EP1961851B1 - Method for manufacturing a tufted product, tufted product and use thereof - Google Patents

Method for manufacturing a tufted product, tufted product and use thereof Download PDF

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Publication number
EP1961851B1
EP1961851B1 EP20080002082 EP08002082A EP1961851B1 EP 1961851 B1 EP1961851 B1 EP 1961851B1 EP 20080002082 EP20080002082 EP 20080002082 EP 08002082 A EP08002082 A EP 08002082A EP 1961851 B1 EP1961851 B1 EP 1961851B1
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EP
European Patent Office
Prior art keywords
process according
fibres
tufted
polymeric component
fibers
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EP20080002082
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German (de)
French (fr)
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EP1961851A1 (en
Inventor
Norbert Goffing
Engelbert Löcher
Ararad Emirze
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Carl Freudenberg KG
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Carl Freudenberg KG
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    • 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
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C15/00—Making pile fabrics or articles having similar surface features by inserting loops into a base material
    • D05C15/04—Tufting
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23943—Flock surface
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition

Definitions

  • the invention relates to a method for producing a tufted product, in particular to a tufted carpet top layer produced thereafter, and to the use of such a tufted product, in particular of such a tufted carpet top layer.
  • Tuftteppichs the so-called tufting or tufting, that is a technique for producing three-dimensional surfaces, used, which works on the principle of a sewing machine.
  • Tuft needles bring a tufted yarn into a basic material, the so-called tufts.
  • the tuft needles mounted on a needle bar are arranged in the width of the base material, for example a nonwoven fabric, and at the same time pierce through the base material.
  • the introduced tuft yarn is held on the underside of the base material by grippers, so-called loopers. This creates loops or loops, so-called knobs, which form the visible side (upper layer) in the finished carpet.
  • Velorsteppich which is used especially in the automotive interior with a share of more than 95%.
  • Non-woven fabrics made of thermoplastic polymers such as, for example, polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are produced by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these consolidation processes, are often used as tufts are bound.
  • thermoplastic polymers such as, for example, polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are produced by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these consolidation processes, are often used as tufts are bound.
  • the known conventional tufts with round fibers used as Tuftschreiben therefore satisfy the different requirements for a particularly good adhesion of the tufted tufted tufts in Tuftschreiben and a flawless Tuftstory in the carpet top layer is not always satisfactory.
  • the document GB 854,335 A describes a method of making a pile fabric having a patterned pile which includes the formation of a base fabric and the pile yarn fuse to provide pile of fibers extending from one side of the base fabric and using synthetic polymer fibers for certain portions of the pile which were previously defined as filaments or fibers, and wherein for certain parts of the pile synthetic polymer fibers are used, which are determined only after the formation in twisted yarns.
  • the base or back fabric consists of a fabric, in particular a woven burlap.
  • the document US 4,617,218 A discloses a method for producing a tufted carpet having a tightly curled appearance of a Persian lamb, comprising the steps of: a) knitting, knotting or knitting an outer carpet yarn composed of continuous filaments or spun staple fibers of a thermoplastic synthetic resin; b) heating the fabric to a temperature at which bends and kinks are produced in the yarn; c) cooling the tissue to room temperature; d) unwinding and unwinding the yarn under tension to re-straighten; e) tufting the yarn as an external yarn into a first backing material and forming a cut pile carpet; f) coating the bottom of the carpet with a heat-setting adhesive, g) heating the coated carpet.
  • the first backing material is preferably made of woven polypropylene and the second backing is woven jute.
  • the document US 3,788,364 A describes tufted pile fabrics and their backs.
  • the back thereby represents a fabric of polyolefin warp yarns and weft yarns, wherein the warp yarns are formed from flat ribbon monofilaments having a substantially rectangular cross section and at close intervals and wherein the weft yarn has a relatively round cross section and substantially (further) Extra-spaced distances.
  • the pitch index as the product of the yarn width and the number of yarns in inches is 1.3 to 1.6 for the warp yarns and 0.15 to 0.45 for the weft yarns, whereby the tufting penetrates the warp yarns by a relatively large proportion of tufted yarns and the weft yarns from a relatively small proportion of tufting yarns.
  • the document GB 816.185 A discloses a method of producing crimped yarns wherein a yarn is tufted into a backing material to obtain a tufted pile fabric which is subjected to a treatment of said pile fabric in which loops are set / sewn into the tufted yarn and wherein the set yarn returns is removed or pulled from the backing material.
  • the backing material is preferably a fabric.
  • the invention has the object of an alternative, possible to provide a simple and economical process for producing a tufted product, in particular a tufted carpet topcoat, with improved nap-sticking properties.
  • the carpet top layer produced by the process is intended to be used in particular in the automotive interior or in the object sector.
  • object area is meant that the carpet is designed especially for heavily to extremely stressed areas, especially in offices, hotels, airports and / or hospitals.
  • splittable fibers in the back of the tufts in the form of a nonwoven or nonwoven fabric are used which splice on tufting at or in the region of the puncture site of the tufts back.
  • Fibers are understood here to mean staple fibers or continuous fibers, so-called filaments.
  • the fibers may also be combined into nonwovens, in particular nonwoven webs, the nonwoven fabric.
  • the tufts backs are locally felted at the puncture site by the separation or disintegration of the spliceable fibers into single filaments or segments, thereby increasing the specific fiber surface in this area of the tufts back and thereby also the static friction and sliding friction between the fibers of the tuft and the back of the tuft is increased.
  • the type of fibers used thus allows the formation of particularly stable Tuftgarnsch secured or nubs and the formation of a particularly flawless Tuftstoryes in the carpet.
  • spliceable fibers are used in a proportion of 10 to 100 wt.%.
  • a mixture of spliceable and non-splittable fibers is used.
  • the ratio of spliceable and non-splittable fibers can be adjusted depending on the carpet or tuft specification.
  • the proportion of spliceable fibers is preferably equal to or less than 50% by weight.
  • the proportion of spliceable fibers is preferably equal to or greater than 75% by weight.
  • At least two mutually incompatible (incompatible) polymer components are used as spliceable fibers.
  • At least one polymer component preferably has a lower one Weight fraction as the other (s) polymer component (s).
  • At least one polymer component has a weight fraction of equal to or less than 20% by weight, preferably equal to or less than 10% by weight, particularly preferably equal to or less than 5% by weight, very particularly preferably up to 3 wt .-%, based on the total weight of the fibers.
  • the production costs for the tufted products, in particular for the tufted carpet top layer can be reduced.
  • Another cost saving potential is that because of the improved nub adhesion, one can reduce the amount of fixative or precoat that is commonly used in the carpet industry for final fixation of the carpet yarn.
  • fixative or precursors such as to latex compounds, odors and emissions can be reduced, especially in confined spaces such as in the passenger compartment of an automobile.
  • undesirable properties of a component such as a low temperature or flame resistance, can be reduced by using only a minimal amount of this component. Also, the significant reduction of a polymer content can improve the recyclability.
  • the desired properties of the tuft products, in particular the tufted carpet top layer can be precisely controlled.
  • a polymer component having a lower melting temperature is used as the polymer component with a lower proportion by weight.
  • At least one polymer component preferably a polymer component with a lower weight fraction than the other (n) polymer component (s), used as adhesive or binder component, wherein the melting temperature of this polymer component at least 10 ° C, preferably at least 20 ° C, below the melting temperature the other polymer component (s).
  • the properties of the tufted product produced therefrom, in particular the tufted carpet top layer can be influenced, in particular its degree or degree of solidification or softness can be adjusted.
  • the non-splittable fibers are selected from mono-, bi-, multi-polymer component fibers and / or blends of such fibers.
  • the fibers are furthermore preferably selected from thermoplastic polymers, in particular from polyesters, preferably polyethylene terephthalate (PET), from polyolefins, preferably polyethylene (PE) and / or polypropylene (PP), from polylactates and / or from polyamides (PA), preferably polyamide 6.6 (PA6.6) and / or copolymers derived therefrom.
  • PET polyethylene terephthalate
  • PA polyamide 6.6
  • PA6.6 polyamide 6.6
  • combinations of incompatible (incompatible) polymer components are selected, preferably combinations of polyethylene terephthalate (PET) and polypropylene (PP), polyethylene terephthalate (PET) and polyamide (PA), preferably polyamide 6 or polyamide 6.6, and / or polypropylene (PP) and polyethylene (PE).
  • incompatible polymer components preferably combinations of polyethylene terephthalate (PET) and polypropylene (PP), polyethylene terephthalate (PET) and polyamide (PA), preferably polyamide 6 or polyamide 6.6, and / or polypropylene (PP) and polyethylene (PE).
  • the fibers selected are those which advantageously have a titre in the range from 5 to 20 dtex, preferably from 5 to 12 dtex.
  • fibers are selected which preferably have round or non-round cross-sectional shapes.
  • Non-round cross-sectional shapes lead to increased fiber-to-fiber friction compared to round fibers and thus result in improved pimple adhesion due to better adhesion to one another.
  • the selected fibers are further preferably solid or hollow.
  • the fibers are used in the form of a spunbonded fabric or a spunbonded nonwoven fabric as tufa backs.
  • the carpet top layer is preferably subjected to a heat treatment after tufting. As a result, the knobbed adhesion of the carpet top layer is further improved.
  • the tufted products produced according to the invention are preferably used in the automotive interior and / or in the object sector, in particular in offices, hotels, airports and / or hospitals.
  • the scanning electron micrographs allow images of the fiber / nonwoven cross sections and the surface structure with the corresponding magnifications.
  • the SEM images were taken with a low pressure scanning electron microscope JEOL JSM-6480LV under an acceleration voltage of 20 kV.
  • spliceable fibers in particular in the form of a nonwoven fabric, are used as tufts for the production of the tufted product, in particular the tufted carpet top layer.
  • a nonwoven fabric having spliceable fibers at a content of 100% by weight is prepared as follows.
  • PET polyethylene terephthalate
  • PP polypropylene
  • the spun filaments have a linear density of 9.5 dtex with strength values of 29 mN / dtex and elongation values of 135% (DIN 53812 and DIN 53816).
  • the fabric produced in this way is preconsolidated by calendering, wherein a smooth and a roughened roll with the surface temperatures of 100 ° C are used and wherein the cylinder pressure is 16 bar.
  • the fabric is finally solidified in an air dryer at an air temperature of 225 ° C.
  • an aqueous polydimethylsiloxane emulsion as textile auxiliaries (Avivage) is applied, wherein the solids concentration is 5 wt .-% and the wet pickup is 7% (0.35 wt.% Avivage based on the Vilesstoffong).
  • the drying of the nonwoven fabric finished with Avivage takes place in an air dryer at an air temperature of 100 ° C.
  • a nonwoven fabric having a weight of 115 g / m 2 which comprises splittable fibers.
  • FIG. 1 shows that between the PET and the PP segments of the spun spliceable PET / PP Pieturan despite the low proportion by weight of the polypropylene (PP) is a very good, that is a clear segmentation.
  • PP polypropylene
  • FIG. 2 shows that after solidification of the segmented PET / PP prepregs, there is already a slight pre-splicing of the spun spliceable PET / PP ply fibers of the nonwoven fabric by the thermal consolidation step.
  • the distance between the tufting needles which bring the Tuftgarn in the back of the tufts, here in the nonwoven tufts, in fractions of an inch. 1/10 ° thus means 10 needles per 2.54 cm, ie a distance of 2.54 mm between the tufting needles.
  • the distance of the stitches along the length of the tuft back is called the stitch length.
  • the number of stitches is given per 10 centimeters. It also determines the number of loops or nubs.
  • Other tuft pitches such as 6/32 ", 1/8", 5/64 ", 1/16" or 1/22 "can also be used to make the top carpets.
  • the tufted yarn used is a commercial PA6 BCF 1300 dtex f128, which stands for bulked continuous filament, in particular for a textured nylon yarn continuous yarn having a denier of 1300 dtex and 128 individual filaments. Other common tuft games can also be used.
  • the tufted yarn is held in place by grippers, so that loops or nubs on the top of the tufa back arise.
  • a loop pile carpet top layer is created.
  • a cut pile carpet top layer or so-called velor carpet top layer is created.
  • FIGS. 4 . 6 and 7 show the surface of a tufted carpet top layer produced according to the invention, that is to say here a tufted non-woven fabric with spliced PET / PP pief fibers after extraction of the tuft yarn in order to obtain a free area for the SEM images.
  • FIGS. 3 and 5 show in comparison to the surface of a conventional tufted carpet top layer, that is, a tufted conventional standard nonwoven fabric (Lutradur ® LDT 53 12) with separated spun PET and PP monofilaments after pulling out the Tuftgarns, in order to obtain a free area for the SEM photographs.
  • the Tuft discipline correspond exactly to the same conditions to which the nonwoven fabric was exposed with spliceable PET / PP Pietician.
  • FIGS. 6 and 7 also show, due to the splicing in the region of the puncture site, the so-called Tuftloch Scheme, pushed out PP fiber parts, which lead to a further increase in the specific fiber surface.
  • the dimpled adhesion depends on the stiction between the fibers of the tuft back, in this case the nonwoven fabric, and the Tuftgarns is due to the smaller contracted Tuftlöcher and the increased specific fiber surface in the tufted nonwoven fabric with spliced fibers, that is, the invention prepared carpet top layer, a in Compared to the tufted conventional standard nonwoven fabric to expect improved pimple adhesion.
  • the untufted tufts back that is, the nonwoven fabric with the spliceable fibers or the non-spliceable fibers attached to a train-elongation device (Zwick) is clamped on a special holder, is engraved from the back with a Einzelte Kunststoffnadel (Groz Beckert).
  • the yarn which was also used for tufting (PA6 BCF 1300 dtex 128f, yarn length 400 mm), is then threaded into the needle, pulled through the back of the tufts and fixed parabolically to the back of the tufts on a very fine-resolution load cell.
  • N spec nonwoven fabric with spliced PET / PP ply fibers: 0.99 N m 2 / g
  • the measurement results confirm that the nubbly adhesion of the tufted nonwoven fabric with the spliced fibers, that is to say that of the carpet top layer produced according to the invention, is improved compared to the tufted conventional standard nonwoven fabric.

Description

Technisches GebietTechnical area

Die Erfindung betrifft ein Verfahren zur Herstellung eines Tuftprodukts, insbesondere eine danach hergestellte getuftete Teppichoberschicht, und die Verwendung eines derartigen Tuftprodukts, insbesondere einer derartigen getufteten Teppichoberschicht.The invention relates to a method for producing a tufted product, in particular to a tufted carpet top layer produced thereafter, and to the use of such a tufted product, in particular of such a tufted carpet top layer.

Zur Herstellung eines Tuftteppichs wird das sogenannte Tuften oder Tufting, das heißt eine Technik zur Herstellung dreidimensionaler Flächen, eingesetzt, die nach dem Prinzip einer Nähmaschine funktioniert.To produce a Tuftteppichs the so-called tufting or tufting, that is a technique for producing three-dimensional surfaces, used, which works on the principle of a sewing machine.

Dabei bringen Tuftnadeln ein Tuftgarn in ein Grundmaterial, den sogenannten Tuftrücken, ein. Die an einer Nadelstange montierten Tuftnadeln sind in der Breite des Grundmaterials, beispielsweise eines Vliesstoffes, angeordnet und stechen gleichzeitig durch das Grundmaterial. Bevor die Tuftnadeln wieder nach oben in ihre Ausgangsstellung zurückkehren, wird das eingebrachte Tuftgam auf der Unterseite des Grundmaterials von Greifern, sogenannten Loopern, festgehalten. So entstehen Schlaufen oder Schlingen, sogenannte Noppen, die im fertigen Teppich die Sichtseite (Oberschicht) bilden.Tuft needles bring a tufted yarn into a basic material, the so-called tufts. The tuft needles mounted on a needle bar are arranged in the width of the base material, for example a nonwoven fabric, and at the same time pierce through the base material. Before the tuft needles return up to their original position, the introduced tuft yarn is held on the underside of the base material by grippers, so-called loopers. This creates loops or loops, so-called knobs, which form the visible side (upper layer) in the finished carpet.

Je nach Anwendung können diese Schlingen unter Einsatz spezieller Messer bereits während des Tuftvorgangs geschnitten werden. Dabei entsteht der sogenannte Veloursteppich, der speziell im Automobilinnenbereich bevorzugt mit einem Anteil von über 95% eingesetzt wird.Depending on the application, these slings can already be cut using special knives during the tufting process. This creates the so-called Velorsteppich, which is used especially in the automotive interior with a share of more than 95%.

Als Tuftrücken werden häufig Vliesstoffe aus thermoplastischen Polymeren, wie zum Beispiel aus Polyethylenterephthalat(PET)-Fasern und/oder aus Polypropylen(PP)-Fasern eingesetzt, die durch Vernadelung, Punktverschweißung, mittels eines chemischen Bindemittels, mittels Bindefasern oder mittels Kombinationen von diesen Verfestigungsprozessen gebunden sind.Non-woven fabrics made of thermoplastic polymers, such as, for example, polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are produced by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these consolidation processes, are often used as tufts are bound.

Die Verwendung von ausschließlich punktverschweißten oder ausschließlich bindergebundenen Vliesstoffen ist nachteilig, da sie für die Herstellung von dreidimensionalen Formteilen wegen einer schlechten Verformbarkeit, insbesondere bei der Verwendung im Automobilbereich, nicht besonders gut geeignet sind.The use of exclusively spot-welded or exclusively binder-bonded nonwovens is disadvantageous, since they are not particularly well suited for the production of three-dimensional molded parts because of poor deformability, in particular for use in the automotive sector.

Beim Einsatz von herkömmlichen runden Fasern sind die Kontaktfläche und die Reibung zwischen den im Tuftrücken-Vliesstoff eingesetzten Fasern und den Tuftgarnen relativ klein, so dass die Haltekraft für das Tuftgam speziell bei komplizierten Teppichoberflächenstrukturen, wie zum Beispiel bei sogenannten Hoch-Tief-Velours- bzw. Schlingenqualitäten oder Cross-Over-Veloursqualitäten (mit Polnoppenversatz), häufig nicht ausreichend ist. Das nach dem Durchstechen und Zurückziehen der Tuftnadel in den Tuftrücken eingebrachte Tuftgam kann bereits durch die Kombination von geringen Tuftrückendichten- und Gamspannungs- sowie Garnqualitätenschwankungen seine vorgesehene Position, das heißt beispielsweise die Höhe oder Lage der Noppe, verlieren, und unter Umständen kann das Tuftgam sogar aus dem Tuftrücken herausgezogen werden. Dies kann in beiden Fällen zu deutlich sichtbaren Fehlern und zu unerwünschte Designabweichungen in der getufteten Teppichoberschicht führen.When using conventional round fibers, the contact area and the friction between the fibers used in Tuftrücken nonwoven fabric and Tuftgarnen are relatively small, so that the holding force for Tuftgam especially in complicated carpet surface structures, such as in so-called high-low velor or Loop qualities or cross-over velor qualities (with polnoppene offset) are often insufficient. The introduced after piercing and retracting the tufting needle in the tufts back already by the combination of low Tuftrückendichten- and Gamspannungs- and Garnqualitätenschwankungen its intended position, that is, for example, the height or position of the knob, and possibly the Tuftgam even be pulled out of the tufa back. In both cases, this can lead to clearly visible defects and undesirable design deviations in the tufted carpet top layer.

Die bekannten als Tuftrücken eingesetzten herkömmlichen Vliesstoffe mit runden Fasern genügen daher den unterschiedlichen Anforderungen an eine besonders gute Haftung der eingetufteten Tuftgarne im Tuftrücken sowie an ein fehlerfreies Tuftbild in der Teppichoberschicht nicht immer zufriedenstellend.The known conventional tufts with round fibers used as Tuftrücken therefore satisfy the different requirements for a particularly good adhesion of the tufted tufted tufts in Tuftrücken and a flawless Tuftbild in the carpet top layer is not always satisfactory.

Aus dem Dokument US 6,740,385 B2 ist es bekannt, die Mustergleichmäßigkeit und die Dimensionsstabilität, insbesondere die Stabilität gegen Deformationen während und nach dem Tuftvorgang dadurch zu verbessern, dass enggewebte Textilien mit einer gleichmäßigen Vliesstoffschicht aus Stapelfasern in Kontakt gebracht und miteinander verschmolzen werden.From the document US 6,740,385 B2 It is known to improve the pattern uniformity and the dimensional stability, in particular the stability against deformation during and after the tufting process, by bringing intertwined textiles into contact with a uniform nonwoven layer of staple fibers and fusing them together.

Das Dokument GB 854,335 A beschreibt ein Verfahren zur Herstellung eines Florgewebes mit einem gemusterten Flor, das die Bildung eines Basisgewebes und die Sicherung mit Florgamen dazu umfasst, um Flore von Fasern zu erhalten, die sich von einer Seite des Basisgewebes erstrecken und wobei für bestimmte Teile des Flors synthetische Polymerfasern verwendet werden, welche vorher als Filamente oder Fasern festgelegt wurden, und wobei für bestimmte Teile des Flors synthetische Polymerfasern verwendet werden, welche erst nach der Bildung in gedrehte bzw. verdrillte Garne festgelegt werden. Das Basis- oder Rückengewebe besteht dabei aus einem Gewebe, insbesondere einem gewebten Sackleinen.The document GB 854,335 A describes a method of making a pile fabric having a patterned pile which includes the formation of a base fabric and the pile yarn fuse to provide pile of fibers extending from one side of the base fabric and using synthetic polymer fibers for certain portions of the pile which were previously defined as filaments or fibers, and wherein for certain parts of the pile synthetic polymer fibers are used, which are determined only after the formation in twisted yarns. The base or back fabric consists of a fabric, in particular a woven burlap.

Das Dokument US 4,617,218 A offenbart ein Verfahren zur Herstellung eines getufteten Teppichs mit einem dicht gelockten Erscheinungsbild eines persischen Lammes, das folgende Schritte umfasst: a) das Stricken, Knüpfen oder Wirken eines Teppichaußengarns, zusammengesetzt aus kontinuierlichen Filamenten oder gesponnenen Stapelfasern eines thermoplastischen, synthetischen Harzes; b) das Erhitzen des Gewebes auf eine Temperatur, bei der im Garn Kurven und Knicke erzeugt werden; c) das Abkühlen des Gewebes auf Raumtemperatur; d) das Entknüpfen und Abwickeln des Garns unter Spannung zum wieder Glätten; e) das, Tuften des Garns als Außengam in ein erstes Teppichrückenmaterial und die Bildung eines geschnittenen Florteppichs; f) das Beschichten der Unterseite des Teppichs mit einem hitzeabbindenden Kleber, g) das Erhitzen des beschichteten Teppichs.
Das erste Teppichrückenmaterial ist bevorzugt hergestellt aus gewebtem Polypropylen und der zweite Rücken aus gewebter Jute.The document US 4,617,218 A discloses a method for producing a tufted carpet having a tightly curled appearance of a Persian lamb, comprising the steps of: a) knitting, knotting or knitting an outer carpet yarn composed of continuous filaments or spun staple fibers of a thermoplastic synthetic resin; b) heating the fabric to a temperature at which bends and kinks are produced in the yarn; c) cooling the tissue to room temperature; d) unwinding and unwinding the yarn under tension to re-straighten; e) tufting the yarn as an external yarn into a first backing material and forming a cut pile carpet; f) coating the bottom of the carpet with a heat-setting adhesive, g) heating the coated carpet.
The first backing material is preferably made of woven polypropylene and the second backing is woven jute.

Das Dokument US 3,788,364 A beschreibt getuftete Florgewebe und deren Rücken. Der Rücken stellt dabei ein Gewebe aus Polyolefin-Kettgarnen und - Schussgarnen dar, wobei die Kettgarne gebildet sind aus flachen Band-Monofilamenten mit einem im Wesentlichen rechteckigen Querschnitt und mit engen Abständen und wobei die Schussgame einen relativ runden Querschnitt aufweisen und im Wesentlichen (weiter) außereinanderliegende Abstände. Der Abstandsindex als Produkt der Garnbreite und der Anzahl der Garne in inch beträgt bei den Kettgamen 1,3 bis 1,6 und bei den Schussgarnen 0,15 bis 0,45, wodurch beim Tuften die Kettgarne von einem relativ großen Anteil an Tuftgarnen durchdrungen werden und die Schussgarne von einen relativ kleinen Anteil an Tuftgarnen.The document US 3,788,364 A describes tufted pile fabrics and their backs. The back thereby represents a fabric of polyolefin warp yarns and weft yarns, wherein the warp yarns are formed from flat ribbon monofilaments having a substantially rectangular cross section and at close intervals and wherein the weft yarn has a relatively round cross section and substantially (further) Extra-spaced distances. The pitch index as the product of the yarn width and the number of yarns in inches is 1.3 to 1.6 for the warp yarns and 0.15 to 0.45 for the weft yarns, whereby the tufting penetrates the warp yarns by a relatively large proportion of tufted yarns and the weft yarns from a relatively small proportion of tufting yarns.

Das Dokument GB 816,185 A offenbart ein Verfahren zur Herstellung von gekräuselten Garnen, wobei ein Garn in ein Rückenmaterial getuftet wird, um ein getuftetes Florgewebe zu erhalten, das genannte Florgewebe einer Behandlung unterworfen wird, bei der Schlaufen in das getuftete Garn gesetzt/genäht werden und wobei das gesetzte Garn wieder aus dem Rückenmaterial entfernt bzw. gezogen wird. Bei dem Rückenmaterial handelt es sich bevorzugt um ein Gewebe.The document GB 816.185 A discloses a method of producing crimped yarns wherein a yarn is tufted into a backing material to obtain a tufted pile fabric which is subjected to a treatment of said pile fabric in which loops are set / sewn into the tufted yarn and wherein the set yarn returns is removed or pulled from the backing material. The backing material is preferably a fabric.

Darstellung der ErfindungPresentation of the invention

Die Erfindung hat sich die Aufgabe gestellt, ein alternatives, möglichst einfaches und wirtschaftliches Verfahren zur Herstellung eines Tuftprodukts, insbesondere einer getufteten Teppichoberschicht, mit verbesserten Noppenhaftungseigenschaften anzugeben. Die nach dem Verfahren hergestellte Teppichoberschicht soll dabei insbesondere im Automobilinnenbereich oder im Objektbereich Verwendung finden. Mit dem Begriff "Objektbereich" ist gemeint, dass der Teppichbelag besonders für stark bis extrem beanspruchte Flächen ausgelegt ist, insbesondere in Büros, Hotels, Flughäfen und/oder Krankenhäusern.The invention has the object of an alternative, possible to provide a simple and economical process for producing a tufted product, in particular a tufted carpet topcoat, with improved nap-sticking properties. The carpet top layer produced by the process is intended to be used in particular in the automotive interior or in the object sector. By the term "object area" is meant that the carpet is designed especially for heavily to extremely stressed areas, especially in offices, hotels, airports and / or hospitals.

Die Lösung der gestellten Aufgabe wird mit den Merkmalen des Anspruchs 1 bzw. des Anspruchs 17 erreicht.The solution of the problem is achieved with the features of claim 1 and of claim 17.

Danach werden im Verfahren zur Herstellung eines Tuftprodukts, insbesondere einer getufteten Teppichoberschicht, spleißfähige Fasern im Tuftrücken in Form eines Vlieses oder Vliesstoffes, eingesetzt, die beim Tuften an oder im Bereich der Einstichstelle des Tuftrückens aufspleißen.Thereafter, in the process for producing a tufted product, in particular a tufted carpet top layer, splittable fibers in the back of the tufts in the form of a nonwoven or nonwoven fabric are used which splice on tufting at or in the region of the puncture site of the tufts back.

Unter Fasern werden hier Stapelfasern oder Endlosfasern, sogenannte Filamente, verstanden. Die Fasern können ebenfalls zu Vliesen, insbesondere zu verfestigten Vliesen, den Vliesstoffes, zusammengelegt sein.Fibers are understood here to mean staple fibers or continuous fibers, so-called filaments. The fibers may also be combined into nonwovens, in particular nonwoven webs, the nonwoven fabric.

Die mechanische Belastung des Einstechens der Tuftnadeln in die Fasern des Tuftrückens führt dazu, dass die spleißfähigen Fasern aufspleißen.The mechanical stress of piercing the tufting needles into the fibers of the tuft back causes the spliceable fibers to splice.

Die Folge ist, dass der Tuftrücken lokal an der Einstichstelle durch die Trennung oder den Zerfall der spleißfähigen Fasern in Einzelfilamente oder Segmente quasi verfilzt, wodurch die spezifische Faseroberfläche in diesem Bereich des Tuftrückens vergrößert und dadurch auch die Haft- und Gleitreibung zwischen den Fasern des Tuftgarns und des Tuftrückens erhöht wird.The result is that the tufts backs are locally felted at the puncture site by the separation or disintegration of the spliceable fibers into single filaments or segments, thereby increasing the specific fiber surface in this area of the tufts back and thereby also the static friction and sliding friction between the fibers of the tuft and the back of the tuft is increased.

Damit ist gewährleistet, dass das mit der Tuftnadel eingeführte Tuftgarn besonders gut im Tuftrücken haftet und ein unerwünschtes Herausziehen des Tuftgams verhindert wird.This ensures that the tufted yarn introduced with the tufting needle adheres particularly well to the back of the tufts and prevents unwanted pulling out of the tufting yarn.

Die Art der eingesetzten Fasern erlaubt folglich die Bildung besonders stabiler Tuftgarnschlaufen oder Noppen und die Bildung eines besonders fehlerfreien Tuftbildes im Teppich.The type of fibers used thus allows the formation of particularly stable Tuftgarnschlaufen or nubs and the formation of a particularly flawless Tuftbildes in the carpet.

Die Unteransprüche stellen vorteilhafte Weiterbildungen des Erfindungsgegenstands dar.The dependent claims represent advantageous developments of the subject invention.

Vorzugsweise werden dabei spleißfähige Fasern mit einem Anteil von 10 bis 100 Gew.% eingesetzt.Preferably spliceable fibers are used in a proportion of 10 to 100 wt.%.

In bevorzugter Ausgestaltung des Verfahrens wird eine Mischung aus spleißfähigen und nicht-spleißfähigen Fasern eingesetzt. Das Verhältnis aus spleißfähigen und nicht-spleißfähigen Fasern kann abhängig von der Teppich- bzw. Tuftspezifikation eingestellt werden. Bei vergleichsweise einfachen Tuftspezifikationen, wie zum Beispiel bei geradeaus und ohne Versatz getufteter Veloursware, beträgt der Anteil an spleißfähigen Fasern bevorzugt gleich oder kleiner 50 Gew.%. Bei vergleichsweise komplizierten Tuftspezifikationen, wie zum Beispiel bei Hoch-Tief- oder Cross-Over-Veloursware, beträgt der Anteil an spleißfähigen Fasern bevorzugt gleich oder größer 75 Gew.-%.In a preferred embodiment of the method, a mixture of spliceable and non-splittable fibers is used. The ratio of spliceable and non-splittable fibers can be adjusted depending on the carpet or tuft specification. For comparatively simple tuft specifications, such as velvets tufted straight and without offset, the proportion of spliceable fibers is preferably equal to or less than 50% by weight. For comparatively complicated tuft specifications, such as high-low or cross-over suede, the proportion of spliceable fibers is preferably equal to or greater than 75% by weight.

Vorteilhafterweise werden als spleißfähige Fasern mindestens zwei miteinander unverträgliche (inkompatible) Polymerkomponenten eingesetzt.Advantageously, at least two mutually incompatible (incompatible) polymer components are used as spliceable fibers.

Bevorzugt weist zumindest eine Polymerkomponente einen geringeren Gewichtsanteil auf als die andere(n) Polymerkomponente(n).At least one polymer component preferably has a lower one Weight fraction as the other (s) polymer component (s).

In bevorzugter Ausgestaltung des Verfahrens weist zumindest eine Polymerkomponente einen Gewichtsanteil von gleich oder kleiner 20 Gew.-% auf, bevorzugt von gleich oder kleiner 10 Gew.-%, besonders bevorzugt von gleich oder kleiner 5 Gew.%, ganz besonders bevorzugt von bis zu 3 Gew.-%, bezogen auf das Gesamtgewicht der Fasern.In a preferred embodiment of the method, at least one polymer component has a weight fraction of equal to or less than 20% by weight, preferably equal to or less than 10% by weight, particularly preferably equal to or less than 5% by weight, very particularly preferably up to 3 wt .-%, based on the total weight of the fibers.

Durch den minimalen Gewichtsanteil einer Komponente, insbesondere von vergleichsweise teuren Polymeren, können die Herstellungskosten für die Tuftprodukte, insbesondere für die getuftete Teppichoberschicht, reduziert werden. Ein weiteres Kostenerspamispotential besteht darin, dass man wegen der verbesserten Noppenhaftung die Menge an Fixierungsmittel oder Vorstrich, der in der Teppichindustrie üblicherweise zur endgültigen Fixierung des Teppichgarns eingesetzt wird, reduzieren kann. Zudem kann durch die Herabsetzung der erforderlichen Menge an Fixierungsmittel oder Vorstrichen, wie beispielsweise an Latexverbindungen, die Geruchs- und Emissionsbildung, insbesondere in geschlossenen Räumen, wie zum Beispiel im Fahrgastinnenraum eines Automobils, reduziert werden.Due to the minimal proportion by weight of a component, in particular of comparatively expensive polymers, the production costs for the tufted products, in particular for the tufted carpet top layer, can be reduced. Another cost saving potential is that because of the improved nub adhesion, one can reduce the amount of fixative or precoat that is commonly used in the carpet industry for final fixation of the carpet yarn. In addition, by reducing the required amount of fixative or precursors, such as to latex compounds, odors and emissions can be reduced, especially in confined spaces such as in the passenger compartment of an automobile.

Ferner können unerwünschte Eigenschaften einer Komponente, wie beispielsweise eine niedrige Temperatur oder Flammbeständigkeit, durch den Einsatz eines lediglich minimalen Anteils dieser Komponente verringert werden. Auch kann die deutliche Herabsetzung eines Polymeranteils die Recyclingfähigkeit verbessern.Furthermore, undesirable properties of a component, such as a low temperature or flame resistance, can be reduced by using only a minimal amount of this component. Also, the significant reduction of a polymer content can improve the recyclability.

Zudem können durch den Einsatz spezifischer Gewichtsanteile der verwendeten Polymere die gewünschten Eigenschaften der Tuftprodukte, insbesondere der getufteten Teppichoberschicht, genau gesteuert werden.In addition, by using specific proportions by weight of the polymers used, the desired properties of the tuft products, in particular the tufted carpet top layer, can be precisely controlled.

In weiter bevorzugter Ausgestaltung des Verfahrens wird als Polymerkomponente mit einem geringeren Gewichtsanteil eine Polymerkomponente mit einer niedrigeren Schmelztemperatur eingesetzt.In a further preferred embodiment of the process, a polymer component having a lower melting temperature is used as the polymer component with a lower proportion by weight.

Vorteilhafterweise wird zumindest eine Polymerkomponente, bevorzugt eine Polymerkomponente mit einem geringeren Gewichtsanteil als die andere(n) Polymerkomponente(n), als Klebe- oder Bindekomponente eingesetzt, wobei die Schmelztemperatur dieser Polymerkomponente mindestens 10°C, bevorzugt mindestens 20°C, unter der Schmelztemperatur der anderen Polymerkomponente(n) liegt.Advantageously, at least one polymer component, preferably a polymer component with a lower weight fraction than the other (n) polymer component (s), used as adhesive or binder component, wherein the melting temperature of this polymer component at least 10 ° C, preferably at least 20 ° C, below the melting temperature the other polymer component (s).

Durch diese Maßnahme können die Eigenschaften des daraus hergestellten Tuftprodukts, insbesondere der getufteten Teppichoberschicht, beeinflusst werden, insbesondere kann dessen oder deren Grad der Verfestigung bzw. Weichheit eingestellt werden.By means of this measure, the properties of the tufted product produced therefrom, in particular the tufted carpet top layer, can be influenced, in particular its degree or degree of solidification or softness can be adjusted.

Bevorzugt werden die nicht-spleißfähigen Fasern ausgewählt aus Mono-, Bi-, Mehrpolymerkomponentenfasern und/oder aus Mischungen derartiger Fasern.Preferably, the non-splittable fibers are selected from mono-, bi-, multi-polymer component fibers and / or blends of such fibers.

Die Fasern werden ferner vorzugsweise ausgewählt aus thermoplastischen Polymeren, insbesondere aus Polyestern, bevorzugt Polyethylenterephthalat (PET), aus Polyolefinen, bevorzugt Polyethylen (PE) und/oder Polypropylen (PP), aus Polylactaten und/oder aus Polyamiden (PA), bevorzugt Polyamid 6.6 (PA6.6) und/oder aus daraus abgeleiteten Copolymeren.The fibers are furthermore preferably selected from thermoplastic polymers, in particular from polyesters, preferably polyethylene terephthalate (PET), from polyolefins, preferably polyethylene (PE) and / or polypropylene (PP), from polylactates and / or from polyamides (PA), preferably polyamide 6.6 (PA6.6) and / or copolymers derived therefrom.

Für spleißfähige Bikomponentenfasem werden Kombinationen von miteinander unverträglichen (inkompatiblen) Polymerkomponenten ausgewählt, bevorzugt Kombinationen von Polyethylenterephthalat (PET) und Polypropylen (PP), von Polyethylenterephthalat (PET) und Polyamid (PA), bevorzugt Polyamid 6 oder Polyamid 6.6, und/oder von Polypropylen (PP) und Polyethylen (PE).For spliceable bicomponent fibers, combinations of incompatible (incompatible) polymer components are selected, preferably combinations of polyethylene terephthalate (PET) and polypropylene (PP), polyethylene terephthalate (PET) and polyamide (PA), preferably polyamide 6 or polyamide 6.6, and / or polypropylene (PP) and polyethylene (PE).

Als Fasern werden solche ausgewählt, die vorteilhafterweise einen Titer im Bereich von 5 bis 20 dtex aufweisen, bevorzugt von 5 bis 12 dtex.The fibers selected are those which advantageously have a titre in the range from 5 to 20 dtex, preferably from 5 to 12 dtex.

Zur Verstärkung der Noppenhaftung werden Fasern ausgewählt, die vorzugsweise runde oder nicht-runde Querschnittsformen aufweisen. Nicht-runde Querschnittsformen führen gegenüber runden Fasern zu einer erhöhten Faser-Faser-Reibung und bedingen somit durch eine bessere Haftung untereinander eine verbesserte Noppenhaftung.To enhance the nub adhesion, fibers are selected which preferably have round or non-round cross-sectional shapes. Non-round cross-sectional shapes lead to increased fiber-to-fiber friction compared to round fibers and thus result in improved pimple adhesion due to better adhesion to one another.

Die ausgewählten Fasern sind ferner bevorzugt massiv oder hohl ausgestaltet.The selected fibers are further preferably solid or hollow.

In bevorzugter Ausgestaltung des Verfahrens zur Herstellung einer Teppichoberschicht werden die Fasern in Form eines Spinnvlieses oder eines Spinnvliesstoffes als Tuftrücken eingesetzt.In a preferred embodiment of the method for producing a carpet top layer, the fibers are used in the form of a spunbonded fabric or a spunbonded nonwoven fabric as tufa backs.

Zur Bildung von Klebepunkten zwischen dem Tuftgarn und zumindest einer Polymerkomponente, insbesondere der aufgespleißten Fasern, wird die Teppichoberschicht vorzugsweise nach dem Tuften einer Wärmebehandlung unterzogen. Dadurch wird die Noppenhaftung der Teppichoberschicht weiter verbessert.To form adhesive dots between the Tuftgarn and at least one polymer component, in particular the spliced fibers, the carpet top layer is preferably subjected to a heat treatment after tufting. As a result, the knobbed adhesion of the carpet top layer is further improved.

Die erfindungsgemäß hergestellten Tuftprodukte, insbesondere die getufteten Teppichoberschichten, finden bevorzugt Verwendung im Automobilinnenbereich und/oder im Objektbereich, insbesondere in Büros, Hotels, Flughäfen und/oder Krankenhäusern.The tufted products produced according to the invention, in particular the tufted carpet topcoats, are preferably used in the automotive interior and / or in the object sector, in particular in offices, hotels, airports and / or hospitals.

Ausführung der ErfindungEmbodiment of the invention

Der Gegenstand der Erfindung wird anhand eines Beispiels näher erläutert.

In Figur 1
ist eine REM-Aufnahme des Querschnitts segmentierter PET/PP-Piefasern mit einem Gewichtsverhältnis von 95 : 5 direkt nach dem Verspinnen in 1000-facher Vergrößerung gezeigt,
in Figur 2
ist eine REM-Aufnahme des Querschnitts segmentierter PET/PP-Piefasern mit einem Gewichtsverhältnis von 95 : 5 nach dem Verfestigen in 1000-facher Vergrößerung gezeigt,
in Figur 3
ist eine REM-Aufnahme eines 10-fach vergrößerten Ausschnitts der Oberfläche einer herkömmlichen Teppichoberschicht (nach dem Herausziehen des Tuftgams) gezeigt,
in Figur 4
ist eine REM-Aufnahme eines 10-fach vergrößerten Ausschnitts der Oberfläche einer erfindungsgemäß hergestellten Teppichoberschicht (nach dem Herausziehen des Tuftgams) gezeigt,
in Figur 5
ist eine REM-Aufnahme eines 100-fach vergrößerten Ausschnitts der Oberfläche der herkömmlichen Teppichoberschicht gemäß Figur 3 gezeigt,
in Figur 6
ist eine REM-Aufnahme eines 100-fach vergrößerten Ausschnitts der Oberfläche der erfindungsgemäß hergestellten Teppichoberschicht gemäß Figur 4 gezeigt,
in Figur 7
ist eine REM-Aufnahme eines 200-fach vergrößerten Ausschnitts der Oberfläche der erfindungsgemäß hergestellten Teppichoberschicht gemäß Figur 6 gezeigt.
The object of the invention will be explained in more detail with reference to an example.
In Figure 1
FIG. 3 shows an SEM image of the cross section of segmented PET / PP puff fibers with a weight ratio of 95: 5 directly after spinning at 1000 × magnification,
in FIG. 2
FIG. 3 shows a SEM image of the cross section of segmented PET / PP puff fibers with a weight ratio of 95: 5 after solidification at a magnification of 1000 ×. FIG.
in FIG. 3
FIG. 3 is an SEM photograph of a 10X enlarged section of the surface of a conventional carpet topcoat (after pulling out the tufting yarn). FIG.
in FIG. 4
FIG. 3 shows an SEM image of a 10-fold enlarged section of the surface of a carpet top layer produced according to the invention (after pulling off the tufted yarn), FIG.
in FIG. 5
is an SEM photograph of a 100-fold enlarged section of the surface of the conventional carpet top according to FIG FIG. 3 shown,
in FIG. 6
is an SEM image of a 100-fold enlarged section of the surface of the inventive carpet top layer according to FIG. 4 shown,
in FIG. 7
is an SEM image of a 200-fold enlarged section of the surface of the inventive carpet top layer according to FIG. 6 shown.

Die Rasterelektronenmikroskop-Aufnahmen (REM-Aufnahmen) ermöglichen Aufnahmen der Faser/Vliesquerschnitte und der Oberflächenstruktur mit den entsprechenden Vergrößerungen. Die REM-Aufnahmen wurden mit einem Niederdruck-Rasterelektronenmikroskop JEOL JSM-6480LV unter einer Beschleunigungsspannung von 20 kV erstellt.The scanning electron micrographs (SEM images) allow images of the fiber / nonwoven cross sections and the surface structure with the corresponding magnifications. The SEM images were taken with a low pressure scanning electron microscope JEOL JSM-6480LV under an acceleration voltage of 20 kV.

Gemäß der Erfindung werden zur Herstellung des Tuftprodukts, insbesondere der getufteten Teppichoberschicht, spleißfähige Fasern, insbesondere in Form eines Vliesstoffes, als Tuftrücken eingesetzt.According to the invention, spliceable fibers, in particular in the form of a nonwoven fabric, are used as tufts for the production of the tufted product, in particular the tufted carpet top layer.

Herstellung eines Vliesstoffes mit spleißfähigen FasernProduction of a nonwoven fabric with spliceable fibers

Ein Vliesstoff mit spleißfähigen Fasern mit einem Anteil von 100 Gew.-% wird beispielsweise wie folgt hergestellt.For example, a nonwoven fabric having spliceable fibers at a content of 100% by weight is prepared as follows.

a) Flächenwarea) fabric

Eingesetzt werden handelsübliches Polyethylenterephthalat (PET) mit einer intrinsischen Lösungsviskosität von 0,65 und Polypropylen (PP) mit einem MFI-Wert (Melt-Flow-Index, Schmelzflussindex) von 19 g/ 10 min (230°C/ 2,16 kg) in einem Gewichtsverhältnis von 95 : 5.Commercially available polyethylene terephthalate (PET) having an intrinsic solution viscosity of 0.65 and polypropylene (PP) having an MFI value (melt flow index, melt flow index) of 19 g / 10 min (230 ° C./2.16 kg) is used. in a weight ratio of 95: 5.

Diese werden zu PET/PP-Piefasern, insbesondere mit je vier Segmenten PET und PP, ausgesponnen und auf einem Siebband mit einer Bandgeschwindigkeit von 13 m/min abgelegt.These are spun off into PET / PP pief fibers, in particular with four segments each PET and PP, and laid down on a sieve belt with a belt speed of 13 m / min.

Die gesponnenen Filamente haben einen Titerwert von 9,5 dtex mit Festigkeitswerten von 29 mN/dtex und Dehnungswerten von 135 % (DIN 53812 und DIN 53816).The spun filaments have a linear density of 9.5 dtex with strength values of 29 mN / dtex and elongation values of 135% (DIN 53812 and DIN 53816).

b) Vorverfestigungb) preconsolidation

Die derart hergestellte Flächenware wird durch Kalandrierung vorverfestigt, wobei eine glatte und eine aufgeraute Walze mit den Oberflächentemperaturen von 100°C eingesetzt werden und wobei der Zylinderdruck 16 bar beträgt.The fabric produced in this way is preconsolidated by calendering, wherein a smooth and a roughened roll with the surface temperatures of 100 ° C are used and wherein the cylinder pressure is 16 bar.

c) Verfestigungc) solidification

Anschließend wird die Flächenware in einem Lufttrockner bei einer Lufttemperatur von 225°C endverfestigt.Subsequently, the fabric is finally solidified in an air dryer at an air temperature of 225 ° C.

d) Ausrüstungd) equipment

Daraufhin wird beispielsweise mit einer Sprühanlage eine wässrige Polydimethylsiloxan-Emulsion als Textilhilfsmittel (Avivage) aufgetragen, wobei die Feststoffkonzentration 5 Gew.-% und die Nassaufnahme 7 % beträgt (0,35 Gew.% Avivage bezogen auf das Vilesstoffgewicht).Then, for example, with a spray system an aqueous polydimethylsiloxane emulsion as textile auxiliaries (Avivage) is applied, wherein the solids concentration is 5 wt .-% and the wet pickup is 7% (0.35 wt.% Avivage based on the Vilesstoffgewicht).

Die Trocknung des mit Avivage ausgerüsteten Vliesstoffes erfolgt in einem Lufttrockner bei einer Lufttemperatur von 100°C.The drying of the nonwoven fabric finished with Avivage takes place in an air dryer at an air temperature of 100 ° C.

Damit wird ein Vliesstoff mit einem Gewicht von 115 g/m2 erhalten, der spleißfähige Fasern umfasst.Thus, a nonwoven fabric having a weight of 115 g / m 2 is obtained, which comprises splittable fibers.

Die Figur 1 zeigt, dass zwischen den PET- und den PP-Segmenten der gesponnenen spleißfähigen PET/PP-Piefasern trotz des niedrigen Gewichtsanteils des Polypropylens (PP) eine sehr gute, das heißt eine klare Segmentierung vorliegt.The FIG. 1 shows that between the PET and the PP segments of the spun spliceable PET / PP Piefasern despite the low proportion by weight of the polypropylene (PP) is a very good, that is a clear segmentation.

Die Figur 2 zeigt, dass nach dem Verfestigen der segmentierten PET/PP-Piefasem bereits eine leichte Vorspleißung der gesponnenen spleißfähigen PET/PP-Piefasern des Vliesstoffes durch den thermischen Verfestigungsschritt vorliegt.The FIG. 2 shows that after solidification of the segmented PET / PP prepregs, there is already a slight pre-splicing of the spun spliceable PET / PP ply fibers of the nonwoven fabric by the thermal consolidation step.

Tuftentufting

Ein als Tuftrücken eingesetzter Vliesstoff wird mit einem handelsüblichen Tuftgarn wie folgt getuftet.

  • 1/10" Teilung und in der Teppichbranche, insbesondere im Kraftfahrzeugbereich, Veloursausführung
  • Stichzahl: 56/10 cm
  • Tuftgarn: PA6 BCF 1300 dtex f128
  • Tuftgarngewicht; 400 g/ m2
A non-woven fabric used as tufts is tufted with a commercial Tuftgarn as follows.
  • 1/10 "pitch and in the carpet industry, especially in the automotive sector, velor finish
  • Number of stitches: 56/10 cm
  • Tuftgarn: PA6 BCF 1300 dtex f128
  • Tuftgarngewicht; 400 g / m 2

Dabei wird der Abstand der Tuftnadeln, die das Tuftgarn in den Tuftrücken, hier in den Vliesstoff-Tuftrücken, einbringen, in Bruchteilen von Zoll angegeben. 1/10° bedeutet somit 10 Nadeln pro 2,54 cm, also einen Abstand von 2,54 mm zwischen den Tuftnadeln.The distance between the tufting needles, which bring the Tuftgarn in the back of the tufts, here in the nonwoven tufts, in fractions of an inch. 1/10 ° thus means 10 needles per 2.54 cm, ie a distance of 2.54 mm between the tufting needles.

Der Abstand der Stiche entlang der Länge des Tuftrückens wird als Stichlänge bezeichnet. Die Zahl der Stiche wird pro 10 Zentimeter angeben. Sie bestimmt auch die Anzahl der Schlingen oder Noppen. Andere Tuftteilungen, wie zum Beispiel 6/32", 1/8", 5/64", 1/16" oder 1/22" können ebenfalls zur Herstellung der Teppichoberschichten eingesetzt werden.The distance of the stitches along the length of the tuft back is called the stitch length. The number of stitches is given per 10 centimeters. It also determines the number of loops or nubs. Other tuft pitches, such as 6/32 ", 1/8", 5/64 ", 1/16" or 1/22 "can also be used to make the top carpets.

Als Tuftgarn wird ein handelsübliches PA6 BCF 1300 dtex f128 eingesetzt, das für bulked continuous filament steht, insbesondere für ein texturiertes Endlosgarn aus Polyamid 6-Gamen mit einem Titer von 1300 dtex und aus 128 Einzelfilamenten. Andere übliche Tuftgame können ebenfalls eingesetzt werden.The tufted yarn used is a commercial PA6 BCF 1300 dtex f128, which stands for bulked continuous filament, in particular for a textured nylon yarn continuous yarn having a denier of 1300 dtex and 128 individual filaments. Other common tuft games can also be used.

Bevor die Tuftnadeln wieder zurücklaufen, wird das eingebrachte Tuftgarn von Greifern festgehalten, so dass Schlaufen oder Noppen auf der Oberseite des Tuftrückens entstehen.Before the tufting needles run back, the tufted yarn is held in place by grippers, so that loops or nubs on the top of the tufa back arise.

Auf diese Weise entsteht eine Schlingenflor-Teppichoberschicht. Wenn die Schlingen mit einem Messer aufgeschnitten werden, entsteht eine Schnittflor-Teppichoberschicht oder sogenannte Velours-Teppichoberschicht.In this way, a loop pile carpet top layer is created. When the loops are cut open with a knife, a cut pile carpet top layer or so-called velor carpet top layer is created.

ErgebnisseResults

Die erzielten physikalischen Werte einer derart hergestellten Teppichoberschicht, bei dem die spleißfähigen Fasern des Vliesstoffes nach dem Tuften im Bereich der Einstichstelle aufgespleißt sind, gestalten sich gegenüber einem getufteten herkömmlichen Standard-Vliesstoff Lutradur ® LDT 5312 (Freudenberg) wie folgt: erfindungsgemäß hergestellte Teppichoberschicht herkömmliche Teppichoberschicht Standard-Vliesstoff Lutradur ® LDT 53 12 Höchstzugkraft (Längs)
[N/5 cm]
(EN 29073 Teil 3) 218 (211 - 225) 287 (228 - 319) Höchstzugdehnung (Längs)
[%]
(EN 29073 Teil 3) 79 (78 - 80) 63(54-71) Weiterreißkraft (Längs)
[N]
(DIN 53859 Teil 3) 295 (276 - 314) 198(185-208) The obtained physical values of a carpet top layer produced in this way, in which the spliceable fibers of the nonwoven fabric are spliced after tufting in the area of the puncture site, are as follows compared to a tufted conventional standard nonwoven fabric Lutradur® LDT 5312 (Freudenberg): Carpet top layer produced according to the invention conventional carpet topcoat standard nonwoven Lutradur® LDT 53 12 Maximum tensile force (longitudinal)
[N / 5 cm]
(EN 29073 part 3) 218 (211 - 225) 287 (228 - 319) Maximum tensile strain (longitudinal)
[%]
(EN 29073 part 3) 79 (78 - 80) 63 (54-71) Tearing force (longitudinal)
[N]
(DIN 53859 part 3) 295 (276 - 314) 198 (185-208)

Die hohen Dehnungs- und Weiterreißkraftwerte zeigen, dass beim Tuften keine Schädigung der Vliesstoff-Fasern eingetreten ist,The high elongation and tear propagation values show that tufting did not damage the nonwoven fibers,

Die Figuren 4, 6 und 7 zeigen die Oberfläche einer erfindungsgemäß hergestellten getufeten Teppichoberschicht, das heißt hier eines beispielhaft unter den oben genannten Bedingungen getufteten Vliesstoffes mit aufgespleißten PET/PP-Piefasern nach dem Herausziehen des Tuftgarns, um eine freie Fläche für die REM-Aufnahmen zu erhalten.The FIGS. 4 . 6 and 7 show the surface of a tufted carpet top layer produced according to the invention, that is to say here a tufted non-woven fabric with spliced PET / PP pief fibers after extraction of the tuft yarn in order to obtain a free area for the SEM images.

Die Figuren 3 und 5 zeigen im Vergleich dazu die Oberfläche einer herkömmlichen getufteten Teppichoberschicht, das heißt eines getufteten herkömmlichen Standard Vliesstoffes (Lutradur ® LDT 53 12) mit getrennt gesponnenen PET- und PP-Monofasern nach dem Herausziehen des Tuftgarns, um eine freie Fläche für die REM-Aufnahmen zu erhalten. Die Tuftbedingungen entsprechen dabei genau den gleichen Bedingungen, denen der Vliesstoff mit spleißfähigen PET/PP-Piefasern ausgesetzt wurde.The Figures 3 and 5 show in comparison to the surface of a conventional tufted carpet top layer, that is, a tufted conventional standard nonwoven fabric (Lutradur ® LDT 53 12) with separated spun PET and PP monofilaments after pulling out the Tuftgarns, in order to obtain a free area for the SEM photographs. The Tuftbedingungen correspond exactly to the same conditions to which the nonwoven fabric was exposed with spliceable PET / PP Piefasern.

Während beim getufteten herkömmlichen Standard-Vliesstoff die Einstichstelle, das sogenannte Tuftloch, noch sehr gut sichtbar ist (Figuren 3 und 5), ziehen sich die Tuftlöcher des getufteten Vliesstoffes mit aufgespleißten Fasern nach dem Herausziehen des Tuftgarns zu kleineren Tuftlöchern zusammen (Figuren 4, 6 und 7).While the puncture site, the so-called tuft hole, is still very visible on the tufted conventional standard nonwoven fabric ( Figures 3 and 5 ), the tufted holes of the tufted nonwoven fabric with spliced fibers pull together after pulling the Tuftgarns to smaller tuft holes together ( FIGS. 4 . 6 and 7 ).

Die Figuren 6 und 7 zeigen außerdem, bedingt durch das Spleißen im Bereich der Einstichstelle, dem sogenannten Tuftlochbereich, herausgedrückte PP-Faserteile, die zu einer weiteren Erhöhung der spezifischen Faseroberfläche führen.The FIGS. 6 and 7 also show, due to the splicing in the region of the puncture site, the so-called Tuftlochbereich, pushed out PP fiber parts, which lead to a further increase in the specific fiber surface.

Da die Noppenhaftung von der Haftreibung zwischen den Fasern des Tuftrückens, vorliegend des Vliesstoffes, und des Tuftgarns abhängt, ist bedingt durch die kleineren zusammengezogenen Tuftlöcher und die erhöhte spezifische Faseroberfläche bei dem getufteten Vliesstoff mit aufgespleißten Fasern, das heißt der erfindungsgemäß hergestellten Teppichoberschicht, eine im Vergleich zu dem getufteten herkömmlichen Standard-Vliesstoff verbesserte Noppenhaftung zu erwarten.Since the dimpled adhesion depends on the stiction between the fibers of the tuft back, in this case the nonwoven fabric, and the Tuftgarns is due to the smaller contracted Tuftlöcher and the increased specific fiber surface in the tufted nonwoven fabric with spliced fibers, that is, the invention prepared carpet top layer, a in Compared to the tufted conventional standard nonwoven fabric to expect improved pimple adhesion.

Messung der NoppenhaftungMeasurement of knob adhesion

Um die Noppenhaftung zu messen, wird folgende Messmethode eingesetzt:To measure the knot adhesion, the following measuring method is used:

Der ungetuftete Tuftrücken, das heißt der Vliesstoff mit den spleißfähigen Fasern bzw. den nicht-spleißfähigen Fasern, der an einem Zug-Dehnungsgerät (Fa. Zwick) an einer speziellen Halterung eingespannt wird, wird von der Rückseite mit einer Einzeltuftnadel (Fa. Groz Beckert) gestochen. Anschließend wird das Garn, das auch zum Tuften eingesetzt wurde (PA6 BCF 1300 dtex 128f, Garnlänge 400 mm) in die Nadel eingefädelt, durch den Tuftrücken gezogen und parabel zum Tuftrücken an einer sehr fein auflösenden Kraftmessdose befestigt.The untufted tufts back, that is, the nonwoven fabric with the spliceable fibers or the non-spliceable fibers attached to a train-elongation device (Zwick) is clamped on a special holder, is engraved from the back with a Einzelteluftnadel (Groz Beckert). The yarn, which was also used for tufting (PA6 BCF 1300 dtex 128f, yarn length 400 mm), is then threaded into the needle, pulled through the back of the tufts and fixed parabolically to the back of the tufts on a very fine-resolution load cell.

Anschließend wird das vorgelegte Tuftgarn durch den Vliesstoff-Tuftrücken gezogen und die dafür aufzubringende Kraft gemessen. Je höher die Kraft ist, desto höher ist die Reibung zwischen dem Tuftgam und den Fasern des Vliesstoffes und desto höher ist die Noppenhaftung.Then the Tuftgarn presented is pulled through the fleece Tuftrücken and measured the force applied for it. The higher the force, the higher the friction between the tuft yarn and the fibers of the nonwoven fabric, and the higher the nub adhesion.

Es wurden 10 Messungen pro Material durchgeführt, wobei jedes Mal eine definierte Garnlänge von 400 mm mit einer Zuggeschwindigkeit von 200 mm/min durch den Tuftrücken-Vliesstoff gezogen wurde. Je Messung wurde der Mittelwert der Zugkraft über die 400 mm Garnlänge gebildet. Die Kraftdose mit einer Auflösung von ± 0,1 N hatte einen Maximalwert von 2 N.Ten measurements per material were made, each drawing a defined yarn length of 400 mm at a draw speed of 200 mm / min through the tuft back nonwoven fabric. For each measurement, the mean value of the tensile force over the 400 mm yarn length was formed. The power box with a resolution of ± 0.1 N had a maximum value of 2 N.

Ergebnisse der NoppenhaftungsmessungResults of the knot adhesion measurement

Die Noppenhaftungsmessung unter Einsatz des oben genannten Tuftgams (PA6 BCF 1300 dtex f128) liefert folgende Ergebnisse der spezifischen Noppenhaftung Nspez [N m2/ g] (in Anlehnung an EN 29073).The pint adhesion measurement using the abovementioned tufting yarn (PA6 BCF 1300 dtex f128) gives the following results of the specific nub adhesion N spec [N m 2 / g] (based on EN 29073).

Nspez (Standard-Vliesstoff, Lutradur ® LDT 5312): 0,94 N m2/ gN spec (standard nonwoven, Lutradur® LDT 5312): 0.94 N m 2 / g

Nspez (Vliesstoff mit aufgespleißten PET/PP-Piefasern): 0,99 N m2/ gN spec (nonwoven fabric with spliced PET / PP ply fibers): 0.99 N m 2 / g

(mit einer Standardabweichung von 0,02 N m2/ g)(with a standard deviation of 0.02 N m 2 / g)

Die Messergebnisse bestätigen, dass die Noppenhaftung des getufteten Vliesstoffes mit den aufgespleißten Fasern, das heißt die der erfindungsgemäß hergestellten Teppichoberschicht, gegenüber dem getufteten herkömmlichen Standard-Vliesstoff verbessert ist.The measurement results confirm that the nubbly adhesion of the tufted nonwoven fabric with the spliced fibers, that is to say that of the carpet top layer produced according to the invention, is improved compared to the tufted conventional standard nonwoven fabric.

Claims (17)

  1. Process for producing a tufted product, more particularly a tufted face layer of a carpet, wherein splittable fibres are used in the tuftable backing in the form of a fibrous nonwoven web or nonwoven which split open at and/or in the region of the point of insertion in the course of tufting.
  2. Process according to Claim 1, wherein splittable fibres are used in a proportion of 10% to 100% by weight.
  3. Process according to Claim 1 or 2, wherein a mixture of splittable and non-splittable fibres is used.
  4. Process according to any one of Claims 1 to 3, wherein splittable fibres are selected from at least two mutually incompatible polymeric components.
  5. Process according to Claim 4, wherein at least one polymeric component has a lower weight fraction than the other polymeric component(s).
  6. Process according to Claim 4 or 5, wherein at least one polymeric component has a weight fraction of not more than 20% by weight, preferably of not more than 10% by weight, more preferably of not more than 5% by weight and most preferably of not more than 3% by weight, based on the total weight of the fibres.
  7. Process according to any one of Claims 4 to 6, wherein a polymeric component having a lower melting temperature is used as polymeric component having a lower weight fraction.
  8. Process according to any one of Claims 4 to 7, wherein at least one polymeric component, preferably a polymeric component having a lower weight fraction than the other polymeric component(s), is used as bonding or binding component, the melting temperature of this polymeric component being at least 10°C and preferably at least 20°C below the melting temperature of the other polymeric component(s).
  9. Process according to any one of Claims 2 to 8, wherein the non-splittable fibres are selected from mono-, bi-, multipolymeric component fibres and/or from mixtures of such fibres.
  10. Process according to any preceding claim, wherein the fibres are selected from thermoplastic polymers, more particularly from polyesters, preferably polyethylene terephthalate (PET), from polyolefins, preferably polyethylene (PE) and/or polypropylene (PP), from polylactates and/or from polyamides (PA), preferably nylon-6,6 (PA66) and/or from copolymers derived therefrom.
  11. Process according to any preceding claim, wherein the splittable fibres are selected from combinations of polyethylene terephthalate (PET) and polypropylene (PP), of polyethylene terephthalate (PET) and polyamide (PA) and/or of polypropylene (PP) and polyethylene (PE).
  12. Process according to any preceding claim, wherein fibres selected have a linear density in the range from 5 to 20 dtex, preferably from 5 to 12 dtex.
  13. Process according to any preceding claim, wherein fibres selected have round and/or non-round cross-sectional shapes.
  14. Process according to any preceding claim, wherein fibres selected are solid or hollow.
  15. Process according to any preceding claim, wherein the fibres are used in the form of a spunbonded web or of a spunbonded nonwoven.
  16. Process according to any preceding claim, wherein the tufted product, more particularly the tufted face layer of a carpet, is subjected to at heat treatment after tufting.
  17. Use of a tufted product produced according to any one of process Claims 1 to 16, more particularly a thereby produced tufted face layer of a carpet, in the automotive interior sector and/or in the contract sector, more particularly in offices, hotels, airports and/or hospitals.
EP20080002082 2007-02-12 2008-02-05 Method for manufacturing a tufted product, tufted product and use thereof Not-in-force EP1961851B1 (en)

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ATE463601T1 (en) 2010-04-15
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