POLYESTER TRANSPORT CARPET AND METHOD FOR MANUFACTURING A POLYESTER TRANSPORT CARPET

Description

Technical field

[0001] The invention relates to a flame-resistant mat suitable for use inside means of transport, preferably aircraft.

[0002] The invention relates, in a second aspect, also to a method for manufacturing a flame-resistant carpet suitable for use inside means of transport, preferably aircraft. State of the art

[0003] Carpets are standard equipment in aircraft interiors, as well as in other modes of transport such as trains and ships. In addition to the floor, sections of the interior walls of aircraft are often carpeted. Carpets in aircraft are subject to very strict requirements. In particular, they must be flame-resistant, and in the event of a fire, the release of toxic fumes and vapors must not exceed stringent limits. Generally, corresponding standards are legally mandated. Especially in the case of commercial airliners, only carpets that also meet these standards may be used, for example, ABD 0031 regarding the release of toxic fumes and vapors, FAR 25853 regarding flammability, and ISO 6356 regarding the tendency of textile and laminated particleboard floor coverings to generate static electricity.

[0004] In addition to these strict standards, airlines expect aircraft carousels to be highly resistant to wear and tear. Every day, many passengers walk and roll their suitcases across the carousel. This represents a significant load that the carousel must withstand. Therefore, aircraft carousels are replaced regularly.

[0005] Therefore, carpeting must have a low weight per unit area to reduce an aircraft's fuel consumption. Aircraft contain a large amount of carpeting. Reducing the weight per unit area of ​​the carpeting results in significant annual savings for airlines.

[0006] Such a device is known, among other things, from WO 2007 / 112608, which describes a flame-retardant carpet for aircraft interiors. The carpet comprises a woven top layer, needle-punched felt as the bottom layer, and an intermediate layer to laminate the two layers together. It is a lightweight carpet (weight per unit area) that can be quickly installed in an aircraft using Velcro strips.

[0007] The device described in WO 2015 / 014335 is also known. WO 2015 / 014335 relates to a textile floor covering, specifically for use in aircraft interiors. The carpet comprises a top layer, which may be a pile fabric, a smooth fabric, or a tufted carpet; needle-punched felt as a bottom layer; and an intermediate layer to laminate the two layers together. Beneath the needle-punched felt, an acrylic latex backing is applied. This acrylic latex layer prevents the carpet from slipping, allowing it to be installed in the aircraft without the use of Velcro strips, glue, or double-sided tape.

[0008] JP 2000 308604 describes a base fabric for a carpet for dust control.

[0009] JP 2000 282347 describes a pile rug.

[0010] JP 2005 152159 describes a woven carpet.

[0011] WO 2005 / 113229 describes a hybrid of vinyl flooring and soft padded carpet.

[0012] EP 3 192 906 describes a fray-resistant carpet featuring fusible threads.

[0013] WO 2012 / 076348 describes a process for manufacturing a textile product and the textile product resulting from said process.

[0014] EP 3 196 344 describes a fray-resistant carpet featuring natural fibers.

[0015] WO 2007 / 112608 has the disadvantage that its top layer is a lightweight fabric. Consequently, the fabric itself is not sufficiently resistant to the heavy loads of everyday passengers and luggage trolleys and lacks sufficient dimensional stability. The fabric is reinforced by the application of a polyacrylate-based adhesive as an intermediate layer between the fabric and the needle-punched felt. The adhesive laminates the fabric to the needle-punched felt but also holds the growing warp and weft threads together. For this to work, the adhesive must partially mix with the warp and weft threads. The intermediate layer adds weight to the carpet. Furthermore, the intermediate layer complicates carpet recycling because the fabric and needle-punched felt threads can be difficult to separate from the intermediate layer. This is a significant disadvantage given the frequent replacement of carpets on aircraft.

[0016] WO 2015 / 014335 has similar disadvantages. When a tufted carpet or pile fabric is used, the top layer itself is stronger and has greater dimensional stability, but both are heavier than a smooth fabric, which can be a disadvantage. Furthermore, a tufted carpet or pile fabric is less suitable for rolling on suitcases and is more susceptible to wear. When using a smooth fabric, it is again necessary to keep the warp and weft yarns together. WO 2015 / 014335 uses melt lamination to bond the top layer and the needle-punched felt, keeping the warp and weft yarns together. This again leads to an increase in weight and complicates the recycling of the top layer and the needle-punched felt.

[0017] The present invention aims to provide a solution to overcome these drawbacks. Summary of the invention

[0018] In a first aspect, the present invention relates to a device according to claim 1.

[0019] The advantage of such a carpet is that some of the warp threads on the reverse side of the machine-woven fabric are at least partially fused together. Consequently, the fabric itself is already quite strong and has good dimensional stability. It won't tear easily under the weight of passengers and luggage trolleys. The warp threads, and therefore also the weft threads, have limited freedom of movement relative to each other, which increases wear resistance.

[0020] Because the fabric is already reinforced through fusion bonding, there is no need for a heavy intermediate layer to reinforce the fabric and laminate the needle-punched felt. A lighter intermediate layer can be used to laminate only the fabric and needle-punched felt. This results in a reduction in the rug's weight per unit area. Since the adhesive does not need to be partially mixed with the warp and weft yarns, it is easier to separate and recycle the fabric and needle-punched felt.

[0021] Furthermore, the invention uses 100% flame-retardant thermoplastic polyester (PES) for both the fabric and the needle-punched felt. Consequently, the mat meets the required standards, for example, ABD 0031 for the development of toxic fumes and vapors and FAR 25.853 for flammability. In addition, there is a further advantage that, due to the use of only flame-retardant polyester (PES), the recycling process for both the fabric and the needle-punched felt is carried out simultaneously.

[0022] Preferred embodiments of the device are described in claims 2 to 9.

[0023] In one specific embodiment, the invention relates to a device according to claim 7. In the intermediate layer, PES is also used as an adhesive to laminate the fabric and needle-punched felt. This further improves recycling. Now, it is no longer necessary to separate the fabric and needle-punched felt. The intermediate layer can even be processed and recycled together with the fabric and needle-punched felt.

[0024] In a second aspect, the present invention relates to a method according to claim 10. Because, before the fabric and needle-punched felt are laminated, the fabric is passed along a heated surface to melt at least partially some of the warp threads on the reverse side of the fabric, which is mechanically or mechanically woven together, this method has the advantage, among others, of producing a fabric that is sufficiently strong and has dimensional stability. The fabric can be laminated to the needle-punched felt with a lightweight intermediate layer, and the fabric and needle-punched felt can easily be separated later for recycling.

[0025] Preferred embodiments of the device are described in dependent claims 11 to 13.

[0026] In a third aspect, the present invention relates to the manufacture of a carpet according to the first aspect, using a method according to the second aspect. Description of figures

[0027] There figure 1 shows a section of an embodiment of the present invention. There figure 2 schematically shows a molecular model of a bond between a fabric and a needle-punched felt according to an embodiment of the present invention. There figure 3 shows a suitable device for at least partially melting a portion of the warp threads together according to an embodiment of the method of the present invention. Detailed description

[0028] Unless otherwise stated, all terms used in the description of the invention, including technical and scientific terms, are used in the sense generally understood by a specialist in the technical field of the invention. For a better understanding of the description of the invention, the following terms are explained explicitly.

[0029] "Un", "une", "le", "la", and "les" refer in this document to both the singular and plural forms, except where the context clearly implies otherwise. "Un segment" means, for example, one or more segments.

[0030] When "approximately" or "about" is used in this document, a measurable quantity, parameter, duration, or time, etc., means variations of + / -20% or less, preferably + / -10% or less, more preferably + / -5% or less, even more preferably + / -1% or less, and even more preferably + / -0.1% or less of the stated value, as long as such variations apply to the aforementioned invention. However, the value of the quantity with which the term "approximately" or "about" is used must itself be specifically stated.

[0031] The terms "include", "comprising", "composed of", "composed of", "intended to", "contain", "containing", "containing" are synonyms and are inclusive or open terms indicating the presence of the following, and not excluding or preventing other components, characteristics, elements, members, phases, known of or described in the prior art.

[0032] Quoting numerical intervals by means of endpoints includes all integers, fractions, and / or real numbers between the endpoints, including those endpoints.

[0033] The term "thermoplastic" refers to a polymer material that can be bent, kneaded, or liquefied above a specific temperature and that hardens substantially upon cooling. Examples of thermoplastic polymers include, but are not limited to, vinyl, including thermoplastics such as polyvinyl chloride, polyvinyl acetate, polyvinyl alcohol, and other vinyl and vinylidene resins and their copolymers; polyethylene compounds such as low-density polyethylene and high-density polyethylene and their copolymers; styrene compounds such as ABS, SAN, and polystyrenes and their copolymers, polypropylene and its copolymers; saturated and unsaturated polyesters; acrylic; and polyamides. engineering plastics such as acetyl, polycarbonate, polyimide, polysulfon, polyphenylene oxide and sulfide resins and others.

[0034] The term "float" refers to a section of yarn appearing on the surface of a fabric. Floats can be top floats and / or bottom floats. The term "top float" refers to a section of yarn appearing above the fabric. A top float is formed by a bond pattern with a warp:weft bond density of 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, or higher. This means that each weft yarn floats above at least two warp yarns, at least three warp yarns, and so on. Alternatively, each warp yarn floats above at least two weft yarns, at least three weft yarns, and so on. The term "bottom float" refers to a section of yarn appearing below the fabric. A lower float is formed by a bonding pattern with a warp:weft bonding density of 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8, 1:9, 1:10 or less.This means that each weft thread floats beneath at least two warp threads, beneath at least three warp threads, and so on. Alternatively, each warp thread floats beneath at least two weft threads, beneath at least three weft threads, and so on. The term "bonding" is used to refer to the weaving of weft threads with warp threads to form a fabric.

[0035] The term "weft float" refers to a float formed by weft yarns. The term "warp float" refers to a float formed by warp yarns.

[0036] The yarn number refers to the thickness of the yarn. The measurement is indicated as the ratio of the weight to the length of a piece of yarn. When using weight numbering, the weight of a fixed length of yarn is determined. When using length numbering, the length of a fixed weight of yarn is determined. Tex is an example of weight numbering, where tex indicates the weight in grams of 1000 m of yarn. Dtx is more commonly used, which is the weight in grams of 10,000 m of yarn. Another example of weight numbering is denier, denoted den, where the weight in grams of 9000 m of yarn is indicated. For yarns containing filaments, denier weight numbering is also used for filaments. Last per filament, or DPF, refers to the weight number of a single filament in the yarn.

[0037] In a first aspect, the invention relates to a flame-resistant carpet suitable for use inside means of transport, more particularly airplanes.

[0038] According to one embodiment, the device comprises a machine-woven or mechanically woven fabric with a maximum weight of 650 g / m², comprising a front face as a surface of use and a back face, comprising warp and weft yarns of essentially 100% flame-retardant thermoplastic polyester (PES), a needle-punched felt with a maximum weight of 220 g / m² of essentially 100% flame-retardant thermoplastic polyester (PES), an intermediate layer between the needle-punched felt and the machine-woven or mechanically woven fabric with a maximum weight of 180 g / m², in which a portion of the warp yarns on the back face of the machine-woven or mechanically woven fabric have at least partially fused together.

[0039] The fabric has a front and a back. The front is the surface on which passengers walk and roll their trolleys and suitcases. After installation, it is the visible part of the carpet.

[0040] A fabric has the advantage over a tufted carpet that a base, such as a fabric or needle felt, is not required, through which a pile thread is pierced. Due to the lack of a base in a fabric, the weight can be reduced compared to a tufted carpet. In addition, tufted carpets often have a long pile, which makes it difficult to roll with trolleys and suitcases. In addition, such long-pile carpets wear out more quickly.

[0041] The fabric should preferably be smooth. A pile fabric has the same disadvantage as a long-pile tufted carpet when used with trolleys and suitcases: it will wear out more quickly. A second disadvantage of pile fabrics is that, in addition to the pile yarn used to form the fibers, the warp yarn also includes extra yarns to bind the fibers together. Consequently, the fabric becomes heavier compared to a smooth fabric.

[0042] The fabric preferably has a smooth bond. In a smooth bond, each weft yarn alternately extends over and under a warp yarn, and each warp yarn alternately extends over and under a weft yarn. This is the simplest and strongest possible bond. The heavy daily load on the fabric from passengers and trolleys can pull the warp and weft yarns apart and reduce dimensional stability. A strong bond is advantageous in combating this. Additionally, a strong bond will ensure that the warp and weft yarns are less mobile relative to each other under the influence of the load from passengers and trolleys, resulting in less friction between the yarns and, consequently, less wear. This does not affect yarn wear from friction with, for example, passengers' shoes and trolley wheels.

[0043] In another embodiment, the bond in the fabric is a weft repeat. Each weft yarn extends alternately over and under two adjacent warp yarns, and each warp yarn alternately over and under a weft yarn. This provides a different visual effect than a smooth bond. Because the weft yarn extends only over or under two adjacent warp yarns in a weft repeat, this is always a strong bond.

[0044] The fabric preferably has a limited number of floats, both upper and lower. Floats can be used in combination with different colored yarns to weave patterns, emblems, or markings into the fabric. The disadvantage of using floats is that it introduces a deviation from a smooth bond and therefore weakens the bond in the fabric locally.

[0045] Floats preferably have a bond density less than or equal to 7:1 and greater than or equal to 1:7, more preferably a bond density less than or equal to 5:1 and greater than or equal to 1:5, and even more preferably less than or equal to 2:1 and greater than or equal to 1:2.

[0046] In one embodiment, the fabric is a Jacquard fabric. A Jacquard fabric includes complex patterns and / or emblems that cannot be woven using frames on a loom. Frame weaving means that all the warp threads that pass through the same frame are located either all on one side or all on the other side of each weft thread in the fabric. A Jacquard fabric is woven using a loom with a Jacquard mechanism. The Jacquard mechanism allows an individual warp thread to be positioned on one side or the other of the weft thread, independent of the position of the other warp threads.

[0047] The fabric comprises warp and weft yarns made of essentially 100% flame-retardant thermoplastic polyester (PES). PES is very strong, rigid, has good dimensional stability, and minimal creep. It is therefore suitable for high-load applications. The yarn is resistant to mold and bacteria. This is advantageous because spills of liquids and food on an aircraft can lead to mold and bacteria growth. PES absorbs almost no liquids. It is highly resistant to acids, oxidizing agents, and diluted alkaline detergents. It can be sterilized using steam. Thanks to these characteristics, the fabric is suitable for efficient and rapid cleaning, which is also beneficial for carpeting on an aircraft.

[0048] Flame-retardant PES has excellent heat resistance. It is difficult to ignite, extinguishes flames, and results in limited smoke development. Thanks to these characteristics, it meets the requirements of ABD 0031 regarding the development of toxic fumes and vapors and FAR 25.853 regarding flammability.

[0049] The carpet also includes a needle felt of essentially 100% flame-retardant thermoplastic polyester (PES). Therefore, the needle felt meets the ABD 0031 standard for the development of toxic fumes and vapors and the FAR 25.853 standard for flammability. Needle felt is a non-woven textile. The needle felt has a thickness of 0.5 mm to 4 mm, preferably 0.5 mm to 3 mm, more preferably 0.5 mm to 2 mm, and even more preferably 0.5 mm to 1 mm.

[0050] Needle-punched felt is attached to the back of the fabric using an intermediate layer. Needle-punched felt is suitable for mechanically reinforcing the fabric. It provides rigidity to carpets with sharp edges, gives the carpet high dimensional stability, increases walking comfort, and improves sound insulation and thus the acoustics inside an aircraft.

[0051] Because needle-punched felt is a non-woven textile, the carpet is suitable for quick installation and replacement on an aircraft. The carpet is attached to the aircraft floor using Velcro strips. The Velcro strips adhere to the aircraft floor. The hooks of the Velcro strips catch on the threads of the needle-punched felt, thus immobilizing the carpet. The carpet can be easily removed by peeling it off the Velcro strips. The Velcro strips are reusable and remain adhered to the aircraft floor. A new carpet according to the invention can be easily installed by adhering the new carpet to the existing Velcro strips, thus immobilizing it.

[0052] A Velcro strip is made of a flame-retardant material and meets the flammability standard FAR 25.853 (a)(1)(ii). An unrestricted advantage of a suitable material is polyamide PA6. The weight is preferably less than 0.60 kg / m², more preferably less than 0.55 kg / m², even more preferably less than 0.55 kg / m², and even more preferably less than 0.45 kg / m². Velcro strips include hooks on one side of the strip, configured to catch the threads, and on the opposite side, an adhesive. The adhesive has a bond strength of at least 10.0 N / cm on aluminum, preferably at least 12.0 N / cm on aluminum, and even more preferably at least 13.0 N / cm on aluminum. The force required to pull the mat off the hooks of the Velcro strip is at least 0.60 N / cm, preferably at least 0.70 N / cm and even more preferably at least 0.80 N / cm.The shear strength of the Velcro strip is at least 20 N / cm², preferably at least 25 N / cm², and preferably even more, at least 29 N / cm². The loop tension is at least 5 N / cm², preferably at least 7 N / cm², and preferably even more, at least 8 N / cm². An example of a suitable Velcro strip is HTH 577 from the Velcro company.

[0053] The fabric has a maximum weight of 650 g / m². The needle-punched felt has a maximum weight of 220 g / m². The intermediate layer has a maximum weight of 180 g / m². The total weight of a carpet is therefore a maximum of 1050 g / m². A standard carpet can weigh up to 2000 g / m² and even 3000 g / m². This makes a carpet according to the invention particularly suitable for application in an aircraft, where a reduction in weight results in a reduction in fuel consumption.

[0054] A portion of the warp threads in machine-woven or mechanically woven fabrics have fused at least partially to each other on the back side. A warp thread is preferably fused over at least 10% of its length, more preferably over at least 20%, even more preferably over at least 30%, and even more preferably over at least 50% of the length of adjacent warp threads. Because some of the warp threads have fused to each other, their relative movement is limited. Consequently, dimensional stability increases, and there is less friction between the threads, resulting in less wear. This strengthens the fabric and the carpet. In the case of carpets made according to the prior art, the fabric is reinforced by applying a layer of glue or a fusion coating that bonds the knots of the fabric.The glue or fusion coating must then penetrate between the fabric fibers, so more glue or fusion coating is needed than simply to attach the fabric to the needle-punched felt. In the case of a carpet according to the invention, this results in a further weight reduction compared to the prior art. Another advantage is that the glue or fusion coating does not need to penetrate between the fibers, making it easier to recycle the fabric fibers and the needle-punched felt.

[0055] According to one embodiment, the yarn number of the warp and weft yarns is 1100 dtex to 4400 dtex.

[0056] A higher thread count means a heavier and thicker thread. A high thread count is indicated for heavy and strong fabrics with high dimensional stability. A low thread count is indicated for light and flexible fabrics. A conveyor belt is preferably lightweight, strong, and maintains its shape under the daily load of passengers and trolleys. A thread count of 1100 dtex to 4400 dtex, preferably 1500 dtex to 3700 dtex, and even more preferably 1800 dtex to 3100 dtex is indicated for a conveyor belt. The belt is then sufficiently light and strong.

[0057] The warp and weft yarns include filaments. To obtain a lightweight fabric, lightweight filaments are specified. The filament has a weight number from 2 DPF to 20 DPF, preferably from 2 DPF to 15 DPF, preferably from 2 DPF to 10 DPF, and even preferably from 2 DPF to 5 DPF.

[0058] In an alternative embodiment, it is necessary to make the fabric stronger to achieve sufficient dimensional stability. In this case, slightly stronger filaments are indicated. The filament has a weight number of 2 DPF to 20 DPF, preferably 5 DPF to 20 DPF, preferably 8 DPF to 20 DPF, and preferably even more, 10 DPF to 20 DPF.

[0059] According to one embodiment, weft and warp yarns are so-called continuous filament yarns and yarns comprise continuous filaments.

[0060] According to one embodiment, the warp and weft yarns are so-called continuous filament yarns, and the yarns comprise continuous filaments in which the texture of the yarns is modified by means of air jets, in which small loops are formed. This provides additional insulation and strength.

[0061] According to one embodiment, the number of warp threads per cm of fabric ranges from 8 to 30.

[0062] The number of warp threads per centimeter of fabric also determines the fabric's density. A denser fabric will be stronger and have greater dimensional stability, but it will also be heavier. A lower number of warp threads per centimeter of fabric makes the fabric lighter and more supple, but it will be less strong and have less dimensional stability. The number of warp threads per centimeter of fabric ranges from 8 to 30, preferably from 13 to 25, and even more preferably from 15 to 20. At this level, the rug is sufficiently light and strong.

[0063] According to one embodiment, the number of weft threads per cm of fabric ranges from 3 to 10.

[0064] The number of weft threads per centimeter of fabric also determines the fabric's density. A denser fabric will be stronger and have greater dimensional stability, but it will also be heavier. A lower number of weft threads per centimeter of fabric makes the fabric lighter and more supple, but it will be less strong and have less dimensional stability. The number of weft threads per centimeter of fabric typically ranges from 3 to 10, preferably from 3 to 8, and even more preferably from 3 to 7. At this level, the rug is sufficiently light and strong.

[0065] According to one embodiment, the weight per unit area of ​​the carpet amounts to a maximum of 950 g / m².

[0066] The weight of the rug is determined by the weight of the fabric, the backing layer, and the needle-punched felt. The rug's weight can be optimized through careful selection of the fabric, backing layer, and needle-punched felt. A heavier fabric is inherently stronger and requires a thinner needle-punched felt for good dimensional stability. Because some of the warp threads in machine-woven or woven fabrics have at least partially fused to each other on the back side, the backing layer is minimal. The backing layer acts as a bond between the fabric and the needle-punched felt. A lighter fabric requires a slightly thicker needle-punched felt for good dimensional stability. The backing layer can still be minimal.Thanks to a good choice of fabric thickness, determined among other things by the thread number, the number of warp threads per cm of fabric and the number of weft threads per cm of fabric, and an appropriate needle-punched felt, the weight of the rug is a maximum of 950 g / cm², preferably a maximum of 925 g / cm², even more preferably a maximum of 900 g / cm² and even more preferably 875 g / cm².

[0067] According to one embodiment, the machine-woven or mechanically woven fabric and the needle felt are laminated to each other using the intermediate layer.

[0068] Machine-woven or mechanically woven fabric and needle felt are bonded together. Needle felt provides dimensional stability and strengthens the fabric because they are bonded to the fabric. The fabric and needle felt are laminated to each other using the interlayer.

[0069] According to one embodiment, the intermediate layer comprises the PES adhesive.

[0070] Thanks to the use of PES as an adhesive, the conveyor belt can be easily recycled. The fabric, needle-punched felt, and the adhesive in the intermediate layer all contain PES, so the entire belt can be recycled together. There is no need to separate the fabric and needle-punched felt. The PES adhesive can be, for example, a PES melt-on adhesive film, a PES melt-on powder, or another suitable form.

[0071] According to one embodiment, the mat comprises reactive molecules to form thermoreversible covalent interactions in the intermediate layer.

[0072] This embodiment reverses the covalent interactions by heating the carpet. This facilitates easy recycling of the carpet. By reversing the reaction between the reactive molecules, the original bonding structure in the intermediate layer, which binds the fabric and the needle-punched felt, breaks down into smaller molecules. These smaller molecules can be removed more easily from the fabric and needle-punched felt than with a traditional adhesive or a fusion coating. For example, the remaining smaller molecules can be dissolved in a mild solvent and then recovered from the solvent. Another possibility is to recycle the molecules along with the fabric and / or needle-punched felt, for example, by mixing the molecules with the fabric yarns and / or the needle-punched felt filament.

[0073] Thermoreversible covalent reactions are already known from chemistry. A non-exhaustive list of examples includes Michael reactions, nitroso dimerization reactions, cyclic anhydride reactions in which ester compounds are formed, urethane formation reactions, aliphatic ion formation reactions, and phenol-azlactone adduction formation reactions.

[0074] In another embodiment, the reaction is between a first molecule, comprising a conjugated diene group, and a second molecule comprising a dienophyll group. Such reactions between a conjugated diene group and a dienophyll group are referred to as Diels-Alder reactions. The advantage of Diels-Alder reactions is that thermal reversibility can occur at relatively low temperatures. This can prevent potential physical and chemical damage to the fabric and the needle-punched felt.

[0075] A conjugated diene is an acyclic hydrogen with a molecular structure comprising two hydrogen-hydrogen double bonds separated by a single bond. The conjugated diene group can be part of a molecule containing atoms other than carbon and hydrogen. A dienophyll is the alkene component (carbon double bond) of a reaction between an alkene and a diene. The dienophyll group can be part of a molecule containing atoms other than carbon and hydrogen.

[0076] According to another embodiment, the diene group is a furan (such as furfuryl), anthracene, thiophene, or pyrrole. The dienophyll group is a maleimide, fumarate, maleate, or alkyne. These groups are suitable for application in the invention. It is clear that this embodiment does not preclude the use of other diene and / or dienophyll groups.

[0077] According to one embodiment, a portion of the weft yarns on the back side of the machine-woven or mechanically woven fabric have been at least partially fused with a portion of the warp yarns.

[0078] Because some of the weft threads are fused with the warp threads, the weft and warp threads have limited mobility relative to each other. Consequently, some of the knots in the weft and warp threads are fixed. This increases dimensional stability and reduces friction between the threads, resulting in less wear. This strengthens the fabric and the carpet. In the case of carpets according to the prior art, the fabric is reinforced by applying a layer of glue or a fusion coating that bonds the fabric knots. The glue or fusion coating must then penetrate between the fabric threads, requiring more glue or fusion coating than simply attaching the fabric to the needle-punched felt. Therefore, in the case of a carpet according to the invention, there is a further weight reduction compared to the prior art.Another advantage is that it is not necessary for glue or fusion coating to penetrate between the threads, so it is simpler to recycle the threads from the fabric and needle-punched felt.

[0079] In a second aspect, the invention relates to a method for manufacturing a flame-resistant carpet suitable for use inside means of transport, particularly aircraft.

[0080] According to one embodiment, the method comprises the steps of mechanically or mechanically weaving a fabric, comprising a front face as a use surface and a back face, comprising warp and weft yarns of essentially 100% flame-retardant thermoplastic polyester (PES), manufacturing a needle felt of essentially 100% flame-retardant thermoplastic polyester (PES), laminating the needle felt to the fabric using an intermediate layer, wherein the method comprises the additional step before lamination of leading the back face of the fabric along a heated surface to at least partially melt a portion of the warp yarns to the back face of the fabric woven mechanically or mechanically.

[0081] The fabric preferably has a weight of maximum 650 g / m 2< . The needle felt has a weight of maximum 220 g / m 2< . The intermediate layer has a weight of maximum 180 g / m 2< .

[0082] Machine or mechanical weaving of fabrics using a loom is known in the state of the art.

[0083] The formation of needle-punched felt from filaments is known in the prior art. This can be done in two ways: a continuous method and a batch method. In the continuous method, filaments are formed directly in an uninterrupted process by extrusion from granules, a needle-punched felt is formed, and the filaments are joined within the felt. In the batch method, filament strands are fed from spools to a needle-punching machine. There, the filament strands are opened, shaped into the desired form of needle-punched felt, and then joined. Preferably, a mechanical method is used for joining the filaments in the needle-punched felt. One example is needle-punching the felt using barbed needles.Needle punching entangles the filaments, but there are still many loose filament ends or loops that can get caught in the hooks of the Velcro strip when attaching it to the aircraft floor. Chemical reinforcement of needle felt is less preferred because it can affect the recycling of needle felt. Thermal reinforcement of needle felt can reduce the number of loops or loose filament ends that can get caught in the hooks of a Velcro strip.

[0084] Needle-punched felt is laminated to the fabric. For the lamination stage, the back side of the fabric is directed through a heated surface to melt at least some of the warp threads together. The fabric is directed through a series of support rollers. Between two support rollers, there is a heated surface. The heated surface pushes against the back side of the fabric. The heated surface is preferably adjustable so that it can apply more or less pressure against the back side of the fabric. The back side here refers to a face of the fabric and not the position of the heated surface relative to the fabric. The heated surface can be positioned horizontally or vertically, above, below, to the left or right, in front of, or under the fabric. It is clear to those skilled in the art how the arrangement of the support rollers and the orientation of the fabric must be adjusted so that the heated surface pushes against the back side of the fabric.

[0085] In one embodiment, the heated surface is a heating plate, a heating roller, a metal foil with a tip, another suitable surface, or a combination of the foregoing.

[0086] Because the fabric is fed back-side down through the heated surface, some of the warp threads will at least partially melt together. By pushing the heated surface more or less against the warp threads, the degree of melting can be adjusted. Other parameters that influence this are the temperature of the heated surface and the speed at which the fabric is fed through the heated surface.

[0087] The fabric may be directed through one, two, three, or more heated bodies, depending on the desired degree to which some of the warp threads have fused together.

[0088] According to one embodiment, on the other side of the fabric, facing the heated body, an additional support roller can be positioned. This support roller supports the fabric while the heated body pushes against the back side of the fabric. By using a support roller facing the heated body, it is possible to push the heated surface more strongly against the fabric without the fabric tearing.

[0089] According to one embodiment, the lamination includes the use of PES as an adhesive in the intermediate layer.

[0090] According to one embodiment, a PES melt-bonded self-adhesive film is used during lamination. The fabric is unwound from a first roll, the PES melt-bonded self-adhesive film from a second roll, and the needle felt from a third roll. The fabric, the self-adhesive film, and the needle felt are joined together, in which the self-adhesive film touches the back of the fabric and the needle felt. The whole is heated so that the PES melt-bonded self-adhesive film becomes sticky and is pushed tightly against each other between two rolls. After cooling, the fabric and the needle felt are joined together by the self-adhesive film. The self-adhesive film forms an intermediate layer.

[0091] According to one embodiment, a PES melt powder is used during lamination. The fabric is unwound from a first roll and the needle felt from a second roll. The PES melt powder is distributed using a suitable dispenser across either the back side of the fabric or one side of the needle felt or the back side of the fabric and one side of the needle felt. The fabric and the needle felt are joined, in which the back side of the fabric is facing the needle felt and the PES melt powder is located between the fabric and the needle felt. The whole is heated, so that the PES melt powder becomes sticky, and is pushed strongly against each other between two rolls. After cooling, the fabric and the needle felt are joined using the PES melt powder. The PES melt powder forms an intermediate layer.

[0092] According to one embodiment, the lamination comprises the use of reactive molecules to form thermoreversible covalent interactions in the intermediate layer.

[0093] According to one embodiment, a composition comprising reactive molecules A is applied to the back side of the fabric. To one side of the needle felt, a composition comprising reactive molecules B is applied. The fabric and the needle felt are joined, wherein the back side of the fabric and the side of the needle felt with the composition thereon touch each other and wherein the circumstances are such that the molecules A and B react and thus form thermoreversible covalent interactions. A thin intermediate layer is formed which connects the fabric and the needle felt.

[0094] According to another embodiment, a composition comprising reactive molecules B is applied to the back side of the fabric. To one side of the needle felt, a composition comprising reactive molecules B is also applied. The fabric and the needle felt are joined, wherein the back side of the fabric and the side of the needle felt with the composition thereon are oriented towards each other. Between the fabric and the needle felt, a thin intermediate layer comprising reactive molecules A is applied. The circumstances are such that the molecules A and B react and thus form thermoreversible covalent interactions. The thin intermediate layer connects the fabric and the needle felt.

[0095] According to one embodiment, the method comprises the additional step before lamination of directing the back face of the fabric along a heated surface to at least partially melt a portion of the weft yarns to the back face of the fabric woven mechanically or mechanically with a portion of the warp yarns.

[0096] By increasing the temperature of the at least one heated surface, or as a result of the speed with which the fabric is directed along the heated surface, or as a result of, for example, the pressure with which the heated surface pushes against the back side of the fabric, it is possible to at least partially melt not only a part of the warp threads, but also to at least partially melt a part of the weft threads to the warp threads. This provides an even stronger fabric, in which the weft and warp threads are less mobile relative to each other, which increases dimensional stability and reduces mutual friction and thus wear.

[0097] In a third aspect, the invention relates to the manufacture of a carpet according to the first aspect, using a method according to the second aspect.

[0098] It will be clear to a person skilled in the art that a carpet according to the present invention is suitable not only for use in airplanes, but also for use in other means of transport, such as trains and boats, where low weight, high wear resistance and the fact that it is difficult to ignite are required.

[0099] The present invention is now described in more detail with reference to non-limiting examples or figures. FIGURE DESCRIPTION

[0100] There figure 1shows a section of an embodiment of the present invention. A polyester conveyor belt comprises a needle felt 1, which is laminated to a smooth fabric 6 by means of an intermediate layer 2. The intermediate layer 2 comprises the PES adhesive or reactive molecules to form thermoreversible covalent interactions. The smooth fabric 6 comprises a first group of warp yarns 3 and a second group of warp yarns 4. The warp yarns 3 and 4 are juxtaposed alternately in the longitudinal direction of the fabric. The smooth fabric 6 comprises weft yarns 5. The weft yarns 5 lie transversely to the direction of the warp yarns 3 and 4. A first weft yarn 5 lies below the warp yarns 3 and above the warp yarns 4. The next weft yarn 5 then lies above the warp yarns 3 and below the warp yarns 4. The fabric is then formed in this way. The resulting bond is a flat bond.A weft rep can be obtained similarly if groups of two warp yarns 3 and groups of two warp yarns 4 are alternately juxtaposed in the longitudinal direction of the fabric. Some of the warp yarns 3 and 4 have fused at least partially to each other on the back side of the smooth fabric 6. This is shown in Figure 1. figure 1 . Preferably, a portion of the warp threads 3 and 4 have melted at least partially on the back face of the smooth fabric 6 to a portion of the weft threads 5. There figure 2The diagram schematically shows a molecular model of a bond between a fabric and a needle-punched felt according to an embodiment of the present invention. A composition comprising reactive molecules B is applied to the back of the fabric 6 and to one face of the needle-punched felt 1. The back of the fabric 6 and the face of the needle-punched felt 1 bearing the applied composition comprising reactive molecules B are brought into close proximity, with an intermediate layer of reactive molecules A between these faces. After the reaction between molecules A and B has occurred, a bond 7 is formed between the fabric 6 and the needle-punched felt 1. The bond 7 utilizes the covalent interactions between molecules A and B. There figure 3 shows a device suitable for at least partially melting a portion of the warp threads to each other according to an embodiment of the method of the present invention.

[0101] The fabric 50' is directed through support rollers 41 and 42. The direction is from support roller 41 to support roller 42. Between the two support rollers 41 and 42, there is the heated surface 30. The heated surface pushes with a tip 33 against the back side of the fabric 50'. A part of the warp threads are mutually fused at least partially to the back side of the fabric 50'. The molten warp threads are distributed to an essentially flat surface by movement through the tip 33 of the heated surface 30. Afterwards, they cool and form the fabric 50, which is stronger, has greater dimensional stability and is more wear-resistant than the fabric 50'.

[0102] The heated surface 30 can be moved over a distance d. This distance d is, for example, from 0 mm to 50 mm. By taking a distance d greater than 0 mm, the tip 33 of the heated surface 30 pushes against the back side of the fabric. The required distance d is determined by the desired result of at least partial melting of a part of the warp threads, together with the temperature of the heated surface 30 and its tip 33, the speed with which the fabric 50' is directed through the tip 33 and the fabric 50' itself. If a fabric 50' is not resistant to a large distance d, further variations of the parameters speed, distance d and temperature of the heated surface 30 and its tip 33 are possible to achieve the desired result. EXAMPLES

[0103] The invention will now be described with the aid of the following example, without being limited thereto.

[0104] The example relates to an embodiment of a polyester conveyor belt, more particularly an aircraft conveyor belt, according to the invention. The aircraft conveyor belt comprises a smooth fabric, an intermediate layer, and a needle-punched felt.

[0105] Both the smooth fabric and the needle-punched felt are made of 100% flame-retardant PES. The intermediate layer contains PES adhesive. Therefore, the aircraft carpet is 100% recyclable and easily recycled after being replaced with a new one.

[0106] Needle-punched felt is a non-woven textile. HTH577 type Velcro strips are glued to the aircraft floor. Any loose filaments or loops in the needle-punched felt catch on the hooks of the Velcro strip. Therefore, the aircraft carpet can be quickly installed and replaced. The old carpet is simply peeled off the Velcro strips, and the new carpet is adhered to the Velcro strip. There are no adhesive residues to remove from the aircraft floor. Similarly, there are no adhesive residues on the needle-punched felt, simplifying recycling.

[0107] The fabric comprises warp and weft yarns with a yarn count of 2200 dtex. The yarns have an average elongation at break of 30% and a minimum tensile strength of 3 g / den, tested according to ISO 2062. The average boiling shrinkage of the yarns is 1.5%, according to ISO 12590. There are 17 warp yarns per cm² of fabric and 5 weft yarns per cm² of fabric. This results in a strong yet lightweight fabric. The fabric weight is limited to 570 g / m².

[0108] A portion of the warp and weft yarns have at least partially fused together on the back side of the fabric. This strengthens the fabric and increases dimensional stability. The warp and weft yarns are less mobile relative to each other, leading to less friction between them and therefore less wear under the daily load of passengers and luggage trolleys. Because the fabric is stronger and has greater dimensional stability due to the at least partial fusion of some of the warp and weft yarns, it is not necessary to use glue to secure the knots between the warp and weft yarns. The intermediate layer, which contains glue, is therefore lighter. The weight of the intermediate layer is limited to 130 g / m².

[0109] Needle felts are suitable for providing the necessary dimensional stability to aircraft carpets. Needle felt is suitable for increasing the walking comfort of passengers on aircraft carpets and for serving as sound insulation. Because the fabric is stronger due to the at least partial melting of some of the warp and weft threads, the fabric already has a certain dimensional stability. Therefore, it is possible to use thinner needle felt for aircraft carpets. Needle felt has a maximum weight of 150 g / m 2< . The total weight of a carpet is therefore 850 g / m 2< .

[0110] The aircraft carpet was tested according to FAR 25.853 for flammability, specifically FAR 25.853(A)-App.f Part I para (a)(1)(ii) Measurement of flammability of aircraft material. The test was conducted in a draft-free cabinet in accordance with Federal Test Method Standard 191, Method 5903.2. Three 75 mm x 305 mm samples of the aircraft carpet were exposed for 60 s to a Bunsen burner flame with a temperature of at least 843°C. The samples were suspended vertically in their longitudinal direction 20 mm above the tip of the Bunsen burner. The Bunsen burner flame had a height of 40 mm measured from the tip of the Bunsen burner. The aircraft carpet then burned for an average of no more than 2 s over a length and width of less than 80 mm. There were no hot parts of the airplane carpet falling off.Therefore, the aircraft carpet meets the standard, which requires that, after removal of the flame, the carpet continues to burn for a maximum of 15 s, that the carpet burns over a maximum length of 152 mm and that burning parts of the carpet burn for a maximum of 5 s.

[0111] The aircraft carpet has been subjected to a Vetterman test and a Lisson test. The Vetterman test simulates wear under laboratory conditions. The Lisson test determines mass loss and fiber or thread binding after the aircraft carpet has been subjected to a prescribed number of double passes of a quadruped wheel. For both tests, the aircraft carpet achieved the highest classification of 33, meaning it is suitable for heavy intensive use. The aircraft carpet is suitable for the daily heavy load of passengers and trolley suitcases.

[0112] The aircraft carpet meets the ISO 6356 standard concerning the tendency of static electricity formation in textile and laminated chipboard floor coverings.

Claims

1. A flame retardant carpet suitable for use inside means of transport, preferably aircrafts, comprising: - a mechanically woven fabric with a maximum weight of 650 g / m2, comprising a front face as a use surface and a back face, comprising warp and weft yarns of essentially 100% thermoplastic flame retardant polyester, - a needle felt with a maximum weight of 220 g / m2 of essentially 100% thermoplastic flame retardant polyester, - an intermediate layer between the needle felt and the mechanically woven fabric with a maximum weight of 180 g / m2, characterized in that a portion of the warp threads on the back side of the mechanically woven fabric have at least partially fused to each other.

2. Carpet according to claim 1, characterized in that the thread number of the warp and weft threads is 1100 dtex to 4400 dtex.

3. Carpet according to claim 1 or 2, characterized in that the number of warp threads per cm of fabric is 8 to 30.

4. Carpet according to one of the preceding claims 1 to 3, characterized in that the number of weft threads per cm of fabric is 3 to 10.

5. Carpet according to one of the preceding claims 1 to 4, characterized in that the weight of the carpet is at most 950 g / m2.

6. Carpet according to one of the preceding claims 1 to 5, characterized in that the mechanically woven fabric and the needle felt are laminated to each other with the aid of the intermediate layer.

7. Carpet according to one of the preceding claims 1 to 6, characterized in that the intermediate layer comprises polyester adhesive.

8. Carpet according to one of the preceding claims 1 to 6, characterized in that the carpet comprises reactive molecules for the formation of thermoreversible covalent interactions in the intermediate layer, in which the thermoreversible covalent interactions are Michael reactions, nitroso dimerization reactions, cyclic anhydride reactions in which ester compounds are composed, urethane formation reactions, aliphatic ion formation reactions, phenol- azlactone adduction formation reactions or reactions between a first molecule, comprising a conjugated diene group and a second molecule comprising a dienophile group .

9. Carpet according to one of the preceding claims 1 to 8, characterized in that a part of the weft threads of the mechanically woven fabric has at least partially fused with a part of the warp threads.

10. Method for manufacturing a flame retardant carpet suitable for the interior of means of transport, preferably aircrafts, comprising: - mechanical weaving of a fabric with a maximum weight of 650 g / m2, comprising a front face as a use surface and a back face, comprising warp and weft yarns of essentially 100% flame retardant thermoplastic polyester, - the manufacture of a needle felt with a maximum weight of 220 g / m2 of essentially 100% flame retardant thermoplastic polyester, - lamination of needle felt with a maximum weight of 180 g / m2 to the fabric using an intermediate layer, characterized in that the method comprises the additional step prior to lamination of directing the back face of the fabric along a heated surface to at least partially melt a portion of the warp yarns on the back face of the mechanically woven fabric together.

11. The method of claim 10, characterized in that the lamination comprises the use of PES as an adhesive in the intermediate layer.

12. The method of claim 10, characterized in that the lamination comprises using reactive molecules to form thermoreversible covalent interactions in the intermediate layer, wherein the thermoreversible covalent interactions are Michael reactions, nitroso dimerization reactions, cyclic anhydride reactions in which ester compounds are composed, urethane forming reactions, aliphatic ion forming reactions , phenol- azlactone adduction forming reactions or reactions between a first molecule comprising a conjugated diene group and a second molecule comprising a dienophile group.

13. The method according to claim 10, 11 or 12, characterized in that the method comprises the additional step before lamination of directing the back face of the fabric along a heated surface to at least partially melt a part of the weft yarns at the back face of the mechanically woven fabric with a part of the warp yarns.