Method for manufacturing a textile complex which serves as primary backing for tufted carpets, in addition to a carpet obtained thereby

Abstract

 The invention relates to a method for manufacturing a textile complex which can be used as substrate for the manufacture of tufted carpets.
The invention has for its object to offer a method for a textile complex which can be used as substrate for tufted carpets, and which in addition to meeting already existing requirements also satisfies the following require­ments:

a) the product has as backing for tufted carpets a broad area of use and with a single product more stitch num­bers and needle distributions can be achieved than with exis­ting products.

b) the product possesses an excellent dimensional stability, i.e. the strength, stretch and shrink properties are the same in all directions.

c) the product gives a restful pile image.

d) the product can be used both as backing for tufted carpets and for coating and layering textile products, and can also serve as reinforcing material in all applications suitable for this purpose and for which a textile product is also suitable.

In order to achieve the above objects the invention proposes a method of the type referred to in the preamble which is characterized by the following steps:

(1) the provision of a first component comprising a flexible textile layer, and

(2) the mechanical connecting thereto of a structure consisting of at least one thread, fibre or the like.

Description

[0001] The invention relates to a method for manufacturing a textile complex which can be used as substrate for the manufacture of tufted carpets.

[0002] Such a product is for instance known from the Ne­therlands patent application NL-77.04148. The art described therein relates exclusively to fine-tufted carpets.

[0003] A number of developments can be discerned in the international carpet industry. Firstly there is a development towards carpets with a finer pile distributions, and as a consequence there is a greater demand for a primary backing suitable for these carpets. Secondly there is a desire within the carpet industry for a substrate which has an improved dimensional stability (i.e. the same strength, stretch and shrink properties in all directions), a good and restful pile image (also in the case of fine pile distributions) and which is also multi-purpose.

[0004] A possible answer to the first development is of­fered by finer woven materials; these woven materials possess more yarn and weft threads per unit of length. In addition to the fact that such a product is more expensive because of higher production costs it still also gives an insufficiently restful pile image in the case of very fine pile distribu­tions. Furthermore the requirements stated in the second development are insufficiently fulfilled.

[0005] Another solution is that of making use of fibre fleeces FLWs (Fleece Locked Weave) and CLWs (Calander Locked Weave), a product described in the Netherlands patent appli­cation NL-77.04148.

[0006] Fibre fleeces FLWs and CLWs have a better pile image in the case of fine pile distributions and a better dimensional stability than woven substrates.

[0007] The dimensional stability of a backing is of prior importance if geometric patterns such as lines and rectangles occur in the tufted carpet. If there is insufficient dimen­sional stability, deformation of these patterns will result. The properties of a backing should for these and other reasons be the same in all directions. A fibre fleece possesses this dimensional stability. During the manufacture of a carpet with geometric patterns the backing has to have a certain stretch and elasticity. Fibre fleeces do not have sufficient stretch and elasticity and this can lead among other things to damage occurring.

[0008] Fibre fleeces, particularly in the case of threads with a linear density of more than 3000 dtex, moreover have an insufficient tuft-lock. This means that the hole resulting from penetration of the substrate by the tufting needle does not close up sufficiently after this penetration. The pile threads are therefore not held sufficiently firmly in place.

[0009] Fibre fleeces are furthermore unsuitable because their price is markedly higher than that of a woven substrate of FLW or a CLW.

[0010] FLWs and CLWs are unsuitable because their multi-­purpose use is limited, and also because the pile image in the case of very fine tufted carpets is inadequate.

[0011] The invention has for its object to offer a method for a textile complex which can be used as substrate for tufted carpets, and which in addition to meeting already existing requirements also satisfies the following require­ments:

a) the product has as backing for tufted carpets a broad area of use and with a single product more stitch num­bers and needle distributions can be achieved than with exis­ting products.

b) the product possesses an excellent dimensional stability, i.e. the strength, stretch and shrink properties are the same in all directions.

c) the product gives a restful pile image.

d) the product can be used both as backing for tufted carpets and for coating and layering textile products, and can also serve as reinforcing material in all applications suitable for this purpose and for which a textile product is also suitable.

[0012] In order to achieve the above objects the invention proposes a method of the type referred to in the preamble which is characterized by the following steps:

(1) the provision of a first component comprising a flexible textile layer, and

(2) The mechanical connecting thereto of a structure consisting of at least one thread, fibre or the like.

[0013] Step (2) can for instance be performed by a yarn knit process, while in appropriate circumstances a stitching or sewing process may be suitable.

[0014] In a further elaboration the method may be charac­terized by the following steps:

(3) the provision of at least one further component consisting of a flexible textile layer;

(4) the laying of the components onto each other;

(5) the mechanical connecting of the components to each other by means of step (2).

[0015] If desired an obtained complex can be densified by application of the following step:

(6) the subjecting of the complex obtained to a calander process.

[0016] The method according to the invention can be further characterized by the following step:

(7) the selection of the component(s) stated in (1), (2), (3) and (5) from the group to which belong:
- a woven material
- a substrate on the basis of a woven material
- a fibre fleece
- a substrate on the basis of a fibre fleece
- a thread system
- a complex consisting of at least two thread sys­tems with preselected relative orientation
- a netting, for instance an extruded and bi-orien­ted netting.

[0017] Finally, the invention relates to a textile complex obtained by application of a method as specified above.

[0018] The invention will now be elucidated with reference to a number of examples. See examples (A)-(E).

[0019] Following below is an explanation of the examples.

[0020] As a result of combining different components it becomes possible that a better solution is offered to meet the requirements stated at the beginning of this patent app­lication than is possible with existing substrates. In complex (A) the length and breadth thread system ensures strength in two directions. In complex (B), (C), D) and (E) this is ac­complished through respectively a netting, a strip weave and a leno-weave.

[0021] The thread system resulting from the yarn knit process and the connection this thread system makes between the different components improve the dimensional stability and the strength properties in all directions.

[0022] Pile image improvement is brought about by making use of a fleece and by improving the dimensional stability. The needling process of the knitting operation also gives an improvement in the pile image because the complex becomes softer and more flexible; as a result fewer needle deviations occur during tufting.

[0023] It has been found in practice that the yarn knit-­thread system improves the tuft-lock to a significant extent.

[0024] Tests assessed by independent persons skilled in the art demonstrate that for a single substrate both the range of the needle distributions and of the stitch number are increased.

[0025] In complex (D) no use is made of a fleece. Tests have shown that the finer needle distribution (E12) used in the yarn knit process has a good influence on the multi-pur­pose usability and the pile image.

[0026] If as binder thread for the yarn knit a thread that can be dyed is chosen the dye susceptibility of the whole substrate can be improved.

Claims

1. Method for manufacturing a textile complex, for example a substrate for tufted carpets characterized by the following steps:

(1) the provision of a first component comprising a flexible textile layer, and

(2) the mechanical connecting thereto of a structure consisting of at least one thread, fibre or the like.

2. Method as claimed in claim 1, characterized in that step (2) is performed by a yarn knit process.

3. Method as claimed in claim 1, characterized in that step (2) is performed by a stitching or sewing process.

4. Method as claimed in any of the foregoing claims, characterized by the following steps:

(3) the provision of at least one further component consisting of a flexible textile layer;

(4) the laying of the components onto each other;

(5) the mechanical connecting of said components to each other by means of step (2).

5. Method as claimed in any of the foregoing claims, characterized by the following step:

(6) the subjecting of the obtained complex to a calander treatment.

6. Method as claimed in any of the foregoing claims, characterized by the following step:

(7) the selection of the component(s) from the group to which belong:
- a woven material
- a substrate on the basis of a woven material
- a fleece
- a substrate on the basis of a fleece
- a thread system
- a complex consisting of at least two thread sys­tems with preselected relative orientation
- a netting, for instance an extruded and bi-orien­ted netting.

7. Complex obtained with a method as claimed in any of the foregoing claims.

8. Tufted carpet with a primary backing manufactured with a method as claimed in any of the foregoing claims.