U.S. patent application number 12/114159 was filed with the patent office on 2009-02-26 for method for producing a ductile tufted product, a ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automobile interior area.
This patent application is currently assigned to CARL FREUDENBERG KG. Invention is credited to Ararad EMIRZE, Ulrike Maass, Peter SANDER.
Application Number | 20090053460 12/114159 |
Document ID | / |
Family ID | 39730830 |
Filed Date | 2009-02-26 |
United States Patent
Application |
20090053460 |
Kind Code |
A1 |
EMIRZE; Ararad ; et
al. |
February 26, 2009 |
Method for producing a ductile tufted product, a ductile tufted
product, particularly a ductile tufted top carpet layer,
particularly for the automobile interior area
Abstract
The invention is intended to provide a simple and economical
method for producing a ductile tufted product, particularly a
tufted upper carpet layer that is particularly ductile, in
particular for the automotive interior area. For this purpose, a
melt-blown non-woven fabric is placed on a ductile polyester tufted
backing and the melt-blown non-woven fabric and the polyester
tufted backing are tufted together.
Inventors: |
EMIRZE; Ararad;
(Kaiserslautern, DE) ; SANDER; Peter;
(Bruchmuehlbach, DE) ; Maass; Ulrike;
(Kaiserslautern, DE) |
Correspondence
Address: |
GROSSMAN, TUCKER, PERREAULT & PFLEGER, PLLC
55 SOUTH COMMERICAL STREET
MANCHESTER
NH
03101
US
|
Assignee: |
CARL FREUDENBERG KG
Weinheim
DE
|
Family ID: |
39730830 |
Appl. No.: |
12/114159 |
Filed: |
May 2, 2008 |
Current U.S.
Class: |
428/91 ;
28/159 |
Current CPC
Class: |
B32B 2262/0276 20130101;
D06N 2211/263 20130101; B32B 2262/0253 20130101; D06N 2203/061
20130101; Y10T 428/2395 20150401; B32B 5/26 20130101; D06N 7/0068
20130101; D05C 17/023 20130101; D06N 2203/065 20130101; B32B
2307/5825 20130101; B32B 2605/08 20130101; D06N 2201/02 20130101;
B32B 5/022 20130101; B32B 2471/02 20130101; D04H 11/08 20130101;
D06N 2209/025 20130101; B60R 13/083 20130101; D06N 2203/042
20130101; D04H 13/00 20130101; B32B 2307/54 20130101; B32B
2262/0261 20130101 |
Class at
Publication: |
428/91 ;
28/159 |
International
Class: |
D05C 17/02 20060101
D05C017/02; D06C 11/00 20060101 D06C011/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 2, 2007 |
DE |
10 2007 020 818.0 |
Claims
1. A method for producing a ductile tufted product, particularly a
ductile tufted top carpet layer, particularly for the automotive
interior area, wherein a melt-blown non-woven fabric is placed on a
ductile polyester tufted backing, and wherein the melt-blown
non-woven fabric and the polyester tufted backing are tufted
together.
2. The method according to claim 1, wherein the tufted product is
introduced in the further carpet manufacturing process solely by a
thermal treatment from the tufting piercing side, particularly
without latex application.
3. The method according to claim 1, wherein a polyester spun-bond
non-woven is used as the polyester tufted backing, preferably
having a basis weight of 70 g/m.sup.2 up to 140 g/m.sup.2, more
preferred from 100 g/m.sup.2 to 120 g/m.sup.2.
4. A method according to claim 1, wherein the melt-blown non-woven
fabric having a basis weight of preferably 70 g/m.sup.2 up to 500
g/m.sup.2 is used, more preferred from 80 g/m.sup.2 to 200
g/m.sup.2, even more preferred from 80 g/m.sup.2 to 130
g/m.sup.2.
5. A method according to claim 1, wherein a thermoplastic raw
material that can be spun or processed by injection molding is used
as the raw material for the melt-blown non-woven fabric,
particularly one selected from polyolefins, copolyolefins,
polyesters, copolyesters, polyamides, and/or copolyamides having an
MFI value (melt flow index) (according to DIN 1238 or ISO 1133) of
100 to 300 g/10 min.
6. A method according to claim 1, wherein the melt-blown non-woven
fabric having a thickness of 0.5 mm to 1.5 mm is used, with 0.5 mm
to 1.0 mm being particularly preferred.
7. A method according to claim 1, wherein the melt-blown non-woven
fabric having a fiber titer of 0.06 dtex to 0.2 dtex, preferably of
0.06 dtex to 0.1 dtex, is used.
8. A method according to claim 1, wherein the melt-blown non-woven
fabric and the polyester tufted backing are tufted together with a
tufting gauge of 1/8'' to 1/16'' without prior needling or
calendaring.
9. A method according to claim 1, wherein the melt-blown non-woven
fabric is advantageously strengthened by means of an ultrasonic
calendar with a bonding surface of less than 5%, preferably of less
than 2%, and tufted together with the polyester tufted backing with
a gauge of 1/8'' to 1/16''.
10. A method according to claim 1, wherein the melt-blown non-woven
fabric and the polyester tufted backing are strengthened together
by means of an ultrasonic calendar with a bonding surface of less
than 5%, preferably of less than 2%, and tufted together with a
gauge of 1/8'' to 1/16''.
11. A method according to claim 2, wherein an acoustic non-woven
material and/or at least one other insulating layer is applied on
the tufting piercing side of the tufted product as a further carpet
manufacturing process.
12. A ductile tufted product, particularly a ductile tufted top
carpet layer, particularly for the automotive interior area,
produced using a method according to claim 1, which at room
temperature has: a maximum tensile force in the longitudinal
direction (according to EN 29073-3) of 250 N/5 cm to 400 N/5 cm,
preferably of 275 N/5 cm to 375 N/5 cm); a maximum tensile force in
the transverse direction (according to EN 29073-3) of 180 N/5 cm to
300 N/5 cm, preferably of 203 N/5 cm to 250 N/5 cm; a maximum
tensile elongation in the longitudinal direction (according to EN
29073-3) of 45% to 60%; and a maximum tensile elongation in the
transverse direction (according to EN 29073-3) of 42% to 55%.
13. A ductile tufted product, particularly a ductile tufted top
carpet layer, particularly for the automotive interior area,
produced using a method according to claim 1, which at 140.degree.
C. has: a maximum tensile force in the longitudinal direction
(according to EN 29073-3) of 185 N/5 cm to 200 N/5 cm; a maximum
tensile force in the transverse direction (according to EN 29073-3)
of 85 N/5 cm to 120 N/5 cm; a maximum tensile elongation in the
longitudinal direction (according to EN 29073-3) of 65% to 70%; and
a maximum tensile elongation in the transverse direction (according
to EN 29073-3) of 65% to 70%.
14. A ductile tufted product, particularly a ductile tufted top
carpet layer, particularly for the automotive interior area,
produced using a method according to claim 1, which at room
temperature has a tear propagation force in the longitudinal
direction (according to DIN 53859-3) of 170 N to 240 W.
Description
TECHNICAL FIELD
[0001] The invention relates to a method for producing a ductile
tufted product, particularly a ductile tufted top carpet layer
produced with it, particularly for the automotive interior
area.
[0002] For the production of a tufted carpet, a method referred to
as tufting is employed, which is to say a technique for producing
three-dimensional surfaces, which operates based on the principle
of a sewing machine.
[0003] During the process, tufting needles introduce a tuft yarn
into a base material, referred to as the tufted backing. The
tufting needles mounted to a needle bar are disposed in the width
of the base material, for example a non-woven fabric, and
simultaneously pierce the base material. Before the tufting needles
return again upward into their starting position, the introduced
tuft yarn is held on the bottom of the base material by hooks,
referred to as loopers. In this way loops or pile, referred to as
naps, are produced, which in the finished carped form the visible
top (upper layer). Depending on the application, these loops can
already be cut during the tufting process, using special blades.
This produces the cut-pile carpets, which are used particularly in
the automotive interior area, preferably at a percentage of over
95%.
DESCRIPTION OF THE INVENTION
[0004] It is the object of the invention to provide a method for
producing a ductile tufted product, particularly an easily ductile
tufted top carpet layer, wherein the method is as simple and
economical as possible. The top carpet layer produced according to
the method is supposed to be used particularly in the automotive
interior area, or in the properties area. The term "properties
area" shall encompass that the top carpet layer is designed
particularly for high-traffic or extremely strained surfaces,
particularly for offices, hotels, airports, hospitals, and the
like.
[0005] This object is achieved by the characteristics of claim
1.
[0006] In the method, a melt-blown non-woven fabric is placed on a
ductile polyester tufted backing, and the melt-blown non-woven
fabric and the polyester tufted backing are tufted together. By
applying the melt-blown non-woven fabric on the tufted backing
synchronously with the tufting process, the method is particularly
economical.
[0007] Due to the special combination of the material selection and
the design of the method, the resulting tufted product,
particularly as a top automobile carpet layer for applications in
the interior automotive area, is characterized by particularly good
ductility and accordingly high strength, elongation and tear
propagation force data.
[0008] The dependent claims are advantageous refinements of the
subject matter of the invention.
[0009] In a preferred embodiment of the method, the tufted product
is introduced in the further carpet manufacturing process solely by
a thermal treatment from the tufting piercing side, particularly
without latex application.
[0010] In the tufting production, the latex represents a
pretreatment of the raw product for a variety of methods for
coating the backing or tufted backing. The latex is intended to
lock the naps into the base material and/or the tufted backing. In
this way, the desired integration of the naps is achieved,
preventing the pulling of threads or fraying of the pile material.
The latex material typically comprises synthetic latex with filler
material.
[0011] By eliminating this latex application in the inventive
production process, one step is eliminated. In addition, it is more
compatible with the environment because during the production,
recycling, and disposal processes the waste water is not polluted
with latex residue, and because during the use of a tufted product
treated in this way no emissions are formed by the latex
application.
[0012] Consequently, the inventive method also satisfies the
environmental stipulations and industrial standards, which have
become more stringent, particularly in recent times.
[0013] Advantageously, for the method a polyester spun-bond
non-woven is used as the polyester tufted backing, preferably
having a basis weight of 70 g/m.sup.2 up to 140 g/m.sup.2, more
preferred from 100 g/m.sup.2 to 120 g/m.sup.2.
[0014] Furthermore, in the method the melt-blown non-woven fabric
having a basis weight of preferably 70 g/m.sup.2 up to 500
g/m.sup.2 is used, more preferred from 80 g/m.sup.2 to 200
g/m.sup.2, even more preferred from 80 g/m.sup.2 to 130
g/m.sup.2.
[0015] Due to the particularly low basis weights, the material
consumption can be kept particularly low and the processing speed
can be increased, allowing additional cost savings.
[0016] According to a preferred embodiment of the method, a
thermoplastic raw material that can be spun or processed by
injection molding is used as the raw material for the melt-blown
non-woven fabric, particularly one selected from polyolefins,
copolyolefins, polyesters, copolyesters, polyamides, and/or
copolyamides having an MFI value (melt flow index) (according to
DIN 1238 or ISO 1133) of 100 to 300 g/10 min.
[0017] Due to the low viscosity of the melt-blown raw material
because of a high melt flow index, and the low viscosity of the
melt-blown non-woven fabric that is produced, the penetration of
the melted melt-blown non-woven wear layer in the tufted backing is
favored. As a result, a three-dimensional composite layer is
produced such that undesirable delamination between the wear layer
and the tufted backing is prevented.
[0018] Preferably, a melt-blown non-woven fabric having a thickness
of 0.5 mm to 1.5 mm is used, with 0.5 mm to 1.0 mm being
particularly preferred.
[0019] The fiber titer of the melt-blown non-woven fabric is
advantageously 0.06 dtex to 0.2 dtex, with 0.06 dtex to 0.1 dtex
being preferred.
[0020] The bulky, soft melt-blown non-woven wear layer having a
high specific fiber surface, lower fiber titer, and high fiber
mobility facilitates the tufting without needle deviation and
increases the number of contact points between the melt-blown
non-woven wear layer and the fibers of the tufted backing, thus
evenly strengthening the bond between the wear layer and the tufted
backing across the cross-section.
[0021] The joint tufting of the melt-blown non-woven fabric and
polyester tufted backing preferably occurs without prior needling
or calendaring with a gauge of 1/8'' to 1/16''.
[0022] Alternatively, the melt-blown non-woven fabric is
advantageously strengthened by an ultrasonic calendar having a
bonding surface of less than 5%, preferably of less than 2%, and
tufted together with the polyester tufted backing with a gauge of
1/8'' to 1/16''.
[0023] In a particularly preferred embodiment of the method, the
melt-blown non-woven fabric and the polyester tufted backing are
strengthened together by an ultrasonic calendar having a bonding
surface of less than 5%, preferably of less than 2%, and tufted
together with the polyester tufted backing with a gauge of 1/8'' to
1/16''.
[0024] Due to the joint strengthened, particularly good handling
and better process stability than in the case of separate layers
are guaranteed. Furthermore, the combination with the very small
bonding surface at the same time allows sufficiently high fiber
mobility, so that fiber damage during tufting can at least be
reduced, thus increasing the quality of the tufted product,
particularly with respect to ductility.
[0025] In a further carpet production process, preferably an
acoustic non-woven material and/or at least one other insulating
layer, for example a heavy layer having basis weights of, for
example, 2 to 7 kg/m.sup.2 made of ethylene-vinyl
acetate/ethylene-propylene-diene rubber, or coextruded film
comprising polyethylene/polyamide (polyethylene), is applied to the
tufting piercing side of the tufted product.
[0026] The tufted products produced according to the invention, at
a tear propagation force in the longitudinal direction at room
temperature (according to DIN 53859-3) of preferably 170 N to 240
N, have a particularly high tear propagation force value, and
therefore particularly good ductility, so that these tufted
products are particularly well suited for use as top carpet layers
in the automotive interior area as automobile top carpet
layers.
[0027] The ductile tufted products, particularly the ductile tufted
automobile top carpet layers, at room temperature furthermore
preferably have
[0028] a maximum tensile force in the longitudinal direction
(according to EN 29073-3) of 250 N/5 cm to 400 N/5 cm, more
preferred of 275 N/5 cm to 375 N/5 cm,
[0029] a maximum tensile force in the transverse direction
(according to EN 29073-3) of 180 N/5 cm to 300 N/5 cm, more
preferred of 203 N/5 cm to 250 N/5 cm,
[0030] a maximum tensile elongation in the longitudinal direction
(according to EN 29073-3) of 45% to 60%, and
[0031] a maximum tensile elongation in the transverse direction
(according to EN 29073-3) of 42% to 55%.
[0032] At 140.degree. C., the ductile tufted products, particularly
the ductile tufted automobile top carpet layers, advantageously
have
[0033] a maximum tensile force in the longitudinal direction
(according to EN 29073-3) of 185 N/5 cm to 200 N/5 cm,
[0034] a maximum tensile force in the transverse direction
(according to EN 29073-3) of 85 N/5 cm to 120 N/5 cm,
[0035] a maximum tensile elongation in the longitudinal direction
(according to EN 29073-3) of 65% to 70%, and
[0036] a maximum tensile elongation in the transverse direction
(according to EN 29073-3) of 65% to 70%.
EXECUTION OF THE INVENTION
[0037] The subject matter of the invention will be explained in
more detail based on an example.
Production of a Melt-Blown Non-Woven Fabric:
[0038] As the raw material for the melt-blown non-woven fabric,
polyethylene having a melt flow index (MFI) of 155 g/10 min
according to DIN 1133 is used and spun through a melt-blowing
spinneret. The polyethylene fibers obtained in this way have a
fiber titer of 0.07 dtex.
[0039] Thereafter, the fibers are deposited in a suction drum,
which has a distance of approximately 600 mm to the spinning
nozzle, in order to produce a bulky and soft fibrous web, the fiber
mobility of which is maintained in the tufting process.
[0040] The fibrous web weighing 80 g produced in this way can then
optionally be strengthened by means of an ultrasonic calendar using
light sonotrode pressing pressures of about 0.006 bar with a
bonding surface of less than 5%, preferably of less than 2%, thus
obtaining a still substantially bulky non-woven fabric.
Alternatively, also light thermal strengthening using engraved or
roughened calendaring rollers is conceivable.
Production of a Tufted Product:
[0041] The melt-blown non-woven fabric weighing 80 g produced
according to the above-described method in the present case is
placed on the tufted backing in non-strengthened form and
strengthened only together with the tufted backing by means of an
ultrasonic calendar using light sonotrode pressing pressures of
about 0.006 bar with a bonding surface of about 1.6%. A polyester
spun-bond non-woven material, Lutradur.RTM. LDT 5312 (Freudenberg),
having a basis weight of 120 g/m.sup.2 is used as the tufted
backing.
[0042] This composite made of melt-blown non-woven fabric and
polyester tufted backing, the composite being slightly
prestrengthened by means of ultrasound, is fed to the tufting loom
infeed, wherein the melt-blown non-woven fabric side represents the
needle or tufting piercing side.
[0043] The laboratory tufting loom has a needle working width of
about 50 cm and a needle gauge of 1/10 inch (10 needles per 2.54
cm) pile quality.
[0044] The stitch density is about 56/10 cm. A BCF yarn, which is a
bulked continuous filament, is used as the tuft yarn and has a
polyamide 6 quality having a total strength of 1300 dtex and 128
individual filaments. Other conventional tuft yarns can likewise be
used.
[0045] The tuft yarn weight is about 400 g/m.sup.2. The complete
laboratory tufting arrangement produces, in the narrow width, a
carpet design that is typically used in the automotive field (with
the exception of the additionally inserted layer).
[0046] Before the tufting needles return again, the inserted tuft
yarn is held by hooks such that loops or naps are produced. In this
way, a loop pile carpet is produced. If the loops, as in this
example, are cut with a blade, a cut-pile carpet is produced.
[0047] After the melt-blown non-woven fabric has been tufted
together with the polyester tufted backing, thermal treatment is
provided from the tufting piercing side until the polyethylene of
the melt-blown non-woven fabric has melted. The top carpet layer
produced in this way is analyzed for the following properties.
Properties of the Top Carpet Layer Produced in this way at Room
Temperature:
[0048] maximum tensile force in the longitudinal direction
(according to EN 29073-3): 368 N/5 cm
[0049] maximum tensile force in the transverse direction (according
to EN 29073-3): 203 N/5 cm
[0050] maximum tensile elongation in the longitudinal direction
(according to EN 29073-3): 58%
[0051] maximum tensile elongation in the transverse direction
(according to EN 29073-3): 44%
[0052] tear propagation force in the longitudinal direction
(according to DIN 53859-3): 218 N
[0053] The higher the values of the tear propagation force, the
higher the ductility.
[0054] By comparison, the tear propagation force of the tufted
backing alone (Lutradur.RTM. LDT 53 12, 120 g/m.sup.2), which is to
say without the melt-blown non-woven fabric, is 198 N, and the tear
propagation force of the tufted backing (Lutradur.RTM. LDT 5312,
120 g/m.sup.2) having a conventional latex or latex binder
treatment (approx. 100 g/m.sup.2) is 150 N.
[0055] With a conventional latex treatment, ductility is
consequently negatively influenced, while the tufted product
manufactured according to the invention has a particularly high
tear propagation force value and therefore particularly good
ductility, so that this tufted product is particularly well-suited
for use as a top carpet layer in the automotive interior area.
Properties of the Top Carpet Layer Produced in this way at
140.degree. C.:
[0056] maximum tensile force in the longitudinal direction
(according to EN 29073-3): 196 N/5 cm
[0057] maximum tensile force in the transverse direction (according
to EN 29073-3): 111 N/5 cm
[0058] maximum tensile elongation in the longitudinal direction
(according to EN 29073-3): 75%
[0059] maximum tensile elongation in the transverse direction
(according to EN 29073-3): 69%
[0060] In addition to determining the force and elongation
behaviors of the tufted product by means of measurements on a
tensile elongation test machine, the ductility properties of the
tufted product were determined using an internal measuring method.
To this end, circular samples of the tufted product having a
diameter of 24 cm are punched out, clamped in a clamping ring, and
fixed by means of brass screws and threaded bolts. At the back,
which is to say from the tufting piercing side, the fixed sample is
heated by infrared heating to a defined temperature, in the present
example to 140.degree. C., wherein a constant distance of 16 cm to
the infrared field is maintained.
[0061] After reaching the temperature, the clamping ring with the
carpet sample fixed thereon is automatically placed on a
displaceable hollow cylinder, which travels upward at a speed of 50
mm/s against a metal ball. The metal ball is cooled with water to
18.degree. C. and has a diameter of 10 cm. In this process, the
carpet sample is deformed from the tufting piercing side. The
deformation depths that are measured are used to compute the
deformation in percent.
TABLE-US-00001 At a maximum deformation depth of 12.2 cm, maximum
deformation is: 106% and the maximum deformation force is: 1543 N.
At a deformation depth of 9 cm, maximum deformation is: 50% and the
maximum deformation force is: 723 N.
[0062] The example of the top carpet layer produced according to
the invention has the further advantage that it can be laminated
with a heavy layer, without the additional application of
polyethylene powder, which is common in the conventional carpet
industry. Dispensing with this polyethylene powder application can
be attributed to the fact that a bonding agent layer made of
polyethylene is already provided on the carpet piercing side of the
top carpet layer in the example.
* * * * *