WO2007144042A1 - Method for the production of strip material with a fleecy surface - Google Patents

Abstract

The invention relates to the production of strip material (10) for tufting carpets, pile carpets, and/or plush fabric with a fleecy surface, with the strip material (10) formed from at least one carrier layer (12) and one non-woven material (13) containing fusion fiber, which is combined with the carrier layer (12) in a punctiform manner (6) and forms a composite layer (5), at the reverse side (12.1) of which only loosely held lisle threads are inserted in the form of pile loops (13.1). The object of the invention is to achieve an improvement in the tying of lisle fibers into the carrier layer. This object is achieved, in that the pile loops (13.1) that are incorporated in the composite layer (5) are treated with the help of an aqua jet procedure and/or hydrodynamic needle-punching in such a way that the pile loops (13.1) that protrude from and/or are at least partially attached to the reverse side and/or the useful side of a carrier layer (12.4) are at least partially roughened, opened, or split into their separate filaments.

Description

Method for producing a web with a fluffy top

The invention relates to a method 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 from a comprising a carrier layer and a melt fibers nonwoven, the punctiform 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 carpet or carpeting with a wear layer having filaments (DE 19506845 A1), wherein carpet yarns are connected by tufts with the support layer. The support layer with Schmelzfaservfliesauflage for filament binding is connected by a melting and cooling or mechanically with the base support material. For this purpose, originally fusible and cured components are present in the area of the base layer. Furthermore, the base layer is made as a tufting base of a nonwoven fabric or fabric of conventional material or with one or two-sided pad of fusible material, the latter consist in particular of high proportions of fused fibers.

It is also known (EP 1081263) to use a method for the continuous stabilization of a pile fabric such as pile carpet, tufted carpet, plush fabric, the sheet-like product is provided with a visible side, which must not be changed in their structure and quality and has a back which is still unstable at first. In this back side, therefore, the flor-forming fibers must still be anchored by fixing the pile fibers into a primary carrier made of a spunbonded non-woven of synthetic fibers (primarily polyester fibers), a woven or knitted fabric. B. tufted and then to anchor the only loosely held in the primary carrier pile fibers of the back of the web with a backing the pile fibers backing layer (melt fiber fleece)

April 25, 2007 is provided. The backside of the primary carrier applied to the pile fibers, preferably a nonwoven, is attached by hydrodynamic watering.

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 means of a latex precoat (the currently generally customary manner), with which at first adequate bonding of the pile layer in the initial backing 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 environmentally harmful both in the manufacture and disposal of 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 possibility is to "glue" the secondary backing together with the latex primer, and it has already been proposed to join the tufted carpet and secondary backing by hydroentanglement, but without latex priming, only insufficient nub-break or loop tear-off resistance is achieved.

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.

Starting from 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 the yarns in the carrier layer.

The object is achieved according to the invention in that, in a first phase, with very dense fiber loops, the poisons introduced into the composite layer

April 25, 2007 p loops are treated with the aid of an aqua jet method or a hydrodynamic needling (or high-pressure steam or compressed air) in such a way that the pile loops on the back of the web are at least partially roughened, opened or split into their individual filaments.

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 inventive web, a carpet produced in this way can be recycled.

For this purpose, it is advantageous that the back of the web material is treated by means of hydrodynamic or with the aid of a steam or compressed air needling, wherein the outstanding on the back of the web pile loops of pile yarns are needled with the fibers of at least one fleece.

An additional possibility, according to a development of the invention, that the needling is carried out with the aid of at least one oscillating nozzle beam. The oscillating movement of the nozzle bar gives the desired roughened surface on the back of the web without adversely affecting the structure of the web.

Further, it is advantageous that the advancing movement of the web or the carrier layer for oscillating movement of the nozzle bar (x divided by y is equal to or less than 1) X: Y <1 or X: Y <2 or X: Y <10.

It is also advantageous that in a further step after the introduction of the Pohlschlingen (13.2) into the composite layer and after applying a further melt fiber layer and needling a heat treatment of the web can be done. As a result, the pile loop can be anchored even better in the web. Due to the water jet treatment, the PoI

April 25, 2007 o loops split into their individual filaments and thus roughened outstanding. A subsequent heat treatment results in a much better bonding, the per se viscous melt with the pile loops. Since the pile loops and the two layers of fused fiber on the underside of the web are already heavily interlocked and much more surface is available for melting, you get a robust pile carpet, from which the filaments of pile loops can not be pulled out.

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 at least selectively with the carrier layer to a composite layer with the aid of a heatable calender or by means of a needling or mechanical needling

b) the pile loops are tufted on the back of the thus prepared composite layer,

c) the pile loops introduced into the back of the carrier or the composite layer are treated hydrodynamically or with compressed air or with steam with the aid of at least one oscillating nozzle beam,

d) thereafter, the further melt fiber layer is applied to the back of the composite layer or the web material with the open Pohl loops,

e) thereafter the melt fiber layers are connected to the pile fiber with the aid of water jet needling or other media,

f) finally, the web is subjected to a drying and / or heat treatment for the purpose of melting the melt fiber and for connection with the individual filaments or the melt fiber and the pile loops with the carrier material.

April 25, 2007 Λ Of particular importance for the present invention is that a spunbonded nonwoven or a staple fiber nonwoven or a ribbon fabric or a composite of the aforementioned materials is used as the carrier layer.

It is also advantageous that are used as melt fibers of 100 ⁰ C to 150 ⁰ C preferably 120 ⁰ C to 130 ⁰ C meltable man-made fibers or biocomponent fibers.

Further, it is advantageous that the web material for tufted carpets, pile rugs and / or plush fabric is formed with a fluffy top, at least from the carrier layer and on its back the fusible fibers comprising fleece, which is connected at least in some places with the carrier layer and a Formed composite layer on the back pile yarns were introduced in the form of pile loops. In addition, it is advantageous for at least one second nonwoven material comprising a carrier layer and a melt fiber layers to be applied to the backside of the composite layer comprising a carrier layer and a melt fiber layers and to be connected thereto and / or with the opened pile loops.

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,

3 shows the web material with a further melt fiber layer and, depending on the embodiment, with a third melt fiber layer,

April 25, 2007 4a-4c is a schematic representation of the individual process 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

Feed movement of the web.

In FIGS. 1 to 4c, denoted by 5 is a composite layer which consists of a carrier layer 12 and of a spunbonded nonwoven, PA ribbon fabric or nonwoven fabric 12.3.

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 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. As a result, the composite layer 5 formed from melt fibers 12. 3 and carrier layer 12 is obtained.

On or in the composite layer 5, the pile fiber or pile loop 13.1 is then tufted. In this case, the pile loops 13.1 are introduced or tufted on the rear side of the carrier layer 12, which then rest relatively close to the lower side or also the rear side 12.1 of the melt fiber layer 12.3 or the carrier layer 12.

The outstanding, but very close to the back 12.1 of the support layer 12 adjacent pile loops 13.1 (Fig. 4b) are treated on the back of a carrier layer 12 by means of an aqua jet method or a hydrodynamic needling or with compressed air or steam, so that the relatively solid roughened on the back or useful side of the support layer 12 adjacent pile loops 13.1 or at least partially open or

April 25, 2007 o be split into their individual filaments and thus 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 the 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 x of the web 10.1 or the carrier layer 12 can be changed to the oscillating movement y of the nozzle bar. Here, X is the advancing movement of the web and Y is the oscillating movement of the nozzle bar, compare the graph of FIG. 5. The pile loops are not separated during needling but merely roughened.

The water jet (FIG. 4b) on the web 10 or on the back of the carrier layer 12 performs a sinusoidal movement, so that a very well roughened, fluffy pile layer is formed, with which the melt fibers 12.3 can make the desired firm connection.

After this process step (FIG. 4 c), the next or second layer in the form of a further melt fiber layer 14 is applied to a top side or back side 12. 1 of the carrier layer 12 of the web 10. Thereafter, the melt fiber layer 14 is connected to the open Pohlschlinge 13.2 hydrodynamically or with the aid of compressed air or steam with the help of needling or water jet needling. 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.

April 25, 2007 The carrier layer 12 may be provided on one or both sides with a melt fiber layer 12.3, 15 and be connected at least punctually 6 with the carrier layer 12 to a 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 thermal bonder oven, wherein first dried and then heat treated at a temperature of about 100 ° to 15O ⁰ C, preferably from 120 ⁰ C to 130 ⁰ C heat treatment becomes. In this way, 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 created (4c).

By the fused to the filaments of the pile loops 13.2 and 12.1 to the back of the carpet backing melt fiber components in conjunction with the other process steps to obtain a very durable carpet.

The carrier layer 12 used is preferably a spunbond or a ribbon fabric. As melt fibers can be used up to about 120 ⁰ C fusible chemical fibers or biocomponent fibers.

The heating of the melt fibers should be chosen so that the heating takes only a very short time and thereby 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

April 25, 2007 g Polschlingen 13.2 a second melt fiber layer 14 is applied to ensure that the melt fiber layer 14 with the open pole loops 13.2 enters into a close connection.

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 also consists of the composite layer 5 formed of two layers, the pile or the opened pile loops 13.2 and a second melt fiber fleece 14. A further or third melt fiber layer 15 can are applied to the top of the carrier 12 (see, dashed line illustration of the melt fiber web 15 in Figures 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 needling device or water jet needling device or another medium, for example a steam jet, or a gas medium or hot air jet.

As a result, more individual fibers penetrate into the back side 12.1 of the Tuftware and between the individual filaments of the opened pile loops 13.2 with the aid of the needling device, for example the oscillating water beam.

April 25, 2007 It is particularly advantageous at low temperatures, for example at a melting temperature of 100 ° to 150 ° C, preferably between 110 ⁰ C and 13O 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 much more filaments come into contact with the melt fibers. 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 finer the melt fiber layer, the better it penetrates into the individual filaments of pile 13.1.

The melt fiber fleece 14 can also be applied by an airlay method on the side with open Pohlschlingen 13.2.

Overall, as already mentioned, with the help of a needling or the Wasserstrahlvernadelung 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 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 the pole loops 13.2 and the filaments of the pile loops 13.2 can not be pulled out.

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

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

April 25, 2007 10 LIST OF REFERENCE NUMBERS

5 composite layer

6 punctuation

10 web goods

10.1 web goods

12 carrier layer, carrier 12.1 rear side

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

13.1 pile, pile fiber

13.2 PolClock, open (Fi I la | ment of the Polschlinge the chemically-technically produced, almost endless fiber as a component of yarns and cables) 14 2. melt fiber, melt fiber layer, fleece

15 3. Melt fiber, melt fiber layer, fleece

16 top of the web

X movement excursion nozzle bar with oscillating movement

Y feed movement of the web 10

April 25, 2007 <j -j

Claims

claims: 1. A method for producing a web (10) for tufted carpets, pile carpets 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 a melt fibers ( 12.3) 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 in that the pile loops (13.1) introduced into the composite layer (5) are treated by means of an aqua jet method or a hydrodynamic sewing such that the pile loops (13.2) protruding and / or at least partly fitting on the back of the web (10) at least partially roughened, opened or split into their individual filaments. 2. The method according to claim 1, characterized in that the rear side (12.1) of the web (10) is treated by means of hydrodynamic or by means of a steam or compressed air needling, wherein the protruding on the back of the web goods Polschlingen (13.2) the pile yarns are needled with the fibers of at least one fleece. 3. The method according to claim 1 or 2, characterized in that the needling is performed by means of at least one oscillating nozzle beam. 4. The method according to claim 1 or 3, characterized in that the advancing movement (Y) of the web or the carrier layer (12) for oscillating movement (X) of the nozzle beam X: Y <1 or X: Y <2 or X: Y < 10 is. April 25, 2007 - | 2 5. The method according to claim 1, characterized in that in a further step after the introduction of Pohlschlingen (13.2) in the composite layer (5) and after placing a further melt fiber layer (14) and the needling a heat treatment of the web (10) can take place , 6. A method for producing a web (10) with a fluffy top (16) according to claim 1, 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 needling or mechanical needling at least selectively (6) with the carrier layer (12) to form a composite layer (5) be connected b) the pile loops (13.1) are tufted onto the rear side (12.1) 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) thereafter the further melt fiber layer (14) is applied to the rear side of the composite layer (5) or the web product (10) with the opened pile loops (13.2), e) thereafter, with the aid of water jet needling or other media, the melt fiber layers (12.3, 14) are joined to the pile fiber (13.1), f) finally, the web (10) is subjected to drying and / or heat treatment. April 25, 2007 * o 7. The method according to any one of the preceding claims, characterized in that the carrier layer (12) is a spunbond or a staple fiber fleece or a fabric or a ribbon fabric or a composite of the aforementioned materials is used. 8. 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 12O ⁰ C to 130 ⁰ C fusible chemical fibers or biocomponent fibers are used. 9. web (10) for tufted carpets, pile rugs and / or plush fabric with a fluffy top, wherein the web (10) at least from the carrier layer (12) and on its back the fusible fibers comprising fleece is formed, at least in some places is connected to the carrier layer (12) and the composite layer (5) forms on the back (12.1) pile yarns in the form of pile loops (13.1) were introduced, characterized in that on the back of a carrier layer (12) and a Fibrous fiber layers (12.3) having composite layer (5) at least a second melt fibers comprehensive fleece (14) is applied and connected to this and / or with the open Pohlschlingen (13.2). April 25, 2007 14