Stock material or miscellaneous articles – Pile or nap type surface or component
Patent
1994-01-25
1996-08-20
Morris, Terrel
Stock material or miscellaneous articles
Pile or nap type surface or component
428 95, 428282, 428283, 428296, 28112, 156 72, 156148, B32B 302, B32B 516, D04M 146
Patent
active
055477313
DESCRIPTION:
BRIEF SUMMARY
FIELD OF THE INVENTION
The invention concerns a needled multilayered carpet and a process for producing such a needled carpet.
BACKGROUND OF THE INVENTION
The known needled multilayered carpets have a backing of film or woven tape. An intermediate layer of fibers is arranged on this backing, which is covered by a top layer of carpet made of better fibers that are visible in use. These three layers are needle-punched together, and fibers from the top layer are needle-punched into the intermediate layer and the backing.
The bottom or intermediate layer make the carpet thicker, for one thing, and for another, the intermediate layer is used to achieve a better hold for the fibers needled through from the top layer of the carpet. As a rule, this intermediate layer is 2-3 mm thick. Although cheaper fibers are used for the intermediate layer, substantial costs are involved in processing these fibers.
After being needled, the fibers in the intermediate layer are tightly integrated by impregnating the carpet with a binder, like latex, or at least slop-padded from beneath up to the upper edge of the intermediate layer. This way, the fibers in the top layer of the carpet are reinforced and anchored fast, so they cannot be pulled out as the carpet is used. The process of drying a carpet produced in this process is expensive in terms of time and energy. Large machinery is required, and the process must be closely supervised. Integrating the latex into the carpet and cross-linking it represents a large and hence onerous production expense, and special drainage and ventilation problems occur. These carpets also have the disadvantage that old carpets are very difficult to dispose of, since the latex components are very difficult to separate from the other components in the carpet, and the ratio of elastomers to total raw materials is bound to be non-uniform, for the most part.
Many attempts have been made to improve or optimize the properties of needled-felt carpets. Thus, it is known from AT 305 942, how to put a thermoplastic film between the top and bottom layer, which is bonded to the top and bottom layer by needling, and then surround it with a foamed PVC paste in such a way that the film disappears in it.
The use of polyethylene films processed with needled felt is known from DEZ Chemiefaser 2/69, pp. 103-106. These films are used in order to improve the expansion properties of the carpets produced with them.
In the carpet known from DE OS 22 19817, strips of polypropylene are used as woven tape.
But none of the carpets disclosed in the documents named eliminate the disadvantages mentioned at the beginning of complicated, expensive and environmentally harmful production processes.
SUMMARY OF THE INVENTION
The task of the invention is to design a process whereby a needled multilayered carpet is produced so that latex need no longer be used and production time is cut substantially compared to the known processes.
This task is solved by process and by the needled carpet as claimed herein.
According to the invention, lumpy, three-dimensional thermoplastic film material is used as an intermediate layer. The film material used is "volume-enhanced," so that it provides a three-dimensional material as opposed to a planar intermediate layer. It can be "volume-enhanced" pieces such as film with a nap or cam, in which the planes have projecting bumps or strips or pieces of film, whose volume is increased particularly by coiling, curling, stamping and the like. As noted, pieces of film may be with bumps, like nap, cams, deep-drawn parts or bumps produced by stretching in many sub-areas, especially small sub-areas in the film pieces. The film material is especially easy to handle; it can be layered during the production process into uniform layers by being thrown off of a delivery device. If a number of such parts, strips or pieces of film lie one on top of the other prior needling, together they take up a very large volume, which corresponds to many times the volume of the smooth or flat film material formed. The lumpy t
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