EP0055362A1 - Process for producing a textile sheet material and the textile product so produced - Google Patents

Abstract

A textile flat structure is manufactured by needle processing of a pile yarn tufted into a carrier layer so that some pile loops of the pile yarn forming an upper layer are engaged by needles and their height and shape are changed, whereas at least one pile yarn is pulled toward the carrier layer, whereby a texture and/or pattern is produced. The textile flat structure has a carrier layer, a pile yarn tufted into the carrier layer and having pile loops at an upper side of the carrier layer and connecting base loops at a lower side thereof, whereas the pile loops forming an upper layer have at least non-uniform different heights.

Description

The invention relates to a method for producing a textile fabric with a structure and / or pattern on its top, in which pile yarn is tufted into a carrier layer, so that pile loops protrude from an upper layer and base loops are present on the back of the carrier layer, and a fabric made using the process.

It is known to produce structured, tufted textile fabrics by tufting the pile yarn with different pile heights into the carrier layer so that the pile loops are not at the same height and a high-low structure can be produced. The pole heights are uniformly different, ie areas with a uniformly low pole height alternate with areas with a higher pole height. Such a uniform high-low structure is due to the predetermined arrangement or setting of the tufting device, by means of which alternately uniformly high and low pole loop regions can be achieved. There is also the further disadvantage that the production of different pole heights in order to achieve a desired pattern and / or structure is coupled with the tufting process and is therefore not only tied to the tufting process itself but also to the previously mentioned tufting device. A change of pattern therefore requires extensive changes to the Tufting process, or its preparation and working conditions. The known tufted products are therefore limited to predetermined, uniform structures and / or patterns.

It is also known (DE-OS 2452136) to manufacture a top layer of pile loops by tufting a pile yarn into a backing layer and to needle individual fibers from a bottom layer into free spaces of the top layer through the backing layer. This is intended to achieve full coverage of the product, which has an extremely low pile weight. However, very specific work is required to completely fill the free spaces with a large amount of individual fibers. Patterning possibilities of such textile fabrics are limited to the properties of the needled, openly protruding individual fibers, which should give the top layer the appearance of a tip-shear article or an open-pole article with a uniform structure.

It is the object of the present invention to create a manufacturing method of the type mentioned at the beginning for a textile fabric without the disadvantages of the known manufacturing methods, with which a tufted product with a structure and / or pattern can be produced independently of material that has already been tufted or complex tufting processes and with which a textile fabric is to be created which can be structured and / or patterned in a variety of ways on its upper side.

In the method of the type mentioned at the outset, the object is achieved in that some of the protruding pole loops are gripped by needles pushed through the carrier layer and their pole height and shape are changed, with at least one non-gripped pole loop connected to the gripped pole loop via the common base loop is drawn in in the direction of the carrier layer.

With the method according to the invention, therefore, the pile height and shape change can be carried out in a surprising manner subsequently on an already tufted product and the textile fabric with a structure and / or pattern, e.g. a high-low structure. The gripping of the pole loops according to the invention can advantageously produce an irregular structure that cannot be achieved by tufting alone. In particular, the nature and character of the top of the tufted textile fabric can be changed in a simple manner, namely by simply inserting needles from the back of the carrier layer. The method therefore meets the requirement of generating a diverse structure and / or pattern regardless of the starting product which has already been tufted.

It is therefore advantageously possible to create a textile fabric with pile yarn tufted into a carrier layer, which forms a top layer with protruding pile loops on the upper side of the fabric and in which the top layer has at least uneven, different pile heights of the pile loops.

This creates a product in which the different pile heights of the pile loops alternate unevenly and e.g. there can be arbitrarily different pole heights, so that e.g. one can speak of "anarchically" existing pole heights. The textile fabric allows a wide range of applications and is e.g. can be used in particular as a floor or wall covering or decorative or upholstery fabric in which a structure and / or pattern is desired. As a result of the tufted pile yarn and the change in pile height and shape due to needling, the textile fabric is preferably in non-woven form.

The pole loops gripped are increased in their pole height, for example, and at least one pole loop that is not gripped is reduced in their pole height, for example. The different _P heights can be non-uniform, for example randomly distributed in the top layer of the fabric. In this case, the adjacent pole loop which has not been gripped can also be withdrawn entirely in or even through the carrier layer, so that a particularly pronounced uneven high-low structure can be achieved. An irregular structure can be produced, which can be similar to a structure made from a ply yarn, for example, as is used for a carpet. To increase the pile height or to change the shape of the pile loop, a replenishment of pile yarn is required. A portion of the pile yarn can therefore be pulled over the common base loop from at least one non-gripped pile loop, since the pile loops can be tufted so that they can be pulled out, that is to say unsecured in the carrier layer and therefore unfixed therein.

The shape of the pile loops can be changed in a particularly advantageous manner by gripping the needles, which can capture the pile loops in such a way that they are, for example, grubbed, plucked or roughened. In this way, the shape of the pole loops can be made uneven, for example defaced, and a further configuration of the structure and / or pattern can be achieved. Normal felting needles with barbs or special felting needles, such as conventional sidehoc needles, fork needles or loop needles, such as are available from Singer Spezialnadelfabrik GmbH, D 5102 Würselen, can be used as needles. After piercing through the carrier layer, the pole loops can be gripped at any point with such needles and their pole height and shape can be influenced in the process. By changing the shape, for example defacing the pile loops, for example in the presence of a pile yarn made of synthetic fibers or filaments, for example multifilaments, the uniform appearance of the synthetic material can be eliminated and the appearance of a natural yarn spun from fibers can be achieved. After needling, ie, for example, by simply inserting the needles from the back, the pole loops can also be bent to the side, so that, for example, they are essentially horizontal Can take direction. A further structural revitalization can be achieved in this way. A further reinforcement of the structuring can also be achieved by increasing the pole height of the gripped pole loops with an unequal length, as a result of which a further disfigurement and / or anarchic arrangement of the same can be achieved.

Depending on the needle density, more or less of the pole loops can be gripped and the non-gripped pole loops can be withdrawn. The pile loops can be gripped, for example, with a needle density of 5 to 80, preferably 20 to 30, punctures / cm ² , and, for example, 20 to 30% of the pile loops / m ^{2 of} the fabric can be gripped. The textile fabric can therefore have, for example, 20-30% of the pile loops with a greater pile height than the other pile loops. The pole loops with the larger pole height can have the irregular shape or shape described above. The pole height of the pole loops can be increased, for example, by 20-100% compared to an original pole height. If the original pole height is, for example, 3 mm, it can be increased or lengthened to, for example, 5-6 mm using the method according to the invention.

It can ei _- nem finished, already tufted product be assumed and the same according to the invention are needled. The tufted product can therefore be stored in an advantageous manner and processed with the method according to the invention for the respective production of the patterned and / or structured textile fabric. However, it may etuftet the pile yarn in the backing layer ^g in successive operations and, for example, after the pile height and shape of the Folschlingen changed by the needles of the back of the carrier layer immediately forth. This brings the advantage, for example, that .; the textile fabric manufactured according to the invention can be manufactured continuously at one production site: The tufted starting product can have pole loops with the same or different polar heights, as can be achieved, for example, by the known tufting process described at the beginning.

In another embodiment of the method, after the pile yarn has been tufted, a fiber material from a lower layer can be needled through the carrier layer into the upper layer with the pile loops in such a way that after changing the pile height and shape, at least some spaces in the upper layer are caused by needling of delimited fiber structures can be filled out. This enables a textile fabric to be achieved in which the pile loops are mixed with delimited fiber structures, some of which are still in the underlayer and / or carrier layer and can be anchored there. Such a process and product is described, for example, in the previously unpublished CH-PS No. (corresponding to CH patent application No. 9 506 / 80.-5 filed on December 23, 1980, entitled "Process for the Production of a Nonwoven Textile Fabric, and also a Product Manufactured with it Flat structures ") described, to which reference is made here for a more detailed explanation. In this way, a further possibility for structuring and / or patterning can be achieved, which can also be designed in color if the delimited fiber structures have, for example, a different color than the material of the pile loops or even a different color from one another. The delimited fiber structures can be present not only in the top layer itself, that is to say, for example, between the pile loops thereof, but also on the top side or even on the top side thereof, so that a variety of structuring and / or patterning options can exist. In this context, reference is again made to the previously mentioned CH-PS No. for further explanation. The delimited fiber structures can, for example, be needled into the upper layer at points of the pile loops with a reduced pile height. This makes it possible, for example, to specifically fill or fill in deep pole points, as may be caused by the reduced pole loops. For example, structures and / or patterns which are strongly optically distinctive can thus be achieved. In particular, ball yarns made of spherically entangled fibers or threads can be needled as the delimited fiber structures into free spaces of the upper layer, which are present, for example, between the pile loops. but can only be created by the needles when needling according to the invention. Due to the needling of ball yarns from the back, a dot-like or spot-like pattern can advantageously be achieved. The ball yarns are known, for example, from EP publications 0013427 and 0013428, to which reference is also made here for a more detailed explanation.

• Fig. 1 einen Teil eines getufteten textilen Flächengebildes in schematischer Darstellung im Schnitt,
• Fig. 2 das textile Flächengebilde von Fig. 1 mit veränderter Polhöhe.,
• Fig. 3 einen Teil eines anderen getufteten textilen Flächengebildes mit veränderter Polhöhe und Form in schematischer Darstellung im Schnitt und
• Fig. 4 einen Teil eines weiteren getufteten textilen Flächengebildes in schematischer Darstellung im Schnitt.

The invention is explained below in exemplary embodiments with reference to the drawing. Show it:

• 1 shows a part of a tufted textile fabric in a schematic representation in section,
• 2 shows the textile fabric of FIG. 1 with a modified pile height.
• Fig. 3 shows a part of another tufted textile fabric with changed pile height and shape in a schematic representation in section and
• Fig. 4 shows a part of another tufted textile fabric in a schematic representation in section.

According to FIG. 1, a pile yarn 1 is tufted into a carrier layer 2, so that an upper layer 4 with protruding pile loops 5 is formed on its upper side 3, has the same pile height H and is connected via base loops 6 on the lower side 7 of the carrier layer 2. In the tufted product thus produced in a known manner, needles are inserted from the bottom side 7 through the carrier layer 2, which are arranged in such a way that some of the pole loops 5 are gripped and changed, in particular are pushed out from the carrier layer 2. Needling leads to a textile fabric 8, as shown in FIG. 2, in which the same parts as in FIG. 1 have the same reference numerals.

Pole loops 5a seized during needling are increased in their pole height, i.e. the pole height of the latter is greater than the pole height H before needling, as is shown for comparison by the pole loop 5 shown in dashed lines in FIG. 2 from FIG. At the same time, at least one other pole loop 5b that was not gripped by the needles, i.e. in an area without needle insertion or detection by the needles and which is connected to the respective pole loop 5a via the respective base loop 6, reduced in its pole height compared to the original pole height H. This reduction in the pile height of the non-gripped pile loop 5 b takes place in that, when the pile height of the pile loop 5 a seized has been increased, a portion of the pile yarn 1 has been drawn or delivered via the common base loop 6 from at least one pile loop 5 b not gripped. The pole heights of both the pole loops 5a and the pole loops 5b are different from one another.

A textile fabric 8 is thus created, the top side 9 of which has uneven, different pile heights, which are distributed unevenly or irregularly, for example arbitrarily. When needling, however, there is also a change in shape of the pole loops 5 of FIG. 1, as the pole loops 5a shown show. When the pole loops 5 are gripped and pushed out, the needles can influence the loop shape and change them more or less, for example unevenly. Here, the pile yarn 1 is attacked, for example, more or less easily, so that tufts of fibers 10 have formed on the pile loops 5a. This favors, for example, the formation of a structured surface and, for example, gives a product the appearance of natural fiber material if the pile yarn 1 consists, for example, of synthetic fiber material. The design of the pile loops 5a gripped depends, for example, on the type of pile yarn or the original pile loop 5, for example their arrangement or density, or on the needling conditions, for example the type of needles. The textile fabric 8 therefore has a structure and / or pattern that is characterized by the different pile heights _P olschlingen 5a and 5b, and is characterized by the irregular shape of the pile loops 5a.

In the case of a textile fabric 11 according to FIG. 3, a pile yarn 12 is tufted into a carrier layer 13. On the upper side 14 of the carrier layer 13 there is an upper layer 15 with projecting pole loops 16 and 17, which are connected on the underside 18 of the carrier layer 13 via base loops 19. After the pile yarn 12 had been tufted, a product according to FIG. 1 being obtained, needles were inserted from the carrier layer 13, as described in connection with FIGS. 1 and 2 in the above exemplary embodiment, so that the pile loops 16 and 17 have different pile heights . When needling, pole loops corresponding to pole loops 16 were gripped by needles and increased in their pole height. In contrast, pole loops that were not used and correspond to pole loops 17 were reduced in their pole height, i.e. drawn in in the direction of the carrier layer 13. Due to the needling, the pole loops 16 in turn have an irregular shape and fiber tufts 20, which are created by gripping by means of the needles, as was described above in the exemplary embodiment for FIGS. 1 and 2. Due to the irregular shape, in addition to the different and arbitrarily irregular pile heights, a structure is created that the textile fabric 10 e.g. that can give plucked, scrubbed or roughened appearance.

FIG. 4 also shows a textile fabric 21 with a pile yarn 22, which is tufted into a carrier layer 23, so that in a top layer 24 there are pile loops 25 and 26 which are connected by base loops 27. The previously tufted product was needled from the carrier layer 23 by inserting needles, as was described above in the exemplary embodiment for FIGS. 1 and 2, wherein the tufted product according to FIG. 1 can again be assumed. The pole loops 25 gripped by the needles have a greater pole height than the pole loops 26 not gripped by the needles. The pole loops 25 are in the upper layer 24 preferably distributed arbitrarily and irregularly and have different pole heights among themselves, which is also the case with the pole loops 26 which are not engaged. The different pole heights of the pole loops 25 and 26 are distributed non-uniformly or irregularly, so that an irregular structure or a structure and / or pattern with an irregular appearance is produced.

Between the pile loops 25 and 26 and also on and on the upper side 28 of the upper layer 24 there are delimited fiber structures in the form of ball yarns 29 made of spherically entangled fibers or threads. To insert the ball yarns 29 after needling the previously tufted product, i.e. after producing the pile loops 25 and 26 with the different pile heights, an underlayer 30 is placed on the underside 31 of the carrier layer 23, in which the ball yarns 29 are embedded in a fiber material 32 for arrangement on the underside 31. The ball yarns 29 are gripped by needles and e.g. pushed like a packet through the carrier layer 23. When grasped by the needles and forced through the carrier layer 23, e.g. tail or neck-like tufts of fibers 32, with which the ball yarns 29 in the lower. layer 30 and the support layer 23 remain anchored and are thus attached. The introduction of delimited fiber structures is described in detail in the already mentioned CH-PS No., which is why reference is made to the same at this point for a more detailed explanation.

.The ball yarns 29 can for example fill or fill in vacancies between the pile loops 25 and 26 or over the pile loops 26 with the smaller pile height. The textile fabric 21 therefore has a structure and / or pattern which is characterized by a combination of the different pile heights of the pile loops 25 and 26 with the ball yarns 29 introduced. The needling to produce the pile loops 25 and 26 with different pile heights and the introduction of the ball yarns 29 into the upper layer 24 can therefore be used to achieve versatile, novel structures and / or patterns. For clarity of illustration, the pole loops are shown in FIGS. 1-4 and also in FIG. 4, for example, the delimited fiber structures are shown schematically. In fact, they can be at different distances from one another or with different dimensions and, for example, be closer or closer together.

Claims (19)

1. A method for producing a textile fabric with a structure and / or pattern on its top, in which pile yarn is tufted into a carrier layer so that pile loops protrude from an upper layer and base loops are present on the back of the carrier layer, characterized in that some of the protruding pole loops are gripped by needles pushed through the carrier layer and their pole height and shape are changed, at least one non-gripped pole loop connected to the respective pole loop being pulled in via the common base loop in the direction of the carrier layer. 2. The method according to claim 1, characterized in that the pile loops seized increases in their pile height and at least one pile loop not seized is reduced in pile height, a portion of the pile yarn required to enlarge the pile height via the common base loop made of at least one pile loop not seized is tightened. 3. The method according to claim 1 or 2, characterized in that the gripped pole loops have an irregular shape, e.g. plucked, grubbed or roughened. 4. The method according to claim 1 or 2, characterized in that the pole heights of the gripped pole loops are increased with an unequal length. 5. The method according to claim 1, characterized in that the pile loops are taken with a needle density of 5 - 80, preferably 20 - 30 punctures / cm ² . 6. The method according to claim 1 or 5, characterized in that 20 - 30% of the pile loops / m ^{2 of} the fabric are taken. 7. The method according to claim 1 or 2, characterized in that the pole height. Of the pole loops is increased by 20-100% of the original pole height. 8. The method according to claim 1 or 2, characterized in that the pile yarn is tufted in the carrier layer in successive operations and then at least the pile height of the pile loops is increased by needling from the back of the carrier layer. 9. The method according to claim 1, in which after the tufting of the pile yarn, a fiber material is needled from a lower layer through the carrier layer into the upper layer with the pile loops, characterized in that after the change in pile height and shape at least some spaces in the upper layer by Needles of defined fiber structures are filled in. 10. The method according to claim 9, characterized in that the delimited fiber structures are needled into the upper layer at points of the pile loops with a reduced pile height. 11. The method according to claim 9 or 10, characterized in that ball yarns made of spherically entangled fibers or threads as the delimited fiber structures in the e.g. free spaces of the upper class are needled into it. 12. Textile fabric with a pile thread tufted into a carrier layer, which forms an upper layer with protruding pile loops on the upper side of the fabric, produced by the method according to one of the claims 1 to 11, characterized in that the upper layer has at least uneven, different pile heights of the pile loops. 13. Textile fabric according to claim 12, characterized in that the different pile heights are uneven, e.g. arbitrary, distributed. 14. Textile fabric according to claim 12, characterized in that 20 - 30% of the pile loops / m2 of the fabric have a greater pile height than the other pile loops. 15. Textile fabric according to claim 14, characterized in that the pile loops with the larger pile height have an irregular shape, e.g. have a plucked, grubbed or roughened shape. 16. Textile fabric according to claim 12, in which there is an underlayer from which fiber material extends through the carrier layer into the upper layer with the pile loops, characterized in that the pile loops are present with mixed fiber structures originating from the underlayer, which are mixed with a Part are anchored in the lower layer and / or carrier layer. 17. Textile fabric according to claim 16, characterized in that the delimited fiber structures between or on the pile loops, e.g. on top of the top layer. 18. Textile fabric according to claim 16, characterized in that the delimited fiber structures are spherical yarns made of spherically entangled fibers or threads. 19. Textile fabric according to claim 16, characterized in that the delimited fiber structures present mixed with the pile loops differ in their shape from those in the lower layer.

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