CS220889B1 - A method of manufacturing tufted shape memory fabrics - Google Patents

Abstract

The invention relates to a method of producing a tufted textile with shape memory according to the basic Czechoslovak invention PV 3914-79 using a laminated preform on the basis of an upper fibrous thermoplastic self-adhesive layer and a lower woven or non-woven base layer. A patterning yarn with a higher melting point by at least 20 °C than the polyethylene fibers used in this layer is sewn on top of the thermoplastic fibrous layer in a conventional manner. The tufted product is then provided with a fixing and/or weighting roller coating, heat-treated and plastically patterned by shaping. The tufted, plastically patterned textile according to the invention has shape memory and is suitable for interior furnishings in the form of carpets, upholstery, curtains and similar utility objects, depending on the weight and fineness of the tufted product.

Description

220889

BACKGROUND OF THE INVENTION The present invention relates to a method for producing a shape memory and plastically formed face using a backing in a layered laminate subfloor of a thermoplastic thermoplastic laminate layer comprising 20 to 50% by weight of the pre-fabricated mono and / or bi-component fibers. polyethylene and bottom] woven], butane-coated.

In practice, a variety of woven and nonwoven sub-pads are known, based on natural, synthetic, and glass fibers, strips, foil, fibrillated, as well as bonded fibrous formations with various combinations of enhancement, e.g., spinning, or evenly spaced runes, high puncture rate. All known substrates form the arresting part of the tufted product, ensuring integrity and some of its important physical-mechanical properties, such as dimensional stability, uniformity, foaming, ductility, etc., but directly affecting the process and results. plastic pattern.

The main patterning pattern of plastic visors, dyeing, printing, or producing various optical effects is the patterning yarn.

The plastic patterns on the front side of the tufted product are formed predominantly on the sewing machine by mechanical, electronic or pneumatic patterning devices, such as the Scroll, Slat and the like. delivery of different quantities of each needle, according to the established program. Geometrically arranged plastic patterns with lower and higher loops are obtained, or all, possibly some loops, different types of high and low velor, different types of loop-velor patterns and the like are obtained. However, in the patent literature other tufted carpet patterning systems are known. Podl'a franc. No. 2,374,454, an adhesive finish is applied to the laminated fiber fabric according to the desired pattern. Subsequently, the trimmed part of the fibers is cut off by the cutting tool and left to the embossed pattern on the fabric.

According to U.S. Pat. No. 3,751,777, tufting a fibrillatable yarn by subsequently applying a high-velocity, fluid-directed fluid stream, fibrillation and thus the formation of optical and somewhat plastic effects occurs.

Also known are plastic patterning systems for carpets, knitted furniture mats, and the like. with a pile face, and a thermoplastic fiber, e.g., by shaping a hot patterning tool, which may consist of a steel punch, a steel pattern roller, or a combination of a steel template and a brush system. Furthermore, there is known a method of producing plastic-embossed needles according to Authentic Certificate No. 214 516 using a needle-punched section consisting of a granular layer made of synthetic or natural staple fibers and a self-bonding intermediate layer. thermoplastic spun low melting point. Layered needles are laminated to each other and bonded by needling, interlacing, or bonding, and the layered product is subsequently plasticized by heat at the thermoplastic point of the thermoplastic fibers of the interlayer and is thermally patterned at the same time and simultaneously strengthens into formybehun or molding.

Finally, it is also known that tufted articles are mainly formed in four combinations of non-thermoplastic or thermoplastic face and backing. For these thermoforming combinations, the most preferred variant is the use of a non-thermoplastic backing and a thermoplastic face, e.g. with polypropylene yarn. However, and in this case, it is necessary to use a molding temperature at the point of swelling of the polypropylene of 150 to 160 degrees Celsius and close to its melting point of 160 to 175 ° C if a certain stability of the plastic pattern is to be provided.

The use of a polypropylene backing for this plastic patterning system is technologically unmanageable in practice. This is also the case when using polyamide or polyester materials only at higher temperature levels. Most of the above drawbacks are eliminated by the method of manufacturing a tufted fabric with a molded and plastically patterned face of the invention, using a backing in a layered laminate backing on a subfloor fibrous itermoplastic layer comprising 20 to 50% by weight of the pre-fabricated mono / or bicomponent fibers having predominantly polyethylene and lower woven or nonwoven layers. This process is characterized in that a patterning yarn with a higher melting point of at least 20 ° C is sewn above the fibrous layer of the preform, as a polyethylene portion of the thermoplastic fibers of the a-layer layer, after which a fixative and / or filament is applied on the reverse side of the tufted product. or a load-bearing deposit, the article is thermoformed above the melting point of the thermoplastic autohesive layer, and at this temperature simultaneously or sequentially flat and / or spatially shaped by the face molding by means of a molding tool, as required by a negative the plastic pattern and the resulting plastic pattern, or imbedded molded part, is fixed by cooling the product to room temperature. 220889

The thermoplastic fibrous layer, after tufting, forms an intermediate layer between the underside of the undercarriage and the face pattern yarn. The heat treatment of the tufted product arranged according to the invention above the melting point of the thermoplastic fibrous interlayer results in the melting and flowing of the thermoplastic melt to the root of the yarn in the substrate. In principle, the patterning yarn is partially or completely fixed in the liner of the bezel. Subsequent operation of the cold forming tool of the die side of the molding yarn onto the molten intermediate layer of the patterning yarn and the surface-shaped pattern retains the predetermined plastic pattern after the product has been cooled to the temperature. In order to measure the efficiency of the embedded] polyethylene fibrous interlayer in the tufted fabric, samples of velor carpets were used in the PAD aPOP layer of mechanically shaped 2670/100 dtex plunger and POP 2670 / 140dtex, woven] bases of POP strips of an average of 123 g / m < 2 > in the back and polyethylene web 100, 150 and 200 g / m < 2 > It was tufted with 32.5 punches / 10 cm. The height of the cut hair was between 8 and 10 mm. Plain tufted samples were chemically modified, but without backsheet saplasitified in laboratory dryer, freely laid at 143 ° C half-life for 4 minutes and subsequently flat-shaped with a cold molding tool at an average pressure of 16.9N / cm 2 until cool .

For the measurement of the degree of deformation, the recess of the pressed pile at the point of the plastic pattern limitation, a form of a steel ring of 0 13 mm was used. with a width of 6 mm and a height of 5 mm.

With the given quality of the respective cable, the density and the height of the hair, the following dependence of the stability of the shaped pattern was measured in millimeters over time. The height of the pressed-in pile by surface shaping in mm POP moss. face. káblik

Without PE 2670/100 dtex 100 g / m2 PE 150 g / m2 PE Before shaping 9.43 8.68 8.39 After shaping 10 min. 2,65 1,9 1,75 After shaping 1 hour 4,54 2,23 2,01 After forming 24 hours 5,46 2,41 2,07 After shaping 6 days 6,38 2,42 1,99 PAD mech. face. cable 2670/140 dtex 200 g / m2 PE Without PE 1100 g / m2 PE 150 g / m2 PE 200 g / m2 PE 8.81 9.88 8.69 8.37 9.13 1.75 3.05 2, 77 2.68 2.43 1.99 5.46 3.85 3.46 2.85 2.33 6.43 4.63 3.79 3.30 2.35 7.48 4.55 3.81 3 From the results of the experiments carried out, it can be seen unequivocally in both types of lids that by pressing the cut pile into the molten thermoplastic intermediate layer and subsequently cooling it, the formed plastic impression is permanently fixed. There is a necessary relaxation of the whole tufted carpet within one week, which, however, stabilizes after this time. The embossing of the embossed pattern remains constant.

Without the thermoplastic interlayer, the molded plastic pattern is very quickly equalized and practically disappears in both test blanks.

Another experiment aimed at verifying the hypothesis that the plasticizing molten thermoplastic fibrous intermediate layer flows to the roots of the tufted loop and causes some fixation of the loop fibers in the substrate.

Strength of hair anchoring in NPOP moss. face. káblik2670 / 100 dtex PAD mech. face. cable 2670/140 dtex

Without PE intermediate layer 100 g / m2 PE150 g / m2 PE 200 g / m2 PE) 0 6,016 6,885 6,932 0 6,409 9,287 23,156

The results in the table confirmed that the use of the PE fibrous interlayer results in a partial fixation of the tuft to the backing, which may have an impact on the reduction of the fixation or load coat on the basis of dispersions, latexes or other polymers. The methods of making tufted textiles with a plastically patterned face according to the invention are described in the examples. Example 1

For the production of the plastically patterned tufted floor, a fabric of polypropylene base fabric is prepared with an average weight of 112 g / m 2 with 95 tapes / m in warp and 50 tapes / m in weft which overlaps with a self-bonded polyethylene web of 100 to 150 g / m 2 s mp 98 to 102 ° C. The two layers are bonded mechanically, preferably on a puncture machine with 40 to 70 punctures per cm 2, from the backing according to the desired layer consistency.

A 2070/100 dtex polypropylene blob base with 32.5 microns per 10 cm, 700 to 750 g / m < 2 > Furthermore, the tufted product is chemically treated with a fixative and load-dispersion dispersion of the acrylate copolymer with the polyvinyl acetate from the back of the article in an amount of 400 to 800 g / m 2. The product is further dried and then plasticized in a hot air dryer at 140-143 ° C until the backsheet is dry and the polyethylene layer is simultaneously wetted.

The hot plasticized product is formed between the rolls of the patterning sheet with the water-cooled rollers at a pressure of 15 to 20 N / cm2 in a wider way. The formed plastic pattern on the faced carpet is further cooled in a cooling section, subsequently cut, wrapped, measured, cut to packs, packs and dispatches. Example 2

The process for producing the pre-tufted, tufted and gritty coatings is carried out as in Example 1. The chemically treated tufted carpet is fed into the cooling zone, undocked, and clipped and folded into storage and stored in intermediate storage.

The bulkheads are provided with a separate patterning device as required. which consists of an infrapola, a patternland, a cooling zone and an adjustment step. The tufted carpet is passed through an in-frapole, in which the layer is fused, and the polyethylene layer is melted at 135-143 ° C. The hot, plasticized product leads in a quicker way between the rolls of the sample calender, where it is flat-shaped, subsequently cooled and adjusted according to Example 1. Example 3

To produce a plastically patterned tufted base, a fabric polypropylene backing is prepared, which is coated with a self-bonded polyethylene irons of 200 g / m 2. Both layers of saspoja as in Example 1.

A polyamide 2670 // 140 dtex weave of 750 to 780 g / m2 and a pile width of Θ to 8 mm is sewn into the prepared pre-stock from the side of the base. The tufted product closes from the reverse side, dries, plasticizes, flat shapes, cools and adjusts as in Example 1, but Example 2.

To produce the plastically patterned tufted flooring, a preform is prepared from a self-bonded polypropylene backing overlaid with a self-bonded polyethylene web having a weight of 100 to 200 g / m 2. The two layers are bonded mechanically as in Example 1.

The podium of example 1, 2, or bo! 3, the cables are sewn from the side of the base, the tufted product is then treated, dried, plasticized, flat-shaped, cooled and adjusted according to Example 1a.

To produce a plastically patterned, tufted flooring, a non-woven polyester backing is prepared which overlaps with a layer of hemi-component fibers of polypropylene / polyethylene having a weight of 150 to 250 g / m 2. Both layers are mechanically bonded to the side of the bicomponent moiety as in Example 1.

Into the prepared preform, the cable is tufted from the side of the base and the tufted product is further processed according to Example 1, 2 or 3.

Claims (1)

9 19 220839 ARTICLE A method for producing a woven fabric with a molded memory and a plastically patterned face, using a stock in the form of a preformed upper fibrous thermoplastic layer, comprising 20-50% by weight of the article, of a mono and / or bicomponent fiber with a predominantly polyethylene and a woven or nonwoven layer, wherein a patterning yarn is added above the fibrous layer of the fabric by a higher point of at least 20 ° C and a polyethylene portion of thermoplastic fibers. a layer of autohesic layer, after which a spinning and / or load-bearing coating is applied to the tufted layer of the tufted product, the article is heat treated above the tufting point of the thermoplastic layer and at that temperature simultaneously or sequentially. / or generously molds the pressure of the face using a molding tool, according to the needs of the provided nega the composite pattern on the cylinder, or the internally-sulfur fitting of the fitting and the resulting plastic pattern or patterned molding is fixed by cooling the article to room temperature.