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US3705064A - Process for the manufacture of varicolored,ornamentally designed needled non-woven fabrics - Google Patents

Process for the manufacture of varicolored,ornamentally designed needled non-woven fabrics Download PDF

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Publication number
US3705064A
US3705064A US2976A US3705064DA US3705064A US 3705064 A US3705064 A US 3705064A US 2976 A US2976 A US 2976A US 3705064D A US3705064D A US 3705064DA US 3705064 A US3705064 A US 3705064A
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US
United States
Prior art keywords
web
fabric
needled
webs
needling
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
US2976A
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English (en)
Inventor
Herbert Lochner
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
KELEKTROCHEMISCHE FABRIK KEMPEN GMH
Original Assignee
Cik Chemische Industrie Kempen GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from DE19691901753 external-priority patent/DE1901753C3/de
Application filed by Cik Chemische Industrie Kempen GmbH filed Critical Cik Chemische Industrie Kempen GmbH
Application granted granted Critical
Publication of US3705064A publication Critical patent/US3705064A/en
Assigned to KELEKTROCHEMISCHE FABRIK KEMPEN GMH reassignment KELEKTROCHEMISCHE FABRIK KEMPEN GMH ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CIKALON-VLIESSTOFFWERK G.M.B.H.
Assigned to CIKALON-VLIESSTOFFWERK GESELLSCHAFT MIT BESCHRANKTER HAFTUNG reassignment CIKALON-VLIESSTOFFWERK GESELLSCHAFT MIT BESCHRANKTER HAFTUNG CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). , EFFECTIVE AUG. 19, 1971 Assignors: CIK-CHEMISCHE INDUSTRIE KEMPEN GESELLSCHAFT MIT BESCHRANKTER
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • 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
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • 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
    • Y10T428/23929—Edge feature or configured or discontinuous surface
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/659—Including an additional nonwoven fabric
    • Y10T442/666—Mechanically interengaged by needling or impingement of fluid [e.g., gas or liquid stream, etc.]
    • Y10T442/667—Needled

Definitions

  • a process for manufacturing varicolored, ornamentally designed needled non-woven fabrics which comprises applying to a first web of a needled, single-colored or blended non-woven fabric, a second web of non-woven fabric of a different color contrasting from the color of the first fabric, said second web having been glued and dried in accordance with a desired pattern, attaching the two Webs to one another by a needling operation in such a manner that the areas free of glue of said second web are passed through by needles whereby fibers of said fabric are taken along and will appear at the rear face of the first Web of non-woven fabric forming a finished pile thereon, while at the glued areas only a partial connection of the two fabric webs is effected by needling without the fibers being passed through to the rear face of said first web.
  • the manufacture of needled non-woven fabrics which may be used e.g. as punched felt-floor coverings, is carried out by making webs of non-woven fabrics in a known manner, either by carding or aerodynamically, and reinforcing the webs mechanically on needle machines, and subsequently by additional treatment with binding agents.
  • Chemical binders used are, preferably crosslinked polyacrylic esters, butadieneacrylonitrile, butadiene-styrene, and similar compounds.
  • All the known needled non-woven fabrics which are preferably used as floor coverings, are monochromatic (single-colored) or, in case a mixture of differently colored fibers are fed to the machine producing the nonwoven fabrics, they form blended fabrics.
  • the blended type has found wide acceptance.
  • the process of the invention is distinguished from the known techniques by using, preferably without carrier fabric, a single-colored web of a needled, non-woven fabric onto which is applied, by needling, another web of non-woven fabric of a different color.
  • glue is applied to the second web preparing those areas or spots which, in accordance with the desired patterns, are not to be needled, the glue being applied superficially to such an extent and to such depth that the needles penetrating the fabric at these glued places will not catch fibers with their books, or will only catch the fibers in a reduced number
  • the gluing of the web to be needled corresponds in this method to the art of printing with dyes, inasmuch as it is possible to reduce in a regulated flow, the passage of the fibers to the other side, or to stop it entirely, in the glued places, as compared to those that have no reinforcing glue applied thereto, depending on the amount of glue applied.
  • the effects of the patterning in the process of the invention are dependent on several factors, viz: on the type of needles used, the frequency at which a certain area is needled, the depth of penetration of the needles, the speed at which needling is carried out, also on the selection of the adhesive and the thickness and density of the film of adhesive applied in the surface gluing.
  • the particular usefulness of the gluten glues is probably due to the films they form which are of optimum low thermoplasticity.
  • the needles pull the fibers of the patterning web through and cause pattern formation.
  • EXAMPLE 1 In a known manner, but without carrier web, we first prepare a non-woven fabric of single-colored black polypropylene staple fiber by needling together several layers of non-woven fabric having a fiber length of 90 mm., a fiber weight of 14 den. and a width of 210 cm.; the weight of the fabric is 200 grams per square meter.
  • the non-woven propylene fiber web is subjected to glue application according to the desired pattern, in a suitable gluing apparatus, adhesive being applied at the areas to be glued so that it will penetrate into the web to a depth corresponding to about 50% of the web thickness, whereby the web will be glued at the said areas to the corresponding depth.
  • the fabric web which has now been glued in accordance with the desired pattern, is subsequently passed through a channel dryer and after drying is needled together with a second prefabricated web of non-woven fabric of 210 cm. width; the second web consists of several layers of light red polypropylene staple fibers having a length of 90 mm. and a fiber weight of 14 den.
  • the needles used in the needling process are so designed that they have in front of and behind the notches diameters which are either the same or difier only slightly; the depth to which the needles penetrate the fabric is so adjusted that in the areas free of glue, the fibers of the patterning web pass through to the surface of the lower fabric web, whereas at the impregnated places only an internal bonding of the two webs will occur.
  • a third prefabricated fabric web likewise of 210 cm. width and of the same fiber material and the same color as the lower web, is attached by needling. In that case, too, the depth to which the needles penetrate, is so adjusted that the three webs become closely connected, however, without the fibers being passed through to the surface of the patterned lower web.
  • the back of the base of the carpet or rug is now bright red in solid color, whereas the front is patterned bright red and dark red corresponding to the prepared pattern.
  • the base of the carpet consisting of three webs of non-woven fabrics, which are at first only mechanically reinforced are now reinforced by chemical binders, either by impregnation through immersion in tubs, or by padding or doctoring (with squeegee) on the back side, by foam application or by a combined process of impregnation and padding.
  • chemical binders either by impregnation through immersion in tubs, or by padding or doctoring (with squeegee) on the back side, by foam application or by a combined process of impregnation and padding.
  • Example 2 The first stages of the process are as described in EX- ample 1 until two webs of non-woven fabrics have been combined by mechanical needling and by reinforcing through gluing.
  • reversible glues e.g. gluten glues, vegetable glues, or polyvinyl alcohol
  • the procedure described can be so changed that instead of covering the patterning web by a third web, only the two first mentioned webs, i.e. the lower web and the patterning web may be mechanically combined by needling and then fed into a temperature-controlled water bath, where during passage of the combined web the reversible glue dissolves and becomes evenly distributed throughout the entire web of non-woven fabrics.
  • the gluten glue which was used as an auxiliary agent for bringing about the desired pattern, and which was used in the amount of 75 grams per square meter, may be used as an additional binder in the impregnation bath whereby the usual amount of binder may be reduced and some saving accomplished.
  • FIG. 1 is an exploded view of the three webs constituting the fabric
  • FIG. 2 shows the three webs in superimposed position prior to the needling operation and also indicates the needles used in the needling operation;
  • FIG. 3 is a cross-sectional view through the finished needled fabric structure.
  • FIG. 4 is a front elevational view corresponding to FIG. 3 showing the patterned fabric structure.
  • the fabric 10 has a face side 1 and a rear side 2 and is of a single color or of blended color.
  • the second web is of a color contrasting from the color of web 10 and comprises unglued portions 3 and glued portions 4. It will be noted that the contours of the glued portions 4 correspond to a predetermined pattern.
  • a third fabric 30 may be superimposed on the second fabric 20.
  • the superimposed webs are then needled by the needles 7, as indicated in FIG. 2, the arrow A indicating the reciprocating movement of the needles.
  • a larger number of needles may be used.
  • fibers of the unglued areas 3 of the Second web 20 penetrate through the body of the first web 10 and form the pile 8 on the face side 1 f the web 10.
  • substantially no pile is formed by the fibers of the glued areas 4 of the web 20. In this manner, a pattern such as shown in FIG. 4 may be obtained.
  • the third web 30 is attached 6 to the second web 20 by needling.
  • the depth to which the needles penetrate is so adjusted that the three webs become closely connected, however, without the fibers being passed through to the surface of the patterned lower web.
  • a process for manufacturing varicolored, ornamentally designed needled non-woven fabrics which comprises superimposing on a first web of a needled, Single-colored or blended non-woven fabric a second web of non-woven fabric of a color contrasting from the color of the first fabric, said second web having been glued and dried in accordance with a desired pattern to form glued and unglued areas, attaching the two webs to one another by a needling operation in such a manner that the unglued areas of said second web are passed through by needles whereby fibers of said second web are taken along, penetrate through said first web and appear at the face of the first web of non-woven fabric forming a finished pile thereon, while at the glued areas connection of the two fabric webs is effected by needling without the fibers of the second web penetrating to the face of said first web.
  • each web is composed of a plurality of layers which have been needled together.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
US2976A 1969-01-15 1970-01-14 Process for the manufacture of varicolored,ornamentally designed needled non-woven fabrics Expired - Lifetime US3705064A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19691901753 DE1901753C3 (de) 1969-01-15 Verfahren zur Herstellung eines genadelten und ornamental gemusterten Vliesstoffes

Publications (1)

Publication Number Publication Date
US3705064A true US3705064A (en) 1972-12-05

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Country Status (11)

Country Link
US (1) US3705064A (ja)
AT (1) AT322229B (ja)
BE (1) BE744462A (ja)
CH (1) CH45170A4 (ja)
DK (1) DK138807B (ja)
ES (1) ES375425A1 (ja)
FR (1) FR2030147B1 (ja)
GB (1) GB1267764A (ja)
NL (1) NL151754B (ja)
NO (1) NO125854B (ja)
SE (1) SE372782B (ja)

Cited By (16)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3849223A (en) * 1973-02-26 1974-11-19 Armstrong Cork Co Method of making a non-woven needled fabric having a random linear streaked design
US3935046A (en) * 1972-11-06 1976-01-27 Imperial Chemical Industries Limited Non-woven fabrics
US4047269A (en) * 1973-04-07 1977-09-13 Cikalon-Vliesstoff-Werke Gmbh Method and apparatus for producing ornamentally patterned, needled, nonwoven pile fabrics
US4211593A (en) * 1977-04-18 1980-07-08 Cikalon Vliesstoffwerk Gmbh Method of making a needled and ornamentally patterned fleece material
US4828914A (en) * 1987-12-14 1989-05-09 Armstrong World Industries, Inc. Non-woven flannel fabric
US6022447A (en) * 1996-08-30 2000-02-08 Kimberly-Clark Corp. Process for treating a fibrous material and article thereof
US6487762B1 (en) * 1999-11-24 2002-12-03 Fleissner Gmbh & Co., Maschinenfabrik Method and device for color patterning of a web by hydrodynamic treatment
US6671936B1 (en) * 2000-06-23 2004-01-06 Polymer Group, Inc. Method of fabricating fibrous laminate structures with variable color
US6733861B1 (en) * 1997-04-04 2004-05-11 Belanger, Inc. Vehicle laundry element and method of making same
WO2008131883A1 (en) * 2007-04-27 2008-11-06 Colbond B.V. Process to manufacture tufted backing materials
US20110083792A1 (en) * 2008-06-05 2011-04-14 Entwicklungsgesellschaft Fuer Akustik (Efa) Mit Beschraenkter Haftung Velour carpet with tufting-like surface
CN110177478A (zh) * 2016-01-19 2019-08-27 耐克创新有限合伙公司 具有材料间的毡合过渡部的鞋类
CN111074665A (zh) * 2019-12-16 2020-04-28 山东冠骏清洁材料科技有限公司 一种彩色木浆复合布生产工艺
US11083246B2 (en) 2016-01-19 2021-08-10 Nike, Inc. Footwear with embroidery transition between materials
FR3118071A1 (fr) * 2020-12-17 2022-06-24 Faurecia Automotive Industrie Revêtement intérieur à motif, notamment pour un véhicule
US12161192B2 (en) 2016-10-18 2024-12-10 Nike, Inc. Systems and methods for manufacturing footwear with felting

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3935046A (en) * 1972-11-06 1976-01-27 Imperial Chemical Industries Limited Non-woven fabrics
US3849223A (en) * 1973-02-26 1974-11-19 Armstrong Cork Co Method of making a non-woven needled fabric having a random linear streaked design
US4047269A (en) * 1973-04-07 1977-09-13 Cikalon-Vliesstoff-Werke Gmbh Method and apparatus for producing ornamentally patterned, needled, nonwoven pile fabrics
US4211593A (en) * 1977-04-18 1980-07-08 Cikalon Vliesstoffwerk Gmbh Method of making a needled and ornamentally patterned fleece material
US4828914A (en) * 1987-12-14 1989-05-09 Armstrong World Industries, Inc. Non-woven flannel fabric
US6022447A (en) * 1996-08-30 2000-02-08 Kimberly-Clark Corp. Process for treating a fibrous material and article thereof
US6733861B1 (en) * 1997-04-04 2004-05-11 Belanger, Inc. Vehicle laundry element and method of making same
US6487762B1 (en) * 1999-11-24 2002-12-03 Fleissner Gmbh & Co., Maschinenfabrik Method and device for color patterning of a web by hydrodynamic treatment
US6557224B2 (en) 1999-11-24 2003-05-06 Fleissner Gmbh & Co., Mashinenfabrik Method and device for color patterning of a web hydrodynamic treatment
US6735834B2 (en) 1999-11-24 2004-05-18 Fleissner Gmbh & Co., Maschinenfabrik Method and device for color patterning of a web by hydrodynamic treatment
US6671936B1 (en) * 2000-06-23 2004-01-06 Polymer Group, Inc. Method of fabricating fibrous laminate structures with variable color
US20040053551A1 (en) * 2000-06-23 2004-03-18 Carlson Cheryl Lynn Method of fabricating fibrous laminate structures with variable color
WO2008131883A1 (en) * 2007-04-27 2008-11-06 Colbond B.V. Process to manufacture tufted backing materials
US20100092721A1 (en) * 2007-04-27 2010-04-15 Colbond B.V. Process to manufacture tufted backing materials
CN101668889B (zh) * 2007-04-27 2012-05-23 考勒邦德有限公司 制造簇绒背衬材料的工艺
US8448589B2 (en) 2007-04-27 2013-05-28 Bonar B.V. Process to manufacture tufted backing materials
US20110083792A1 (en) * 2008-06-05 2011-04-14 Entwicklungsgesellschaft Fuer Akustik (Efa) Mit Beschraenkter Haftung Velour carpet with tufting-like surface
CN110177478A (zh) * 2016-01-19 2019-08-27 耐克创新有限合伙公司 具有材料间的毡合过渡部的鞋类
US11083246B2 (en) 2016-01-19 2021-08-10 Nike, Inc. Footwear with embroidery transition between materials
US11311079B2 (en) * 2016-01-19 2022-04-26 Nike, Inc. Footwear with felting transition between materials
US11864627B2 (en) 2016-01-19 2024-01-09 Nike, Inc. Footwear with embroidery transition between materials
US12161192B2 (en) 2016-10-18 2024-12-10 Nike, Inc. Systems and methods for manufacturing footwear with felting
CN111074665A (zh) * 2019-12-16 2020-04-28 山东冠骏清洁材料科技有限公司 一种彩色木浆复合布生产工艺
FR3118071A1 (fr) * 2020-12-17 2022-06-24 Faurecia Automotive Industrie Revêtement intérieur à motif, notamment pour un véhicule

Also Published As

Publication number Publication date
AT322229B (de) 1975-05-12
DK138807C (ja) 1979-04-09
ES375425A1 (es) 1973-02-01
NL7000492A (ja) 1970-07-17
DE1901753A1 (de) 1971-01-14
FR2030147A1 (ja) 1970-10-30
NO125854B (ja) 1972-11-13
FR2030147B1 (ja) 1973-12-21
DE1901753B2 (de) 1973-03-01
DK138807B (da) 1978-10-30
SE372782B (ja) 1975-01-13
GB1267764A (en) 1972-03-22
NL151754B (nl) 1976-12-15
BE744462A (fr) 1970-06-15
CH45170A4 (ja) 1971-06-15

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AS Assignment

Owner name: KELEKTROCHEMISCHE FABRIK KEMPEN GMH, KEMPEN GERMAN

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:CIKALON-VLIESSTOFFWERK G.M.B.H.;REEL/FRAME:004010/0543

Effective date: 19820615

Owner name: CIKALON-VLIESSTOFFWERK GESELLSCHAFT MIT BESCHRANKT

Free format text: CHANGE OF NAME;ASSIGNOR:CIK-CHEMISCHE INDUSTRIE KEMPEN GESELLSCHAFT MIT BESCHRANKTER;REEL/FRAME:004028/0001

Effective date: 19801013