DE1685157A1 - Multi-layer pile or knobbed structure and process for its production - Google Patents

Description

The invention relates to multi-layer synthetic fiber textiles with a large number of pile-like fiber tufts or Yarn knobs, which are flexibly supported by a foam layer and a fabric layer, as well as a method for the production of such structures.

Pile or knobbed fabrics, sometimes also "tufted" fabrics are often used for the production of floor coverings, such as carpets, or absorbent materials, such as towels, used. One of the desirable properties of such a fabric is its relative size deep pile or in its long knobs, which gives the fabric the feel and appearance of plush goods. Fabrics of different pile or knob lengths can be produced, their appearance and "feel" to a certain extent by changing the distance between the various groups of fibers or nubs relative to one another

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let control. For example, it is common to have carpets or the like. to be produced in such a way that the fibers or knobs are very close to one another and to one another support so that a smooth-surfaced appearance is maintained.

One of the disadvantages of such pile or hop structures has so far been that the individual pile fibers or try to press down knobs after prolonged use as a result of the constant pressure effect, so that even if they are arranged very close to one another, the pile fibers that are adjacent to one another support provided or nubs is not sufficient, the To keep pile fibers or knobs in an upright position in heavily used areas. In addition, the production of pile fibers or knobs lying very close to one another is very expensive, since this affects the pile or the Pimple-forming material is usually of the highest quality and is generally the most expensive component of the multilayer structure represents. Another in the production of! Textiles with closely spaced The disadvantage of pile fibers or knobs is that the end product becomes hard to the touch and tends to lose its cushioning effect, as the individual fibers or knobs are very tightly attached to one another.

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lie. This seems to be for a relatively long time Pile fibers or knobs apply.

In contrast, the invention provides a method for producing a multilayer pile or knobbed structure, which is characterized in that first a base layer and a thin layer of a flexible cellular material with a plurality of cellular cavities are united with one another and then a yarn-like material in the form of knobs through the base layer and the cellular layer Material is pulled through it, the nubs a plurality of over the surface of the layer of cellular Material form outwardly protruding tufts of fibers, which are increased by the latter in order to ensure Depth of the upholstery effect are supported resiliently or resiliently.

The support of the - # ea? Pile fibers or knobs over This makes it possible through its entire lower section by means of a flexible layer of cellular material the pile fibers or nubs to maintain a practically solid position, the cellular material a Upholstery effect guaranteed. The surface of the multilayer structure shows essentially only the upper

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Most, support-free sections of the pile or knobs, so that its appearance resembles that of a real pile or knobbed structure, whereby it is due to the support given by the layer of cellular material to the pile fibers or knobs in their lower sections even after a long time using tet a uniform appearance of the surface bending ₌ and beyond is characterized by an enlarged cushion depth.

If the pile fibers or knobs are far apart, parts of the layer can be made of cellular material be visible on the surface between them. This effect can be used in the multi-layered Structure due to the contrast between the pile or knobbed sections on the top and the surface of the layer to create specific surface patterns from cellular material. In some cases it has been found to be Proven advantageous to modify the visible surface of the layer of cellular material in that on A fabric consisting of individual particles is glued to it, depending on the desired effect and the intended one A variety of different particles can be used for the purpose. The one from the foam layer outwards protruding fibers can either take the form of

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have closed loops, resulting in what is known as a knobbed material, or they can be made from cut open loops Loops with free ends exist, resulting in a so-called pile. The mutual The distance between the individual fibers and their distribution across the structure can be changed as required to produce predetermined patterns or to modify the functional properties of the structure.

The method according to the invention provides a multilayer structure, the top of which consists of a pile or knobbed layer and, compared to the previously known pile or knobbed fabrics, is characterized by a greater depth of cushioning effect and at the same time by a smooth, uniform surface appearance. In other words, the invention creates a composite, layered fabric which is capable of fulfilling the same tasks as the conventional pile or knobbed structures, but which further improves the desirable properties of such structures, such as cushioning depth or plush-like appearance, and at the same time which has long been in use In connection with pile or knobbed structures, known disadvantages, such as mat formation and uneven surface appearance in places of heavy use, reduced to a minimum or even switched off.

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The invention is explained in more detail below with reference to the drawings. Show it:

1 shows a section, on a greatly enlarged scale, through a section of a multilayer hop structure with the features of the invention,

Figure 2 is a perspective view of a typical cellular cavity of uncured foam layer, on a greatly enlarged scale,

FIG. 3 shows an analysis similar to FIG. 2 of a typical one cage-like cavity of a cross-linked foam layer and

Fig. 4 is a detailed view illustrating the manner of application of leilchenmaterial on the visible surface of the foam layer of the layering as well as the The way in which the knobs over a. Part of its length through the foam layer be yieldingly supported.

According to the figures, the multi-layered

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term nub structure 10 a base layer 11, which is made of a fabric, for example cotton, wool, Rayon or nylon of any weight and any weaving fineness can be made and on which one Layer 12 made of flexible, open-cell polyester-polyurethane foam is glued on. Due to the multilayer consisting of this base layer 11 and this foam layer 12 A large number of yarn-like tufts 13 made of twisted threads or fiber strands are drawn through it, which either, as shown, form a plurality of knobs 14, which extend over the exposed Surface 15 of the foam layer 12 extend out, or the ends protruding from the surface 15 of the foam layer at their ends to form a pile are cut open. Whenever "knobs" are used in the following description, both closed knobs as well as cut knobs, i.e. a pile. According to Fig. 1, the yarn-like Tufts 13 over the exposed side 16 of the base layer, which is the rear side of the multilayer structure 11 connected to each other, although the tufts can also consist of individual tufts that are attached to the base layer 11 are glued. However, it is simpler in terms of normal manufacturing processes and less expensive to use a yarn-like fiber or

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Plastic strand according to a known knob setting process incorporated into a fabric, resulting in a plurality of knobs 14, which consist of one or more Loops can consist of yarn-like material and protrude from the foam layer 12 to the outside. Obviously, several thread catchers could be used at the same time be pulled through the layer structure so that in each nub or in each yarn-like tuft of fibers several loops are formed.

There is an essential feature of the invention in each pail in that the yarn-like tufts 15 according to FIG. 1 and even more clearly according to FIG. 4 over a section their length above the base layer 11 by the compliant foam layer 12 are supported. the the foam layer 12 inherent compliance increases the depth of the cushioning effect of the finished structure, which is due to the support-free, free-standing ends of the the knobs 14 forming yarn-like tufts 13 is still supported. This way the surface is preserved of the structure according to the invention an appearance which is similar to that of the more expensive and difficult to manufacture, previously used nub structures desired and sought, without, however, the the same nub density would be required, which such

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makes known structures much more expensive. In addition, the structures according to the invention also retain their appearance after long-term application of pressure and wear and tear as a result of the resilient support of the knobs and the yarn-like Tufts 13 through the foam layer 12. While the previous pile or knobbed structures through immediate Passing the pile or knobbed fibers through a supporting fabric in a comparatively dense arrangement were produced, so that due to the dense arrangement of adjacent yarn-like tufts a hard surface and consequently a loss of the desired padding. TrittdämpfVermögens showed, capable of the invention Forms a combination of the properties sought so far in an effective way and at the same time to ensure a considerable reduction in manufacturing costs.

The special type of foam layer 12 of the multiple fabric 10 is best illustrated in FIGS. 2 and 3, which are greatly enlarged views of FIG Single cells made from a typical cellular polyurethane foam represent. Each cell forms a three-dimensional network of interconnected webs 17, which form nodes between the surfaces or walls of the cells of the foam body. Most of the so-

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called "open-cell" polyurethane foams, for which the cell according to Pig. 2 is typical, possess at least over some or some of the cell areas away in Fig. 2 at 18 indicated thin membrane-like material films, while other cell surfaces, such as those in 19 indicated areas, are open because the membrane-like Material on this surface has been broken up during the foaming process.

Polyurethane synthetic resins or polymers are produced by reacting a diisocyanate with a polyhydroxy material. These synthetic resins can generally be classified according to the chemical nature of their polymeric units, for example in polyether or polyester-polyurethanes, but there are also other, less frequently used types, which depend on the type of polymer with which the isocyanate is implemented, can be divided. A polyurethane foam is formed by generating CO ₂ , for example as a result of the reaction of water with an isocyanate, or another gas in the reaction mixture, for example by evaporation of a volatile liquid under the heat of conversion, when the liquid form of the polymer is converted into a solid one Shape, for example through cross-linking or other

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increase in the molecular weight of the liquid polymer.

In the production of foamed polymeric cell structures a gas or steam is generated while the substance to be formed is in a plastic state finds. As a result of this gas generation, bubbles of approximately spherical shape arise when they expand Cells with a more or less specific geometric configuration form. The optimal arrangement of the A spherical bubble is one in which each spherical bubble is surrounded by twelve other spherical bubbles; has accordingly it has been shown that the cells formed by the expansion of the gas bubbles to the point of contact, so that low-density, open-celled Cell structures result, essentially have the shape of dodecahedra with pentagonal sides. This is a general rule, although cells of varying geometrical configuration are found in each foam mass Find. At the intersections of the cell surfaces there are thicker material webs, while between the very thin membrane-like films are present in the webs forming the cell walls. In general, part of the breaks Cell areas during foaming, so that the Cells are connected to each other. Such a one

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Foam mass is called off unicellular.

Although there are numerous processes for foam crosslinking are known, it has been shown that foams are particularly expedient according to that in the US patent 5,171,820 described method satisfactorily to an open-cell polyester-polyurethane foam can be crosslinked for use as an intermediate layer 12 in a modified embodiment of the invention multilayer structure 10 provided type is suitable. This networking process will be practically all of the remaining membranes 18, which are shown in FIG. 2 and which form the cell walls, are removed, so that a large number is formed by skeletal outline possessing, cage-shaped cavities. An example of a typical The cell of the foam layer 12 after this crosslinking of this type is shown in FIG. 3 on a greatly enlarged scale shown. In the case of such a foam mass, as is known, there is no flat surface, but rather it has this foam mass a series of cavities formed by the webs 20.

For many applications of the so-called "open-cell is ¹¹ polyurethane foam because of its flexibility and its greater load carrying capacity for the appropriation

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Application is preferred in the multiple structures according to the invention. It is believed that these properties are mainly are due to the fact that the remaining unbroken cell walls or membranes Stiffen the structure and structurally hold it under greater loads than would be the case if this Residual membranes would be removed, for example, by crosslinking. In applications such as carpets or rugs, in which the load capacity of the material is a significant factor, is for the inventive multilayer structures preferably use this type of uncrosslinked polyurethane foam according to FIG. 2,

In those cases where a softer textile product is used and the load capacity of the multilayer Structure is of less importance than the softness, flexibility and resilience of the structure in connection with its uniform appearance, on the other hand, it has proven advantageous to have a cross-linked polymer structure of the type shown by the cell of FIG. 3 to be used. In this case the conventional one open-cell foam mass has been subjected to an after-treatment, in which the membranes of practically all Areas of the cell have been removed and only the integrally interconnected webs 20 remain. Insight

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Licherweise is a cell structure or a foam layer 12 with cells in Pig. 3, when a force is applied, it is "more flexible ^11" and is not able to underserve the knobs of the multilayer structure according to the invention as rigidly as is the case with the non-crosslinked foam structure, despite its excellent pedal action and ability to spring back to be occupied with knobs, since the knobbed needles do not need to break open any residual membranes and since less frictional force acts on the tufts of pas during the knob-setting process - Patent 3 171 820.

In another embodiment of the invention a multilayer structure 10 according to Pig. 1 with on comparatively wide spaced tufts of knobs occupied, so that exposed sections the surface 15 remain visible to the eye. Goal of the production of the structure and in particular before the nubs are set For example, an adhesive coating is applied to the exposed surface 15 or

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applied to the webs 17 and membranes 18 forming this surface and a decorative particulate material on this applied, so that at least some of these particles on the surface as well as on these forming webs and membranes adheres. After the nubs have been set, the particulate material is between the tufts of pas visible through it and offers an appealing surface effect. The colors and The structure for the production of patterns can be varied.

Satisfactory results can be obtained with a flake material made from randomly cut nylon flakes with an average fiber length of less than 0.5 mm, although a wide variety of other materials can be applied in a similar manner. The application of such a particle gives the background surface forming foam sheet 12 has a suede-like surface appearance.

The layer 12 of cellular material can consist of a any flexible, resilient, light material exist, which according to the invention according to a knobbed setting process can be occupied with knobs, with polyurethane foam layers, both networked and non-networked, proven to be excellent for this purpose

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be liable. Although, in principle, a variety of materials can be used, it has been found to be advantageous found a polyurethane foam layer with a thickness of about 1.6 - 6.35 now and a pore size from about 23.5-47 pores / cm (about 60-120 pores 3e inches) to be used.

The yarn-like material used for pimple formation "or the twisted fiber strands can be made from any" Type of fiber and; have any construction. These yarns can be used to form Nubs made of several yarns can be combined with other yarns or used on their own. The determination these factors primarily depend on the intended use. The knobs can be up to about 12.7 mm and even more, as shown in FIG. 1, protrude beyond the surface 15 of the foam layer.

As mentioned, in a special embodiment According to the invention, the uppermost portions of the knobs are cut to a predetermined height for the purpose of forming a pile thereby forming a plurality of fiber bundles 14 extending upward through the foam layer 1.2 extend through and their outer ends have free ends instead of the closed loops.

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The pimple-setting process can be carried out on a conventional Knob setting machine are done as they are normally used for the occupation of fabrics with knobs is used. In general it can be said that this machine is the yarn-like Strands passed through the multilayer fabric, with the over the surface of the foam layer 12 protruding loops 14 are formed, and then pulls the strands back a little.

The base layer 11 according to FIG. 1 can, for example made of plastic, rubber, paper or fabric, both "woven" and "non woven" ~ Q? yp. When permeability is essential and flexibility is required, a fabric is preferred, for example Cotton print, tricot, cotton percaline or the like. The gluing of the cellular layer 12 to the load-bearing base layer 11 can be done by heat treatment or welding or to avoid breaking the connection take place when bending the material using a preferably flexible adhesive.

The layers according to the invention are used in numerous different areas, for example as Curtain or upholstery material, as cover materials for outerwear and the like, as bath towels, bed rugs and so on.

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like carpets and floor coverings. The following examples illustrate some typical embodiments the invention.

example 1

A sheet of flexible, cross-linked polyurethane foam with a pore size of about 31.5 pores / cm (linear) and a thickness of about 1.6 mm was through Glued onto a strip of nylon ma-rquisette fabric. The composite structure thus obtained was then compared with two-strand Orion yarn of 1100 denier in a open pattern with knobs, so that parts of the foam surface remained visible. the The stud setting machine was set to a needle spacing of about 4.0 mm and 2.75 stitches or stitches per centimeter (7 stitches or stitches per inch) with a pile length from about 6.35 mm above the foam surface set. The multi-layer burl structure obtained in this way was effectively suitable for many uses, such as for curtains, as upholstery material and the like.

Example 2

A sheet of flexible, cross-linked polyurethane foam with about 31.5 pores per cm (linear) and a thickness

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of about 2.0 mm was glued to a web of bleached cotton percaline and the composite structure thus obtained was then studded in a comparatively open pattern with white rayon yarn of 1100 denier, so that the foam surface remained partially visible. The nubs setting machine was a needle distance of about 4 _t 0 mm and about 2.75 stitches / cm at a Florschlingenhöhe of about 6.35 mm above the foam surface set. The multilayer structure obtained in this way could be used effectively for draperies or curtains, bed rugs, outerwear, towels, carpets and upholstery purposes.

Example 3

A sheet of flexible, uncrosslinked polyurethane foam with about 31 ^ 5 pores / cm (linear) and a thickness of about 1.6 mm was glued to a cotton percale sheet and the layer structure thus obtained was then coated with two-tone synthetic ⁿ Novelty type ^M yarn trimmed with knobs. The knobbed setting machine was set to a needle spacing of about 2.0 mm and about 4 stitches per cm with an indiscriminate loop pile height of 0.8-12.7 mm above the foam surface. The needles of the burling machine were set so that each

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empty five threads with a needle spacing of 2.0 mm of 5 Needle positions were followed. This scheme repeated itself over the whole machine and resulted an end product with dimpled strips that are separated from each other through the foam substrate were separated.

Example 4

Foam and cotton percale were put together to form a layer in the manner described in Example 2, which was trimmed with 1 / 11s Dacron polyester yarn with knobs. The nub setting machine was at a needle distance of about 4.0 mm and 2 meshes per cm with a cut pile height of about 3.2 mm above the foam surface set. During this treatment, puff-like or bump-like spots appeared on the areas which the fabric was studded with nubs.

Example 5

A fabric produced according to Example 4 was passed through a shearing machine which was set so as to that the yarn knobs were sheared at a height of about 3.2 mm above the foam surface. At this Treatment resulted in fine spots where the fabric had been studded.

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Example 6

Uncrosslinked foam and cotton fabric were layered in the manner described in Example 2 assembled, whereupon the exposed side of the Foam sprayed with an adhesive and with randomly cut R-4 nylon flakes from Clarement ! "lock Corp., Clarement, N.H./USA with an average Fiber length of less than 0.5 mm was sprinkled. This dusty material made a suede-like, highly abrasion-resistant, cheap background and a pad for what is done according to the previous examples Knobs.

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Claims (10)

Claims 1. Method of making a multilayer Pile or knobbed structure, characterized in that first a base layer and a thin layer made of a resilient cellular material with a plurality of cellular cavities with each other are combined and then a yarn-like material in the form of knobs through the base layer and the layer of cellular material is pulled through, wherein the knobs a plurality of over the Surface of the layer of cellular material form outwardly protruding tufts of fibers, which through the latter is supported flexibly or resiliently in order to ensure increased depth of the upholstery effect will. 2. The method according to claim 1, characterized in that that the upstanding tufts each contain at least one closed loop, their outermost ends protruding beyond the layer of cellular material to form a plurality are cut open by separate, upwardly protruding pile fibers with free ends. 109844/0287 - 23 - 3. The method according to claim 1 or 2, characterized in that that on the exposed surface of the layer of cellular material without filling the An adhesive is applied to cavities in the cells and a particulate material is then applied to this surface which adheres to the layer of cellular material as a result of the adhesive. 4. According to the method according to one of the preceding claims produced multilayer pile or Knob structure, characterized in that it has a basic layer on at least one side is glued to a layer of a flexible, resilient, cellular material, which is a Contains a plurality of cellular cavities, and that a plurality of tufts of yarn-like material the basic layer and the layer of cellular material penetrate and on in an outward direction from the Surface of the layer of cellular material distant places run out, these tufts for the purpose Ensuring greater depth of the cushioning effect over part of its length by resilient the layer of cellular material are supported. 109844/0287 -24- 5. Multi-layer structure according to claim 4, characterized in that that the layer of cellular material is a foam layer. 6. Multi-layer structure according to claim 5, characterized in that that the flexible foam layer is crosslinked and a variety of cage-shaped Has cavities. 7. Multi-layer structure according to one of claims 4 to 6, characterized in that the tufts made of yarn-like material each contain at least one closed loop made of the yarn-like material. 8. Multi-layer structure according to one of the claims 4 to 7, characterized in that the base layer is a coarse (scrim) cotton fabric. 9. Multi-layer structure according to one of the claims 4 to 8, characterized in that the cellular material is a crosslinked polyurethane foam with about 23.5-63 pores / cm (linear) and a thickness of about 1.6-12.7 mm. 109844/0287 10. Multi-layer structure according to one of claims 4 to 9, characterized in that the exposed Surface of the layer of cellular material from which the tufts of fibers protrude, with one without complete filling of the empty spaces of the cells on the exposed surface of the layer of cellular Material adhered particulate material is covered. 109844 / ΠΖΒ7 R e r s e