Tufted carpet including secondary carpet backing fabric

Abstract

1. A tufted carpet comprising a tufted primary carpet backing, pile yarns tufted into the primary carpet backing, a secondary carpet backing adjacent to the primary carpet backing on a side of the primary carpet backing where the backstitch is visible, and an optional precoat and / or polymer coat, wherein the secondary carpet backing includes at least a reinforcing layer of fiber, and the secondary carpet backing has a fiber yield of at least 1000 l / m2 as measured in accordance with ISO 9237:1995. 2 Tufted carpet with a breathability of s.

Description

[Technical Field]

[0001] This application relates to a tufted carpet including a carpet secondary base fabric, and to a method for manufacturing such a tufted carpet including a carpet secondary base fabric.

[0002] In the manufacture of traditional carpet tiles, there are many layers of various materials behind the visible pile yarns. The structure behind the pile yarns includes a carpet primary base fabric to which the pile yarns are tufted, and the carpet primary base fabric includes a precoat to fix the pile yarns. Conventional carpet tiles include a polymer layer, a reinforcing layer, an additional polymer layer, and an optional carpet secondary base fabric beneath the tufted and precoated primary base fabric.

[0003] This reinforcing layer can be, for example, a nonwoven or scrim made of fiberglass, and is responsible for reinforcing the carpet tile in the planar (x and y dimensions). To transmit the forces generated when applied to the carpet tile in the x and / or y directions to the reinforcing layer, a layer of polymer coating is required between the primary carpet backing and the reinforcing layer, and between the secondary carpet backing and the reinforcing layer.

[0004] These polymer coatings are expensive, and carpet tile manufacturers strive to minimize the mass of these two layers of polymer coatings, although a minimum amount of polymer is required because it is crucial for sufficient bonding between the reinforcing layer and the carpet primary backing and / or between the reinforcing layer and the carpet secondary backing.

[0005] In some carpet tiles, the reinforcing layer has been moved from between the two polymer layers to just above the carpet secondary substrate, which reduces the two layers of expensive polymer coating to just one, thus reducing the total mass of polymer in the carpet tile.

[0006] British Patent Application Publication No. 1,409,068 discloses a method for imparting a secondary base fabric to a tufted primary base fabric. Thereafter, the reinforcement of the secondary base fabric is carried out by longitudinal threads integrated into the knitted structure, which are introduced during and as part of the knitting process.

[0007] International Publication No. 2006 / 093861, U.S. Patent No. 6,060,145, and U.S. Patent Application Publication No. 2004 / 0142142 disclose carpet secondary fabrics with high permeability, but because they are plain weave and use flat yarn / ribbon, a physical barrier is formed in the carpet secondary fabric, preventing bleeding of the filler / binder mixture through to the ground.

[0008] However, while it is possible to reduce the number of polymer coating layers by moving the reinforcing layer onto the carpet secondary base fabric, this has the drawback of requiring the use of additional adhesive to bond the reinforcing layer to the carpet secondary base fabric. Although not bound by theory, it is thought that moving the reinforcing layer onto the carpet secondary base fabric would have a negative effect on the flatness stability (perpendicular to the plane of the carpet tile, z dimension), such as edge warping or curling of the carpet tile.

[0009] In addition, if the polymer coating layer has a high affinity for the carpet's primary base fabric, the polymer coating may be visible on the carpet's surface, a phenomenon known as latex bleeding.

[0010] The object of this application is to provide a tufted carpet comprising a carpet secondary base fabric, and a method for manufacturing such a tufted carpet comprising a carpet secondary base fabric, thereby preventing or at least mitigating the aforementioned drawbacks.

[0011] The objective is to provide a tufted carpet comprising a tufted carpet primary base fabric, pile yarns tufted within the carpet primary base fabric, a carpet secondary base fabric adjacent to the carpet primary base fabric on the side of the carpet primary base fabric where backstitching is visible, and an optional precoat and / or polymer coat, wherein the carpet secondary base fabric comprises at least a fiber reinforcement layer, and the carpet secondary base fabric has a density of at least 1000 l / m² as measured according to ISO 9237:1995. 2 This is achieved by tufted carpets with a breathability of s.

[0012] To clarify, the measurement of air permeability according to ISO 9237:1995 is performed with a pressure difference of 200 Pa and a 20 cm gap. 2 This is done with samples having a sample size of [specified size].

[0013] The fact that the carpet secondary base fabric contains a fiber reinforcement layer improves the stability of the carpet tile's flatness perpendicular to the plane (z-dimension), such as edge warping or curling. The fact that the carpet secondary base fabric has minimal air permeability also improves the penetration of precoats and / or polymer coats applied to the tufted carpet, allowing the precoats to penetrate the carpet secondary base fabric.

[0014] While not bound by theory, it is thought that by adding a precoat and / or polymer coat to a tufted carpet including a primary carpet base and a secondary carpet base, any forces that may be applied can be transmitted to the reinforcing layer of the secondary carpet base via the precoat and / or polymer coat.

[0015] Furthermore, by directly placing the secondary carpet base fabric onto the primary carpet base fabric, it is believed that additional pre-coating and / or polymer coating can be saved.

[0016] For clarity, explanations of some terms and phrases used in this application are provided below.

[0017] The term "composite material" should be understood as a material manufactured from two or more constituent materials with significantly different physical or chemical properties, and combining these results in a material having characteristics different from those of the individual constituent elements.

[0018] The phrase "substantially parallel" means that, for example, since the fibers of a unidirectional layer are arranged apart from each other, the fibers do not contact the adjacent fibers of the fibers of the unidirectional fiber layer.

[0019] The terms "spunbond" and "spinlace" mean the production of a non-woven layer of fibers in which the fibers are extruded from a spinneret, subsequently laid on a conveyor belt as a web of filaments, and then the web is bonded to form a non-woven layer of fibers, or the filaments are spun, drawn using, for example, a draw godet or an air jet, preferably wound onto a bobbin in the form of a multifilament yarn, and subsequently the multifilament yarn is unwound and the filaments are laid on a conveyor belt as a web of filaments, and the web is bonded to form a non-woven layer of fibers by means of a two-step process in which the above steps are carried out.

[0020] Within the scope of this application, the term "fiber" is understood to refer to both staple fibers and filaments. Staple fibers are fibers having a defined relatively short length in the range of 2 to 200 mm. A filament is a fiber having a length exceeding 200 mm. In one embodiment, the filament has a length exceeding 500 mm. In one embodiment, the filament has a length exceeding 1000 mm. The filament may be virtually infinite, for example, when formed by continuous extrusion and spinning of the filament through the spinning holes of a spinneret.

[0021] The term "carpet face" needs to be understood as the face of the carpet that is visible when the carpet is laid on the floor. The face that is not visible when the carpet is laid on the floor is the face on which the backstitch of the tufting is visible.

[0022] A tufted carpet includes a tufted primary carpet backing, a secondary carpet backing, and an optional precoat and / or polymer coating. The secondary carpet backing is disposed adjacent to the primary carpet backing on the side of the primary carpet backing where the backstitch is visible, and a precoat or polymer coating can be applied to the secondary carpet backing and / or the primary carpet backing.

[0023] The secondary carpet backing has a breathability of at least 1000 l / m 2 ·s measured in accordance with ISO 9237:1995. Without being bound by theory, due to this breathability, it is considered that an optional precoat and / or polymer coating can move from the back side of the secondary carpet backing through the secondary carpet backing to the primary carpet backing.

[0024] In one embodiment, the breathability of the secondary carpet backing is at least 3000 l / m 2 ·s. In one embodiment, the breathability of the secondary carpet backing is at least 5000 l / m 2 ·s. In one embodiment, the breathability of the secondary carpet backing is at least 7000 l / m 2 ·s. In one embodiment, the breathability of the secondary carpet backing is at least 9000 l / m 2 ·s. In one embodiment, the breathability of the secondary carpet backing is at least 10500 l / m 2 ·s. In one embodiment, the breathability of the secondary carpet backing is at least 12000 l / m 2 ·s. In all cases, it is measured in accordance with ISO 9237:1995.

[0025] In one embodiment, the carpet secondary fabric can be impregnated with a precoat and / or polymer coat. In this regard, the term “impregnation” should be understood as the secondary fabric being permeated with the precoat and / or polymer coat, resulting in the absence of voids or only negligible voids in the impregnated secondary fabric. In one embodiment, negligible voids constitute less than 5 volume% of the volume of the impregnated secondary fabric. In one embodiment, negligible voids constitute less than 4 volume% of the volume of the impregnated secondary fabric. In one embodiment, negligible voids constitute less than 3 volume% of the volume of the impregnated secondary fabric. In one embodiment, negligible voids constitute less than 1 volume% of the volume of the impregnated secondary fabric.

[0026] The plastisol according to this application is a suspension of polymer particles, for example, PVC in a liquid plasticizer. Upon heating, the particles dissolve in the plasticizer, forming a high-viscosity gel. It is known to those skilled in the art that plastisols tend to remain on the surface of the fabric rather than impregnate into the fibers. Therefore, the woven material must be carefully selected for proper impregnation with the plastisol.

[0027] In one embodiment, the plasticizer comprises phthalate esters such as DEHP, DINP, and DIDP. In one embodiment, the plasticizer comprises aliphatic dibasic acid esters such as glutarate, adipate, azelate, or sebacate. In one embodiment, the plasticizer comprises benzoic acid esters. In one embodiment, the plasticizer comprises phthalate esters such as DEHP, DINP, and DIDP. In one embodiment, the plasticizer comprises trimellitate esters of alcohols having 8, 9, or 10 carbon atoms. In one embodiment, the plasticizer comprises polyester. In one embodiment, the plasticizer comprises citrate esters. In one embodiment, the plasticizer is bio-based and comprises epoxidized soybean oil (ESBO), epoxidized linseed oil (ELO), castor oil, palm oil, other vegetable oils, starch, or sugar. In one embodiment, the plasticizer comprises chlorinated paraffin. In one embodiment, the plasticizer comprises alkyl sulfonic acid esters. The plasticizer may comprise any mixture of the compounds mentioned.

[0028] In one embodiment, the plastisol includes a heat stabilizer based on a metal salt such as calcium stearate.

[0029] In addition to plastisol, other organic binders or adhesives can also be used. Possible organic binders include latex or hot-melt adhesives.

[0030] The openability of the carpet primary base fabric allows for the use of adhesives with increased solid content compared to the prior art. In one embodiment, a solid content of 5% by weight can be used. In one embodiment, a solid content of 30% by weight can be used. In one embodiment, a solid content of 40% by weight can be used. In one embodiment, a solid content of 50% by weight can be used. In one embodiment, a solid content of 60% by weight can be used. In one embodiment, a solid content of 70% by weight can be used. In one embodiment, a solid content of 80% by weight can be used. In one embodiment, a solid content of 90% by weight can be used. In one embodiment, a solid content exceeding 90% by weight can be used.

[0031] In one embodiment, the reinforcing layer included in the carpet secondary base fabric may be a nonwoven fabric, a woven fabric, a scrim woven fabric, a laid scrim, or a unidirectional fiber layer.

[0032] In one embodiment, the fibers (e.g., filaments) of a unidirectional fiber layer having a very large length in terms of width and height are spaced apart from each other at a constant distance over the entire length of the unidirectional fiber layer.

[0033] As is well known to those skilled in the art, a scrim is an open lattice structure composed of at least two sets of parallel threads, whether laid or woven, wherein a first group of parallel threads is oriented relative to a second group of parallel threads at a certain angle, typically 90°. The first group of parallel threads can be bonded to the second group of parallel threads by chemical bonding, and / or the first group of parallel threads can be woven together with the second group of parallel threads to form a scrim fabric. In one embodiment, the openings of the scrim have at least one dimension of at least 1 mm in the plane of the supporting material. In one embodiment, the openings of the scrim have at least one dimension of at least 2 mm in the plane of the supporting material. In one embodiment, the openings of the scrim have at least one dimension of at least 5 mm in the plane of the supporting material. In one embodiment, the openings of the scrim have two dimensions of at least 1 mm in the plane of the supporting material. In one embodiment, the openings of the scrim have two dimensions of at least 2 mm in the plane of the supporting material. In one embodiment, the opening of the scrim has two dimensions, at least 5 mm in the plane of the supporting material.

[0034] The fibers of the reinforcing layer of the carpet secondary base fabric can be made from any suitable material that can provide reinforcement.

[0035] There are several classifications of available materials, such as high-elasticity materials, low-shrinkage materials, and materials that are resistant to compression.

[0036] Each category of material possesses unique properties that are advantageous to the stability of the carpet secondary fabric. High-elasticity materials impart the advantageous property of increased stability against elongation to the carpet secondary fabric. Low-shrinkage materials impart the advantageous property of increased stability against shrinkage to the carpet secondary fabric, for example, when temperatures exceeding the ambient temperature affect the carpet primary fabric. Furthermore, compression-resistant materials increase the stability of the carpet secondary fabric against compression, such as rigidity, for example, when compressive forces impact the carpet secondary fabric.

[0037] In one embodiment, the reinforcing layer of the carpet secondary base fabric preferably includes highly elastic fibers composed of materials selected from the group including glass, carbon, basalt, rock wool, high modulus low shrinkage (HMLS) polyester, inorganic materials, aramids such as para-aramid (PPTA) and meta-aramid (MPTA), and ultra-high molecular weight polyethylene (UHMWPE).

[0038] In one embodiment, the fibers of the fiber reinforcement layer have a tensile modulus of at least 25 GPa. In one embodiment, the fibers of the fiber reinforcement layer have a tensile modulus of at least 40 GPa. In one embodiment, the fibers of the fiber reinforcement layer have a tensile modulus of at least 50 GPa. In one embodiment, the fibers of the fiber reinforcement layer have a tensile modulus of at least 75 GPa.

[0039] In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 50 tex. In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 40 tex. In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 30 tex. In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 28 tex. In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 20 tex. In one embodiment, the fibers of the reinforcing layer have a maximum linear density of 15 tex.

[0040] While not bound by theory, it is generally believed that the higher the linear density of the fibers in the reinforcing layer, the higher the bending stiffness of the reinforcing layer. Therefore, the upper limit of the linear density of the fibers in the reinforcing layer is virtually infinite, but it is limited by the technical constraints of the manufacturing machinery.

[0041] The secondary base fabric of tufted carpets does not need to contain any woven fabric other than scrim.

[0042] The secondary base fabric of a tufted carpet may include at least one nonwoven fabric layer.

[0043] The secondary base fabric of a tufted carpet may also include two nonwoven layers of fibers, and a reinforcing layer may be placed between the two nonwoven layers of fibers.

[0044] In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 50 g / m². 2 It has an average weight of 30 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 30 g / m². 2 It has an average weight of 25 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 25 g / m². 2 It has an average weight of 20 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 20 g / m². 2 It has an average weight of 15 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 15 g / m². 2 It has an average weight of 10 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 10 g / m². 2 It has an average weight of 7 g / m². In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric of the tufted carpet are up to 7 g / m². 2It has an average weight. In all cases, the average weight was measured according to DIN / ISO EN29073-1.

[0045] In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet have an average diameter of at least 30 μm. In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet have an average diameter of at least 35 μm. In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet have an average diameter of at least 40 μm. In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet have an average diameter of at least 50 μm. In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet have an average diameter of at least 60 μm.

[0046] Due to the relatively large average diameter of at least one, more, or all of the fibers in the nonwoven fiber layer, it is possible to reduce the surface coverage of each fiber in the nonwoven fiber layer, thereby achieving higher air permeability.

[0047] In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet are up to 30 g / m². 2 Preferably a maximum of 25 g / m² 2 More preferably, up to 20 g / m² 2 More preferably, up to 15 g / m² 2 Most preferably a maximum of 10 g / m² 2 The carpet has an average weight of [amount], and each fiber in the nonwoven fabric layer of the carpet secondary base fabric of the tufted carpet has an average diameter of at least 30 μm, preferably at least 35 μm, more preferably at least 40 μm, even more preferably at least 50 μm, and most preferably at least 60 μm.

[0048] While not bound by theory, it is thought that a combination of the relatively low average weight of at least one, multiple, or all of the nonwoven fiber layers of the carpet secondary base fabric and the relatively large average diameter of at least one, multiple, or all of the fibers in the nonwoven fiber layers of the carpet secondary base fabric can lead to a decrease in the surface coverage of at least one, multiple, or all of the nonwoven fiber layers of the carpet secondary base fabric, thereby providing higher air permeability.

[0049] In one embodiment, at least one, more, or all of the fibers in the nonwoven fabric layer of the carpet secondary base fabric include at least one thermoplastic polymer material. In one embodiment, the thermoplastic polymer material is selected from the group consisting of polyolefins such as polyethylene (PE) and polypropylene (PP); polyesters such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene-1,2-frangicaboxylate (PEF), and polylactic acid (PLA); polyamides such as polyamide 6 (PA6) and polyamide 6,6 (PA6,6); and copolymers and blends thereof.

[0050] In one embodiment, one, more, or all of the nonwoven fiber layers include two or more types of fibers, each type containing a different thermoplastic polymer material. In one embodiment, one, more, or all of the nonwoven fiber layers include fibers in which different domains of a single fiber contain different thermoplastic polymer materials. In one embodiment, the fiber includes a core made of a first polymer material and a sheath made of a second polymer material.

[0051] In one embodiment, at least one, more, or all of the fibers in the nonwoven layers of the carpet secondary base fabric contain at least 50% by weight of thermoplastic material. In one embodiment, the fibers in the nonwoven layers of the carpet secondary base fabric contain at least 75% by weight of thermoplastic material. In one embodiment, the fibers in the nonwoven layers of the carpet secondary base fabric contain at least 85% by weight of thermoplastic material. In one embodiment, the fibers in the nonwoven layers of the carpet secondary base fabric contain at least 95% by weight of thermoplastic material. In one embodiment, the fibers in the nonwoven layers of the carpet secondary base fabric contain at least 97% by weight of thermoplastic material.

[0052] In this regard, thermoplastic polymer materials may contain additives such as flame retardants, colorants, fillers, disinfectants, and / or antimicrobial agents.

[0053] In one embodiment, at least one, more, or all of the nonwoven fiber layers of the secondary base fabric include one-component fibers, two types of one-component fibers, and / or two-component fibers.

[0054] In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric can be manufactured by any suitable process such as a spunlaid process, an airlaid process, a wetlaid process, a meltblown process, or a carding process.

[0055] In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric are manufactured by a spunlaid process, the fibers being manufactured from a thermoplastic polymer material. In the spunlaid process, the bonding of each fiber in the nonwoven fiber layer can be carried out by any suitable process including chemical bonding, water entanglement, needling, ultrasonic bonding, calendering, and other thermal bonding methods such as hot air bonding.

[0056] In one embodiment, at least one, more, or all of the nonwoven fiber layers of the carpet secondary base fabric include two types of one-component fibers comprising two chemically different thermoplastic polymer materials, the melting temperatures of which differ by at least 10°C. In one embodiment, the melting temperatures of these two chemically different thermoplastic polymer materials differ by at least 20°C. In one embodiment, the melting temperatures of these two chemically different thermoplastic polymer materials differ by at least 30°C. In one embodiment, the melting temperatures of these two chemically different thermoplastic polymer materials differ by at least 50°C. The melting temperatures of the thermoplastic polymer materials are determined by differential scanning calorimetry (DSC) in accordance with ISO 11357-3.

[0057] In one embodiment, at least one, more, or all of the fibers in the nonwoven fiber layer of the carpet secondary base fabric are two-component fibers of a concentric, eccentric core / sheath model, a side-by-side model, a segmented pie model, or a sea-island structure model.

[0058] In one embodiment, each fiber in the nonwoven fiber layer of the carpet secondary base fabric is a two-component fiber of a concentric core / sheath model, and the fibers are made of thermoplastic polymer materials of the same classification or of chemically different thermoplastic polymer materials.

[0059] Within the scope of this application, thermoplastic materials of the same classification mean that the same monomer units of the polymer can be used, but thermoplastic polymer systems may differ by different polymer chain lengths, different densities of thermoplastic polymer systems, or different orientations of monomer units, which may be isotactic, syndiotactic, or atactic.

[0060] The core of the two-component fiber may include a thermoplastic polymer material having a higher melting temperature than the thermoplastic polymer material of the sheath. In one embodiment, the melting temperatures of the thermoplastic polymer material of the core and the thermoplastic polymer material of the sheath differ by at least 10°C. In one embodiment, the melting temperatures of the thermoplastic polymer material of the core and the thermoplastic polymer material of the sheath differ by at least 20°C. In one embodiment, the melting temperatures of the thermoplastic polymer material of the core and the thermoplastic polymer material of the sheath differ by at least 30°C. In one embodiment, the melting temperatures of the thermoplastic polymer material of the core and the thermoplastic polymer material of the sheath differ by at least 50°C. The melting temperature of the thermoplastic polymer material is determined by differential scanning calorimetry (DSC) in accordance with ISO 11357-3.

[0061] In one embodiment, the carpet primary base fabric comprises at least three layers, the first and third layers comprising nonwoven fiber layers, the second layer comprising a reinforcing fiber layer, the second layer being located between the first and third layers, and the nonwoven fiber layer of the first layer having a maximum density of 8000 l / m² as measured according to ISO 9237:1995. 2 · The air permeability is s, and the third layer of nonwoven fiber fabric has an air permeability of at least 3500 l / m² as measured according to ISO 9237:1995. 2 The material has an air permeability of s, with the nonwoven fiber layer of the first layer having a lower air permeability than the nonwoven fiber layer of the third layer. Furthermore, this characteristic, where the nonwoven fiber layer of the first layer has a lower air permeability than the nonwoven fiber layer of the third layer, is also referred to as "asymmetry in the air permeability of the carpet primary backing fabric" for readability and conciseness.

[0062] The thermoplastic polymer materials of the fibers in the nonwoven fabric layer of the first layer and / or the nonwoven fabric layer of the third layer can be selected from the group including polyolefins such as polyethylene (PE) and polypropylene (PP); polyesters such as polyethylene terephthalate (PET), polytrimethylene terephthalate (PTT), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polyethylene-1,2-flangecapoxylate (PEF), and polylactic acid (PLA); polyamides such as polyamide 6,6 (PA6,6) and polyamide 6 (PA6); and copolymers or blends thereof.

[0063] In one embodiment, the primary base fabric included in the tufted carpet is composed of a thermoplastic polymer material and has a maximum density of 8000 l / m² as measured according to ISO 9237:1995. 2 It comprises at least a first layer containing a nonwoven fabric layer of fibers having an air permeability of s.

[0064] The fact that the carpet primary base fabric includes a fiber reinforcement layer improves the stability of the carpet tile's flatness perpendicular to the plane (z-dimension), such as edge warping or curling. The fact that the carpet primary base fabric includes a third layer containing a fiber nonwoven fabric layer with minimal air permeability improves the penetration of the precoat applied to the tufted carpet primary base fabric, while the first layer containing the low-air-permeability fiber nonwoven fabric layer prevents the latex of the precoat from bleeding onto the carpet tile surface.

[0065] In one embodiment, the asymmetry in the air permeability of the carpet primary base fabric is introduced by the weight ratio of the fiber nonwoven fabric layer of the first layer to the fiber nonwoven fabric layer of the third layer, and it is desirable that the fiber nonwoven fabric layer of the first layer has a greater weight than the fiber nonwoven fabric layer of the third layer.

[0066] Preferably, the first layer of the carpet primary base fabric is placed on the carpet surface of the tufted carpet, followed by the second and third layers being placed behind the first layer.

[0067] The weight ratio of the first layer to the third layer may be at least 70:30, more preferably at least 80:20, and even more preferably at least 90:10.

[0068] By increasing the weight of the nonwoven fiber layer of the first layer of the carpet's primary base fabric, the surface coverage of the nonwoven fiber layer of the first layer of the primary base fabric can be increased.

[0069] In one embodiment, the first layer, including the nonwoven fiber layer, has a surface coverage of 1% to 40%. In another embodiment, the first layer, including the nonwoven fiber layer, has a surface coverage of 2% to 30%. In yet another embodiment, the first layer, including the nonwoven fiber layer, has a surface coverage of 3% to 25%. In yet another embodiment, the first layer, including the nonwoven fiber layer, has a surface coverage of 5% to 20%. The surface coverage A is calculated by the following method: A = χ * d; In the formula, χ is the number of filaments per filament layer, and d is the diameter of the filament. The number of filaments per layer, χ, is calculated as follows: χ = N / L; In the formula, N is the number of filament layers, and L is the total length of the filament per unit area. The quantities N and L are calculated as follows: N = T / d; In the formula, d is the thickness of the filament when a monofilament is used, and d is the thickness of the filament core when a two-component filament is used. L = M * t; In the formula, T is the thickness of the first layer of fiber, M is the basis weight of the first layer of fiber, and t is the linear density of the filament. The thickness T is 25 cm 2 The pressure is determined according to DIN ISO 9073-2 using a clamp and a pressure of 0.05 kPa.

[0070] The reduced weight of the third layer allows for a lower surface coverage rate of the nonwoven fiber layer of the third layer of the carpet's primary base fabric.

[0071] In one embodiment, the third layer, which includes a nonwoven fiber layer, has a surface coverage of 1% to 40%. In one embodiment, the third layer, which includes a nonwoven fiber layer, has a surface coverage of 2% to 30%. In one embodiment, the third layer, which includes a nonwoven fiber layer, has a surface coverage of 3% to 25%. In one embodiment, the third layer, which includes a nonwoven fiber layer, has a surface coverage of 5% to 20%.

[0072] While not bound by theory, increasing the surface coverage of the nonwoven fiber layer in the first layer can result in lower air permeability, which can further reduce the permeability of fluids such as polymer coatings and / or pre-coatings. Due to the lower air permeability of the first layer of the carpet primary base fabric, optional pre-coats and / or polymer coatings cannot penetrate the first layer of the carpet primary base fabric, and as a result, latex bleeding is made impossible.

[0073] Reducing the surface coverage of the fibers in the nonwoven fabric layer of the third layer of the carpet primary base fabric can result in higher air permeability and can also increase the permeability of fluids such as polymer coatings and / or pre-coatings. Due to the higher air permeability, optional pre-coats and / or polymer coatings can pass through the third layer of the carpet primary base fabric and enter on and / or within the second layer, thereby allowing forces in the x and / or y directions to be transmitted to the reinforcing layer of the second layer of the carpet primary base fabric.

[0074] In a preferred embodiment, the first layer of the carpet primary base fabric has a lower air permeability than the third layer of the carpet primary base fabric.

[0075] While not bound by theory, it is thought that a combination of a first layer having lower permeability than a third layer can prevent latex bleeding and allow forces in the x and / or y directions to be transmitted to the reinforcing layer of the second layer of the carpet primary base fabric.

[0076] The asymmetry in the air permeability of the carpet primary base fabric can also be introduced by the different average diameters of the fibers contained in the nonwoven fiber layer of the first layer and the third layer of the carpet primary base fabric.

[0077] The nonwoven fiber layers of the first layer and / or the third layer of the carpet primary base fabric may include mono-component fibers, two types of mono-component fibers, and / or bi-component fibers.

[0078] In this regard, the nonwoven fiber layers of the first layer and / or the third layer of the carpet primary base fabric can be manufactured by any suitable process such as a spunlaid process, an airlaid process, a wetlaid process, a meltblown process, or a carding process.

[0079] In one embodiment, the fiber nonwoven layers of the first layer and / or the fiber nonwoven layers of the third layer are manufactured by a spunlaid process, and the fibers are manufactured from a thermoplastic polymer material. In the spunlaid process, the bonding of the fibers of the fiber nonwoven layers of the first layer and / or the fiber nonwoven layers of the third layer can be carried out by calendering, water entanglement, needling, ultrasonic bonding, chemical bonding, and other thermal bonding methods such as hot air bonding.

[0080] In one embodiment, the nonwoven fiber layer of the first layer and / or the nonwoven fiber layer of the third layer of the carpet primary base fabric comprises two types of one-component fibers comprising two chemically different thermoplastic polymer materials, wherein the melting temperatures of these two types of one-component fibers differ by at least 10°C. In one embodiment, the melting temperatures of these two types of one-component fibers differ by at least 20°C. In one embodiment, the melting temperatures of these two types of one-component fibers differ by at least 30°C. In one embodiment, the melting temperatures of these two types of one-component fibers differ by at least 50°C. The melting temperature of the thermoplastic polymer material is determined by differential scanning calorimetry (DSC) in accordance with ISO 11357-3.

[0081] In one embodiment, the fibers of the nonwoven fabric layer of the first layer of the carpet primary base fabric and / or the nonwoven fabric layer of the third layer are two-component fibers of a concentric or eccentric core / sheath model, side-by-side model, segmented pie model, or sea-island structure model.

[0082] In one embodiment, the fibers of the nonwoven fabric layer of the first layer of the carpet primary base fabric and / or the fibers of the nonwoven fabric layer of the third layer are two-component fibers of a concentric core / sheath model, and the fibers are made of thermoplastic polymer materials of the same classification or of chemically different thermoplastic polymer materials.

[0083] In one embodiment, the fibers of the nonwoven fabric layer of the first layer of carpet primary backing have an average diameter of up to 50 μm. In one embodiment, the fibers of the nonwoven fabric layer of the first layer of carpet primary backing have an average diameter of up to 40 μm. In one embodiment, the fibers of the nonwoven fabric layer of the first layer of carpet primary backing have an average diameter of up to 30 μm. In one embodiment, the fibers of the nonwoven fabric layer of the first layer of carpet primary backing have an average diameter of up to 25 μm. In one embodiment, the fibers of the nonwoven fabric layer of the first layer of carpet primary backing have an average diameter of up to 20 μm. The average diameter of the fibers is measured by microscope as the average of 10 samples.

[0084] In one embodiment, the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 30 μm. In one embodiment, the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 35 μm. In one embodiment, the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 40 μm. In one embodiment, the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 50 μm. In one embodiment, the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 60 μm. The average diameter of the fibers is measured by microscope as the average of 10 samples.

[0085] Although not bound by theory, it is thought that a difference in the surface coverage of the nonwoven fabric layer of the fibers can be obtained by having a smaller average fiber diameter in the nonwoven fabric layer of the first layer of the carpet primary base fabric, and a larger average fiber diameter in the nonwoven fabric layer of the third layer of the carpet primary base fabric.

[0086] For example, in the nonwoven fiber layer of the first layer of carpet primary base fabric, if the layer has a constant weight and the average diameter of the fibers in the nonwoven fiber layer of the first layer of carpet primary base fabric is reduced, the value of the length of the fibers per square meter of the nonwoven fiber layer of the first layer (m / m 2 This increases, which can lead to an increase in the surface coverage of the nonwoven fabric layer of the first layer of fibers.

[0087] Conversely, for example, in the third layer of the carpet's primary base fabric, if the layer has a constant weight and the average diameter of the fibers in the third layer of the nonwoven fabric is increased, the value of the length of the fibers per square meter of the third layer of the nonwoven fabric (m / m) 2 This decreases, which can lead to a decrease in the surface coverage of the nonwoven fabric layer of the third layer of fibers.

[0088] Therefore, although not bound by theory, it is thought that, particularly in the nonwoven fiber layer of the first layer of carpet primary backing fabric, combining a larger fiber layer with a smaller average diameter of fibers in the layer can synergistically support the effect of lower air permeability and inherently lower permeability for fluids such as polymer coatings and / or pre-coatings.

[0089] In particular, combining a smaller fiber weight and a larger average fiber diameter in the third layer of the nonwoven fiber layer of the carpet primary base fabric can synergistically support greater air permeability and high permeability for fluids such as polymer coatings and / or pre-coatings.

[0090] The tufted carpet according to this application can be manufactured by tufting a carpet primary base fabric, which may be a nonwoven fiber layer or a composite material, with pile yarns, applying a carpet secondary base fabric adjacent to the tufted primary base fabric on the side of the carpet primary base fabric where the backstitch is visible, and optionally applying a pre-coat coating and / or a polymer coating.

[0091] In one embodiment, the application of an optional pre-coat coating and / or polymer coating is performed by pressing the pre-coat and / or polymer coating into the carpet primary base fabric through the carpet secondary base fabric.

[0092] In one embodiment, the carpet primary base fabric comprises at least two layers, which are tufted as individual layers adjacent to each other on their main surfaces, or which are tufted as a composite material.

[0093] In one embodiment, at least two layers of the carpet primary base fabric are tufted as a composite material.

Claims

1. A tufted carpet comprising a tufted primary carpet base fabric, pile yarns tufted within the primary carpet base fabric, and a secondary carpet base fabric adjacent to the primary carpet base fabric on the side of the primary carpet base fabric where backstitching is visible, wherein the secondary carpet base fabric comprises at least a fiber reinforcement layer, and the secondary carpet base fabric has a density of at least 5000 l / m² as measured according to ISO 9237:1995. ２ - It has an air permeability of s, and the fibers of the reinforcing layer of the fibers have a tensile modulus of at least 25 GPa. The carpet primary base fabric comprises at least three asymmetrical layers, wherein the first and third layers comprise nonwoven fiber layers, the second layer comprises a reinforcing fiber layer, the second layer is located between the first and third layers, the first layer of the carpet primary base fabric is located closest to the tufted pile yarns, and the second and third layers are located behind the first layer, the nonwoven fiber layer of the first layer has an air permeability of up to 8000 l / m²·s as measured according to ISO 9237:1995, the nonwoven fiber layer of the third layer has an air permeability of at least 3500 l / m²·s as measured according to ISO 9237:1995, and the nonwoven fiber layer of the first layer has a lower air permeability than the nonwoven fiber layer of the third layer. The tufted carpet further comprises a pre-coat and / or polymer coat.

2. The carpet secondary base fabric has a density of at least 7000 l / m² as measured in accordance with ISO 9237:1995. ２ A tufted carpet according to claim 1, characterized in that it has an air permeability of s.

3. The tufted carpet according to claim 1 or 2, characterized in that the reinforcing layer is a scrim or a unidirectional fiber layer, and the fibers of the unidirectional fiber layer are aligned substantially parallel to each other in the direction of flow and spaced apart from each other.

4. A tufted carpet according to any one of claims 1 to 3, characterized in that the reinforcing layer of the fibers comprises a highly elastic material and / or a low-shrinkage material selected from the group including glass, carbon, basalt, rock wool, high modulus low shrinkage (HMLS) polyester, inorganic materials, aramid, and ultra-high molecular weight polyethylene (UHMWPE).

5. A tufted carpet according to any one of claims 1 to 4, characterized in that the carpet secondary base fabric includes two nonwoven fabric layers of fibers, and the reinforcing layer is disposed between the two nonwoven fabric layers of fibers.

6. Each of the nonwoven fabric layers of the fibers contained in the carpet secondary base fabric has a maximum density of 50 g / m². ２ The tufted carpet according to claim 5, characterized in that it has an average weight of [a certain amount].

7. The tufted carpet according to claim 5 or 6, characterized in that the fibers in the nonwoven fabric layer of the fibers contained in the secondary carpet base fabric have an average diameter of at least 30 μm.

8. The tufted carpet according to any one of claims 5 to 7, characterized in that the nonwoven fabric layer of the fibers contained in the carpet secondary base fabric includes one-component fibers, two types of one-component fibers, and / or two-component fibers.

9. The tufted carpet according to any one of claims 5 to 8, characterized in that the fibers in the nonwoven fabric layer of the fibers contained in the carpet secondary base fabric include a thermoplastic polymer material selected from the group including polyolefins; polyesters; polyamides; and copolymers or blends thereof.

10. The carpet primary base fabric is composed of a thermoplastic polymer material and has a maximum density of 8000 l / m² as measured according to ISO 9237:1995. ２ A tufted carpet according to any one of claims 1 to 9, characterized in that it comprises at least a first layer including a nonwoven fabric layer of fibers having an air permeability of s.

11. The tufted carpet according to claim 1, characterized in that the fibers of the nonwoven fabric layer of the first layer of the carpet primary base fabric have an average diameter of up to 50 μm, and the fibers of the nonwoven fabric layer of the third layer of the carpet primary base fabric have an average diameter of at least 30 μm.

12. A method for manufacturing a tufted carpet according to any one of claims 1 to 11, comprising tufting a carpet primary base fabric, which may be a nonwoven fiber layer or a composite material, with pile yarn, and applying a carpet secondary base fabric adjacent to the tufted primary base fabric on the surface of the tufted primary base fabric where the backstitch is visible.

13. The method according to claim 12, characterized in that the application of the precoat and / or polymer coat is carried out by pushing the precoat and / or polymer coat into the carpet primary base fabric through the carpet secondary base fabric.

14. A carpet tile comprising a tufted carpet according to any one of claims 1 to 11.