Classifications

• • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B32—LAYERED PRODUCTS
  • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
  • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
  • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
  • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
  • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
• • 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
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/23907—Pile or nap type surface or component
  • Y10T428/23979—Particular backing structure or composition
• • 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
  • Y10T442/322—Warp differs from weft

Definitions

• the present invention relates to a textile support for producing a tufted product such as an artificial turf or carpet.
• the object of the present invention thus makes it possible to produce a tufted product having improved mechanical strength properties.
• tufted product means any textile product whose surface is covered by a multitude of “bristles”, that is to say more or less short strands secured to a textile support by mechanical means and possibly by gluing.
• the present invention also relates to a method of manufacturing such a support.
• tufted products such as artificial turfs and carpets
• tufting fibers within and through a textile support, this support possibly being a woven fabric, a nonwoven fabric, or another type of tissue.
• the fibers used to form the tufting strands or bristles are generally made of polymeric plastic materials, such as polypropylene, polyethylene or polyamide. The choice of these materials depends on the performance and functions that the tufted product has to fulfill, and therefore on its end use. For example, in the case of an artificial turf used to cover a sports field, it is easy to imagine that it must have a relatively low elongation or deformation to constitute an adequate sports field.
• the mechanical resistance to elongation in the two main directions of the tufted product are of particular importance to ensure the strength, stability and longevity of the product.
• the main directions of the tufted product are defined on the one hand by the direction of travel of the production machine and on the other hand by the direction perpendicular to this direction of travel.
• the mechanical stresses associated with the implementation of the tufting operation lead to the use of a textile support that is highly resistant to tensile stresses, but also has a low resistance to perforation so as to be easily pierced by the needles performing tufting, that is to say, guiding the fibers or strands through the support.
• the tufted products of the prior art may exhibit a relatively large deformation under the forces generated by accelerations or abrupt stops of a user of sports ground, because of the very structure of the textile support which composes them. .
• the present invention therefore relates to a textile support whose choice does not depend on the compromise described above and whose application performance is not limited by such a compromise.
• the present invention relates to a textile support whose mechanical strength properties are improved, while having a high ability to be perforated during tufting.
• the invention relates to textile support for producing a tufted product such as an artificial turf or carpet, this support comprising at least one woven web.
• technical threads extending in one or two directions are secured to said ply so as to reinforce it, this joining being carried out by binding threads, thus making it possible to maintain the cohesion between the ply and the technical threads.
• the binding yarns are assembled with the sheet by means of knitting on a knitted loom, the technical yarns extending firstly in the warp direction, and secondly according to the weft direction over all or part of the width of the web.
• the textile support - object of the present invention is composed of one or more plies of different characteristics, reinforced (s) by technical son in one or two dimensions.
• Such a structure ensures efficient maintenance and reliable positioning of these technical threads.
• such an assembly method makes it possible to produce the textile support at low cost and at a high rate, while ensuring good cohesion of the technical threads adapted to the end use.
• the support may comprise at least two superposed sheets, one of these sheets being intended to support the tufting, the other sheet being intended to provide multidirectional reinforcement.
• the textile support can perform various functions as necessary, these functions being fulfilled by one and / or by the other of the sheets that compose it.
• one of the superposed sheets is made of a nonwoven suitable for drainage.
• the technical threads may have some mobility at their points of attachment to said web, to facilitate the tufting operation without the risk of weakening the reinforcement technical son.
• the technical threads may have a relatively loose attachment to the sheet, which prevents their deterioration by the needles performing tufting. Indeed, this mobility or travel allows the technical thread to escape when pushed by a needle.
• the technical threads may be made of glass fibers or high temperature polyethylene terephthalate (PET HT), or polypropylene.
• said technical threads may have sizes or titles of between 300 tex and 2,400 tex.
• such technical threads may have an elongation suitable for breaking for specific applications such as artificial turf.
• the web may consist of a woven having an elongation limit at break of the order of 12 to 20%. and technical reinforcement yarns with an elongation at break of around 2.5%.
• such a sheet gives the textile support the appropriate mechanical strength properties combining flexibility of the upper face of the material and overall strength.
• the support may be composed of two or more continuous superimposed sheets, so as to confer other mechanical characteristics in several directions, said layers being reinforced by technical fibers for the resistance.
• the binding yarns may be densely distributed over the whole of said sheet, so as to form numerous reliefs for the attachment of a coating layer applied during the treatment. tufting operation.
• the many binding threads are so many hanging points for the coating layer, which increases the cohesion of this layer on the textile support and thus the strength and longevity of the tufted product.
• the reinforcing son may be arranged on either side of one of the plies. Furthermore, the present invention relates to a method of manufacturing a textile support as described above.
• the present invention relates to a tufted product, such as an artificial turf or carpet, composed of a textile support according to the invention.
• FIG. 1 is a diagrammatic representation in perspective of a textile support according to a first embodiment of the invention
• Figure 2 is a schematic sectional representation of the textile support illustrated in Figure 1
• FIG. 3 represents a diagram illustrating a comparison between the mechanical properties of a textile support according to the present invention and those of a textile support of the prior art
• Figure 4 is a schematic representation in section of a textile support according to a second embodiment of the invention
• Figure 5 is a schematic representation in plan view of a third embodiment of the invention
• FIG. 6 is a diagrammatic representation in section of the textile support illustrated in FIG.
• the textile support illustrated in FIG. 1 comprises a sheet 101 consisting of a woven product.
• technical threads 102 and 103 are secured by means of binding threads 104.
• the threads 102 extend in the direction of production or warp direction, while the threads 103 are perpendicular to them.
• the assembly of the technical threads 102 and 103 on the sheet 101 by means of binding yarns 104 is carried out by means of a knit loom, for example of the Karl Mayer® or Liba® brand.
• the wires 102 are arranged in the warp direction and the wires 103 in the weft direction.
• part of the ply 101 is covered by strands or fibers 105. These strands 105 are tufted through the ply 101 as shown in more detail in FIG. 2.
• the assembly of the technical threads 102 and 103 on the web 101 by means of the binding threads 104 is made by means of a knitting machine with knit stitches of the type Rachel framer with insertion of webs in multiple materials.
• the son 102 and 103 are son of technical type, that is to say made of glass fibers with very high deformation module.
• binding yarns 104 pass through the web 101 at regular intervals, as can be seen in FIG. 2.
• These binding yarns 104 may be made of polyester or polypropylene yarns. Their density and their distribution on the surface of the ply 101 as well as the number of attachment points depend on the mechanical strength that it is desired to confer on the assembly of the textile support.
• the wires 102 are spaced at regular intervals 106, the size of which is adapted according to the end use of the tufted product.
• a "reaction force” that is to say a relatively high resistance to deformation
• the technical threads 103 are spaced by intervals 107 whose length can be adapted as necessary.
• the technical threads 103 can be selected so as to have mechanical properties (modulus of elasticity, elongation at break, linear weight, etc.) similar to or different from the mechanical properties of the technical threads 102.
• One of the advantages of knitting with a knitted loom is that the technical yarns 102 and 103 can be arranged perfectly straight on the web 101, which gives the tufted product greater reactivity to fabrics. efforts made during its use. Indeed, in the tufted products of art prior using especially a woven web, the warp and weft son are crossed alternately above and below, which induces a waviness or "embossing" and thus an additional elongation detrimental to certain uses of tufted product.
• the present invention offers a significant economic advantage insofar as it makes it possible to produce a textile support reinforced by large-diameter threads that are inserted in a discontinuous manner instead of using a continuous network of thinner fibers and therefore more expensive, but also more expensive to assemble.
• the technical threads 102 and 103 consist of glass filaments or "rovings" having a linear density that can be between 600 tex and 1200 tex.
• the intervals 106 and 107 are here of the order of 20 mm. Consequently, the resistance according to one and the other of the two main dimensions of the ply 101 is between 15 kN / m and 30 kN / m. Obviously, it is possible to vary the parameters mentioned above so as to obtain different mechanical strength values ranging from 5 kN / m to 200 kN / m.
• FIG. 3 represents a tensile diagram illustrating the tensile strength F as a function of the elongation at break ⁇ of a textile support according to the invention (curve 302), as well as the strength of a textile support of prior art (curve 301). Curves 301 and 302 are obtained during traction setting according to international standards.
• the reinforcement of a sheet by technical threads made of glass and high-modulus plastic polymer materials gives the textile support elongations at break ⁇ of from 2% to 10% maximum.
• the modulus of elasticity at the origin represented by the initial slope of the curves 301 and 302, that is to say in the field of weak deformations of the support, is significantly higher in the case of the curve 302 of the support - object of the present invention compared to that of the curve 301 of a standard product.
• this parameter represents a prime performance for the resistance of the tufted product during its use.
• the textile support object of the invention is more "reactive" to the efforts that it is subject to and less subject to deformation.
• a tufted product composed of a textile backing according to the present invention has a breaking strength identical to that of a standard tufted product, it exhibits a superior "immediate" reactivity as shown by the initial slopes of curves 301 and 302.
• the final tufted product is likely to have a better resistance to deformation during accelerations or abrupt stops of people using the artificial turf or the carpet that composes it.
• FIG. 4 illustrates a second embodiment of the invention in which a nonwoven 406 is inserted between a ply 401 and technical threads 402 and 403.
• the assembly of the textile support being assembled, as in the case of FIG. by knitting on a loom knit by means of binding threads 404.
• binding threads 404 There are also shown strands or bristles 405 as can be observed at the end of the tufting operation.
• the nonwoven 406 makes it possible to fulfill additional functions, such as drainage for example.
• this nonwoven 406 may be more or less dense and may be made of glass fibers, polyester fibers, polypropylene fibers or others.
• FIG. 5 illustrates a third embodiment of the invention in which binding yarns 504 are disposed on the superposition of a web 501 and a nonwoven 506 more densely than the binding yarns 104 and 404 of the invention.
• FIGS. 1 and 4 Indeed, as seen in FIG. 5, the interval between two consecutive technical threads 502 also comprises two binding threads, which therefore only retain the technical threads 503.
• these numerous binding yarns 504 represent as many additional attachment points when it is desired to coat one of the faces of the support with a coating layer 507 intended to ensure the maintenance of the tufting fibers.
• binding yarns 504 makes it possible to better assemble the support, to give it greater mechanical strength and finally to improve the retention of the tufting fibers by helping to maintain the coating layer 507. shown in Figure 6.
• the binding yarns 104, 404, or 504 may for example be made of polyester, a material which has a suitable affinity with the latex or polyurethane which are capable of forming the coating 507.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Knitting Of Fabric (AREA)
• Woven Fabrics (AREA)

Applications Claiming Priority (2)

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Family Applications (1)

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Family Cites Families (6)

• 2006
  • 2006-11-21 FR FR0655016A patent/FR2908789B1/fr active Active
• 2007
  • 2007-11-20 US US12/447,135 patent/US20100040810A1/en not_active Abandoned
  • 2007-11-20 WO PCT/FR2007/052366 patent/WO2008062134A2/fr not_active Ceased
  • 2007-11-20 EP EP07858719A patent/EP2092103A2/de not_active Withdrawn

Non-Patent Citations (1)

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