Note: Descriptions are shown in the official language in which they were submitted.
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The present invention relates to a method of manufacturing of a non-
woven multi-layer Elat textile structure, in accordance with which, into a pile-
containing upper layer tufted into a carrier layer, fiber material is brought
Ercm a lower layer through said carrier layer and into the upper layer. The
invention also relates to a non-woven multi-layer flat textile structure with
a tufted pile-containing upper layer on a carrier layer and with a lower layer
from which a fiber material extends through the carrier layer and into the
upper layer.
In a known method of the above mentioned general art disclosed, for
example, in the DE-OS 2,452,136 individual fi~ers are brought by needles from
the lower layer into free spaces. Since the tufted upper layer has a lower
pile weight, intensive and strong needle-processing is required for complete
coating of the upper side. In addition, a great quantity of the individual
fibers must be brought by needling into the free spaces for complete filling of
the same, which is necessary to provide a product with a uniform upper surface.
In the known flat textile structures possibilities of providing patterns are
limited by the properties of the needle-processed loosely projecting in-
dividual fibers so as to impart to the upper layer the appearance of a tip-shear
article or a loose-pile article with a uniform texture.
Accordingly, it is an object of the present invention to provide a
method of manufacturing a flat textile structure, which avoids the disadvantages
of the prior art.
More particularly, it is an object of the present invention to provide
a method of manufacturing a flat textile structure, which allows an arbitrary
or intended completion of the upper layer with a fiber material and makes it
possible to produce a flat textile structure which has any pattern and/or texture
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In keeping with these objects and with others which will become
apparent hereinafter, one feature of the present invention resides, briefly
stated, in a method in accordance with which definite fiber structures are
at least partially brought through a carrier layer into an upper layer.
In a broad aspect the invention resides in a method of manufacturing
a non-woven multi-layer flat textile structure, comprising the steps of
providing a carrier layer; tufting an upper pile-containing layer into said
carrier layer; arranging a lower layer of a fiber material under said
carrier layer, said lower layer including definite fiber structures formed
by ball-like to worm-like yarns composed of spherically intertwined fibers;
and bringing said fiber material from said lower layer through said carrier
layer into said upper layer, said bringing step including at least partially
introducing said definite fiber structure with the aid of needles through said
carrier layer into said upper layer and thereby reshaping said ~iber structures
from the ball-like to worm-like shape into a pear-like shape with the reduced
part of the pear-shape retained at least in the carrier layer.
~hen the method is performed in accordance Wit]l the present invention,
it has been surprisingly shown that structures composed of fibers and having
definite dimensions, namely structures which are composed of a plurality of
fibers and are, for example, greater or thicker than the individual fibers,
can be brought through the carrier layer into the upper layer to complete the
latter. Because of the definite fiber structures, the upper layer can be
filled or completed with small consumption of fiber material. It is
advantageous to provide a non-woven multilayer flat textile structure with a
tufted pile-containing upper layer on a carrier layer and with a fiber-
containing upper layer on a carrier layer and with a fiber-containing lower
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layer from which the fiber material extends through the carrier layer into
the upper layer. The fiber material used here is the definite fiber structure
projecting from the lower layer and at least partially, i.e., with their parts,
extending into the upper layer.
Many possibilities are thereby provided for textures and/or patterns
of the flat textile structure since the definite fiber structures can be
arranged so that they are distributed in arbitrary or desired manner, for
example by a Mali process. Advantageously, the fiber structures are forced
through the carrier layer by needling, whereby a particularly simple process
can be utilized for manufacturing the flat textile structure. The definite
fiber structure can be formed as elongated or convoluted thread pieces, nap-
like, flake-like or loop-shaped fiber material or fiber bundles, which are
needled through the carrier layer and extend into the upper layer. Slightly
felted wool nap can be used as the nap-like material. The fiber structures
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can also be formed by ball yarns composed of spherically intertwined fibers
or threads which also extend through the carrier layer. Such ball yarns are
described, for example, in the EP-publications 001342~ and 0013427 to which
references are made herein.
The effect of pushing the definite fiber structures through the car-
rier layer depends upon the properties, such as for example density of the
fiber structure and the fiber type, so that they can be pushed or forced
through the carrier layer or openings provided therein without considerable
damage or destruction. In accordance with an advantageous feature of the in-
vention, the fiber structures have a high fiber density therein. It is possible
to use ball yarns with a density of fibers or threads of for example, 0.3-1
g/cm . The fiber s~ructures can extend only up to the upper side of ~he up-
per layer or outwardly beyond the same. They can be brought by needles only
to the upper layer, for example into its free spaces and arranged between the
loops of a tufted pile yarn of which the upper layer can be composed. The pile
yarn can contain open or closed pile loops. The upper layer, depending upon
its design, can already have free spaces. It is also possible that the Eree
spaces are first formed by introducing the fiber structures into the upper
layer, for example with displacement of the pile loops.
The pile containing upper layer can be manufactured by tufting the
pile yarn with the aid of looming or knitting, namely by a process in accordance
with which the pile or loops such as pile loops or velour-like surfaces can
be delivered and thereafter the pile-containing tufted upper layer is brought
to standing position.
When, for example, the thread pieces or threads are placed and
needled through, they can be arranged loop-shaped in the upper layer. This
depends on the
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location at which the thread pieces an be engaged by the needle during the
needle-processing. When for example the nap-like or flake-like fiber ag-
glomerates or structures or fiber bundles are brought by needles through the
carrier layer, the flat textile structure can be formed with the respective
appearance. Thereby a plurality of possibilities of providing patterns or
textures are available.
The defini*e fiber structures can be so needle-processed that they
remain with their parts in the lower layer and/or in the carrier layer and are
anchored in the same. In the event of pushing or needling the fiber structures
through the carrier layer, they can change their shape as compared with the
fiber structures remaining in the lower layer, so that the fiber structures
in the upper layer can have a shape differing from the shape of the fiber
structures when they were originally located in the lower layer.
The fiber structures can remain anchored with their tails or bundles
in the lower layer and/or the carrier layer. When the ball yarns are brought
by needles from the lower layer into the upper layer, the ball shape can be
changed during forcing through the carrier layer so that the fiber structures
assume the shape of a pear and are retained by lts reduced parts in the carrier
layer and/or the lower layer.
It is also possible to produce an upper layer in which~ in addition
to the pile yarns, a fiber material of another shape in ~orm of the definite
fiber structures is provided. A plurality of possibilities for providing
patterns and textures take place, particularly when the fiber structuresbrought
through by needling have another color than the tufted pile, or are of dif-
ferent colors themselves. It is yossible to force through substan~ially all
fiber structuresaccor.lmodated in the lower layer or only some of them, so that
thereby also different possibilities for providing patterns and/or textures can
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be obtained.
The inventive method can start from an alread~- tufted product and
proceed with bringing the fiber structures into the same. It is, however,
also possible to produce the upper layer by successive working steps of
tufting a pile yarn into the carrier layer formed, for example, as a ground
fabric or a fiber binding material, and subsequently, for example, immediately
thereafter to bring the definite fiber structures onto the carrier layer and
then needle the same through the carrier layer. It is advantageous when the
definite fiber structures contain natural and/or synthetic fibers or threads,
such as multi-filaments or spun yarns.
The tufted upper layer can have a pile weight of 100-1500 g/m2,
advantageously 300-600 g.m2. Between 20 000 and 120 000, advantageously
30 000-90 000 pile loops per m2 can be provided. The definite fiber structures
can be needle-processed with a needle density which is greater than the
number of pile loops per m2 and the pile density in the upper layer, and
equal to 5-50 stitches per cm2. The fiber structures can have dimensions,
for example a thickness in at least the direction o its elongation which is
at least equal to lmm. Thus, the ball yarn has a thickness of 1-25 mm,
advantageously 50-150mm. When required, the lower layer can be formed in an
advantageous manner as a rear layer of the flat structure. It can be
reinforced ater needle-processing of the fiber structures, with a binding
medium such as latex, in conventional manner.
In a further broad aspect, the invention resides in a non-woven
multi-layer flat textile structure comprising a carrier layer; a pile-
containing upper layer tufted into said carrier layer; a lower layer arranged
under said carrier layer; and a fiber material being formed as definite
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structures, said definite fiber structures being formed by ball yarns
composecl of spherically intertwined fibers, one part of the definite fiber
structure remaining in said lower layer and a second part of the definite
fiber structures extending from said lower layer through said carrier layer
and being at least partially introduced into said upper layer having a shape
differing from the fiber structures of said one part.
The flat textile structure in accordance with the present invention
can be used as a floor or wall covering or a decorating material. It can be
formed as a tufting loop carpet from endless filaments as the pile yarn,
in which the fiber structures with the above-mentioned form or shape are
arranged between the pile loops. It is thereby possible to produce a tufted
carpet with
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the definite fiber structures of a natural fiber material, which not only has
a color pattern because of the fiber structures, but also tlle synthetic features
oE the tufting loops can be eliminated. It is thereby possible to manufacture
the tufting carpet with a nap effect on its upper surface or in connection with
fiber structures of spun yarns of staple fibers.
The fiber structures can extend at the upper side beyond the pile
loops so as to produce an embossed texture. A pattern can be produced by
pattern-like placing of the definite Eiber structures, for example ball yarns.
A pattern can also be produced by loose tufting, i.e., the pile yarn loops can
be brought into the carrier layer with small density or small weight and the
fiber structures form, by filling the free spaces of the upper layer, a re-
quired pattern. These possibilities for providing patterns and/or textures
of the textile flat structures are disclosed in our Canadian patent application
entitled "Method of Manufacturing a Textile Flat Structure and Textile ~Veb
ManufacturedThereby" filed concurrently herewith, to which references are made
herein. The pile yarn loops can be brought, however, in accordance with a pat-
tern into the carrier layer and the free space; produced by this pattern can
be filled by the definite fiber structure. In the lower layer~ the definite
fiber structures can be arranged separately or as a mixture with a fiber
material of another shape.
In accordance with the invention, a uniform texture of multi-filaments
as pile yarns can be converted by needling of the definite fiber structures,
into a product with nap properties which has the appearance of a woolen yarn
product which is expensive to manufacture. It is particularly possible with
the smooth pile yarn to produce effects of flames, etc., by the introduced
definite fiber structures. This is kno~n Eor the expensive spun nap yarns
which, however, can lead during tufting to disruptive process interruptions
because of tearing off of the nap. By the subsequent introduction of the
definite fiber structures, the method can start from a smooth tufted pile yarn
which can be tufted in a wrong manner because of failures in the nap. In the
method in accordance with the present invention, a smooth tufted product can
be subsequently provided with a texture or pattern in a desired manner, for
example, provided with nap formed by the definite fiber structures.
With the aid of the definite fiber structures, the pile loops can be
sufficiently supported and protected from bending. The pile loops can be bent
vertically, horizontally or substantially horizontally. Thereby an additional
pattern can be provided. When the thread pieces extend as loops. they can be
arranged both inside the pile loops and in the spaces between the pile loops so
as as to form a double pile. Ball yarns mixed with thread pieces can be pro-
vided in the lower :Layer, so tllat after needle-processing a mixture of the ball
yarns with thread pieces is introduced into the upper layer. Thereby :Eurther
possibilities for providing patterns are obtained.
The needle-processing of the :Elat structures can be carried out on
conventional needling machines and with conventional needles which can provide
for engagement with the definite fiber structures, for example the ball yarns
or the thread pieces. The needlescan be felt needles or needles with barbs.
The invention can be understood from the following description of pre-
ferred embodiments in conjunction with the drawings, in which,
Figure 1 is a large scale schematic sectional view that shows a non-
woven multi-layer flat textile structure in accordance with one embodiment of
the invention;
Figure 2 is a view substantially corresponding to the view of Figure 1,
but showing a modification; and
Figure 3 is a view also substantially corresponding to the view of
Figure 1, but showing still a further modification.
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A non-woven flat textile structure shown in Figure 1 is identified
intoto by reference numeral 1 and has a pile yarn 2 tufted into a carrier layer
3 so that pile loops 5 project from an upper side 4 of the carrier layer 3 and
form a pile-containing upper layer 6. Base loops 8 are located at a lower
side 7 of the carrier layer 3 and connect the pile loops 5 with one another.
Rall yarns 9 are brought from a lower layer 10 into the upper layer 6 by needle-
processing and extend in the upper layer as definite fiber structures 11 pro-
jecting from the lower layer 10.
The ball yarns 9 contain spherically interwined fibers which are dis-
closed, for example, in the above-mentioned EP publication. By needle-process-
ing from the lower layer 10, the individual ball yarns 9 are engaged in packet-
like manner and pushed or forced through the carrier layer 3 so that they are
more or less compressed. Then can be brought by needles through openings
(not shown) in the carrier layer, which can be carried out, for example, by
needles during the needle-processing step. When the carrier layer 3 is composed
of a ground abric, the openings which are provided therein can be sufficient.
This depends on the size or -thickness of the ball yarns or the intensity and
type of the needle-processing.
During forcing of the ball yarns 9 through the carrier layer 3, they
become slimmer as compared with their shape in the lower layer 10, to greater
or smaller extent, and thereby change their shape. After they are extended
through the carrier layer 3 upwardly, the ball yarns can more or less expand,
so that the ball yarns in the upper layer 6 have a ball-shaped head 13 sub-
stantially corresponding to the original shape 12. As a result of the forcing
through, a smaller tail-shaped or neck-shaped part 14 remains on the ball yarns
9, which extends into the carrier layer 3 and the lower layer 10 so that the
ball yarns are anchored and thereby fixed in these layers. The smaller part
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14 can also be composed of only individual fibers of the ball yarn 9, so that
the ball yarns 9 in the upper layer 6 have substantially the same original
shape and can be recognized as such.
Depending upon the intensity and type of needle-processing, the ball
yarns 9 can remain with their parts 14 only in the carrier layer 3 and be
anchored there. Because the ball yarns are brought by needles through the
carrier layer, the lower layer lO is depleted of the same, so that less ball
yarn 9 remains in the lower layer as compared with conditions before the needle-
processing. After needle-processing which is carried out by simple stitching
by needles in the lower layer 10 from its lower side 15, all or substantially
all ball yarns originally located in the lower layer 10 can be needled into the
upper layer 6. This can depend, for example, on the type of needle-processing
the dimensions and type of the ball yarns, or the openings in the carrier layer
3.
The definite fiber structures ll projecting from the lower layer 10
and extending into the upper layer 6 can provicle the flat structures 1 with
a textured or patterned upper side having, for example, an erratic upper sur-
face. l'he ball yarns can be brought as the lower layer 10, for example,
with a pattern and complekely needle-processed, or completely applied and
needle-processed in strip-like manner. One part of the ball yarns 9 or fiber
structures 11 which is displaced by needles through the carrier layer is lo-
cated, for example, between the pile loops 5, whereas another part of the same
extends up to or on the upper side 16. For arranging the ball yarns 9 on a
lower side 7, they are embedded into the lower layer 10 in a fiber material 17.
In a flat textile structure 18 shown in Figure 2, a pile yarn has
pile loops 19 and base loops 20 and is tufted into a carrier layer 22 so that
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a pile-containing upper layer 23 is formed. Definite fiber structures extend
again from a lower layer 24, in the form of ball yarns 25 composed of spherical-
ly interwined fibers, through the carrier layer 22 up to an upper side 24 of
the upper layer 23. The ball yarns arranged in the lower layer 24, are em-
bedded into a fiber material 27. The ball yarns 25 are brought, for example,
by needles from the lower layer 24 into the upper layer 23. The form or shape
of the ball yarns brought into the upper layer is changed as compared with
the ball yarns 25 remaining in the lower layer 24, as descriled in the previous
embodiment.
The ball yarns 25 fill with their head parts 28 the upper layer 23 or
spaces in the latter which are available, for example, between the pile loops
19 or can be formed by displacement of the pile loops wi-th needles ~not shown).
A thinner or smaller part 29, as compared with the head part 28~ of the deformed
ball yarns 25 is located in the lower layer 24 in which non-engagcd yarns 25
are also located. A plurality of the ball yarns 25 extend with their head
parts beyond the pile loops 19 so that an embossed texture is formed at the
upper side 26 of the upper layer 23~
A flat textile structure 30 shown in Figure 3 has a pile-containing
upper layer 31 composed of pile loops 32 of a pile yarn 33 tufted into a car-
rier layer 34. A lower layer 36 is composed of a fiber material 35, and fiber
pieces or fiber structures 37 are displaced by needles through the carrier
layer 34 into the upper layer 31 where they are arranged in loop-like manner
as definite fiber structures between the pile loops 32. Legs 38 of the fiber
pieces 37 remain in the lower layer 36 or in the carrier layer 34 and are fixed
in these layers against pulling out. The lower layer 36 contains only the
fiber material 3'~ which is not engaged during needle-processing.
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The fiber pieces 37 extend up to an upper side 39 of the upper layer
31 and can extend to a pile height ~l or beyond the latter as can be seen for
some fiber pieces 37. The needle-processing can be carried out by needles
with barbs which can engage the fiber pieces 37 and push them as loops through
the carrier layer 34. Depending upon the type and intensity of the needle-
processing, the loops can be brought more or less high into the upper layer 31.
This also depends on the locations over the length of the fiber pieces at which
they are engaged by the needles. The high and low loop-shaped fiber pieces
37 can be visible as a further pile, i.e., as a double pile arranged between
the pile loops 32. Because of the fiber structure 37 located at the upper side
39, the flat structure 30 obtains a texture and/or pattern. The fiber pieces
37 can fill not only the spaces between the pile loops 32 and thereby to com-
plete the upper layer 31 with fiber material, but they can also support the
pile loops 32. Therefore a low pile density ccm be provided, since the spaces
which take place in this case can be :Eilled with the fiber pieces 37. This is
naturally also possible in the above described embodiments of Figures l and 2.
For the sake of clarity, the pile loops and the definite fiber
structures are shown only schematically in Figures 1-3. In practice, other
distances and dimensions can be provided, and more dense or narrow arrangement
2Q can take place.
In accordance with one embodiment of the invention, the tufted pile
loops 5, 19 or 32 are arranged in mutually parallel straight rows, as practical-
ly can be appreciated from Figures 1-3. In known tufted flat structures the
pile loops are offset as a rule, contrary to this inventive feature, and par- .
ticularly are zig-~ag in arrangement. By introducing the definite fiber struc-
tures 11~ 25 and 37 at least partially through the carrier layer 3, 22 and 34
into the upper layer 6, 23 and 31, an effect is produced that the tufted and
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needle-processed flat structure 1, 18 and 30 has a woven appearance. The
inventive flat structure corresponds, however, with regard to its behavior
and service more closely resembles woven flat structure, than a tufted flat
structure which is easier to manufacture than the latter.
When the distances between the pile loops 5, 19 and 32 are so great
that in the upper layer 6, 23 and 31 by tufting with a low density free spaces
remain, these free spaces are filled with the ball yarns 9 and 25 mixed with
the fiber pieces or fiber structures 37.
The fiber structures such as ball yarns, fiber pieces or fibers, which
are needle-processed throughor into the upper layer between the rows of the
pile loops, support the freely standing pile loops and prevent inclining of
the upwardly extending pile loops under the action of applied pressure.
The fiber structures introduced by needles between the pile loops,
particularly when thelr fibers have another darker degree oE color~ provide
for shading increasing the weaving effect. Moreover, the Elat structure obtains
a better cohesion.
We wish it to be understood that we do not desire to be limited to the
exact detailsof construction shown and described, for obvious modificatiolls
will occur to a person skilled in the art.
