CN1067459A - 簇绒地毯 - Google Patents

簇绒地毯 Download PDF

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CN1067459A
CN1067459A CN92102969A CN92102969A CN1067459A CN 1067459 A CN1067459 A CN 1067459A CN 92102969 A CN92102969 A CN 92102969A CN 92102969 A CN92102969 A CN 92102969A CN 1067459 A CN1067459 A CN 1067459A
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tufting
carpet
tufted carpet
substrate
polyamide
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CN1030783C (zh
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爱伦·卡尔-海茨
格里威·里金纳
黑德胡斯·罗伯特
霍普内·弗兰克
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Norddeutsche Faserwerke GmbH
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    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04G—MAKING NETS BY KNOTTING OF FILAMENTARY MATERIAL; MAKING KNOTTED CARPETS OR TAPESTRIES; KNOTTING NOT OTHERWISE PROVIDED FOR
    • D04G3/00—Making knotted carpets or tapestries
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    • 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
    • D06N7/0076—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 a thermoplastic material applied by, e.g. extrusion coating, powder coating or laminating a thermoplastic film
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    • 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
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    • D06N2205/10—Particulate form, e.g. powder, granule
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    • Y10T428/00—Stock material or miscellaneous articles
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    • Y10T428/23979—Particular backing structure or composition
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    • Y10T428/23986—With coating, impregnation, or bond
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Abstract

描述了一种簇绒地毯，其中包括簇绒基底，绒毛 材料以及地毯衬垫，而且基本上仅由聚酰胺6组成。 通过在簇绒地毯的所有部件中使用化学上均匀的材 料，使后者能作为一个整体被回收，用来再生一种单 体始料，而无需分离成各个部分，这是至今为止一直 妨碍簇绒地毯的回收使用并产生主要的废物处理的 问题。

Description

本发明涉及一种簇绒地毯及其作为地板和墙壁覆盖物的应用。
地毯是由人造纤维，羊毛、麻纱、丝绒和绵纱经过簇绒化，纺织、编织和针织而成的。簇绒法是工厂生产的地毯的一种主要的生产技术。人造纤维，且特别是聚酰胺（主要是聚酰胺6.6）长丝纱线和人造短纤维线的使用占主导地位。工厂生产的既可用作地板覆盖物，又可用作墙壁覆盖物的簇绒地毯，不仅舒适，而且在隔热方面提供了许多优点，并因此有助于房间的热平衡。
簇绒地毯结构目前通常主要包括三个组成部分，即簇绒基底部，绒毛材料及地毯衬垫。各种化学名称各不相同且不能彼此再生的材料，例如：聚丙烯，聚酰胺、聚氨酯、聚氯乙烯及黄麻纤维被用在这三部分上。由聚丙烯用作基底纺织物;聚酰胺用作绒毛材料和聚氨酯用作衬垫覆盖层的组合方式占优势。
簇绒基底是一种主要包括聚丙烯的纺织织物或由聚酯或聚丙烯制成的无纺织物。麻纺织物很少采用。
绒毛材料主要由聚酰胺制成的、接着纺纱并然后簇绒的人造短纤维组成或由已经单一或多步处理过程中被挤压成被拉伸和卷曲变形的连续长丝（BCF线＝臌体纱线）的聚酰胺组成。
地毯衬垫起着几种作用。在簇绒地毯中加入一种橡胶或SB乳胶预涂层以固定簇环。在日常使用的簇绒地毯的情况下，通常粘结一个主要包含聚脂纺织织物的第二衬垫。为在住宅区使用，部分地填充基于乳胶或聚氨酯的泡沫塑料通常会增加舒适感。
以所述方式构成的簇绒地毯一旦在其使用过后，存在一个重要的报废或废弃处理问题，因为它们是以大量（体积大和重量大）形式存在的，且实际上根本不能粉碎或只能很缓慢地粉碎。分离成为各自独立的部分并将这些部分再次使用也是极为困难的或事实上根本不可能，因此，到目前为止由于纯粹经济上的原因一直没有考虑这个问题。考虑到日益增长的废物处理问题，则迫切需要一种容易处理或使用后能回收利用的簇绒地毯。
因此，本发明的一个目的就是提供一种易处理或最好是使用后可回收利用（可重复利用）的簇绒地毯。
本发明涉及一种簇绒地毯，其中包括簇绒基底，绒毛材料及地毯衬垫，且其特征在于基本上仅包括聚酰胺6。
本发明的另一个主题是本发明的地毯作为地板和墙壁覆盖物的应用。
本发明的优选实施例及优越性将从下列对本发明的具体描述及下面的权利要求书中变得显而易见。
人们惊奇地发现，如果对于地毯各个组成部分所用的材料按其必要特性仔细选择的话，用基本上一种单一的化学均匀物质（除去通常的辅助品，如染料、抗静电剂等）生产簇绒地毯是可能的。通过在簇绒地毯的所有部分中使用一种化学上均匀的物质，在加工和回收利用使用过的地毯时，不再必需将其各部件及其组成部分彼此分离。相反，由于聚酰胺6可以通过简单的解聚作用被回收成为单体初始产物，已内酰胺，因此，地毯可以作为一个整体回收，以再生单体始料。
此外，本发明还提供了这样的优点，即在簇绒地毯的所有部件中使用一种化学上均匀的物质提供了绒毛和基底相同的可染色性。因此与传统的使用聚丙烯作为簇绒基底的情况相比，增加了光稳定性。此外，本发明的簇绒地毯具有更高的弹性，允许使用更高的染色和整理温度，且因此产生了好的总体经济效果。
本发明簇绒地毯的簇绒基底包括由聚酰胺6制成的纺织织物，编织织物，无纺的或一种拉伸的薄膜。如果采用一种由经线编织方式生产的纺织织物的话，则编织物应主要由下列纱层产生：
梳栉1（经绒）  102-454
梳栉2（编链）  100-011
（簇绒）毛圈/厘米  20
节距（针号）  E28
这种形式的编织物给出了一种稳定的，不卷边的产品织物，且在其给予适当的纵向和横向延伸后本身是厚实的。由于梳栉1中强的横移，在簇绒针上的纱线有任何损坏的情况下所选择的纱层，防止了总体结构的破坏。
编织物产生了一种能够通过下面的衬垫固定而被稳定，但为了拉伸的需要仍具有必要的3%至7%可延伸性的可延伸的簇绒地毯。编织物还表现出高位移强度，因此，例如由低位移强度引起的地毯在梳针条板处撕裂等问题得以避免。
用于该编织物的纱线，主要是长丝纱线在20dtex到200dtex（1dtex＝0.9
Figure 921029691_IMG1
）的登尼尔范围内。具有44dtex或67dtex登尼尔的纱线已被证实是特别合适的。这些长丝线表现出Ca.14%的收缩性，这种收缩可通过加热（固定）引发。如果在固定之前将绒毛簇绒则引发收缩将导致表面的压缩，提高了簇绒地毯的质量。另一方面，人们可以簇绒来取得粗纺机节距的好处并利用被引发的收缩来获得一个如同用更细节距的簇绒机获得的产品表面，例如，利用上述经线编织产品作为载体材料簇绒产品（1/10″节距，8毫米绒毛，45针距/厘米）从1270克/米2到1600克/米2收缩25%。如果不想要这种收缩效应的话，则可用完全固定的并且被这样稳定化的同样结构作为簇绒基底。
用纺织产品作为簇绒基底，则为了获得在经线和纬线上的均匀稳定性，平纹组织是优选的。经线和纬线的纱线密度依赖于所采用的纱线的粗细。最合适的是细度在200到4000dtex范围内的纱线。对于细度为300dtex的纱线，典型的纱线密度为经线8至14根/厘米，而对于1100dtex细度的纱线，在纬线上为5至10根/厘米。粗纺织物的位移强度和对角稳定性可通过另外加入一层无纺织物加以改进。在纺织产品的情况下，因为由编织方式引起显著的弹力吸收，其可延伸性处于低水平，以至必须选择3%的更低的拉伸范围。
然而，具有更大的延伸性的地毯在此也可以采用卷曲变形纱制成，即具有更高弹性的聚酰胺纱线，并可以对尺寸进行精修以满足使用需要。
作为地毯基底的无纺织物在所有方向上呈现出均匀的强度，并具有可通过固定进行调节的可延伸性，但其强度小于其它基底产品。特别合适的是具有90至200克/米2，且最好为110至150克/米2的重量，和纵向上具有130至170牛顿/5厘米，最好为140至160牛顿/5厘米的强度，横向上具有100至150牛顿/5厘米，且最好为110至140牛顿/5厘米的强度的无纺织物。
以通常方式由人造短纤维再次纺成的连续的拉伸-卷曲变形的长丝纱线或另一种仅由聚酰胺6以任何方式制造的纱线被用作绒毛或簇绒材料。主要处于800dtex到4000dtex登尼尔范围内的纱线可被通常用来进行卷曲变形化或另外整修或加捻并整修。
通过利用一种聚酰胺膜或利用聚酰胺熔化粘结粉或部分溶解的聚酰胺熔化物进行粘接来固定簇绒环。
为了固定簇绒环，聚酰胺膜或聚酰胺粉必须被加热，直到其能够流动或者加入一种液态的部分溶解的聚酰胺熔化物以便令人满意地固定簇绒环。一种特征在于降低了熔化点的共聚多酰氨被用来促进熔点降低，但要选择最高可能比例的聚酰胺6，特别是具有聚酰胺6含量在至少80重量%且最好至少为90重量%的共聚多酰氨。相对于所用材料的总重量加入最低限度的辅助成份是不很重要的，且因此对于通过解聚作用进行循环利用以及有关试图再生初始成份，已内酰胺来说是不存在问题的。适用于这种目的的共聚多酰氨是市场上以薄膜形式及粉末形式销售的标准的熔化粘结剂。
固定的程度可根据应用和用途通过共聚物的类型及薄膜厚度或粉末数量来调整。30至90克/米2，且最好为40至70克/米2的涂层是最常用的。同时，拉伸时地毯的可延伸性，特别是当使用编织物作为地毯基底时，是由固定程度预先设置的。
当固定簇绒环时，为了地毯的辅助稳定性可以同时加上由聚酰胺6制成的纺织表面，例如纺织织物，毛纺织物或编织物作为第二衬垫。本发明的地毯结构设置有或不设置一层单独的隔热层，不用粘结，而通过在梳针板条上方的拉伸进行安装。该隔热层本身则可在使用过后被回收，并单独地重复使用。由此，铺过的地毯可再次使用。
本发明的实施将从下列非限制性实例中变得更加显而易见。
例1
通过簇绒方法制成的纺织的地板覆盖物结构的实例：
簇绒基底：由聚酰胺6制成的经线编织产品，
机器细度：  28E
梳栉1：  材料dtex44
织纹：  经绒102-454
梳栉2：  材料dtex44
织纹：  纤维100-011
（簇绒）毛圈/厘米：  20
重量克/米290
绒毛：聚酰胺6地毯纱线
类型：  dtex1250f68
X2.215T/m，
S-wire
整修过的
抗静电的
簇绒：机器节距  1/10″
绒毛高度（毫米）：  8
（簇绒）毛圈数/10厘米，
未加工的：  46
绒毛输入重量，未加工的（克/米2）：1270
染色后绒毛输入重量，
未切制，（克/米2）：1604
固定：共聚多酰氨薄膜（视觉熔点DIN53376B110至115℃）-重量40克/米2
固定：  115-122℃
例2
带有第二衬垫的用簇绒方法制成的纺织的地毯覆盖物结构实例：
簇绒基底：类似于例1
绒毛：类似于例1
簇绒：类似于例1
固定：共聚多酰氨薄膜（熔点范围如例1）-40克/米2-且类似于簇绒基底的经线编织产品叠加在簇绒结构上（温度115-122℃）。

Claims (11)

1、包括簇绒基底、绒毛材料以及地毯衬垫的簇绒地毯，其特征在于：它基本上仅包括聚酰胺6。
2、根据权利要求1所述的簇绒地毯，其特征在于簇绒基底是编织物。
3、根据权利要求2所述簇绒地毯，其特征在于簇绒基底由20dtex至200dtex登尼尔范围的纱线组成。
4、根据权利要求2或3所述簇绒地毯，其特征在于簇绒基底由长丝纱线组成。
5、根据权利要求2至4所述簇绒地毯，其特征在于簇绒基底是用下列纱层生产出来的编织物：
梳栉1（经绒）  102-454
梳栉2（纤维）  100-011
（簇绒）毛圈/厘米  20
节距  E28
6、根据权利要求1所述簇绒地毯，其特征在于簇绒基底是纺织织物。
7、根据权利要求6所述簇绒地毯，其特征在于簇绒基底由细度在200至4000dtex范围内的纱线组成，且编纹是平纹组织。
8、根据权利要求1所述簇绒地毯，其特征在于簇绒基底是无纺织物。
9、根据权利要求1至8之一所述簇绒地毯，其特征在于地毯衬垫由一层薄膜，一种熔化粘接粉末或一种由聚酰胺6组成的或由具有高聚酰胺6含量的共聚多酰氨组成的部分溶解的熔化物组成并粘到簇绒环上。
10、根据权利要求1至9中之一的簇绒地毯作为地板和墙壁覆盖物的应用。
11、根据权利要求10所述的应用，其特征在于该地板或墙壁覆盖物是通过拉伸进行铺设的。
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CN102713042A (zh) * 2009-12-09 2012-10-03 考勒邦德有限公司 地毯基底布
CN102885564A (zh) * 2012-09-24 2013-01-23 浙江家园地毯实业有限公司 一种簇绒尼龙染色地毯的加工方法及产品

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CN1103125C (zh) * 1997-12-19 2003-03-12 原田工业株式会社 伸缩杆式天线装置
CN1308540C (zh) * 2000-06-05 2007-04-04 美利肯公司 轻质衬垫地毯及其制作方法
CN101855077A (zh) * 2007-11-08 2010-10-06 纳幕尔杜邦公司 水蒸汽可透过的地毯底衬
CN102713042A (zh) * 2009-12-09 2012-10-03 考勒邦德有限公司 地毯基底布
CN102885564A (zh) * 2012-09-24 2013-01-23 浙江家园地毯实业有限公司 一种簇绒尼龙染色地毯的加工方法及产品
CN102885564B (zh) * 2012-09-24 2014-08-27 浙江家园地毯实业有限公司 一种簇绒尼龙染色地毯的加工方法及产品

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