Method for manufacturing a textile product, textile product and recycling process

Abstract

The present invention relates to a method for manufacturing a textile product (P), in particular for use as a floor covering and / or as a sound-insulating covering, comprising the steps of: a) providing a first layer (10) with yarns (G) attached thereto, wherein the first layer (10) has a first surface and a second surface, the yarns (G) extending at least from the first surface; b) applying a first layer of a first hot-melt adhesive (16) to the second surface; c) applying at least one intermediate layer (12) to the first layer (16); d) applying at least one second layer of a second hot-melt adhesive (18) to the intermediate layer (12); and e) applying a carrier layer (14) to the second layer (18). The intermediate layer (12) has a lower basis mass than the carrier layer (14) and is thinner than the carrier layer (14).

Description

[0001] The present disclosure relates to a process for manufacturing a textile product, in particular for use as a floor covering and / or as a sound insulation covering, and further relates to a textile product and processes for recycling such a textile product.

[0002] In general, this disclosure relates to the field of textile surfaces and textile composites, in particular textile floor coverings. The disclosure further relates to the field of recyclable textiles and plastic composites.

[0003] Textile products used as floor coverings (e.g., carpets) are typically manufactured by sewing yarn onto a primary material to form a primary, yarn-bearing layer with yarn tufts protruding from its surface. This yarn-bearing layer is usually impregnated with a latex made from a crosslinkable polymer. After the latex polymer is impregnated into the product, it crosslinks to permanently anchor the yarn tufts. The combination of yarn, primary material, and latex has historically often been referred to as a primary layer (also called a primary backing and / or primary mat).

[0004] To improve the mechanical properties such as the dimensional stability of the resulting textile product, a secondary layer made of a carrier material (also referred to as secondary layer and / or support layer in the prior art) was used, which is usually glued to the back of the primary layer to obtain a laminated textile product with the desired properties.

[0005] Hot melt adhesive (HMA) was used to bond the primary and secondary layers in roll carpets because hot melt adhesives are relatively inexpensive and readily available.

[0006] Typically, the primary layer, the secondary layer, and the adhesive bonding them are made of very different materials with different mechanical properties, as they are designed for different functions.

[0007] Using crosslinkable latex to create the primary layer has several disadvantages. If the latex polymer is water-based, the textile product may have low water resistance, allowing moisture to penetrate. This increases the risk of mold and mildew growth, which can lead to a deterioration of product quality. Furthermore, residual monomer traces, often present in latex polymers, can also affect air quality, posing an environmental hazard. Therefore, if a latex-based floor covering is exposed to high humidity, such as in entryways or bathrooms, it may need to be replaced frequently.

[0008] Alternatively, if the latex is a hydrophobic polymer dispersed in water with surfactants, the presence of surfactants can increase the product's sensitivity to moisture. Some types of latex may contain styrene (e.g., as styrene-butadiene rubber (SBR)), which can lead to undesirably high residual styrene levels in the product. However, for environmental and other reasons, it is desirable to keep the amount of volatile organic compounds (VOCs) in textile products as low as possible.

[0009] Because latex textile products use different materials for the primary and secondary layers, these components must be separated for reuse. However, the yarn and the primary material are firmly embedded in the chemically cross-linked (e.g., vulcanized) latex adhesive. Therefore, the primary layer components in a latex-based textile product are not easily separated. Although some recovery technologies have been developed to address some of these issues, these processes are expensive and do not allow for the complete recovery of all materials used. Consequently, recycling latex-based textile floor coverings is not practical, and they are simply disposed of, incinerated, or shredded.Shredded floor coverings are usually disposed of in landfills, and since the cross-linked latex is not widely biodegradable, the shredded remains will be present for many years to come.

[0010] To solve some of these problems, various synthetic polymers such as polyolefins and polyurethanes have been developed to replace latex polymers in textile products. However, these substitutes are not entirely satisfactory.

[0011] Document EP 3 008 238 B1 discloses a textile product comprising: A) a first layer with yarns attached to it by (i) a first fastener, wherein the first layer has a first surface and a second surface and the yarns extend at least from the first surface of the first layer; and (ii) a second fastener, wherein the yarns have been at least partially fused to the first layer and / or to each other, optionally by heat and / or pressure; (iii) a third fastener, wherein the third fastener is a hot melt adhesive (HMA) with a viscosity of less than or equal to 500 Pa.s at 150 °C and a melting point below that of all other components of the product, which is substantially located on the second surface of the first layer; B) optionally a dimensionally accurate second layer attached to the second surface of the first layer, optionally by the hot melt adhesive; with the provisos that, if the second layer is omitted, the HMA (component (I) (iii)) comprises substantially unembedded HMA and preferably consists thereof; wherein in the second fastener (component (I) (ii)) the yarns have been at least partially fused to the first layer and / or to each other by a mechanical force applied to a molten fraction of the yarns in a direction parallel to the surface of the first layer; wherein the first layer and the second layer (if present) do not exceed 20 wt.-% of the total amount of HMA present in the textile product are embedded in these layers and this yarn and wherein the hot melt adhesive comprises a polymer P in an amount of at least 50 wt.% of the hot melt adhesive composition, and wherein the polymer P is a polyester, wherein the polymer P is semi-crystalline and has a melting point of 40 to 200 °C, a glass transition temperature below 50 °C and a melt viscosity at 150 °C of less than 500 Pa.s.

[0012] State-of-the-art textile products often lack sufficient dimensional stability. Dimensional stability refers to the ability of textile products to maintain their dimensions even under conditions such as elevated temperatures, humidity, or mechanical stress. Dimensional stability is particularly important for carpet tiles. If a carpet tile changes in length or width, gaps will appear between the layers after installation. If only one layer of the fibers changes, this can lead to a change in the tile's flatness, resulting in warping or cupping. Both of these conditions can create tripping hazards when using the carpet.

[0013] On the other hand, the polymers used in textile products generally differ in terms of abrasion resistance, resilience, and recyclability. However, polymers with these properties do not necessarily also have the best dimensional stability.

[0014] Against this background, it is an object of the invention to provide an improved method for manufacturing a textile product, an improved textile product and an improved method for recycling a textile product.

[0015] This problem is solved by a method for manufacturing a textile product with the features of claim 1, in particular for use as a floor covering and / or as a sound insulation covering, comprising the steps of: a) Providing a first layer with yarns attached to it, the first layer having a first surface and a second surface, the yarns extending at least from the first surface; b) Applying a first layer of a first hot melt adhesive to the second surface; c) Applying at least one intermediate layer to the first layer or to the second surface; d) Applying at least one second layer of a second hot-melt adhesive to the intermediate layer or to the second surface; and e) Applying a carrier layer to the second layer or to the second surface, wherein the intermediate layer has a lower surface mass than the carrier layer, and wherein the intermediate layer is thinner than the carrier layer.

[0016] Furthermore, the above problem is solved by a method for manufacturing a textile product with features of claim 2, comprising the steps: a) Providing a first layer with yarns attached to it, the first layer having a first surface and a second surface, the yarns extending at least from the first surface; b) Applying a first layer of a first hot melt adhesive to the second surface; c) Applying at least one intermediate layer to the first layer; d) Applying at least one second layer of a second hot-melt adhesive to the intermediate layer; and e) Applying a carrier layer to the second layer, wherein the intermediate layer has a lower basis mass than the carrier layer, wherein the intermediate layer is thinner than the carrier layer, and wherein the intermediate layer has a basis mass of greater than or equal to 80 g / m² 2 and of less than or equal to 300 g / m² 2 , preferably greater than 100 g / m² 2 and down to less than 180 g / m² 2 exhibits.

[0017] Furthermore, the above problem is solved by a method for manufacturing a textile product with the features of claim 3, comprising the steps: a) Providing a first layer with yarns attached to it, the first layer having a first surface and a second surface, the yarns extending at least from the first surface; b) Applying a first layer of a first hot melt adhesive to the second surface; c) Applying at least one intermediate layer to the first layer; d) Applying at least one second layer of a second hot-melt adhesive to the intermediate layer; and e) Applying a carrier layer to the second layer, wherein the intermediate layer has a lower basis mass than the carrier layer, wherein the intermediate layer is thinner than the carrier layer, and wherein the intermediate layer has a thickness of less than or equal to 3 mm and greater than or equal to 0.5 mm, and / or wherein the intermediate layer has a density of greater than or equal to 0.120 g / m³ 3 and less than or equal to 0.320 g / m² 3 exhibits.

[0018] Furthermore, the above task is solved by a textile product, in particular in the form of a floor covering or a sound-insulating covering, with: - a first layer with yarns attached to it, the first layer having a first surface and a second surface, the yarns extending at least from the first surface; - an interlayer having a first interlayer surface and a second interlayer surface, wherein the first interlayer surface is bonded to the second surface of the first layer by means of a first hot-melt adhesive; and - a carrier layer having a first carrier layer surface and a second carrier layer surface, wherein the first carrier layer surface is connected to the second intermediate layer surface by means of a second hot melt adhesive, wherein the intermediate layer has a lower surface mass than the carrier layer, and wherein the intermediate layer is thinner than the carrier layer.

[0019] Preferably, the textile product, in particular in the form of a floor covering or a sound insulation covering, is provided by a method for manufacturing a textile product having the features of one or more of claims 1, 2 or 3, or of the dependent claims thereof.

[0020] Furthermore, the above problem is solved by a method for recycling a textile product according to claim 14, comprising the steps of: providing a used textile product of the type specified above; heating the first hot melt adhesive so that the interlayer can be separated from the first layer; and / or heating the second hot melt adhesive so that the carrier layer can be separated from the interlayer; and removing the first layer from the interlayer in order to recycle the interlayer and / or the first layer; and / or removing the carrier layer from the interlayer in order to recycle the carrier layer and / or the interlayer.

[0021] Furthermore, the above problem is solved by a method for recycling a textile product according to claim 15, comprising the steps of: providing a used textile product of the type specified above; heating the used textile product as a whole, thereby melting the polymer contained in the yarns, the first layer, the first hot melt adhesive, the intermediate layer, the second hot melt adhesive and the carrier layer; and reusing the polymer obtained.

[0022] Furthermore, the above problem according to claim 11 is achieved by using a nonwoven fabric or woven fabric with a basis weight of greater than or equal to 80 g / m². 2 up to and including 300 g / m² 2 as an intermediate layer in a textile floor covering.

[0023] Furthermore, the above problem according to claim 16 is solved by using a textile product of the type mentioned above as a floor covering.

[0024] The above problem according to claim 17 is also solved by a method for applying a textile product to a floor, comprising the steps of: applying a textile product of the type specified above to a floor and attaching the textile product to the floor.

[0025] Finally, the above problem according to claim 18 is solved by a floor which is covered with a textile product of the type specified above and / or which is obtained and / or available by means of a manufacturing process of the type described above.

[0026] The textile product is, in particular, a flat textile product, especially a plastic textile product. As a floor covering, the textile product can be in the form of a carpet, a tile, or a mat.

[0027] The first layer is, for example, a tufted layer, meaning a layer where the yarns are inserted into a base layer, such as needle felt, creating a loop or a cut pile. These loops or piles form the top layer (first surface), which is visible and comes into contact with the fabric. The tufted layer formed from the base layer and yarns then constitutes the first layer.

[0028] The first layer can, for example, also be a woven (woven / knitted) layer, meaning a layer in which yarns are interwoven in a structurally fixed arrangement. Weaving is achieved by crossing warp threads (lengthwise threads) and weft threads (crosswise threads), which are joined together to form a firm fabric.

[0029] The first surface of the first layer is preferably a pile side. The second surface of the first layer is preferably a back side. The first hot-melt adhesive is applied to the second surface preferably at a temperature lower than the melting point of the yarns.

[0030] The step of applying the first layer of the first hot melt adhesive to the second surface of the first layer and the application of at least one intermediate layer to the second surface can be carried out in a single step or sequentially.

[0031] The second hot melt adhesive, which is applied to the second surface, in particular to a surface of the intermediate layer, is preferably the same hot melt adhesive as the first hot melt adhesive.

[0032] The step of applying at least one second layer of a second hot melt adhesive and applying a carrier layer can be carried out in one step or can be carried out one after the other.

[0033] The steps of applying at least one intermediate layer to the second surface and applying at least one second layer of the second hot-melt adhesive can be repeated several times, if necessary, so that a plurality of intermediate layers are arranged between the first layer and the carrier layer. Preferably, however, exactly one single intermediate layer is arranged between the first layer and the carrier layer.

[0034] The term "application to the second surface" generally refers to application to one side of the second surface, with something possibly placed between them. For example, the application of the at least one intermediate layer to the second surface is preferably carried out by applying the intermediate layer to the first hot-melt adhesive. Similarly, the application of the carrier layer to the second surface is preferably carried out by applying the carrier layer to the second layer of the second hot-melt adhesive, which in turn is applied to the intermediate layer.

[0035] According to the invention, the intermediate layer has a lower surface mass than the supporting layer. The surface mass of a layer is the mass or weight of the respective layer per square meter. 2This can also be referred to as basis weight or area-related mass. To determine it, a square meter of the interlayer material is typically weighed to ascertain the weight in grams. This weight is then extrapolated to the area.

[0036] In a preferred embodiment, the surface mass or weight is measured in accordance with the DIN test standard EN29073-1 or the DIN test standard EN ISO 9073-1:2023-09.

[0037] In general, with a multi-layered structure, the surface mass is greater the further the assigned layer is from the second surface of the first layer.

[0038] According to the invention, the intermediate layer is thinner than the backing layer. The thickness of the intermediate layer, the first layer, and the backing layer, or of fabric layers for use in flooring in general, is measured using a special thickness gauge. This device typically consists of a flat pressure plate and a measuring pin or sensor that precisely measures the thickness of the layer between these two points. The pressure plate exerts a defined force on the carpet tile to ensure that the measurement is consistent and reproducible. A pressure of 2 kPa is typically used to minimize the impact on the textile material. Before measurement, the layers are stored in a controlled environment to ensure that temperature and humidity do not affect the measurements. A commonly used condition is a relative humidity of 65% and a temperature of 20°C.To determine an accurate and representative thickness, several measurements are taken at various points on the layer, typically at the corners and in the middle. The average of these measurements is then considered the layer thickness.

[0039] The thickness measurement of a layer, here e.g. the intermediate layer, the first layer and the support layer, is preferably carried out in accordance with the DIN test standard DIN EN ISO 9073-2, wherein a load of 0.5 kPa is preferably applied when measuring the intermediate layer, and a load of 2.0 kPa is preferably applied when measuring the first layer or support layer.

[0040] Preferably, the thickness measurement of the finished textile product is carried out in accordance with the DIN test standard ISO 1765 or ASTM D6859.

[0041] The intermediate layer and the backing layer are both dimensionally stable, and their combination can significantly improve the dimensional stability of the finished textile product, especially in conjunction with the hot-melt adhesives used. It is assumed that the use of a relatively thin intermediate layer and its bonding to the product with hot-melt adhesive on both sides is what creates the high dimensional stability. Furthermore, warping of carpet tiles is prevented or reduced. Overall, this also results in greater resilience against bending, which is particularly beneficial when laying the carpet or carpet tiles.

[0042] The task is thus completely solved.

[0043] In one embodiment, it is preferred if the intermediate layer has a surface mass greater than or equal to 80 g / m². 2 and / or of less than or equal to 300 g / m² 2 , preferably of 100 g / m² 2, and / or less than or equal to 300 g / m² 2 on, especially of greater than or equal to 115 g / m² 2 and of less than or equal to 200 g / m² 2 It is particularly preferred if the intermediate layer has a basis weight of greater than or equal to 120 g / m². 2 up to and including 170 g / m² 2 has a density of preferably about 140 g / m² 2 , 150 g / m 2 , or 160 g / m² 2 .

[0044] Furthermore, in one embodiment it is preferred if the intermediate layer has a thickness that is preferably greater than or equal to 0.5 mm and less than or equal to 3 mm, and preferably greater than or equal to 0.5 mm and less than or equal to 1.5 mm, more preferably greater than or equal to 0.9 mm and less than or equal to 1.3 mm, and preferably 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm or 0.9 mm.

[0045] According to preferred embodiments, the intermediate layer has a basis mass of greater than or equal to 80 g / m². 2 and of less than or equal to 300 g / m² 2, in particular a surface mass in the range of greater than or equal to 120 g / m² 2 up to and including 170 g / m² 2 , preferably of 140 g / m² 2 , 150 g / m 2 , or 160 g / m² 2 , and a thickness that is preferably less than or equal to 3 mm and greater than or equal to 0.5 mm, in particular less than or equal to 2 mm and greater than or equal to 0.6 mm, and preferably less than or equal to 1.5 mm and greater than or equal to 0.6 mm, more preferably less than or equal to 1.3 mm and greater than or equal to 0.9 mm, and preferably 1.3 mm, 1.2 mm, 1.1 mm, 1.0 mm or 0.9 mm.

[0046] In a preferred embodiment, particularly in combination with the above-mentioned areas with regard to the areal mass and thickness of the intermediate layer, the areal mass of the carrier layer is in a range of greater than or equal to 400 g / m². 2 up to and including 900 g / m² 2 , especially in a range of greater than or equal to 500 g / m² 2up to and including 800 g / m² 2 , of particular advantage in a range of greater than or equal to 600 g / m² 2 up to and including 700 g / m² 2 .

[0047] In a preferred embodiment, particularly in combination with the above-mentioned areas relating to the areal mass and thickness of the intermediate layer, as well as relating to the aforementioned areas relating to the areal mass of the support layer, the support layer has a thickness of greater than or equal to 0.6 mm to less than or equal to 5 mm, preferably greater than or equal to 0.6 mm to less than or equal to 4 mm, further preferably greater than or equal to 0.9 mm to less than or equal to 4 mm, and further preferably greater than or equal to 1 mm to less than or equal to 3 mm.

[0048] According to a preferred embodiment, the intermediate layer has a density greater than or equal to (≥) 0.120 g / m². 3 and less than or equal to (≤) 0.320 g / m² 3 Preferably, the intermediate layer has a density greater than or equal to 0.150 g / m². 3 and less than or equal to 0.180 g / m²3 , especially greater than or equal to 0.160 g / m² 3 and less than or equal to 0.170 g / m² 3 , and preferably about 0.165 g / m³ 3 .

[0049] The density of a (material) layer, such as the intermediate layer in this case, refers to the amount of material contained in a specific unit volume and is also called volume density. The volume density of a (material) layer is the ratio of mass to volume, measured in grams per cubic meter (kg / m³). 3 This measurement takes into account not only the basis weight but also the thickness of the material. To measure this, the basis weight / mass (in g / m²) is first determined. 2 ) (see above) and the thickness of the carpet (see below) in mm. The volume of the layer per square meter is calculated by dividing the basis weight by the thickness of the material. The volume density is then given as: Volume density (g / m³) 3) = basis weight (g / m²) 2 ): Thickness (m).

[0050] In a particularly preferred embodiment, the intermediate layer has a basis mass of greater than or equal to 140 g / m². 2 and less than or equal to 160 g / m² 2 , especially 140 g / m² 2 , 150 g / m 2 , or 160 g / m² 2 , and a thickness of approximately 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, or 1.3 mm. Thus, the intermediate layer, with a basis weight of 150 g / m², 2 and a thickness of 1.1 mm, in a preferred embodiment, a density of 0.165 g / m³ 3 In this context, "approximately" means that at least on the one hand, the specified numbers are included or meant, and on the other hand, the numerical values ​​immediately adjacent within usual measurement tolerances are meant, especially those in the decimal range.

[0051] In the second aspect of the disclosed process, the intermediate layer comprises or is formed by a nonwoven fabric or a woven fabric.

[0052] A nonwoven fabric is a material made up of fibers held together by chemical, mechanical, adhesive, or fusion agents. Generally, a nonwoven fabric can be any type of layer produced by a process other than weaving.

[0053] Woven fabrics consist of interwoven warp and weft threads. Nonwovens are produced by mechanically, chemically, or thermally felting fibers, without interweaving them as in woven fabrics. Materials used for nonwovens include, for example, synthetic fibers such as polyester and polyamide, or specialty fibers such as glass fibers; the material can also be recycled.

[0054] In a preferred embodiment, the nonwoven material of the interlayer is a mechanically and thermally bonded fiber nonwoven, made from fibers with a melt fiber content.

[0055] The use of a nonwoven fabric with a basis weight of greater than or equal to 80 g / m² 2 up to 300 g / m² 2 An intermediate layer, optionally with a thickness preferably less than or equal to 3 mm and greater than or equal to 0.5 mm, used as an interlayer in a textile covering, is considered a separate invention. In this context, its use as an interlayer means that the interlayer is not exposed on either the pile side or the back. Preferably, the interlayer is in contact with another layer of the textile covering on both of its surfaces, most preferably via an adhesive layer in the form of a hot-melt adhesive.

[0056] In a preferred embodiment, a nonwoven fabric is used as an intermediate layer, having a thickness of less than or equal to 1.3 mm and greater than or equal to 0.9 mm, in particular about 1.1 mm, and a basis weight of greater than or equal to 130 g / m². 2 and less than or equal to 160 g / m² 2 , especially of greater than or equal to 140 g / m² 2 and less than or equal to 160 g / m² 2 , especially of about 140 g / m² 2 , 150 g / m 2 , or 160 g / m² 2 , especially of about 150 g / m² 2 Optionally, this intermediate layer has a density greater than or equal to 0.160 g / m². 3 and less than or equal to 0.170 g / m² 3 , in particular about 0.165 g / m³ 3 .

[0057] In a preferred embodiment, the nonwoven material of the interlayer is made of 100% polyester (PES) including melt fiber content.

[0058] Accordingly, in a further preferred embodiment, the nonwoven fabric of the interlayer is made of 100% PES and has a thickness of less than or equal to 1.3 mm and greater than or equal to 0.9 mm, in particular of about 1.1 mm, and a basis weight of greater than or equal to 140 g / m². 2 and less than or equal to 160 g / m² 2 , especially of about 140 g / m² 2 , 150 g / m 2 , or 160 g / m² 2 , especially of about 150 g / m² 2 ; wherein preferably the first layer, the carrier layer and the hot melt adhesive also consist of 100% PES; wherein preferably the carrier layer has a basis weight of greater than or equal to 600 g / m² 2 up to and including 700 g / m² 2having a thickness of greater than or equal to 1 mm to less than or equal to 4 mm (inclusive in each case), and further preferably the first layer having a thickness in the range of greater than or equal to 3.5 mm to less than or equal to 30 mm, and a basis weight in the range of greater than or equal to 450 g / m² 2 up to and including 3,000 g / m² 2 lies.

[0059] The first hot-melt adhesive is preferably applied with a thickness of 1.5 mm or less, preferably 1 mm or less, and preferably 0.5 mm or less. Similarly, the second hot-melt adhesive is applied or provided as a layer with a thickness of 1.5 mm or less, preferably 1 mm or less, and preferably 0.5 mm or less. The layer of the first hot-melt adhesive and / or the second hot-melt adhesive is preferably provided with a thickness greater than 0.1 mm, particularly in the range of 0.2 mm to 1.5 mm.

[0060] Generally, the first hot-melt adhesive has a lower melting point than the yarn and the first layer. The second hot-melt adhesive preferably has a lower melting point than the intermediate layer and the carrier layer. The term melting point can be understood synonymously with melting range.

[0061] In the disclosed manufacturing process, it is particularly advantageous if the first layer, the intermediate layer, and the carrier layer, and optionally also the yarns, are made of mutually compatible thermoplastic materials, preferably each of the same polymer R. Mutually compatible thermoplastic materials preferably comprise thermoplastic-containing materials, preferably materials consisting of thermoplastics, which do not substantially penetrate the first hot melt adhesive layer and / or the second hot melt adhesive layer and do not mix with the material of another layer. The polymers of the first layer, the intermediate layer, and the carrier layer, and optionally also the yarns, therefore do not (or substantially do not) penetrate the polymers of the respective adjacent layers and can be separated from one another, particularly for recycling.

[0062] In one embodiment, it is preferred that the first layer, the intermediate layer, and the carrier layer, and optionally also the yarns, consist of a 100% thermoplastic flame-retardant (flame-resistant) material. To form a 100% flame-retardant material, e.g., 100% flame-retardant polyester, the commonly used material is made flame-retardant by adding additives, e.g., during polymerization, before extrusion, or as a coating. Examples of flame-resistant polyesters are Trevira CS®, Diolen® Safe, or Flamex® polyester yarns.

[0063] These measures may make it possible to recycle the textile product produced in this way, preferably by melting down the used textile product as a whole in order to reuse the polymer it contains.

[0064] It is particularly advantageous if the first layer, the intermediate layer and the carrier layer, and optionally also the yarns and / or optionally the hot melt adhesive, are essentially the same type of polymer.

[0065] According to a further preferred embodiment of the manufacturing process, the carrier layer comprises a nonwoven fabric having a basis weight of greater than or equal to 300 g / m². 2 and / or of less than or equal to 900 g / m² 2 exhibits.

[0066] In one embodiment, it is preferred if the first layer has a thickness in the range of greater than or equal to 3.5 mm to less than or equal to 30 mm, and a basis weight in the range of greater than or equal to 450 g / m². 2 up to and including 3,000 g / m² 2 lies.

[0067] It is understood that the dimensional specifications mentioned herein for the areas of the first layer, the intermediate layer and the support layer, in combination with each other, belong to the invention.

[0068] This provides a backing layer that offers good damping properties and dimensional stability. In a textile floor covering, the backing layer is typically the bottom layer, designed to bond to the subfloor.

[0069] Furthermore, in the manufacturing process it is advantageous if the first hot melt adhesive and / or the second hot melt adhesive has a thermoplastic material that has a lower melting point than the respective layer(s) to which it is applied.

[0070] If the respective hot melt adhesive is applied between two layers, these layers usually each have a higher melting point than the hot melt adhesive.

[0071] According to a further preferred embodiment, the respective layer onto which a hot melt adhesive is applied is first heated to a temperature that is higher than the melting point of the hot melt adhesive.

[0072] This results in good processability.

[0073] A hot melt adhesive can preferably be applied in a molten state at a temperature of 60 °C to 150 °C (inclusive), preferably in a range of 75 °C to 130 °C (inclusive), particularly at a viscosity of less than or equal to 500 Pa.s, preferably less than or equal to 200 Pa.s, at 150 °C and at a melting temperature in a range of 60 °C to 130 °C and / or at a crystallization temperature of 60 °C to 130 °C.

[0074] According to a preferred embodiment, the first layer, the intermediate layer and the carrier layer, and optionally also the yarns, and optionally also the first and / or second hot melt adhesive, are made of mutually compatible thermoplastic materials, preferably each of a polymer P, a polymer O and / or a polymer R.

[0075] The first layer is preferably made of a first plastic material, preferably of a polymer R. The yarns are preferably made of a compatible thermoplastic material, preferably also of a polymer R. The first layer can also be a needle felt.

[0076] In the provisioning step, the yarns are preferably first temporarily attached to the first layer and then bonded to the first layer under heat and / or pressure.

[0077] The yarn is preferably a plastic yarn, in particular a thermoplastic plastic yarn, preferably a polymer compatible with the polymer of the first layer, in particular a polymer R.

[0078] According to a further preferred embodiment, the first hot melt adhesive and / or the second hot melt adhesive comprises at least 50 wt.% of a polymer P.

[0079] In general, it is preferred if the polymer P is a polyester, whereby this term also includes copolyesters, if the polymer O is a polyolefin, and / or if the polymer R is a polyester, a polyamide, preferably polyamide 6 or polyamide 6.6.

[0080] The first hot melt adhesive and / or second hot melt adhesive may therefore, in particular, contain at least 50 wt% of a polyester, wherein optionally the polyester is semi-crystalline and has a melting point of 40 °C to 200 °C, measured according to the technical specifications, a glass transition temperature below 50 °C, measured according to the technical specifications, and a melt viscosity at 150 °C of less than or equal to 500 Pa·s, measured according to the technical specifications.

[0081] With regard to the technical specifications and the test procedures used, reference is made to the original disclosure of document EP 3 008 238 B1 in paragraphs

[0243] to

[0251] therein, the content of which is included here by reference.

[0082] The polymer P and / or the polymer R are each obtained independently by polycondensation, ring-opening polymerization of cyclic monomers (e.g., cyclic esters and / or cyclic amides) and / or a stepwise polymerization process and / or are recycled polycondensates.

[0083] Furthermore, it is advantageous if the polymer P, polymer O, or polymer R used for the yarn, the first layer, the carrier layer, the interlayer, and the hot-melt adhesive is essentially the same material. In other words, in one embodiment, it is preferred if the same polymer is used for the first layer (optionally including yarns), the carrier layer, the interlayer, and optionally the hot-melt adhesive—for example, for all of the aforementioned polyesters.

[0084] Furthermore, it is advantageous if any polymer P or R comprises one or more polymers and / or copolymers selected from the group consisting of: (Co)polyurethane(s); (Co)polycarbonate(s); (Co)polyester(s); (Co)polyamide(s); (Co)poly(esteramide)(s); mixtures thereof and / or copolymers thereof. The polymer P and / or the polymer R is a polycondensate.

[0085] It is particularly advantageous if all polymers in the textile product are a (co)polyester.

[0086] Polyamides, such as polyamide 6.6, and polyesters can already provide a comparatively high level of dimensional stability. Polyamide 6 is advantageous with regard to the required properties of carpet fibers, such as abrasion resistance, resilience, and recyclability.

[0087] However, due to the intermediate layer provided in the manufacturing process, the required dimensional stability can also be provided when polyamide 6 is used as polymer R.

[0088] In the manufacturing process, it is further preferred if the step of providing the first layer includes the following steps: heating the second surface of the first layer, thereby at least partially melting the yarns attached to the first layer in order to bond the yarns to the first layer; applying pressure to the second surface of the first layer; and exerting a mechanical force on the molten fraction of the yarns in a direction parallel to the second surface of the first layer.

[0089] In this embodiment, it is preferred if the yarns are first temporarily attached to the first layer before the step of heating the second surface, and if the yarns extend at least from the first surface, but preferably also from the second surface.

[0090] By heating the second surface and applying pressure and a mechanical force in a direction parallel to the second surface of the first layer, the second surface and the yarns attached to it are fused. The molten yarn mass is smeared and smoothed by the mechanical force parallel to the second surface.

[0091] Preferably, the pressing is carried out by a doctor blade and by establishing a relative speed between the doctor blade and the second surface. The doctor blade is preferably heated and simultaneously serves to heat the second surface of the first layer in order to at least partially melt the yarns attached to it, thus bonding the yarns to the first layer.

[0092] This type of first layer preparation creates a fiber binding, in which the yarns or fibers are mechanically locked to the first layer in such a way that they cannot simply be removed by pulling them by hand.

[0093] In this step, the second surface of the first layer can be fully or partially calendered, wherein adhesive is applied by applying molten hot melt adhesive to the calendered second surface of the first layer, and wherein the calendered second surface of the first layer has a temperature above the melting temperature of the hot melt adhesive when the adhesive is applied.

[0094] In the present disclosure, the following terms are used with the meanings given below.

[0095] A layer is generally a two-dimensional material and can include both cut pieces with finite dimensions and continuous films or webs fed from a roll. The layers are preferably flat.

[0096] In this context, reuse is understood to mean the same as a recycling process. This implies that at least individual components of a product are capable of being reused, reprocessed, and / or refurbished, in whole or in part, to produce new raw materials (for example, a polymer) that can then be used to manufacture other products, optionally other textile products, optionally other textile products such as floor coverings.

[0097] Calendering is a finishing process used to make a textile smooth and shiny, for example by pressing it with a roller, optionally also at high temperature.

[0098] Hot melt adhesives are thermoplastic adhesives designed to be melted, for example, heated (typically above a standard temperature) to transition from a solid to a liquid state, bonding or joining materials together after they solidify again. Hot melt adhesives are typically non-reactive and contain little or no solvents, so cross-linking or curing and drying are typically not necessary to provide adequate adhesion.

[0099] Melting means heating above a temperature at which the material reaches a state where it can flow under gravitational forces (for example, in the form of a liquid). Heat can be supplied using various energy sources, such as radiation, convection of hot material like steam or water, conduction through contact with a hot material, or by applying mechanical forces such as pressure, or by a combination of different energy sources.

[0100] A substrate with linear dimensions that do not change by more than 10% (preferably by no more than 7%, and preferably by no more than 5%) is considered dimensionally stable or dimensionally accurate if it is subjected to one or more of the following conditions: mechanical stress (such as walking on it) and other loads typical for floor coverings, e.g., a load of 80 kg / cm². 2for 24 hours), a variation in temperature (for example, exposure to a temperature of 0 °C to 160 °C for 24 hours); and / or a variation in humidity (for example, exposure to a relative humidity of 0% to 70% for up to 24 hours under standard conditions).

[0101] Regarding the measurement of dimensional stability, reference is made to DIN EN 986 (German version EN 986:2005), which is used to determine the dimensional change due to the effects of changing humidity and temperature conditions and vertical surface deformation of textile floor coverings.

[0102] A textile is a flexible material (typically woven) made from a network of natural or synthetic fibers, often referred to as yarn. Yarn is produced by spinning raw fibers to create long strands. Textiles can be manufactured by weaving, knitting, crocheting, knotting, or pressing fibers (felting). A textile product is a product made from a textile and other components such as backing layers, carrier materials, and / or adhesives, which serve, for example, to improve its mechanical and / or other properties. Examples of textile products include carpets, mats, runners, and the like. Mats and carpets are generally loose-laid floor coverings, while carpets (both wide woven carpets and tiles) are typically permanently affixed to the surface using methods such as nails, rods, or adhesives.

[0103] Further definitions of terms used herein can be found in the original disclosure of document EP 3 008 238 B1, specifically in paragraphs

[0193] to

[0242] , the contents of which are included here by reference.

[0104] In the disclosed recycling process, in which the intermediate layer is removed from the first layer and / or the carrier layer is removed from the intermediate layer, it is advantageous if the process includes heating the first and / or the second hot melt adhesive so that the respective layers can separate, and wherein the process further includes picking up the respective layers in separate streams and subsequently heating the separate streams further above their melting temperature to obtain a recycled polymer that can then be reused.

[0105] In the recycling process where the used textile product is heated as a whole, it is advantageous if the melting is carried out in one melting step and the process is carried out without a separation step between melting and reuse.

[0106] The textile product is preferably used as a floor covering and can be a polyester carpet tile.

[0107] The textile product is further applied and attached to a floor using a process for applying a textile product.

[0108] Furthermore, a floor is disclosed which is covered with a textile product of the type described above and / or is covered with a textile product obtained by the manufacturing process disclosed above.

[0109] Overall, it is advantageous that by providing the intermediate layer between the first layer and the support layer, a particularly high dimensional stability and a high restoring force against mechanical deformations in a direction transverse to the surface of the textile product are achieved.

[0110] Accordingly, the present disclosure further includes the use of a nonwoven fabric with a basis weight of greater than or equal to 80 g / m². 2 up to 300 g / m² 2 , preferably of 130 g / m² 2 , 140 g / m 2 , 150 g / m 2 , or 160 g / m² 2 , as an intermediate layer in a textile covering.

[0111] This means that the intermediate layer is not exposed to either the front or the back and that preferably both surfaces of the intermediate layer are bonded to their respective adjacent layers using a hot melt adhesive.

[0112] In particular, it is advantageous if a first interlayer surface of the interlayer is connected to a layer of the textile covering adjacent to the first interlayer surface via a first hot melt adhesive, and / or if a second interlayer surface of the interlayer is connected to a layer of the textile covering adjacent to the second interlayer surface via a second hot melt adhesive.

[0113] It is understood that the features mentioned above and those to be explained below can be used not only in the combinations specified, but also in other combinations or on their own, without leaving the scope of the present invention.

[0114] Exemplary embodiments of the invention are shown in the drawing and are explained in more detail in the following description. They show: Fig.1 a schematic cross-sectional view of a textile product; Fig. 2 A schematic cross-sectional view of a step for providing a first layer for the textile product of the Fig. 1; Fig. 3 diagrams for evaluating the dimensional stability (longitudinal and transverse) of exemplary textile products manufactured according to the invention, namely three different textile products with different intermediate layers according to the invention (A), and a comparison of a comparative example without an intermediate layer with a textile product with an intermediate layer according to the invention (B); and Fig. 4 the results of the test of the bending stiffness of a comparison product without an intermediate layer in comparison with an example of a textile product with an intermediate layer according to the invention.

[0115] In Fig. Figure 1 shows a schematic partial cross-sectional view of a textile product P, which is made up of several layers.

[0116] The textile product P comprises a first layer 10, which has a first surface 10a and a second, opposite surface 10b. The surfaces 10a and 10b are oriented substantially parallel to each other and extend substantially parallel to a plane spanned by a first direction x and a second direction y.

[0117] Yarns G are attached to the first layer 10, extending from the first surface 10a.

[0118] The first layer 10 has a thickness T10 which is in the range of 3.5 mm to 30 mm (inclusive) and a basis weight which is in the range of 450 g / 2 up to 3,000 g / m² 2 (each including) lies. Preferably, the first layer consists of the initially loose composite of yarn and nonwoven fabric and / or woven material.

[0119] The first layer 10 is preferably a layer of 100% polyester. The yarns G are also 100% polyester yarns, which are, for example, tufted to the first layer 10. Alternatively, the first layer can also be a woven / knitted fabric.

[0120] The textile product P further comprises an intermediate layer 12, which is made of a polyester nonwoven fabric and has a thickness T12. The thickness of the intermediate layer is between 0.5 mm and 3 mm, preferably between 0.5 mm and 1.5 mm. The intermediate layer 12 is bonded to the second surface 10b of the first layer 10 via a first hot-melt adhesive 16. The first hot-melt adhesive 16 has a thickness T16, which is between 0.2 mm and 1.5 mm. The first hot-melt adhesive 16 is a polyester-based hot-melt adhesive.

[0121] The textile product P further comprises a carrier layer 14 made of a polyester nonwoven fabric, which has a thickness T14 of between 0.6 mm and 3 mm. The carrier layer 14 is bonded to the intermediate layer 12 (on one side opposite the first layer 10) via a second hot-melt adhesive 18, which has a thickness T18 of between 0.2 mm and 1.5 mm.

[0122] The second hot melt adhesive 18 is preferably identical to the first hot melt adhesive 16.

[0123] The textile product P is designed as a floor covering, e.g., in roll form or as carpet backing. The floor covering, which is constructed from the textile product P, is laid on a floor B, either dry or using a standard flooring adhesive.

[0124] The textile product P is produced by a process in which the first layer 10 with attached yarns G is first provided.

[0125] The provision of the first layer 10 with the yarns attached to it is preferably carried out by a fiber bonding process, as schematically shown in Fig. 2 is shown.

[0126] In this process, the yarns G are first attached, typically in themselves, to a first layer 10 of polyester material, preferably essentially loosely. The layer can be a polyester spunbond nonwoven or woven fabric, as well as PES+PP fabric, preferably in the case of PA 6.

[0127] The second surface 10b (which will later become the back surface to which the intermediate layer 12 is bonded via the first hot-melt adhesive 16) is then subjected to pressure P and heating. For this purpose, a doctor blade 30, a roller, or a similar device is provided, the tip of which is heated to an elevated temperature, preferably higher than the melting point of the yarns G. The doctor blade 30 is moved at a relative velocity V with respect to the second surface 10b and parallel to it, along the x-direction and / or the y-direction. This melts the yarns G on the second surface 10b and, if necessary, the second surface 10b itself, and smears them across the second surface 10b due to the relative velocity, resulting in a firm and permanent bond between the yarns G and the first layer 10.This process is described in detail in documents EP 2 649 234 B1 and EP 3 008 238 B1, which are hereby incorporated by reference, so that their disclosure in this respect is contained herein by reference.

[0128] After the step of providing the first layer 10 with the yarns attached to it, the intermediate layer 12 is applied to the second surface 10b over the first hot melt adhesive 16, and then the carrier layer 14 is applied to the intermediate layer 12 over the second hot melt adhesive 18.

[0129] The thickness T12 of the intermediate layer 12 is smaller than the thickness T14 of the support layer 14. The intermediate layer 12 also has a lower surface mass than the support layer 14.

[0130] The intermediate layer preferably comprises a non-woven fabric made of polyester (100% PES with melt fiber content) with a basis weight of greater than or equal to 80 g / m². 2 and / or of less than or equal to 300 g / m² 2exhibits a density of 130 g / m². A density of 130 g / m² is particularly preferred. 2 up to 170 g / m² 2 , especially of 150 g / mm 2 , and optionally has a density greater than or equal to 0.120 g / m³ 3 and less than or equal to 0.320 g / m² 3 Preferably, the intermediate layer has a density of between 0.160 g / m². 3 and 0.170 g / m² 3 (each including) and preferably about 0.165 g / m³ 3 .

[0131] The support layer 14 has a surface mass in the range of 300 g / m². 2 up to 900 g / m² 2 , particularly preferably in a range of 600 g / m² 2 up to 700 g / m² 2 .

[0132] The carrier layer 14 is preferably also a layer made of a polyester nonwoven fabric.

[0133] The first layer 10, the intermediate layer 12 and the carrier layer 14 are preferably made of the same material, in particular 100% polyester.

[0134] The first hot melt adhesive 16 and the second hot melt adhesive 18 are preferably also polyester-based.

[0135] The hot-melt adhesives 16 and 18 are applied in a liquefied state to the respective layers, which may have been preheated to a temperature above the melting point of the hot-melt adhesive. This allows for a strong bond between the individual layers 10, 12, and 14.

[0136] The textile product P is preferably entirely recyclable, whereby the recycling can either be carried out by removing the individual layers after heating them above the melting point of the hot melt adhesives 16, 18 in order to be recycled.

[0137] However, it is preferred if the textile product P is heated as a whole after its use in order to melt the polyester contained in the yarns, the first layer, the first hot melt adhesive, the intermediate layer, the second hot melt adhesive and the backing layer, which can then be recycled.

[0138] In one embodiment, the following materials are used for the first layer: For the yarns / pile yarn: PET or PA 6 or PA6.6, and as the base layer a PET spunbond nonwoven, also with copolyester, or a carrier material made of PET fabric, or a carrier material made of PET / PP fabric; for the hot melt adhesive, a polyester hot melt is preferably used (e.g. from Covestro); for the intermediate layer a PET nonwoven (100% PES including melt fiber content), and a PET nonwoven is also preferably used for the carrier layer.

[0139] Exemplary textile products were manufactured, each comprising a first layer, an intermediate layer, and a backing layer, bonded together with a hot-melt adhesive. The manufactured exemplary textile products were compared with regard to their dimensional stability (DIN EN 986:1995) and flexural stiffness. The results are presented in the tables below and in Fig. 3 and Fig. 4 shown.

[0140] For dimensional stability, the “dimensional movement” “longitudinal” and “transverse” in % was determined according to DIN EN986:1995, once for three examples with different intermediate layers according to the invention ( Fig. 3A), as well as for a comparison product without an intermediate layer and an example with an intermediate layer for comparison ( Fig.3B). The conditions or treatment cycle were / were as follows, whereby the same sample was used successively for the treatments according to the aforementioned DIN standard: 2 hours at 60 °C in a heating oven, 2 hours lying flat in water (H₂O), 24 hours at 60 °C in a heating oven, and 48 hours under normal climate conditions. The change in dimensions is determined as a percentage of the mean value, with shrinkage indicated by a minus sign (-) and expansion by a plus sign (+).

[0141] The results of these measurements are shown in Table 1 below: Table 1: Dimensional stability of three examples (longitudinal and transverse) Along 2h 60 °C 2h H2O 24h 60 °C 48h Example 1 : 0,11 0,03 -0,01 -0,15 First layer, 150g; Intermediate layer pattern, 1,600g; Carrier layer Example 2: First layer, 120g; Intermediate layer, pattern 2, 600g; Carrier layer 0,01 0,04 -0,14 -0,2 Example 3: First layer, 120g; Intermediate layer, pattern 3, 600g; Carrier layer 0,02 -0,01 -0,1 -0,19 Cross 2h 60 °C 2h H2O 24h 60 °C 48h Example 1: First layer, 150g; Intermediate layer, pattern 1,600g; Carrier layer 0,09 0,03 0,07 -0,05 Example 2: First layer, 120g; Intermediate layer, pattern 2, 600g; Carrier layer 0,04 0,17 0,01 -0,01 Example 3: First layer, 120g; Intermediate layer, pattern 3, 600g; Carrier layer 0,25 0,09 -0,1 -0,19

[0142] It can be seen that all three examples showed good properties with regard to dimensional stability, and in particular, no unusual shrinkage and expansion values ​​could be measured. This is also evident in Fig.3A is shown in the diagram. The intermediate layer used / tested in Example 1 had a basis weight of 150 g / m². 2 , the intermediate layers of examples 2 and 3 have a surface mass of 120 g / m² 2 The intermediate layer according to Example 1 consisted of 100% PES including melt fiber content. A PES carrier layer with a weight of 600 g / m² was used as the backing layer. 2 Area measurement used.

[0143] Next, tests were carried out on the dimensional stability of a textile product according to the invention with an intermediate layer in comparison to a reference product without an intermediate layer, also under the aforementioned DIN EN 986:1995 standard. The conditions or treatment cycle were the same in each case: 2 hours at 60 °C in a heating oven, 2 hours lying flat in water (H₂O), 24 hours at 60 °C in a heating oven, and 48 hours under normal climate conditions. Here, too, the dimensional changes are given as a percentage of the mean value, and shrinkage is indicated by a minus sign (-) and expansion by a plus sign (+). The results are also presented in Fig. 3B is shown in a diagram. Table 2: Dimensional stability of one example compared to a comparison example without an intermediate layer (longitudinal and transverse) Along 2h 60 °C 2h H2O 24h 60 °C 48h Example 1: First layer, 150g; Intermediate layer, Pattern 1, 600g; Carrier layer 0,11 0,03 -0,01 -0,15 Comparative example: First layer, 600g carrier layer; no intermediate layer -0,07 0,15 -0,58 -0,57 Cross 2h 60 °C 2h H2O 24h 60 °C 48h Example 1: First layer, 150g; Intermediate layer, Pattern 1, 600g; Carrier layer 0,09 0,03 0,07 -0,05 Comparative example: First layer, 600g carrier layer; no intermediate layer 0,22 0,27 0,24 0,05

[0144] Table 2 and the results show that Example 1 (according to the invention with a 150g interlayer, corresponding to Example 1 from Table 1) has a significantly improved dimensional stability compared to the comparison product without an interlayer: While, for example, Example 1 only shows a shrinkage value of -0.01 after 24 hours at 60 °C, the comparison example showed a value (shrinkage) of -0.58 (longitudinal).

[0145] In further tests, the flexural stiffnesses of various intermediate layers were compared, as well as the flexural stiffness of a reference product and that of a textile product according to the invention. For this purpose, three different examples (see Table 3) of isolated intermediate layers, each with different gauge lengths of 5 cm, 10 cm, or 15 cm, were weighted at one end, and the downward deflection ("gauge length") under load with a 3 g weight was compared to the unweighted free end. The properties of the compared intermediate layers and their values ​​are shown in the table below: Table 3: Comparison of flexural stiffness of intermediate layers (isolated) Measuring length Measuring length with 3g attachment weight Article density 5 10 15 5 10 15 Weight in g / m 2 ing / cm 3 in cm in cm in cm in cm in cm in cm Example 1: 120g Sample 2 129 0,253 0,90 3,80 5,20 2,60 7,10 12,00 Example 2: 120g Sample 3 123 0,3075 1,00 3,30 6,50 2,20 6,90 11,70 Example 3: 150g Sample 1 150 0,165 2,00 5,70 10,10 3,50 8,30 13,20

[0146] As can be seen in Table 3, example 3 (sample 1, 150g; corresponds to example 1 in Tables 1 and 2) had the greatest change in downward deflection in all measurement lengths, and thus a lower bending stiffness compared to examples 1 and 2.

[0147] Next, a comparison was made between a reference product (first layer and 600g carrier layer) without an intermediate layer and an example of a textile product according to the present invention (first layer, intermediate layer, carrier layer), also by means of bending stiffness measurements, analogous to those described above. These results are shown in Table 4. Furthermore, Fig. 4. For illustration, a representation of the measuring arrangement / reading for the comparison product without the intermediate layer according to the invention and the example with the intermediate layer according to the invention. Table 4: Comparison of flexural stiffness of the reference product and the textile product according to the invention Measuring length Measuring length with 3g attachment weight Article Weight density 5 10 15 5 10 15 in g / m 2 ing / cm 3 in cm in cm in cm in cm in cm in cm Comparison product: first layer, carrier layer, without intermediate layer 1729 0,2343 0,50 1,20 1,80 0,90 2,10 3,40 Example 1: first layer, 150g intermediate layer, carrier layer 2265 0,2766 0,50 0,80 1,20 0,60 1,10 1,70

[0148] It was shown that the textile product manufactured according to the invention with an intermediate layer had a significantly improved bending stiffness than the comparison product (1.70 cm compared to 3.40 cm).

[0149] Surprisingly, it was shown that an intermediate layer which in itself has a very low flexural stiffness (see Table 3, Example 3) could give the final textile product improved flexural stiffness, which is mainly due to the density of the intermediate layer. Reference symbol list: 10 first layer 10a first surface (10) 10b second surface (10) 12 Intermediate layer (fleece) 14 Support position 16 first hot melt adhesive 18 second hot melt adhesive 30 squeegees 32 squeegee tip P Textile product G Yarns B Floor V Relative motion 30 / 10 T10 Thickness (10) T12 Thickness (12) T14 Thickness (14) T16 Thickness (16) T18 Thickness (18) x first direction y second direction z third direction QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] EP 3 008 238 B1 [0011, 0081, 0103, 0127] EP 2 649 234 B1

[0127] Cited non-patent literature

[0000] DIN test standard EN ISO 9073-1:2023-09

[0036] German version EN 986:2005

[0101] DIN EN986:1995

[0139] Longitudinal and transverse in % according to DIN EN986:1995

[0140]

Claims

[1] Method for manufacturing a textile product (P), in particular for use as a floor covering and / or as a sound insulation covering, comprising the steps: a) Providing a first layer (10) with yarns (G) attached to it, wherein the first layer (10) has a first surface and a second surface, the yarns (G) extending at least from the first surface; b) Applying a first layer of a first hot melt adhesive (16) to the second surface; c) Applying at least one intermediate layer (12) to the first layer (16); d) Applying at least one second layer of a second hot melt adhesive (18) to the intermediate layer (12); and e) Applying a carrier layer (14) to the second layer (18), characterized by , that the intermediate layer (12) has a lower surface mass than the support layer (14) and wherein the intermediate layer (12) is thinner than the support layer (14). [2] Method according to claim 1 or according to the preamble of claim 1, wherein the intermediate layer (12) has a basis mass of greater than or equal to 80 g / m² 2 and of less than or equal to 300 g / m² 2 , preferably greater than 100 g / m² 2 down to less than 180 g / m² 2 exhibits. [3] Method according to claim 1 or 2 or according to the preamble of claim 1, wherein the interlayer has a thickness of less than or equal to 3 mm and greater than or equal to 0.5 mm, and / or wherein the interlayer (12) has a density of greater than or equal to 0.120 g / m³ 3 and less than or equal to 0.320 g / m² 3 exhibits. [4] Method according to any one of claims 1 to 3, wherein the first layer (10), the intermediate layer (12) and the carrier layer (14), and optionally also the yarns (G), and optionally also the first and / or second hot melt adhesive (16, 18) are made of mutually compatible thermoplastic materials, preferably each of a polymer P, a polymer O, and / or a polymer R. [5] Method according to any one of claims 1 to 4, wherein the support layer (14) comprises a nonwoven fabric having a basis weight of greater than or equal to 300 g / m² 2 and / or of less than or equal to 900 g / m² 2 exhibits. [6] Method according to any one of claims 1-5, wherein the first hot melt adhesive (16) and / or the second hot melt adhesive (18) comprises a thermoplastic material having a lower melting point than the respective layer to which it is applied. [7] Method according to any one of claims 1-6, wherein the respective layer to which a hot melt adhesive is applied is first heated to a temperature greater than the melting point of the hot melt adhesive. [8] Method according to any one of claims 1-7, wherein the first hot melt adhesive (16) and / or the second hot melt adhesive (18) comprises at least 50 wt.% of a polymer P or a polymer R. [9] Method according to claim 4 or 8, wherein the polymer P is a polyester, and / or wherein the polymer O is a polyolefin, and / or wherein the polymer R is a polyamide, preferably a polyamide 6 or a polyamide 6.

6. [10] Method according to any one of claims 1 to 9, wherein the step of providing the first layer (10) comprises the following steps: - Heating the second surface of the first layer (10), thereby at least partially melting the yarns (G) attached to the first layer (10) in order to bond the yarns (G) to the first layer (10); and optionally - Applying pressure (F) to the second surface of the first layer (10); and optionally - Applying a mechanical force (V) to the molten fraction of the yarns (G) in a direction parallel to the second surface of the first layer (10). [11] Use of a nonwoven or woven fabric with a basis weight greater than 80 g / m² 2 and of less than 180 g / m² 2 as an intermediate layer (12) in a textile floor covering. [12] Use according to claim 11, wherein a first interlayer surface of the interlayer (12) is connected to a layer of the covering adjacent to the first interlayer surface via a first hot melt adhesive (16) and / or wherein a second interlayer surface of the interlayer (12) is connected to a layer of the covering adjacent to the second interlayer surface via a second hot melt adhesive (18). [13] Textile product (P), in particular in the form of a floor covering or a sound-insulating covering, with - a first layer (10) with yarns (G) attached to it, wherein the first layer (10) has a first surface and a second surface, wherein the yarns (G) extend at least from the first surface; - an intermediate layer (12) having a first intermediate layer surface and a second intermediate layer surface, wherein the first intermediate layer surface is connected to the second surface of the first layer (10) by means of a first hot melt adhesive (16); and - a carrier layer (14) having a first carrier layer surface and a second carrier layer surface, wherein the first carrier layer surface is connected to the second intermediate layer surface by means of a second hot melt adhesive (18), characterized by , that the intermediate layer (12) has a lower surface mass than the support layer (14), and that the intermediate layer (12) is thinner than the support layer (14). [14] Method for recycling a textile product (P), comprising the steps: - Providing a used textile product (P) according to claim 13; - Heating the first hot melt adhesive (16) so that the intermediate layer (12) can be separated from the first layer (10), and / or heating the second hot melt adhesive (18) so that the carrier layer (14) can be separated from the intermediate layer (12); and - Removing the first layer (10) from the intermediate layer (12) in order to reuse the intermediate layer (12) and / or the first layer (10), and / or removing the carrier layer (14) from the intermediate layer (12) in order to reuse the carrier layer (14) and / or the intermediate layer (12). [15] Method for recycling a textile product (P), comprising the steps: - Providing a used textile product (P) according to claim 13; - Heating the used textile product (P) as a whole, thereby melting the polymer contained in the yarns (G), the first layer (10), the first hot melt adhesive (16), the intermediate layer (12), the second hot melt adhesive (18) and the carrier layer (14); - Reusing the recovered polymer. [16] Use of a textile product (P) according to claim 13 as a floor covering. [17] Method for applying a textile product (P) to a floor (B), comprising the steps: - Applying a textile product (P) according to claim 13 to a floor (B) and attaching the textile product (P) to the floor (B). [18] Floor (B) covered with a textile product (P) according to claim 13 and / or obtained according to a method according to claim 17.

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