EP0603774A1 - Carpet-interlayer consisting of a nonwoven - Google Patents

Abstract

The invention relates to a mat fabric (2) produced on the basis of a nonwoven (1). In order to provide a novel mat fabric of this type, the invention proposes using fibrous constituents which consist predominantly of synthetic material and which are partly thermoplastic and low-melting and partly higher-melting, cohesion being achieved by melting on the low-melting thermoplastic fibre fractions (4). <IMAGE>

Description

The invention relates to a mat made on the basis of a nonwoven.

Mat products of this type are known.

The object of the present invention is to provide a new type of mat made on the basis of a nonwoven.

This object is achieved by the invention specified in claim 1.

The subclaims represent advantageous developments.

As a result of this configuration, there is a new type of mat made on the basis of a fleece, which has a high degree of flexibility due to the confusion of low-melting and high-melting components. The mat goods mainly consist of fibrous plastic components, some of which are thermoplastic and low-melting and some of which are higher-melting. By melting the low-melting thermoplastic fiber parts, the fibrous components are held together. Polyamide fibers which have a melting point of approximately 220 ° C. are preferably used as the high-melting fiber components. The latter is significantly higher than that of the thermoplastic and low-melting fiber components. Here, polyolefins such as polypropylene, polyethylene or the like are preferred. By means of the action of heat on the fibers, which are loosely scattered or laid out in the form of a mat, the low-melting thermoplastic fiber components such as polypethylene are melted or polypropylene, which leads to an adhesion between the low-melting and the higher-melting components. The temperature during exposure to heat corresponds approximately to the melting point of the low-melting fiber components, ie approx. 120-170 ° C. The stiffness and inherent load-bearing capacity of the mat can be influenced. For example, this increases with an increasing proportion of low-melting thermoplastic fiber parts within the mat material or also with longer exposure to heat, the lower-lying low-melting fiber parts also being melted on. The mat fabric can also have proportions of polyester fiber material and proportions of styrene-butadiene, styrene-acrylate or else ethylene vinyl acetate. It has proven particularly advantageous that the melted regions are arranged in an island-like or island-like network. This results in a mesh-like support structure of the mat fabric, the tightness of the mesh and thus the rigidity and the intrinsic load-bearing capacity of the mat fabric being dependent on the quantitative ratio between low-melting and high-melting components and on the duration of the heat application. It is preferred here to arrange the melted areas only on the surface. This means that the areas melted on the surface of the mat fabric achieve a cohesion of the fiber parts and thus form a stabilizing "outer skin". The high-melting parts and the low-melting parts not melted by the action of heat adhere to one another due to their random position and on the other hand to the melted areas with the low-melting parts. In a preferred embodiment it is provided that the melted areas are arranged lying on one side on the surface. The mat fabric thus shows only a stabilizing "outer skin" on one side. It has also proven to be particularly advantageous that the mat fabric produced as a nonwoven is set to be conductive, for example by portions of carbon fibers or metal-vapor-coated, conductive fibers (the latter in turn preferably based on polyamide).

The invention also relates to a method for producing a mat product based on a nonwoven, for example a mat product of the previously described embodiment. In this context, it is based on the fact that a carpet consisting predominantly of plastic fibers, which preferably consists of a pole material based on preferably polyamide 6.6, preferably of a carrier material made of polypropylene nonwoven or polypropylene tape fabric, further preferably from a primer Styrene-butadiene, ethylene-vinyl acetate, styrene-acrylate or the like, further preferably from a laminating adhesive based on polyolefins such as polyethylene and polypropylene and further preferably from a backing layer based on polyolefins, preferably consisting of polypropylene or the like, is torn into fibrous components, an optionally needled fleece is laid from this and this fleece is subjected to heat at least on the surface in such a way that the low-melting thermoplastic components melt. This requires the application of heat, which melts the polyolefinic components, but not the fibrous parts, based in particular on polyamide. For example, polyamide has a melting point of 220 ° C, while the polyolefins used soften and melt at 120-170 ° C. As a result, the low-melting fiber portions arranged on the surface of the nonwoven are melted, which results in point-like bonding of the components arranged in a random position on the surface of the nonwoven. As already described, the melted areas can be arranged in an island-like or island-like network. In order to achieve an improved adhesion of the components to one another, it is preferred that the mat goods are compacted after melting. This also increases the stability of the mat. It is advantageous to compress the mat goods after melting between press cooling rolls. Finally, it is provided that the fleece is placed on a carrier web, which in any case runs along with the melting of low-melting thermoplastic components. In this way, manageability is achieved despite the cohesion of the fiber components given only by the random position of the individual components before the action of heat.

In addition, the invention relates to a carpet, in particular with a pile layer made of pile threads, a backing layer consisting of fiber or ribbon material made of polyolefins or polyester, and a back coating, the pile threads possibly being firmly connected to and made of the backing layer with the backing layer a comparatively high temperature resistant plastic, in particular polyamide 6 or 6.6. This is based on the fact that an intermediate layer consists of a mat material, the mat material predominantly comprising plastic, fibrous components which are partly thermoplastic and low-melting and partly higher-melting, whereby cohesion is achieved by melting the low-melting thermoplastic fiber parts, preferably produced from this in a process in which a carpet consisting predominantly of plastic fibers is torn open to form fibrous components if necessary, needled fleece is placed and this fleece is subjected to heat at least on the surface such that low-melting thermoplastic components melt. The mat goods described in the previous embodiments can be used on the one hand as an underlay for tensioned carpets or as an intermediate layer in a carpet. It can be provided that the mat fabric is covered on the underside by a fabric layer. Finally, it can advantageously be provided that the mat is laminated to an intermediate layer, in particular by melting the low-melting thermoplastic components. This can be done in such a way that the melting of the low-melting thermoplastic parts of the fleece form both the cohesion between the fibrous components of the mat and the adhesion to an intermediate layer. This can be done in one operation, provided that the components of the carpet to be provided with the mat goods consist of high-temperature-resistant thermoplastic components.

Figur 1

eine schematische Darstellung einer auf Basis eines Vlieses hergestellten Mattenware in stark vergrößerter Draufsicht,

Figur 2

den Schnitt gemäß der Linie II-II in Figur 1,

Figur 3

eine stark vergrößerte Ausschnittsdarstellung der Figur 1 im Bereich von inselartig angeordneten aufgeschmolzenen Bereichen niedrigschmelzender thermoplastischer Faseranteile,

Figur 4

eine schematische Darstellung einer Vorrichtung zur Herstellung einer auf Basis eines Vlieses hergestellten Mattenware und

Figur 5

einen schematischen, teilweise aufgetrennt dargestellten Teppichboden, welcher mit einer aus einer Mattenware gemäß Figur 1 bestehenden Zwischenschicht versehen ist.

The invention is further explained below with reference to the accompanying drawing, which, however, only represents exemplary embodiments. Here shows:

Figure 1

1 shows a schematic representation of a mat product produced on the basis of a fleece in a greatly enlarged top view,

Figure 2

the section along the line II-II in Figure 1,

Figure 3

a greatly enlarged sectional view of Figure 1 in the region of island-like melted areas of low melting thermoplastic fiber components,

Figure 4

is a schematic representation of a device for producing a mat made on the basis of a nonwoven and

Figure 5

a schematic, partially separated carpet, which is provided with an intermediate layer consisting of a mat according to Figure 1.

Shown and described is first of all, with reference to FIG. 1, a mat fabric 2 produced on the basis of a fleece 1, which mainly has fibrous components 3 consisting of plastic. These fibrous components 3 are a mixture of thermoplastic low-melting fiber components 4 and higher-melting fiber components 5. The low-melting fiber components 4 consist, for example, of polyolefins such as polyethylene, polypropylene or the like. The high-temperature-resistant fiber portions 5 are preferably those made of polyamide 6 or polyamide 6.6. used. The fiber parts 4 and 5 are arranged in a tangled position, so that there is a cohesion of the fiber parts 4 and 5, which is reinforced by regions 7 of melted low-melting fiber parts 4 arranged on one surface 2 'of the mat fabric 2. As can be seen in particular from FIG. 3, the higher-melting polyamide fibers 5 are connected to one another by the low-melting fiber portions 4, which, like the reference number 6, for example, partially glue the polyamide fibers 5 together in an envelope-like manner. There are also larger accumulations, as explained by reference number 8, of the thermoplastic components. This results in fiber groups 8, which are connected to other fiber groups 8 ′ due to longer polyamide fibers 5 are. There are further areas 9 melted on the surface 2 'of the mat fabric 2 in the form of adhesive dots. Through these island-like arranged adhesive dots, an improved cohesion of the fiber parts within the mat fabric 2 is achieved. Depending on the frequency of the low-melting fiber components 4, these adhesive spots 9 can also merge into one another in a network. There is thus a carrier structure, the glue dots 9 consisting of melted low-melting fiber portions 4 partially enclosing the higher-melting fiber portions 5. Due to the confusion, these in turn form a cohesion with one another. As can be seen from FIG. 2, only the low-melting fiber parts 4 arranged near the surface 2 'are fused to form adhesive points 9. The low-melting fiber portions 4, which are located away from the surface 2 ', ie in the middle or on the opposite side, have not melted and fit into the tangle. Due to the island-like or island-like crosslinked bonding of the fiber parts 4 and 5 and the tangle of the fibrous parts, the mat fabric 2 is flexible.

In addition, the mat fabric has 2 conductive substances. These can consist, for example, of carbon fibers 26 or of metallized conductive fibers (the latter in turn preferably based on polyamide). FIG. 4 shows a device 10 for producing a mat product 2 produced on the basis of a fleece 1. For this purpose, fibrous constituents 11, which are obtained from a torn-open carpet consisting predominantly of plastic fibers, are turned into a loose fleece in a first device 12, which is only held together by the tangled position of the individual fiber parts 4 and 5, for example by means of a slide device 13, shaped and placed on a carrier web 14 in the form of a continuous endless belt. The fleece formed only by the tangle of the fibrous components 3 is provided with the reference number 15 in FIG. The fleece resting on the carrier web 14 now passes under a melting device 16, in which the low-melting fiber portions 4 arranged on the surface 2 'of the mat fabric 2 are melted and thus form a stabilizing "outer skin". In the further course of the transport after the melting device 16 has passed in the direction of the arrow x, the mat goods are acted upon and compressed by press cooling rolls 18.

FIG. 5 shows an example of the use of a mat fabric 2 produced in this way, the latter serving here as an intermediate layer 19 of a carpet 20. This carpet 20, which is shown schematically in FIG. 5, has pile threads 21, which form a pile layer, made of polyamide 6 or polyamide 6.6 on. These pile threads 21 are needled into a carrier material 22. The carrier material 22 can be a fleece or ribbon fabric made of polypropylene. A first consolidation of the pile threads 21 with the carrier material 22 is achieved by a so-called primer 23, which is shown here as an exaggerated layer. In reality, the primer coating is very thin. The primer consists of copolymers of eg styrene-acrylate, styrene-butadiene, ethylene vinyl acetate and others. The carrier material 22 with the needled and solidified pile threads 21, for example due to the primer 23, is connected to the mat material 2 designed as an intermediate layer 19 by means of a lamination 24, which is also shown here for reasons of demonstration as an exaggeratedly thick layer. However, this connection can also be made by melting the low-melting thermoplastic fiber portions 4 of the mat fabric 2. Underside the mat is covered by a fabric layer 25. The latter can be, for example, a fabric based on polypropylene.

The mat goods 2 shown and described can, however, also be used as an independent product in the sense of an underlay for tensioned carpets.

The features of the invention disclosed in the above description, the drawing and the claims can be of importance both individually and in any combination for the implementation of the invention. All the features disclosed are essential to the invention. The disclosure content of the associated / attached priority documents (copy of the prior application) is hereby also included in full in the disclosure of the application.

Claims (20)

Mat goods (2) produced on the basis of a fleece (1), characterized by fibrous components (3) consisting predominantly of plastic, which are partly thermoplastic and low-melting and partly higher-melting, whereby cohesion is achieved by melting the low-melting thermoplastic fiber parts (4) is. Mat goods according to claim 1 or in particular according thereto, characterized in that the fibrous components (3) are composed of at least two types of plastics such as polyethylene, polyester, polypropylene, polyamide or the like. Mat fabric according to one or more of the preceding claims or in particular according thereto, characterized in that the mat fabric has polypropylene components. Mat fabric according to one or more of the preceding claims or in particular according thereto, characterized in that the mat fabric has polyethylene components. Mat fabric according to one or more of the preceding claims or in particular according thereto, characterized in that the mat fabric has polyester components. Mat fabric according to one or more of the preceding claims or in particular according thereto, characterized in that the mat fabric has polymer components based on styrene-acrylate components. Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that that the mat fabric has polymer components based on styrene-butadiene components. Mat fabric according to one or more of the preceding claims or in particular according thereto, characterized in that the mat fabric has polymer components based on ethylene vinyl acetate components. Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that the melted-on areas (9) are arranged in an island-like manner. Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that the melted-on areas (9) are arranged in an island-like network. Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that the melted-on areas (9) are arranged lying on the surface (2 '). Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that the melted-on areas (9) are arranged lying on one side on the surface (2 '). Mat goods according to one or more of the preceding claims or in particular according thereto, characterized in that the fleece (1) is made conductive, for example by portions of carbon fibers (26) or metal-vapor-coated fibers. A process for the production of a mat product (2) based on a fleece (1), in particular a mat product (2) according to claims 1 to 13, characterized in that a carpet consisting predominantly of plastic fibers, preferably with a pile material based on preferably polyamide 6 or polyamide 6.6, preferably a backing material made of a polypropylene nonwoven or polypropylene ribbon fabric, more preferably a primer made from copolymers based on ethylene vinyl acetate, styrene-butadiene or styrene-acrylate or the like, more preferably a laminating adhesive and more preferably a backing layer based on polyolefins such as polypropylene or the like is torn into fibrous constituents (3), an optionally needled nonwoven (1) is placed therefrom and this nonwoven (1) is exposed to heat at least on the surface in such a way that low-melting melt on thermoplastic parts (4) elzen. Method for producing a mat product (2) produced on the basis of a fleece (1) according to claim 14 or in particular according thereto, characterized in that the mat product (2) is compressed after melting. Method for producing a mat fabric (2) produced on the basis of a fleece (1) according to one or more of claims 14 or 15 or in particular according thereto, characterized in that the mat fabric (2) is compressed after the melting by press cooling rolls (18) . A process for producing a mat fabric (2) produced on the basis of a fleece (1) according to one or more of claims 14 to 16 or in particular according thereto, characterized in that the fleece (1) is placed on a carrier web (14), which in any case to to succeed Melting of low-melting thermoplastic portions (4) runs along. Carpeting (20), in particular with a pile threads (21) forming a pile layer, a backing layer (22) consisting of fiber or ribbon material made of polyolefins or polyester, and a back coating, the pile threads (21) optionally being coated with the back coating Carrier layer (22) are firmly connected and consist of a comparatively high-temperature-resistant plastic, in particular polyamide 6 or 6.6, characterized in that an intermediate layer (19) made of a mat (2), in particular according to claims 1 to 13, preferably produced according to a method of claims 14 to 17 exists. Carpeting according to claim 18 or in particular according thereto, characterized in that the mat fabric (2) is covered on the underside by a fabric layer (25). Carpeting according to one of claims 18 or 19 or in particular according thereto, characterized in that the mat fabric (2) is laminated to an intermediate layer, in particular by melting the low-melting thermoplastic components (4).

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