Tufted carpet for automobile applications

FIELD: chemistry.

SUBSTANCE: tufted carpet for application for automobiles consists of burry layer and, at least, main base layer. Burry layer has poil weight and consists of yarn from bulk-continuous-filaments (BCF yarn), containing specified number of threads, which have specified diameter. Carpet is subjected to tufting with specified size. BCF yarn consists of polypropylene (PP) thread with tear strength between 2.6 cN/dtex (centinewton per decitex) and 3.2 cN/dtex (centinewton per decitex) with elongation from 50% to 70% or polyethyleneterephthalate (PET) with tear strength between 2.6 cN/dtex (centinewton per decitex) and 3.4 cN/dtex (centinewton per decitex) with elongation from 20% to 40%.

EFFECT: obtaining tufted carpet.

15 cl, 2 dwg

 

The invention relates generally to pile carpets and, more specifically, to a pile carpets for automotive applications.

In the automotive industry tufted carpets are used for numerous purposes and for different applications. One such goal is the attenuation of the noise. Another purpose is to enhance the comfort of the surrounding space for the driver. These goals are achieved through systems for the floor of the vehicle, the main floors, finishes the side walls in the trunks, including cargo floor and trunk lid.

These applications can be found in vehicles for people type of cars or vans, or trucks. Raised floor systems in vehicles consist of several layers: the superficial or fleecy layer base layer base, a layer of glue, the bottom (latex) layer and the separating layer. The breakaway layer is the layer that is in contact with the body without painting and priming, and its role is to reduce any noise or vibration in the body without painting and priming coming from the passenger cabin. The breakaway layer is usually based on a foam or fibrous material. The bottom layer may be absorbent or barrier and can be based on the combination of materials, fibers and foam, to form the basis of reg is generated porosity. The layer of glue is made to securely hold the beams in the main layer basis. Alternatively, a thermal process, in which the beams and the base layer basics are securely connected together by melting, can replace the layer of glue. The main layer of the framework is formed from woven or non-woven material. Fleecy layer formed of beams. Fleecy layer and the base layer basics are the carpet, while the adhesive coating layer is intermediate to the base layer. Usually inside of a floor system for a vehicle fleecy layer and the base layer basics form the carpet.

Upholstery side wall can also be found in the vehicles for the person, the type of cars or vans, or trucks. Upholstery body side contain the carpet, the adhesive layer of the coating or its alternatives, and, if necessary, a second or more layers of the substrate. The Mat is formed from a fleecy layer and the base layer of the framework.

Other applications of pile carpets in cars can be additional mats for the floor or other parts of the interior trim.

The design of the upholstery or Mat in accordance with their applications differs in its structure and design to meet the requirements. The design consists of the NAP of the carpet, which consists of fleecy layer and the base layer basics, glue the first coating layer and additional layers, designed to meet the specific requirements of the application. The most complex requirements apply to pile carpets used in systems to floor vehicle.

Regardless of the application tufted carpet with its fleecy layer consists mainly of construction carpeted surface of two different types, as there are layers with bobbed hair and with an exhaust pile. Deep pile carpets usually include composite design as a base layer basics, which introduced the tufts of carpet yarn. The beams form a fleecy layer. The base layer basics usually formed from non-woven or woven material made of polyamide, polyester, polyolefin, or cotton, or mixtures of the above polymers. Usually nonwoven main layers of the framework formed by bonding spinning.

After the tufting process, the resin coating can then be superimposed on the lower side of the carpet construction, in order to securely hold the NAP material in the core layer basis. It is preferable, from the viewpoint of processing, to choose for beams and the base layer basics of synthetic materials of the same type. The adhesive coating layer contains, for example, latex. Also known application of other synthetic materials other than latex, by squeezing on nor is the Nuits side of the carpet construction, with the same purpose adhesive layer coating. Unlike the adhesive layer coating the hold of the pile of material in the core layer base can be performed by a thermal process in which the beams and the base layer basics melted together.

Carpet yarn used in NAP mats for use in automobiles, is usually hand-made yarn consisting of polyamide, polyester or polyolefin. These yarns are yarns of the type BCF (yarn from space-cordlike strands), comprising a number of separate strands. Yarn type BCF are bundles of filaments, which were melted, twisted, stretched and textured. The most common BCF yarn, which is used as a carpet yarn for applications in automobiles, is a polyamide (PA). The development of technology has led to alternative yarn, other than yarn PA, which is used in the construction of pile carpets. This alternative yarn consists of polyethylene terephthalate (PET) filaments and yarns made from polypropylene (PP).

The predominant factor in the creation of carpets for vehicles are the costs. Next, pile carpets should be assessed from the viewpoint of abrasion, wybielania under the application of forces and weight as the most important properties of carpets used for applications in automobiles. The other condition is s quality is the ease of cleaning, aesthetic properties, tactile properties and processability of the materials used.

The desire to improve the technology of manufacturing of carpets influenced compromise between maximum properties abrasion and minimum weight in order to optimize the cost. In order to meet the standard requirements to abrasion, a certain weight of material to create a tufted carpet. Abrasion can be tested in accordance with DIN 53754 (German industrial standard). This procedure is a method for determining the resistance to wear of the upholstery using a caliper for a sample in the form of a turntable and machine type double abrasive wheels. Circles jam on fleecy layer of the sample while rotating the sample.

After a certain number of revolutions of the sample to measure the loss of his weight and appreciate its visible appearance. Weight loss indicates the resistance to wear or abrasion to Taber according to the device for testing, made "Taber Industries. Another effect caused by the test Taber, is bleaching when the application efforts. Physical or visible appearance changes. This effect is caused by a change in light reflection, which occurs due to rupture and mechanical damage to the threads due to abrasion.

By use the use of polypropylene (PP) yarn as carpet yarn, the weight of the material must be increased in comparison with polyamide (PA) yarn in the set of requirements to abrasion. On the other hand tufted rugs are made of polypropylene (PP) yarn are characterized by higher resistance against stains compared with pile carpets are made of polyamide (PA) yarn; and ease of cleaning is an important property of the carpet, which is to be used in vehicles.

Use yarn PET as carpet yarn leads to the creation of the carpet, which is not as durable as the carpet is made of polyamide (PA), and only recommended for wear conditions from mild to moderate. Yarn PET also has a natural property of resistance against stains, which eliminates the problem of polyamide (PA) yarn, consisting of the use of chemical substances for resistance against stains, due to the high exposure of the yarn to the formation of spots.

The objective of the invention is to provide a carpet with a high resistance against stains, made of polypropylene (PP) yarn or polyethylene terephthalate (PET) yarn, which is characterized by improved abrasion resistance without increasing the weight of the carpet or the cost of its manufacture.

Addressing the above objectives of the invention are represented by the features indicated in paragraph 1 is ormula invention. The task is solved by the NAP of the carpet with fleecy layer and at least the base layer basics, which fleecy layer has a pile weight and consists of yarn from space-BCF yarns (BCF). The BCF yarn consists of a given number of threads that have the specified diameter. The BCF yarn consists of polypropylene (PP) yarn with a tensile strength of between 2.6 cN/dtex (centinewton on decitex) and 3.2 cN/dtex (centinewton on decitex) when pulling from 50% to 70%, or from polyethylene terephthalate (PET) with tensile strength being between 2.6 cN/dtex (centinewton on decitex) and 3.4 cN/dtex (centinewton on decitex) when the elongation of from 20% to 40%.

Research different types of carpets and a large variety of yarn BCF showed that the wear resistance of carpet for use in vehicles depends on the physical properties of the used yarn BCF, as well as its material. One such physical property is tensile strength. In order to achieve a given tensile strength, the yarn is pulled to a certain extent during the process of its production. The more elongated strands, the higher is the tensile strength. Because there is a limit to the degree of stretching, pulling the yarn after some point will break the thread. Due to past experience generally believe that the higher the tensile strength is not required in order to improve the characteristics of the eristic resistance to abrasion, and, in addition, creates ongoing problems during the manufacture of the yarn so that the yarn PP BCF and BCF yarn PET produce at the optimal level of tensile strength, in order to have good performance (without thread breakage). In contrast to the common belief was that the increased tensile strength to some extent for yarn PP or PET, without increasing the gap of the thread (with the same performance characteristics), leads to an increase of the mode of wear in the carpets. It turned out that the PP yarn or yarn PET have preferred performance regarding abrasion resistance, when they are obtained in the field of high tensile strength. So it is possible to combine the advantages of PET yarn or yarn PP compared with yarn RA in relation to resistance to stains with improved wear resistance by increasing the tensile strength.

As for the mode abrasion NAP carpet, best results are obtained when using yarn BCF PP with a tensile strength of 2.6 cN/dtex (centinewton on decitex) to 3.2 cN/dtex (centinewton on decitex) when the elongation of from 50% to 70%. Preferably the tensile strength of the used yarn PP is in the range from 2.8 cN/dtex (centinewton on decitex) to 3.1 cN/dtex (centinewton on decitex) when the elongation of from 50% to 65%. Unexpectedly, this mode applies the m to the BCF yarn PET. As for the mode abrasion NAP carpet, best results are obtained when using yarn BCF PET with a tensile strength of 2.6 cN/dtex (centinewton on decitex) to 3.4 cN/dtex (centinewton on decitex) when the elongation of from 20% to 40%. Preferably, the tensile strength of the used yarn PET is in the range from 2.8 cN/dtex (centinewton on decitex) to 3.2 cN/dtex (centinewton on decitex) when the elongation of from 25% to 35%.

In order to reduce the weight of the carpet, the diameter of a single filament is reduced. The diameter of the filaments is in the range from 5 to 20 dpf (decitex on the thread or yarn, PP or PET yarn. Preferably, PP yarn, used for the manufacture of the pile of the carpet has a diameter of from 6 to 12 dpf (decitex on the thread). The best results for PP yarn in combination with a specific tensile strength mode abrasion obtained with a diameter equal to 7 dpf (decitex on the thread). Preferably used for the manufacture of the pile of the carpet yarn PET has a diameter of from 10 to 20 dpf (decitex on the thread). The best results for PET yarn in combination with a specific tensile strength mode abrasion obtained with a diameter equal to 15 dpf (decitex on the thread). The ratio of the change should be close to unity to have a great uniformity in the fiber diameter. Usually for BCF yarn coefficient of variation is between 0.9 and 1.1.

In order to achieve comparable characteristic is cteristic abrasion for commonly used carpet fibers, as with PA, use less material by weight by making up into rugs from yarn PP with small dpf (decitex on the thread) or equal to less material by weight by making up into rugs from yarn PET with a small dpf (decitex on the thread). Yarn PP contains from 120 to 150 filaments, preferably from 130 to 140 filaments. The best ratio weight for operation can be performed with yarn PP 135 threads. The PET yarn contains from 70 to 100 threads, preferably from 75 to 90 threads. The best ratio weight for operation can be implemented with PET yarn of 80 threads.

The number of threads per square metre also affects tactile properties or touching Varsovia carpet, tactile properties increase with a larger number of threads.

Tests on abrasion according to DIN 53754 showed resistance to wear, comparable to the famous carpets, made of yarn PA. Properties on wear fleecy layer in accordance with the present invention, is higher than that known in the art pile carpets made of PP yarn or yarn PET by increasing their tensile strength.

Thread PP, as well as the threads of the PET produced with cross sections of different shapes, as for example, there are threads with round, rectangular, polygonal or other shape of cross section, as well as hollow or filaments with a core of the shell. The BCF yarn of polypropylene (PP) or polyethylene terephthalate (PET) preferably consists of strands trandellchicago type for the manufacture of a carpet according to the present invention.

Pile weight pile carpet according to the present invention is from 200 gsm (grams per square meter) up to 750 gsm (grams per square meter) depending on the application in the technical field of manufacturing automotive carpets. For example, the pile weight of the carpet yarn PP or PET yarn according to the present invention, when the carpet is used in the floor system of a vehicle having high standards of abrasion, is in the range from 250 gsm (grams per square meter) up to 450 gsm (grams per square meter). Together with the potential of recycling compared to other, non-PP and PET, hand-made fibers used in pile carpets, light weight is more important in light of the desire to improve the sustainability applications in cars pile carpets. The BCF yarn used in the carpet according to the present invention may be fabricated using from 20% to 80% recycled post-industrial waste, as well as the main layer of the framework.

One type of dyeing carpet for use in vehicles is the piece dyeing. For single staining the carpet is made in white the m color and paint after the tufting process before application of the adhesive layer of the coating. Another type of coloring exists to be used for tufting yarn, BCF, which is the type of yarn being dyed in a solution. The staining solution has the advantage in the manufacture of that pile carpet is ready for use after tufting. The PP yarn is a yarn, preferably colored in solution, whereas carpets, made of yarn PET, are in most cases, carpets, dyed in the piece.

In the process of making the size of the tufting choose preferably at the level of 5/64 inch for finer yarns PP, in order to achieve optical and tactile properties, despite the use according to the present invention. Then, in case of yarn PET are preferred sizes 5/64 inch, 1/10 inch. The choice of the size of the tufting also affects bleaching when the application efforts, the more threads per square metre, the less wybielania when the application's efforts appears when the carpet shape, due to the profile of the floor or upholstery. Common sizes tufting, which can also be used for any polymer, are 1/18 inch, 5/32 inch and 1/10 of an inch.

The above and other advantages of the present invention will become apparent from the following detailed descriptions of preferred options for implementation of the present invention, considered in the light of the attached drawings, on which:

Fig.1 is a schematic view of the cross-section of the system to the floor of the vehicle;

Fig.2 is a schematic view of the cross-section of the pile carpet cut pile in accordance with the present invention.

The present invention relates in General to systems for floors, upholstery side in the boots, optional matting or other parts of the interior trim in vehicles and, more specifically, to pile polypropylene (PP) pile carpets or polyethylene terephthalate (PET) carpets and to methods for their manufacture.

As can be seen in Fig.1, illustrates an implementation option 1 for floors in accordance with the prior art. The system 1 for the floor of the vehicle contains three main elements: first, the carpet with 2 decorative upper layer 3 of the fiber, and the second base 4, and a third separating layer 5 layers, absorbing sound and vibration. Breakaway layer 5 is a layer which is in contact with the body without painting and priming, work the body 6 of the vehicle. The breakaway layer is generally based on the foam and fibrous material.

The base 4 may be absorbent or barrier and can be based on the combination of materials, fiber is n and foam to create a base with adjustable porosity.

Carpet 2 is made of two layers, a layer of the pile and the base layer basics. Decorative upper layer 3 is made of pile yarn is napped layer. Tufts sewn into the base layer basics. The main layer of the framework is made of woven or non-woven material. The layer of the pile and the base layer basics are the carpet, in which the adhesive coating layer is an intermediate layer to the base. Usually inside of a system for the floor of the vehicle layer of the pile and the base layer basics form the carpet.

As can be seen in Fig.2, a variant implementation of the NAP of the carpet 2 with cut pile is illustrated in schematic form in accordance with the present invention. The design of the carpet 2 of clipped and stretched knitted pile is the same, despite the nature of the beams 7. Tufted carpet contains bundles of 7, which is injected into the base layer 8. Then the beams cut on the upper side of the Mat 2. Layer 7 of the pile and the main layer 8 bases form a tufted carpet according to the present invention. There are several known in the art capabilities in order to secure the beams 7 in their seats in the main layer 8. For example, the adhesive layer 9 of the coatings are formed adjacent to the core layer 8, in order to keep the beams 7 in the core layer 8. Or beams 7 and the base layer basics melted together on the N. is the old side of the carpet. Depending on the provisions in the system for a floor or other applications in vehicles and intended function of the Mat 2 can be attached third or more protective layers adjacent to the adhesive layer 9 covering.

Beams 7 form a pile layer, which sees and feels the user of the vehicle. Fleecy layer consists of pile yarn PP or PET, containing the specified number of threads. Due to the thin filaments, weight per square meter of carpet according to the present invention does not exceed the weight of the carpet manufactured as known in the art of coating.

1.Tufted carpet for use in automotive applications with fleecy layer and at least the base layer basics, this fleecy layer has a pile weight and consists of yarn from space-BCF yarns (BCF) containing the specified number of threads that have a given diameter, wherein the BCF yarn consists of polypropylene (PP) yarn with a tensile strength of between 2.6 cN/dtex (centinewton on decitex) and 3.2 cN/dtex (centinewton on decitex) when the elongation of from 50% to 70% or polyethylene terephthalate (PET) with a tensile strength of between 2.6 cN/dtex (centinewton on decitex) and 3.4 cN/dtex (centinewton on decitex) when the elongation of from 20% to 40%.

2. The carpet under item 1, characterized in that the predetermined diameter of the mentioned thread is from 5 to 20 dpf (decit the COP on the thread).

3. The carpet under item 1 or 2,characterized in that the specified number of threads varies from 70 to 150 threads mentioned BCF yarn.

4. The carpet under item 3, PP yarn contains from 120 to 150 threads.

5. The carpet under item 3, characterized in that the yarn PET contains from 70 to 100 threads.

6. The carpet under item 1, characterized in that the yarn contains threads trandellchicago type.

7. The carpet under item 1, characterized in that the pile weight is from 200 gsm (grams per square meter) up to 750 gsm (grams per square meter).

8. The carpet under item 1, characterized in that the carpet is a carpet, painted the piece after the tufting process.

9. The carpet under item 1, characterized in that the yarn is a yarn type yarn, dyed in solution.

10. The carpet under item 1, characterized in that the main layer of the substrate and the BCF yarn made of synthetic material of the same type, either PP or PET.

11. The carpet under item 10, characterized in that the underside of the carpet is attached one or more additional layers, made of synthetic material of the same type as the carpet.

12. A method of manufacturing a NAP carpet yarn BCF on PP.1-7, characterized in that exercise tufting yarn BCF size 5/64 inch base layer basics, with sewn tufts of the pile and put the bottom layer on the tufting by extrusion or coating of latex or by those of the economic process, to attach the pile yarn to the core layer, the basics.

13. The method according to p. 12, characterized in that before applying the bottom cover tufted carpet piece paint.

14. The method according to p. 12 or 13, characterized in that the main layer of the framework consists of a synthetic material of the same type as the beams.

15. The method according to p. 12 or 13, characterized in that the yarn and the base layer basics contain from 20% to 80% recycled post-industrial waste.



 

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FIELD: textile industry, in particular, finishing of various articles and materials with pile patterns produced by electric flocculation process.

SUBSTANCE: method involves sequentially applying piles of various colors in electric field divided, according to pile advancement direction, into two zones: initial and final; finally applying piles in homogeneous field having one zone; simultaneously varying electric field intensity during all application stages except for final stage, said variations being provided simultaneously at initial zone within the range of from Ei=(U-U1)/(h-h1) to Ei≈0, and in final zone after passage by piles of interface boundary within the range of from Ef=(U1-U0)/h1 to Ef=(U-U0)/h1, by setting zone interface boundary potential from U1=(U-U0)h1/h to U1=U, where U potential of outer boundary of flocculation initial zone; U0 is potential of outer boundary of flocculation initial zone; h1 is size of final flocculation zone in direction of advancement of pipe; h is total size of both flocculation zones in direction of advancement of piles.

EFFECT: wider range of adjustment of pattern shapes and distinctness of color transition sites owing to formation of pile pattern by varying of electric field intensities.

1 dwg, 1 tbl, 1 ex

FIELD: textiles, paper.

SUBSTANCE: in the method for manufacturing needle-punched silica thermal barrier materials comprising preparing a fibrous mixture, forming fibrous web with aerodynamic method and formation of needle-punched web as feedstock, the silica fibers with the diameter of 5-7 microns and 8-20 microns are used or their mixture in a ratio of (10-90):(90-10)% which are divided in fibers on serrated drum, forming a fibrous web is carried on a conveyor of web-forming machine due to combining aerodynamic and mechanical methods. Then, the resulting fibrous web is subjected to the action of the needle board of the needle-punching machine equipped with percussion needles with serrations in both forward and reverse directions, forming the needle-punched web of thickness 3.0-10.0 mm is carried out per one process cycle, and forming of needle-punched web of thickness 12.0-30.0 mm - in two stages. First the webs-blanks are made with preliminary percussion in two directions per one pass of the web through the needle-punching machine. Then the webs-blanks are folded to the desired thickness followed by final punching in two directions per one pass through the needle-punching machine, the formed nonwoven needle-punched web enters the device of cutting and winding, and the silica fibers have a porous structure with pore size of 3-10 A (angstroms) and the production line for production of needle-punched silica thermal barrier materials, comprising a device of mixing fibrous mass, a feeding conveyor, a web-forming unit, a needle-punching machine which has a table with a needle board and with needles fixed on it. At that the percussion needles fixed to the needle board, are made with serrations in the forward and reverse directions. Moreover, the number of rows of needles with serrations in the forward direction located at the inlet to the needle board, is 2-3 times greater than the number of rows of needles in reverse direction of serrations disposed in the final part of the needle board and the two-sided percussion of web (from up to down and from the bottom up) is carried out per one technological progress of the needle in one needle-punching machine, percussion needle size and serrations is proportional to the diameter of the silica fiber.

EFFECT: use in the production of silica fibers.

4 cl

FIELD: medicine.

SUBSTANCE: liquid-permeable structured fibre cloth provides the optimum liquid absorption and distribution properties. The liquid-permeable structured fibre cloth comprises a first surface and a second surface, a thermoplastic fibres, a first area and a number of second discrete areas arranged around the first area. The second discrete areas form discontinuities on the second surface of the fibre cloth and comprise shifted fibres on the first surface of the fibre cloth; at least 50%, but less than 100% fibres have free ends extended aside from the first surface of the fibre cloth. The fibre cloth is characterised by a post-ageing thickness less than 1.5 mm, a vertical liquid capillary distribution height making min. 5 mm, a permeability min. 10,000 cm2 Pas) and a specific volume of the structured substrate min. 5 cm3/g.

EFFECT: better liquid absorption and capillary distribution.

21 cl, 29 dwg, 9 tbl

FIELD: chemistry.

SUBSTANCE: tufted carpet for application for automobiles consists of burry layer and, at least, main base layer. Burry layer has poil weight and consists of yarn from bulk-continuous-filaments (BCF yarn), containing specified number of threads, which have specified diameter. Carpet is subjected to tufting with specified size. BCF yarn consists of polypropylene (PP) thread with tear strength between 2.6 cN/dtex (centinewton per decitex) and 3.2 cN/dtex (centinewton per decitex) with elongation from 50% to 70% or polyethyleneterephthalate (PET) with tear strength between 2.6 cN/dtex (centinewton per decitex) and 3.4 cN/dtex (centinewton per decitex) with elongation from 20% to 40%.

EFFECT: obtaining tufted carpet.

15 cl, 2 dwg

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