Method for manufacturing a laminated pile textile product
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Solution Overview
Problem
Existing methods for manufacturing textile products, such as those described in EP 1598476 and WO 2012/076348, face challenges in achieving durable mechanical anchorage of yarns to the primary backing, particularly in high-load applications like car interiors, trains, and offices, where additional adhesives or latex are often required to ensure yarn stability.
Innovation Solution
A method involving a porous thermoplastic layer with a porosity of 50% to 99% is applied to the back surface of the primary backing before melting, allowing the thermoplastic material to melt and solidify, forming a continuous locking mechanism that securely anchors the yarns, providing enhanced mechanical strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoplastic yarns are stitched through the primary backing and heated to melt the locked ends, then the yarns are anchored to the backing, but the anchoring strength is insufficient for high-load applications without additional adhesives
Solution Approach 1:
A porous layer is applied to the back surface of the primary backing before stitching the yarns. This porous layer provides a structure that enhances mechanical interlocking of the yarn locked ends with the backing, significantly improving anchoring strength without requiring additional adhesives or latex.
Solution Approach 2:
The primary backing is combined with a porous layer to create a composite structure. This composite material provides both the structural integrity of the backing and the enhanced mechanical interlocking capability of the porous layer, achieving strong yarn anchoring through material composition rather than additional chemical adhesives.
2Reliability
If additional adhesive or latex is applied to the backing to provide sufficient mechanical anchorage, then yarn stability is improved, but the manufacturing complexity and material costs increase
Solution Approach 1:
The invention extracts and eliminates the need for additional adhesive or latex application steps by incorporating the anchoring function directly into the porous layer structure. This simplifies the manufacturing process while maintaining yarn stability through mechanical interlocking alone.
Solution Approach 2:
The porous layer provides self-service by inherently providing the mechanical interlocking structure needed for yarn anchoring. The layer's porous structure automatically engages with the yarn locked ends through heat melting, eliminating the need for separate adhesive application and curing processes.
3Strength
If the primary backing is made from a dense material to provide mechanical stability, then structural integrity is improved, but the ability of the material to melt and mingle with yarns during processing is reduced
Solution Approach 1:
The backing system is segmented into two functional layers: a dense primary backing layer that provides structural integrity and stability, and a porous layer that provides processing ease by melting and mingling with the yarns. This segmentation allows each layer to optimize its specific function without compromising the other.
Solution Approach 2:
Different regions of the backing system have different properties: the primary backing is dense for structural support, while the porous layer has high porosity for easy melting and interlocking. This local quality differentiation allows the system to simultaneously achieve structural integrity and processing ease in different locations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a durable and mechanically strong bond between the yarns and the primary backing, preventing yarn removal under load, even without additional adhesives, and maintains the integrity of the woven backing, preventing fraying and enhancing the textile product's mechanical properties.
Implementation Method 1
passing the intermediate product along a body having a heated surface, the back of the product being contacted with (e.g. pressed against) the said heated surface, to at least partly melt the locked ends of the one or more yarns
Implementation Method 2
the back of the product being contacted with (e.g. pressed against) the said heated surface
Implementation Method 3
the thermoplastic material to melt and solidify, forming a continuous locking mechanism that securely anchors the yarns
Implementation Method 4
the porous layer comprising a thermoplastic material, melting at least a fraction of this thermoplastic material, and cooling the molten fraction of the thermoplastic material, thereby connecting the locked end of the one or more yarns to the first sheet
Data Source
Figure 1
Figure 2A~2B
Figure 3~4
AI summary
The invention pertains to a method for manufacturing a textile product comprising providing a first sheet having a front surface and a back surface, covering the back surface of the sheet with a porous layer having a porosity of 50% to 99%, the layer comprising a thermoplastic material, forming a pile on the front surface of first sheet by stitching one or more yarns through the first sheet, the one or more yarns having a free end that forms the said pile and a locked end that extends into the porous layer, thereby forming an intermediate product, processing the intermediate product by feeding this product along a body having a heated surface, the porous layer being pressed against the said heated surface, to melt at least a fraction of the thermoplastic material, cooling the molten fraction of the thermoplastic, thereby connecting the locked end of the one or more yarns to the first sheet, and optionally connecting a second sheet to the processed intermediate product, using an adhesive applied between the processed surface of the intermediate product and the second sheet. The invention also pertains to a primary backing for use in this method and to a method for manufacturing this primary backing.