First carpet base material

Abstract

A first carpet base material comprising a nonwoven fabric comprising a first sheath-core bicomponent fiber having a first thermoplastic polymer in its core and a second thermoplastic polymer in its sheath, and a second sheath-core bicomponent fiber having a third thermoplastic polymer in its core and a fourth thermoplastic polymer in its sheath, wherein the first thermoplastic polymer in the core of the first sheath-core bicomponent fiber is a polymer of a different polymer series from the third thermoplastic polymer in the core of the second sheath-core bicomponent fiber, and the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber and the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber are preferably polymers of the same polymer series having the same melting temperature.

Description

[Technical field]

[0001] The present invention relates to a first carpet backing material, particularly a first carpet backing material for tufted carpets, particularly a first carpet backing material for carpet tiles, a method for producing the first carpet backing material, a tufted carpet comprising the first carpet backing material, and a carpet tile comprising the first carpet backing material and / or tufted carpet.

[0002] EP 3009553 A1 discloses a carpet primary backing comprising at least one nonwoven layer made from sheath-core bicomponent fibers comprising a polyamide polymer in the core and a polymer obtained by polymerization of an olefin having terminal or non-terminal double bonds in the sheath.

[0003] Although the first backing fabric of the carpet of EP 3009553 can facilitate chemical recycling of the tufted carpet, particularly when the pile yarn of the tufted carpet is formed from polyamide, the processing stability of the first backing fabric of such a carpet is not necessarily sufficient during the manufacturing process of the tufted carpet.

[0004] Therefore, it remains desirable to provide a carpet first backing material that has sufficient processing stability at both 22° and 100° after wetting, and that also enables chemical recycling of tufted carpets containing the carpet first backing material.

[0005] Accordingly, it is an object of the present invention to provide a first carpet backing material having sufficient processing stability while facilitating the recycling of tufted carpets including said first carpet backing material.

[0006] The object of the invention is achieved by a material according to any one of claims 1 to 11.

[0007] A first carpet backing material includes a nonwoven fabric including a first sheath-core bicomponent fiber having a first thermoplastic polymer in the core and a second thermoplastic polymer in the sheath, and a second sheath-core bicomponent fiber having a third thermoplastic polymer in the core and a fourth thermoplastic polymer in the sheath, wherein the first thermoplastic polymer in the core of the first sheath-core bicomponent fiber is a polymer of a different polymer series from the third thermoplastic polymer in the core of the second sheath-core bicomponent fiber, and the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber and the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber are polymers of the same polymer series. This first carpet backing material provides a carpet first backing having sufficient processing stability while facilitating recycling of a tufted carpet including the first carpet backing material.

[0008] The core of the first sheath-core bicomponent fiber comprises one or more thermoplastic polymers in an amount of at least 75% by weight, preferably at least 85% by weight, more preferably at least 90% by weight, based on the total weight of the core, but may comprise commonly used additives, such as spinning aids, fillers, flame retardants, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, colorants, or any combination thereof, in an amount of up to 25% by weight, preferably up to 20% by weight, more preferably up to 15% by weight, even more preferably up to 10% by weight, and most preferably up to 5% by weight, based on the total weight of the core.

[0009] The core of the first sheath / core bicomponent fiber comprises a first thermoplastic polymer as a main component, where the term main component is understood to mean that the core of the first sheath / core bicomponent fiber comprises more than 50% by weight, preferably at least 75% by weight, more preferably at least 90% by weight, more preferably at least 95% by weight of the first thermoplastic polymer. The core of the first sheath / core bicomponent fiber can consist of the first thermoplastic polymer and optionally commonly used additives.

[0010] The core of the second sheath-core bicomponent fiber comprises one or more thermoplastic polymers in an amount of at least 75% by weight, preferably at least 85% by weight, more preferably at least 90% by weight, based on the total weight of the core, but may comprise commonly used additives, such as spinning aids, fillers, flame retardants, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, colorants, or any combination thereof, in an amount of up to 25% by weight, preferably up to 20% by weight, more preferably up to 15% by weight, even more preferably up to 10% by weight, and most preferably up to 5% by weight, based on the total weight of the core.

[0011] The core of the second sheath / core bicomponent fiber comprises a third thermoplastic polymer as a major component, where the term major component is understood to mean that the core of the second sheath / core bicomponent fiber comprises more than 50% by weight, preferably at least 75% by weight, more preferably at least 90% by weight, more preferably at least 95% by weight of the third thermoplastic polymer. The core of the second sheath / core bicomponent fiber can consist of the third thermoplastic polymer and optionally commonly used additives.

[0012] The sheath of the first bicomponent core-sheath fiber comprises one or more thermoplastic polymers in an amount of at least 75% by weight, preferably at least 85% by weight, more preferably at least 90% by weight, based on the total weight of the sheath, but may comprise commonly used additives, such as spinning aids, fillers, flame retardants, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, colorants, or any combination thereof, in an amount of up to 25% by weight, preferably up to 20% by weight, more preferably up to 15% by weight, even more preferably up to 10% by weight, and most preferably up to 5% by weight, based on the total weight of the core.

[0013] The sheath of the first sheath-core bicomponent fiber comprises the second thermoplastic polymer as the main component, where the term main component is understood to mean that the sheath of the second sheath-core bicomponent fiber comprises more than 50% by weight, preferably at least 75% by weight, more preferably at least 90% by weight, more preferably at least 95% by weight of the second thermoplastic polymer. The sheath of the first sheath-core bicomponent fiber can consist of the second thermoplastic polymer and optionally commonly used additives.

[0014] The sheath of the second sheath-core bicomponent fiber comprises one or more thermoplastic polymers in at least 75% by weight, preferably at least 85% by weight, more preferably at least 90% by weight, based on the total weight of the sheath, but may comprise commonly used additives, such as spinning aids, fillers, flame retardants, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, colorants, or any combination thereof, in an amount of up to 25% by weight, preferably up to 20% by weight, more preferably up to 15% by weight, even more preferably up to 10% by weight, and most preferably up to 5% by weight, based on the total weight of the core.

[0015] The sheath of the second sheath-core bicomponent fiber comprises the fourth thermoplastic polymer as the main component, where the term main component is understood to mean that the sheath of the second sheath-core bicomponent fiber comprises more than 50% by weight, preferably at least 75% by weight, more preferably at least 90% by weight, more preferably at least 95% by weight of the fourth thermoplastic polymer. The sheath of the second sheath-core bicomponent fiber can consist of the fourth thermoplastic polymer and optionally commonly used additives.

[0016] The term polymers of the same polymer series is understood to mean that the monomers in one polymer and the monomers in the further polymer are linked by the same type of chemical bond, as is well known to those skilled in the art.For example, if in a first polymer two monomers are linked by ester units, i.e. ester bonds, and in a second polymer two monomers are linked by ester bonds, then the first polymer and the second polymer are members of the polyester polymer series.For example, if in a first polymer two monomers are linked by amide units, i.e. amide bonds, and in a second polymer two monomers are linked by amide bonds, then the first polymer and the second polymer are members of the polyamide polymer series.

[0017] Preferably, at least 50% of the chemical bonds between monomers in the second thermoplastic polymer contained in the sheath of the first sheath-core bicomponent fiber are the same chemical bonds as at least 50% of the chemical bonds between monomers in the fourth thermoplastic polymer contained in the sheath of the second sheath-core bicomponent fiber. More preferably, at least 75% of the chemical bonds between monomers in the second thermoplastic polymer contained in the sheath of the first sheath-core bicomponent fiber are the same chemical bonds as at least 75% of the chemical bonds between monomers in the fourth thermoplastic polymer contained in the sheath of the second sheath-core bicomponent fiber. More preferably, at least 90% of the chemical bonds between monomers in the second thermoplastic polymer contained in the sheath of the first sheath-core bicomponent fiber are the same chemical bonds as at least 90% of the chemical bonds between monomers in the fourth thermoplastic polymer contained in the sheath of the second sheath-core bicomponent fiber. Even more preferably, at least 95% of the chemical bonds between the monomers in the second thermoplastic polymer in the sheath of the first bicomponent sheath / core fiber are the same as at least 95% of the chemical bonds between the monomers in the fourth thermoplastic polymer in the sheath of the second bicomponent sheath / core fiber. Most preferably, at least 98% of the chemical bonds between the monomers in the second thermoplastic polymer in the sheath of the first bicomponent sheath / core fiber are the same as at least 98% of the chemical bonds between the monomers in the fourth thermoplastic polymer in the sheath of the second bicomponent sheath / core fiber.

[0018] The second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber can have substantially the same melting temperature as the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber. The term substantially the same melting temperature is understood to mean that the melting temperature of the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber does not deviate by more than 10° C. from the melting temperature of the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber. Preferably, the melting temperature of the fourth thermoplastic polymer does not deviate by more than 5° C., more preferably does not deviate by more than 3° C., and most preferably does not deviate by more than 1° C. By having the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber have substantially the same melting temperature as the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber, the first carpet backing material can be thermally bonded at a temperature above the melting temperature of the second thermoplastic polymer, forming bond points at the fiber contact points without the risk of the fourth thermoplastic polymer not contributing to the formation of bond points at the fiber contact points, which would occur if the fourth thermoplastic polymer had a significantly higher melting temperature than the second thermoplastic polymer, or vice versa. Furthermore, undesirable degradation of the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber during thermal bonding is prevented or at least reduced, which would occur if the fourth thermoplastic polymer had a significantly lower melting temperature than the second thermoplastic polymer, or vice versa.

[0019] In one embodiment, the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber has the same melting temperature as the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber, where the term same melting temperature is understood to mean that the melting temperature of the fourth thermoplastic polymer deviates from the melting temperature of the second thermoplastic polymer by less than 1°C, preferably less than 0.5°C.

[0020] The second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber and the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber can be the same polymer, thereby reducing the number of raw materials required to manufacture the first carpet backing material.

[0021] The weight ratio of the core of the first sheath / core bicomponent fiber to the sheath of the first sheath / core bicomponent fiber can vary from 90:10 to 40:60, but is preferably in the range of 85:15 to 45:55, and more preferably in the range of 80:20 to 60:40.

[0022] The weight ratio of the core of the second sheath / core bicomponent fiber to the sheath of the second sheath / core bicomponent fiber can vary from 90:10 to 40:60, but is preferably in the range of 85:15 to 45:55, and more preferably in the range of 80:20 to 60:40.

[0023] In the first carpet backing material, the first sheath / core bicomponent fiber can exhibit any cross-sectional shape. Preferably, the cross-sectional shape of the first sheath / core bicomponent fiber is circular or elliptical. However, the cross-sectional shape of the first sheath / core bicomponent fiber may also be triangular, rectangular, or multilobal, such as bilobal or trilobal.

[0024] In the first carpet backing material, the second sheath / core bicomponent fiber can exhibit any cross-sectional shape. Preferably, the cross-sectional shape of the second sheath / core bicomponent fiber is circular or elliptical. However, the cross-sectional shape of the second sheath / core bicomponent fiber can also be triangular, rectangular, or multilobal, such as bilobal or trilobal.

[0025] By selecting a particular cross-sectional shape of the first sheath / core bicomponent fiber and / or the second sheath / core bicomponent fiber, the bond strength between the first sheath / core bicomponent fiber and / or the second sheath / core bicomponent fiber can be fine-tuned to improve friction between the first carpet backing material and the pile yarn.

[0026] Within the scope of the present invention, the term fiber is understood to refer to both staple fibers and filaments. Staple fibers are fibers having a specific, relatively short length in the range of 2 to 200 mm. Filaments are fibers having a length of more than 200 mm, preferably more than 500 mm, more preferably more than 1000 mm. Filaments may even be substantially endless, for example when formed by continuous extrusion and spinning of filaments through spinneret spinneret holes. Preferably, the first sheath-core bicomponent fiber contained in the nonwoven fabric of the first carpet backing material is a filament, and / or the second sheath-core bicomponent fiber contained in the nonwoven fabric of the first carpet backing material is a filament, thereby further improving the breaking strength and / or tear strength of the first carpet backing material and / or the tufted carpet and / or the carpet tile.

[0027] In the first carpet backing material, the linear density of the first sheath / core bicomponent fiber may vary, but preferably the linear density of the first sheath / core bicomponent fiber is in the range of 1 dtex to 25 dtex, more preferably in the range of 2 to 20 dtex, and most preferably in the range of 5 to 15 dtex. The linear density of the fiber is expressed in dtex, which is the weight in grams per 10,000 meters of fiber length.

[0028] In the first carpet backing material, the linear density of the second sheath / core bicomponent fiber may vary, but preferably the linear density of the second sheath / core bicomponent fiber is in the range of 1 dtex to 25 dtex, more preferably in the range of 2 to 20 dtex, and most preferably in the range of 5 to 15 dtex.

[0029] A carpet primary backing material comprising a first sheath / core bicomponent fiber having these preferred linear density ranges and / or a nonwoven comprising a second sheath / core bicomponent fiber having these preferred linear density ranges can provide a primary backing that has a minimum level of process stability as well as a minimum level of stitch retention, i.e., ability to hold tufts in place, during tufting of the carpet primary backing.

[0030] The first carpet backing material can include a first sheath / core bicomponent fiber having a mixture of different linear densities and / or can include a second sheath / core bicomponent fiber having a mixture of different linear densities.

[0031] The nonwoven fabric contained in the first carpet backing material may in principle be any type of nonwoven fabric, such as, for example, a staple fiber nonwoven fabric produced by known processes such as carding, wet-laid, air-laid, etc., or any combination thereof. However, preferably, the nonwoven fabric contained in the first carpet backing material is a nonwoven fabric composed of filaments produced by the known spunbond process, in which the filaments are extruded through a spinneret and then laid as a web of filaments on a conveyor belt, which is then subjected to a bonding process, also known as bonding, to form a nonwoven fabric, or by a two-stage process, in which the filaments are spun and wound onto bobbins, preferably in the form of multifilament yarns, and then the filaments or multifilament yarns are unwound, the filaments are laid as a web of filaments on a conveyor belt, which is then subjected to a bonding process to form a nonwoven fabric.

[0032] The nonwoven fabrics in the first carpet backing material may be bonded by any suitable known bonding technique, including mechanical bonding, such as stitching, mechanical needling and / or hydrodynamic bonding by fluid jets, especially hydroentanglement, chemical bonding, such as by applying a binder dispersion or solution to the web, which is generally dried and optionally cured, and / or thermal bonding, such as calendaring, ultrasonic bonding and / or hot air bonding. Preferably, the nonwoven fabrics in the first carpet backing material are bonded by thermal bonding, more preferably hot air bonding.

[0033] In one embodiment, the second thermoplastic polymer in the sheath of the first bicomponent core / sheath fiber is a polyamide and the fourth thermoplastic polymer is a polyamide.

[0034] The melting temperature of the polyamide may vary, but preferably the melting temperature of the polyamide is in the range of 180°C to 300°C, more preferably 200°C to 270°C, and most preferably 215°C to 230°C.

[0035] The polyamide comprising the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber and the polyamide comprising the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber may each be an independently selected polyamide or copolyamide, preferably selected from the group consisting of polyamide-6, recycled polyamide-6, bio-based polyamide-6, i.e. polyamide-6 polymerized from monomers obtained from renewable sources, and copolymers and / or blends thereof. The selection of recycled polyamide-6 and / or bio-based polyamide-6 further allows the first base material to be produced in a more sustainable manner.

[0036] In one embodiment, the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber is polyamide-6, and the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber is polyamide-6.

[0037] In one embodiment, the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber is a polyolefin, and the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber is a polyolefin.

[0038] The melting temperature of the polyolefin may vary, but preferably, the melting temperature of the polyolefin is in the range of 80°C to 200°C, more preferably 100°C to 180°C, and most preferably 150°C to 170°C.

[0039] The polyolefin comprising the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber and the polyolefin comprising the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber may each be a polyolefin independently selected from the group consisting of polyethylene, polypropylene, such as isotactic polypropylene, syndiotactic polypropylene, or atactic polypropylene, and copolymers and / or blends thereof.

[0040] In one embodiment, the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber is polypropylene and the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber is polypropylene.

[0041] In one embodiment, the first thermoplastic polymer in the core of the first sheath / core bicomponent fiber is a polyester and the third thermoplastic polymer in the core of the second sheath / core bicomponent fiber is a polyamide.

[0042] The polyester included in the core of the first sheath-core bicomponent fiber may be recycled polyester, preferably recycled polyethylene terephthalate, to enable production of the first base material in a more sustainable manner.

[0043] In one embodiment, the first thermoplastic polymer in the core of the first sheath-core bicomponent fiber is a polyester and the third thermoplastic polymer in the core of the second sheath-core bicomponent fiber is a polyamide, particularly when the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber is a polyolefin and the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber is a polyolefin. When the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber is a polyamide, particularly polyamide-6, the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber is a polyamide, particularly polyamide-6, and the first thermoplastic polymer in the core of the first sheath-core bicomponent fiber is a polyester, preferably polyethylene terephthalate, it has been observed that the stability of tufted carpets, particularly carpet tiles, is improved compared to the dimensional stability of tufted carpets, particularly carpet tiles, made of sheath-core bicomponent fibers having a polyamide core and a polyolefin sheath.

[0044] In a preferred embodiment, the first thermoplastic polymer in the core of the first sheath / core bicomponent fiber is a polyester, preferably polyethylene terephthalate, the third thermoplastic polymer in the core of the second sheath / core bicomponent fiber is polyamide-6, preferably the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber is polypropylene, and preferably the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber is polypropylene, allowing chemical recycling of tufted carpets comprising the first carpet backing material and / or carpet tiles comprising the first carpet backing material and / or tufted carpet in a process comprising depolymerization of polyamide-6 to its constituent monomers and repolymerization to polyamide-6, particularly when the pile yarn of the tufted carpet comprises or consists of polyamide-6. In a chemical recycling process, the polyamide can be depolymerized into its monomers, which can be used to synthesize new polyamides without costly separation steps to remove the undesired monomers. The first thermoplastic polymer can be a polyester, preferably polyethylene terephthalate, to provide sufficient processing and / or dimensional stability for tufted carpets, especially carpet tiles that include the first carpet backing material.

[0045] In one embodiment, the first thermoplastic polymer is a polyester, preferably polyethylene terephthalate, and the third thermoplastic polymer is a polyolefin, such as polypropylene or polymethylpentene, preferably polypropylene.

[0046] In one embodiment, the first thermoplastic polymer is a polyester and the third thermoplastic polymer is a polyolefin, particularly when the second thermoplastic polymer in the sheath of the first sheath / core bicomponent fiber is a polyamide and the fourth thermoplastic polymer in the sheath of the second sheath / core bicomponent fiber is a polyamide.

[0047] In a preferred embodiment, the first thermoplastic polymer is polyethylene terephthalate, the third thermoplastic polymer is a polyolefin, preferably polypropylene or polymethylpentene, preferably the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber is a polyamide, in particular polyamide-6, and preferably the fourth thermoplastic polymer in the sheath of the second sheath-core bicomponent fiber is a polyamide, in particular polyamide-6. The first thermoplastic polymer being a polyester, preferably polyethylene terephthalate, can provide sufficient processing and / or dimensional stability to the tufted carpet, particularly the carpet tile comprising the first carpet backing material, while the polyamide, particularly polyamide-6, contained in the sheath of the first sheath-core bicomponent fiber and in the sheath of the second sheath-core bicomponent fiber allows chemical recycling of the tufted carpet comprising the first carpet backing material and / or the carpet tile comprising the first carpet backing material and / or the carpet tile comprising the tufted carpet in a process comprising a step of depolymerizing polyamide-6 to its constituent monomers and a step of repolymerizing said monomers to polyamide-6, particularly when the pile yarn of the tufted carpet comprises polyamide-6. The third thermoplastic polymer contained in the core of the second sheath-core bicomponent fiber is a polyolefin, which allows the first carpet backing material to be produced more economically, allows chemical recycling of the tufted carpet and / or the carpet tile, and provides sufficient processing stability to the carpet backing material.

[0048] The first carpet backing material can include one or more fibrous layers including a mixture, preferably a homogeneous mixture, of first sheath / core bicomponent fibers and second sheath / core bicomponent fibers, which can prevent or at least reduce delamination between the fibrous layers of the first carpet backing material.

[0049] The first carpet backing material may include a first fibrous layer including a first sheath-core bicomponent fiber and a second fibrous layer including a second sheath-core bicomponent fiber to improve the processing stability of the first carpet backing material. The first fibrous layer is preferably made of the first sheath-core bicomponent fiber. The second fibrous layer is preferably made of the second sheath-core bicomponent fiber.

[0050] The first carpet backing material may further comprise a third fibrous layer comprising the first sheath / core bicomponent fibers and / or a fourth fibrous layer comprising the second sheath / core bicomponent fibers. The third fibrous layer is preferably comprised of the first sheath / core bicomponent fibers. The fourth fibrous layer is preferably comprised of the second sheath / core bicomponent fibers.

[0051] The third fibrous layer comprising the first sheath / core bicomponent fiber can be positioned directly adjacent to the first fibrous layer comprising the first sheath / core bicomponent fiber, preferably in a plane parallel to the first fibrous layer comprising the first sheath / core bicomponent fiber, allowing the first carpet backing material to have improved processing stability.

[0052] A fourth fibrous layer comprising the second sheath / core bicomponent fiber can be positioned directly adjacent to the second fibrous layer comprising the second sheath / core bicomponent fiber, preferably in a plane parallel to the second fibrous layer comprising the second sheath / core bicomponent fiber.

[0053] In one embodiment, a fourth fibrous layer comprising the second sheath / core bicomponent fiber is arranged directly adjacent to a third fibrous layer comprising the first sheath / core bicomponent fiber, preferably in a plane parallel to the third fibrous layer comprising the first sheath / core bicomponent fiber; the third fibrous layer comprising the first sheath / core bicomponent fiber is arranged directly adjacent to a second fibrous layer comprising the second sheath / core bicomponent fiber, preferably in a plane parallel to the second fibrous layer comprising the second sheath / core bicomponent fiber; and the second fibrous layer comprising the second sheath / core bicomponent fiber is arranged directly adjacent to a first fibrous layer comprising the first sheath / core bicomponent fiber, preferably in a plane parallel to the first fibrous layer comprising the first sheath / core bicomponent fiber.

[0054] In one embodiment, a second fibrous layer comprising a second sheath / core bicomponent fiber and / or a fourth fibrous layer comprising a second sheath / core bicomponent fiber is disposed between the first fibrous layer comprising the first sheath / core bicomponent fiber and the third fibrous layer comprising the first sheath / core bicomponent fiber, thereby preventing or at least reducing dishing or doming of the carpet tile due to differences in shrinkage and / or expansion effects between the individual layers.

[0055] In a preferred embodiment, the first fibrous layer comprising the first sheath / core bicomponent fiber and / or the third fibrous layer comprising the first sheath / core bicomponent fiber are disposed between the second fibrous layer comprising the second sheath / core bicomponent fiber and the fourth fibrous layer comprising the second sheath / core bicomponent fiber, thereby preventing or at least reducing dishing or doming of the carpet tile due to differences in shrinkage and / or expansion effects between the individual layers, and enabling the first carpet backing material to have improved processing stability.

[0056] The third fibrous layer and / or the fourth fibrous layer can be comprised of a mixture, preferably a homogenous mixture, of the first sheath / core bicomponent fiber and the second sheath / core bicomponent fiber, which allows for improved peel strength between the fibrous layers of the first carpet backing material.

[0057] The nonwoven fabric contained in the first carpet base material is 30 g / m 2 ~250g / m 2 weight, preferably 40 g / m 2 ~200g / m 2 weight, more preferably 50 g / m 2 ~150g / m 2 weight, more preferably 60 g / m 2 ~140g / m 2 weight, more preferably 65 g / m 2 ~125g / m 2 weight, most preferably 70 g / m 2 ~120g / m 2 The weight of the sintered body may be 1.0 to 1.0 kg.

[0058] The carpet primary backing material may include a reinforcing layer, preferably a scrim, to further improve the processing stability of such carpet primary backing at both 22°C and 100°C after wetting.

[0059] The scrim may be a laid scrim or a woven scrim. As is well known to those skilled in the art, a scrim, whether a laid scrim or a woven scrim, is an open lattice structure composed of at least two sets of parallel yarns, the first set of parallel yarns being oriented at an angle, typically a 90° angle, to the second set of parallel yarns. The first set of parallel yarns may be connected to the second set of parallel yarns by chemical bonds to form a laid scrim, and the first set of parallel yarns may be interwoven with the second set of parallel yarns to form a woven scrim. In one embodiment, the openings in the scrim have at least one dimension in the plane of the scrim that is at least 1 mm, preferably at least 2 mm, more preferably 5 mm.

[0060] Preferably, the first backing material comprises at most 45% by weight of polyester based on the total weight of the first carpet backing material, and more preferably, the first backing material comprises at most 40% by weight of polyester based on the total weight of the first carpet backing material.

[0061] The objects of the present invention may further be achieved by a tufted carpet comprising a first carpet backing material according to any of the above-described embodiments and pile yarns fixedly connected to the first backing.

[0062] The pile yarn comprises one or more thermoplastic polymers at least 75% by weight, preferably at least 85% by weight, more preferably at least 90% by weight, based on the total weight of the pile yarn, but may comprise commonly used additives such as spinning aids, fillers, flame retardant materials, UV inhibitors, crystallization retarders / accelerators, plasticizers, heat stabilizers, antimicrobial additives, antistatic agents, colorants or any combination thereof in an amount of up to 25% by weight, preferably up to 20% by weight, more preferably up to 15% by weight, even more preferably up to 10% by weight, most preferably up to 5% by weight, based on the total weight of the core.

[0063] The pile yarns fixedly connected to the first backing may comprise any suitable polyamide, preferably polyamide-6. Preferably, the pile yarns comprise polyamide, most preferably polyamide-6, as a main component, where the term main component is understood to mean that the pile yarns comprise more than 50% by weight of polyamide, preferably at least 75% by weight, more preferably at least 90% by weight, more preferably at least 95% by weight, which may enable efficient chemical recycling of tufted carpets comprising the first carpet backing material and / or carpet tiles comprising the tufted carpet in a process comprising depolymerization steps of polyamide-6 to its constituent monomers and repolymerization steps of the monomers to polyamide-6.

[0064] The tufted carpet may comprise a first carpet backing material, wherein the second thermoplastic polymer in the sheath of the first sheath-core bicomponent fiber is a polyamide, preferably polyamide-6, and the fourth thermoplastic polymer is a polyamide, preferably polyamide-6, and the tufted carpet may comprise a pile yarn fixedly connected to the first backing, wherein the pile yarn comprises a polyamide, preferably polyamide-6, and a thermal bond is formed between the pile yarn and the first carpet backing material, for example by applying a process as disclosed in EP 1 598 476 A or WO 2012 / 076348 A, thereby providing the tufted carpet with increased tuft bond strength according to ISO 4919.

[0065] The tufted carpet may include a reinforcing layer, preferably a scrim, to further improve the dimensional stability of the tufted carpet. The reinforcing layer may be included in the primary carpet backing material or may be included in the tufted carpet so as to underlie the primary carpet backing and pile yarns.

[0066] The scrim may be a laid scrim or a woven scrim. As is well known to those skilled in the art, a scrim, whether a laid scrim or a woven scrim, is an open lattice structure composed of at least two sets of parallel yarns, the first set of parallel yarns being oriented at an angle, typically a 90° angle, to the second set of parallel yarns. The first set of parallel yarns may be connected to the second set of parallel yarns by chemical bonds to form a laid scrim, and the first set of parallel yarns may be interwoven with the second set of parallel yarns to form a woven scrim. In one embodiment, the openings in the scrim have at least one dimension in the plane of the scrim that is at least 1 mm, preferably at least 2 mm, more preferably 5 mm.

[0067] A tufted carpet comprising a first carpet backing material according to any of the above-mentioned embodiments as a first backing and a pile yarn fixedly connected to the first backing allows the tufted carpet to be chemically recycled in a polyamide-6 recycling process. Preferably, the tufted carpet comprises at most 10% by weight, more preferably at most 6% by weight, of polyester based on the total weight of the first carpet backing material and the pile yarn. Preferably, the tufted carpet comprises at most 5% by weight, more preferably at most 4% by weight, most preferably at most 3% by weight, of polyester based on the total weight of the first carpet backing material and the pile yarn, allowing efficient chemical recycling of the tufted carpet in a process comprising a step of depolymerizing polyamide-6 into its constituent monomers and a step of repolymerizing it into polyamide-6, especially when the pile yarn comprises polyamide as a main component or is made of polyamide, especially polyamide-6.

[0068] The object of the present invention may further be achieved by a carpet tile comprising a first carpet backing material according to any of the above-mentioned embodiments and / or a tufted carpet according to any of the above-mentioned embodiments.

[0069] The carpet tile may further include a separation layer between the tufted carpet primary backing, which includes pile yarns fixedly connected to the primary carpet backing material, and the underlying structure, thereby enabling separation of the underlying structure from the primary carpet backing material and the pile yarns to improve the chemical recycling process.

[0070] Working Example Example 1 A first carpet backing material was provided comprising a nonwoven fabric comprising four fibrous layers, where the fibers had a linear density of 15 dtex.

[0071] The first fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0072] The second fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0073] The third fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0074] The fourth fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0075] The third fibrous layer is positioned directly adjacent to the first fibrous layer, the first fibrous layer is positioned directly adjacent to the fourth fibrous layer, and the fourth fibrous layer is positioned directly adjacent to the second fibrous layer.

[0076] The weight of the nonwoven fabric is 110g / m 2 It was.

[0077] Example 2 A first carpet backing material was provided comprising a nonwoven fabric comprising four fibrous layers, where the fibers had a linear density of 15 dtex.

[0078] The first fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0079] The second fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0080] The third fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0081] The fourth fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0082] The third fibrous layer is positioned directly adjacent to the fourth fibrous layer, which is positioned directly adjacent to the first fibrous layer, which is positioned directly adjacent to the second fibrous layer.

[0083] The weight of the nonwoven fabric is 110g / m 2 It was.

[0084] Example 3 A first carpet backing material was provided comprising a nonwoven fabric comprising four fibrous layers, where the fibers had a linear density of 15 dtex.

[0085] The first fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0086] The second fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0087] The third fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0088] The fourth fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0089] The fourth fibrous layer is positioned directly adjacent to the third fibrous layer, which is positioned directly adjacent to the first fibrous layer, which is positioned directly adjacent to the second fibrous layer.

[0090] The weight of the nonwoven fabric is 110g / m 2 It was.

[0091] Example 4 A first carpet backing material was provided comprising a nonwoven fabric comprising four fibrous layers, where the fibers had a linear density of 15 dtex.

[0092] The first fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0093] The second fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0094] The third fiber layer is composed of a first core-sheath type bicomponent filament having a core of polyethylene terephthalate with a melting temperature of 250°C and a sheath of polypropylene with a melting temperature of 165°C and a melt flow index of 25 g / 10 min in a weight ratio of 80:20.

[0095] The fourth fiber layer is made of a second core-sheath type bicomponent filament having a core of polyamide-6 with a melting temperature of 220° C. and a sheath of polypropylene with a melting temperature of 165° C. and a melt flow index of 25 g / 10 min in a weight ratio of 77:23.

[0096] The third fibrous layer is positioned directly adjacent to the fourth fibrous layer, which is positioned directly adjacent to the second fibrous layer, which is positioned directly adjacent to the first fibrous layer.

[0097] The weight of the nonwoven fabric is 110g / m 2 It was.

[0098] Comparative Example 1 A carpet first backing material was provided comprising a nonwoven fabric consisting of four fibre layers according to EP 3009553 A1, where the fibres had a linear density of 15 dtex and each fibre layer consisted of a sheath-core bicomponent filament comprising a polyamide-6 core and a polypropylene sheath in a weight ratio of 77:23.

[0099] The weight of the nonwoven fabric is 110g / m 2 It was.

[0100] The first carpet backing material was tufted into a tufted carpet comprising a first carpet backing material and a pile yarn fixedly connected to the first backing. The pile yarn was a polyamide-6 pile yarn having a linear density of 2700 dtex. The tufted carpet comprised pile yarns spaced 1 / 10 inch across and 50 pile yarns per 10 cm in the machine direction.

[0101] 1m for carpet base material 50cm wide and 600cm long 2 The processing stability of a first carpet backing material at 22°C is determined by applying a load of 30 kg / m in the machine direction under wet conditions by spraying an area of ​​200 ml of water onto the material, which is defined as the dimensional change in the machine direction and cross direction.

[0102] A load of 30 kg / m is applied in the machine direction to a carpet base material 50 cm wide and 600 cm long, and the 2 The processing stability of a first carpet backing material at 100°C is determined by measuring the dimensional changes in the machine and cross directions at 100°C under wet conditions by spraying an area of ​​200 ml of water. The first carpet backing material is heated until it reaches a temperature of 100°C. After reaching 100°C, the first carpet backing material is removed from the oven. Processing stability is defined as the dimensional changes in the machine and cross directions, which are measured immediately after the first carpet backing material is removed from the oven.

[0103] The free shrinkage of a tufted carpet comprising a first carpet backing material and pile yarns fixedly connected to the first backing is determined by heating a tufted carpet 50 cm wide and 50 cm long in an oven at 100°C for 15 minutes and measuring the dimensional changes in the machine direction and cross direction.

[0104] [Table 1]

[0105] The carpet first base fabric materials according to Examples 1 to 4 have significantly improved processing stability, i.e., exhibit less dimensional change in both the machine direction (MD) and cross machine direction (CMD), at 22°C and a load of 30 kg / m, than Comparative Example 1.

[0106] The carpet first backing materials according to Examples 1 to 4 have significantly improved processing stability, i.e., exhibit less dimensional change in both the machine direction (MD) and cross machine direction (CMD), at 100°C and a load of 30 kg / m, than Comparative Example 1 after wetting.

[0107] The carpet first backing materials according to Examples 1 to 4 have improved free shrinkage rates compared to Comparative Example 1, at least in the machine direction.

[0108] The carpet first backing materials according to Examples 1 and 3 have even further improved processing stability than Examples 2 and 4 at 22°C and a load of 30 kg / m, i.e., they exhibit less dimensional change in both the machine direction (MD) and cross direction (CMD).

[0109] The carpet first backing materials according to Examples 1 and 3 have further improved processing stability after wetting at 100°C and a load of 30 kg / m compared to Examples 2 and 4, i.e., they show less dimensional change in both the machine direction (MD) and cross direction (CMD).

[0110] The carpet first base material according to Example 3 includes a symmetric build-up in the order of fiber layers for the first sheath / core bicomponent fiber and the second sheath / core bicomponent fiber, thereby preventing or at least reducing the risk of dishing or doming of carpet tiles including the carpet first base material due to differential shrinkage and / or expansion effects between the individual fiber layers compared to Example 1.

[0111] The carpet primary backing material is primarily suitable for use as a carpet primary backing, although the material may also be used as a carrier for (cushioned) vinyl flooring, filtration media, roofing underlayment or bituminous roofing membranes.

Claims

1. A first base fabric material for carpets, comprising a non-woven fabric containing a first core-sheath type bicomponent fiber having a first thermoplastic polymer in the core part and a second thermoplastic polymer in the sheath part, and a second core-sheath type bicomponent fiber having a third thermoplastic polymer in the core part and a fourth thermoplastic polymer in the sheath part, wherein the first thermoplastic polymer contained in the core part of the first core-sheath type bicomponent fiber is a polymer of a different polymer series from the third thermoplastic polymer contained in the core part of the second core-sheath type bicomponent fiber, and the second thermoplastic polymer contained in the sheath part of the first core-sheath type bicomponent fiber and the fourth thermoplastic polymer contained in the sheath part of the second core-sheath type bicomponent fiber are polymers of the same polymer series having preferably substantially the same melting temperature.

2. The first base fabric material for carpets according to claim 1, wherein the second thermoplastic polymer contained in the sheath part of the first core-sheath type bicomponent fiber and the fourth thermoplastic polymer contained in the sheath part of the second core-sheath type bicomponent fiber are the same polymer.

3. The first base fabric material for carpets according to claim 1, wherein the second thermoplastic polymer contained in the sheath part of the first core-sheath type bicomponent fiber is a polyolefin, preferably polypropylene, and the fourth thermoplastic polymer contained in the sheath part of the second core-sheath type bicomponent fiber is a polyolefin, preferably polypropylene.

4. The first base fabric material for carpets according to claim 1, wherein the first thermoplastic polymer contained in the core part of the first core-sheath type bicomponent fiber is a polyester, preferably polyethylene terephthalate, and the third thermoplastic polymer contained in the core part of the second core-sheath type bicomponent fiber is a polyamide, preferably polyamide-6.

5. The first base fabric material for carpets according to claim 1, wherein the second thermoplastic polymer is a polyamide, preferably polyamide-6, and the fourth thermoplastic polymer is a polyamide, preferably polyamide-6.

6. The first base fabric material for carpets according to claim 1, wherein the first thermoplastic polymer is a polyester, preferably polyethylene terephthalate, and the third thermoplastic polymer is a polyolefin, preferably polypropylene.

7. The first base fabric material for carpet according to claim 1, wherein the nonwoven fabric includes a first fiber layer containing first core-sheath type bicomponent fibers and a second fiber layer containing second core-sheath type bicomponent fibers.

8. The first base fabric material for carpet according to claim 7, wherein the nonwoven fabric includes a third fiber layer containing first core-sheath type bicomponent fibers and / or a fourth fiber layer containing second core-sheath type bicomponent fibers.

9. The first base fabric material for carpet according to claim 8, wherein the third fiber layer containing first core-sheath type bicomponent fibers is arranged so as to be directly adjacent to the first fiber layer containing first core-sheath type bicomponent fibers.

10. The first base fabric material for carpet according to claim 8, wherein the first fiber layer and / or the third fiber layer is arranged between the second fiber layer and the fourth fiber layer.

11. The first base fabric material for carpet according to claim 8, wherein the second fiber layer and / or the fourth fiber layer is arranged between the first fiber layer and the third fiber layer.

12. A tufted carpet comprising the first base fabric material for carpet according to claim 1 as a first base fabric and a pile yarn fixedly connected to the first base fabric.

13. The tufted carpet according to claim 12, wherein the pile yarn mainly contains a polyamide polymer, preferably a polyamide-6 polymer.

14. A carpet tile comprising the first base fabric material for carpet according to claim 1 and / or the tufted carpet according to claim 12.

15. A method for manufacturing a first base fabric material for carpets according to claim 1, the method comprising: providing a first core-sheath type bicomponent fiber containing a first thermoplastic polymer in a core part and a second thermoplastic polymer in a sheath part; providing a second core-sheath type bicomponent fiber containing a third thermoplastic polymer in a core part and a fourth thermoplastic polymer in a sheath part; and forming the first core-sheath type bicomponent fiber and the second core-sheath type bicomponent fiber into a nonwoven fabric, wherein the first thermoplastic polymer contained in the core part of the first core-sheath type bicomponent fiber is a polymer of a polymer series different from the third thermoplastic polymer contained in the core part of the second core-sheath type bicomponent fiber, and the second thermoplastic polymer contained in the sheath part of the first core-sheath type bicomponent fiber and the fourth thermoplastic polymer contained in the sheath part of the second core-sheath type bicomponent fiber are preferably polymers of the same polymer series having substantially the same melting temperature.