US3755055A - Non-woven needled pile fabric and method for its manufacture - Google Patents

Non-woven needled pile fabric and method for its manufacture Download PDF

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Publication number
US3755055A
US3755055A US00117626A US3755055DA US3755055A US 3755055 A US3755055 A US 3755055A US 00117626 A US00117626 A US 00117626A US 3755055D A US3755055D A US 3755055DA US 3755055 A US3755055 A US 3755055A
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fabric
face
woven
printed
backing
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US00117626A
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H Lochner
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Cik Chem Ind Kempen dt GmbH
CIK CHEM IND KEMPEN GmbH
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CIK CHEM IND KEMPEN GmbH
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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—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 entanglement of layered webs
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • 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
    • 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
    • Y10T428/2395—Nap type 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
    • Y10T428/23986—With coating, impregnation, or bond
    • 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
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
    • Y10T428/24901—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material including coloring matter

Definitions

  • the backing fabric and the Filed; 1971 face fabric are needled together so that the fibers of the [21] Appl.,No.: 117,626 backing fabric penetrate through the face fabric and mmgle with the fibers of the face fabr1c to form a pile on the face side of the face fabric.
  • the ornamental pat- 1 l Foreign Application Priority Data tern is thereby imparted with a soft three-dimensional Feb. 24, 1970 Germany P 20 08 439.3 appearance.
  • a method for producing [52] U.S. Cl 161/62, 28/722 R, 156/148, nomwoven pile fabric According to the method, a web 161/63 161/641 161/801 161/97 161/154 of a non-woven backing fabric is placed in face-to face [5 l] Int. Cl D0411 11/00 relationship with a web of nomwoven face fabric [58] Field of Search 161/62, 63, 64, 80, having a decorative pattern of pigment color primed on 161/154 67; 28/722 R; 156/148 its face side, with the printed face side of the face fabric facing away from the backing fabric.
  • the two webs are [56] References cued then needled from the free or uncovered side of the UNITED STATES PATENT backing fabric in a direction towards the face side of 3,191,257 6/1965 Smith 161/154 the face fabric 80 that the fibers 0f the backing fabric 2.132530 10/1938 Greiser. 28/722 penetrate through the face fabric and mingle with the 2,158,533 5/l939 Cavey 28/722 fibers of the printed face fabric to form a pile layer on the printed face side.
  • the backing fabric and the face Primary Examiner-George F. Lesmes fabric may be of a single color or of blended colors. Assistant Examiner-M. E.
  • the invention relates to needled and decoratively patterned non-woven fabrics which are composed of at least two non-woven fabric webs, stabilized or reinforced by needling.
  • Such needled, non-woven fabrics are primarily used as floor coverings and are either single-colored or, in the event that the fabric is made from a mixture of fibers of different colors, and this mixture is supplied to the web producing machine of blended color.
  • This blended type of non-woven fabric is more popular and has found wide acceptance. It is also feasible to print such needled, non-woven fabrics over their entire surface and throughout. This, however, requires considerably expenditure in machinery and costs. In practice, it has been suggested to accomplish the printing by means of pigment dyes or by generally soluble dyestuffs. Soluble dyes are preferred to pigment dyes since the former do not substantially affect the surface structure and appearance of the non-woven fabric in respect to its textile character.
  • the printing is effected with soluble dyes
  • the surface characteristics of the non-woven fabric retain their textile character after the printing.
  • the printing is customarily carried out after the mechanical stabilization by needling but prior to the subsequent stabilization by means of binders, to wit, prior to the impregnation of the fabric.
  • the web is subjected to a washing treatment.
  • This entails considerable technical difficulties, particularly in respect to webs of relatively great width since the washing treatment causes substantial distortions, both in the longitudinal and the transverse direction.
  • the washing step entails additional expenditure and requires a subsequent drying procedure, which again increases the costs.
  • Another object of the invention is to provide for a method of producing needled non-woven pile fabrics having decorative patterns of three-dimensional ap-' pearance which is exceedingly simple to carry out and which results in pile fabrics of superior quality and appearance.
  • a still further object of the invention is to provide a method of the indicated kind which renders an intermediate washing treatment, as required in the prior art procedures, unnecessary.
  • a needled, non-woven pile fabric comprises a first web of non-woven fabric which is of the nature of a backing fabric, and a second web of non-woven fabric which is in the nature of a face fabric.
  • the face fabric has its face side printed with an ornamental pattern, the printing being effected with pigment color or colors.
  • the two webs are placed in face-to-face relationship with the printed face side of the face fabric facing away from the backing fabric.
  • the backing fabric and the face fabric are needled together with the fibers of the backing fabric penetrating through the face fabric, the fibers of the backing fabric being mingled with the fibers of the printed face fabric and forming a pile on the face side of the face fabric.
  • the backing fabric may be of a single color or it may consist of fibers. of different colors so that a blended color results for the backing fabric.
  • a decorative pattern of one pigment color or of several pigment colors may be chosen.
  • the backing fabric web and the face fabric web which latter is printed on its face side with pigment color or colors to form a decorative pattern, are placed in face-to-face relationship so that the printed face side of the face fabric facesaway from the backing fabric.
  • the two fabrics are then needled, the barbed needles being pushed through the structure from'the free or uncovered rear side of the backing fabric through the face fabric.
  • the needling causes fibers of the backing fabric to penetrate the face fabric so that the penetrating backing fabric fibers mingle with the fibers of the printed face fabric and form a pile layer on the printed face side of the face fabric. In this manner the originally flat printed decorative pattern on the face side of the face fabric is transformed into a soft three-dimensional pattern.
  • the consumption of dyes is considerably reduced in the inventive procedure, as compared to the dye consumption in prior art procedures. Assuming that about half of the face side of the fabric is printed, only about one fourth of the dye stuff consumption of the prior art procedures is required. Further, since in accordance with the invention, pigment dyes are to be used, the subsequent washing treatment, as referred to above, is eliminated. In this manner the disadvantages of the washing treatment resulting in considerably longitudinal and transverse distortions and drafts are entirely obviated. The number of dyes or dye stuff to be used in the inventive procedure is unlimited.
  • a non'woven backing fabric was produced in conventional manner from polypropylene fibers of a staple length of 90 mm and a detex value of 17.
  • the fiber weight was 300 g/m.
  • the polypropylene fibers were spun dyed with a red color.
  • the face fabric was also of the non-woven kind and consisted of spun dyed polypropylene fibers of 90 mm length, a detex value of 17 and a m -W6lgl"
  • the color of the spun dyed fibers was also red.
  • the face fabric was now printed according to the screen printing procedure so as to impart it with the desired decorative pattern. In the present example, the printing was effected with a black pigment dye.
  • the face fabric was dried and the pattern was fixed.
  • the printing was effected on one side of the face fabric only, to wit, its face side.
  • the two fabric webs were then placed in face-to-face relationship with the printed face side of the face fabric being lowermost, and the backing fabric placed on top of the unprinted face of the face fabric.
  • the two webs were then subjected to needling, the needles passing through the web strucutre from the top so that they first penetrated the backing fabric and then the face fabric. Due to the needling, fibers of the backing fabric pass or penetrate through the face fabric and mingle, both at the printed areas and at the unprinted areas of the face fabric to form a color mixture while at the same time forming a pile on top of the face side of the face fabric.
  • the mixing of the printed fibers of the face fabric with the spun dyed fibers of the backing fabric under simultaneous formation of a pile from the fibers of the backing fabric causes a substantial elimination of the originally flat printing image. In fact, the desired three-dimensional textile effect is
  • FIG. 1 is an exploded view of the backing fabric and the face fabric in section;
  • FIG. 2 shows the backing fabric and the face fabric in face-to-face relationship with the needles of the needling machine being positioned above the structure;
  • FIG. 3 is a sectional view of the finished needled fabric structure
  • FIG. 4 shows a plan view of the structure of FIG. 3, the view being on the face side of the fabric.
  • reference numeral 10 generally indicates the backing fabric
  • reference numeral 20 generally refers to the face fabric.
  • Each fabric is of the non-woven kind and is composed of a multitude of fibers l and 2, respectively.
  • the face fabric has a face side 3 which is printed with a decorative pattern 4.
  • the decorative pattern is printed with pigment dyes and penetrates to some depth of the face fabric 20.
  • the two fabrics 10 and 20, shown in exploded view in FIG. 1 are superimposed into the formation shown in FIG. 2 in which the face side 3 of the face fabric 20 points in a downward position. Needles 6 having barbs 7 are now passed through the structure formed by the two webs 10, 20, the needles being mounted in a conventional needle machine not shown.
  • the backing fabric 10 Due to the needling, fibers l of the backing fabric 10 penetrate through the face fabric 20 and mingle with the printed and unprinted fibers 2 of the face fabric 20 to form a pile layer 9 on top of the face side 3 of the face fabric 20. In this manner a soft three-dimensional appearance is obtained.
  • the backing fabric 10 is of a single color. The same applies to the face fabric 20. However, the two fabrics could as well be of blended colors.
  • the finished structure may primarily be used for floor coverings in which event, of course, the pile carrying face side will point upwardly.
  • a method of producing a needled, decoratively patterned non-woven pile fabric which comprises: placing in face-to-face relationship a web of a nonwoven backing fabric and a web of a non-woven face fabric having a decorative pattern of pigment color printed on its face side, with the printed side of the fabric facing away from said backing fabric, and needling said webs from the uncovered side of the backing fabric towards said face side of the face fabric so that fibers of the backing fabric penetrate through said face fabric, mingle with fibers of the printed face fabric, and said mingled fibers form a pile layer on the printed face side of the face fabric, whereby said printed ornamental pattern is imparted with a soft, three-dimensional appearance.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Treatment Of Fiber Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Coloring (AREA)
  • Woven Fabrics (AREA)

Abstract

A needled, non-woven pile fabric comprises a non-woven backing fabric and a non-woven face fabric. The face fabric has its face side printed with an ornamental pattern of pigment color. The backing fabric and the face fabric are needled together so that the fibers of the backing fabric penetrate through the face fabric and mingle with the fibers of the face fabric to form a pile on the face side of the face fabric. The ornamental pattern is thereby imparted with a soft three-dimensional appearance. A method is also disclosed for producing the non-woven pile fabric. According to the method, a web of a non-woven backing fabric is placed in face-to face relationship with a web of nonwoven face fabric having a decorative pattern of pigment color printed on its face side, with the printed face side of the face fabric facing away from the backing fabric. The two webs are then needled from the free or uncovered side of the backing fabric in a direction towards the face side of the face fabric so that the fibers of the backing fabric penetrate through the face fabric and mingle with the fibers of the printed face fabric to form a pile layer on the printed face side. The backing fabric and the face fabric may be of a single color or of blended colors.

Description

Lochner NON-WOVEN NEEDLED PILE FABRIC AND METHOD FOR ITS MANUFACTURE Aug. 28, 1973 [57] ABSTRACT the [ lnvemofi Herbert LOChIIeHKemPCmGeTmaHY A needled, non-woven pile fabric comprises a non- [73] Assigneea Cik Chemische lndustrie Kempen woven backing fabric and a non-woven face fabric. The GmbH face fabr1c has 1ts face s1de printed w1th an ornamental pattern of pigment color. The backing fabric and the Filed; 1971 face fabric are needled together so that the fibers of the [21] Appl.,No.: 117,626 backing fabric penetrate through the face fabric and mmgle with the fibers of the face fabr1c to form a pile on the face side of the face fabric. The ornamental pat- 1 l Foreign Application Priority Data tern is thereby imparted with a soft three-dimensional Feb. 24, 1970 Germany P 20 08 439.3 appearance.
A method is also disclosed for producing [52] U.S. Cl 161/62, 28/722 R, 156/148, nomwoven pile fabric According to the method, a web 161/63 161/641 161/801 161/97 161/154 of a non-woven backing fabric is placed in face-to face [5 l] Int. Cl D0411 11/00 relationship with a web of nomwoven face fabric [58] Field of Search 161/62, 63, 64, 80, having a decorative pattern of pigment color primed on 161/154 67; 28/722 R; 156/148 its face side, with the printed face side of the face fabric facing away from the backing fabric. The two webs are [56] References cued then needled from the free or uncovered side of the UNITED STATES PATENT backing fabric in a direction towards the face side of 3,191,257 6/1965 Smith 161/154 the face fabric 80 that the fibers 0f the backing fabric 2.132530 10/1938 Greiser. 28/722 penetrate through the face fabric and mingle with the 2,158,533 5/l939 Cavey 28/722 fibers of the printed face fabric to form a pile layer on the printed face side. The backing fabric and the face Primary Examiner-George F. Lesmes fabric may be of a single color or of blended colors. Assistant Examiner-M. E. McCamish Atmmey 'roren & McGeady 5 Claims, 4 Drawing Figures "W i ,1 W1 1' l I l h Tl Patented Aug. 28, 1973 hf aw L r7624 MVE/Yrm a HERBERT LOCHNER awe We 0 WWW 5 FIELD OF THE INVENTION The invention relates to needled and decoratively patterned non-woven fabrics which are composed of at least two non-woven fabric webs, stabilized or reinforced by needling.
BACKGROUND INFORMATION AND PRIOR ART Such needled, non-woven fabrics are primarily used as floor coverings and are either single-colored or, in the event that the fabric is made from a mixture of fibers of different colors, and this mixture is supplied to the web producing machine of blended color. This blended type of non-woven fabric is more popular and has found wide acceptance. It is also feasible to print such needled, non-woven fabrics over their entire surface and throughout. This, however, requires considerably expenditure in machinery and costs. In practice, it has been suggested to accomplish the printing by means of pigment dyes or by generally soluble dyestuffs. Soluble dyes are preferred to pigment dyes since the former do not substantially affect the surface structure and appearance of the non-woven fabric in respect to its textile character. Thus, if the printing is effected with soluble dyes, the surface characteristics of the non-woven fabric retain their textile character after the printing. If soluble dyes are used, the printing is customarily carried out after the mechanical stabilization by needling but prior to the subsequent stabilization by means of binders, to wit, prior to the impregnation of the fabric. In this still relatively unstable condition of the non-woven fabric web, the web is subjected to a washing treatment. This, however, entails considerable technical difficulties, particularly in respect to webs of relatively great width since the washing treatment causes substantial distortions, both in the longitudinal and the transverse direction. In addition, of course, the washing step entails additional expenditure and requires a subsequent drying procedure, which again increases the costs.
Finally, it should be mentioned that the printing of non-woven fabrics results in relatively sharply defined pattern contours, an observation which applies to the printing of textile goods in general. These relatively sharp contours cause an undesired flat image or appearance, particularly with relatively voluminous textile structures, as for example, carpets. This fiat image or appearance is in contrast to woven fabrics. The flat appearance is undesired because with a carpet the character of the carpet structure is largely determined by the three-dimentional structure of the coloration.
SUMMARY OF THE INVENTION It is a primary object of the present invention to provide for a needled, non-woven fabric structure which overcomes the disadvantages of the prior art and which has a decoratively patterned face side of a soft and three-dimensional appearance.
Another object of the invention is to provide for a method of producing needled non-woven pile fabrics having decorative patterns of three-dimensional ap-' pearance which is exceedingly simple to carry out and which results in pile fabrics of superior quality and appearance.
Generally it is an object of the invention to improve on the art of non-woven needled fabric structures as presently practiced.
It is also an object of the invention to provide a method for the production of needled, decoratively patterned non-woven fabrics, composed of at least two non-woven fabric webs, stabilized or reinforced by needling in which, in spite of the printing for the decorative pattern, a three-dimensional color effect is obtained.
A still further object of the invention is to provide a method of the indicated kind which renders an intermediate washing treatment, as required in the prior art procedures, unnecessary.
. Finally, it is an object of the invention to provide a method of the indicated kind which is exceedingly economical.
Briefly, and in accordance with the invention, a needled, non-woven pile fabric comprises a first web of non-woven fabric which is of the nature of a backing fabric, and a second web of non-woven fabric which is in the nature of a face fabric.'The face fabric has its face side printed with an ornamental pattern, the printing being effected with pigment color or colors. The two webs are placed in face-to-face relationship with the printed face side of the face fabric facing away from the backing fabric. The backing fabric and the face fabric are needled together with the fibers of the backing fabric penetrating through the face fabric, the fibers of the backing fabric being mingled with the fibers of the printed face fabric and forming a pile on the face side of the face fabric. In this manner, the ornamental pattern is imparted with a soft, three-dimensional appearance. The backing fabric may be of a single color or it may consist of fibers. of different colors so that a blended color results for the backing fabric. The same applies to the face fabric which, however, on its face side is printed with the pigment colors. A decorative pattern of one pigment color or of several pigment colors may be chosen.
In accordance with the inventive method, the backing fabric web and the face fabric web, which latter is printed on its face side with pigment color or colors to form a decorative pattern, are placed in face-to-face relationship so that the printed face side of the face fabric facesaway from the backing fabric. The two fabrics are then needled, the barbed needles being pushed through the structure from'the free or uncovered rear side of the backing fabric through the face fabric. The needling causes fibers of the backing fabric to penetrate the face fabric so that the penetrating backing fabric fibers mingle with the fibers of the printed face fabric and form a pile layer on the printed face side of the face fabric. In this manner the originally flat printed decorative pattern on the face side of the face fabric is transformed into a soft three-dimensional pattern.
The mixing of the fibersof the printed non-woven face fabric with the fibers of the unprinted backing fabric, resulting in the formation of a pile on the face side appearance of the printed patterns so that the desired three-dimensional textile effect is achieved.
The consumption of dyes is considerably reduced in the inventive procedure, as compared to the dye consumption in prior art procedures. Assuming that about half of the face side of the fabric is printed, only about one fourth of the dye stuff consumption of the prior art procedures is required. Further, since in accordance with the invention, pigment dyes are to be used, the subsequent washing treatment, as referred to above, is eliminated. In this manner the disadvantages of the washing treatment resulting in considerably longitudinal and transverse distortions and drafts are entirely obviated. The number of dyes or dye stuff to be used in the inventive procedure is unlimited.
The invention will now be described by an example, it being understood, however, that this example is given by way of illustration and not by way of limitation, and that many changes may be effected without affecting in anyway the scope and spirit of the invention as recited in the appended claims.
EXAMPLE A non'woven backing fabric was produced in conventional manner from polypropylene fibers of a staple length of 90 mm and a detex value of 17. The fiber weight was 300 g/m. The polypropylene fibers were spun dyed with a red color. The face fabric was also of the non-woven kind and consisted of spun dyed polypropylene fibers of 90 mm length, a detex value of 17 and a m -W6lgl"|l of 200 g/m. The color of the spun dyed fibers was also red. The face fabric was now printed according to the screen printing procedure so as to impart it with the desired decorative pattern. In the present example, the printing was effected with a black pigment dye. After the printing, the face fabric was dried and the pattern was fixed. The printing was effected on one side of the face fabric only, to wit, its face side. The two fabric webs were then placed in face-to-face relationship with the printed face side of the face fabric being lowermost, and the backing fabric placed on top of the unprinted face of the face fabric. The two webs were then subjected to needling, the needles passing through the web strucutre from the top so that they first penetrated the backing fabric and then the face fabric. Due to the needling, fibers of the backing fabric pass or penetrate through the face fabric and mingle, both at the printed areas and at the unprinted areas of the face fabric to form a color mixture while at the same time forming a pile on top of the face side of the face fabric. The mixing of the printed fibers of the face fabric with the spun dyed fibers of the backing fabric under simultaneous formation of a pile from the fibers of the backing fabric causes a substantial elimination of the originally flat printing image. In fact, the desired three-dimensional textile effect is obtained.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this specification. For a better understanding of the invention, its operating advantages and specific objects attained by its use, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated and described a preferred embodiment of the invention.
IN THE DRAWINGS FIG. 1 is an exploded view of the backing fabric and the face fabric in section;
FIG. 2 shows the backing fabric and the face fabric in face-to-face relationship with the needles of the needling machine being positioned above the structure;
FIG. 3 is a sectional view of the finished needled fabric structure; and
FIG. 4 shows a plan view of the structure of FIG. 3, the view being on the face side of the fabric.
Referring now to the drawings, reference numeral 10 generally indicates the backing fabric, while reference numeral 20 generally refers to the face fabric. Each fabric is of the non-woven kind and is composed of a multitude of fibers l and 2, respectively. The face fabric has a face side 3 which is printed with a decorative pattern 4. The decorative pattern is printed with pigment dyes and penetrates to some depth of the face fabric 20. For producing the inventive fabric structure, the two fabrics 10 and 20, shown in exploded view in FIG. 1, are superimposed into the formation shown in FIG. 2 in which the face side 3 of the face fabric 20 points in a downward position. Needles 6 having barbs 7 are now passed through the structure formed by the two webs 10, 20, the needles being mounted in a conventional needle machine not shown. Due to the needling, fibers l of the backing fabric 10 penetrate through the face fabric 20 and mingle with the printed and unprinted fibers 2 of the face fabric 20 to form a pile layer 9 on top of the face side 3 of the face fabric 20. In this manner a soft three-dimensional appearance is obtained. In the embodiment here shown, the backing fabric 10 is of a single color. The same applies to the face fabric 20. However, the two fabrics could as well be of blended colors.
The finished structure may primarily be used for floor coverings in which event, of course, the pile carrying face side will point upwardly.
What is claimed is:
l. A method of producing a needled, decoratively patterned non-woven pile fabric, which comprises: placing in face-to-face relationship a web of a nonwoven backing fabric and a web of a non-woven face fabric having a decorative pattern of pigment color printed on its face side, with the printed side of the fabric facing away from said backing fabric, and needling said webs from the uncovered side of the backing fabric towards said face side of the face fabric so that fibers of the backing fabric penetrate through said face fabric, mingle with fibers of the printed face fabric, and said mingled fibers form a pile layer on the printed face side of the face fabric, whereby said printed ornamental pattern is imparted with a soft, three-dimensional appearance.
2. A method as claimed in claim 1, wherein said web of non-woven backing fabric is of a single color or of blended colors.
3. A method as claimed in claim 1, wherein said fabric is of a single color or of blended colors.
4. A method as claimed in claim 1, wherein said pattern is printed with a single or with several pigment colors.

Claims (4)

  1. 2. A method as claimed in claim 1, wherein said web of non-woven backing fabric is of a single color or of blended colors.
  2. 3. A method as claimed in claim 1, wherein said fabric is of a single color or of blended colors.
  3. 4. A method as claimed in claim 1, wherein said pattern is printed with a single or with several pigment colors.
  4. 5. The product made by the process of claim 1.
US00117626A 1970-02-24 1971-02-22 Non-woven needled pile fabric and method for its manufacture Expired - Lifetime US3755055A (en)

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DE19702008439 DE2008439B1 (en) 1970-02-24 1970-02-24 Process for the production of needled and ornamentally patterned nonwovens composed of at least two nonwoven webs consolidated by needling

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AT (1) AT319623B (en)
BE (1) BE763256A (en)
CH (2) CH205171A4 (en)
DE (1) DE2008439B1 (en)
DK (1) DK139233C (en)
ES (1) ES388343A1 (en)
FI (1) FI47671C (en)
FR (1) FR2080715B1 (en)
GB (1) GB1333462A (en)
IE (1) IE34953B1 (en)
NL (1) NL7102222A (en)
NO (1) NO126492B (en)

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3873388A (en) * 1972-04-21 1975-03-25 Hunter Mildred B Mattress pad and method and apparatus for constructing the same
US4144366A (en) * 1977-09-06 1979-03-13 Armstrong Cork Company Multi-colored pattern bonded fabric
US4211593A (en) * 1977-04-18 1980-07-08 Cikalon Vliesstoffwerk Gmbh Method of making a needled and ornamentally patterned fleece material
US5725927A (en) * 1995-05-23 1998-03-10 Firma Carl Freudenberg Cleaning cloth
US8778174B2 (en) 2010-10-15 2014-07-15 Alfa Laval Ashbrook Simon-Hartley Inc. Methods and apparatus for treating water and wastewater employing a cloth disk filter
US8852445B2 (en) 2011-10-28 2014-10-07 Alfa Laval Ashbrook Simon-Hartley, Inc Methods and apparatus for treating water and wastewater employing a cloth disk filter
WO2016034529A1 (en) 2014-09-03 2016-03-10 Alfa Laval Corporate Ab Filtering apparatus
WO2016034530A1 (en) 2014-09-03 2016-03-10 Alfa Laval Corporate Ab Filtering apparatus
WO2016034535A1 (en) 2014-09-02 2016-03-10 Alfa Laval Corporate Ab Methods and apparatus for treating water and wastewater
DE102019100919A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needle-punched carpet surface (II)
DE102019100922A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needle-punched carpet surface (III)
DE102019100916A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needled carpet surface
WO2021001439A1 (en) 2019-07-04 2021-01-07 Adler Pelzer Holding Gmbh Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface
US11529573B2 (en) 2019-04-23 2022-12-20 Greatpyr Resources Llc Systems and processes employing wet/dry suction filter

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CH610695GA3 (en) * 1976-04-05 1979-05-15 Process for producing a single- or multi-coloured patterned flat structure
DE2615519C3 (en) * 1976-04-09 1982-07-08 Elektrochemische Fabrik Kempen Gmbh, 4152 Kempen Process for the production of a needled and ornamentally patterned nonwoven fabric
DE3334191A1 (en) * 1982-09-24 1984-06-20 VEB Forster Tuchfabriken, DDR 7570 Forst Process for the finishing of textile sheet-like structures
EP0411248B1 (en) * 1989-08-03 1995-10-25 Oskar Dilo Maschinenfabrik KG Method for producing patterned textile needled felt or needled fleece sheets

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US2132530A (en) * 1935-12-13 1938-10-11 Carthage Mills Inc Decorative needled fabric
US2158533A (en) * 1938-02-02 1939-05-16 Carthage Mills Inc Means and method for the manufacture of decorative needled fabrics
US3191257A (en) * 1961-03-13 1965-06-29 Fiberwoven Corp Method for making a decorative napped needled fabric

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US2132530A (en) * 1935-12-13 1938-10-11 Carthage Mills Inc Decorative needled fabric
US2158533A (en) * 1938-02-02 1939-05-16 Carthage Mills Inc Means and method for the manufacture of decorative needled fabrics
US3191257A (en) * 1961-03-13 1965-06-29 Fiberwoven Corp Method for making a decorative napped needled fabric

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3873388A (en) * 1972-04-21 1975-03-25 Hunter Mildred B Mattress pad and method and apparatus for constructing the same
US4211593A (en) * 1977-04-18 1980-07-08 Cikalon Vliesstoffwerk Gmbh Method of making a needled and ornamentally patterned fleece material
US4144366A (en) * 1977-09-06 1979-03-13 Armstrong Cork Company Multi-colored pattern bonded fabric
US5725927A (en) * 1995-05-23 1998-03-10 Firma Carl Freudenberg Cleaning cloth
US8778174B2 (en) 2010-10-15 2014-07-15 Alfa Laval Ashbrook Simon-Hartley Inc. Methods and apparatus for treating water and wastewater employing a cloth disk filter
US8852445B2 (en) 2011-10-28 2014-10-07 Alfa Laval Ashbrook Simon-Hartley, Inc Methods and apparatus for treating water and wastewater employing a cloth disk filter
US10905981B2 (en) 2011-10-28 2021-02-02 Alfa Laval Corporate Ab Methods and apparatus for treating water and wastewater employing a cloth filter
WO2016034535A1 (en) 2014-09-02 2016-03-10 Alfa Laval Corporate Ab Methods and apparatus for treating water and wastewater
WO2016034530A1 (en) 2014-09-03 2016-03-10 Alfa Laval Corporate Ab Filtering apparatus
WO2016034529A1 (en) 2014-09-03 2016-03-10 Alfa Laval Corporate Ab Filtering apparatus
DE102019100919A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needle-punched carpet surface (II)
DE102019100922A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needle-punched carpet surface (III)
DE102019100916A1 (en) 2019-01-15 2020-07-16 Adler Pelzer Holding Gmbh Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needled carpet surface
WO2020148145A1 (en) 2019-01-15 2020-07-23 Adler Pelzer Holding Gmbh Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface
WO2020148150A1 (en) 2019-01-15 2020-07-23 Adler Pelzer Holding Gmbh Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface
WO2020148147A1 (en) 2019-01-15 2020-07-23 Adler Pelzer Holding Gmbh Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface (ii)
US11529573B2 (en) 2019-04-23 2022-12-20 Greatpyr Resources Llc Systems and processes employing wet/dry suction filter
WO2021001439A1 (en) 2019-07-04 2021-01-07 Adler Pelzer Holding Gmbh Motor vehicle floor covering, boot or trunk covering or load compartment covering having a structurally needle-punched carpet surface
DE102019118163A1 (en) * 2019-07-04 2021-01-07 Adler Pelzer Holding Gmbh Motor vehicle floor paneling, luggage compartment paneling or loading floor paneling with textured needled carpet surface (IV)

Also Published As

Publication number Publication date
CH205171A4 (en) 1972-12-15
IE34953L (en) 1971-08-24
NO126492B (en) 1973-02-12
CH535311A (en) 1972-12-15
FI47671B (en) 1973-10-31
IE34953B1 (en) 1975-10-01
FI47671C (en) 1974-02-11
GB1333462A (en) 1973-10-10
DE2008439B1 (en) 1971-08-26
DK139233B (en) 1979-01-15
FR2080715A1 (en) 1971-11-19
DK139233C (en) 1979-07-02
BE763256A (en) 1971-07-16
AT319623B (en) 1974-12-27
ES388343A1 (en) 1974-01-16
FR2080715B1 (en) 1974-02-15
NL7102222A (en) 1971-08-26

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