[go: up one dir, main page]

TWI390093B - 用於製造可變形的簇絨產品的方法及可變形的簇絨產品 - Google Patents

用於製造可變形的簇絨產品的方法及可變形的簇絨產品 Download PDF

Info

Publication number
TWI390093B
TWI390093B TW97114090A TW97114090A TWI390093B TW I390093 B TWI390093 B TW I390093B TW 97114090 A TW97114090 A TW 97114090A TW 97114090 A TW97114090 A TW 97114090A TW I390093 B TWI390093 B TW I390093B
Authority
TW
Taiwan
Prior art keywords
deformable
nonwoven fabric
flocked
tufted product
melt
Prior art date
Application number
TW97114090A
Other languages
English (en)
Other versions
TW200912080A (en
Inventor
Ararad Emirze
Peter Sander
Ulrike Maass
Original Assignee
Freudenberg Carl Kg
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Freudenberg Carl Kg filed Critical Freudenberg Carl Kg
Publication of TW200912080A publication Critical patent/TW200912080A/zh
Application granted granted Critical
Publication of TWI390093B publication Critical patent/TWI390093B/zh

Links

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
    • D04H11/00—Non-woven pile fabrics
    • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • 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
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • 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
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • 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
    • 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
    • B32B2262/0261—Polyamide fibres
    • 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
    • B32B2262/0276—Polyester fibres
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • 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
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets
    • 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
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0815—Acoustic or thermal insulation of passenger compartments
    • B60R13/083—Acoustic or thermal insulation of passenger compartments for fire walls or floors
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/042—Polyolefin (co)polymers
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/061—Polyesters
    • 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
    • D06N2203/00—Macromolecular materials of the coating layers
    • D06N2203/06—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N2203/065—Polyamides
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/02—Properties of the materials having acoustical properties
    • D06N2209/025—Insulating, sound absorber
    • 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
    • D06N2211/00—Specially adapted uses
    • D06N2211/12—Decorative or sun protection articles
    • D06N2211/26—Vehicles, transportation
    • D06N2211/263—Cars
    • 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
    • Y10T428/2395—Nap type surface

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Carpets (AREA)
  • Passenger Equipment (AREA)

Description

用於製造可變形的簇絨產品的方法及可變形的簇絨產品
本發明關於一種製造一種可變形的簇絨產物，特別是一種依此方法製造的可變形的簇絨化(植絨)的地毯表層，它特別是用於汽車內部區域者。
要製造一種所謂的簇絨地毯(Tufttppich)，係使用所謂的簇絨化(植絨)(Tuften,英：tufting)－亦即一種製造三度空間的面的技術－－它係依一縫紉機的原理作用。該簇絨針再向上回到其開始位置之前，該被帶入的簇絨紗在底材的下側被夾線器[所謂的起圈器(Looper)]固定住。因此產生紗圈(Schlaufe,英：loop)或紗扭結(Schlingen,英：snarling)－－所謂的毛粒(Noppe,英：nep)，它們在製成的地毯中構成觀看側(上層)。
各依應用而定，這些紗扭結在簇絨化過程時已可利用特殊刀具切斷。在此產生所謂的天鵝絨地毯(Veloursteppich)，它特別是在汽車內部範圍宜以操過95%的比例使用。
本發明的目的在提供一種儘量簡單和經濟的方法以製造一種可變形的簇絨化的地毯表層。依此方法製造的地毯表層特別用於汽車內部領域或在「目標範圍」。「目標範圍」一詞表示該地毯表層特別設計成供受強力到極端的應力的面用者，特別是用於辦公室、旅館、飛機場、醫院等。
這種目的係利用申請專利範圍第1項的特點達成。
在這種方法中，將一熔吹不織布放到一可變形的聚酯植絨載體上，並將該熔吹不織布和聚酯植絨載體共同植絨。藉著和植絨程序同步地將熔吹不織布施加到該植絨載體上，該方法可特別經濟。
由於將該材料的選擇以經程序的設計作特殊組合，因此，如此製造的簇絨產物特別是用在汽車內部區域當作汽車地毯覆層時，有特佳的可變形性及對應地高的強度資料、拉伸資料及進一步斷裂力量資料。
該申請專利範圍附屬項係為本發明標的之有利的進一步特點。
在該方法之較佳實施例中，該簇絨產物單獨利用一道熱處理從簇絨縫入側[特別是沒有預塗底(Vorstrich)的情形]進入該進一步的地毯製造程序。
在製造簇絨時，該預塗底將粗布作預處理，以使背材或植絨載體作各種不同的施覆方法。該預塗底使絨頭毛粒(Polnoppe,英：pile nep)錨固在底材或植絨載體中。如此可使毛粒如所希望地結合進去，且防止該絨頭、材料之線拉出或起毛邊(Ausfransen,英：fringed)的情事。此預塗底材料一般由具有填充材料的合成膠乳構成。
在本發明的製造程序中由於省却了這種膠乳預塗底故省却一道程序步驟。此外不會污染環境，因位在製造、回收及廢棄處理程序中，廢水不含剩餘的膠乳，且在使用如此所處理的簇絨產品時，不會由於膠乳預塗底而形成排放 物。
因此本發明的方法也適合近年提高的環保要求及工業標準。
對此方法。使用之聚酯植絨載體宜為一種聚酯紡絲不織布，其單位面積重量宜為70克/平方米~140克/平方米，尤宜為100克/平方米~120克/平方米。
此外該方法中使用之熔吹不織布的單位面積重量宜為70克/平方米~500克/平方米，尤宜為80克/平方米~200克，更宜為80克/平方米到130克/平方米。
由於單位面積重量特別小，材料的消耗可保持特別少，且加工速度提高，如此可進一步節省成本。
在此方法的特佳實施例中，使用的熔吹不織布的生原料為一種熱塑性之可紡絲的或可作射出成形加工的原料，特別是由以下之物選出者：聚烯、共聚烯、聚酯、共聚酯、聚醯胺及/或共聚烯胺，其MFI值(熔流指數)(依DIN1238或ISO1133)為100~300克/10分。
由於由此方法所製的熔吹不織布的熔流指數高而粘度低，且該由此所做的熔吹不織布的粘度低，因此有利於該熔融的熔吹不織布的應用層侵入該植絨的簇絨載體中。結果產生一種三度空間的複合層。因此可防止應用層與植絨載體之間發生不想要的層剝離(Delaminierung)的情事。
所用之熔吹不織布的厚度宜為0.5mm~1.5mm，尤宜0.5mm~1.0mm。
該熔吹不織布的纖維纖度宜為0.06dtex到0.2dtex，且 宜0.06dtex到0.1dtex。
一種具有高的纖維比表面積、低的纖維纖度以及高的纖維可動性的大體積之柔軟的熔吹不織布應用層使得一齊植絨較容易而不會有針偏差，且增加熔吹不織布應用層和植絨載體的纖維之間的接觸點數目，如此應用層與植絨載體之間的結合在橫截面的範圍均勻地加強。
該熔吹不織布與聚酯植絨載體的共同植絨作業不作先前之針軋或砑光而以1/8”~1/16”的簇絨劃分度達成。
如不用此方式，也可將該絨吹不織布有利地利用一超音波砑光機以小於5%(且宜小於2%)的熔接面積作鞏固，且用該聚酯植絨載體以1/8”~1/16”的簇絨劃分度作植絨。
在此方法特別有利的實施例中，該熔吹不織布與該聚酯植絨載體共同利用一超音波砑光機以小於5%(且宜小於2%)的熔接面積鞏固，然後共同地以1/8”~1/16”的簇絨劃分度作植絨。
利用該共同的鞏固作業，可確保特別好的可操作性以及比在分別的層的場合更佳的程序穩定性。此外，加上熔接面積很小，可同時確保夠高的纖維可動性，且因此簇絨產品的品質(特別是在可變形性方面)提高。
在另外的地毯製造程序中，宜將一種吸音不織布(Akustikvliesstoff)及／或至少另一絕緣的層[它係由乙烯乙烯基乙酸酯/乙烯－丙烯－二烯橡膠或由具有聚乙烯/聚醯胺/(聚乙烯)的共押出之膜構成者]到該簇絨載體的簇絨縫入側上。
依本發明製的簇絨產品[在室溫時沿縱方向之進一步斷裂力量(依DIN 538 59－3)宜為170N~240N]具有特高的進一步斷裂值。因此有特佳的可變形性，因此這種簇絨產品特宜用於當作在汽車內部區域當作地毯表層(作汽車地毯表層)。
此外，該可變形的簇絨產物，特別是該可變形的植絨的汽車地毯表層在室溫時宜具有：－－沿縱方向的最大拉力(依EN 29073－3)為250N/5cm到400N/5cm，且宜275N/5cm到375N/5cm，－－沿橫方向的最大拉力(依EN 29073－3)為180N/5cm到300N/5cm，且宜203N/5cm到250N/5cm，－－沿縱方向的最大拉伸(依EN 29073－3)為45%到60%，－－沿橫方向的最大拉伸(依EN 29073－3)為42%到55%。
在140℃時，該可變形的簇絨產品，特別是該可變形的植絨的汽車地毯表層宜具有：－－沿縱方向的最大拉力(依EN 29073－3)為185N/5cm到200N/5cm，－－沿橫方向的最大拉力(依EN 29073－3)為85N/5cm到120N/5cm，－－沿縱方向的最大拉伸(依EN 29073－3)為65%到70%，－－沿橫方向的最大拉伸(依EN 29073－3)為65%到 70%。
本發明的標的利用一實施例詳細說明。
﹝製造一種熔吹不織布﹞
所用之熔吹不織布的原料為聚乙烯，其熔流指數(MFI)為155克/10分(依DIN 1133)，且用一熔融噴嘴紡絲。在此紡成的聚乙烯纖維的纖度為0.07dtex。
然後將此纖維在一「吸取轉筒」上集層，該轉筒距紡絲噴嘴距離約600mm，俾造成一大體程而軟的不織布，其纖維可運動性在植絨程序中保持不失。
然後可選擇性地將如所製的80克重的絮料利用一超音波以約0.006巴的輕的聲極(Sonotrode)壓力以小於5%(且宜小於2%)的熔接面積鞏固，因此得到體積更大的不織布。如不用此方式，也可靠經由鑴刻(gravieren)或粗糙化的砑光羅拉作輕度之熱鞏固。
﹝製造簇絨產品﹞
將依上述方法製造的80克重的絨吹不織布(此時仍呈未預鞏固的形式)放到植絨載體上，再共同與該植絨載體共同地利用一超音波砑光機以輕的聲極壓力(約0.06巴)用約1.6%的熔接面積鞏固，所用之植絨載體為一種聚酯紡絲不織布LutradurLDT 5312(Freudenberg公司)，其單位面積重量為120克/平方米。
將這種由絨吹不織布及聚酯植絨載體構成之用輕超音波預鞏固的複合材料送到簇絨台入口，其中熔吹不織布側 為針或簇絨的縫入側。
此實驗空氣枱的針工作寬度約50cm，而針分劃為1/10吋(每2.54公分10支針)的天鵝絨品質。
針腳密度約為56/10cm，所用簇絨紗為所謂的BCF紗，它代表膨鬆(bulked)連續長絲(無端紗)，該紗具有聚醯胺6品質，總厚度1300dtex及具128條個別長絲。其他習用之簇絨紗也同樣可用。
簇絨紗重量約400克/平方米，完全的實驗植絨裝置沿狹的寬度側產生一種在汽車領域常用的地毯結果(但另外加入的層為例外)。
在該簇絨針再跑回前，將縫入的簇絨紗用夾器固定住，因此產生紗圈或毛粒，用此方式造成一種「紗扭結絮料地毯。如果紗扭結一如此處所述用一刀具切斷，則產生一種切絮料或天鵝絨地毯。
該熔吹不織布與聚酯植絨載體植絨在一起後，從簇絨織入側作一道熱處理，直到該熔吹不織布的聚乙烯熔解為止。如此所製造之地毯表層對以下的性質作試驗。
﹝如此所製的地毯表層在室溫的性質﹞
－－沿縱方向的最大拉力(依EN 29073－3)：368N/5cm －－沿橫方向的最大拉力(依EN 29073－3)：203N/5cm －－沿縱方向的最大拉伸(依EN 29073－3)：58% －－沿橫方向的最大拉伸(依EN 29073－3)：44% －－沿縱方向的進一步斷裂力量(依DIN53859－3)218N進一步斷裂力量的值越大，則可變形性越高。
為了作比較，該植絨之植絨載體單獨時的進一步斷裂力量(LutradurLDT 53 12,120克/平方米)，亦即無絨吹不織布為198N，且利用傳統預塗底或膠乳結合處理(約100克/平方米)的植絨簇載體(LutradurLDT 5312,120克/平方米)為150N。因此，利用傳統預塗底處理，會對可變形性有負面影響，而依本發明製造的簇絨產品有特高的進一步斷裂力量值，且因此有特佳約可變形性，因此這種簇絨產品特別適合用於當作汽車內部區域的地毯表層。
﹝如此所製的地毯表層在140℃的性質﹞
－－沿縱方向的最大拉力(依EN 29073－3)：196N/5cm －－沿橫方向的最大拉力(依EN 29073－3)：111N/5cm －－沿縱方向的最大拉伸(依EN 29073－3)：75% －－沿橫方向的最大拉伸(依EN 29073－3)：69%
除了在拉伸測試機上測量求出該簇絨產品的力量及拉伸性質外，利用一內部測量方法測定該簇絨產品的變形性質。在此將該簇絨產品沖出一個圓形檢體，直徑24cm，將它夾入在一夾緊環中並利用黃銅螺絲及螺栓固定。此固定的檢體在後側(即簇絨縫入側)利用紅外線加熱到一預定溫度(此處熱到140℃)，其中距紅外線場保持16cm恆定距離。
在達到此溫度後，該夾緊環隨固定地毯檢體自動地被放到一個運動的空心轉筒，該轉筒以50mm/秒的速度相對一金屬球作快速移行。此金屬球用水冷却到18℃，且直徑為10cm。在此，地毯檢體從簇絨縫入側變形。由測量之變形深度計算出變形百分比。
在12.2cm的最大變形深度時 －－最大變形程度 106%且 －－最大變形力量 1543N
在變形深度9cm時 －－最大變形程度 50% －－最大變形力量 723N
依本發明製造的地毯表層的實施例有另一優點，即：它可以用重層作施覆層疊而不需施覆傳統地毯工業習用之聚乙烯粉末。能省却此聚乙烯粉末施覆的原因在於：此實施例的地毯表層的地毯縫入側上已有一個由聚乙烯構成之附著性賦與層存在。

Claims (30)

  1. 一種用於製造可變形的簇絨產品的方法，其中將一熔吹不織布放到一可變形之聚酯植絨載體上，且其中將該熔吹不織布與該聚酯植絨載體共同地植絨，其中，所使用之聚酯簇絨載體為一聚酯紡絲不織布；且其中，該植絨不織布利用一種超音波砑光機以熔接面積小於5%作鞏固，或者該熔吹不織布與聚酯植絨載體共同利用一超音波砑光機以小於5%的熔接面積作鞏固。
  2. 如申請專利範圍第1項之方法，其中：該植絨不織布以小於2%之熔接面積作鞏固。
  3. 如申請專利範圍第1項之方法，其中：該熔吹不織布與聚酯植絨載體共同以小於2%的熔接面積作鞏固。
  4. 如申請專利範圍第1項之方法，其中：該可變形的簇絨產品有一可變形的植絨之地氈表層。
  5. 如申請專利範圍第1項之方法，其中：該可變形的簇絨產品為汽車內部區域用的可變形之植絨地氈表層。
  6. 如申請專利範圍第1項之方法，其中：該聚酯紡絲不織布的單位面積重量為70克/平方米~140克/平方米。
  7. 如申請專利範圍第1項之方法，其中：該簇絨產品單獨利用一道熱處理從該簇絨縫入側(特別是沒有預塗底的情形)送入進一步之地毯製造程序。
  8. 如申請專利範圍第1或第2項之方法，其中：使用之熔吹不織布的單位面積為70g/m2 ~500g/m2 。
  9. 如申請專利範圍第1或第2項之方法，其中：所使用之熔吹不織布的原料為一種熱塑性可紡的或可作射出成形加工的原料，其MFI值(熔流指數)(依DIN 1238或ISO 1133)為100~300克/10分。
  10. 如申請專利範圍第9項之方法，其中：該原料由以下物選出：聚烯、共聚烯、聚酯、共聚酯、聚醯胺及/或共聚醯胺。
  11. 如申請專利範圍第1或第2項之方法，其中：該使用之熔吹不織布的厚度0.5mm~1.5mm。
  12. 如申請專利範圍第11項之方法，其中：該厚度為0.5mm~1.0mm。
  13. 如申請專利範圍第1或第2項之方法，其中：所使用之熔吹不織布的纖維纖度為0.06分德士到0.2分德士。
  14. 如申請專利範圍第13項之方法，其中：該纖維纖度為0.06分德士~0.1分德士。
  15. 如申請專利範圍第1或第2項之方法，其中：該熔吹不織布共同地與該聚酯植絨載體以1/8”到1/16”的簇絨劃分度作植絨。
  16. 如申請專利範圍第2項之方法，其中：所做之地毯製造程序係將一吸音不織布及/或至少另一絕緣層施到該簇絨產物的簇絨縫入側上。
  17. 如申請專利範圍第1項之方法，其中：該載體單位面積為100g/m2 ~120g/m2 。
  18. 如申請專利範圍第8項之方法，其中：該不織布單位面積為80g/m2 ~200g/m2 。
  19. 如申請專利範圍第18項之方法，其中：該不織布單位面積為80g/m2 ~130g/m2 。
  20. 一種可變形的簇絨產物，其係依申請專利範圍第1項的方法製造者，其在室溫時具有--沿縱方向的最大拉力(依EN 29073-3)為250N/5cm到400N/5cm，--沿橫方向的最大拉力(依EN 29073-3)為180N/5cm到300N/5cm，--沿縱方向的最大拉伸(依EN 29073-3)為45%到60%，--沿橫方向的最大拉伸(依EN 29073-3)為42%到55%。
  21. 如申請專利範圍第20項之可變形的簇絨產物，其中：其沿縱向最大拉力275N/5cm~375N/5cm。
  22. 如申請專利範圍第20項之可變形的簇絨產物，其中：其沿橫向最大拉力203N/5cm~250N/5cm。
  23. 如申請專利範圍第20項之可變形的簇絨產物，其中： 其係為可變形之簇絨化地毯表材。
  24. 如申請專利範圍第20項之可變形的簇絨產物，其中：其係用於汽車內部範圍者。
  25. 一種可變形的簇絨產物，其係依申請專利範圍第1項的方法製造者，其在140℃時具有--沿縱方向的最大拉力(依EN 29073-3)為185N/5cm到200N/5cm，--沿橫方向的最大拉力(依EN 29073-3)為85N/5cm到120N/5cm，--沿縱方向的最大拉伸(依EN 29073-3)為65%到70%，且--沿橫方向的最大拉伸(依EN 29073-3)為65%到70%。
  26. 如申請專利範圍第25項之可變形的簇絨產物，其中：其係為可變形之簇絨化地毯表材。
  27. 如申請專利範圍第25項之可變形的簇絨產物，其中：其係用於汽車內部範圍者。
  28. 一種可變形的簇絨產物，其係依申請專利範圍第1到第19項任一項的方法製造者，其在室溫時沿縱向進一步斷裂力量(DIN 53859-3)為170N到240N。
  29. 如申請專利範圍第28項之可變形的簇絨產物，其 中：其係為可變形之簇絨化地毯表材。
  30. 如申請專利範圍第28項之可變形的簇絨產物，其中：其係用於汽車內部範圍者。
TW97114090A 2007-05-02 2008-04-18 用於製造可變形的簇絨產品的方法及可變形的簇絨產品 TWI390093B (zh)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE200710020818 DE102007020818B3 (de) 2007-05-02 2007-05-02 Verfahren zur Herstellung eines verformbaren Tuftprodukts

Publications (2)

Publication Number Publication Date
TW200912080A TW200912080A (en) 2009-03-16
TWI390093B true TWI390093B (zh) 2013-03-21

Family

ID=39730830

Family Applications (1)

Application Number Title Priority Date Filing Date
TW97114090A TWI390093B (zh) 2007-05-02 2008-04-18 用於製造可變形的簇絨產品的方法及可變形的簇絨產品

Country Status (10)

Country Link
US (1) US20090053460A1 (zh)
EP (1) EP1988204B1 (zh)
KR (1) KR101126942B1 (zh)
AR (1) AR066365A1 (zh)
AT (1) ATE522651T1 (zh)
AU (1) AU2008201959B2 (zh)
BR (1) BRPI0801265A2 (zh)
DE (1) DE102007020818B3 (zh)
PL (1) PL1988204T3 (zh)
TW (1) TWI390093B (zh)

Families Citing this family (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009004786A1 (de) * 2009-01-13 2010-07-15 Fleissner Gmbh Verfahren und Vorrichtung zur Verfestigung von textilem Material
DE102009013948A1 (de) * 2009-03-19 2010-09-23 Fleissner Gmbh Verfahren und Vorrichtung zur Verfestigung eines Teppichrückens
JP2012024457A (ja) * 2010-07-27 2012-02-09 Hasetora Spinning Co Ltd タフテッドカーペット
US10370799B2 (en) 2013-12-13 2019-08-06 Dfs Europe Nv Tufted structure for landscape and sports
US10190267B2 (en) 2013-12-13 2019-01-29 Bfs Europe Nv Artificial turf for landscape and sports
WO2015086626A1 (en) * 2013-12-13 2015-06-18 Orotex Belgium Nv Tufted structure for landscape and sports
CN112301577B (zh) * 2020-09-03 2023-03-31 诺奥(福建)环保家居用品有限公司 一种阻燃有色弯头纱满铺毯制造方法
DE102021106621A1 (de) 2021-03-18 2022-10-20 Adler Pelzer Holding Gmbh Absorptives Trägervlies für Tufting-Teppich

Family Cites Families (39)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3360421A (en) * 1963-05-10 1967-12-26 Du Pont Bonded nonwoven backing material having perforate selvage and carpet made therefrom
US3359934A (en) * 1967-05-08 1967-12-26 Patchogue Plymouth Company Tufted carpet having splittable filling yarns in the primary backing
US3630816A (en) * 1969-07-25 1971-12-28 Chevron Res Nonwoven sheets made from rectangular cross section monofilaments
CA948388A (en) * 1970-02-27 1974-06-04 Paul B. Hansen Pattern bonded continuous filament web
US4140071A (en) * 1977-08-09 1979-02-20 E. I. Du Pont De Nemours And Company Process for preparing tufted carpet
EP0018789A1 (en) * 1979-04-27 1980-11-12 The Buckeye Cellulose Corporation Tufted material having a laminated film primary tufting substrate and method of manufacture thereof
US4242394A (en) * 1979-07-09 1980-12-30 Armstrong Cork Company Reinforced primary backing for tufted pile fabrics
EP0030126A1 (en) * 1979-11-29 1981-06-10 DON BROTHERS BUIST & COMPANY LIMITED Process for producing tufted fabric, backing therefor and fabric produced by the process
US4426415A (en) * 1981-12-11 1984-01-17 V&L Manufacturing Company, Inc. Tufted carpeting, especially artificial turf, with tufts stitched through multiple layers of pre-woven backing material of differing gauge
US4668566A (en) * 1985-10-07 1987-05-26 Kimberly-Clark Corporation Multilayer nonwoven fabric made with poly-propylene and polyethylene
US5114787A (en) * 1990-09-21 1992-05-19 Amoco Corporation Multi-layer nonwoven web composites and process
US5256224A (en) * 1991-12-31 1993-10-26 E. I. Du Pont De Nemours And Company Process for making molded, tufted polyolefin carpet
DE19506845A1 (de) * 1995-02-28 1996-08-29 Wesertechno Gmbh Produktentwic Teppichboden sowie Verfahren zur Herstellung desselben
US20050147787A1 (en) * 2000-08-08 2005-07-07 Bailey Larry M. Carpet construction and carpet backings for same
ATE210214T1 (de) * 1995-03-17 2001-12-15 Bp Corp North America Inc Teppich und teppichrücken dafür
DE19609586C1 (de) * 1996-03-12 1997-06-26 Freudenberg Carl Fa Tuftträger
US5962101A (en) * 1997-04-29 1999-10-05 Donald A. Irwin, Sr. Dimensionally stable tufted carpet
US6475592B1 (en) * 1997-04-29 2002-11-05 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
US6207599B1 (en) * 1998-08-27 2001-03-27 Akzo Nobel Nv Nonwoven backing and carpet comprising same
US6280818B1 (en) * 1999-03-03 2001-08-28 Wayn-Tex, Inc. Carpet backing components and methods of making and using the same
US20030152743A1 (en) * 1999-04-26 2003-08-14 Atsushi Matsunaga Base cloth for tufted carpet and tufted carpet using the same
US6176935B1 (en) * 1999-05-25 2001-01-23 Mg Industries System and method for refining sugar
DE10108092B4 (de) * 2001-02-19 2007-01-04 Carl Freudenberg Kg Verfahren zur Herstellung eines Tuftingträgers
US6740385B2 (en) * 2001-03-28 2004-05-25 Bp Corporation North America Inc. Tuftable and tufted fabrics
US6544334B1 (en) * 2001-10-23 2003-04-08 General Electric Company Systems and methods for the deposition and curing of coating compositions
US6866912B2 (en) * 2002-03-13 2005-03-15 Milliken & Company Textile constructions with stabilized primary backings and related methods
US20030175475A1 (en) * 2002-03-13 2003-09-18 Higgins Kenneth B. Textile constructions, components or materials and related methods
US6808786B2 (en) * 2003-02-04 2004-10-26 Freudenberg Nonwovens Automotive tufted carpet with enhanced acoustical properties
US20050022919A1 (en) * 2003-07-28 2005-02-03 Burlington Industries, Inc. Alternate method for applying hot melt adhesives to carpet
EP1745167B1 (en) * 2004-04-30 2011-02-23 Dow Global Technologies Inc. Improved nonwoven fabric and fibers
US20050249912A1 (en) * 2004-05-06 2005-11-10 C&A Floorcoverings, Inc. Floor covering containing polyvinyl butyral and method of making same
US20050249911A1 (en) * 2004-05-06 2005-11-10 C&A Floorcoverings, Inc. Polyvinyl butyral backed floor covering
US7695794B2 (en) * 2005-01-27 2010-04-13 Colbond B.V. Tufted nonwoven, bonded nonwoven, methods for their manufacture and uses
US7364634B1 (en) * 2006-08-07 2008-04-29 Darwin Enterprises Carpet construction having secondary backing
EP1964956B1 (de) * 2007-01-31 2010-07-28 Ivo Ruzek Hochfester leichter Tuftingträger und Verfahren zu seiner Herstellung
DE102007006759A1 (de) * 2007-02-12 2008-08-14 Carl Freudenberg Kg Verfahren zur Herstellung eines getufteten Vliesstoffes, getufteter Vliesstoff und dessen Verwendung
US7790264B2 (en) * 2007-04-17 2010-09-07 Aplix, Inc. Loop material for loop and hook type fastener used in a disposable article or garment
US8608817B2 (en) * 2007-11-09 2013-12-17 Hollingsworth & Vose Company Meltblown filter medium
US8728581B2 (en) * 2009-07-17 2014-05-20 Columbia Insurance Company Embossed carpet backing

Also Published As

Publication number Publication date
KR101126942B1 (ko) 2012-03-20
ATE522651T1 (de) 2011-09-15
AU2008201959B2 (en) 2011-01-27
DE102007020818B3 (de) 2009-01-02
AR066365A1 (es) 2009-08-12
EP1988204B1 (de) 2011-08-31
EP1988204A3 (de) 2009-12-02
KR20080097940A (ko) 2008-11-06
TW200912080A (en) 2009-03-16
AU2008201959A1 (en) 2008-11-20
US20090053460A1 (en) 2009-02-26
PL1988204T3 (pl) 2012-01-31
BRPI0801265A2 (pt) 2008-12-16
EP1988204A2 (de) 2008-11-05

Similar Documents

Publication Publication Date Title
TWI390093B (zh) 用於製造可變形的簇絨產品的方法及可變形的簇絨產品
KR100235419B1 (ko) 성형가능한 폴리올레핀 터프티드 카페트(turfted carpet)의 제조방법
AU2015218484B2 (en) Fiber-based carpet cushion with added resilience from vertically oriented fiber construction
KR101969340B1 (ko) 자동차 부품
TWI394879B (zh) 製造簇絨產品的方法
US20060019570A1 (en) Multicomponent spunbonded nonwoven, method for its manufacture, and use of the multicomponent spunbonded nonwovens
CN104662223B (zh) 地毯基底布和包括地毯基底布的簇绒地毯
JP6752331B2 (ja) 複合構造体
KR20120106971A (ko) 제１ 카펫 백킹
JP2019501077A (ja) 中実多葉形繊維を用いた自動車用カーペット
CN101821442A (zh) 针刺的非织造拉绒织物及其用途
AU2015345267A1 (en) Primary carpet backing for latex free tufted carpets
US20190010640A1 (en) Microfiber nonwoven composite
CN110637118B (zh) 针刺丝绒地毯的生产方法
US3889028A (en) Non-woven materials
WO2024213934A1 (en) Nonwoven fabric and method of forming the same
JP2019500990A (ja) 中実多葉形繊維を用いたイベントまたは展示会カーペット
TWI829062B (zh) 紡絲黏合不織布、包括其的地毯以及其製造方法
KR102558453B1 (ko) 스펀본드 부직포 및 그 제조방법
JP3659433B2 (ja) タフテッドカーペット成形品
CN109572126A (zh) 一种汽车内饰地毯的制造方法及制成的汽车内饰地毯
WO2025215422A2 (en) Nonwoven fabric and method of forming the same
TW202039949A (zh) 針織用繩及針織製品
Malkan Hunter Douglas, Broomfield, CO, United States
CA3017267A1 (en) Non-woven structure with fibers catalyzed by a metallocene catalyst

Legal Events

Date Code Title Description
MM4A Annulment or lapse of patent due to non-payment of fees