EP0073919A2 - Use of a laminated flat article as textile material - Google Patents

Abstract

1. The use as a textile material of a laminated flat article with an upper layer (2) containing fibres or filaments, with an inner layer (5) of granular particles (6) of at least one non-reactive mineral material and with a supporting layer (3), the upper layer (2) and the supporting layer (3) being needled together through the inner layer (5).

Description

The invention relates to a flat laminate for textile applications as a carpet, upholstery element, floor or wall covering or the like, according to the preamble of claim 1.

In a known laminated body of the type mentioned at the outset (DE-OS 23 44 835), two cover layers are sewn together through the granular filler layer. The filler particles must consist of a mass which as such has no defined shape so that it can be penetrated when sewing. In this known laminate synthetic foams are used as advantageous fillers, which are characterized in particular by their light weight. The use of these known laminates is limited to the properties of the fillers used. Sewing this laminated body is a very complex process, which also requires an expensive sewing thread. If the sewing thread is damaged, there is also the risk that the sewing seam will tear open, which means that the cohesion of the fillers between the seams can no longer be guaranteed.

Carpets are also known in which loose fiber material is needle-punched from edge strips produced during production between a base layer and an upper layer.

The invention has for its object to provide a generic laminate that should allow a versatile, unrestricted use by the filler.

According to the invention, this object is achieved by the subject matter of claim 1. Due to the needled top layers, an intermediate layer of granular particles made of at least one mineral, inert material is advantageously interspersed with a large number of fibers or threads which hold the particles in their position. This gives the laminate its own cohesion, with damage, e.g. the fiber or threads, the needling remains in the undamaged areas, since the needled fibers or threads are not connected to each other. This also ensures that the particles e.g. can only exit at the damaged area, since the other needled areas act like a bolt. A e.g. uniform mixing of the particles with fiber material and a dense arrangement of the same with a conventional needling process without costly measures such as e.g. is inaccessible by sewing the cover layers. A trickle of the granular particles in the laminate is completely prevented, whereby a closed spatial shape of the laminate is achieved, which can be used in many ways as a textile fabric. The addition of the heavy, granular particles also makes this fabric heavier overall, which has a very positive effect in various applications.

The granular particles used according to the invention can be brittle and / or also have abrasive properties, in particular if they are sand or gravel, and have a hardness which makes them indestructible when needling. The particles therefore have properties that speak against needling. However, it has surprisingly been found that the top layer and the base layer with conventional needling techniques, ie by means of needling needles with barbs, for example conventional felting needles, without significant damage, for example wear or tear disturbance of the same, can be needled through the layer of the granular particles. This is partly due to the fact that the granular particles are preferably displaceable relative to one another prior to needling and that particles hit by needles can laterally evade.

The laminate according to the invention can advantageously be used as a carpet, in which case e.g. Sand with a basis weight of 100 - 1000 g / m2 is present. As a result, a heavier carpet can be produced in an inexpensive way, which has a better impact sound improvement measure and a higher sound absorption level than a lighter carpet.

The laminated body according to the invention can also be used as another wall or floor covering, as a support, and also as a cushion element. In particular due to its weight, it is also suitable in stripes as a weight band. While in most applications this laminate insert, e.g. is present as a web, of course, several, preferably 2, laminated bodies with one another, e.g. as a pillow, sack or tube.

In its simplest form, the inner layer of the laminate consists exclusively of granular sand. In this way, for example, floor coverings can be produced which can be used as heavy carpets lying on their own, this carpeting nestling unevenness. As a self-laying carpet, the basis weight of the sand layer can be between 2 and 7 kg / m2. Such a laminate can now be advantageously cut, since there are no sewing seams, and then laid, for example, as a web or carpet tile. When the laminate is divided into smaller sections, such as these tiles, granular particles only fall out in the direct area of the cut edge, since the individual particles are brought in by the Holding fibers, as set out above, are held individually. Such a possibility is only opened by the fact that the top layer and the top layer, including the granular particles, such as sand, are no longer sewn together, as was done previously, but are now needled together. Such a layer density over the entire surface of the laminated body can only be produced when needling and is inconceivable when sewing. A carpet web and in particular carpet tile produced in this way need not be glued to the floor, since it comes to rest on the floor due to its own weight. In addition, if an inner layer of rock particles such as sand or the like is used, binders such as cement or the like or synthetic resins can also be added to this sand layer. If a carpet with cement particles is then placed on a damp surface, it can set with it.

The granular, filler-forming particles can also be cement, heavy spar or a light metal, such as Aluminum hydroxide or the like may be formed. These materials, including the sand or gravel mentioned above, improve the properties of the laminate in relation to its behavior in the event of fire, in particular such a laminate acts as a fire barrier.

A laminated body according to the invention can also advantageously be used as a wall covering, with here too as a binder, for example Cement or a synthetic resin can be supplied to the inner layer. So that the laminated body does not fall down again beforehand during the setting on the wall, it can be attached to the wall with nails, pens or the like during attachment. Such nails or pins can be driven through the laminate without destroying it and removed again after the setting process has been completed. Due to the elasticity, at least of the upper layer, the holes formed during nailing or the like close automatically after the nail is pulled out.

Because this laminated body according to the invention can be cut into differently shaped parts, it is also particularly suitable for use as upholstery, e.g. for sofas or armchairs.

When using sand as granular particles in a laminated body according to the invention, this shows positive properties in fire protection due to the large thermal capacity and the poor thermal conductivity of the sand. Textile wall hangings, which up to now could only be supplied as flame retardant, now show even better behavior when they are filled with sand. A laminated body according to the invention can therefore also e.g. can be used as a so-called "iron curtain", which, however, is optically more appealing due to its textile design.

The granular particles can also be in the form of a powder, in particular insofar as binders such as cement or the like are concerned. Granular particles of different materials can be mixed. The grain diameter is preferably between 0.02 and 2 mm. These laminated bodies can be produced with different weights and resulting total thicknesses, which are also based in particular on the specific application. For example, Sand as granular particles, the total thickness can be about 4 - 5 mm with a flat weight of the particle layer of 4 kg / m2, while a laminate with a surface weight of the particle layer of about 12 kg / m2 can have a total thickness of about 8 - 10 mm.

Depending on the desired overall thickness of the laminate, the fibers or threads from which a fleece is formed have sufficient length at least in the actively needlable top layer and are preferably 40 to 120 mm in length so that they pass through a sufficient thickness of the laminate from the top layer into the base layer _. one can extend. These two layers are preferably needled with one another over the entire surface of the laminated body, so that a sufficient needling density can be achieved, for example 50-200 punctures / cm. If he required or desired, the laminated body can be needled both from the top layer and from the support layer.

In a further embodiment, the support layer can be made of a fiber-free material, e.g. consist of a plastic film, so that further variants of the laminate can be made possible. At least the base layer can then e.g. with a reflective layer, e.g. a metal layer, be provided or equipped. However, a fabric sheet or a nonwoven fabric can also be used as a passively needled carrier layer.

In a preferred embodiment, the support layer can have depressions filled with the particles, which e.g. are well-shaped or elongated. This makes it possible, e.g. a particularly flexible to obtain the webs between the recesses bendable laminated body, which can be wound up in a particularly advantageous manner. The cover layers can be needled to one another at the recess-free locations and present without needles at the recesses. Depending on the specific application, the holding fibers can engage at different depths in the carrier layer provided with depressions, i.e. the penetration depth can on the one hand be smaller than the height of the depressions, then these would not be perforated by the needles. If this is desired, however, the penetration depth can also be chosen to be larger, in which case the holding fibers may also penetrate the bottom of the depressions. As an intermediate possibility, it is also envisaged to let the needle tips perforate the bottom of the depressions, but not to pull the holding fibers down to the bottom.

Thanks to the holding fibers that penetrate the sand layer and connect the top layer and the base layer to one another Since the individual grains of sand between the cover layers are kept elastic, the laminate as such can still be rolled up without the individual grains changing their position in the laminate.

If you use the upper layer e.g. Ball yarns made of spherically wound fibers, e.g. are described in EU-OS (A 1) 0 013 428, so when needling is obtained a particularly dense top layer through which particularly powdery particles cannot escape.

Further details and advantages of the invention emerge from the subclaims and from the exemplary embodiments described below with reference to the drawing. In the drawing, layered bodies according to the invention are shown schematically and enlarged in section.

• Fig. l eine erste Ausführungsform eines Schichtkörpers, bei dem sowohl die Trageschicht, als auch die Oberschicht aus einem Faservlies besteht und die Partikel gleichmässig flächig verteilt sind;
• Fig. 2 eine zweite Ausführungsform des Schichtkörpers, bei dem die Trageschicht mit näpfchenartigen Vertiefungen versehen ist, in der sich die Partikel befinden;
• Fig.3 eine dritte Ausführungsform des Schichtkörpers, bei der die Oberschicht aus voneinander abgegrenzten Kugelgarnen besteht, und
• Fig. 4 eine vierte Ausführungsform des Schichtkörpers, bei der die Partikel streifenförmig in dem Schichtkörper angeordnet sind.

It shows:

• 1 shows a first embodiment of a laminated body in which both the support layer and the top layer consist of a nonwoven fabric and the particles are uniformly distributed over the surface;
• 2 shows a second embodiment of the laminated body, in which the support layer is provided with cup-like depressions in which the particles are located;
• 3 shows a third embodiment of the laminated body, in which the upper layer consists of ball yarns delimited from one another, and
• 4 shows a fourth embodiment of the laminate, in which the particles are arranged in strips in the laminate.

A laminated body 1 here has an upper layer 2, which can be actively needled here and consists of a nonwoven fabric or fibers spherically wound as ball yarns (FIG. 3). A support layer 3, which can be at least passively needled, is held relative to the upper layer 2 by holding fibers 4 removed from the upper layer 2. A layer 5 made of granular particles 6 is arranged between the top layer 2 and the support layer 3. The two layers 2 and 3 are needled together through the particle layer 5. The needling can be done according to a needle method known in needle felting technology, e.g. by R. Krcma in the "Handbook of Textile Composites" (Deutscher Fachverlag, Frankfurt am Main, 1970, pages 198 - 202). In this technology, felting needles with a triangular needle shaft and lateral barbs directed towards the tip are most often used for needling Other shapes, such as fork needles and loop needles, are also common. The sewing needles mentioned in the aforementioned book can also be used accordingly for needling the laminated body 1. The felting needles capture individual or tufts of fibers 4 from this upper layer when piercing the upper layer and interweave them with the base layer 3. The top layer 2 must be actively needled for this purpose, ie fibers from this layer should be able to be grasped, a portion of these fibers 4 still being anchored in the layer 2.

The needling process not only connects the top layer 2 and the base layer 3 to one another, it also prevents the granular particles 6 of the layer 5 from laterally shifting due to the holding fibers 4 which are distributed throughout the entire surface of the layer body 1. This makes it possible to cut the laminate into any shape, in particular sheets or tiles, without the particles dropping out of the cut edge in a substantial amount.

The layer 5 of granular particles 6 here consists of Ge Stone particles of small grain size, for example made of sand, which by definition has a grain size of 0.02 - 2 mm. Depending on the intended use, larger particles 6 can also be used. Advantageous features of these rock particles are their relatively large weight in relation to a certain layer thickness, their relatively high heat capacity and in particular their inert behavior towards other substances.

As can be seen from the drawing, the support layer 3 can consist of different materials. This base layer 3 should not splinter when the needles are pierced and should hold the pierced holding fibers 4, e.g. elastic, hold, e.g. by clamping or interlacing, i.e. the base layer 3 should be at least passively needled.

For this, e.g. Plastic films 7 made of soft elastic material (compare e.g. Figure 2), fiber layers in sufficient density, which are further compressed and felted by the needle process itself so that they retain the particles 6, as well as adhesive bonded fiber composites, nonwovens or spunbonds. The support layer 3 can itself be actively needled, which allows the layered body 1 to be additionally needled from the opposite side, as shown in the right half of FIG. It is also possible to provide a further actively needled fiber layer under a plastic film or the like as the base layer 3 and to needle the laminated body 1 from both sides. The support layer 3 can itself be designed as a spring back or, which is not shown, have a spring back on its side facing away from the top layer 2.

The fiber layer, whether used as a top layer 2 or as a base layer 3, can be pre-compacted by separate needling. , it can be needled onto a carrier layer such as a plastic film, a fiber composite or the like, in order to facilitate handling during manufacture and / or by to prevent the leakage of fine sand particles 6 and in particular of binder particles 13 (compare FIG. 3) before the layered body 1 is needled.

A wide variety of textile fibers can be used as the fiber material for the nonwoven and also for the ball yarns (FIG. 3). Natural fibers are particularly suitable for this, e.g. Cotton, wool, animal hair fibers or the like, or synthetic fibers or a mixture thereof.

The embodiment according to FIG. 1 has only distributed rock particles 6 such as granular sand, these rock particles having a basis weight of approximately 100-1,000 g / m 2. According to this embodiment, e.g. to improve a carpet. Until now, a carpet designed in this way had a weight per unit area of 700 - 800 g / m2, but by adding about 400 g of fine-grained sand per m2, its weight can be increased by around 50%. By embedding the sand particles 6 in this carpet, the hard / soft effect is obtained in a relatively inexpensive manner, as a result of which the impact sound improvement measure and the degree of sound absorption can be increased. If sand with a basis weight of 2 - 7 kg / m2 is added to a carpet and needled in it, this carpet is self-laying as a sheet, but especially as a carpet tile, and does not need to be glued on.

A laminated body according to the embodiment according to FIG. 1 can, however, also be used as a curtain, in which it shows particularly positive behavior in the event of fire due to the added sand particles. Due to the poor thermal conductivity and the high heat capacity of the sand, which then e.g. with a grain size of 1 - 2 mm and a weight per unit area of 0.5 - 2.5 kg / m2, this laminate can be used as a fire protection partition curtain, e.g. as a so-called "iron curtain", e.g. can be used in theaters or as a spark protection curtain.

As FIG. 2 in particular shows, this film 7 can be provided with depressions 8, which e.g. can be achieved by deep drawing in the hot plastic state. According to FIG. 2, these depressions 8 are cup-shaped. However, these depressions can also be elongated, in which case they then lie parallel to one another and e.g. can be staggered in their position. The depressions 8 open towards the top layer 2, so that the particles 6 can be introduced into these depressions. In the exemplary embodiment according to FIG. 2, the layer 5 of particles 6 is therefore not contiguous, but is divided into numerous portions. The needle punctures can be evenly distributed over the entire surface of the laminated body 1, as is shown in the three left wells of FIG. 2, where the holding fibers 4 also reach through the bases of the wells. If the retaining fibers 4 were needled less deeply, as corresponds to an embodiment that is not shown, these retaining fibers end in the region of the depressions 8 themselves, while the retaining fibers penetrate the recess-free locations 9 of the plastic film 7, as a result of which the top layer 2 with the is formed as a plastic film 7 support layer. In this case, when the layered body is needled, the procedure can be such that the needle tips still perforate the bottom of the depressions 8, so that fluids can also flow into the depressions 8 from the side of the support layer 3. According to the illustration in the right half of FIG. 2, the top layer 2 is connected to the plastic film 7 only in the region of the recess-free points 9 by means of holding fibers 4. Although the well-shaped recesses 8 themselves are quite stiff, the laminated body 1 has a relatively high degree of flexibility, since the recess-free points 9 acting as webs act like a hinge.

In the embodiment of the laminated body 1 shown in FIG. 3, grains of sand 6 and smaller binders which can be activated with water, such as e.g. Cement powder, deposited as layer 5, on the then ball yarns. from spherically wound fibers 14 are deposited as an upper layer. These three layers 2, 5 and 3 are then needled from above, the holding fibers 4 being removed from the ball yarns 14.

This ball yarn top layer 2 is particularly dense, so that neither the particles 6 or 13 can fall out of the layer body, nor can dirt particles falling onto the layer body from outside penetrate through this top layer 2. The embodiment according to FIG. 3 is particularly suitable as a carpet due to its surface structure. By moistening the surface on which this carpet is to be placed, the holding fibers 4 in particular suck in the moisture and bring it into contact with the binders, which then also set in relation to the surface.

In the embodiment of the laminated body 1 shown in FIG. 4, 3 rows 11 or strips of granular particles 6, such as sand, are deposited on an actively needlable fiber layer as the base layer. These form an interrupted intermediate layer 5, through which needling is carried out. On these rows 11 of particles 6, an actively needled fiber layer is deposited as a cover layer 2 and the layered body 1 is needled from above. In the right half of this figure 4 it is shown that this layered body 1 can also be needled from below, i.e. the holding fibers 4 are removed both from the top layer 2 and from the base layer 3. Both designs now have in common that they form a kind of hinge at the particle-free locations 12, as a result of which they are also arranged when a plurality of particles 6 are arranged transversely to the extent of the laminated body, as shown in the left half of FIG. still bend and roll slightly.

From the following table, which is broken down line by line by particle diameter ranges of the particles 6, preferred size ranges to be used result for the particle weight per unit area, the fiber thickness, the fleece weight per fiber layer per unit area, the needle thickness and the stitch density.

Is rage layer as _T -. 3 eine.Kunststoff film 7 is used as in the case of Figure 2, so is the film thickness between 30 and 200 microns, with a thicker film must be used in larger grain diameter.

Example for the production of a laminated body 1, according to FIG. 1:

The top layer 2 and the base layer. 3 were made identically from the same material in the following manner. A fiber mixture of 200 g / m ² of polyester fibers with a fiber titer of 3.3 and 17 dtex and a stack length of 90 mm was placed on a carrier film (not shown in FIG. 1) made of polyethylene 0.1 mm thick. The fibers were with Pre-needled the film using conventional felting needles with 45 stitches per cm ² . Such a pre-needled fiber layer was placed with the fiber beards facing upwards on the feed table of the needling machine, then a layer of washed quartz sand with a grain size of 0.5-0.75 mm was sprinkled in an amount of 7 kg / m ² . The layer was then covered with an identical pre-needled fiber layer with the fiber whiskers facing downwards. The whole laminate was

with conventional 25 - gauge felting needles and needled with 30 stitches per cm 2. The result was a laminate of approximately 7.4 kg per m ² basis weight.

• Als Trageschicht 3 wurde eine Noppenfolie 7 aus Polyäthylen mit zylinderischen Vertiefungen (Noppen) von 1 cm Durchmesser und 5 mm Tiefe, 7'700 Noppen pro m 2 verwendet. Die Noppen wurden mit Quarzsand gestrichen gefüllt, dann mit einer Schicht von Polypropylen-Fasern 17 dtex, Stappellänge 90 mm, 200 g/m² zugedeckt. Der Schichtkörper wurde mit konventionellen 25 - gauge Filznadeln mit 30 Stichen pro cm² vernadelt. Es entstand ein Schichtkörper 1 von zirka 1.8 kg pro m² Flächengewicht. Die Noppen waren durch die Nadeleinstiche perforiert worden. Der Sand konnte jedoch nicht herausfallen.

Example for the production of a laminated body 1, according to FIG. 2:

• A pimpled film 7 made of polyethylene with cylindrical depressions (pimples) of 1 cm in diameter and 5 mm in depth, 7,700 pimples per m 2 was used as the base layer 3. The knobs were filled with quartz sand, then covered with a layer of polypropylene fibers 17 dtex, staple length 90 mm, 200 g / m ² . The laminate was needled with conventional 25-gauge felting needles with 30 stitches per cm ² . A laminated body 1 of approximately 1.8 kg per m ² basis weight was produced. The knobs had been perforated by the needle punctures. However, the sand could not fall out.

Claims (36)

1. Flat laminate for textile applications as a carpet, upholstery element, floor or wall covering or the like, with an upper layer that contains fibers or filaments, and a support layer, these two layers including an inner layer of a granular filler between them and through them inner layer are interconnected, characterized in that the top layer (2) and the support layer (3) are needled through the granular particles (6) of at least one mineral, inert material containing inner layer (5). 2. Laminated body according to claim 1, characterized in that the granular particles (6) from rock particles, such as Sand, gravel or the like, cement, heavy spar or a light metal such as aluminum hydroxide or the like. consist. 3. Laminated body according to claim 1 or 2, characterized in that the grain size is less than 4 mm, preferably between 0.02 and 2 mm. 4. Laminated body according to one of the preceding claims, characterized in that the particles have a hardness which makes them indestructible when needling. 5. Laminated body according to one of the preceding claims, characterized in that the particles (6) with a Weight per unit area of 0.1 - 12 kg / m2. 6. Laminate according to one of the preceding claims, characterized in that in addition to the inert particles, such as Rock particles (6) further particles (13) are provided. 7. Laminated body according to claim 6, characterized in that the other particles (13) are binders, such as cement, powdered adhesive or the like. 8. Laminated body according to one of the preceding claims, characterized in that at least the top layer (2) consists of a fleece. 9. Laminated body according to claim 8, characterized in that the fleece (2, 3) is pre-needled. 10. Laminated body according to one of the preceding claims, characterized in that the fleece (2, 3) contains fibers with a stack length of 40-150 mm. 11. Laminated body according to one of the preceding claims, characterized in that the particles (6, 13) against Ver. shift in the direction of the plane of the upper layer (2) by individual or tufts of holding fibers (4) or filaments produced by needling. 12. Laminated body according to one of the preceding claims, characterized in that at least the top layer (2) is actively needled by holding fibers (4) or filaments originating from it. 13. Laminated body according to one of the preceding claims, characterized in that the support layer (3) consists of a fiber or filament fleece. 14. Laminated body according to claim 13, characterized in that the laminated body (1) is needled both from the top layer (2) and from the support layer (3). 15. Laminated body according to one of claims 1-12, characterized in that the lower support layer (3) consists of a nonwoven fabric. 16. Laminated body according to one of claims 1-12, characterized in that the lower support layer (3) consists of a fabric web. 17. Laminated body according to one of claims 1-12, characterized in that the lower support layer (3) consists of a fiber or filament-free material. 18. Laminate according to claim 17, characterized in that the lower support layer (3) consists of a film (7), in particular a preferably tough plastic film. 19. Laminated body according to one of claims 15 - 18, characterized in that the lower support layer (3) has depressions (8). 20. Laminated body according to claim 19, characterized in that the depressions (8) are cup-shaped or elongated. 21. Laminated body according to claim 19 or 20, characterized shows that the particles (6, 13) are in particular only arranged in the depressions (8). 22. Laminated body according to one of claims 19 - 21, characterized in that the holding fibers (4) removed from the upper layer (2) penetrate the lower support layer (3) at the recess-free locations (9). 23. layered body according to claim 22, characterized in that the depth of penetration of the holding fibers (4) into the recesses (8) is smaller than the height thereof. 24. Laminated body according to claim 22, characterized in that the holding fibers (4) penetrate the lower support layer (3) also in the region of the depressions (8). 25. Laminated body according to one of the preceding claims, characterized in that it is present with a needling density of 50-200 punctures / cm 2. 26. Laminated body according to one of the preceding claims, characterized in that a spring back (14) is arranged on the lower support layer (3) on its side facing away from the upper layer (2). 27. Laminated body according to one of claims 1-25, characterized in that the lower support layer (3) is designed as a spring back (14). 28. Laminated body according to one of the preceding claims, characterized in that it is treated with latex. 29. Laminate according to one of the preceding claims, characterized in that it is needled or glued to a further textile layer (15) arranged on the top layer (2). 30. Use of the laminated body according to one of the preceding claims as a floor covering. 31. Use of the laminated body according to one of claims 1-29 as a wall covering. 32. Use of the laminated body according to claim 29 or 30 as a carpet, the granular particles having a basis weight of 100-1000 g. 33. Use of the laminated body according to one of claims 1-29 as a curtain. 34. Use of the laminated body according to one of claims 1-29 as a cushion covering for armchairs, sofas or the like. 35. Use of the laminated body according to one of claims 1 - 29 as a self-laying carpet fleece. 36. Use of the laminated body according to one of claims 1 - 29 in strip form as a weight band.

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