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EP3371366B1 - Procédé pour fabriquer un produit textile, son utilisation, le produit lui-même et dispositif permettant d'appliquer ce procédé - Google Patents

Procédé pour fabriquer un produit textile, son utilisation, le produit lui-même et dispositif permettant d'appliquer ce procédé Download PDF

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Publication number
EP3371366B1
EP3371366B1 EP16793825.7A EP16793825A EP3371366B1 EP 3371366 B1 EP3371366 B1 EP 3371366B1 EP 16793825 A EP16793825 A EP 16793825A EP 3371366 B1 EP3371366 B1 EP 3371366B1
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EP
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Prior art keywords
sheet
yarns
polyamide
pile
layer
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German (de)
English (en)
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EP3371366A1 (fr
Inventor
Chris Reutelingsperger
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Covestro Netherlands BV
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DSM IP Assets BV
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0078—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing the back coating or pre-coat being applied as a hot melt
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0071—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing
    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2201/00—Chemical constitution of the fibres, threads or yarns
    • D06N2201/02—Synthetic macromolecular fibres
    • D06N2201/0263—Polyamide fibres
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N2211/00—Specially adapted uses
    • D06N2211/06—Building materials
    • D06N2211/066—Floor coverings

Definitions

  • the present invention pertains to a method to manufacture a textile product, in particular a carpet product such as broadloom carpet, carpet tiles, mats and rugs, comprising a first sheet having polyamide yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polyamide yarns through the sheet to form the pile on a first surface of the sheet, the pile extending for a predetermined length from this first surface, and to form loops of the yarns at a second surface of the sheet, and fastening the yarns to the sheet by creating a layer of fused material on the second surface of the sheet using heat.
  • the invention also pertains to a method to use a textile product obtained with the new method, the textile product itself and a device for applying the said method.
  • textile products such as carpet products are made by firstly forming an intermediate material of yarns being stitched, typically tufted or woven, into a primary backing (the first sheet), and optionally cut, to form a pile on top of the first surface this primary backing, and loops of the yarns on the second surface (the back side) of this backing.
  • the yarns can be pulled out of the backing by using a light pulling force, for example by pulling on a yarn by hand.
  • a layer of fused material may be created on the back surface of the primary backing.
  • the fused layer may be a simple molten and thereafter solidified thermoplastic material (such as hot melt adhesive), a cured layer of resin (such as latex), or a hardened layer of a rubbery substance (such as a bituminous material) etc.
  • a fused layer By creating such a fused layer, the loops of the yarns are anchored to the primary backing and therewith adequately mechanically attached to withstand normal mechanical loads.
  • the intermediate product with the starting material for the fused layer is normally transported through a long oven (50-100 meters), typically at 180-200°C in order to create an adequate fused layer.
  • EP 1598476 (Klieverik Heli ) describes a method in which no latex or bituminous layer is used to anchor the yarns to the primary backing.
  • the layer of molten material is created by feeding the backing (yarn upwards) along a heated roller surface while its underside is pressed against the roller so the yarns will at least partly melt to form a layer of fused material, the layer optionally incorporating an adhesive applied in the form of a powder before the back side of the primary backing is processed using the heated roller.
  • pressure may be applied after heating (e.g.
  • WO 2012/076348 (Niaga ) describes a method for manufacturing textile products that even improves the anchor strength of the yarn with respect to the method as described in EP 1598476 .
  • this method when the primary backing is pressed against the heated surface, a relative speed between the primary backing and the heated surface is introduced. Due to this relative speed, an additional mechanical force is provided on the molten material in the machine direction (i.e. the direction of transport of the primary backing). This force spreads the material of the yarn whilst it is still molten resulting in a more homogenous layer of fused material and thus a stronger overall bond between the primary backing and the yarns.
  • polyamide yarns are often used for the pile of textile products.
  • Polyamide PA or nylon
  • PA polyamide
  • nylon are very resistant to wear and abrasion, have good mechanical properties even at elevated temperatures, and have good chemical resistance.
  • polyamide has a very low stain resistance
  • polyester used for yarns in non-high end applications generally has a good stain resistance.
  • the polyamide material is at least to some part amorphous.
  • the amorphous part of polyamide can be oriented or non-oriented (see for example Appl Spectrosc. 2005 Jul;59(7):897-903 ).
  • the number of amino and acid groups available for stains to attach to, is believed to be higher in the non-oriented amorphous zones. Heat setting generally increases the percentage of this stain sensitive non-oriented amorphous part.
  • the invention is also directed to the use of a textile product obtainable according to the invention to cover a surface of a building or any other artificial or natural construction.
  • the invention is also directed to a device for use in manufacturing a textile product comprising a first sheet having polyamide yarns fastened to this sheet to form a pile thereon, the yarns being stitched through the sheet to form the pile on a first surface of the sheet, the pile extending for a predetermined length from this first surface, and loops of the yarns at a second surface of the sheet, wherein the device comprises respectively a heating means for heating the second surface of the sheet, a means for creating a mass of fused material on the second surface of the sheet, and cooling means for cooling at least the distal half of the length of the pile to a temperature at least 70°C, preferably at least 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88,
  • the invention is also directed to a textile product comprising a sheet having a top surface and a bottom surface, the textile product having polyamide yarns stitched through this sheet to form a pile on the surface of the sheet, the pile extending for a predetermined length from this first surface, the yarns being fastened to the bottom surface of the sheet by forming a layer of fused polyamide material on this bottom surface, the yarns in the pile have a decreased amorphous content with respect to yarns of the same polyamide annealed at a temperature of about 43°C (i.e. between 40 and 45°C) below the melting temperature of the polyamide for 1 hour.
  • a textile product comprising a sheet having a top surface and a bottom surface, the textile product having polyamide yarns stitched through this sheet to form a pile on the surface of the sheet, the pile extending for a predetermined length from this first surface, the yarns being fastened to the bottom surface of the sheet by forming a layer of fused polyamide material on this bottom surface, the yarn
  • a textile product is a product that comprises textile (i.e. material made mainly of natural or artificial fibres, often referred to as thread or yarn), optionally with other components such as backing layers, carrier layers and/or adhesives.
  • Laminated textile products typically comprise an upper layer of pile attached to a backing (where the raised pile fibres are also denoted as the "nap" of the product), but may also be flat weave.
  • Such products can be of various different constructions such as woven, needle felt, knotted, tufted and/or embroidered, though tufted products are the most common type.
  • the pile may be cut (as in a plush carpet) or form loops (as in a Berber carpet).
  • Polyamide yarns are yarns containing at least 10% of polyamide material, preferably at least 20, 30, 40, 50, 60, 70, 80, 85, 90, 95 up to 100% of polyamide.
  • Polyamide (PA or nylon) is the generic name for all long-chain fiber-forming polyamides with recurring amide groups. Depending on the type of PA, melting temperatures may range from 190 to 350°C, typically between 220 and 260° for polyamides used for making yarns for textile materials such as carpet (mainly PA6 and PA66). PA is always at least partly amorphous (either completely amorphous or semi-crystalline). PA6 (nylon 6), also called polycaprolactam, is a polymer developed by Paul Schlack to reproduce the properties of PA66 (nylon 6,6). Like PA66, it is a semicrystalline polyamide. Unlike most other nylons, PA6 is not a condensation polymer, but instead is formed by ring-opening polymerization. It's melting temperature is around 220°C.
  • a loop of a yarn is a length of this yarn that may be curved away from the basic part of the yarn (not excluding that the loop is longer than the main part itself).
  • the basic part of the yarn is the part that forms the upper, visible part of the product.
  • this is the part of the yarns that forms the pile.
  • the loop is the part that extends from the back surface of the product.
  • a sheet is a substantially two dimensional mass or material, i.e. broad and thin, typically, but not necessarily, rectangular in form, and inherently has two opposite surfaces.
  • Stitching is a method of mechanically making a yarn part of an object by stitches or as if with stitches, such as by tufting, knitting, sewing, weaving etc.
  • a layer is a thickness of material, laid on or spread over a surface.
  • a layer may be inhomogeneous with respect to thickness and may be discontinuous in the sense that it may have holes in it.
  • a laminate is a structure comprising multiple stacked layers mechanically connected to each other.
  • Resilient means to be able to deform and automatically return to the original configuration.
  • a hot melt adhesive is a thermoplastic adhesive that is designed to be melted, i.e. heated to transform from a solid state into a liquid state to adhere materials after solidification.
  • Hot melt adhesives are typically non-reactive, crystalline and comprise low or no amount of solvents so curing and drying are typically not necessary in order to provide adequate adhesion.
  • Fibrous means consisting basically out of fibres.
  • the term "basically” in this respect means that the basic mechanical constitution is arranged out of fibres: the fibres may however be impregnated or otherwise treated or combined with a non-fibrous material such that the end material also comprises other constituents than fibres.
  • Typical fibrous sheets are woven and non-woven textile products, or combinations thereof.
  • the distal half of the length of the pile is maintained at a temperature at least 100°C below the melting temperature of the polyamide. It was found that although 70°C is already well below the melting temperature, and thus, heat setting was expected to be not or hardly present, the method could be improved by maintaining the temperature of the yarns at least 100°C below the melting temperature of the polyamide. Apparently, heat setting still occurs to some relevant extent even in the range of 70-100 degrees celsius below the melting temperature of the polyamide. It is found that the heat setting can be prevented substantially completely when the temperature is maintained at 125 - 150°C below the melting temperature of the polyamide.
  • the at least distal half of the length of the pile is maintained at the temperature below the melting temperature of the polyamide using cooling means.
  • cooling means may for example be a chilled roller contacted with the pile side of the first sheet, or a blower for blowing cold gas over this pile side, while the back of the sheet is heated in order to form the fused layer.
  • any other passive or active means for maintaining the temperature of the pile at a temperature as defined according to the invention may be used instead.
  • the second surface of the sheet is contacted with a surface of a hot body to at least partly melt the loops of the yarns to create the mass of fused material.
  • the layer of fused layer to anchor the yarns is created using methods as known for example from EP 1598476 , WO 2014/198731 , US 2002/132084 , US 5556684 , US 2012/0219751 , EP 2172589 and WO 2012/076348 .
  • the temperature of the pile (at least the distal half of the pile) can be kept below a temperature where heat setting significantly influences the stain resistance of the polyamide.
  • This can be done using either active cooling means, or depending mainly on the height of the pile, the density of pile, the exact materials used, and the required time of contact with heated surface to create the layer of fused material, by simply relying on the heat transport through the pile (by conduction, radiation and/or convection) being too slow to heat up the top half of pile above the critical temperature regarding inducing a staining problem.
  • the surface of the hot body has a relative speed (and thus moves at a relative speed greater than 0 m/s) with respect to the second surface of the first sheet.
  • a hot body that has a relative speed with respect to the second surface during the melting process of the yarns is known from WO 2012/076348 . It now appears that this feature is ideally suitable for use in a method wherein the yarns are polyamide yarns, aiming at an increased stain resistance of the pile.
  • the surface of the hot body is stationary, whereas the first sheet is transported along the hot body.
  • the textile product is a laminate of the first sheet and a second sheet
  • an adhesive is applied to this second surface to which adhesive the second sheet is adhered.
  • the adhesive is a hot melt adhesive, for example a hot melt adhesive that comprises at least 50% by weight of a polymer chosen from the group consisting of polyurethane, polycarbonate, polyester, polyamide, poly(ester-amide), polyolefine, mixtures thereof and/or copolymers thereof.
  • an intermediate layer is provided between the first sheet and the second sheet wherein the intermediate layer is resilient to allow local deformation of this layer along the second surface of the first sheet or along the surface of the second sheet adjacent to the intermediate layer.
  • curling of edges or corners is a problem since the edges in general to not coincide with an edge of the surface to be covered, and thus, the curled up edges or corners may lead to irregularities in center areas of the covered surface.
  • internal strain may lead to deformation such that interstices are formed at the joint of two sections of carpet.
  • internal strain may lead to bulges and local excessive wear.
  • An important reason for the occurrence of internal strain is that the laminate inherently comprises different layers (note: the term “layer” or "sheet” does not exclude that the layer or sheet is actually constituted out different sublayers) that need to provide very different properties to the textile product: the first sheet (the primary backing) needs to stably bear the pile yarns.
  • the second sheet (the secondary backing) in general provides dimensional stability to the textile product. For this reason, the structure of the different layers is inherently different. And thus, even when for example the first and second sheet are made of the same material, the occurrence of internal strain due to different deformations by the action of moist and temperature, is inherently present. The problem is even increased when different materials are being used for constituting the sheets, in particular when these materials per se expand and contract differently due to moist and or temperature.
  • the pile yarns are polyamide yarns, whereas the polymer used for the primary and secondary backing is mostly polyester. These polymers have totally different deformation characteristics due to moist and temperature.
  • each of the sheets may expand or contract ("deform") in the horizontal direction independently of an expansion or contraction of the other sheet, and thus, that no (or only low) internal strain (which may lead to curl or other deformation) may arise.
  • the intermediate layer is a fibrous layer. Fibres can be easily assembled to form a stable layer, and still provide for the option of local deformation. For example when fibres are entangled but not mechanically connected at the sites were fibres cross, deformation may stay locally, while the layer as a whole has significant mechanical stability.
  • the intermediate layer is a non woven layer.
  • Non woven layers are easy to assemble, even when using very short fibres and are therefore economically attractive. While short fibres may prevent deformation to be easy transferred over distances considerably longer than the fibres themselves, long fibres, due to the non-woven arrangement (for example meandering like a river) may also be perfectly capable of allowing local deformation and not transferring forces to the neighbouring areas.
  • the intermediate layer is a knitted layer.
  • a knitted layer although the fibres are in essence endless, appears to be perfectly suitable to allow only local deformation. Like a tubular knitted sock that fits every curve of a foot, a knitted layer can easily deform locally without transferring forces to neighboring areas.
  • a knitted layer for use in the present invention is for example Caliweb®, obtainable from TWE, Emsdetten, Germany.
  • Figure 1 schematically shows a cross section of a textile product manufactured according to the invention
  • Figure 2 schematically shows a configuration for applying a yarn melting process
  • Figure 3 schematically shows details of an active cooling means
  • Figure 4 schematically represents a laminating configuration
  • Example 1 provides process parameters for a method according to the invention
  • Example 2 is an example of a specific laminated textile product according to the invention
  • Example 3 provides a method to establish dirt retaining properties of carpet.
  • Example 4 provides a method to determine whether or not the textile product is a product according to the invention.
  • Example 1 provides process parameters for a method according to the invention.
  • the process parameters for a set up as depicted in figure 3 are given.
  • the textile product is heated with heating body 505 to a temperate of 235°C.
  • the temperature of the top of the pile is about 95°C (about 125°C below the melting point of PA).
  • the product arrives at the cooling beam, its temperature at the side bearing the layer of fused material is still around 160°C.
  • the beam actively cools this hot surface very quickly, due to the intensive contact, to a temperature of about 100°C at the end of the length L 1 of the beam. This temperature is reached within 10 seconds after the second surface is heated with heating body 505.
  • Example 2 is an example of a specific laminated textile product according to the invention. Reference numbers refer to parts corresponding to the textile product as shown in Figure 1 .
  • the textile product of this example comprises a first sheet 2 (the primary backing), which is a 100% polyester non-woven having a weight of 120 g/m 2 obtained from Freudenberg Vliesstoffe SE & Co. KG Neuenburg, Germany.
  • This primary backing is tufted with a cut pile of 100% PA6 yarns (available from Aquafil (Cartersville, Georgia, USA).
  • the polyamide yarns 5 extend from the first surface 3 of the primary backing and are sealed to the second surface 4 of the primary backing using the fibre binding method as described with reference to Figure 2 .
  • the total weight of this tufted sheet is about 700 g/m 2 .
  • the textile product comprises a secondary backing (second sheet 6), in this case a backing of a polyester needle felt backing fleece obtained as Qualitex Nadelvlies from TWE, Emsdetten, Germany.
  • the weight of this second sheet is about 900 g/m 2 .
  • the layers are glued together using a polyester hot melt glue from DSM, Geleen, The Netherlands (available under the trade name Uralac®), applied at a weight of about 300 g/m 2 (which is the same amount as typically used for textile products having polyamide yarns tufted to the primary backing and processed with the same fibre binding method).
  • the total weight of the carpet tile is thus about 1.9 kg/m 2 .
  • the laminated textile product appears to be very durable and resistant against delamination.
  • a piece of carpet made in accordance with example 2 was tested regarding its properties to retain dirt (or, to let go dirt).
  • a piece of carpet having dimensions of 180 x 600 mm is firstly intensively contacted with dirt, by adding 15 grams of so called "VNTF" dirt (a standard type of dirt, a predetermined mixture of pigmented organic and inorganic solid materials, mineral oil, and quartz crystal sand, standardized by the Organisation of Dutch Carpet Producers; available from the TFI Institute in Aachen, Germany), and fixing the dirt in a Tetrapod machine (see Journal of the Textile Institute Transactions, Volume 56, Issue 3, 1965 ) during 800 rotations.
  • VNTF so called "VNTF” dirt
  • This annealing step corresponds to a (minimal) annealing step when a carpet is made using a traditional technique where the carpet as a whole is heated in an oven to fix the secondary backing.
  • both carpet types were treated in the same tetrapod machine, and both pieces of carpet were cleaned in the same machine.
  • the results of the amounts of dirt released by the carpets are indicated in Table 1 below.
  • Table 1 Amount of dirt extracted (grams) Experiment PA carpet, heat annealed PA carpet of the invention 1 4.1014 6.0891 2 5.4162 6.6511 3 6.1916 6.6508 4 6.1331 7.0993
  • Example 4 provides a method to determine whether or not the textile product is a product according to the invention.
  • the polyamide material which is the same as the material used for the yarns in the textile product is subjected to an annealing temperature well below 180°C.
  • This temperature is chosen since it is a typical temperature for any conventional backing oven used to fuse a secondary backing to a textile material and is about 43°C below the melting temperature of a typical PA used for making carpet.
  • the fact that the amorphous content of the material after 1 hour of annealing is below that of the same material annealed at 180°C, demonstrates that such a material processed according to the method of the invention will also lead to a product according to the invention.
  • Table 2 Depicted in Table 2 are the results from the annealing experiment of PA6 material tycially used for yarns of carpet products.
  • the material is presented as non-fiber bondend fibers, and heated for 1h at different temperatures as indicated. The lowest temperature is about 150 °C below the melting temperature of the polyamide. The middle-temperature is slightly over 70°C below the melting temperature.
  • Tg glass transition temperature
  • Tm melting temperature

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)

Claims (15)

  1. Procédé de fabrication d'un produit textile comprenant une première feuille ayant des fils de polyamide fixés à cette feuille pour former un empilement sur celle-ci, le procédé comprenant :
    - la fourniture de la feuille,
    - la couture des fils de polyamide à travers la feuille pour former l'empilement sur une première surface de la feuille, l'empilement s'étendant sur une longueur prédéterminée depuis cette première surface, et pour former des boucles des fils au niveau d'une seconde surface de la feuille,
    - la fixation des fils à la feuille par création d'une couche de matériau fusionné sur la seconde surface de la feuille au moyen de chaleur,
    caractérisé en ce que lors de la création de la couche de matériau fusionné, au moins la moitié distale de la longueur de l'empilement est maintenue à une température d'au moins 70 °C au-dessous de la température de fusion du polyamide.
  2. Procédé selon la revendication 1, caractérisé en ce que la moitié distale de la longueur de l'empilement est maintenue à une température d'au moins 100 °C au-dessous de la température de fusion du polyamide.
  3. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce qu'au moins la moitié distale de la longueur de l'empilement est maintenue à la température au-dessous de la température de fusion du polyamide en utilisant des moyens de refroidissement.
  4. Procédé selon l'une quelconque des revendications précédentes, caractérisé en ce que pour fixer les fils à la feuille, la seconde surface de la feuille est mise en contact avec une surface d'un corps chaud pour fondre au moins partiellement les boucles des fils pour créer la masse de matériau fondu.
  5. Procédé selon la revendication 4, caractérisé en ce que la surface du corps chaud a une vitesse relative par rapport à la seconde surface de la première feuille.
  6. Procédé selon la revendication 5, caractérisé en ce que la surface du corps chaud est stationnaire, tandis que la première feuille est transportée le long du corps chaud.
  7. Procédé selon l'une quelconque des revendications précédentes, le produit textile étant un stratifié de la première feuille et d'une deuxième feuille, caractérisé en ce qu'après que la seconde surface de la première feuille a été traitée selon l'une quelconque des revendications précédentes, un adhésif est appliqué sur cette seconde surface sur laquelle l'adhésif la deuxième feuille est collé.
  8. Procédé selon la revendication 7, caractérisé en ce que l'adhésif est un adhésif thermofusible.
  9. Procédé selon la revendication 8, caractérisé en ce que l'adhésif thermofusible comprend au moins 50 % en poids d'un polymère choisi dans le groupe constitué par le polyuréthane, le polycarbonate, le polyester, le polyamide, les poly(ester-amides), la polyoléfine, leurs mélanges et/ou leurs copolymères.
  10. Procédé selon l'une quelconque des revendications 7 à 9, caractérisé en ce qu'une couche intermédiaire est fournie entre la première feuille et la deuxième feuille, la couche intermédiaire étant élastique pour permettre une déformation locale de cette couche le long de la seconde surface de la première feuille ou le long de la surface de la deuxième feuille adjacente à la couche intermédiaire.
  11. Procédé selon la revendication 10, caractérisé en ce que la couche intermédiaire est une couche fibreuse.
  12. Procédé selon la revendication 11, caractérisé en ce que la couche intermédiaire est une couche non tissée.
  13. Procédé selon la revendication 12, caractérisé en ce que la couche intermédiaire est une couche tricotée.
  14. Utilisation d'un produit textile pouvant être obtenu selon l'une quelconque des revendications 1 à 13, pour couvrir une surface d'un bâtiment ou toute autre construction artificielle ou naturelle.
  15. Produit textile comprenant une feuille ayant une surface supérieure et une surface inférieure, le produit textile ayant des fils de polyamide cousus à travers cette feuille pour former un empilement sur la surface de la feuille, l'empilement s'étendant sur une longueur prédéterminée depuis cette première surface, les fils étant fixés à la surface inférieure de la feuille par formation d'une couche de matériau polyamide fusionné sur cette surface inférieure, caractérisé en ce que les fils de l'empilement ont un contenu amorphe réduit par rapport aux fils du même polyamide recuits à une température entre 40 °C et 45 °C au-dessous de la température de fusion du polyamide pendant 1 heure.
EP16793825.7A 2015-11-05 2016-11-04 Procédé pour fabriquer un produit textile, son utilisation, le produit lui-même et dispositif permettant d'appliquer ce procédé Active EP3371366B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP15193216 2015-11-05
PCT/EP2016/076683 WO2017077043A1 (fr) 2015-11-05 2016-11-04 Procédé de fabrication d'un produit textile, utilisation de celui-ci, le produit lui-même, et dispositif d'application du procédé

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EP3371366A1 EP3371366A1 (fr) 2018-09-12
EP3371366B1 true EP3371366B1 (fr) 2019-12-25

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US (1) US20180320310A1 (fr)
EP (1) EP3371366B1 (fr)
JP (1) JP2019501680A (fr)
KR (1) KR20180079416A (fr)
CN (1) CN108350649A (fr)
AU (1) AU2016348719A1 (fr)
BR (1) BR112018009021A8 (fr)
DK (1) DK3371366T3 (fr)
MX (1) MX2018005521A (fr)
WO (1) WO2017077043A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BE1025677B1 (nl) * 2017-10-30 2019-05-28 Ivc Bvba Werkwijze voor het vervaardigen van een tapijttegel
EP3543397B1 (fr) 2018-03-20 2021-07-07 Aladdin Manufacturing Corporation Procédé pour la fabrication d'un tapis ou d'une moquette

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US5556684A (en) 1994-02-04 1996-09-17 Forero; Miguel Manufacturing process for synthetic fiber carpets fixed by fusion at regular intervals with crest or tufts, without using glues or using small amounts of glues, where threads do not loosen and thus obtaining the carpets
US20020132084A1 (en) 1992-02-10 2002-09-19 Fink Wilbert E. Carpet and carpet making methods
EP2172589A1 (fr) 2008-09-25 2010-04-07 N.T.T. di Adriano Moioli & C. S.A.S. Tapis synthétique et son procédé de fabrication
WO2012076348A2 (fr) 2010-12-06 2012-06-14 Niaga Bv Procédé pour fabriquer un produit textile et produit textile résultant dudit procédé
US20120219751A1 (en) 2009-11-09 2012-08-30 Kaneka Corporation Pile fabric and process for producing same
WO2014198731A1 (fr) 2013-06-10 2014-12-18 Dsm Ip Assets B.V. Procédé permettant de produire des produits textiles, produits obtenus à partir de ce dernier, et procédé permettant de mettre en valeur les produits
WO2015104395A1 (fr) 2014-01-10 2015-07-16 Dsm Ip Assets B.V. Produit textile et ses utilisations, procédé de production d'un tel produit et procédé de recyclage du produit

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US6475592B1 (en) * 1997-04-29 2002-11-05 Darwin Enterprises, Inc. Carpet backing that provides dimensional stability
AU4224900A (en) * 1999-04-12 2000-11-14 Tennessee Valley Patent Development Company Carpet and carpet making methods
US20040079468A1 (en) * 2002-09-13 2004-04-29 Reisdorf Raymond Joseph Process for producing carpet
US7335234B2 (en) * 2002-10-16 2008-02-26 Columbia Insurance Company Method of treating fibers, carpet yarns and carpets to enhance repellency
DE102013012843A1 (de) * 2013-08-02 2015-02-05 Anker-Teppichboden Gebr. Schoeller Gmbh + Co. Kg Textiler Fußbodenbelag, insbesondere zur Verwendung im Innenraum von Flugzeugen

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US20020132084A1 (en) 1992-02-10 2002-09-19 Fink Wilbert E. Carpet and carpet making methods
US5556684A (en) 1994-02-04 1996-09-17 Forero; Miguel Manufacturing process for synthetic fiber carpets fixed by fusion at regular intervals with crest or tufts, without using glues or using small amounts of glues, where threads do not loosen and thus obtaining the carpets
EP2172589A1 (fr) 2008-09-25 2010-04-07 N.T.T. di Adriano Moioli & C. S.A.S. Tapis synthétique et son procédé de fabrication
US20120219751A1 (en) 2009-11-09 2012-08-30 Kaneka Corporation Pile fabric and process for producing same
WO2012076348A2 (fr) 2010-12-06 2012-06-14 Niaga Bv Procédé pour fabriquer un produit textile et produit textile résultant dudit procédé
WO2014198731A1 (fr) 2013-06-10 2014-12-18 Dsm Ip Assets B.V. Procédé permettant de produire des produits textiles, produits obtenus à partir de ce dernier, et procédé permettant de mettre en valeur les produits
WO2015104395A1 (fr) 2014-01-10 2015-07-16 Dsm Ip Assets B.V. Produit textile et ses utilisations, procédé de production d'un tel produit et procédé de recyclage du produit

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KR20180079416A (ko) 2018-07-10
BR112018009021A8 (pt) 2019-02-26
WO2017077043A1 (fr) 2017-05-11
EP3371366A1 (fr) 2018-09-12
BR112018009021A2 (pt) 2018-10-30
US20180320310A1 (en) 2018-11-08
MX2018005521A (es) 2018-08-01
JP2019501680A (ja) 2019-01-24
CN108350649A (zh) 2018-07-31
DK3371366T3 (da) 2020-03-16
AU2016348719A1 (en) 2018-05-10

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