CA2700204A1 - Needle-punched nonwoven velour and use thereof - Google Patents
Needle-punched nonwoven velour and use thereof Download PDFInfo
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- CA2700204A1 CA2700204A1 CA2700204A CA2700204A CA2700204A1 CA 2700204 A1 CA2700204 A1 CA 2700204A1 CA 2700204 A CA2700204 A CA 2700204A CA 2700204 A CA2700204 A CA 2700204A CA 2700204 A1 CA2700204 A1 CA 2700204A1
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- Prior art keywords
- filaments
- needle
- velour
- punched nonwoven
- textile covering
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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
- 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
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- 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
- B32B5/06—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 characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
- D01D5/30—Conjugate filaments; Spinnerette packs therefor
- D01D5/34—Core-skin structure; Spinnerette packs therefor
-
- 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
- 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
- D04H3/147—Composite 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
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/04—Floor or wall coverings; Carpets
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/12—Vehicles
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
Abstract
A needle-punched nonwoven velour is described which is produced by placing an optionally pre-bonded nonwoven fabric on a brush-type stitching base and needling the nonwoven fabric on said base. The needle-punched nonwoven velour according to the invention is characterized in that the nonwoven fabric comprises a spun-bonded fabric with filaments which encompass multicomponent filaments including at least one high-melting component and at least one thermally activatable low-melting component. The needle-punched nonwoven velour according to the invention has good mechanical properties and, in particular, is extremely environmentally friendly and non-hazardous, making it suitable for use as a textile lining in the private domain and especially in objects.
Description
= 1 Needle-punched nonwoven velour and use thereof Description Technical field The invention relates to a needle-punched nonwoven velour produced by laying an optionally preconsolidated web down on a brushlike base and needling the web on this base. The invention further relates to preferred uses of the velour needled nonwoven web.
Prior art DE 34 44 763 Al discloses an apparatus and a process for producing a needle-punched nonwoven velour wherein a preneedled staple fibre web is laid down onto a circulating brushlike stitching base and is then needled to form a pile on the side facing the stitching base. Since, in this process, the fibres captured by the needles are needled into the brush of the stitching base, the nonwoven web needled in this way acquires a velourlike appearance.
To enhance the distortion resistance of such a needle-punched nonwoven velour, 771 Al proposes laying the staple fibre web down onto the brushlike stitching base with interposition of a layer having a higher distortion resistance than the staple fibre web, particularly with interposition of a spunbonded web, and then conducting the process such that, in the needling step, the pile fibres are pulled through the layer having the higher distortion resistance. Here, according to the reference, care must be taken in particular to ensure that the basis weight of the interlayer of spunbonded web is as low as possible, so that pile formation through the interlayer is not impaired and, on the other hand, the interlayer does not make an appearance in the visual appearance of the needle-punched nonwoven velour of staple fibres.
Needle-punched nonwoven velour of the type described are increasingly used for lining motor vehicle interiors. One disadvantage in this connection is that, to achieve the abrasion resistance required for this use, 200 to 300 g/m2 of deep-drawable latex binder has to be added to the needle-punched nonwoven velour. Latex binder is not only very costly, it also contains volatile organic compounds (VOCs) which escape into the motor vehicle interior (fogging). With regard to universally rising awareness of environmental, health and quality concerns, such emissions in interiors for example in motor vehicles, building products, or else residential interiors are no longer acceptable.
Summary of the invention It is an object of the invention to provide a needle-punched nonwoven velour, particularly for lining interiors, which meets the high expectations of environniental and health compatibility and quality and yet is notable for very good mechanical properties, such as high abrasion resistance for example.
This object is achieved by a needle-punched nonwoven velour according to Claim 1.
Claim 9 concems a textile covering comprising a needle-punched nonwoven velour according to the invention. Claims 19 and 20 are directed to preferred uses of the textile covering. Dependent claims relate to preferred embodiments of the invention.
In what follows, filaments for the purposes of the invention are continuous fibres. Fibres or staple fibres shall in contrast are understood as meaning hereinbelow fibres of finite length.
The invention provides in relation to a needle-punched nonwoven velour produced by laying an optionally preconsolidated web down on a brushlike stitching base and needling the web on this base that the web comprises a spunbonded web comprising filaments comprising multicomponent filaments having at least one high-melting component and at least one thermally activatable low-melting component.
Surprisingly, a needle-punched nonwoven velour of the type described above was ascertained to provide very high abrasion resistances even without the use of an additional chemical binder. The latex coat typically applied to the back of a needle-punched nonwoven velour to be used in motor vehicle interiors to increase its abrasion resistance need not be used at all. A needle-punched nonwoven velour according to the invention is therefore free of active foggants. The harmful emission of volatile hydrocarbons which is associated with the known latex coat is completely avoided with a needle-punched nonwoven velour according to the invention. The needle-punched nonwoven velour according to the invention therefore meets the highest expectations with regard to health and environmental compatibility and quality. Moreover, the elimination of latex binder, additionally leads to a distinct cost benefit.
According to the invention, the needle-punched nonwoven velour comprises a spunbonded web comprising filaments. The use of a spunbonded web has more than just the advantage of endowing the textile fabric with a certain strength in a conventional manner.
Spunbonded webs are also very economical to produce. However, spunbonded webs -unlike staple fibre webs - typically have a very smooth, low-bulk appearance.
The filaments lie almost exclusively in a horizontal plane. The materials are clearly devoid of loft and velourlike characteristics. They therefore appear at a first glance unsuitable for forming a velourlike needled web. Accordingly, it is expressly mentioned in the DE 44 09 771 Al reference described at the beginning that the basis weight of the spunbonded web inserted as a reinforcing ply needs to be kept so low that it does not make a visual appearance.
However, it has now emerged, surprisingly, that even spunbonded webs, at high basis weights, when needled on a brushlike stitching base as described in DE 43 44 763 Al for example, provide a lofty textile fabric which has a velourlike appearance.
Even the property of loft recovery from load, important for needle-punched nonwoven velour, is achieved. All the while, the needled spunbonded web does retain its well-known good properties, such as high distortion resistance, very good fonnability, high dimensional stability and abrasion resistance.
The properties of a needle-punched nonwoven velour according to the invention with regard to recovery, distortion resistance and dimensional stability can be additionally enhanced when the needle-punched nonwoven velour according to the invention is additionally subjected to thennal consolidation after needling.
Prior art DE 34 44 763 Al discloses an apparatus and a process for producing a needle-punched nonwoven velour wherein a preneedled staple fibre web is laid down onto a circulating brushlike stitching base and is then needled to form a pile on the side facing the stitching base. Since, in this process, the fibres captured by the needles are needled into the brush of the stitching base, the nonwoven web needled in this way acquires a velourlike appearance.
To enhance the distortion resistance of such a needle-punched nonwoven velour, 771 Al proposes laying the staple fibre web down onto the brushlike stitching base with interposition of a layer having a higher distortion resistance than the staple fibre web, particularly with interposition of a spunbonded web, and then conducting the process such that, in the needling step, the pile fibres are pulled through the layer having the higher distortion resistance. Here, according to the reference, care must be taken in particular to ensure that the basis weight of the interlayer of spunbonded web is as low as possible, so that pile formation through the interlayer is not impaired and, on the other hand, the interlayer does not make an appearance in the visual appearance of the needle-punched nonwoven velour of staple fibres.
Needle-punched nonwoven velour of the type described are increasingly used for lining motor vehicle interiors. One disadvantage in this connection is that, to achieve the abrasion resistance required for this use, 200 to 300 g/m2 of deep-drawable latex binder has to be added to the needle-punched nonwoven velour. Latex binder is not only very costly, it also contains volatile organic compounds (VOCs) which escape into the motor vehicle interior (fogging). With regard to universally rising awareness of environmental, health and quality concerns, such emissions in interiors for example in motor vehicles, building products, or else residential interiors are no longer acceptable.
Summary of the invention It is an object of the invention to provide a needle-punched nonwoven velour, particularly for lining interiors, which meets the high expectations of environniental and health compatibility and quality and yet is notable for very good mechanical properties, such as high abrasion resistance for example.
This object is achieved by a needle-punched nonwoven velour according to Claim 1.
Claim 9 concems a textile covering comprising a needle-punched nonwoven velour according to the invention. Claims 19 and 20 are directed to preferred uses of the textile covering. Dependent claims relate to preferred embodiments of the invention.
In what follows, filaments for the purposes of the invention are continuous fibres. Fibres or staple fibres shall in contrast are understood as meaning hereinbelow fibres of finite length.
The invention provides in relation to a needle-punched nonwoven velour produced by laying an optionally preconsolidated web down on a brushlike stitching base and needling the web on this base that the web comprises a spunbonded web comprising filaments comprising multicomponent filaments having at least one high-melting component and at least one thermally activatable low-melting component.
Surprisingly, a needle-punched nonwoven velour of the type described above was ascertained to provide very high abrasion resistances even without the use of an additional chemical binder. The latex coat typically applied to the back of a needle-punched nonwoven velour to be used in motor vehicle interiors to increase its abrasion resistance need not be used at all. A needle-punched nonwoven velour according to the invention is therefore free of active foggants. The harmful emission of volatile hydrocarbons which is associated with the known latex coat is completely avoided with a needle-punched nonwoven velour according to the invention. The needle-punched nonwoven velour according to the invention therefore meets the highest expectations with regard to health and environmental compatibility and quality. Moreover, the elimination of latex binder, additionally leads to a distinct cost benefit.
According to the invention, the needle-punched nonwoven velour comprises a spunbonded web comprising filaments. The use of a spunbonded web has more than just the advantage of endowing the textile fabric with a certain strength in a conventional manner.
Spunbonded webs are also very economical to produce. However, spunbonded webs -unlike staple fibre webs - typically have a very smooth, low-bulk appearance.
The filaments lie almost exclusively in a horizontal plane. The materials are clearly devoid of loft and velourlike characteristics. They therefore appear at a first glance unsuitable for forming a velourlike needled web. Accordingly, it is expressly mentioned in the DE 44 09 771 Al reference described at the beginning that the basis weight of the spunbonded web inserted as a reinforcing ply needs to be kept so low that it does not make a visual appearance.
However, it has now emerged, surprisingly, that even spunbonded webs, at high basis weights, when needled on a brushlike stitching base as described in DE 43 44 763 Al for example, provide a lofty textile fabric which has a velourlike appearance.
Even the property of loft recovery from load, important for needle-punched nonwoven velour, is achieved. All the while, the needled spunbonded web does retain its well-known good properties, such as high distortion resistance, very good fonnability, high dimensional stability and abrasion resistance.
The properties of a needle-punched nonwoven velour according to the invention with regard to recovery, distortion resistance and dimensional stability can be additionally enhanced when the needle-punched nonwoven velour according to the invention is additionally subjected to thennal consolidation after needling.
A needle-punched nonwoven velour according to the invention is obtainable by means of a process as described for example in the abovementioned DE 34 44 763 Al reference.
Particular process variants, leading to structuring of the surface of a needle-punched nonwoven velour for example, are additionally known from EP 0 411 647 Al.
Forked and/or crowned needles are used for example depending on the desired structuring.
Accordingly, single- or multi-stage processes are described. These processes can also be applied to a needle-punched nonwoven velour according to the invention without restriction of generality.
According to the invention, the filaments comprise multicomponent filaments having at least one high-melting component and at least one thermally activatable low-melting component, preferably,bicomponent filaments. Bicomponent filaments are well known.
They include a low-melting component comprising a low-melting polymer and a high-melting component comprising a high-melting polymer.
The abovementioned thermally activatable low-melting component assumes according to the invention the function of a binder or latex binder without, however, having the disadvantages associated with the use of this binder or any other chemical binder, such as fogging, low recyclability, etc. The melting point of the low-melting component should preferably be about 10 C to 20 C below the melting point of the higher-melting component in order that the latter not be destroyed in the course of thermal activation.
The proportion of bicomponent filaments in the spunbonded web should not be less than 5% (based on the total basis weight of the needle-punched nonwoven velour) since otherwise the abrasion resistance would cleteriorate too much. The proportion is preferably above 15%.
The spunbonded web may have a single- or multi-ply construction. It may consist of one or more species of filament. The admixture of staple fibres is also possible.
However, in this case, the proportion of staple fibres should not exceed a value of 75%
based on the total basis weight of the needle-punched nonwoven velour, since tensile strength and shape stability as well as the abrasion resistance decrease substantially at higher values.
The staple fibres can likewise be fonned of multicomponent, preferably bicomponent, fibres, in which case the above observations apply with regard to the polymers preferably used.
One way to admix staple fibres is to inject staple fibres into the spunbonded web filament stream. However, it is also possible to lay the staple fibres down on a spunbonded web ply or between two spunbonded web plies and to introduce the fibres into the spunbonded web plies via the needling operation. It is further possible for the two plies to be produced separately and only be joined together in a downstream step, for example by means of the needling step.
By admixing crimped staple fibres it is possible to further improve the loft and loft recovery. This effect can also be achieved through the use of crimped continuous filaments.
However, the addition of staple fibres may also advantageously be used to achieve a reproducible and homogeneous colouration of the velour needlefelt. In such colouration, the staple fibres are the sole carriers of colour. The colour is controlled via the amount added. Such reproducible colouration can also be achieved via pigmentation of the continuous filaments in the continuous spinning operation. However, the staple fibre operation is generally significantly more flexible and therefore quicker for implementing colour changes.
According to the invention, a plurality of different fibres or filaments can be used.
Differences can reside for example in the composition or else in the fibre or filament thickness. The plies of different fibres and/or filaments can have a stagewise or else gradientwise construction. For instance, the formation of discrete transitions between plies having different fibres and/or filaments or alternatively a continuous enrichment in one filament or fibre species in the direction of one of the surfaces is conceivable. When such a fibre or filament comprises a low-melting heat-activatable binder polymer, an adhesion-promoter layer can be formed in this simple way. In a gradientwise construction, such a binder polymer additionally leads to consolidation and stabilization in the interior of the ply.
A textile covering comprising a needle-punched nonwoven velour according to the invention has particular mechanical stability as well as environmental and health compatibility and quality and therefore is very useful for applications in the commercial sector. That includes all target groups including those not assignable to the private sector, for example offices, schools, banks, insurance companies, hotels, the social and care sector, sports facilities, particularly also the interior trim in the automotive sector, in shipping, railways, etc.
The commercial sector has very high requirements with regard to technical quality. These requirements are met by a textile covering according to the invention.
Preference is here given to applications in the sector of motor vehicle interior lining not only in the passenger compartment but also in the trunk or boot, and also carpet flooring, not only as continuous sheet material but also in the form of tiles. But other applications for such a textile covering are also possible, for example as wall covering, dividing walls, etc.
It is clear from the above remarks that a textile covering according to the invention can of course also be used in the private sector, for example in the residential sector.
A textile covering according to the invention can also be finished for the abovementioned applications to be flame retardant, antistatic or antimicrobial, for example.
The possible uses of a needle-punched nonwoven velour according to the invention or of a textile covering according to the invention are certainly not limited to the concrete fields of application mentioned above.
Particularly for applications in the lining of motor vehicle interiors or in carpet flooring can it be advantageous for the textile covering according to the invention to be provided with a so-called heavy layer. Use of heavy layers in the sector of motor vehicle interior linings is known per se. They provide decoupling according to the mass-spring principle.
The heavy layer is extruded either by means of a layer of PE with supply of heat or .._ ......... ....
Particular process variants, leading to structuring of the surface of a needle-punched nonwoven velour for example, are additionally known from EP 0 411 647 Al.
Forked and/or crowned needles are used for example depending on the desired structuring.
Accordingly, single- or multi-stage processes are described. These processes can also be applied to a needle-punched nonwoven velour according to the invention without restriction of generality.
According to the invention, the filaments comprise multicomponent filaments having at least one high-melting component and at least one thermally activatable low-melting component, preferably,bicomponent filaments. Bicomponent filaments are well known.
They include a low-melting component comprising a low-melting polymer and a high-melting component comprising a high-melting polymer.
The abovementioned thermally activatable low-melting component assumes according to the invention the function of a binder or latex binder without, however, having the disadvantages associated with the use of this binder or any other chemical binder, such as fogging, low recyclability, etc. The melting point of the low-melting component should preferably be about 10 C to 20 C below the melting point of the higher-melting component in order that the latter not be destroyed in the course of thermal activation.
The proportion of bicomponent filaments in the spunbonded web should not be less than 5% (based on the total basis weight of the needle-punched nonwoven velour) since otherwise the abrasion resistance would cleteriorate too much. The proportion is preferably above 15%.
The spunbonded web may have a single- or multi-ply construction. It may consist of one or more species of filament. The admixture of staple fibres is also possible.
However, in this case, the proportion of staple fibres should not exceed a value of 75%
based on the total basis weight of the needle-punched nonwoven velour, since tensile strength and shape stability as well as the abrasion resistance decrease substantially at higher values.
The staple fibres can likewise be fonned of multicomponent, preferably bicomponent, fibres, in which case the above observations apply with regard to the polymers preferably used.
One way to admix staple fibres is to inject staple fibres into the spunbonded web filament stream. However, it is also possible to lay the staple fibres down on a spunbonded web ply or between two spunbonded web plies and to introduce the fibres into the spunbonded web plies via the needling operation. It is further possible for the two plies to be produced separately and only be joined together in a downstream step, for example by means of the needling step.
By admixing crimped staple fibres it is possible to further improve the loft and loft recovery. This effect can also be achieved through the use of crimped continuous filaments.
However, the addition of staple fibres may also advantageously be used to achieve a reproducible and homogeneous colouration of the velour needlefelt. In such colouration, the staple fibres are the sole carriers of colour. The colour is controlled via the amount added. Such reproducible colouration can also be achieved via pigmentation of the continuous filaments in the continuous spinning operation. However, the staple fibre operation is generally significantly more flexible and therefore quicker for implementing colour changes.
According to the invention, a plurality of different fibres or filaments can be used.
Differences can reside for example in the composition or else in the fibre or filament thickness. The plies of different fibres and/or filaments can have a stagewise or else gradientwise construction. For instance, the formation of discrete transitions between plies having different fibres and/or filaments or alternatively a continuous enrichment in one filament or fibre species in the direction of one of the surfaces is conceivable. When such a fibre or filament comprises a low-melting heat-activatable binder polymer, an adhesion-promoter layer can be formed in this simple way. In a gradientwise construction, such a binder polymer additionally leads to consolidation and stabilization in the interior of the ply.
A textile covering comprising a needle-punched nonwoven velour according to the invention has particular mechanical stability as well as environmental and health compatibility and quality and therefore is very useful for applications in the commercial sector. That includes all target groups including those not assignable to the private sector, for example offices, schools, banks, insurance companies, hotels, the social and care sector, sports facilities, particularly also the interior trim in the automotive sector, in shipping, railways, etc.
The commercial sector has very high requirements with regard to technical quality. These requirements are met by a textile covering according to the invention.
Preference is here given to applications in the sector of motor vehicle interior lining not only in the passenger compartment but also in the trunk or boot, and also carpet flooring, not only as continuous sheet material but also in the form of tiles. But other applications for such a textile covering are also possible, for example as wall covering, dividing walls, etc.
It is clear from the above remarks that a textile covering according to the invention can of course also be used in the private sector, for example in the residential sector.
A textile covering according to the invention can also be finished for the abovementioned applications to be flame retardant, antistatic or antimicrobial, for example.
The possible uses of a needle-punched nonwoven velour according to the invention or of a textile covering according to the invention are certainly not limited to the concrete fields of application mentioned above.
Particularly for applications in the lining of motor vehicle interiors or in carpet flooring can it be advantageous for the textile covering according to the invention to be provided with a so-called heavy layer. Use of heavy layers in the sector of motor vehicle interior linings is known per se. They provide decoupling according to the mass-spring principle.
The heavy layer is extruded either by means of a layer of PE with supply of heat or .._ ......... ....
directly onto the carpet and then does not require any further adhesion promoter. The heavy layer typically consists of CaCO3 and EVA. On top, a decoupler such as cotton shoddy or a foam is applied. The heavy layer in a preferred embodiment of the invention, however, can also be applied in the form of a nonwoven web, particularly in the form of a spunbonded web. This not only simplifies process management, but may also result in advantages from the aspect of recyclability, as will be further described hereinbelow.
Furthermore, in a further preferred embodiment, a covering according to the invention can be equipped with a sound-absorbing ply either in combination with the heavy layer or alone. The sound-absorbing ply can be formed in a conventional manner by cotton shoddy with interply, which limits the air permeability, or else by a microfibre web in combination with cotton shoddy or a needled web or by a needled web itself.
The above-described plies and/or layers are preferably connected together by means of tie layers. Traditional binders can be used for the tie layers. From the aspect of environmental and health compatibility as wcll as from economic aspects (simplified process management, fewer operations) these tie layers in a particularly preferred embodiment of the invention likewise utilize plies of multicomponent filaments and/or fibres, preferably bicomponent filaments and/or fibres. The tie layer may additionally or solely also utilize monofilaments or -fibres which consist of a low-melting polymer, for example a copolymer. Chemical binders, which can lead to the familiar fogging problem, can then be completely eliminated with these last-mentioned embodiments.
Bicomponent filaments and/or fibres for the uses described in the present application utilize in one preferred embodiment of the invention core-sheath, Side-By-Side, Island-In-The-Sea and/or PIE (including Hollow PIE) filaments or fibres. Bicomponent filaments or fibres of trilobal geometry or fibres or filaments from spinneret dies having a dumbbell-shaped capillary geometry (= concentrated arrangement of binder and matrix polymer) lead to better anchoring of the fibres or filaments in the nonwoven web and hence to a still further increased tensile strength and abrasion resistance for the material.
_._.........
Furthermore, in a further preferred embodiment, a covering according to the invention can be equipped with a sound-absorbing ply either in combination with the heavy layer or alone. The sound-absorbing ply can be formed in a conventional manner by cotton shoddy with interply, which limits the air permeability, or else by a microfibre web in combination with cotton shoddy or a needled web or by a needled web itself.
The above-described plies and/or layers are preferably connected together by means of tie layers. Traditional binders can be used for the tie layers. From the aspect of environmental and health compatibility as wcll as from economic aspects (simplified process management, fewer operations) these tie layers in a particularly preferred embodiment of the invention likewise utilize plies of multicomponent filaments and/or fibres, preferably bicomponent filaments and/or fibres. The tie layer may additionally or solely also utilize monofilaments or -fibres which consist of a low-melting polymer, for example a copolymer. Chemical binders, which can lead to the familiar fogging problem, can then be completely eliminated with these last-mentioned embodiments.
Bicomponent filaments and/or fibres for the uses described in the present application utilize in one preferred embodiment of the invention core-sheath, Side-By-Side, Island-In-The-Sea and/or PIE (including Hollow PIE) filaments or fibres. Bicomponent filaments or fibres of trilobal geometry or fibres or filaments from spinneret dies having a dumbbell-shaped capillary geometry (= concentrated arrangement of binder and matrix polymer) lead to better anchoring of the fibres or filaments in the nonwoven web and hence to a still further increased tensile strength and abrasion resistance for the material.
_._.........
The proportion of multicomponent or bicomponent filaments and/or fibres is a simple way to set/adjust the stiffness of the textile covering. The higher this proportion, the stiffer the material becomes.
The low-melting component of the bicomponent filaments or fibres preferably comprises, without loss of generality, CoPET (copolyester), CoPA (copolyamide), PA
(polyamide), PP (polypropylene), copolypropylene (CoPP), atactic PP and/or PE
(polyethylene), while the high-melting component preferably comprises PET (polyester), PA
(polyamide), PLA
(polylactide), PBT (polybutylene) and/or PP (polypropylene). The same holds as well for the at least one low-melting component and, respectively, the at least one high-melting component of multicomponent filaments and fibres used according to the invention.
In a further particularly preferred embodiment of the invention, the filaments and/or fibres of all plies and/or layers consist of one and the same polymer and/or its derivatives. This has the advantage of simpler recyclability. Preferably, the textile covering consists of polypropylene and/or its derivatives or of polyester and/or its derivatives or of polyamide and/or its derivatives. Particularly in the case of textile linings, it is frequently the case that shaped articles are die cut out of the continuous sheet material. The die-cutting scraps can be reused for filament and/or staple fibre production when the above materials are used.
The low-melting component of the bicomponent filaments or fibres preferably comprises, without loss of generality, CoPET (copolyester), CoPA (copolyamide), PA
(polyamide), PP (polypropylene), copolypropylene (CoPP), atactic PP and/or PE
(polyethylene), while the high-melting component preferably comprises PET (polyester), PA
(polyamide), PLA
(polylactide), PBT (polybutylene) and/or PP (polypropylene). The same holds as well for the at least one low-melting component and, respectively, the at least one high-melting component of multicomponent filaments and fibres used according to the invention.
In a further particularly preferred embodiment of the invention, the filaments and/or fibres of all plies and/or layers consist of one and the same polymer and/or its derivatives. This has the advantage of simpler recyclability. Preferably, the textile covering consists of polypropylene and/or its derivatives or of polyester and/or its derivatives or of polyamide and/or its derivatives. Particularly in the case of textile linings, it is frequently the case that shaped articles are die cut out of the continuous sheet material. The die-cutting scraps can be reused for filament and/or staple fibre production when the above materials are used.
Claims (20)
1. A needle-punched nonwoven velour produced by laying an optionally preconsolidated web down on a brushlike stitching base and needling the web on this base, characterized in that the web comprises a spunbonded web comprising filaments comprising multicomponent filaments having at least one high-melting component and at least one thermally activatable low-melting component.
2. The needle-punched nonwoven velour according to Claim 1, characterized in that the multicomponent filaments comprise bicomponent filaments.
3. The needle-punched nonwoven velour according to Claim 1 or 2, characterized in that the proportion of bicomponent filaments is greater than 5%
and preferably greater than 15% based on the total weight of the needle-punched nonwoven velour.
and preferably greater than 15% based on the total weight of the needle-punched nonwoven velour.
4. The needle-punched nonwoven velour according to Claim 2 or 3, characterized in that the bicomponent filaments are configured as core-sheath, Side-By-Side, Island-In-The-Sea and/or PIE (including Hollow PIE) filaments.
5. The needle-punched nonwoven velour according to any one of Claims 2 to 4, characterized in that the low-melting component of the bicomponent filaments comprises CoPET, CoPA, PA, PP, CoPP, atactic PP and/or PE.
6. The needle-punched nonwoven velour according to any one of Claims 2 to 5, characterized in that the high-melting component comprises PET, PLA, PBT, PA and/or PP.
7. The needle-punched nonwoven velour according to any one of Claims 1 to 6, characterized in that the spunbonded web contains up to 75% of the total basis weight of staple fibres.
8. The needle-punched nonwoven velour according to any one of Claims 1 to 7, characterized in that the fibres and/or filaments comprise crimped fibres and/or filaments.
9. A textile covering, in particular for lining interiors in the commercial and residential sector, comprising at least one ply composed of a needle-punched nonwoven velour and forming a velour surface, characterized by the needle-punched nonwoven velour according to any one of Claims 1 to 8.
10. The textile covering according to Claim 9, characterized in that the textile covering has a heavy layer on its rear surface, i.e. the surface which is remote from the velour surface.
11. The textile covering according to Claim 9 or 10, characterized in that the textile covering has a sound-absorbing ply on its rear surface, i.e. the surface which is remote from the velour surface.
12. The textile covering according to any one of Claims 9 to 11, characterized in that there are tie layers provided between some or all plies and/or layers.
13. The textile covering according to Claim 12, characterized in that the tie layers comprise fibres and/or filaments composed of a low-melting polymer.
14. The textile covering according to Claim 12, characterized in that the tie layers comprise multicomponent, preferably bicomponent, fibres and/or filaments having at least one high-melting component and at least one low-melting component.
15. The textile covering according to any one of Claims 13 to 15, characterized in that the low-melting polymer or component of the multicomponent or bicomponent fibres and/or filaments comprises CoPET, CoPA, PA, PP, atactic PP
and/or PE.
and/or PE.
16. The textile covering according to Claim 15 or 16, characterized in that the high-melting component comprises PET, PA, PLA, PBT and/or PP.
17. The textile covering according to any one of Claims 12 to 16, characterized in that the bicomponent fibres and/or filaments are configured as core-sheath, Side-By-Side, Island-In-The-Sea and/or PIE (including Hollow PIE) filaments.
18. The textile covering according to any one of Claims 10 to 17, characterized in that the filaments and/or fibres of all plies and/or layers consist of one and the same polymer and/or its derivatives.
19. The use of a textile covering according to any one of Claims 1 to 18 for lining motor vehicle interiors, such as a passenger compartment or trunk.
20. The use of a textile covering according to any one of Claims 1 to 18 for carpet flooring.
Applications Claiming Priority (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US97391307P | 2007-09-20 | 2007-09-20 | |
| EP07018532A EP2050850B1 (en) | 2007-09-20 | 2007-09-20 | Non-woven velour fabric and its application |
| EP07018532.7 | 2007-09-20 | ||
| US60/973,913 | 2007-09-20 | ||
| PCT/EP2008/006370 WO2009039914A1 (en) | 2007-09-20 | 2008-08-01 | Needle-punched nonwoven velour, and use thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2700204A1 true CA2700204A1 (en) | 2009-04-02 |
Family
ID=42168000
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2700204A Abandoned CA2700204A1 (en) | 2007-09-20 | 2008-08-01 | Needle-punched nonwoven velour and use thereof |
Country Status (4)
| Country | Link |
|---|---|
| KR (1) | KR101194432B1 (en) |
| AU (1) | AU2008302790B2 (en) |
| CA (1) | CA2700204A1 (en) |
| MX (1) | MX2010002808A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114555512A (en) * | 2019-09-20 | 2022-05-27 | 宜家供应有限公司 | Artificial feather filling material |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AT398211B (en) * | 1993-04-13 | 1994-10-25 | Fehrer Textilmasch | METHOD FOR PRODUCING A VELOUR NEEDLE FELT |
| DE19823272A1 (en) * | 1998-05-26 | 1999-12-02 | Mayer Malimo Textilmaschf | Production of nonwoven fabrics with a velvet pile surface character |
| US20030056883A1 (en) * | 2001-09-26 | 2003-03-27 | Vishal Bansal | Method for making spunbond nonwoven fabric from multiple component filaments |
| JP4394638B2 (en) * | 2005-12-15 | 2010-01-06 | 株式会社林技術研究所 | Molded interior materials for automobiles |
-
2008
- 2008-08-01 MX MX2010002808A patent/MX2010002808A/en active IP Right Grant
- 2008-08-01 AU AU2008302790A patent/AU2008302790B2/en not_active Ceased
- 2008-08-01 CA CA2700204A patent/CA2700204A1/en not_active Abandoned
- 2008-08-01 KR KR1020107007137A patent/KR101194432B1/en not_active IP Right Cessation
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114555512A (en) * | 2019-09-20 | 2022-05-27 | 宜家供应有限公司 | Artificial feather filling material |
Also Published As
| Publication number | Publication date |
|---|---|
| MX2010002808A (en) | 2010-03-31 |
| AU2008302790A1 (en) | 2009-04-02 |
| AU2008302790B2 (en) | 2011-05-12 |
| KR101194432B1 (en) | 2012-10-24 |
| KR20100050569A (en) | 2010-05-13 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued |
Effective date: 20140801 |