Method for Stabilising a Pile Fabric Such as a Pile Carpet with a Reinforcing Backing and a Sheet Cloth Produced by Said Method

Abstract

In the case of pile carpeting, e.g. whose pile fibres are tufted in a support layer, it is known to provide the backing of the support layer with a nonwoven and bond this to the support layer and the backing fibres of the pile fibres by means of hydrodynamic needle-punching. It is furthermore known to apply an intermediate layer to the support layer between support layer and nonwoven comprising at least partly fusible fibres and to bond the two by means of hydrodynamic needle punching to the carpet backing. The invention proposes that the intermediate layer is formed of a hot melt powder, short-staple fusible fibres or a fusible film and these should initially be moved into the backing of the support layer by hydrodynamic needling before the melting process effects the actual fixing of the pile fibres in the support layer.

Description

The method according to the invention produces web goods consisting of a support layer into which pile-forming yarns are inserted and anchored therein by means of hydrodynamic water needle-punching, wherein an intermediate layer of molten powder, molten chemical fibres or a molten film is provided on the back of the support layer provided with pile fibres, and a nonwoven is placed thereover and the backing of the support layer has been subjected twice to hydrodynamic needle-punching, once for intensive bonding of the intermediate layer to the backing fibres of the pile and the support layer and secondly for bonding the nonwoven to the support layer to produce the carpet backing, and then the carpet has been treated with heat to melt the powder, the fusible fibres or the film.

Claims

1. A method for continuous stabilisation of pile carpeting, tufted carpeting or plush carpeting, in any case of web-like goods with a visible side whose structure and quality must not be modified and a backing support layer in which the pile-forming yarns are incorporated and are anchored there by means of hydrodynamic water needle-punching, characterised in that a hot melt powder, short-staple fusible fibres or a hot melt film are applied as an intermediate layer to the back of the support layer provided with pile fibres, a nonwoven is placed thereover and the back of the support layer is then subjected twice to hydrodynamic needle-punching, once for intensive bonding of the intermediate layer to the backing fibres of the pile and the support layer and secondly for bonding the nonwoven to the support layer to produce the carpet backing, and then the carpet is subjected to heat treatment to melt the powder, the fusible fibres or the film.

2. The method according to claim 1, characterised in that after the first hydrodynamic needle-punching the carpet is heat-treated to melt the intermediate layer and subjected to further hydrodynamic needling after application of the nonwoven.

3. Web goods consisting of a support layer into which pile-forming yarns are inserted and anchored therein by means of hydrodynamic water needle-punching, characterised in that an intermediate layer of molten powder, molten chemical fibres or a molten film is provided on the back of the support layer provided with pile fibres, and a nonwoven is placed thereover and the backing of the support layer has been subjected twice to hydrodynamic needle-punching, once for intensive bonding of the intermediate layer to the backing fibres of the pile and the support layer and secondly for bonding the nonwoven to the support layer to produce the carpet backing, and then the carpet has been treated with heat to melt the powder, the fusible fibres or the film.