EP1233097B1 - Substrate for tufted carpet and process of manufacturing - Google Patents

Substrate for tufted carpet and process of manufacturing Download PDF

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Publication number
EP1233097B1
EP1233097B1 EP01130147A EP01130147A EP1233097B1 EP 1233097 B1 EP1233097 B1 EP 1233097B1 EP 01130147 A EP01130147 A EP 01130147A EP 01130147 A EP01130147 A EP 01130147A EP 1233097 B1 EP1233097 B1 EP 1233097B1
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EP
European Patent Office
Prior art keywords
filaments
fibres
tufting
dtex
tufting base
Prior art date
Legal status (The legal status 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 status listed.)
Expired - Lifetime
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EP01130147A
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German (de)
French (fr)
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EP1233097A1 (en
Inventor
Peter Sander
Detlef Barbier
Ulrike Maass
Engelbert Löcher
Ararad Dr. Emirze
Klaus Klein
Christine Dr. König
Rudolf Gärtner
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Carl Freudenberg KG
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Carl Freudenberg KG
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Publication of EP1233097A1 publication Critical patent/EP1233097A1/en
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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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
    • D04H3/033—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random reorientation immediately after yarn or filament formation
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • 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
    • 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
    • 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
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin 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
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/04—Treatments by energy or chemical effects using steam
    • 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
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1628—Dimensional stability
    • 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
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/3187—Triaxially woven fabric

Definitions

  • the object of the invention has been found to provide a tufting, which consists of a spunbonded fabric with low raw material costs without reinforcing yarns, - scrim, wherein the binding without (costly) auxiliary components such as binder fibers or binder takes place.
  • the tufting carrier should continue to be a high Have dimensional stability in the tufting and dyeing process and ensure good carpet yarn incorporation.
  • a tufting carrier which consists only of polyethylene terephthalate.
  • the production of a uniform material simplifies the reusability.
  • the calendering of the fixed fabric was carried out with an embossing roller, which produced a printing area of 18% with 33 diamond-shaped engraving points per cm 2 .
  • Calender surface temperature and line pressure were 220 ° C and 20 daN / cm, respectively.
  • the drying of the spunbond fabric finished with Avivage was carried out in a flat belt dryer at the air temperatures of 110 ° C.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Nonwoven Fabrics (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Automatic Embroidering For Embroidered Or Tufted Products (AREA)

Abstract

Only fibers or filaments with a weight of 1-15dtex are included in the tuft carrier. The weight/unit area of the tuft carrier is 70-110g/m<2>, density 0.18-0.28g/m<3> and the 5% modulus value in the processing direction is NOTLESS 60N/5cm and is preferably NOTLESS 0.6N/g/m<2>. An Independent claim is made for a process for production of the tuft carrier from a spun fleece of thermoplastic fibers or filaments. Fibers weighing 6-15dtex are needled together and those weighing 1-5dtex are hydrodynamically treated to consolidate. Prior to drying and setting the fleece is stretched longitudinally by NOTGREATER 30%, the relative movement of fibers being improved by addition of oil or other lubricants. Preferred Features: Preferred fiber or filament weight is 3-12dtex and 5% modulus value is 70-100N/5cm and NOTLESS 0.7-1.0N/g/m<2>.

Description

Die Erfindung betrifft einen Tuftingträger und ein Verfahren zur Herstellung eines Tuftingträgers aus zu einem Spinnvlies verarbeiteten thermoplastischen Polymerfasern oder -filamenten.The invention relates to a tufting carrier and to a method for producing a tufted carrier from thermoplastic polymer fibers or filaments processed into a spunbonded nonwoven.

Aus dem Dokument EP-A 079 56 37 ist die Verwendung von Vliesstoffen aus Polyester- und Copolyester-Fasern als Tuftträger von Tuftteppichen bekannt, die durch parallel verlaufende, gerade, lastaufnehmende Kunststoff-Endlosfäden verstärkt sind. Durch diese Maßnahme soll trotz eines Flächengewichtes von nur 80 bis 150 g/m2 ein Tuftträger erhalten werden, der gegen Spannungs-, Temperatur- und Feuchteinwirkungen beim Färben, Tuften und Dämpfen während der Herstellung und der Verarbeitung zu Tuftteppichen insbesondere bezüglich des Breitenschwundes resistent ist.From the document EP-A 079 56 37 is the use of nonwoven fabrics of polyester and copolyester fibers known as Tuftträger Tuftteppichen which are reinforced by parallel, straight, lastaufnehmende plastic filaments. By this measure, despite a basis weight of only 80 to 150 g / m 2, a tuft carrier is obtained, which is resistant to stress, temperature and humidity effects during dyeing, tufting and steaming during manufacture and processing Tuftteppichen especially with respect to the latent shrinkage ,

Weiterhin ist aus dem Dokument DE-U 94 11 993 ein Vliesstoff zur Beschichtung von Teppichrücken bekannt, bei dem das verfestigte Elementarfaservlies mit einem Flächengewicht von 20 bis 220 g/m2 durch ein Maliwatt-Verfahren mit Kettfäden aus Folienbändchen verstärkt wird. Dadurch soll der Trittkomfort, die Verbindung mit dem Teppichgewebe, die Form des Teppichs und seine Rezyklisierbarkeit verbessert werden.Furthermore, from the document DE-U 94 11 993 a nonwoven for coating carpet backing, in which the solidified staple fiber nonwoven fabric having a basis weight of 20 to 220 g / m 2 is reinforced by a Maliwatt process with warp threads of film tapes. This is to improve the comfort, the connection with the carpet, the shape of the carpet and its recyclability.

Aus den Dokumenten DE-A 195 01 123 und DE-A 195 01 125 Verfahren bekannt, die durch einen Reckprozeß im Reckungsbereich von 100 bis 400 % sowohl in Längs- als auch in Querrichtung zu einer höheren Festigkeit des Vlieses führen und die Dehnung sowie den Restschrumpf reduzieren sollen. Vorzugsweise soll dadurch jedoch bei vorgegebenen Werten für die Dehnung und den Restschrumpf der Vliesbahnen deren Flächengewicht reduziert werden. Allerdings führt der angegebene Grad der Verstreckung in Verbindung mit einer dadurch hervorgerufenen Verstreckung der Fasern selbst zu einer wesentlichen Einschränkung der Beweglichkeit der Fasern im Vlies, wodurch der Tuftprozess beeinträchtigt wird.From the documents DE-A 195 01 123 and DE-A 195 01 125 Process known by a stretching process in the stretch range of 100 to 400% both in the longitudinal and in the transverse direction to a higher strength of the fleece and should reduce the elongation and the residual shrinkage. Preferably, however, this is to be reduced at given values for the elongation and the residual shrinkage of the nonwoven webs whose weight per unit area. However, the stated degree of stretching, in conjunction with the resulting stretching of the fibers themselves, substantially limits the mobility of the fibers in the web, thereby affecting the tufting process.

Aus dem Dokument JP-A 10-273865 sind Tuftingträger bekannt, die aus kontinuierlichen Filamenten eines thermoplastischen Kunstharzes bestehen und eine thermische Schwindung in Querrichtung bei trockener Erwärmung im Bereich von -10 bis 0 % gemessen gemäß JIS L 1906 zeigen. Die Tuftingträger sind dazu aus einer hochschmelzenden und einer niedrigschmelzenden Komponente aufgebaut.From the document JP-A 10-273865 For example, tufted supports consisting of continuous filaments of a thermoplastic resin and exhibiting transverse transverse thermal shrinkage with dry heating in the range of -10 to 0% measured according to JIS L 1906 are known. The tufting carriers are constructed from a high-melting and a low-melting component.

Das Dokument WO 96/29460 offenbart getuftete Teppiche, die aus einem Tuftingträger und einem klebenden Binder bestehen. Der Binder soll dabei vorzugsweise ein thermoplastisches Polymer sein, das auf den Tuftingträger aufgebracht oder mit ihm verbunden ist.The document WO 96/29460 discloses tufted carpets that consist of a tufted backing and an adhesive binder. The binder should preferably be a thermoplastic polymer, which is applied to the tufted carrier or connected to it.

Das Dokument DE 198 21 848 A1 beschreibt einen hochfesten, leichten Tuftingträger aus Spinnvlies und ein Verfahren zu seiner Herstellung aus synthetischen Fäden, der mit energiereichen Wasserstrahlen derart verfestigt wird, dass er eine spezifische Festigkeit in Längsrichtung von mindestens 4,3 N/5 cm pro g/m2 Flächenmasse sowie einen Anfangsmodul bei 5 % Dehnung von mindestens 0,45 besitzt.The document DE 198 21 848 A1 describes a high-strength, lightweight tufting backing of textile fleece and a method for its production of synthetic threads, which is solidified with high-energy water jets in such a way that it has a specific strength in the longitudinal direction of at least 4.3 N / 5 cm per g / m 2 basis weight and Initial modulus at 5% elongation of at least 0.45.

Die Erfindung hat sich die Aufgabe gestellt, einen Tuftingträger anzugeben, der aus einem Spinnvlies mit geringen Rohstoffkosten ohne Verstärkungsgarne , - gelege besteht, wobei die Bindung ohne (kostenträchtige) Hilfskomponenten wie Bindefasern oder Binder erfolgt. Der Tuftingträger soll weiterhin eine hohe Dimensionsstabilität beim Tuft- und Färbeprozess besitzen und eine gute Teppichgarneinbindung sicherstellen.The object of the invention has been found to provide a tufting, which consists of a spunbonded fabric with low raw material costs without reinforcing yarns, - scrim, wherein the binding without (costly) auxiliary components such as binder fibers or binder takes place. The tufting carrier should continue to be a high Have dimensional stability in the tufting and dyeing process and ensure good carpet yarn incorporation.

Die Erfindung hat sich weiterhin zur Aufgabe gestellt, ein Verfahren zur Herstellung eines Tuftingträgers anzugeben, dass unter Vereinfachung des Produktionsverfahrens preiswerte, leichte Vliesstoffe mit Flächengewichten von 70 bis 110 g/m2 als Tuftingträger verfügbar macht, wobei durch das Verfahren eine verbesserte Dimensionsstabilität erzielt werden.The invention has also set itself the task of providing a method for producing a Tuftingträgers that makes simplifying the production process inexpensive, lightweight nonwovens with basis weights of 70 to 110 g / m 2 available as tufting, whereby the method improved dimensional stability can be achieved ,

Erfindungsgemäß wird die Aufgabe dadurch gelöst, dass der Tuftingträger aus synthetischen Fasern oder Filamenten besteht, die dreidimensional miteinander verschlungen sind, wobei nur Fasern oder Filamente mit einem Titer von 1 bis 15 dtex enthalten sind, das heißt, dass der Tuftingträger ohne zusätzliche Bindekomponente hergestellt und damit umweltfreundlich ist. Weiterhin wird auf Verstärkungshilfsmittel wie Garne oder Gelege verzichtet. Das Flächengewicht des Tuftingträgers beträgt 70 bis 110 g/m2, seine Dichte 0,18 bis 0,28 g/cm3 und der 5% Modulwert in Maschinenlaufrichtung > 60 N / 5 cm jedoch mindestens 0,6 N/g/m2. Der Tuftingträger ist formstabil bei der Weiterverarbeitung im Tuft- und Färbeprozeß.According to the invention, the object is achieved in that the tufting is made of synthetic fibers or filaments, which are entwined three-dimensionally with each other, only fibers or filaments are included with a titer of 1 to 15 dtex, that is, the tufted carrier without additional binder component and so that it is environmentally friendly. Furthermore, is dispensed with reinforcing aids such as yarn or scrim. The basis weight of the tufting carrier is 70 to 110 g / m 2 , its density 0.18 to 0.28 g / cm 3 and the 5% modulus value in the machine direction> 60 N / 5 cm, but at least 0.6 N / g / m 2 , The tufting carrier is dimensionally stable during further processing in the tufting and dyeing process.

Vorteilhafterweise ist der Tuftingträger einer, bei dem die Fasern oder Filamente mit einem Titer von 3 bis 12 dtex besitzen, wobei der 5% Modulwert in Maschinenlaufrichtung 70 bis 100 N/ 5 cm jedoch mindestens 0,7 bis 1,0 N/g/m2 beträgt.Advantageously, the tuft carrier is one in which the fibers or filaments have a denier of 3 to 12 dtex, with the 5% modulus in the machine direction being 70 to 100 N / 5 cm but at least 0.7 to 1.0 N / g / m 2 .

In einer vorteilhaften Ausgestaltung der Erfindung ist der Tuftingträger mit Avivagen oder oberflächenaktiven Substanzen ausgerüstet. Die Ausrüstung erleichtert die Einbringung des Polgarns beim Tuftprozess.In an advantageous embodiment of the invention, the tufting carrier is equipped with lubricants or surface-active substances. The equipment facilitates the insertion of the pile yarn during the tufting process.

Besonders bevorzugt ist ein Tuftingträger, der nur aus Polyethylenterephthalat besteht. Die Herstellung aus einem einheitlichen Material vereinfacht die Wiederverwertbarkeit.Particularly preferred is a tufting carrier which consists only of polyethylene terephthalate. The production of a uniform material simplifies the reusability.

In gleicher Weise bevorzugt ist ein Tuftingträger, der nur aus Polypropylen besteht. Ein solcher Tuftingträger ist recyclefähig.Equally preferred is a tufting carrier which consists only of polypropylene. Such a tufting carrier is recyclable.

Das erfindungsgemäße Verfahren zur Herstellung eines Tuftträgers aus zu einem Spinnvlies verarbeiteten thermoplastischen Polymerfasern oder - filamenten ist dadurch gekennzeichnet, dass die Fasern oder Filamente mit einem Titer von 6 bis 15 dtex durch Vernadeln und die mit einem Titer von 1 bis 5 dtex durch Wasserstrahlen oder durch eine Kombination dieser Verfahren verfestigt werden und vor der Trocknung und Thermofixierung ein Recken in Längsrichtung um bis zu 30 % erfolgt, wobei die Beweglichkeit der Fasern ggf. durch den Zusatz von Öl oder sonstigen Avivagen verbessert wird.The inventive method for producing a Tuftträgers from spunbonded thermoplastic polymer fibers or - filaments is characterized in that the fibers or filaments with a titer of 6 to 15 dtex by needling and those with a titer of 1 to 5 dtex by water jets or by a combination of these methods are solidified and prior to drying and thermosetting stretching in the longitudinal direction by up to 30%, whereby the mobility of the fibers is possibly improved by the addition of oil or other finishing agents.

Vorteilhafter Weise wird der Reckprozeß zwischen den einzelnen Vernadlungsstufen oder nach Abschluß des Vernadelungsprozesses vorgenommen. Der Reckprozeß erfolgt im nassen Zustand kalt oder durch Dampf beheizt (100°C).Advantageously, the stretching process is performed between the individual Vernadlungsstufen or after completion of the needling process. The stretching process is cold or heated by steam (100 ° C) when wet.

Zur Verbesserung der Modulwerte, der Oberflächeneinbindung und der Dickengleichmäßigkeit kann nach der Thermofixierung eine partielle Kompaktierung mittels Prägewalzen vorgenommen, wobei die Gravurpunkte der Prägewalze eine Druckfläche von 18 % bis 25 % einnehmen und eine Rauten-, Linien- oder hexagonale Form bilden.To improve the module values, the surface integration and the thickness uniformity, a partial compaction by means of embossing rolls can be carried out after heat-setting, wherein the engraving points of the embossing roll occupy a printing area of 18% to 25% and form a diamond, line or hexagonal shape.

Die Prägewalzen können eine unregelmäßige Oberflächen-Struktur mit einer Rauhtiefe von 40 bis 100 µm aufweisen.The embossing rollers may have an irregular surface structure with a roughness of 40 to 100 microns.

Die erfindungsgemäß hergestellten Tuftträgervliese weisen folgende Eigenschaften auf:

  • einen Einsprung bei der Teppichherstellung von maximal 5 % und
  • einen Anfangsmodul von 0,6 bis 1,0 N/g/m2.
The Tuftträgervliese produced according to the invention have the following properties:
  • an entrance in the carpet production of a maximum of 5% and
  • an initial modulus of 0.6 to 1.0 N / g / m 2 .

Die Erfindung wird durch die nachfolgenden Beispiele genauer erläutert:The invention is explained in more detail by the following examples: Beispielexample Herstellungsschritte für ein 90 g/m2 100% Polyethylenterephthalat (PET) SpinnvliesProduction steps for a 90 g / m 2 100% polyethylene terephthalate (PET) spunbonded web a) Halbmaterial (Flächenware)a) semi-finished material (fabric)

Das Ausspinnen von PET-Fasern und Ablegen derselben auf einem Siebband zu einem Spinnvlies erfolgte mit einer Bandgeschwindigkeit von 15 m/min. Hierzu wird ein handelsüblicher PET-Rohstoff mit einer Lösungsviskosität (Intrinsic viscosity - IV-Wert) von 0,67 eingesetzt. Die gesponnenen Filamente haben einen Titerwert von 4,3 dtex mit Festigkeits- und Dehnungswerten von 30 mN/dtex beziehungsweise 110 %. Der Kochschrumpfwert der Filamente lag unter 1%.The spinning out of PET fibers and depositing them on a sieve belt into a spunbonded web took place at a belt speed of 15 m / min. (I ntrinsic v iscosity - IV value) For this purpose a commercially available PET raw material having a solution viscosity of 0.67 is used. The spun filaments have a denier of 4.3 dtex with strength and elongation values of 30 mN / dtex and 110%, respectively. The boiling shrinkage value of the filaments was less than 1%.

b) Vorverfestigungb) preconsolidation

Die Vorverfestigung der Flächenware erfolgte durch Vernadelung, wobei die Einstichtiefe bei 6mm und die Einstichdichte bei 60 E/cm2 lag. Die eingesetzten Nadeln 15x18x40 waren von der Fa. Groz Beckert.The pre-consolidation of the fabric was carried out by needling, wherein the penetration depth was 6 mm and the puncture density at 60 E / cm 2 . The used needles 15x18x40 were from Groz Beckert.

c) Wasserstrahlverfestigungc) hydroentanglement

Die vorverfestigte Flächenware wurde einer Wasserstrahlanlage mit 5 Wasserstrahlbalken zugeführt. Die Verschlaufung und Verhakung der Filamente erfolgte wie folgt in dem Wasserdruckbereich v. 20 - 150 bar.

  • Balken 1 : 20 bar
  • Balken 2 : 100 bar
  • Balken 3 : 150 bar
  • Balken 4 : 150 bar
  • Balken 5 : 150 bar, wobei das Vlies alternierend von oben und von unten mit Wasserstrahlen behandelt wurde.
The pre-consolidated fabric was fed to a water jet system with 5 water jet beams. The entanglement and entanglement of the filaments was carried out as follows in the water pressure range v. 20 - 150 bar.
  • Bar 1: 20 bar
  • Bar 2: 100 bar
  • Bar 3: 150 bar
  • Bar 4: 150 bar
  • Bar 5: 150 bar, wherein the fleece was treated alternately from above and from below with water jets.

d) Reckend) stretching

Der Reckprozeß mit dem wasserstrahlverfestigten Produkt erfolgte in der Spalte von zwei Walzen, die mit einer Differenzgeschwindigkeit von 15 % laufen. Die Flächenware wurde durch eine S-Umschlingung um das Walzenpaar geführt, wobei die Walzenoberflächentemperatur 150°C betrug.
Trocknung und Fixierung der PET-Filamente wurde in einem Saug-Trockner bei den Temperaturen von 180 °C durchgeführt.The stretching process with the hydroentangled product took place in the nip of two rolls running at a differential speed of 15%. The fabric was passed around the pair of rolls by an S-wrap, the roll surface temperature being 150 ° C.
Drying and fixing of the PET filaments was carried out in a suction dryer at temperatures of 180 ° C.

e) Thermofixierunge) heat setting

Die Kalandrierung der fixierten Flächenware erfolgte mit einer Prägewalze, die mit 33 rautenförmigen Gravurpunkten pro cm2 eine Druckfläche von 18% erzeugte. Die Kalanderoberflächentemperatur und der Liniendruck lagen bei 220 °C bzw. 20 daN/cm.The calendering of the fixed fabric was carried out with an embossing roller, which produced a printing area of 18% with 33 diamond-shaped engraving points per cm 2 . Calender surface temperature and line pressure were 220 ° C and 20 daN / cm, respectively.

f) Ausrüstungf) equipment

Der Avivageauftrag wurde an einer Sprühanlage mit einer Polydimethylsiloxan-Emulsion durchgeführt. Der Feststoffkonzentration und die Naßaufnahme betrugen 1,9% bzw. 11%.The softening application was carried out on a spray system with a polydimethylsiloxane emulsion. The solids concentration and the wet pick-up were 1.9% and 11%, respectively.

Die Trocknung des mit Avivage ausgerüsteten Spinnvlieses erfolgte in einem Flachbandtrockner bei den Lufttemperaturen von 110 °C.The drying of the spunbond fabric finished with Avivage was carried out in a flat belt dryer at the air temperatures of 110 ° C.

Das durch die o.g. Prozessschritte hergestellte Spinnvlies mit einem Flächengewicht von 90 g/qm wies folgende physikalische Werte auf:

  • Dicke : 0,45 mm
  • Kraft bei 5% Dehnung(Längs) : 91 N/5 cm (Spez.-Modul: 1 N/g/qm)
  • Kraft bei 5% Dehnung(Quer) : 40 N/5 cm
The spunbonded nonwoven produced by the abovementioned process steps with a surface weight of 90 g / m 2 had the following physical values:
  • Thickness: 0.45 mm
  • Force at 5% elongation (longitudinal): 91 N / 5 cm (spec. Modulus: 1 N / g / qm)
  • Force at 5% elongation (cross): 40 N / 5 cm

Das aus PET Filamenten bestehende Spinnvlies ließ sich sehr gut tuften. Bei einer Tuftteilung von 1/10 erzielte man folgende physikalische Werte :

  • Höchstzugkraft(Längs) : 340 N/5 cm
  • Höchstzugkraft(Quer) : 150 N/5 cm
  • Dehnung(Längs) : 50 %
  • Dehnung(Quer) : 65 %
  • Weiterreißkraft(Längs): 210 N
The spunbonded nonwoven made of PET filaments tufted very well. With a tuft pitch of 1/10, the following physical values were achieved:
  • Maximum tensile force (longitudinal): 340 N / 5 cm
  • Maximum tensile force (cross): 150 N / 5 cm
  • Elongation (Longitudinal): 50%
  • Elongation (cross): 65%
  • Tearing force (longitudinal): 210 N

Claims (10)

  1. Tufting base composed of three-dimensionally intertwined synthetic fibres or filaments, characterized in that only fibres or filaments having a linear density of 1 to 15 dtex are present, the basis weight of the tufting base being 70 to 110 g/m2, its density being 0.18 to 0.28 g/cm3 and the fibres or filaments being thermobonded and partially compacted such that the 5% modulus value in the machine direction is > 60 N/5 cm but at least 0.6 N/g/m2.
  2. Tufting base according to Claim 1, characterized in that the fibres or filaments have a linear density of 3 to 12 dtex, the 5% modulus value in the machine direction being 70 to 100 N/5 cm but at least 0.7 to 1.0 N/g/m2.
  3. Tufting base according to Claim 1 or 2, characterized in that it is finished with coatings or surface-active substances.
  4. Tufting base according to one or more of Claims 1 to 3, characterized in that it consists of polyethylene terephthalate only.
  5. Tufting base according to one or more of Claims 1 to 3, characterized in that it consists of polypropylene only.
  6. Process for producing a tufting base from a spunbonded web of thermoplastic polymeric fibres or filaments, characterized in that the fibres or filaments are consolidated by needling when their linear density is in the range from 6 to 15 dtex and by hydroentangling, or by a combination of needling and hydroentangling, when their linear density is in the range from 1 to 5 dtex and stretching in the longitudinal direction by up to 30% is carried out before drying and thermobonding, the mobility of the fibres being improved if appropriate through the addition of oil or other coatings.
  7. Process according to Claim 6, characterized in that the stretching operation is effected between the individual needling stages or after conclusion of the needling operation.
  8. Process according to Claim 6 or 7, characterized in that after thermobonding an additional treatment with a heated pair of rolls is carried out.
  9. Process according to Claim 8, characterized in that surfaces of the rolls have an irregular structure with a roughness depth of 40 to 100 µm.
  10. Process according to Claim 8 or 9, characterized in that at least one of the rolls exhibits an embossing pattern in which the embossing points occupy a bonding area of 18% to 25% and form a diamond, line or hexagonal shape.
EP01130147A 2001-02-19 2001-12-19 Substrate for tufted carpet and process of manufacturing Expired - Lifetime EP1233097B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10108092 2001-02-19
DE10108092A DE10108092B4 (en) 2001-02-19 2001-02-19 Method of making a tufting carrier

Publications (2)

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EP1233097A1 EP1233097A1 (en) 2002-08-21
EP1233097B1 true EP1233097B1 (en) 2007-10-03

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EP (1) EP1233097B1 (en)
JP (1) JP3542993B2 (en)
KR (1) KR100478962B1 (en)
AT (1) ATE374852T1 (en)
DE (2) DE10108092B4 (en)
DK (1) DK1233097T3 (en)
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JP5422874B2 (en) * 2006-02-01 2014-02-19 東レ株式会社 Nonwoven fabric for filter and method for producing the same
DE102007020818B3 (en) * 2007-05-02 2009-01-02 Carl Freudenberg Kg Process for the preparation of a deformable tufted product
KR102228541B1 (en) 2017-09-22 2021-03-15 코오롱인더스트리 주식회사 Non-woven for carpet backing with improved pull-out strength and manufacturing method thereof
CN108265393A (en) * 2018-01-05 2018-07-10 江苏盛纺纳米材料科技股份有限公司 The preparation method of 6 excipient embossed nonwoven materials
DE102021106621A1 (en) 2021-03-18 2022-10-20 Adler Pelzer Holding Gmbh Absorbent backing fleece for tufted carpet

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DE10108092A1 (en) 2002-09-26
KR100478962B1 (en) 2005-03-25
TW554108B (en) 2003-09-21
JP3542993B2 (en) 2004-07-14
EP1233097A1 (en) 2002-08-21
ATE374852T1 (en) 2007-10-15
DK1233097T3 (en) 2008-01-21
KR20020067994A (en) 2002-08-24
US20020127934A1 (en) 2002-09-12
PL202097B1 (en) 2009-06-30
JP2002309471A (en) 2002-10-23
US7437807B2 (en) 2008-10-21
DE50113082D1 (en) 2007-11-15

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