METHOD FOR PRODUCING A NEEDLE PUNCH VELOUR CARPET

Abstract

The present invention relates to a method for producing a needle punch carpet having a velour-type and more wear-resistant surface which has advantageous characteristics over conventional flat needle nonwovens and dilour carpets.

Claims

1. A process for producing a needle punch carpet having a velourized and more wear-resistant surface, comprising: providing a bulky unstable sheet, a needling unit containing needles, and a carding machine with a carding belt; needling the bulky unstable sheet received from the carding belt of the carding machine: the bulky unstable sheet is needled in the needling unit forming the carpet with a stitch-out side, characterized in that the stitch-out side of the carpet has a penetration depth of from 2 to 13 mm, wherein a.) the needle design of the needles in the needling unit is such that needle types can be used in which the notches are arranged in different heights and numbers; b.) the needle density of the needles in the needling unit is at least 9000/m.sup.2; c.) the fiber working weight of the carpet is from 240 to 600 g/m.sup.2; d.) only one single needling unit is employed; e.) the stitch density of the carpet is from 200 to 750 stitches/cm.sup.2; and the carpet is velourized, wherein the carpet, before being subjected to a drying/cross-linking process, is coated with a wax/polymer dispersion on the stitch-out side.

2. The process for producing a needle punch carpet having a velourized and more wear-resistant surface according to claim 1, further comprising a wax/silicone oil emulsion coating agent is applied to the carpet.

3. The process for producing a needle punch carpet having a velourized and more wear-resistant surface according to claim 1, further comprising a modified fatty acid ester coating agent is applied to the carpet.

4. The process for producing a needle punch carpet having a velourized and more wear-resistant surface according to claim 1, further comprising a coating agent is applied by a padding or spraying method.

5. The process for producing a needle punch carpet having a velourized and more wear-resistant surface according to claim 1, further comprising a coating agent is applied to a tufting carpet.

6. The process for producing a needle punch carpet having a velourized and more wear-resistant surface according to claim 1, further comprising a coating agent is applied to a standard dilour carpet.

Description

EXAMPLES

[0050] A customary 370 g/m.sup.2 PET fiber carpet with 80 g/m.sup.2 with a customary acrylate binder with a velourized surface and coating agent was prepared by the above-described process.

[0051] A mixture of wax and polymer dispersion was applied as the coating agent on the stitch-out or pile side by means of a padding machine before the carpet entered the drying furnace; the wet application weight was 110 g/m.sup.2.

[0052] For this coating, a mixture comprising the following ingredients was prepared:

TABLE-US-00001 79.44% by weight water 19.86% by weight wax/polymer dispersion* 0.70% by weight soap *Tubicoat TAB from the CHT R. Beitlich GmbH, Tbingen, DE

[0053] The plant speed was 6 m/min, and the temperature in the drying furnace was 150 C.

[0054] In the following Table 1, the carpet obtained having a velourized and coated surface is compared to a flat-needle punched web of the prior art.

[0055] The arrows represent a comparison of the materials according to the invention with those of the prior art. Meanings (respectively based on similar pile weights):

TABLE-US-00002 .Math. equally good + better better equal worse worse

[0056] As can be seen from this Table, the needle-punched velour carpet materials prepared by the process according to the invention have altogether more favorable properties than is the case with the materials of the prior art.

TABLE-US-00003 TABLE 1 Carpets with a velourized coated Flat-needle surface punched web Fine fiber .Math. Fiber density .Math. Standing condition of + the fibers Abrasion + Cleaning + Degree of drawing + Streak formation + Price .Math.

[0057] The surface rating according to the Taber test is one grade better for the needle-punch carpet with the velourized coated surface as compared to the flat-needle punched web, and the weight loss is 0.14 g.

TABLE-US-00004 Testing conditions following DIN 53 754 according to PrA-014 Cycles N 1000 number of revolutions n 60 min.sup.1 Load F 2 1000 g Abrasion wheel type H18 Set points: Abrasion 0.5

[0058] Since the emission behavior of components gets into the focus increasingly today, it was also examined:

[0059] The test results for fogging (PV 3015), odor C2 and C3 (PV 3900) and formaldehyde emission (PV 3929) were clearly below the limits for the carpets according to the invention.

[0060] Further, the carpet was tested in a so-called heel test. In this test, the abrasion behavior is tested for specified reciprocating movements of a heel (steel heel).

[0061] The results in the dry and wet test met the requirements of the targets determined in the testing protocols of the automobile manufacturers.

[0062] Also, when the process with the wax/polymer dispersion coating according to the invention was applied to a 560 g/m.sup.2 PET fiber carpet with 80 g/m.sup.2 acrylate bonding, this carpet showed significant differences in the wear performance as compared to a standard dilour carpet: weight loss 0.18 g, and a better score in the surface evaluation.

[0063] In the Examples, a significant improvement of the impression performance according to DIN ISO 3415 was also found.