EP0055362B1 - Process for producing a textile sheet material and the textile product so produced - Google Patents

Abstract

A textile flat structure is manufactured by needle processing of a pile yarn tufted into a carrier layer so that some pile loops of the pile yarn forming an upper layer are engaged by needles and their height and shape are changed, whereas at least one pile yarn is pulled toward the carrier layer, whereby a texture and/or pattern is produced. The textile flat structure has a carrier layer, a pile yarn tufted into the carrier layer and having pile loops at an upper side of the carrier layer and connecting base loops at a lower side thereof, whereas the pile loops forming an upper layer have at least non-uniform different heights.

Description

The invention relates to a method for producing a textile fabric according to the preamble of claim 1, and to a fabric produced therewith.

It is known to produce structured, tufted textile fabrics by tufting the pile yarn with different pile heights into the carrier layer so that the pile loops are not at the same height and a high-low structure is produced. The pole heights are evenly different, i. that is, areas with a uniformly low pole height alternate with areas of a higher pole height. Such a uniform high-low structure is due to the predetermined arrangement or setting of the tufting device, by means of which it is only possible to achieve alternately high and low pole loop regions. There is also the further disadvantage that the production of different pole heights to achieve a desired pattern and / or. Structure coupled with the tufting process and therefore not only tied to the tufting process itself, but also to the previously mentioned tufting facility. A change of pattern therefore requires complex changes to the tufting process and its preparation and working conditions. The known tufted products are therefore limited to predetermined, uniform structures and / or patterns.

From DE-A-2452136 it is also known to manufacture a top layer of pile loops by tufting a pile yarn into a backing layer and to needle individual fibers from the bottom layer into free spaces of the top layer through the backing layer. This is intended to achieve full coverage of the product, which has an extremely low pile weight. However, very specific work is required to completely fill the free spaces with a large amount of individual fibers. Patterning possibilities of such textile fabrics are limited to the properties of the needled, openly projecting individual fibers, which are to give the top layer the appearance of a tip-shear article or an open-pole article with a uniform structure.

The invention has for its object to provide a generic method for producing a fabric without the disadvantages of the known manufacturing process, with which a tufted product with a structure and / or pattern can be produced independently of the material already tufted or complex tufting processes and with a textile fabric is to be created which can be structured and / or patterned in a variety of ways on its upper side.

This object is achieved in a generic method in that some of the protruding pile loops are gripped by needles pushed through the backing layer from the back and their pile height is increased and the shape is changed, at least one which is not connected to the towed pile loop via a common base loop seized pole loop is drawn in the direction of the carrier layer.

With the method according to the invention, therefore, the pile height and shape change can subsequently be carried out in a surprising manner on an already tufted product and, independently of a tufting process, the textile fabric with a structure and / or pattern, eg. B. a high-low structure. The gripping of the pole loops according to the invention can advantageously produce an irregular structure that cannot be achieved by tufting alone. In particular, the nature and character of the top of the tufted textile fabric can be changed in a simple manner, namely by simply inserting needles from the back of the carrier layer. The method therefore meets the requirement of generating a diverse structure and / or pattern regardless of the starting product which has already been tufted.

It can therefore advantageously be created a textile fabric with pile yarn tufted into a carrier layer, which forms an upper layer with protruding pile loops on the upper side of the fabric and in which the top layer has unevenly different pile heights of the pile loops.

A product is thus created in which the different pile heights of the pile loops alternate unevenly and e.g. B. can be arbitrarily different pole heights, so that one can speak of "anarchically" existing pole heights. The textile fabric allows a variety of uses and is z. B. in particular as a floor or wall covering or decorative or upholstery fabric in which a structure and / or pattern is desired. As a result of the tufted pile yarn and the change in pile height and shape due to the needling, the textile fabric is preferably in non-woven form.

The pole loops seized are increased in their pole height and at least one pole loop not seized is reduced in their pole height. The different pole heights can be uneven, e.g. B. arbitrarily distributed in the top layer of the fabric. In this case, the adjacent pole loop which has not been gripped can also be withdrawn entirely in or even through the carrier layer, so that a particularly pronounced uneven high-low structure can be achieved. In this way an irregular high-low structure can be achieved. So an un regular structure can be generated, as z. B. is used for carpeting. To increase the pile height or to change the shape of the pile loop, a replenishment of pile yarn is required. A portion of the pile yarn can be pulled over the common base loop from at least one pile loop which has not been gripped, since the pile loops can be tufted so that they can be pulled out, that is to say they are unsecured in the carrier layer and therefore unfixed in the same.

The shape of the pile loops can be changed in a particularly advantageous manner by the engagement of the needles, which can capture the pile loops in a way that the same z. B. plucked or roughened. In this way, the pole loops can be shaped irregularly, e.g. B. be defaced and a further configuration of the structure and / or pattern can be achieved. As needles normal felting needles with barbs or special felting needles, such as. B. conventional Sidehoc needles, fork needles or loop needles such as z. B. from Singer Spezialnadelfabrik GmbH, D-5102 Würselen. After piercing through the carrier layer, the pole loops can be gripped at any point with such needles and their pole height and shape can be influenced. By changing the shape, e.g. B. Defacing the pile loops can be in the presence of a pile yarn made of synthetic fibers or filaments, for. B. multifilaments, which eliminates uniform appearance of the synthetic material and the appearance of a natural, fiber-spun yarn can be achieved. After needling, d. i.e., e.g. B. by simply inserting the needles from the back, the pole loops can be bent to the side so that they can take a substantially more horizontal direction. A further structural revitalization can be achieved in this way. A further reinforcement of the structuring can also be achieved in that the pole height of the gripped pole loops is increased with an unequal length, as a result of which a further disfigurement and / or anarchic arrangement of the same can be achieved.

Depending on the needle density, more or less of the pole loops can be gripped and the pole loops that have not been gripped can be withdrawn. The pile loops can be gripped with a needle density of 5 to 80 punctures / cm ² , preferably 20 to 30 punctures / cm ² , and 20 to 30% pile loops of the fabric can be gripped. The textile fabric can therefore have 20 to 30% of the pile loops with a greater pile height than the other pile loops. The pole loops with the larger pole height can have the irregular shape or shape described above. The pole height can be increased by 20 to 100% compared to an original pole height. Is the original pole height z. B. 3 mm, the same with the inventive method on z. B. 5 to 6 mm enlarged or lengthened.

A finished, tufted product can be assumed and the same can be needled according to the invention. The tufted product can therefore be stored in an advantageous manner and processed with the method according to the invention for the respective production of the patterned and / or structured textile fabric. But it can also tufted the pile yarn in the carrier layer in successive operations and z. B. immediately afterwards the pole height and shape of the pole loops can be changed by needling from the back of the carrier layer. This has the advantage that the textile fabric manufactured according to the invention can be manufactured continuously at one production location. The tufted starting product can have pole loops with the same or different pole height, as z. B. can be achieved by the aforementioned tufting process.

In another embodiment of the method, on the tufting of the pile yarn, a fiber material from a lower layer can be needled through the carrier layer into the upper layer with the pile loops in such a way that after changing the pile height and shape, at least some spaces in the upper layer are caused by needling delimited fiber structures fill out. As a result, a textile fabric can be obtained in which the pile loops are mixed with delimited fiber structures, some of which are still in the lower layer and / or carrier layer and can be anchored there. Such a method and product is e.g. B. is described in EP-A-0 054 686, to which reference is made here for a more detailed explanation. In this way, a further possibility for structuring and / or patterning can be achieved, which can also be designed in color if the delimited fiber structures z. B. a different color than the material of the pole loops or even have different colors. The delimited fiber structures can not only in the upper layer itself, ie. B. between the pole loops of the same, but also on the top or even on the same, so that a variety of structuring and / or patterning options is given. In this connection, reference is again made to the aforementioned EP-A-0 054 686 for a more detailed explanation. The delimited fiber structures can be needled into the upper layer at points of the pile loops with a reduced pile height. This enables a targeted filling or filling of deep pole points, such as those caused by the reduced pole loops. This makes it possible to achieve structures and / or patterns that stand out visually. In particular, spherical yarns made of spherically entangled fibers or threads can be defined as those Fiber structures are needled into free spaces in the upper layer, which, for. B. per se between the pile loops, but can only be created by the needles when needling according to the invention. Due to the needling of ball yarns from the back, a dot-like or spot-like pattern can advantageously be achieved. The ball yarns are e.g. B. from EP-A-0 013 427 and from EP-A-0 013 428, to which reference is also made at this point for further explanation.

The invention is explained in more detail below with reference to exemplary embodiments shown in the drawing.

• Fig. 1 einen Teil eines getufteten textilen Flächengebildes in schematischer Darstellung im Schnitt;
• Fig. 2 das textile Flächengebilde gemäß Fig. 1 mit veränderter Polhöhe;
• Fig. 3 einen Teil eines anderen getufteten textilen Flächengebildes mit veränderter Polhöhe und veränderter Form in schematischer Darstellung im Schnitt, und
• Fig. 4 einen Teil eines weiteren getufteten textilen Flächengebildes in schematischer Darstellung im Schnitt.

It shows

• Figure 1 shows a part of a tufted textile fabric in a schematic representation in section.
• FIG. 2 the textile fabric according to FIG. 1 with a modified pile height;
• Fig. 3 shows a part of another tufted textile fabric with changed pile height and changed shape in a schematic representation in section, and
• Fig. 4 shows a part of another tufted textile fabric in a schematic representation in section.

1, a pile yarn 1 is tufted into a carrier layer 2, so that an upper layer 4 with protruding pile loops 5 is formed on its upper side 3, have the same pile height H and are connected via base loops 6 on the lower side 7 of the carrier layer 2. In the tufted product thus produced in a known manner, needles are inserted from the bottom 7 through the carrier layer 2, which are arranged in such a way that some of the pole loops are gripped and changed by the same, in particular pushed out of the carrier layer 2. Needling leads to a textile fabric 8, as shown in FIG. 2, in which the same parts as in FIG. 1 have the same reference numerals.

Pole loops 5a seized during needling are enlarged in their pole height, i.e. that is, the pile height thereof is greater than the pile height H before needling, as is shown for comparison by the pile loop 5 shown in dashed lines in FIG. 2 from FIG. 1. At the same time, at least one other pole loop 5b, which was not gripped by the needles, i. that is, in an area without needle insertion or detection by the needles and which is connected to the respective pole loop 5a via the respective base loop 6, is reduced in its pole height compared to the original pole height H. This reduction in the pile height of the pile loop 5b which has not been gripped takes place in that, when the pile height of the pile loop 5a gripped has been increased, a portion of the pile yarn 1 has been drawn or delivered via at least one pile loop 5b which has not been gripped via the common base loop 6. The pole heights of both the pole loops 5a and the pole loops 5b are different from one another.

A textile fabric 8 is thus created, the top side 9 of which has uneven, different pile heights, which are uneven and irregular, e.g. B. arbitrarily distributed. When needling, however, there is also a change in shape of the pole loops 5 of FIG. 1, as the pole loops 5a taken show. The needles can influence the loop shape and change more or less, e.g. B. irregular. Here, the pile yarn 1 z. B. attacked more or less easily, so that 5 tufts of fibers are formed on the pile loops 5a. This favors z. B. the formation of a structured surface and gives a product z. B. the appearance of natural fiber material when the polar 1 z. B. consists of synthetic fiber material. The formation of the pole loops 5a depends z. B. on the type of pile yarn or the original pile loop 5, z. B. their arrangement or density, or from the needling conditions, for. B. the type of needles. The textile fabric 8 therefore has a structure and / or pattern, which is characterized by the different pile heights of the pile loops 5a and 5b, and by the irregular shape of the pile loops 5a.

In a textile fabric 11 according to FIG. 3, a pile yarn 12 is tufted into a carrier layer 13. On the upper side 14 of the carrier layer 13 there is an upper layer 15 with projecting pole loops 16 and 17, which are connected on the underside 18 of the carrier layer 13 via base loops 19. After the pile yarn 12 had been tufted, a product according to FIG. 1 being obtained, needles were pierced from the carrier layer 13, as was described in the preceding exemplary embodiment in connection with FIGS. 1 and 2, so that the pile loops 16 and 17 different pole heights. When needling, pole loops corresponding to pole loops 16 were gripped by needles and their pole height increased. In contrast, pole loops which were not seized and correspond to pole loops 17 were reduced in their pole height, i. that is, drawn in in the direction of the carrier layer 13. As a result of the needling, the pole loops 16 again have an irregular shape and tufts of fibers 20 which have arisen through gripping by means of the needles, as was described above in the exemplary embodiment for FIGS. 1 and 2. In addition to the different and arbitrarily irregular pile heights, the irregular shape creates a structure which can give the textile fabric 11 the plucked or roughened appearance.

Fig. 4 shows a textile fabric 21 with a pile yarn 22, which is tufted into a carrier layer 23, so that in a top layer 24 there are 24 pile loops 25 and 26, which are via Ba ^g i-,

loop 27 connected. The previously tufted product was needled from the carrier layer 23 by inserting needles, as was described above in the exemplary embodiment for FIGS. 1 and 2, it again being possible to start from the tufted product according to FIG. 2. The pole loops 25 gripped by the needles have a greater pole height than the pole loops 26 not gripped by the needles. The pole loops 25 are preferably randomly and regularly distributed in the upper layer 24 and have different pole heights among themselves, which also applies to those not gripped Pole loops 26 is the case. The different pole heights of the pole loops 25 and 26 are distributed unevenly or irregularly, so that an irregular structure or structure and / or pattern with an irregular appearance is produced.

Between the pile loops 25 and 26 and also on and on the upper side 28 of the upper layer 24 there are delimited fiber structures in the form of spherical yarns 29 made of spherically twisted fibers or threads. To introduce the ball yarns 29 after needling the previously tufted product, i. that is, after producing the pile loops 25 and 26 with the different pile heights, an underlayer 30 is placed on the underside 31 of the carrier layer 23, in which the ball yarns 29 are embedded in a fiber material 32 for arrangement on the underside 31. The ball yarns 29 are gripped by needles and z. B. pushed like a packet through the carrier layer 23. When gripped by the needles and forced through the carrier layer 23 z. B. tail or neck-like tufts of fibers with which the ball yarns 29 remain anchored in the lower layer 30 and the carrier layer 23 and are thus fastened. The introduction of delimited fiber structures has already been described in detail in the already mentioned EP-A-0 054 686, which is why reference is made to the same at this point for a more detailed explanation.

The ball yarns 29 can, for. B. Fill or fill in gaps between the pole loops 25 and 26 or over the pole loops 26 with the smaller pole height. The textile fabric 21 therefore has a structure and / or pattern which is characterized by a combination of the different pile heights of the pile loops 25 and 26 with the ball yarns 29 introduced. The needling to produce the pile loops 25 and 26 with different pile heights and the introduction of the ball yarns 29 into the upper layer 24 can therefore be used to achieve versatile, novel structures and / or patterns.

1 to 4, the pile loops and in FIG. 4 also the delimited fiber structures are shown in a schematic manner. In fact, they can be at different distances from each other or with different dimensions and e.g. B. be arranged closer or closer together.

Claims (17)

1. Process for producing a textile sheet material (8; 11; 21) having a structure and/or pattern on its upper surface, in which the pile yarn (1; 12; 22) is tufted into a substrate (2; 13; 23) so that pile loops (5; 16,17; 25,26) stand up on the upper face in an upper layer (4; 15; 24) and bottom loops (6; 19; 27) are present on the underside of the substrate (2; 13; 23), characterised in that some of the upstanding pile loops (5a; 16; 25) are engaged by needles forced through the substrate (2; 13; 23) from the rear face and have their height (H) increased and are altered in their shape, at least one pile loop (5b; 17; 26) which is not engaged and which is associated with the respective engaged pile loop (5a; 16; 25) through a common bottom loop (6; 19; 27) being pulled down towards the substrate (2; 13; 23).

2. Process according to Claim 1 characterised in that the pile loops (5a; 16; 25) which are engaged are rendered non-uniform in shape, e. g. teased or roughened.

3. Process according to Claim 1 or 2 characterised in that the heights of the pile loops (5a; 16; 25) which are engaged are increased by unequal lengths.

4. Process according to one of the foregoing claims, characterised in that the pile loops (5a; 16; 25) are engaged with a needle density of 5 to 80 perforations per cm², preferably 20 to 30 perforations per cm2.

5. Process according to one of the foregoing claims characterised in that 20 to 30% of the pile loops (5a; 16; 25) of the sheet material (8; 11; 21) are engaged.

6. Process according to one of the foregoing claims, characterised in that the height of the loops (5a; 16; 25) is increased by 20 to 100% of the original height.

7. Process according to one of the foregoing claims, characterised in that, after the change in the height and shape of the pile, a lower layer (30) containing a fibre material (32) and i_hdividu- al fibre bodies (29) ist applied to the underside (31) of the substrate (23), and that at least some spaces in the upper layer (24) are filled by needling individual fibre bodies (29) through from the lower layer (30).

8. Process according to of the foregoing claim, characterised in that the individual fibre bodies (29) are needled through into the upper layer (24) at the positions of the pile loops (26) of reduced height.

9. Process according to one of the foregoing claims, characterised in that ball yarns (29) made of spherically wound fibres or threads forming the individual fibre bodies are needled through into the, for example, free spaces in the upper layer (24).

10. Textile sheet material (8; 11; 21) having a pile yarn (1; 12; 22) which is tufted into a substrate (2; 13; 23) and which forms on the upper face of the sheet material (8; 11; 21) an upper layer (4; 15; 24) having projecting pile loops (5; 16, 17; 25, 26), produced by the process according to one of the foregoing claims, characterised in that the upper layer (4; 15; 24) has pile loops (5a, 5b; 16, 17; 25, 26) of irregularly differing heights (H).

11. Textile sheet material according to Claim 10, characterised in that the different pile heights (H) are irregularly, e. g. randomly, distributed.

12. Textile sheet material according to Claim 10 or 11, characterised in that 20 to 30% of the pile loops (5a; 16; 25) of the sheet material (8; 11; 21) have a greater height (H) than the remaining loops (5b; 17; 26).

13. Textile sheet material according to one of Claims 10 to 12, characterised in that the pile loops (5a; 16; 25) of greater height (H) are or irregular shape, e.g. they have a teased or roughened form.

14. Textile sheet material according to one of Claims 10 to 13, characterised in that there is present a lower layer (30) containing fibre material (32) and individual fibre bodies (29), individual fibre bodies (29) extending from the lower layer (30) through the substrate (23) into the upper layer (24), and that the loops (25, 26) are present mixed with individual fibre bodies (29) originating from the lower layer (30), these bodies being anchored by parts of themselves in the lower layer (30) and/orthe substrate (23).

15. Textile sheet material according to Claim 14, characterised in that the individual fibre bodies (29) are present between or on the loops (25, 26), e. g. on the upper face of the upper layer (24).

16. Textile sheet material according to one of Claims 14 or 15, characterised in that the individual fibre bodies are ball yarns (29) of spherically wound fibres orthreads.

17. Textile sheet material according to one of Claims 14 to 16, characterised in that the individual fibre bodies (29) present mixed with the pile loops (25, 26) differ in their shape from those in the lower layer (30).

Images