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EP1967631B1 - Method for manufacturing a tufted non-woven fabric, non-woven fabric and its use - Google Patents

Method for manufacturing a tufted non-woven fabric, non-woven fabric and its use Download PDF

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Publication number
EP1967631B1
EP1967631B1 EP20080002084 EP08002084A EP1967631B1 EP 1967631 B1 EP1967631 B1 EP 1967631B1 EP 20080002084 EP20080002084 EP 20080002084 EP 08002084 A EP08002084 A EP 08002084A EP 1967631 B1 EP1967631 B1 EP 1967631B1
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EP
European Patent Office
Prior art keywords
fibres
tufted
process according
nonwoven fabric
fibers
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EP20080002084
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German (de)
French (fr)
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EP1967631A1 (en
Inventor
Norbert Goffing
Engelbert Löcher
Ararad Emirze
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Carl Freudenberg KG
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Carl Freudenberg KG
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Application filed by Carl Freudenberg KG filed Critical Carl Freudenberg KG
Priority to SI200830003T priority Critical patent/SI1967631T1/en
Priority to PL08002084T priority patent/PL1967631T3/en
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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
    • D04H11/00—Non-woven pile fabrics
    • 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
    • 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
    • D04H11/00—Non-woven pile fabrics
    • D04H11/08—Non-woven pile fabrics formed by creation of a pile on at least one surface of a non-woven fabric without addition of pile-forming material, e.g. by needling, by differential shrinking
    • 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
    • Y10T428/23943—Flock surface

Definitions

  • the invention relates to a method for producing a tufted nonwoven fabric and the use of a nonwoven fabric obtained therefrom, in particular as a carpet carrier.
  • Tuftteppichs the so-called tufting or tufting, that is a technique for producing three-dimensional surfaces, used, which works on the principle of a sewing machine.
  • Tuft needles bring a tufted yarn into a base material, the so-called tufa back.
  • the needlestick-mounted tufting needles are arranged in the width of the base material, such as a nonwoven fabric, and pierce through the base material at the same time.
  • the introduced tufting yarn on the underside of the base material is held in place by grippers, known as loopers. This results in loops or loops, so-called knobs that form the visible side (upper layer) in the finished carpet.
  • velor carpet which is used especially in the automotive interior, preferably with a share of more than 95%.
  • Non-woven fabrics made of thermoplastic polymers such as polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are obtained by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these solidification processes, are frequently used as backings are bound.
  • PET polyethylene terephthalate
  • PP polypropylene
  • the contact area and friction between the fibers used in the tuft back nonwoven fabric and the Tuftgarnen is relatively small, so that the holding force for Tuftgarn especially in complicated carpet surface structures, such as in so-called high-low velor or looping qualities or cross-over velor qualities (with polnoppene offset) is often insufficient.
  • the tufting yarn introduced into the back of the tuft after piercing and retracting the tufting needle may already lose its intended position, that is to say, for example, the height or position of the nub, due to the combination of low tuft back density and yarn tension and yarn quality variations, and the tufting yarn may even become loose be pulled out of the tufa back. In both cases, this can lead to clearly visible defects and undesirable design deviations in the tufted carpet top layer.
  • the object of the invention has been found to provide a method for producing a tufted nonwoven fabric, which generates by the nature of the fibers used in the nubs adhesion properties improved nonwoven fabric, in particular an improved carpet backing.
  • the demanding Tuftrati should be much easier and the Tuft Bulgariaen should be increased.
  • the product made therefrom, in particular the carpet should show improved use properties.
  • the object is achieved by the features of claim 1.
  • the inventive method for producing a tufted nonwoven fabric of a round fiber cross section deviating fibers are used which show an adhesion to a Tuftgarn greater than 40 mN, wherein the adhesive force is determined transversely to the longitudinal direction of the fibers.
  • fibers By fibers is meant here staple fibers or continuous fibers, so-called filaments.
  • the fibers can also be combined to form nonwovens, in particular bonded nonwovens, the nonwovens.
  • the proportion of fibers having a fiber cross section deviating from a round cross section is preferably 1 to 99% by weight.
  • the concrete cross-sectional shape of the fibers used plays a subordinate role as long as under the specified conditions a nubbing adhesion to a Tuftgarn in the specified order of magnitude is achieved. It may be fibers with a triangular cross section, called trilobal fibers, star-shaped fibers with four, five or more legs, fibers whose cross-section is flat, oval, T-shaped, M-shaped, S-shaped, Y-shaped or H-shaped Cross section show are used.
  • fibers containing at least two polymer components are used.
  • the fibers used preferably contain the different polymer components in the form of a mixture of monocomponent, multicomponent or mixtures of these fibers.
  • a polymer component can act as a binding component if a thermal solidification takes place, wherein the melting temperature of this component is preferably 10 to 155 ° C below that of the other component.
  • the proportion of the binder components in the fibers or their mixture based on the total weight of the nonwoven fabric is 1 to 20 wt .-%, preferably equal to or less than 10 wt .-%, more preferably equal to or less than 5 wt .-%. This allows the mechanical properties of the manufactured nonwoven fabric can be adapted to the particular use.
  • thermoplastic polymers in particular of polyesters, of polyolefins, preferably polyethylene and / or polypropylene, of polyamides, of polylactates and / or those derived therefrom, for the production of the tufted nonwoven, in particular for use as a carpet carrier Consist of copolymers.
  • the increased fiber-to-fiber friction provides better dimensional stability of the tuft backing and the tufted carpet backing made therefrom, which is beneficial in all carpet making processes.
  • the tufted carpet back is more dimensionally stable because such fibers adhere more than round fibers to each other due to increased static friction and sliding friction and thus improve the dimensional stability in all hydrothermal processes.
  • the tufted nonwovens produced by the process are used as carpet carriers for carpet production, the fibers preferably predominantly consisting of polymers, such as polyesters and / or polyamides.
  • the tufted nonwoven fabrics produced by the process can also be used as filter media or as a distribution layer in absorbent sanitary articles.
  • the suitability of the fibers used to make the tufted nonwoven fabrics is determined in the manner described below.
  • the yarns used for the measurement of the holding force or adhesive force in the carpet industry are customary tufted yarns, such as, for example, bulked continuous filament (BCF) yarn, which consists of 64 individual filaments with a single thickness of 19 dtex. It measures the force that occurs on the fiber or yarn as the stiction is overcome and the fiber or yarn begins to slip.
  • BCF bulked continuous filament
  • a non-woven fabric described in more detail below is produced, which is particularly suitable for use in the carpet industry.
  • the nonwoven fabric consists of 90% by weight of polyethylene terephthalate (PET) fibers as described in U.S. Pat FIGS. 1 and 2 represented, approximately M-shaped cross-sections, which are bound by a copolyester with a lower by about 50 ° C melting temperature and lead by the non-round cross-section to improved adhesion.
  • PET polyethylene terephthalate
  • SEM images Scanning electron micrographs (SEM images) enable images of the fiber-fleece cross sections and the surface structure with the corresponding magnifications.
  • the SEM images were taken with a low pressure scanning electron microscope JEOL JSM-6480LV under an acceleration voltage of 20 kV.
  • the Figures 3 and 4 show in comparison SEM images of fiber cross sections of conventional round PET fibers.
  • the fiber cross sections of the non-round fibers in each case have a significantly larger circumference compared to the fiber cross sections of the round fibers, which leads to a correspondingly larger surface area of the non-round fiber.
  • the elongation is between 90 and 150% (DIN 53812 and DIN 53816).
  • the nonwoven fabric has a basis weight in the range of 65 to 180 g / m 2 .
  • the specific initial modulus in the production direction is 0.97 Nm 2 / g, which is determined at an angle of 90 ° transverse to 1.1 Nm 2 / g.
  • a nonwoven fabric made of round fibers under the same boundary conditions has an initial modulus of 0.88 Nm 2 / g in the production direction and 0.79 Nm 2 / g in the transverse direction.
  • the maximum elongation of such a nonwoven fabric is between 25 and 50% (EN 29073 Part 3).

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

Description

Technisches GebietTechnical area

Die Erfindung betrifft ein Verfahren zur Herstellung eines getufteten Vliesstoffes und die Verwendung eines danach erhaltenen Vliesstoffes, insbesondere als Teppichträger.The invention relates to a method for producing a tufted nonwoven fabric and the use of a nonwoven fabric obtained therefrom, in particular as a carpet carrier.

Zur Herstellung eines so genannten Tuftteppichs wird das so genannte Tuften oder Tufting, das heißt eine Technik zur Herstellung dreidimensionaler Flächen, eingesetzt, die nach dem Prinzip einer Nähmaschine funktioniert.To produce a so-called Tuftteppichs the so-called tufting or tufting, that is a technique for producing three-dimensional surfaces, used, which works on the principle of a sewing machine.

Dabei bringen Tuftnadeln ein Tuftgarn in ein Grundmaterial, den so genannten Tuftrücken, ein. Die an einer Nadelstarige montierten Tuftnadeln sind in der Breite des Grundmaterials, beispielsweise eines Vliesstoffes, angeordnet und stechen gleichzeitig durch das Grundmaterial. Bevor die Tuftnadeln wieder nach oben in ihre Ausgangsstellung zurückkehren wird das eingebrachte Tuftgarn auf der Unterseite des Grundmaterials von Greifern, so genannten Loopern, festgehalten. So entstehen Schlaufen oder Schlingen, so genannte Noppen, die im fertigen Teppich die Sichtseite (Oberschicht) bilden.Tuft needles bring a tufted yarn into a base material, the so-called tufa back. The needlestick-mounted tufting needles are arranged in the width of the base material, such as a nonwoven fabric, and pierce through the base material at the same time. Before the tufting needles return to their original position, the introduced tufting yarn on the underside of the base material is held in place by grippers, known as loopers. This results in loops or loops, so-called knobs that form the visible side (upper layer) in the finished carpet.

Je nach Anwendung können diese Schlingen unter Einsatz spezieller Messer bereits während des Tuftvorgangs geschnitten werden. Dabei entsteht der so genannte Veloursteppich, der speziell im Automobilinnenbereich bevorzugt mit einem Anteil von über 95% eingesetzt wird.Depending on the application, these slings can already be cut using special knives during the tufting process. The result is the so-called velor carpet, which is used especially in the automotive interior, preferably with a share of more than 95%.

Als Tuftrücken werden häufig Vliesstoffe aus thermoplastischen Polymeren, wie zum Beispiel aus Polyethyklenterephthalat(PET)-Fasern und/oder aus Polypropylen(PP)-Fasern eingesetzt, die durch Vemadelung, Punktverschweißung, mittels eines chemischen Bindemittels, mittels Bindefasern oder mittels Kombinationen von diesen Verfestigungsprozessen gebunden sind.Non-woven fabrics made of thermoplastic polymers, such as polyethylene terephthalate (PET) fibers and / or polypropylene (PP) fibers, which are obtained by needling, spot welding, by means of a chemical binder, by means of bonding fibers or by combinations of these solidification processes, are frequently used as backings are bound.

Die Verwendung von ausschließlich punktverschweißten oder ausschließlich bindergebundenen Vliesstoffen ist nachteilig, da sie für die Herstellung von dreidimensionalen Formteilen wegen einer schlechten Verformbarkeit, insbesondere bei der Verwendung im Automobilbereich, nicht besonders gut geeignet sind.The use of exclusively spot-welded or exclusively binder-bonded nonwovens is disadvantageous, since they are not particularly well suited for the production of three-dimensional molded parts because of poor deformability, in particular for use in the automotive sector.

Beim Einsatz von herkömmlichen runden Fasern ist die Kontaktfläche und die Reibung zwischen den im Tuftrücken-Vliesstoff eingesetzten Fasern und den Tuftgarnen relativ klein, so dass die Haltekraft für das Tuftgarn speziell bei komplizierten Teppichoberflächenstrukturen, wie zum Beispiel bei so genannten Hoch-Tief-Velours- bzw. Schlingenqualitäten oder Cross-Over-Veloursqualitäten (mit Polnoppenversatz), häufig nicht ausreichend ist. Das nach dem Durchstechen und Zurückziehen der Tuftnadel in den Tuftrücken eingebrachte Tuftgarn kann bereits durch die Kombination von geringen Tuftrückendichten- und Garnspannungs- sowie Garnqualitätenschwankungen seine vorgesehene Position, das heißt beispielsweise die Höhe oder Lage der Noppe, verlieren, und unter Umständen kann das Tuftgarn sogar aus dem Tuftrücken herausgezogen werden. Dies kann in beiden Fällen zu deutlich sichtbaren Fehlern und zu unerwünschten Designabweichungen in der getufteten Teppichoberschicht führen.When using conventional round fibers, the contact area and friction between the fibers used in the tuft back nonwoven fabric and the Tuftgarnen is relatively small, so that the holding force for Tuftgarn especially in complicated carpet surface structures, such as in so-called high-low velor or looping qualities or cross-over velor qualities (with polnoppene offset) is often insufficient. The tufting yarn introduced into the back of the tuft after piercing and retracting the tufting needle may already lose its intended position, that is to say, for example, the height or position of the nub, due to the combination of low tuft back density and yarn tension and yarn quality variations, and the tufting yarn may even become loose be pulled out of the tufa back. In both cases, this can lead to clearly visible defects and undesirable design deviations in the tufted carpet top layer.

Die bekannten als Tuftrücken eingesetzten herkömmlichen Vliesstoffe mit runden Fasern genügen daher den unterschiedlichen Anforderungen an eine besonders gute Haftung der eingetufteten Tuftgarne im Tuftrücken sowie an ein fehlerfreies Tuftbild in der Teppichoberschicht nicht immer zufrieden stellend. Aus dem Dokument US 6,740,385 B2 ist es bekannt, die Mustergleichmäßigkeit und die Dimensionsstabilität, insbesondere die Stabilität gegen Deformationen während und nach dem Tuftvorgang dadurch zu verbessern, dass eng gewebte Textilien mit einer gleichmäßigen Vliesstoffschicht aus Stapelfasern in Kontakt gebracht und miteinander verschmolzen werden.The known conventional nonwovens with round fibers used as tufts therefore satisfy the different requirements of one particularly good adhesion of the tufted tufted yarns in the back of the tufts and a faultless tufting pattern in the top layer of the carpet is not always satisfactory. From the document US 6,740,385 B2 It is known to improve the pattern uniformity and the dimensional stability, in particular the stability against deformation during and after the tufting by contacting tightly woven textiles with a uniform nonwoven layer of staple fibers and fusing them together.

Darstellung der ErfindungPresentation of the invention

Die Erfindung hat sich die Aufgabe gestellt, ein Verfahren zur Herstellung eines getufteten Vliesstoffes anzugeben, welches durch die Art der eingesetzten Fasern einen in den Noppenhaftungseigenschaften verbesserten Vliesstoff, insbesondere einen verbesserten Teppichträger, erzeugt. Zudem soll der anspruchsvolle Tuftprozess wesentlich erleichtert werden und die Tuftgeschwindigkeiten sollen erhöht werden. Ferner soll das daraus hergestellte Produkt, insbesondere der Teppich, verbesserte Verwendungseigenschaften zeigen.The object of the invention has been found to provide a method for producing a tufted nonwoven fabric, which generates by the nature of the fibers used in the nubs adhesion properties improved nonwoven fabric, in particular an improved carpet backing. In addition, the demanding Tuftprozess should be much easier and the Tuftgeschwindigkeiten should be increased. Furthermore, the product made therefrom, in particular the carpet, should show improved use properties.

Erfindungsgemäß wird die Aufgabe durch die Merkmale des Anspruchs 1 gelöst. Dazu werden gemäß dem erfindungsgemäßen Verfahren zur Herstellung eines getufteten Vliesstoffes von einem runden Faserquerschnitt abweichende Fasern eingesetzt, die eine Haftkraft gegenüber einem Tuftgarn von größer 40 mN zeigen, wobei die Haftkraft quer zur Längsrichtung der Fasern ermittelt wird.According to the invention the object is achieved by the features of claim 1. For this purpose, according to the inventive method for producing a tufted nonwoven fabric of a round fiber cross section deviating fibers are used which show an adhesion to a Tuftgarn greater than 40 mN, wherein the adhesive force is determined transversely to the longitudinal direction of the fibers.

Unter Fasern werden hier Stapelfasern oder Endlosfasern, so genannte Filamente, verstanden. Die Fasern können ebenfalls zu Vliesen, insbesondere zu verfestigten Vliesen, den Vliesstoffen, zusammengelegt sein.By fibers is meant here staple fibers or continuous fibers, so-called filaments. The fibers can also be combined to form nonwovens, in particular bonded nonwovens, the nonwovens.

Bevorzugt beträgt der Anteil an Fasern mit von einem runden Querschnitt abweichenden Faserquerschnitt 1 bis 99 Gew.-%.The proportion of fibers having a fiber cross section deviating from a round cross section is preferably 1 to 99% by weight.

Die konkrete Querschnittsform der eingesetzten Fasern spielt dabei eine untergeordnete Rolle so lange unter den angegebenen Bedingungen eine Noppenhaftkraft gegenüber einem Tuftgarn in der angegebenen Größenordnung erreicht wird. Es können Fasern mit einem dreieckigen Querschnitt, so genannte Trilobalfasern, Fasern in Sternform mit vier, fünf oder mehr Schenkeln, Fasern deren Querschnitt flach, oval, T-förmig, M-förmig, S-förmig, Y-förmig oder einen H-förmigen Querschnitt zeigen eingesetzt werden.The concrete cross-sectional shape of the fibers used plays a subordinate role as long as under the specified conditions a nubbing adhesion to a Tuftgarn in the specified order of magnitude is achieved. It may be fibers with a triangular cross section, called trilobal fibers, star-shaped fibers with four, five or more legs, fibers whose cross-section is flat, oval, T-shaped, M-shaped, S-shaped, Y-shaped or H-shaped Cross section show are used.

Die nachfolgend aufgezeigten Querschnitte stehen zur anschaulichen Verdeutlichung.The cross sections below are illustrative.

Vorteilhafterweise werden in dem Verfahren zur Herstellung des getufteten Vliesstoffes solche Fasern eingesetzt, die mindestens zwei Polymerkomponenten enthalten.Advantageously, in the process for producing the tufted nonwoven fabric, fibers containing at least two polymer components are used.

Die eingesetzten Fasern enthalten vorzugsweise die unterschiedlichen Polymerkomponenten in Form einer Mischung aus Monokomponenten-, Mehrkomponenten- oder Gemischen dieser Fasern.The fibers used preferably contain the different polymer components in the form of a mixture of monocomponent, multicomponent or mixtures of these fibers.

Dabei kann eine Polymerkomponente als Bindekomponente wirken, wenn eine thermische Verfestigung erfolgt, wobei die Schmelztemperatur dieser Komponente bevorzugt 10 bis 155°C unter der der anderen Komponente liegt.In this case, a polymer component can act as a binding component if a thermal solidification takes place, wherein the melting temperature of this component is preferably 10 to 155 ° C below that of the other component.

Vorteilhafterweise beträgt der Anteil der Bindekomponenten in den Fasern oder deren Gemisch bezogen auf das Gesamtgewicht des Vliesstoffes 1 bis 20 Gew.-%, bevorzugt gleich oder kleiner 10 Gew.-%, besonders bevorzugt gleich oder kleiner 5 Gew.-%. Dadurch können die mechanischen Eigenschaften des hergestellten Vliesstoffes an die jeweilige Verwendung angepasst werden.Advantageously, the proportion of the binder components in the fibers or their mixture based on the total weight of the nonwoven fabric is 1 to 20 wt .-%, preferably equal to or less than 10 wt .-%, more preferably equal to or less than 5 wt .-%. This allows the mechanical properties of the manufactured nonwoven fabric can be adapted to the particular use.

Vorzugsweise werden weiterhin für die Herstellung des getufteten Vliesstoffes, insbesondere zur Verwendung als Teppichträger, Fasern eingesetzt, die aus thermoplastischen Polymeren, insbesondere aus Polyestern, aus Polyolefinen, bevorzugt Polyethylen und/oder Polypropylen, aus Polyamiden, aus Polylactaten und/oder aus den daraus abgeleiteten Copolymeren bestehen.Preference is furthermore given to using fibers composed of thermoplastic polymers, in particular of polyesters, of polyolefins, preferably polyethylene and / or polypropylene, of polyamides, of polylactates and / or those derived therefrom, for the production of the tufted nonwoven, in particular for use as a carpet carrier Consist of copolymers.

Im Hinblick auf die geforderten Festigkeitseigenschaften des Vliesstoffes werden vorzugsweise solche Fasern eingesetzt, die einen Titer im Bereich von 5 bis 14 dtex (SI-Einheit: 1 dtex = 1 g/10000 m) aufweisen.In view of the required strength properties of the nonwoven fabric, preference is given to using those fibers having a titre in the range from 5 to 14 dtex (SI unit: 1 dtex = 1 g / 10000 m).

Die erhöhte Faser-Faser-Reibung bringt eine bessere Dimensionsstabilität des Tuftrückens und des daraus hergestellten getufteten Teppichträgers , was bei allen Teppichherstellungsprozessen vorteilhaft ist. Der Tufting-Teppichrücken ist formstabiler, da solche Fasern aufgrund erhöhter Haft- und Gleitreibung mehr als runde Fasern aneinander haften und so die Dimensionsstabilität bei allen hydrothermischen Prozessen verbessern.The increased fiber-to-fiber friction provides better dimensional stability of the tuft backing and the tufted carpet backing made therefrom, which is beneficial in all carpet making processes. The tufted carpet back is more dimensionally stable because such fibers adhere more than round fibers to each other due to increased static friction and sliding friction and thus improve the dimensional stability in all hydrothermal processes.

Erfindungsgemäß werden die nach dem Verfahren hergestellten getufteten Vliesstoffe als Teppichträger für die Teppichherstellung verwendet, wobei die Fasern vorzugsweise überwiegend aus Polymeren, wie Polyestern und/oder Polyamiden bestehen.According to the invention, the tufted nonwovens produced by the process are used as carpet carriers for carpet production, the fibers preferably predominantly consisting of polymers, such as polyesters and / or polyamides.

Weiterhin können die nach dem Verfahren hergestellten getufteten Vliesstoffe auch als Filtermedien oder als Verteilerschicht in absorbierenden Sanitärartikeln Verwendung finden.Furthermore, the tufted nonwoven fabrics produced by the process can also be used as filter media or as a distribution layer in absorbent sanitary articles.

Ausführung der ErfindungEmbodiment of the invention

Der Gegenstand der Erfindung wird anhand eines Beispiels näher erläutert, ohne die Erfindung einzuschränken.The object of the invention will be explained in more detail by means of an example, without limiting the invention.

Die Eignung der für die Herstellung der getufteten Vliesstoffe eingesetzten Fasern wird in der nachfolgend beschriebenen Weise bestimmt.The suitability of the fibers used to make the tufted nonwoven fabrics is determined in the manner described below.

Verschiedene nicht runde Fasern und im Vergleich dazu eine runde Faser werden jeweils eingespannt, ein Teppichgarn wird eingefädelt und dabei über die Fasern gezogen, und die resultierende Zugkraft am Garn wird mit einer Federwaage bestimmt. Alternativ dazu kann auch ein Garn eingespannt und die Faser darüber gezogen werden.Various non-round fibers and, in comparison, a round fiber are clamped in each case, a carpet yarn is threaded and thereby pulled over the fibers, and the resulting tensile force on the yarn is determined with a spring balance. Alternatively, a yarn can be clamped and the fiber pulled over it.

Als Garne werden für die Messung der Haltekraft oder Haftkraft in der Teppichindustrie übliche Tuftgarne verwendet, wie zum Beispiel BCF-Garn (bulked continuous filament, texturiertes Endlosgarn), die aus 64 Einzelfilamenten mit einer Einzelstärke von 19 dtex bestehen. Es wird die Kraft gemessen, die bei der Faser oder dem Garn auftritt, wenn die Haftreibung überwunden wird, und die Faser oder das Garn zu rutschen beginnt. Das Messverfahren ist beispielhaft in Figur 6 schematisch dargestellt.The yarns used for the measurement of the holding force or adhesive force in the carpet industry are customary tufted yarns, such as, for example, bulked continuous filament (BCF) yarn, which consists of 64 individual filaments with a single thickness of 19 dtex. It measures the force that occurs on the fiber or yarn as the stiction is overcome and the fiber or yarn begins to slip. The measuring method is exemplary in FIG. 6 shown schematically.

Mittelwerte aus je 10 Messungen:Average values from 10 measurements each:

M-FaserM-fiber S-FaserS Fiber Y-FaserY fiber T-FaserT Fiber runde Faserround fiber Haftkraft Tuft-Garn über einer FaserAdhesion Tuft yarn over a fiber mNmN 5656 5454 4545 5050 2929

Ausführungsbeispiel:Embodiment:

Aus den beschriebenen Filamenten bzw. Endlosfasern wird ein im Folgenden näher beschriebener Vliesstoff hergestellt, der sich für den Einsatz in der Teppichindustrie besonders eignet.From the described filaments or continuous fibers, a non-woven fabric described in more detail below is produced, which is particularly suitable for use in the carpet industry.

Der Vliesstoff besteht zu 90 Gew.-% aus Polyethylenterephthalat(PET)-Fasern mit, wie in den Figuren 1 und 2 dargestellt, annähernd M-förmigen Querschnitten, die durch ein Copolyester mit einer um ca. 50°C niedrigeren Schmelztemperatur gebunden werden und die durch den nicht runden Querschnitt zu einer verbesserten Haftung führen.The nonwoven fabric consists of 90% by weight of polyethylene terephthalate (PET) fibers as described in U.S. Pat FIGS. 1 and 2 represented, approximately M-shaped cross-sections, which are bound by a copolyester with a lower by about 50 ° C melting temperature and lead by the non-round cross-section to improved adhesion.

Die Rasterelektronenmikroskop-Aufnahmen (REM-Aufnahmen) ermöglichen Aufnahmen der Faser-Nliesquerschnitte und der Oberflächenstruktur mit den entsprechenden Vergrößerungen. Die REM-Aufnahmen wurden mit einem Niederdruck-Rasterelektronenmikroskop JEOL JSM-6480LV unter einer Beschleunigungsspannung von 20 kV erstellt.Scanning electron micrographs (SEM images) enable images of the fiber-fleece cross sections and the surface structure with the corresponding magnifications. The SEM images were taken with a low pressure scanning electron microscope JEOL JSM-6480LV under an acceleration voltage of 20 kV.

Die Figuren 3 und 4 zeigen im Vergleich dazu REM-Aufnahmen von Faserquerschnitten herkömmlicher runder PET-Fasern.The Figures 3 and 4 show in comparison SEM images of fiber cross sections of conventional round PET fibers.

Die Faserquerschnitte der nicht runden Fasern haben im Vergleich zu den Faserquerschnitten der runden Fasern jeweils einen deutlich größeren Umfang, der zu einer entsprechend größeren Oberfläche der nicht runden Faser führt.The fiber cross sections of the non-round fibers in each case have a significantly larger circumference compared to the fiber cross sections of the round fibers, which leads to a correspondingly larger surface area of the non-round fiber.

Die spezifische Festigkeit einer solchen nicht runden, aus einem Polyester gesponnenen Faser mit einer intrinsischen Lösungsviskosität von 0,63 bis 0,69 liegt im Bereich von 25 bis 40 cN/ tex (SI-Einheit: 1 cN/tex = 104 m2/ s2). Die Dehnung beträgt zwischen 90 und 150% (DIN 53812 und DIN 53816).The specific strength of such a non-round, polyester-spun fiber having an intrinsic solution viscosity of 0.63 to 0.69 is in the range of 25 to 40 cN / tex (SI unit: 1 cN / tex = 10 4 m 2 / s 2 ). The elongation is between 90 and 150% (DIN 53812 and DIN 53816).

Der Vliesstoff hat ein Flächengewicht im Bereich von 65 bis 180 g/m2. Der spezifische Anfangsmodul in Produktionsrichtung liegt bei 0,97 Nm2/g, der in einem Winkel von 90° quer dazu bestimmte liegt bei 1,1 Nm2/g.The nonwoven fabric has a basis weight in the range of 65 to 180 g / m 2 . The specific initial modulus in the production direction is 0.97 Nm 2 / g, which is determined at an angle of 90 ° transverse to 1.1 Nm 2 / g.

Ein unter gleichen Randbedingungen jedoch aus runden Fasern hergestellter Vliesstoff hat in Produktionsrichtung einen Anfangsmodul von 0,88 Nm2/g und in Querrichtung von 0,79 Nm2/g. Die maximale Dehnung eines solchen Vliesstoffes beträgt zwischen 25 und 50% (EN 29073 Teil 3).However, a nonwoven fabric made of round fibers under the same boundary conditions has an initial modulus of 0.88 Nm 2 / g in the production direction and 0.79 Nm 2 / g in the transverse direction. The maximum elongation of such a nonwoven fabric is between 25 and 50% (EN 29073 Part 3).

Claims (11)

  1. Process for producing a tufted nonwoven fabric, wherein tufting in the tuftable backing utilizes fibres which deviate from a round fibre cross-section and which exhibit an adherence to a tufted yarn, determined transversely to the longitudinal direction of the fibres, of greater than 40 mN.
  2. Process according to Claim 1, wherein a mixture with round fibres is used in which the proportion of fibres having a cross-section deviating from a round cross-section is in the range from 1% to 99% by weight.
  3. Process according to Claim 1 or 2, wherein the fibres used contain at least two polymeric components.
  4. Process according to any one of the preceding claims, wherein the fibres used contain different polymeric components in the form of a mixture of monocomponents, multicomponents or mixtures of these fibres.
  5. Process according to Claim 3 or 4, wherein one of the polymeric components acts as a binder component in a thermal consolidation, the melting temperature of this component being 10 to 155°C below that of the other component.
  6. Process according to Claim 5, wherein the proportion of the binder component is in the range from 1% to 20% by weight based on the total weight of the nonwoven fabric.
  7. Process according to any one of the preceding claims, wherein the fibres are selected from thermoplastic polymers, such as polyesters, polyolefins, polyamides, polylactates and/or from the copolymers derived therefrom.
  8. Process according to any one of the preceding claims, wherein the fibres have a linear density in the range from 5 to 14 dtex.
  9. Tufted nonwoven fabric obtained by following a process wherein tufting in the tuftable backing utilizes fibres which deviate from a round fibre cross-section and which exhibit an adherence to a tufted yarn, determined transversely to the longitudinal direction of the fibres, of greater than 40 mN.
  10. Carpet backing for carpet production, consisting of a tufted nonwoven fabric according to Claim 9.
  11. Carpet backing for carpet production according to Claim 10, wherein the fibres are selected from polyesters and/or polyamides.
EP20080002084 2007-02-12 2008-02-05 Method for manufacturing a tufted non-woven fabric, non-woven fabric and its use Revoked EP1967631B1 (en)

Priority Applications (2)

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SI200830003T SI1967631T1 (en) 2007-02-12 2008-02-05 Method for manufacturing a tufted non-woven fabric, non-woven fabric and its use
PL08002084T PL1967631T3 (en) 2007-02-12 2008-02-05 Method for manufacturing a tufted non-woven fabric, non-woven fabric and its use

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DE200710006759 DE102007006759A1 (en) 2007-02-12 2007-02-12 Tufted non-woven, for floor coverings, has tufting fibers with an out-of-round cross section at the back of the fabric for anchoring into the material

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EP1967631A1 EP1967631A1 (en) 2008-09-10
EP1967631B1 true EP1967631B1 (en) 2009-06-10

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EP (1) EP1967631B1 (en)
KR (1) KR101027614B1 (en)
AR (1) AR065295A1 (en)
AT (1) ATE433513T1 (en)
AU (1) AU2008200750B2 (en)
BR (1) BRPI0801700A2 (en)
DE (2) DE102007006759A1 (en)
DK (1) DK1967631T3 (en)
ES (1) ES2327470T3 (en)
PL (1) PL1967631T3 (en)
PT (1) PT1967631E (en)
SI (1) SI1967631T1 (en)
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DE102007020818B3 (en) * 2007-05-02 2009-01-02 Carl Freudenberg Kg Process for the preparation of a deformable tufted product
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US20110177283A1 (en) * 2010-01-18 2011-07-21 Futuris Automotive Interiors (Us), Inc. PET Carpet With Additive
KR102228541B1 (en) 2017-09-22 2021-03-15 코오롱인더스트리 주식회사 Non-woven for carpet backing with improved pull-out strength and manufacturing method thereof
EP3543397B1 (en) * 2018-03-20 2021-07-07 Aladdin Manufacturing Corporation Method for manufacturing a carpet or a rug
EP3760769A1 (en) * 2019-07-02 2021-01-06 Carl Freudenberg KG Irregularly shaped polymer fibers
WO2022146005A1 (en) * 2020-12-30 2022-07-07 코오롱인더스트리 주식회사 Spunbonded non-woven fabric and manufacturing method therefor

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KR20080075457A (en) 2008-08-18
BRPI0801700A2 (en) 2008-11-11
DK1967631T3 (en) 2009-09-07
KR101027614B1 (en) 2011-04-06
SI1967631T1 (en) 2009-10-31
DE502008000031D1 (en) 2009-07-23
AU2008200750B2 (en) 2010-04-01
TWI392783B (en) 2013-04-11
ES2327470T3 (en) 2009-10-29
PL1967631T3 (en) 2009-11-30
PT1967631E (en) 2009-08-13
EP1967631A1 (en) 2008-09-10
AU2008200750A1 (en) 2008-08-28
US20080213531A1 (en) 2008-09-04
DE102007006759A1 (en) 2008-08-14
ATE433513T1 (en) 2009-06-15
TW200914671A (en) 2009-04-01
AR065295A1 (en) 2009-05-27

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