EP1233097A1 - Substrate for tufted carpet and process of manufacturing - Google Patents

Substrate for tufted carpet and process of manufacturing Download PDF

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Publication number
EP1233097A1
EP1233097A1 EP01130147A EP01130147A EP1233097A1 EP 1233097 A1 EP1233097 A1 EP 1233097A1 EP 01130147 A EP01130147 A EP 01130147A EP 01130147 A EP01130147 A EP 01130147A EP 1233097 A1 EP1233097 A1 EP 1233097A1
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EP
European Patent Office
Prior art keywords
fibers
filaments
tufting
carrier
dtex
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP01130147A
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German (de)
French (fr)
Other versions
EP1233097B1 (en
Inventor
Peter Sander
Detlef Barbier
Ulrike Maass
Engelbert Löcher
Ararad Dr. Emirze
Klaus Klein
Christine Dr. König
Rudolf Gärtner
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Carl Freudenberg KG
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Carl Freudenberg KG
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Publication of EP1233097A1 publication Critical patent/EP1233097A1/en
Application granted granted Critical
Publication of EP1233097B1 publication Critical patent/EP1233097B1/en
Anticipated expiration legal-status Critical
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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/11—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/03—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
    • D04H3/033—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random reorientation immediately after yarn or filament formation
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/10—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
    • D04H3/105—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D05C17/023—Tufted products characterised by the base fabric
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0254—Polyolefin fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2207/00—Treatments by energy or chemical effects
    • D06N2207/04—Treatments by energy or chemical effects using steam
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2209/00—Properties of the materials
    • D06N2209/16—Properties of the materials having other properties
    • D06N2209/1628—Dimensional stability
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/30—Woven fabric [i.e., woven strand or strip material]
    • Y10T442/3179—Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
    • Y10T442/3187—Triaxially woven fabric

Definitions

  • the invention relates to a tufting carrier and a method for the production of a tufted carrier made from a spunbond thermoplastic polymer fibers or filaments.
  • Document EP-A 079 56 37 discloses the use of nonwovens made from polyester and copolyester fibers as tuft carriers for tufted carpets, which are reinforced by parallel, straight, load-absorbing continuous plastic threads. With this measure, despite a basis weight of only 80 to 150 g / m 2, a tuft carrier is to be obtained which is resistant to the effects of tension, temperature and moisture during dyeing, tufting and steaming during the manufacture and processing into tufted carpets, in particular with regard to the loss of width ,
  • document DE-U 94 11 993 discloses a nonwoven fabric for coating carpet backs, in which the solidified nonwoven element having a basis weight of 20 to 220 g / m 2 is reinforced by a Maliwatt process with warp threads made from foil tapes. This should improve the pedaling comfort, the connection with the carpet fabric, the shape of the carpet and its recyclability.
  • tufted carriers consist of consist of continuous filaments of a thermoplastic synthetic resin and transverse thermal shrinkage when dry show in the range from -10 to 0% measured according to JIS L 1906.
  • the Tufting carriers are made of a high-melting and a low-melting component built.
  • WO 96/29460 discloses tufted carpets which consist of one Tufting carrier and an adhesive binder exist.
  • the binder should be there preferably be a thermoplastic polymer on the tufted carrier upset or connected to it.
  • the invention has for its object to provide a tufted carrier, the from a spunbond with low raw material costs without reinforcing yarns, laid, the binding without (costly) auxiliary components such as binding fibers or binders.
  • the tufting carrier should continue to be high Have dimensional stability in the tufting and dyeing process and a good one Ensure carpet yarn binding.
  • the invention has also set itself the task of specifying a method for producing a tufting carrier that, while simplifying the production process, makes inexpensive, light nonwovens with basis weights of 70 to 110 g / m 2 available as tufting carriers, with the method achieving improved dimensional stability ,
  • the object is achieved in that the tufting carrier consists of synthetic fibers or filaments which are intertwined in three dimensions, only fibers or filaments with a titer of 1 to 15 dtex being contained, that is to say that the tufting carrier is produced without an additional binding component and so it's environmentally friendly. Furthermore, reinforcement aids such as yarns or scrims are not used.
  • the basis weight of the tufting carrier is 70 to 110 g / m 2 , its density 0.18 to 0.28 g / cm 3 and the 5% module value in the machine direction> 60 N / 5 cm, but at least 0.6 N / g / m 2 ,
  • the tufting carrier is dimensionally stable during further processing in the tufting and dyeing process.
  • the tufting carrier is advantageously one in which the fibers or filaments have a titer of 3 to 12 dtex, the 5% module value in the machine direction 70 to 100 N / 5 cm, but at least 0.7 to 1.0 N / g / m 2 is.
  • the tufted carrier is included Finishing agents or surface-active substances.
  • Equipment facilitates the introduction of pile yarn during the tufting process.
  • a tufted carrier that is only made of is particularly preferred There is polyethylene terephthalate. The manufacture from a uniform Material simplifies recyclability.
  • a tufted carrier which is made only of polypropylene consists.
  • Such a tufted carrier is recyclable.
  • the inventive method for producing a tuft carrier from a spunbonded thermoplastic polymer fiber or - filaments is characterized in that the fibers or filaments with a titer of 6 to 15 dtex by needling and those with a titer of 1 up to 5 dtex by water jets or by a combination of these Processes are solidified and before drying and heat setting Stretching in the longitudinal direction takes place up to 30%, the mobility of the Fibers may be improved by adding oil or other additives becomes.
  • the stretching process between the individual is advantageous Needling stages or after completion of the needling process performed.
  • the stretching process takes place cold or through when wet Steam heated (100 ° C).
  • the surface integration and the Thickness uniformity can be partial after heat setting Compacting made using embossing rollers, the engraving points the embossing roller take up a printing area of 18% to 25% and one Form diamond, line or hexagonal shape.
  • the embossing rollers can have an irregular surface structure Have a roughness depth of 40 to 100 ⁇ m.
  • the spinning of PET fibers and placing them on a wire belt to form a spunbonded web was carried out at a belt speed of 15 m / min.
  • a commercially available PET raw material is treated with a solution viscosity - used of 0.67 (I ntrinsic v iscosity IV value).
  • the spun filaments have a titer value of 4.3 dtex with strength and elongation values of 30 mN / dtex or 110%.
  • the filament shrinkage value was below 1%.
  • the surface goods were pre-consolidated by needling, the penetration depth being 6 mm and the penetration density 60 U / cm 2 .
  • the 15x18x40 needles used were from Groz Beckert.
  • the stretching process with the hydroentangled product was carried out in the nip of two rollers which run at a differential speed of 15%.
  • the fabric was passed through an S-loop around the pair of rolls, the roll surface temperature being 150 ° C.
  • the drying and fixing of the PET filaments was carried out in a suction dryer at a temperature of 180 ° C.
  • the fixed fabric was calendered using an embossing roller which, with 33 diamond-shaped engraving points per cm 2, produced a printing area of 18%.
  • the calender surface temperature and the line pressure were 220 ° C and 20 daN / cm.
  • the finish order was placed on a spray system with a polydimethylsiloxane emulsion carried out.
  • the solids concentration and wet pickup were 1.9% and 11%, respectively.
  • the finishing of the spunbonded fabric finished with finishing was carried out in one Flat belt dryer at air temperatures of 110 ° C.

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

Abstract

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

Description

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

Aus dem Dokument EP-A 079 56 37 ist die Verwendung von Vliesstoffen aus Polyester- und Copolyester-Fasern als Tuftträger von Tuftteppichen bekannt, die durch parallel verlaufende, gerade, lastaufnehmende Kunststoff-Endlosfäden verstärkt sind. Durch diese Maßnahme soll trotz eines Flächengewichtes von nur 80 bis 150 g/m2 ein Tuftträger erhalten werden, der gegen Spannungs-, Temperatur- und Feuchteinwirkungen beim Färben, Tuften und Dämpfen während der Herstellung und der Verarbeitung zu Tuftteppichen insbesondere bezüglich des Breitenschwundes resistent ist.Document EP-A 079 56 37 discloses the use of nonwovens made from polyester and copolyester fibers as tuft carriers for tufted carpets, which are reinforced by parallel, straight, load-absorbing continuous plastic threads. With this measure, despite a basis weight of only 80 to 150 g / m 2, a tuft carrier is to be obtained which is resistant to the effects of tension, temperature and moisture during dyeing, tufting and steaming during the manufacture and processing into tufted carpets, in particular with regard to the loss of width ,

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

Aus den Dokumenten DE-A 195 01 123 und DE-A 195 01 125 Verfahren bekannt, die durch einen Reckprozeß im Reckungsbereich von 100 bis 400 % sowohl in Längs- als auch in Querrichtung zu einer höheren Festigkeit des Vlieses führen und die Dehnung sowie den Restschrumpf reduzieren sollen. Vorzugsweise soll dadurch jedoch bei vorgegebenen Werten für die Dehnung und den Restschrumpf der Vliesbahnen deren Flächengewicht reduziert werden. Allerdings führt der angegebene Grad der Verstreckung in Verbindung mit einer dadurch hervorgerufenen Verstreckung der Fasern selbst zu einer wesentlichen Einschränkung der Beweglichkeit der Fasern im Vlies, wodurch der Tuftprozess beeinträchtigt wird.Processes from documents DE-A 195 01 123 and DE-A 195 01 125 known by a stretching process in the stretching range from 100 to 400% in both the longitudinal and transverse directions for greater strength of the fleece and reduce the elongation and the residual shrinkage should. However, this is preferably intended for given values for the Elongation and the residual shrinkage of the nonwoven webs their basis weight be reduced. However, the specified degree of stretching results in Connection with a resulting stretching of the fibers itself to a substantial restriction of the mobility of the fibers in the Fleece, which affects the tufting process.

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

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

Die Erfindung hat sich die Aufgabe gestellt, einen Tuftingträger anzugeben, der aus einem Spinnvlies mit geringen Rohstoffkosten ohne Verstärkungsgarne , - gelege besteht, wobei die Bindung ohne (kostenträchtige) Hilfskomponenten wie Bindefasern oder Binder erfolgt. Der Tuftingträger soll weiterhin eine hohe Dimensionsstabilität beim Tuft- und Färbeprozess besitzen und eine gute Teppichgarneinbindung sicherstellen. The invention has for its object to provide a tufted carrier, the from a spunbond with low raw material costs without reinforcing yarns, laid, the binding without (costly) auxiliary components such as binding fibers or binders. The tufting carrier should continue to be high Have dimensional stability in the tufting and dyeing process and a good one Ensure carpet yarn binding.

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

Erfindungsgemäß wird die Aufgabe dadurch gelöst, dass der Tuftingträger aus synthetischen Fasern oder Filamenten besteht, die dreidimensional miteinander verschlungen sind, wobei nur Fasern oder Filamente mit einem Titer von 1 bis 15 dtex enthalten sind, das heißt, dass der Tuftingträger ohne zusätzliche Bindekomponente hergestellt und damit umweltfreundlich ist. Weiterhin wird auf Verstärkungshilfsmittel wie Garne oder Gelege verzichtet. Das Flächengewicht des Tuftingträgers beträgt 70 bis 110 g/m2, seine Dichte 0,18 bis 0,28 g/cm3 und der 5% Modulwert in Maschinenlaufrichtung > 60 N / 5 cm jedoch mindestens 0,6 N/g/m2. Der Tuftingträger ist formstabil bei der Weiterverarbeitung im Tuft- und Färbeprozeß.According to the invention, the object is achieved in that the tufting carrier consists of synthetic fibers or filaments which are intertwined in three dimensions, only fibers or filaments with a titer of 1 to 15 dtex being contained, that is to say that the tufting carrier is produced without an additional binding component and so it's environmentally friendly. Furthermore, reinforcement aids such as yarns or scrims are not used. The basis weight of the tufting carrier is 70 to 110 g / m 2 , its density 0.18 to 0.28 g / cm 3 and the 5% module value in the machine direction> 60 N / 5 cm, but at least 0.6 N / g / m 2 , The tufting carrier is dimensionally stable during further processing in the tufting and dyeing process.

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

In einer vorteilhaften Ausgestaltung der Erfindung ist der Tuftingträger mit Avivagen oder oberflächenaktiven Substanzen ausgerüstet. Die Ausrüstung erleichtert die Einbringung des Polgarns beim Tuftprozess.In an advantageous embodiment of the invention, the tufted carrier is included Finishing agents or surface-active substances. Equipment facilitates the introduction of pile yarn during the tufting process.

Besonders bevorzugt ist ein Tuftingträger, der nur aus Polyethylenterephthalat besteht. Die Herstellung aus einem einheitlichen Material vereinfacht die Wiederverwertbarkeit. A tufted carrier that is only made of is particularly preferred There is polyethylene terephthalate. The manufacture from a uniform Material simplifies recyclability.

In gleicher Weise bevorzugt ist ein Tuftingträger, der nur aus Polypropylen besteht. Ein solcher Tuftingträger ist recyclefähig.In the same way, preference is given to a tufted carrier which is made only of polypropylene consists. Such a tufted carrier is recyclable.

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

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

Zur Verbesserung der Modulwerte, der Oberflächeneinbindung und der Dickengleichmäßigkeit kann nach der Thermofixierung eine partielle Kompaktierung mittels Prägewalzen vorgenommen, wobei die Gravurpunkte der Prägewalze eine Druckfläche von 18 % bis 25 % einnehmen und eine Rauten-, Linien- oder hexagonale Form bilden.To improve the module values, the surface integration and the Thickness uniformity can be partial after heat setting Compacting made using embossing rollers, the engraving points the embossing roller take up a printing area of 18% to 25% and one Form diamond, line or hexagonal shape.

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

Die erfindungsgemäß hergestellten Tuftträgervliese weisen folgende Eigenschaften auf:

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

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

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

b) Vorverfestigungb) Pre-consolidation

Die Vorverfestigung der Flächenware erfolgte durch Vernadelung, wobei die Einstichtiefe bei 6mm und die Einstichdichte bei 60 E/cm2 lag. Die eingesetzten Nadeln 15x18x40 waren von der Fa. Groz Beckert.The surface goods were pre-consolidated by needling, the penetration depth being 6 mm and the penetration density 60 U / cm 2 . The 15x18x40 needles used were from Groz Beckert.

c) Wasserstrahlverfestigungc) Water jet consolidation

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

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

    • d) Reckend) stretching

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

    e) Thermofixierunge) heat setting

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

    f) Ausrüstungf) equipment

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

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

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

  • Dicke : 0,45 mm
  • Kraft bei 5% Dehnung(Längs) : 91 N/5 cm (Spez.-Modul: 1 N/g/qm)
  • Kraft bei 5% Dehnung(Quer) : 40 N/5 cm
    • The spunbonded fabric produced by the above process steps with a basis weight of 90 g / m2 had the following physical values:
  • Thickness: 0.45mm
  • Force at 5% elongation (longitudinal): 91 N / 5 cm (spec.module: 1 N / g / qm)
  • Force at 5% elongation (cross): 40 N / 5 cm

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

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

    • Claims (10)

    Tuftingträger aus synthetischen Fasern oder Filamenten, die dreidimensional miteinander verschlungen sind, dadurch gekennzeichnet, dass nur Fasern oder Filamente mit einem Titer von 1 bis 15 dtex enthalten sind, wobei das Flächengewicht des Tuftingträgers 70 bis 110 g/m2, seine Dichte 0,18 bis 0,28 g/cm3 und der 5% Modulwert in Maschinenlaufrichtung > 60 N/ 5 cm jedoch mindestens 0,6 N/g/m2 beträgt.Tufting carrier made of synthetic fibers or filaments intertwined three-dimensionally, characterized in that only fibers or filaments with a titer of 1 to 15 dtex are contained, the basis weight of the tufting carrier 70 to 110 g / m 2 , its density 0.18 up to 0.28 g / cm 3 and the 5% module value in the machine direction> 60 N / 5 cm but at least 0.6 N / g / m 2 . Tuftingträger nach Anspruch 1, dadurch gekennzeichnet, dass die Fasern oder Filamente mit einem Titer von 3 bis 12 dtex besitzen, wobei der 5 % Modulwert in Maschinenlaufrichtung 70 bis 100 N/ 5 cm jedoch mindestens 0,7 bis 1,0 N/g/m2 beträgt.Tufting support according to claim 1, characterized in that the fibers or filaments have a titer of 3 to 12 dtex, the 5% module value in the machine direction 70 to 100 N / 5 cm but at least 0.7 to 1.0 N / g / m is 2 . Tuftingträger nach Anspruch 1 oder 2, dadurch gekennzeichnet, dass er mit Avivagen oder oberflächenaktiven Substanzen ausgerüstet ist.Tufting carrier according to claim 1 or 2, characterized in that it is equipped with additives or surface-active substances. Tuftingträger nach einem oder mehreren der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass er nur aus Polyethylenterephthalat besteht.Tufting support according to one or more of claims 1 to 3, characterized in that it consists only of polyethylene terephthalate. Tuftingträger nach einem oder mehreren der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass er nur aus Polypropylen besteht.Tufting support according to one or more of claims 1 to 3, characterized in that it consists only of polypropylene. Verfahren zur Herstellung eines Tuftträgers aus zu einem Spinnvlies verarbeiteten thermoplastischen Polymerfasern- oder filamenten, dadurch gekennzeichnet, dass
    die Fasern oder Filamente mit einem Titer von 6 bis 15 dtex durch Vernadeln und die mit einem Titer von 1 bis 5 dtex durch Wasserstrahlen oder durch eine Kombination dieser Verfahren verfestigt werden und vor der Trocknung und dem Thermofixieren ein Recken in Längsrichtung um bis zu 30 % erfolgt, wobei die Beweglichkeit der Fasern ggf. durch den Zusatz von Öl oder sonstigen Avivagen verbessert wird.    A process for producing a tuft carrier from thermoplastic polymer fibers or filaments processed into a spunbonded nonwoven, characterized in that
    the fibers or filaments with a titer of 6 to 15 dtex by needling and which are fixed with a titer of 1 to 5 dtex by water jets or by a combination of these processes and, before drying and heat setting, stretching in the longitudinal direction by up to 30% takes place, the mobility of the fibers may be improved by adding oil or other additives.         Verfahren nach Anspruch 6, dadurch gekennzeichnet, dass der Reckprozess zwischen den einzelnen Vernadlungsstufen oder nach Abschluß des Vernadelungsprozesses vorgenommen wird.A method according to claim 6, characterized in that the stretching process is carried out between the individual needling stages or after completion of the needling process. Verfahren nach Anspruch 6 oder 7, dadurch gekennzeichnet, dass nach dem Thermofixieren eine zusätzliche Behandlung mit einem beheizten Walzenpaar vorgenommen wird.A method according to claim 6 or 7, characterized in that an additional treatment with a heated pair of rollers is carried out after the heat setting. Verfahren nach Anspruch 8, dadurch gekennzeichnet, dass Oberflächen der Walzen eine unregelmäßige Struktur mit einer Rauhtiefe von 40 bis 100 µm aufweisen.A method according to claim 8, characterized in that surfaces of the rollers have an irregular structure with a roughness of 40 to 100 microns. Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, dass mindestens eine der Walzen eine Prägung besitzt, wobei die Prägepunkte eine Druckfläche von 18 % bis 25 % einnehmen und Rauten-, Linien- oder eine hexagonale Form bilden.A method according to claim 8 or 9, characterized in that at least one of the rollers has an embossing, the embossing points occupying a printing area of 18% to 25% and forming a diamond, line or hexagonal shape.
    EP01130147A 2001-02-19 2001-12-19 Substrate for tufted carpet and process of manufacturing Expired - Lifetime EP1233097B1 (en)

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    DE10108092A DE10108092B4 (en) 2001-02-19 2001-02-19 Method of making a tufting carrier
    DE10108092 2001-02-19

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