquid which becomes liquid when heated ensure that they do not slip or be pulled out of the support when the web material is used extensively in the support layer.

For this purpose, it is advantageous that the adhesive is applied in the heated and liquid state to the back of the pile loops and penetrated into the filaments of the pile loops.

According to a development of the invention, an additional possibility is that the back side of the web material is treated by means of hydrodynamic or water vapor or compressed air needling, the pile loops of the pile yarns projecting on the back of the web material having at least one of the fibers Nonwoven needled and the adhesive is applied in a liquid state on the back of the pile loops or is applied.

Furthermore, it is advantageous for at least one second nonwoven material comprising melted fibers and / or the adhesive in the liquid state to be applied to the back side of the pile loops and connected to these open and / or roughened pile loops on the back side of the composite layer comprising a carrier layer and a melt fiber layer.

It is advantageous for this purpose that after application of the adhesive on the back of the pile loop another fleece is applied or is.

According to a preferred method, it is thus provided that the pile loops introduced into the composite layer are removed by means of an aquajet method. Rens or hydrodynamic needling be treated so that on the back of the web material protruding and / or at least partially applied pile loops at least partially roughened, opened or split into their individual filaments, and that on the at least partially roughened back of the pile loops Glue is applied.

Of particular importance for the present invention is that the needling is carried out with the aid of at least one oscillating nozzle beam.

In connection with the design and arrangement according to the invention, it is advantageous that the advancing movement of the web or the carrier layer for oscillating movement of the nozzle bar X: Y <1 or X: Y ≤ 2 or X: Y <10.

It is also advantageous that in a further step after the roughening of the pile loops in the composite layer and after placing the further melt fiber layer and needling a heat treatment of the web can be done.

The following procedure is advantageous:

a) the carrier layer can be provided on one or both sides with a melt fiber layer and be connected by means of a heatable calender or by means of a needling or mechanical needling at least selectively with the carrier layer to the composite layer,

b) the pile loops are tufted on the back of the carrier or the composite layer prepared in this way,

c) the pile loops introduced into the back of the carrier or the composite layer are made using at least one oscillating duplex hydro-dynamic or compressed air or steam-treated

d) the hotmelt adhesive is then applied to the rear side of the carrier or the composite layer or the web material with the opened pile loops in the liquid state,

e) finally, the web is subjected to drying and / or heat treatment and / or cooling.

Furthermore, it is advantageous that a spunbonded nonwoven fabric, a staple fiber nonwoven fabric, a woven fabric, a ribbon fabric or a composite of the abovementioned materials is used as the carrier layer.

It is advantageous, too, are used as the fusible fibers of 100 ⁰ C to 150 ⁰ C, preferably 120 ⁰ C to 13O ⁰ C fusible fibers or biocomponent.

It is also advantageous that the adhesive is applied to the carrier in a molten state.

It is also advantageous that the adhesive is applied in a temperature range of 100 ° to 15O ⁰ C or 120 ° to 130 ° C on the support.

The method according to the invention serves to solidify the web material with a fluffy top for pile carpets, tufted carpets or plush goods. Despite the aquajet process, the structure and quality of the web should not be changed or significantly changed. Since no latex is used in the web material according to the invention, a carpet produced in this way can be recycled.

According to a further embodiment, it is advantageous to provide a device for roughening a web material for tufted carpets, pile carpets and / or To use plush fabric with a fluffy top using a roughening device for roughening a web with the following features:

The roughening device has at least on its outer side or surface in an area one or more roughening elements.

The device for roughening a web product and / or the roughening element can carry out a picking up movement with the aid of a drive device in relation to a web material.

This ensures that in addition to the water needling a mechanical roughening can also be used very successfully, if that is desired because of certain material properties or if this can be cost savings.

For this purpose, it is advantageous that the roughening element consists of at least one knob, a mandrel, a pencil or a roughened surface. Such roughening elements can be produced inexpensively and install later without problems in existing systems.

An additional possibility is, according to a development of the invention, that the nub, the mandrel or the pin consists of an elastic plastic or metal body. In this way, there is no excessive impairment of the web.

Furthermore, it is advantageous that the roughening elements are fastened on the outside of a cylindrical body, one or more disks or on a beam or a horizontally extending holder. This gives a cost-manufacturable device.

It is also advantageous for this purpose that the roughening elements are detachably connected to the mechanical roughening device. In case of damage leave easily replace the roughening elements without having to replace the entire device.

According to a preferred embodiment of the solution according to the invention, it is finally provided that the roughening device has a vertically or horizontally extending axis or shaft with respect to the web product to be treated, which can be set into a rotational movement, pivoting movement and / or oscillating movement with the aid of a drive device is. Depending on the type and condition, different roughening tools can be used, which can be quickly replaced by existing tools due to detachable devices.

Of particular importance for the present invention that the roughening device has at least one with respect to the web to be treated horizontally extending support which is displaceable by means of a drive device in an oscillating movement and / or pivoting movement. With the help of the oscillating movement and / or pivoting movement is obtained in an optimal way a very good surface texture.

In connection with the design and arrangement according to the invention, it is advantageous that the roughening device consists of several brushes rotatably arranged about the vertical axis and the tilting movement, rotational movement and / or oscillating movement of the roughening device is equal to, smaller or larger than the advancing movement of the web.

Further advantages and details of the invention are explained in the patent claims and in the description and illustrated in the figures. Showing:

1 is a schematic sectional view of a carrier layer formed from a composite layer,

2 shows the pile loops introduced into the composite layer, 3a shows the web with a further melt fiber layer and, depending on the embodiment, with a third melt fiber layer,

Fig. 4a to

4c are schematic representations of the individual method steps for producing a carrier layer formed from a composite layer,

Fig. 5 is a graphic representation of the movement of the nozzle beam and the

Advance movement of the web,

6 is a schematic cross-sectional view of a further exemplary embodiment of a web product with introduced pile loops,

7 shows the application of a molten layer on the web material according to arrow,

8 shows the web material after the diffusion of the melt into the web,

9, the web product according to FIG. 6 with roughened pile loops, FIG.

10 shows the web with roughened pile loops after the diffusion of the melt into the web,

FIG. 11 shows the web material according to FIG. 10 with additional nonwoven layers, FIG.

FIGS. 12 to 14 three different embodiments of a device for

Roughening a web material for tufted carpets, pile carpets and / or plush goods with a fluffy top using a roughening device. In Fig. 1 to 4c is denoted by 5 a composite layer, which consists of a carrier layer 12 and a spunbonded nonwoven, PA ribbon fabric or a melt fibers 12.3 comprehensive fleece.

The composite layer 5 is formed by punctiform 6 (FIG. 1) with the carrier layer 12 on the back or underside of the carrier layer 12 comprising the melt fibers 12.3 comprising fleece, at least in some places of the fleece with the aid of a heatable calender not shown in the drawing firmly connected. The calender used for this, which comes into contact with the melt fibers 12.3, has only in some places corresponding contact points, which cause a selective connection between the melt fibers 12.3 and the carrier layer 12.

On or in the composite layer 5, a pile fiber or pile loop 13.1 is then tufted. In this case, the pile loops 13.1 are introduced or tufted on the back of the carrier layer 12, which then lie relatively close to a bottom or back 12.1 of the melt fiber layer 12.3 and the carrier layer 12.

The protruding, but very close to the back 12.1 of the support layer 12 adjacent pole loops 13.1 (Fig. 4b) are treated by means of an A quay method or a hydrodynamic needling with compressed air or steam, so that the relatively fixed on the back or Use side of the support layer 12 adjacent pile loops 13.1 roughened or at least partially opened or split into their individual filaments and thereby creates a fluffy surface structure, so that the melt fibers 12.3 can form a very good and durable connection after melting with the pile loops 13.1.

The hydrodynamic needling is carried out with the aid of at least one oscillating nozzle beam, so that much better roughened pile loops 13.1 (FIG. 4b) are achieved. An advancing movement Y of a web 10, 10.1 or the carrier layer 12 for the oscillating movement X. of the nozzle bar may be X: Y <1 or X: Y ≤ 2 or X: Y <10. Depending on which surface structure one wishes to obtain, the advancing movement Y of the web 10.1 or the carrier layer 12 can be changed to the oscillating movement X of the nozzle bar. Here, Y is the advancing movement of the web and X is the oscillating movement of the nozzle bar (compare the graph of FIG. 5). The pile loops are not separated during needling but only roughened.

According to a first exemplary embodiment illustrated in FIG. 3a, projecting and / or at least partially fitting pile loops 13.2 are at least partially roughened, opened or split into their individual filaments. Notwithstanding the second exemplary embodiment illustrated in FIG. 4c, described in more detail below, an adhesive 17 is applied to the roughened loop 13.2 in such a way that it penetrates the roughened layer of pile loops 13.2 completely and over the entire surface, thereby surrounding the individual filaments.

The backing may consist of a nonwoven fabric made of staple fibers or continuous filaments which are water entangled in one operation.

A melt fiber layer 14 can be dispensed with according to the embodiments of FIGS. 1 to 3a, since it is replaced by the adhesive 17, which is applied in a molten state to the loosened fiber bundles of the pile loops 13.2 so that it can penetrate more quickly between the voids of the filaments. The penetration of the melt can by suction or by blowing hot air on the z. B. preheated carpet backs are supported, depending on how the web is applied to a dryer drum of the plant for the production of the web.

According to an exemplary embodiment according to FIG. 4b, the water jet leads on the web 10 or on the back of the carrier layer 12 a sinusoidal Mige movement, so that a very well roughened, fluffy pile layer is formed, with the melt fibers 12.3 can enter the desired solid connection.

After the process step (FIG. 4c), the next or second layer in the form of the melt fiber layer 14 is applied to the surface of the reverse side 12.1 of the carrier layer 12 of the web 10. Thereafter, with the help of needling or water jet needling the melt fiber layer 14 with the open pile loop 13.2 connected hydrodynamically, by compressed air or by steam. As a result of the above-described opening of the pile loops 13.1, the melt fibers of the melt fiber layer can penetrate deeply into the filaments of the opened pile loops 13.2.

The carrier layer 12 can be provided on one or both sides with a melt fiber layer 15 and can be connected to the carrier layer 12 at least punctually 6 to the composite layer 5 by means of a heatable calender or by needling or mechanical needling.

The heat treatment can be carried out with the aid of a Thermobondero- fens, wherein first dried and then heat treated at a temperature of about 100 ° to 15O ⁰ C, preferably from 120 ⁰ C to 13O ⁰ C heat treatment becomes. This creates a perfect connection between the individual filaments of the open pile loops 13.2, the melt fiber layer 14 and the melt fibers 12.3 (FIG. 4c).

The fused-fiber components melted onto the filaments of the pile loops 13.2 and / or to the back 12.1 of the backing in conjunction with the other method steps result in a very hard-wearing carpet. The carrier layer 12 used is preferably a spunbond or a ribbon fabric. As melt fibers one can use up to approx. 12O ⁰ C fusible chemical fibers or also biocomponent fibers.

The heating of the melt fibers should be chosen so that the heating takes only a very short time and the melt fiber penetrates sufficiently deep between the filaments of the pile loops 13.2, so that the pile loops 13.2 are anchored securely and firmly in the support layer 12.

For the purposes of the application, web material 10, 10. 1 is to be understood as the composite layer 5 with the roughened or opened pile loop 13.

In the composite layer 5, the pile fiber 13.1 is tufted. On the back 12.1 of the carrier layer 12 with the roughened pile or the open pile loops 13.2, the second melt fiber layer 14 is applied to ensure that it enters into a close connection with the open pile loops 13.2.

The particular advantage of the method according to the invention consists in the combination of water jet treatment and heat treatment and the use of two layers of melt fiber layers 12.3, 14 on the back 12.1 of the web 10th

The melt fiber layer or the melt fiber fleece 12.3 according to the invention consists of 100% low-melting fibers. It can also consist of polyethylene (PE) or polypropylene (PP) or of a mixture of different melt fibers. The melt fiber nonwoven may also have an admixture of non-melting fibers.

According to a further exemplary embodiment according to FIGS. 1 and 4c, the sheet material 10 according to the invention consists of the composite layer 5 formed from two layers, the pile or the opened pile loops 13.2 and the second pile loop 13.2. A further or third melt fiber layer 15 can be applied to the top side of the carrier 12 (see dashed representation of the melt fiber web 15 in FIGS. 1 and 4c).

As already mentioned, the melt fiber layer 14 is applied to the Tuftware or the web 10 with the aid of a veining device or water jet needling device or another medium, for example a steam jet or a gas medium or hot air jet.

This ensures that with the help of the needling device, such as the oscillating water bar, more individual fibers penetrate into the back 12.1 of Tuftware and between the individual filaments of the open pile loops 13.2.

It is particularly advantageous at low temperatures, for example at a melting temperature of 100 ° to 150 ° C, preferably between 11O ⁰ C and 130 ⁰ C, to work so that the melt fibers quickly go into the liquid state. Furthermore, it is advantageous to use thin melt fibers, so that they melt faster. In this way you also get a larger and more active surface or contact surface.

The melt fiber may, as already mentioned, consist of PE or PP.

The less fluid the molten melt fiber layer, the better it penetrates into the individual filaments of the pile 13.1.

As melt fibers are preferably used up to 120 ° C fusible chemical fibers or biocomponent fibers.

Instead of the melt fiber fleece 14 loose fibers by an airlay device (air laying device, apparatus for depositing fibers after the air laying method) on the back 12.1 are applied with open pile loops 13.2.

Overall, as already mentioned, with the help of a needling device or the water jet needling or other media, the melt fiber fleece 12.3, 14 needled with the pile loops 13.2 d. H. connected. Due to the needling, the melt fiber layer 14 penetrates into the individual pile loops 13.2.

Since the opened pile loops 13.2 and the two or three melt fiber layers 12.3, 14, 15 on the web 10 (FIGS. 1 and 4c) are already strongly needled into one another and substantially more surface is available for melting, a robust carpet is obtained in that the pile loops 13.2 or the filaments of the pile loops 13.2 can not be pulled out.

Particularly suitable as a carrier layer is a spunbond or a ribbon fabric.

An alternative to this would also be that the aforementioned nonwoven layer 15 consists of melt fibers, but which must have a higher viscosity than the adhesive. During the warming up of this non-woven fabric layer consisting of melt fibers, suction of the resulting melt into the carrier web 12 can be achieved by a corresponding air flow during the heat treatment.

According to a further embodiment, the web 10 shown in FIGS. 6 to 11 (section in machine direction) here consists of a carrier nonwoven fabric 12 which has been consolidated by means of needle punching and consists of only one layer, into which the multifilament yarn is looped, referred to below as pile loops 13.1 is. Seen in the transverse direction are provided between the needled Multifilamentgamen small spaces or lanes with a few millimeters distance on the web 10. The fleece can also be formed of several layers as shown in FIG. 3a or 4c, as shown in FIG.

On the web 10 10 of FIG. 7, the molten adhesive 17 is applied by means of a wedge-shaped discharge nozzle 18 of a device not shown in the drawing. The nozzle 18 has a direct contact with the web during adhesive application. However, the job can also take place when the discharge nozzle 18 has a small distance from the surface of the web.

The molten or molten adhesive 17 is shown in the form of a meal for better illustration in the drawing. However, it is a uniformly homogeneous mass.

The adhesives used are advantageously thermoplastics from the families of polyolefins, polyesters, polyamides or polyurethanes with low melting points. The melting point of the adhesive should be well below the melting point of the carrier fleece or the multifilament yarns, namely between 100 ° and 150 ⁰ C or between 120 ° and 13O ⁰ C, so as not to influence the molecular orientation of these threads, otherwise a too the drop in the tensile strength or shrinkage of the yarns in the yarn or fleece would be unacceptable to the final product.

The viscosity range of the adhesive may be from less than 1 Pas to over 100 Pas. Low-viscosity adhesives have better wetting or creeping properties, but also lower strengths. In principle, it is also possible to apply dissolved adhesives, but in the normal case, since water can rarely be used as solvent, leads to increased expense of recovery of these solvents. Likewise, the application of reactive adhesives based on polyurethane is possible. However, these adhesives are no longer meltable and prevent recycling. It is advantageous if the viscosity of the adhesive 17 is below 10 Pas, since otherwise the adhesive could not penetrate completely into the bundled multifilament yarn. The size of the viscosity depends on the temperature. With higher temperature, the viscosity value decreases. It is advantageous, therefore, that a preheating of the web takes place in order to prevent too rapid cooling of the adhesive and thereby to allow a better penetration into the multifilament yarns. As a result of this preheating, the adhesive gets more time to cover the penetration path through the bundled multifilament yarn.

Experiments have shown that the melt, as shown in Fig. 3, preferably penetrates only through the web, but does not penetrate into the bundled Multifilamentgame. As a result, individual threads from the interior of this bundle are not adhesively bonded but only cohesively bonded. These threads are plucked out in everyday use of a carpet, especially when cleaning with high-speed brushes, and make the carpet look neglected and worn. Although an increase in the amount of adhesive could eliminate this deficiency, but causes the adhesive on the opposite side of the job exits the fleece again and therefore the pile formed from multifilament yarns quickly soiled after use.

Therefore, it is advantageous if the Multifilamentgame be roughened on the surface by high-energy water jets of FIG. 4, thereby the adhesive penetrates much easier into the bundle interior of the filaments. At the same time, the alleys between the tufted multifilament yarns are predominantly closed with the help of the roughening, thus making it more difficult for the adhesive to penetrate into these normally easily wettable areas.

It is particularly advantageous that the water bar of the needling device, which is not shown in the drawing, is caused to oscillate transversely to the machine direction, and thus every single thin water jet emerging from the water bar has a larger diameter. indicates as one from the non-vibrated water bar. The vibration behavior of the water bar enhances a uniform penetration of the adhesive into the carrier fleece and into the multifilament yarns of the pile loops according to FIG. 5.

As can be seen from FIG. 11, another nonwoven fabric 19, preferably made of recycled material, can be placed on the adhesive application side and pressed on, as this achieves a higher rigidity and a greater weight of the web, thereby improving the laying of the carpet.

On the surface of the web or the carpet should be enough adhesive 17 remain to achieve a proper bonding of the filaments in the web. If a part of the adhesive 17 penetrates through the fleece, the pile can become polluted more quickly. For this reason, it is advantageous if, prior to the tufting of the multifilament yarn onto the carrier fleece 12, a further thin nonwoven layer 19 is connected as a seal to the upper side of the web 10. This nonwoven layer 19 should consist of very fine threads, since this nonwoven fabric is denser overall, although the basis weight of about 10 - 50 g / m ^{2 is} significantly lower than the weight per unit area of the carrier fleece.

In FIG. 13, the device for roughening the web 10 for tufted carpets is shown with a roughening device 20, which has at least on its outside or surface (20.2) in one area one or more roughening elements (20.1).

The device for roughening a web material and / or the roughening 20.1 can perform a Aufraubewegung with respect to a web material with the aid of a drive device, not shown in the drawing.

The roughening 20.1 consists of at least one knob, a mandrel, a pin or a roughened surface. Instead of just one pimple, one

SIGNIFICANT SHEET (RULE 91) Doms or pens can also be used a variety of juxtaposed pimples, thorns or pins.

The knobs, mandrels or pins 20.1 may consist of an elastic plastic or metal body. Furthermore, it is possible to replace one or more nubs or, if these are arranged on a base, and the base with all nubs can be exchanged for a new one. The backing, which is not particularly highlighted in the drawing, can be attached to the surface of the roll or disk by means of an adhesive.

The roughening 20.1 are mounted on the outside of a cylindrical body, one or more discs 22 or on a beam or a horizontally extending bracket or beam 25. In an advantageous manner, the roughening elements 20. 1 are detachably connected to the mechanical roughening device 20.

The roughening device 20 has a with respect to the treated web to be treated 10 vertically and / or horizontally extending axis or shaft 21, 24.1, 24.2, which is displaceable by means of the drive device, not shown in a rotational movement, pivoting movement and / or oscillating movement. The roughening device 20 can also be displaced into an oscillating movement and / or pivoting movement or else tilting movement according to the arrows 26 to 31 in FIG. 14, at least by means of the holder 25, which extends horizontally with respect to the product 10 to be treated.

The roughening device 20 consists of one or more disks arranged rotatably about the vertical axis, on each of which a brush 23 is arranged. As is apparent from Fig. 14, the roughening device 20 can perform a tilting movement 30, rotational movement 27 and / or oscillating movement 28, which is smaller or larger than the advancing movement (26) of the web (10). LIST OF REFERENCE NUMBERS

5 composite layer

6 punctuation 10, 10.1 web goods

12 carrier layer, carrier

12.1 back, bottom

12.3 1. melt fiber, melt fiber layer, melt fiber fleece

13.1 Pole sling, pile, pile fiber 13.2 pile sling, opened and roughened

14 2. Melt fiber, melt fiber layer, fleece

15 3. Melt fiber, melt fiber layer, fleece

16 top of the web

17 glue, hot glue 18 nozzle, discharge nozzle

19 fleece layer, fleece

20 mechanical roughening device

20.1 Roughing element, knob, thorn, pin

20.2 Outer surface or surface of the roughening device 21 Horizontal shaft for brush roller or cylindrical body

22 disc with brushes or brush roller,

23 brush, movable transversely and in the direction of the web,

24.1 axis, vertical

24.2 Axis, horizontal 25 horizontal bracket, beams

26 arrow, feed movement

27 arrow, rotational movement

28 arrow, oscillating motion

30 Arrow, pivoting movement or tilting movement 31 Arrow, pivoting movement or tilting movement

X movement nozzle bar with oscillating movement

Y feed movement of the web 10.

Claims

claims:

A method for producing a web material for tufted carpets, pile carpets and / or plush goods with a fluffy top (16) by means of a roughening device (20), wherein the web (10) at least one support layer or one of a carrier layer (12) and a further web is formed which is selectively (6) connected to the carrier layer (12) and a composite layer (5), on the back (12.1) only loosely held pile yarns in the form of pile loops (13.1) are introduced, characterized by the following Characteristics,

a) that in the composite layer (5) introduced pile loops (13.1) by means of a hydrodynamic needling or mechanical

Auf-raueinrichtung be treated so that on the back of the web (10) protruding and / or at least partially fitting pile loops (13.2) are at least partially roughened, opened or split into their individual filaments,

b) that on the at least partially roughened back of the pile loops, an adhesive (17) is applied.

2. The method according to claim 1, characterized in that the KIe- ber (17) is applied in a heated and liquid state on the back of the pile loops and penetrates into the filaments of the pile loops.

3. The method according to claim 1, characterized in that the back (12.1) of the web (10) is treated by means of hydrodynamic or a steam or compressed air needling, wherein the projecting on the back of the web pile loops (13.2) of the pile name with the Needle fibers of at least one fleece and the adhesive (17) is applied in the liquid state on the back of the pile loops.

4. A method for producing a web material for tufted carpets, pile carpets and / or plush fabric with a fluffy top, wherein the web (10) at least from the carrier layer (12) and on its back the melt fibers comprising fleece is formed, the at least some Points is connected to the carrier layer (12) and the composite layer (5) forms, on the back (12.1) pile yarns were introduced in the form of pile loops (13.1), characterized in that on the back of a carrier layer (12) and a melt fiber layer (12.3) aufwei- composite layer (5) at least a second melt fibers comprising fleece (14) and / or the adhesive (17) applied in the liquid state on the back of the pile loops and with these open and / or roughened pile loops (13.2) is connected ,

5. The method according to claim 4, characterized in that after application of the adhesive (17) on the back of the pile loop (13.2) another fleece (19) is applied.

6 A method for producing a web (10) for tufted carpets, pile carpet and / or plush fabric with a fluffy top (16), wherein the web (10) at least from a carrier layer or one of a carrier layer (12) and another web formed which is selectively (6) connected to the carrier layer (12) and forms a composite layer (5) on the back (12.1) only loosely held pile yarns in the form of loop (13.1) are introduced, characterized by the following features,

a) that in the composite layer (5) introduced pile loops (13.1) by means of a mechanical Aufraueinrichtung (20) and / or an Aquajetverfahrens or a hydrodynamic needling or mechanical Aufraueinrichtung be treated such that on the back of the web (10) protruding and / or at least partially attached pile loops (13.2) are at least partially roughened, opened or split into their individual filaments,

b) that an adhesive (17) are applied to the at least partially roughened back side of the pile loops.

7. The method according to claim 1 or 6, characterized in that the needling is performed using at least one oscillating nozzle beam.

8. The method according to claim 7, characterized in that the feed movement (Y) of the web (10) or the carrier layer (12) for oscillating movement (X) of the nozzle beam X: Y <1 or X: Y ≤ 2 or X: Y <10.

9. The method according to any one of the preceding claims, characterized in that in a further step after roughening the pile loops (13.2) in the composite layer (5) and after placing the further melt fiber layer (14) and the needling a heat treatment of the web (10) can be done.

10. The method according to any one of the preceding claims, characterized by the following method steps:

a) the carrier layer (12) may be provided on one or both sides with a melt fiber layer (12.3, 15) and with the aid of a heatable calender or by means of needling or mechanical needling at least selectively (6) with the carrier layer (12) to the composite layer (5) be connected

b) the pile loops (13.1) are tufted on the back (12.1) of the carrier or of the composite layer (5) prepared in this way, c) the pile loops (13.1) introduced into the rear side (12.1) of the carrier or the composite layer (5) are treated hydrodynamically or with compressed air or with steam with the aid of at least one oscillating nozzle beam, d) then the rear side of the carrier or the composite layer (5) or the web (10) with the opened pile loops (13.2) of the hot melt adhesive (17) applied in the liquid state, e) finally, the web (10) is subjected to drying and / or heat treatment and / or cooling.

11. The method according to any one of the preceding claims, characterized in that a spunbonded nonwoven fabric, a staple fiber nonwoven fabric, a woven fabric, a ribbon fabric or a composite of the aforementioned materials is used as the carrier layer (12).

12. The method according to any one of the preceding claims, characterized in that as melt fibers (12.3) of 100 ⁰ C to 150 ⁰ C preferably 120 ⁰ C to 130 ⁰ C fusible chemical fibers or biocomponent fibers are used.

13. The method according to any one of the preceding claims, characterized in that the adhesive (17) is applied in a molten state to the carrier (12).

14. The method according to any one of the preceding claims, characterized in that the adhesive (17) in a temperature range of 100 ° to 150 ° C or from 120 ° to 130 ⁰ C on the carrier (12) is applied.

15. An apparatus for producing a web (10) for tufted carpets, pile carpet and / or plush fabric with a fluffy top (16) by means of a roughening device (20), for carrying out the method according to one of the preceding method claims, characterized by the following features: the roughening device (20) has at least on its outer side or surface (20.2) in one region one or more roughening elements (20.1),

- The device for roughening a web material and / or the roughening (20.1) can perform a Aufraubewegung with respect to a web using a drive device.

16. The apparatus according to claim 15, characterized in that the roughening element (20.1) consists of at least one knob, a mandrel, pin or a roughened surface.

17. The apparatus according to claim 16, characterized in that the knob, the mandrel or the pin consists of an elastic plastic or metal body.

18. Device according to claim 15, characterized in that the roughening elements (20.1) are fastened on the outside of a cylindrical body, one or more disks or on a beam or a horizontally extending support (25).

19. The apparatus according to claim 15, characterized in that the roughening elements (20.1) are detachably connected to the mechanical roughening device (20).

20. The apparatus according to claim 15, characterized in that the roughening device (20) with respect to the treated web material (10) vertically and / or horizontally extending axis or shaft (21, 24.1, 24.2), with the aid of a Drive device in a rotational movement, pivoting movement and / or oscillating motion is displaceable.

21. The device according to claim 15, characterized in that the roughening device (20) at least one with respect to the treated Web (10) has horizontally extending support (25) which is displaceable by means of a drive device in an oscillating movement and / or pivoting movement.

22. The apparatus according to claim 15, characterized in that the roughening device (20) consists of a plurality of rotatable about the vertical axis arranged brushes (23).

23. The device according to claim 15, characterized in that the tilting movement (30), rotational movement (27) and / or oscillating movement (28) of the roughening device (20) equal, smaller or larger than the advancing movement (26) of the web (10) is.

24. web material for tufted carpets, pile carpet and / or plush fabric with a fluffy top, characterized in that it is prepared according to one or more of the method claims 1 - 14 and having the components specified in these claims.