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
  • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
  • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
• • D—TEXTILES; PAPER
  • 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
  • D04H1/52—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 applying or inserting filamentary binding elements
• • 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
  • D04H13/00—Other non-woven fabrics
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
  • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
  • D04H5/03—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling 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
  • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
  • D04H5/04—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by applying or incorporating chemical or thermo-activatable bonding agents in solid or liquid form
• • 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

Definitions

• the present invention relates to a method for the production of a reinforced non-woven material based on stack fibres as a primary backing for tufted carpets.
• spun-bound fibres i.e. endless filaments.
• the fleece is connected to filaments and /or threads.
• said filaments and/or threads are connected to the non-woven material through needling.
• connection of the filaments and/or threads with the fleece can be performed through one of the following techniques: "stich bounding", water jets, glueing, or by making use of melting filaments and/or threads that are connected to the surface of the fleece by means of heat and pressure.
• Spun-bounds uses thereto have an elongation at break of almost 30 kg/5 cm measured in length and width direction of the non-woven material.
• the tufting needles can penetrate the non-woven material to a sufficient extent so as to damage the structure of the non-woven material as little as possible.
• the fleece is made on the basis of stack fibres, and in fact by making use of one of the well known methods, in particular card or air-laid techniques. Preferably however use will be made of the card technique.
• the stack fibres of which a fleece is built up are synthetic stack fibres or a mixture of synthetic and mineral and/or natural fibres. Also, as is moreover usual in the art, use can be made of melt and/or bicomponent fibres. In the latter case, the non-woven material can be integrally composed of such bicomponent fibres.
• a usual composition consists of a mixture consisting of 70% 3-den PES-filaments (with a length of 150 mm) and 30% of bicomponent fibres.
• the stack fibres of the non-woven material are oriented in width direction as much as possible.
• the non-woven material can be needled in that way, so that the desired tensile strength as well as penetration possibility of the tufting needles is ensured.
• the non-woven material has with respect to its weight, the desired tensile strength in width direction but in longitudinal direction however, this tensile strength is not ensured,
• the tensile strength in longitudinal direction of the non-woven material is considerably increased by connecting filaments and/or threads with the fleece, at the surface of the fleece.
• An excellent technique through which filaments and/or threads can be connected to the surface of the fleece is needling.
• the needling presents the advantage that the threads and/or filaments are integrated into the non-woven material and in that way follow the movement of the non-woven material.
• filaments and/or threads can also be needled to the surface of the fleece in width direction.
• these filaments and/or threads contribute to the conservation of the tensile strength and elasticity of the non-woven material, more precisely after the tufting needles have penetrated throughout the non-woven material.
• the filaments and/or threads used herein can be of synthetic as well as of mineral origin and it is also clear that use can be made of combinations of these filaments and/or threads. Also, use can be made of twinned filaments composed of synthetic filaments and/or mineral filaments and/or natural filaments.
• the desired tensile strength in longitudinal direction is determined by the number of filaments and/or threads that are applied to the surface of the fleece in this direction, through needling.
• a non-woven material that has been treated in this way has the desired tensile strength in length and width direction, but still has the high elasticity in both directions.
• the thermal treatment mentioned under a) When applying the thermal treatment mentioned under a) to the mixture that is used on the basis and consists of synthetic fibres and/or natural and/or mineral fibres, an amount of melting fibres and/or bicomponent fibres (preferably 25 to 30%).
• the basic material can also consist of 100% of bicomponent fibre or an amount of bicomponent fibre replenished with natural and/or mineral fibres.
• the fibres of the mixture consisting of stack fibres are glued to each other by means of a chemical binder (for example by means of a SBR or an acrylester).
• a chemical binder for example by means of a SBR or an acrylester.
• hot air ⁇ 200°C
• the binder is dried and cured. This can be achieved by using a drying oven.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Mechanical Engineering (AREA)
• Nonwoven Fabrics (AREA)

Priority Applications (1)

Applications Claiming Priority (1)

Publications (1)

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Family Applications (1)

Country Status (1)

Cited By (1)

Citations (4)

• 1999
  • 1999-07-12 EP EP99870151A patent/EP1070778A1/fr not_active Withdrawn

Patent Citations (4)

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