TUFTED CARPET AND BACKING THEREFORE

Description

FIELD

The present invention relates to tufted carpeting.

BACKGROUND

Typically, tufted carpeting is produced by stitching a plurality of rows of yarn loops through a previously-manufactured backing so that the yarn protrudes on one surface of the backing as a pile, and is drawn relatively closely against the opposite surface of the backing. The pile of yarn loops may be permitted to remain as loops, or may be sheared or otherwise cut to create a cut pile rather than a looped pile. In order to prevent damage during use, the tufted yarns are bonded to the backing after tufting. The tufted yarn is usually bonded to the backing by applying an adhesive on the bottom side of the backing, in such a manner as to adhere the back loops of the yarn to the backing.

A common application for tufted carpeting in the art is interior automotive parts. For automotive applications, tufted carpets can be formed into shaped parts by molding. Tufted carpeting which is used as a substrate for molding should have specific properties. For molding, the tufted carpeting should be light-weight, such that it can be formed and bent conveniently. It must comprise a sufficient amount of thermoplastic polymer, which renders it susceptible to forming and shaping. The shaped parts should have mechanical stability for long-term use. The tufted carpeting and shaped parts should also be available in a simple and effective process.

WO 2004/071758 A1 relates to an automotive tufted carpet with improved acoustic properties which is formed from a two-layer primary backing. The first layer is a woven or nonwoven or spunbond material, and the second layer is a microfilament spunlaced material. The tufts of yarn are sewn through the primary backing and bonded with an adhesive web. The tufted carpeting may comprise a polyester nonwoven, a nonwoven from polyethylene/polyamide bicomponent filaments, a polypropylene adhesive web and tufts of yarn from polyamide. The automotive tufted carpet can be molded into shaped parts. However, an adhesive layer for bonding increases the complexity of the preparation process and product, but also the weight of the tufted carpet.

JP4376356B2 relates to a primary backing for tufted carpets. The primary backing is made from multiple polyester filament webs, which are bonded and intertwined by needling and preferably further bonded with a binder. The primary backing is tufted with nylon yarns.

In the art, methods for preparing tufted carpeting have been developed, in which the tufts of yarn are thermobonded. Thermobonding is a process in which a thermoplastic substrate, in the present case the yarn, is softened or molten and bonded, without the need for an additional adhesive or adhesive layer. A thermobonding process can be advantageous, because no additional adhesive is required. Thus, the product and process are simpler, and undesirable side effects of adhesives, such as thermal instability or odor, can be avoided.

Because of the polyamide and polyolefin components, the primary backing of WO 2004/071758 A1 cannot be thermobonded when yarns having a higher melting point, such as PET yarns, are included. This is not possible, because the structural primary backing components, which have a lower melting temperature than the yarn, would be molten and disrupted during thermobonding.

U.S. Pat. No. 4,705,706 discloses a method for preparing tufted carpeting, in which the back-loops of the stitches of pile yarn are fastened to the backing by thermal bonding, obviating the need for applying an adhesive coating to the underside of the backing. The pile yarn is from thermoplastic material, which becomes tacky at a temperature below that at which the backing is softened or molten. Specifically, a polyethylene yarn is thermally bonded to a nylon backing.

EP 1,598,476 A1 relates to a device and method for preparing tufted carpeting, in which thermoplastic tufts of yarn are thermobonded to a backing when passing a heated surface of a roll. For improving the stability, an additional thermoplastic adhesive can be applied to the underside of the backing before thermobonding.

When thermobonding the tufts of yarn in such methods, the use of an adhesive can be avoided or at least reduced. However, it is a problem of such methods that the yarn must have a softening temperature which is significantly below the softening temperature of the fibers and materials of the primary backing. Otherwise, the primary backing would also be molten and disintegrated when the heat for thermobonding is applied. Therefore, such thermobonding methods are only suitable for certain types of tufted carpeting, wherein the yarns have a lower melting temperature than the primary backing, such as polyolefin or polyamide yarn tufted on PET primary backing.

In contrast, if yarns from high melting temperature polymers, such as PET, are thermobonded on primary backings which comprise fiber materials and polymers of the same or lower melting temperature, such as PET, polyamide or polyolefin, such polymers of the same and lower melting point can melt and the structure and integrity of the primary backing can be damaged or destroyed. Especially tufting with PET would be desirable, because it has high mechanical and thermal stability and is generally suitable for large scale industrial applications. However, since PET has a relatively high melting temperature of >250° C., thermobonding PET yarns without damaging primary backings from lower melting filaments or PET is difficult.

SUMMARY

In an embodiment, the present disclosure provides a tufted carpet comprising a primary backing which comprises a spunbond nonwoven which comprises polyethylene terephthalate (PET) filaments and a lower melting polymer material which is a filament forming material. The spunbond nonwoven is thermobonded by the lower melting polymer material. The spunbond nonwoven is further consolidated with a binder. The tufted carpet further comprises tufts of yarn from polyethylene terephthalate (PET) which are sewn through the primary backing such that the piles of yarn are on a first surface and backloops of yarn are on a second surface of the primary backing. The backloops of yarn are thermobonded to the primary backing.

DETAILED DESCRIPTION

It would be desirable to provide tufted carpets and methods for their production, which overcome the above-mentioned drawbacks.

Embodiments of the present invention provide tufted carpets, shaped parts and production methods, which overcome the above-mentioned drawbacks. The tufted carpet are especially be suitable for preparing shaped parts by molding, for example for automotive interior applications. The tufted carpets and shaped parts have high mechanical and thermal stability and are relatively lightweight. Preferably, the production method is convenient, simple and efficient.

Tufted carpets based on PET components are provided. In this regard, thermobonded tufted carpeting with PET tuft yarns and methods for its production are also provided.

In an embodiment, the present invention provides a tufted carpet comprising a primary backing which comprises:

• • a spunbond nonwoven which comprises polyethylene terephthalate (PET) filaments and a lower melting polymer material which is a filament forming material, wherein the spunbond nonwoven is thermobonded by the lower melting polymer material, wherein the spunbond nonwoven is further consolidated with a binder; and
  • tufts of yarn from polyethylene terephthalate (PET) which are sewn through the primary backing such that the piles of yarn are on a first surface and the backloops of yarn are on a second surface of the primary backing, wherein the backloops of yarn are thermobonded to the primary backing.

The tufted carpet comprises tufts of PET yarn and a primary backing. As used herein, the term “yarn” refers to any textile fiber or fiber assembly, which is suitable for tufting the primary backing. The yarn can be from interlocked fibers or from a single strand of polymer material. Typically, for obtaining a uniform product, a single type of yarn is used. In principle, the tufted carpet can comprise any conventional tufting yarn, which is preferably thermoplastic. The yarn is from polyethylene terephthalate (PET). This is advantageous, because PET yarn can provide high mechanical and thermal strength to tufted carpets, and is easily available at relatively low costs.

The piles of the tufted yarn, which can be cut open or closed, are on the first surface of the primary backing. This side is also referred to as the upper side or front side, which is exposed to the environment in standard applications. The thermobonded backloops of yarn are on the second surface of the primary backing. This side is also referred to as the lower side or bottom side.

The backloops of yarn are thermobonded to the primary backing. This thermobonding step is for irreversibly bonding the yarns to the primary backing. In the thermobonding process, heat and pressure are applied to the primary backing on the second surface on which the backloops of yarn are present. The heat softens or melts the backloops, and the yarn becomes attached to the primary backing when being solidified. Preferably, the backloops of yarn are also thermobonded to each other, which can further increase the stability of the tufted carpet. Thermobonding can be carried out by passing the tufted carpet over a heated role, for example with a device as described in EP 1 598 476 A1. A tufted carpet is obtained, in which the PET yarn is tightly attached to the primary backing.

Surprisingly, it was found that the thermobonding process can be carried out at a temperature, at which the primary backing would normally be molten and damaged. During thermobonding at a temperature at which the backloops of PET yarn are softened or molten, it seems that the binder can protect the spunbond nonwoven from melting and damages, although it is based on filaments from PET and even a lower melting filament component.

The primary backing comprises a spunbond nonwoven which confers stability to the tufted yarns and the overall tufted carpet. Preferably, the primary backing does not comprise further layer. Preferably, the primary backing consists of the spunbond nonwoven with the binder.

Spunbond nonwovens are prepared from continuous filaments, also referred to as endless filaments. Thus, the spunbond nonwoven is not formed from staple fibers. The spunbond nonwovens are prepared by spinning continuous filaments, thereby obtaining a filament layer, which comprises a higher melting fiber or fiber component, in the present case from PET, and a lower melting fiber or fiber component. Methods for extruding and drawing the fiber polymers, and laying the filament layer are known in the art. The lower melting fiber component is typically a thermoplastic polymer. The filament layer is thermobonded at a temperature, which is below the melting point of the PET filaments, but above the softening or melting point of the lower melting material. When applying pressure at such a temperature, the lower melting fiber component is softened or molten, and bonds the PET filaments together after cooling. As used herein, the term “filaments” refers to continuous filaments, whereas the general term “fibers” can include filaments and staple fibers.

Preferably, the spunbond nonwoven is formed from PET filaments and filaments from the lower melting polymer material; and/or from multicomponent filaments comprising a PET component and a component from the lower melting polymer material. Multicomponent filaments are composed of two or more distinct polymeric components in continuous, longitudinal contact within the fiber. Thus, the spunbond nonwoven always comprises PET filaments. This is because, if multicomponent filaments are used and thermobonded, the lower melting component becomes at least partially molten and displaced, whilst the PET components are not molten, and remain in the form of filaments. The lower melting polymer material bonds the PET filaments together. The nonwoven was spunbonded before it is used for the primary backing. The PET filaments can confer high mechanical and thermal stability to the primary backing.

The PET filaments can be monocomponent PET filaments, or can be from multicomponent filaments comprising a PET component. Preferably, the spunbond nonwoven comprises at least 50 wt. %, more preferably at least 80 or at least 90 wt. % PET, based on all fiber material. It is preferred that all fiber forming material of the spunbond nonwoven is polyester. In a preferred embodiment, the PET has a melting point of >250° C. In another embodiment, the PET is recycled (r-PET). Recycled PET typically has a melting point between 240° C. and 250° C.

The spunbond nonwoven was thermobonded before being included into the primary backing. For thermobonding, the spunbond nonwoven comprises a lower-melting polymer material for bonding the PET filaments together. The spunbond nonwoven is thermobonded upon heating, such that the lower-melting polymer material is softened or molten. The term “lower-melting” means that the polymer material has a lower melting point than the PET, preferably less than 240° C.

The lower melting polymer material can be a conventional fiber forming material, such as copolyester (for example CoPET, CoPBT), polyamide, polyethylene or polypropylene. It is preferred that the lower melting polymer material is CoPET. This can be advantageous, because PET and CoPET have similar structure, which can increase polymer compatibility and product stability. Further, products comprising only polyester filaments can often be processed and recycled more conveniently. For example, the melting temperature T_M of the lower melting polymer, especially CoPET, can be below 240° C. or below 230° C.; preferably between 180° C. and 240° C., more preferably between 185° C. and 230° C.

In a preferred embodiment, the spunbond nonwoven comprises PET filaments and CoPET filaments. In this embodiment, the filaments are monofilaments (monocomponent filaments). In another preferred embodiment, the spunbond nonwoven comprises multicomponent filaments from a PET component and a component from the lower melting polymer material. Especially preferred are bicomponent filaments, preferably of PET/copolyester (CoPET), PET/polyamide, PET/polyethylene or PET/polypropylene type. Preferably, the bicomponent filaments are of the sheath/core type or side/side type, in which the low-melting component is exposed to the surface.

It is especially preferred that the spunbond nonwoven comprises or consists of PET/CoPET bicomponent sheath/core filaments. Such a spunbond nonwoven can confer high stability and high temperature stability to the primary backing for the tufted carpet. It is also highly compatible with tufts of PET yarn, thereby providing a relatively uniform polyester based primary backing. Preferably, the amount of lower melting polymer material in the spunbond nonwoven is about 1 to 30 wt. %, preferably 5 to 25 wt. %, of all fiber material, the rest being preferably the PET. When the filament materials of the spunbond nonwoven are PET and CoPET, the overall tufted carpet is highly compatible with the PET yarn, and highly uniform. This is advantageous for processing, stability and recycling.

Preferably, the spunbond nonwoven is not mechanically consolidated, especially not by needling (needle-punching) and/or hydroentangling. Such treatments are not required for obtaining a stable tufted carpet.

In a preferred embodiment, the PET filaments of the spunbond nonwoven have high crystallinity. Preferably, the degree of crystallinity is more than 20%, more preferably more than 30%, preferably in the range of 20% to 50%, or 30% to 40%. The crystallinity can be increased by drawing the fibers in the spinning process. The use of PET filaments having a high degree of crystallinity is preferred, because they can increase the thermal stability of the primary backing. Preferably, the degree of crystallinity is determined from the melting enthalpy to crystallization enthalpy by formula K %=(DH_melt.−DH_cryst.)×100%/DH_cryst. 100%, as described in “Thermoplastic Materials: Properties, Manufacturing Methods, and Applications”, Cristopher C. Ibeh, CRC Press, ISBN: 13:978-1-4200-9384-1, pages 105 ff. The melting enthalpy and crystallization enthalpy can be determined by differential scanning calorimeter (DSC) according to DIN EN ISO 11357-2 (2014-07).

The spunbonded nonwoven is consolidated with a binder. The binder was added to the spunbonded nonwoven after its production, i.e. after thermobonding the spunbond nonwoven filaments with the lower melting polymer material. Thus, the binder is different from the lower melting polymer material. During consolidation, the binder is solidified. When the binder composition is an aqueous polymer emulsion or dispersion, the spunbond nonwoven is dried during consolidation.

It is unusual that a spunbond nonwoven, which already has been thermobonded, is further consolidated with an additional binder, Surprisingly, the additional binder can protect the spunbond nonwoven from damage when the backloops of yarn are thermobonded. Without being bound to theory, it is assumed that the binder can shield the spunbond nonwoven materials, i.e. the PET filaments, and even the lower melting polymer material, when the heat for thermobonding is applied to the second surface, at least during the limited time span which is required for thermobonding. It seems that this protective effect is achieved because the binder covers or envelopes the fiber materials. Thereby, the basic structure of the spunbond nonwoven can be preserved, when the backloops of yarn from PET are thermobonded.

Preferably, the temperature stability of the consolidated binder is relatively high. Thus, it is preferred that the consolidated binder is not disintegrated when the backloops of yarn on the primary backing are thermobonded. Preferably, the binder is temperature stable after consolidation, i.e. not molten or decomposed, at least up to 270° C. or up to 280° C.

In a preferred embodiment, the binder comprises an additive, which increase thermal stability. For example, the additive can be an inorganic filler, such as titanium oxide, iron oxide or silica. Such additives can increase the thermal stability of the binder, thereby improving the protection of the spunbond nonwoven during thermobonding. In a preferred embodiment, the filaments of the spunbond nonwoven comprise an additive, thereby improving the stability of the spunbond nonwoven during thermobonding.

Preferably, the binder is thermosetting (a thermoset). This means that the binder can be crosslinked (cured) during consolidation. Thermoset binders comprise prepolymers, which can be irreversibly hardened. Curing can be induced by heat or radiation, and can be promoted by applying pressure. During curing, a chemical reaction leads to crosslinking of polymer chains. Thereby, a polymer network is formed. It was found that protection of the spunbond nonwoven materials by the binder during thermobonding can be especially effective, when the binder is at least partially crosslinked. Without being bound to theory, it is assumed that crosslinked binder can confer a higher thermal and mechanical stability to the spunbond nonwoven, and can shield the filaments effectively during thermobonding.

Thermoset binders for consolidating nonwovens are known in the art. In a preferred embodiment, the thermoset binder is selected from acrylic (acrylate), styrene butadiene and polyurethane binder. The acrylic binder can be a homopolymer, copolymer and/or modified polymer, such as styrene acrylate or carboxylated styrene butadiene. Preferably, the binder polymers are based on monomer units which are selected from acrylate, styrene and/or butadiene. Such binders are advantageous, because they can be applied and crosslinked conveniently. Further, they have high thermal stability and provide high adhesive strength. Preferably, the binder is applied in the form of a binder resin, preferably an aqueous binder solution or dispersion. The aqueous binder is preferably dried during consolidation. Preferably, the amount of binder is between 2 and 20 wt. %, more preferably between 5 and 10 wt. %, based on the total weight of the spunbond nonwoven (including the binder).

In a preferred embodiment, the spunbond nonwoven (including the binder) has a base weight between 50 to 200 g/m², especially between 75 to 150 g/m². It was found that such a relatively light weight PET-based nonwoven can confer mechanical stability to the tufted carpet. Typically, the tufted carpet has a base weight between 500 to 1500 g/m². Preferably, the average diameter of the PET filaments of the is between 1 to 15 dtex, more preferably 3 to 12 dtex. It was found that primary backings from filaments having such dimensions are suitable for a tufted carpet for automotive applications and molding.

In a preferred embodiment, the primary backing consists of the spunbond nonwoven. This is advantageous, because the primary backing has a simple and uniform structure and is easily available. Preferably, the spunbond nonwoven is in direct contact with the backloops of yarn. In another embodiment, the primary backing comprises at least one further layer, which can be positioned on the first surface and/or second surface of the spunbond nonwoven before tufting. For example, the spunbond nonwoven can be combined with other functional layers, such as further nonwovens.

Preferably, the primary backing consists of a spunbond nonwoven which comprises polyethylene terephthalate (PET) filaments and lower melting CoPET, wherein the spunbond nonwoven is thermobonded by the CoPET, wherein the spunbond nonwoven is further consolidated with thermoset binder which is at least partially crosslinked.

In a preferred embodiment, all fibers of the primary backing and/or tufted carpet are polyester fibers (including copolyester fibers). This is advantageous, because the primary backing can be highly uniform and stable. Especially, it is preferred that the primary backing does not comprise polyolefins, such as polyethylene or polypropylene, and especially not polyolefin fibers. This is advantageous for thermal stability, because polyolefins have low melting temperature. In an embodiment, the primary backing and/or tufted carpet do not comprise non-melting fibers, such as viscose fibers.

In a preferred embodiment, the tufted carpet comprises a back coating on the second surface of the spunbond nonwoven, which is applied after thermobonding the backloops of yarn. In a preferred embodiment, a secondary backing is adhered to the back coating. Preferably, the back coating and/or secondary coating are from SBR, natural latex, polyethylene, ethylene vinyl acetate or mixtures thereof. Back coatings can be used for covering the thermobonded backloops of yarn and/or conferring desired properties to the tufted carpet.

A method for preparing the tufted carpet according to the present disclosure is provided, the method comprising the steps of:

• • providing a spunbond nonwoven which comprises PET filaments and a lower melting polymer material which is a filament forming material, wherein the spunbond nonwoven is thermobonded by the lower melting polymer material, wherein the spunbond nonwoven is further consolidated with a binder,
  • sewing tufts of yarn through the spunbond nonwoven, such that the piles of yarn are on a first surface and the backloops of yarn are on a second surface of the spunbond nonwoven, and
  • thermobonding the backloops of yarn on the second surface.

Steps (a) to (c) are carried out in consecutive order. In step (b), the tufts of yarn are sewn through the stack in a conventional manner, typically with needles in a tufting device. Depending on the intended use, the piles of yarn on the front side can be opened or can remain closed loops.

For thermobonding step (c), the second surface of the spunbond nonwoven with the backloops of yarn is contacted with a hot surface, preferably a hot roll. Methods and devices for thermobonding tufted carpeting are commercially available and known in the art, for example from EP 1 598 476 A1. Typically, the contact time with the hot surface is short, such that the carpet is heated on the bottom side, whilst heat transfer to the other side is limited. Typically, the contact time between the hot roll and the surface is less than one minute, for example between 1 to 30 seconds. In a preferred embodiment, the thermobonding in step (c) is carried out at a temperature of at least 250° C., preferably at least 250° C. or at least 260° C., or even about 262 to 263° C.; preferably between 250° C. and 263° C. Such high temperatures are suitable for bonding tufted carpets with PET yarns. The thermobonding temperature is adjusted such that the primary backing is not damaged.

In a preferred embodiment, the binder is crosslinked in thermobonding step (c). In this regard, the binder in the consolidated spunbond nonwoven, which is initially provided in step (a), can not be crosslinked at all, or can already be partially crosslinked. During thermobonding, this consolidated binder can be crosslinked or further crosslinked, preferably until crosslinking is completed. Surprisingly, it was found that the protective effect of the binder on the spunbond nonwoven can be improved, when crosslinking of the binder occurs during thermobonding. Without being bound to theory, it is assumed that this is because binder crosslinking is an endothermic reaction. Accordingly, the spunbond material can be cooled to a certain degree, when crosslinking occurs during thermobonding. At the same time, the crosslinking confers additional stability to the binder and product. Especially at sites, where the binder is in contact with softened PET from yarn backloops, an intimate bonded structure can be formed.

Preferably, the tufted yarns are not bonded to the primary backing with an additional adhesive (different from the binder). This is not required, because the tufts of yarn are thermobonded in step (c).

Preferably, the spunbond nonwoven, which is provided in step (a), is prepared by preceding steps, or has been prepared by preceding steps, which are:

• • (a1) providing a spunbond nonwoven which comprises PET filaments and a lower melting polymer material which is a filament forming material, wherein the spunbond nonwoven is thermobonded by the lower melting polymer material, and
  • (a2) applying the binder to the spunbond nonwoven and consolidating the binder.

In step (a2), the binder is applied. The binder can be applied by known means, such as impregnation or coating. Typically, the binder is applied in the form of a binder composition, for example an aqueous binder emulsion or dispersion. The binder composition can comprise additives, for example a dispersant, crosslinker or catalyst. In a preferred embodiment, the binder is applied by coating onto the second surface of the spunbond nonwoven. This can be advantageous, because the binder concentration at the second surface becomes relatively high. Thereby, the binder can protect the spunbond nonwoven materials more effectively from the heat applied during thermobonding. In another embodiment, the nonwoven is impregnated uniformly with the binder, which can be advantageous for uniform protection and stability.

Further in step (a2), the binder is consolidated. This means that the binder is solidified, such that it bonds the filaments. The consolidation comprises drying, if the binder composition comprised a solvent.

Preferably, during or after step (a2) the binder is partially crosslinked or fully crosslinked. Preferably, the binder is crosslinked by heating. For example, the degree of crosslinking can be controlled be adjusting the temperature, heating time, amount of catalyst and/or crosslinker. Also other crosslinking means can be used, such as UV radiation. As outlined above, crosslinking can be advantageous, because the spunbond nonwoven can be stabilized. Moreover, partial crosslinking can be advantageously, because during thermobonding the binder can be crosslinked further and/or completely, thereby supporting the protective effect for the spunbond material.

A shaped part is provided, which comprises at molded tufted carpet as defined above. A method for preparing the shaped part is also provided, the method comprising the steps of:

• • providing a tufted carpet as defined above, and
  • molding the tufted carpet.

The term “shaped part” refers to an object having a defined three dimensional structure, which is purposefully conferred to it. Typically, the shaped part can maintain its structure in the absence of an external force. The tufted carpet can be provided in step (A) in a size and form which corresponds to the dimensions of the shaped part. Typically, the tufted carped is cut to a piece of defined dimensions. Step (B) is carried out in a molding device under sufficient heat and pressure, thereby conferring the desired shape to the tufted carpet. When the molded part is allowed to cool, the thermoplastic components solidify and the shaped part is obtained. If desired, the form of the shaped part can be adapted subsequently, for example by cutting. Typically, the shape of the part is adapted to the intended used, for example such that it fits into an automotive interior structure. The tufted carpet or shaped part can be provided for common applications, especially for the automotive industry, for example for vehicle floor systems, carpets, ceiling parts, panels, covers or acoustic absorbers.

Use of a primary backing comprising a spunbond nonwoven as outlined above is also provided, which is further consolidated with the binder; for preparing a tufted carpet in a thermobonding process. For the shaped part and use, the features and embodiments can be selected as outlined above for the tufted carpet and method.

EXAMPLES

Examples 1 to 3: Preparation of Spunbond Nonwovens

The spunbond nonwovens were prepared from monocomponent PET filaments and monocomponent copolyester filaments as known in the art. Polyester and copolyester are separately molten in an extruder, pressed through a spin pack with holes and the resulting polyester filaments and copolyester filaments are cooled down in the spinning channel (secondary air temperature 29° C., secondary air pressure 16 mbar) and drawn by tertiary air, before they are laid down on the conveyor belt. The resulting material is pre-bonded by a calendar and thermobonded in an air-through dryer before it is wound up.

Example 1

Preparation of PET/CoPET spunbond nonwoven: 92% PET [melting point (mp) 256° C.] and 8% CoPET (mp 192° C.) with normal fiber drawing (tertiary air pressure 1.04 bar). Base weight: 110 g/m²

Example 2

Preparation of PET/CoPET spunbond nonwoven: 92% PET (mp 259° C.) and 8% CoPET (mp 220° C.) with normal fiber drawing (tertiary air pressure 1.04 bar). Base weight: 110 g/m²

Example 3

Preparation of PET/CoPET spunbond nonwoven: 92% PET masterbatch comprising 99% polyester and 1% thermostability additive based on copolyester and 8% CoPET with higher fiber drawing. Base weight: 110 g/m²

Examples 4 to 7: Consolidation with Binder

Example 4

The 1 m wide material of example 2 was treated with a self-crosslinking styrene acrylic binder dispersion with a solids content of 2%, in an impregnation foulard device with the pressure of 10.000 N, and then dried for 1.5 minutes at 120° C. and crosslinked for 1.5 minutes at 150° C. Resulting base weight: 116 g/m².

Example 5

The 1 m wide material of example 4 was treated with a self-crosslinking styrene acrylic binder dispersion with a solids content of 2%, containing 1% alcohol polyglycol ether nonionic surfactant, in an impregnation foulard device with the pressure of 1.000 N, and then dried for 1.5 minutes at 120° C. and crosslinked for 1.5 minutes at 150° C. Resulting base weight: 116 g/m².

Example 6

The 50 cm wide material of example 2 was coated with a self-crosslinking styrene acrylic binder dispersion with a solids content of 3% through a 50 cm wide slot die with a 50 μm template and 200 μm slot, with a throughput of 350 ml/min and a line speed of 4.0 m/min. The material is then dried in an air-through dryer at 120° C. for 45 seconds and crosslinked at 160° C. for 45 seconds. Resulting base weight: 116 g/m²

Example 7

The 50 cm wide material of example 4 was coated with a self-crosslinking styrene acrylic binder dispersion with a solids content of 3% through a 50 cm wide slot die with a 50 μm template and 200 μm slot, with a throughput of 350 ml/min and a line speed of 4.0 m/min. The material is then dried in an air-through dryer at 120° C. for 45 seconds and crosslinked at 160° C. for 45 seconds. Resulting base weight: 116 g/m².

Example 8: Preparation of Tufted Carpets

Tufted carpets were prepared from primary backings of above-mentioned examples 1 to 7 by tufting PET yarn on a Penhill sample tufting machine under the following conditions into the described backings: 1080D 120F BCF PET yarn, 56 stitches per 10 cm, 1/10 ″ gauge cut-pile, 5 mm pile height and 400 g/m². Subsequently the backstitch sides of the materials were lead 20 seconds over the surface of a heated roll having a surface temperature of 258° C. for thermobonding the yarn backstitches into the backing. The backstitches were bound sufficiently into the material.

Examples 9 to 16: Preparation of Shaped Parts and Examination of Properties

Shaped parts were prepared from the thermobonded tufted carpets of example 8 above by molding and the mechanical properties were examined. The samples were prepared by the following procedure:

In a Benz coating line, at a line speed of 0.275 m/min, the backstitch sides of the tufted carpets were strayed with 300 g/m² polyethylene powder (trademark Schaetti Fix 140), heated by an IR field to 160° C., fed with a second nonwoven layer (30 g/m², polyester spunbond), pressed in a calender to 1.4 bar and then dried in the oven at 120° C.

Round samples with a diameter of 24 cm were cut out and placed in a clamping device with the back stitch facing upwards. The samples were heated by an IR field to 180° C. and then pressed into a hollow, water cooled brass sphere with a diameter of 10 cm and a temperature of 18° C. at a speed of 50 mm/seconds.

The mechanical properties of the samples were examined. The maximum force (N) at breakage of the material, the deformation path (cm) at breakage of the material and the force (N) at 9 cm deformation path were detected. The force at a deformation at 9 cm is a good measure for moldability.

The results are summarized in table 1. All samples with acrylic binder (examples 12 to 15 according to the present disclosure) have a significantly higher force at 9 cm, and also higher maximum force, than samples 9 to 11 without acrylic binder. The results show that the tufted carpeting according to the present disclosure can advantageously be used for preparing molded shaped parts.

While subject matter of the present disclosure has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive. Any statement made herein characterizing the invention is also to be considered illustrative or exemplary and not restrictive as the invention is defined by the claims. It will be understood that changes and modifications may be made, by those of ordinary skill in the art, within the scope of the following claims, which may include any combination of features from different embodiments described above.

The terms used in the claims should be construed to have the broadest reasonable interpretation consistent with the foregoing description. For example, the use of the article “a” or “the” in introducing an element should not be interpreted as being exclusive of a plurality of elements. Likewise, the recitation of “or” should be interpreted as being inclusive, such that the recitation of “A or B” is not exclusive of “A and B,” unless it is clear from the context or the foregoing description that only one of A and B is intended. Further, the recitation of “at least one of A, B and C” should be interpreted as one or more of a group of elements consisting of A, B and C, and should not be interpreted as requiring at least one of each of the listed elements A, B and C, regardless of whether A, B and C are related as categories or otherwise. Moreover, the recitation of “A, B and/or C” or “at least one of A, B or C” should be interpreted as including any singular entity from the listed elements, e.g., A, any subset from the listed elements, e.g., A and B, or the entire list of elements A, B and C.