Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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This invention relates to non-woven textile materials, and, more
particularly, to non-woven floor coverings.
Non-woven floor coverings are known from, for example, German pat~nt
2,604,098, in which at least one layer of parallel textile yarns disposed
adjacent to one another are needle-processed to a supporting layer through
fibers having their origin in these yarns. As the needle-processing is accom-
plished by fibers of the yarns, namely from the upper side of the floor covering,
only a small proportion of the fibers of each yarn is needle-processed to the
covering layer at an insufficient density, in view of the risk of destroying
the twisted yarns, and consequently impairing their appearance. This results,
in turn, in an insufficiently rigid connection of the layer of threads to the
supporting layer for many purposes, which, in the event the fibers, which have
their origins in the yarns, are damaged, can lead during use of the floor
covering to a separation of the layer of yarns, and consequently result in the
destruction of the upper side of the floor covering. If it is desired to
accomplish the needle-processing at a greater density based on this known
process, then this may at most lead to a plane felt-like textile material,
where manufacture of individual yarns is not economically worthwhile, even if
a structured appearance can be obtained thereby. The known floor coverings
do not meet therefore the demands posed thereon, and are limited to yarns
; which permit a low needle-processing density, and therefore the floor coverings
are of relatively small thickness. Any attempt to add additional layers above
the first layer of yarns leads in known floor coverings only to the formation
of an additional pattern.
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From German patent 1,7~9,~3, it is also known to manufacture non-
woven carpets from two layers of yarns crossing one another at a strength of,
for example, 20 ktex, which are fastened to one another by needle-processing,
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ancl may also be needle~proce~sed to a carrier. The crossed layer of the yarns
is needle~processed from the yarn side, namely the yarns are actively needle-
processed w~th a carrier layer, and there are always required two layers of
yarns, so that the layers of yarns are pressed to one another again also as a
result of the needle processing.
Floor coverings are also known, for example, from the Belgian
patent 700,540, dated December 27, 1967 of "Centre International Pour
L'Economie et la Technologie, en Abrege "I.C.E.T.", in which yarns or rovings
are needle-processed from the fiber fleece side, which must, however, be always
brought together in the form of a prefabricated layer with the fiber fleece.
The known coverings therefore require prior formation of the yarn la~er or
rovings at a desired pattern, which is, for example, expensive in the case of
any change of patterns, and particularly does not permit any individual patterns.
The fibers from the fiber fleece are particularly needle-processed, however,
through the yarn layer or rovings, so that these protrude from the upper sur-
face of the floor covering, and project therefrom with their free ends in the
layer of yarns or rovings. They are thereby subjected not only to wear and
tear, but also the rigidity of connection of the layer of yarns or rovings on
the fiber fleece is endangered, as the layer can easily become loose due to
wear of needle-processed fibers, and can therefore become separated from the
fiber fleece.
It is therefore a principal object of the invention to devise a
non-woven floor covering of the aforedescribed type without the disadvantages
of known coverings, which shows on its upper side a clearly structured appear-
ance, for example, a handwoven appearance, as a result of the fiber material,
and whose fiber materi~al can be fastened at an adequate rigidity to the carrier
layer in such a manner that, for e~ample, an embossed structure can be accom-
plished without any problems by the manner of the attachment of the fiber
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matcrial.
This object is attained for a floor covering of the aforedescribed
mamler by individual relatively thick strands being passively needle-proc~sed
onto the carrier layer only by connecting fibers from the carrier layer which
at least partially penetrate the strands.
The strands disposed on the upper side of the floor covering are
therefore located, for example, on the actively acting carrier layer, and a
portion of the fibers of the carrier layer has merely passed into the strands
as connecting fibers so as to connect the strands to the carrier layer. This
leaves the upper side of the floor covering substantially free from any connect-
ing fibers projecting therefrom. As a result of the active participation of
the fibers of the carrier layer in the aforedescribed attachment, the strands
are only passively fastened to the carrier layer.
The relatively thick strands, can, according to the invention, be
fastened to the carrier layer without there occurring any risk of their being
destroyed or their appearance impaired, as their fibers are not utilized for
attachment to the carrier layer. In view of the thickness of the strands, the
connecting fibers may pass therethrough at several locationsl as viewed in
cross-section, so that the strands are fastened to the carrier layer at an
adequate rigidity. Thus it is possible to achieve, for example, a high density
of the connecting fibers and therefore passive compacting, so that, for ex-
ample a desired high firmness, and moreover, uniformity of the attachment can
be obtained.
Strands having a thickness of at least 5 mm., but also of 20 mm.,
can be used or processed, which, as a result of their considerable thickness,
can be entered by means of connecting fibers at a plurality of locations, as
viewed in cross-section, and can therefore be attached to the carrier layer at
a high uniformity. The strands may have a fineness between 10 ktex to 100 ktex.
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The connecting fibers may pass through only a portion of the thickness of the
strands, for exa~ple through half their thi:ckness, or may pass tfirough the
en1ire thickness o the strands, 6ut at most up to a surface portion of the
st~ands facing away from the carrier layer.
Tfie strands are preferably fastened to the carrier layer by a con-
ventional needle process, ~here, for example fiaers of the carrier layer are
gripped by means, for example, of barbed needles and merely introduced into
the strands as needle-processing fibers, namely connecting fibers, so that the
strands are passively needle-processed to the carrier layer. For the afore-
described passive attachment also other processes such as Mali processes, can
ae used. Here the carrier layer is preferably needle-processed to the strands
by connecting fibers emanating from the carrier layer,
In what follows the term "actively processed" will be understood to
mean that fibers from a fiber layer may be moved, or withdrawn from the layer
by a needle process with respect to other layers, and twisted therewith, in
other words may acti~ely accomplish some object. These fibers may also be
introduced into another layer border~ng the fibrous layers, so that this other
layer is connected with the fibrous layer.
The term "passively needle-processed" or "passively attached" will
be understood to mean, however, that in a fiber-containing material layer there
can be found fibers from other fiber-containing layers or layer serving as
connecting fibers, but where the fibers of the material layer are not substan-
tially utilized for any active purposes, but remain passive. See, for example,
Swiss patent 43~,2n6, of Brevetex S.A., dated December 15, 1967.
In view of the passive attachment of the strands to the carrier
layer, prefe~ly by ~assive needle-processing, the needles may, for example,
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be inserted through the bottom part of the carrier layer and pass into the
covering thereafter, so that they are not visible to an observer viewing the
upper side of the covering. The strands may therefore be needle-processed from
an actively needle-processable carrier layer by a so called "blind stitch
technique"J namely, invisible technique, so that) for example, they are not
influenced by any wear, and the upper side of the floor covering is not, for
example, damaged or changed by severe wear.
In dependence of the types of the strands, the desired covering, or
the desired or required firmness, the strands may be needle-processed from the
carrier layer side at a needle-processing density between 20 to 200 stitches
per cm. . As a result of the thickness of the strands, for example, 5 mm. it
is, for example, not only possible to obtain a high needle processing density,
but it is also possible to obtain floor coverings having a weight, for example,
in a range from .5 kg. per square meter to 8 kg. per square meter.
In the covering, according to the present invention, it is prefer-
ably possible to obtain a thick product using only a single layer of the strands,
where the strands are clearly visible as an embossed structure and can, for
example, be clearly recognized as a three-dimensional formation, separate and
apart from the carrier layer. Preparation, for example, of a preliminary
pattern is avoided. On the contrary, the strands may be fastened singly, for
example in a desired pattern, onto the carrier layer, which makes it possible
to obtain a multiplicity of patterns or structures or variations of the same.
The strands are preferably not connected to one another, so that they may split
from one another during bending of the floor covering in a direction towards
the carrier layer without, for example, impairing their attachment to the
carrier layer. The floor covering therefore has a pliability which cannot, for
example, be obtained in a needle-processed felt, so that for example, properties
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similar to tufted or woven carpets can be obtained. In view of the passively
penetrating connecting fibers, according to the invention, which may be fastened
to the strands under tension or loosely, there is also avoided any compression
of the strands, and therefore a resulting compressed and flat product, which
may, for example arise during needle-processing from above, particularly at a
high needle processing density.
The strands may have an arbitrary form of shape, for example they may
have a circular or substantially circular, ellipsoid, rectangular, quadratic or
triangular cross-section. The strands may include natural fibers or synthetic
fibers, fiber reinforced plastics or fibers or yarns adhering or glued to one
another, or consisting of such fibers or yarns. The strands may be disposed
parallel or substantially parallel to one another. The strands may also have
different respective diameters, and groups of strands having the same diameter
can be mixed with groups of strands having a different diameter.
These strands may have the shape of a band or yarn, for example, can
be coarse formations and preferably have a cohesion of their own. The strands
may also be constructed in a manner as is described, for example, in South
African patent No. 81/8542, published and granted on November 24, 1982, and
entitled "Fiber Strands and Method for Manufacture Thereof", the construction
and method being therefore not further described here in detail. The strands
may also be spun by imparting a rotation thereto, or contain fibers which sur-
round, for example, a core, such as a fiberous core. They may be wound around
the core in the form of a cylindrical mantle, or helically. In the case of non-
twisted strands, namely strands having nontwisted fibers, the attachment to the
carrier layer may be accomplished by a surrounding yarn or a binding yarn, or
through the~previously mentioned adhesion of fibers or yarns to one another such
as, for example, by means of a glue; the surrounding or binding yarns can
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be inserted by way of the carrier layer and can pass therefrom to the strands,
and treated, for example, by so called slop padding, or impregnation.
In one version of the invention the strands may be surrounded by
a visible binding yarn having a diameter smaller than that of the strands up
to a number of 200 coils per square meter, and thus give the appearance of a
chain thread imitation. It is to be noted that, for example, in known hand-
woven carpets, chains made of yarn are clearly visible, compared to, for
example a coarse woolen yarn or loose wool, and represent a quality feature of
the carpet. In the floor covering, according to the invention, the floor
covering can in a completely surprising manner appear like a handwoven floor
covering as a result of the binding yarn, having the appearance of a floor
covering using chains in handwoven carpets, without such chains actually being
present. Thus the appearance of the needle-processed floor covering can be
avoided, and rather the appearance of a handwoven floor covering can be obtained.
In another version of the invention, binding threads may be wound
around respective strands in such a manner as to result in a plurality of
constrictions in a corresponding strand, so as to give the appearance of a
tufting loop imitation. The binding thread is wound around the strand during
the manufacture thereof so as to be under tension; this makes it possible for
the binding thread to be displaced interiorly within the strand, and apparently
surrounded by the strand in a manner appearing to pass through its longitudinal
axis. On viewing such a strand the binding thread appears extended along the
longitudinal direction, and appears to actually be surrounded by the strand.
The binding thread or surrounding thread is therefore, for example, no longer
recognizable as such, and the fibers of the strands may plastically expand,
for example in a loop form, so that an embossment structure results. The
binding thread may have a fineness from 100 to 8000 dtex, and the tension
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applied to the binding thread during manufacture of the~strand is preferably
below the tearing force required to tear the binding thread. At a fineness of,
for example 4000 dtex, this tension is preferably less than 20 kg.
Reference is again made to the aforecited South African patent No.
81/8542 for other versions of the invention.
Parts of the connecting fibers which have penetrated the strands are
bent back on themselves within the strands, namely in a direction towards the
carrier layer. They may be bent into the shape of a hook, for example a barbed
hook, may be n-shaped, may be shaped in the form of an inverted V, or may be
loop-shaped. As a result of parts of the connecting fibers being bent back on
themselves the resulting hooks or the like can be hooked to the fibers of the
strands, and therefore be securely connected thereto. The strands are therefore
firmly connected to the carrier layer by the other ends of the connecting fibers,
which are located in the carrier layer, where, for example, in the case of a loop
each end of a connecting fiber can be anchored within the carrier layer.
The manufacture of the floor covering, according to the invention,
requires that the connecting fibers of the carrier layer be needled to the
strands with a good aim. This is preferably accomplished by means of needles
which permit the gripping of the connecting fibers by means of hooks or recesses
in the needles, where the connecting fibers are, for example, formed with loops,
so that the needles can grip the loops, but also release the connecting fibers,
when the needles are withdrawn from the strands, so that the connecting fibers
are thereby bent back on themselves within the strands. Needle-processing can
be accomplished with so called close-barbed needles (for example see information
leaflet FOlA, SINGER* Felting Needles). Here, for example, the spacings from
barb to barb, the type of barb, as well as, for example, the penetrating stitch
* Trade Mark
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depth and/or stitch density influence the fact whether individual fibers or
bundles of fibers are to be gripped by a barb, and to what depth and at what
spacing these must be positioned in the strands, and how the connecting fibers
are to be bent back on themselves within the strand, for example, in the form
of a loop. The type of bending the connecting fibers back on themselves, or
formation of a loop is, for example, also depedndent on the staple length of the
fiber material in the carrier layer. By, for example, appropriate arrangement
of the needles in the needle board and the position of the strands, for example,
positioned adjacent to one another, but leaving spaces between respective
strands, the strands can be needle-processed in a desired manner, so that the
connecting fibers will be aimed to merely penetrate the strands.
The carrier layer may contain natural or synthetic fibers, or con-
sist thereof, and may be non-woven, for example a fiber fleece, a fiber connect-
ing material, or only a fiber layer. On the side of the carrier layer facing
away from the strands there may be disposed a support layer, for example a
covering layer customary for the back of floor coverings, for example a springy
layer, which is then needle-processed or glued to the covering layer, so as to
tailor the floor covering to the demands made thereon. The floor covering may
be also a flat structure, for example in the shape of longitudinal strips, in
the form of a piece good, of a sheet or slab-formed.
Further objects and advantages of the invention will be set forth
part in the following specification, and in part will be obvious therefrom
without being specifically referred to, the same being realized and attained
as pointed out in the claims hereof.
For a fuller understanding of the nature and objects of the inven-
tion, reference should be had to the following detailed description, taken in
connection with the accomplnying drawings in which:
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Figure 1 is a perspective view of a floor covering according to the
invention in part section;
Figure 2 is an elevation view of the floor covering in section
along the line II-II of Figure l;
Figure 3 is a perspective view of a floor covering of another ver-
sion of the invention in part section;
Figure 4 (third sheet of drawings) is a photograph of the upper
side of another version of the floor covering; and
Figure 5 is an elevation view of a portion of the strand of the
floor covering of Figure 4 shown in a stretched state.
Referring now to the drawings, and in particular to Figures 1 and
2, a non-woven floor covering 1, for example, a carpet, includes a carrier layer
2 composed of a fiber material 3, and a plurality of substantially parallel
disposed fiber-containing thick strands 4, which have a thickness D (as seen
in Figure 2) of at least 5 mm. The fiber material of the strands 4 is prefer-
ably twisted, so that each strand 4 is cohesive. The carrier layer 2 is
actively needle-processed with the strands 4, namely the strands 4 are connected
through connecting fibers 5~ contained in the carrier layer 2 to the carrier
layer 2, and thus are passively needle-processed therewith. The connecting
fibers S merely penetrate the strands 4, and as seen in the right portion of
Figure 2, penetrate the strands 4 at most up to a surface 6, or a portion of the
surface 6 of the strands 4, which faces away from the carrier layer 2. As is
illustrated in the version on the left portion of Figure 2, the connecting
fibers 5 may penetrate only a portion of the thickness D of the strands 4, and
can therefore extend through half the thickness D, or less than half the thick-
ness D of each strand. The penetration depth of the connecting fibers 5 is,
for example, dependent on the needle-processing conditions and/or the staple
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length of the fiber material of the carrier layer 2. A portion 7 of the
connecting fiber 5 which have penetrated into the strand 4 is bent back on it-
self, and can therefore be hooked onto the fibers or fiber material of the
strand 4, and therefore be connected thereto. The portion 7 of the connecting
fibers 5 may be an end portion 8 of the connecting fibers 5 or a loop 9, which
with its two free ends can remain in the carrier layer 2. This depends on the
length, for example, the staple length of the fiber material 3 or the fiber
portion of the connecting fibers 5 being gripped by the needles during needle-
processing. For the sake of clarity the portions 7 of the connecting fibers 7
or the free ends 10 of the connecting fibers 5 remaining in the carrier layer
have been shown to be more divergent than is the case in practice; in practice
they converge at a narrower angle, in other words, the free ends are disposed
more tightly next to one another. On the lower side 11 of the carrier layer 2,
and consequently of the floor covering 1, there will be seen incisions 12 which
result during needle-processing of the carrier layer 2 to the strands 4, and
which are invisible from the upper side 13 of the covering layer 1. As a
result of the needle-processing having been carried out from the bottom side of
the carrier layer 2, and due to the connecting fibers 5 merely having pene-
trated the strands 4 fro~ below, the upper side 13 of the floor covering 1
therefore remains free of any connecting fibers 5.
The strands 4 adhere to the carrier layer 2 through the connecting
fibers 5 at an adequate strength, as the needle process~ng has accomplished
at a multiplicity of needle processing locations according to the incisions 12.
During the process of manufacture the strands 4 may be disposed individually
on the carrier layer 2 and may remain unconnected to one another in a direction
transverse to their longitudinal direction, so that the floor covering 1 remains
completely bendable and flexible in a direction transverse to the longitudinal
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direction L leaving spaces between the strands 4.
In the floor covering 14, according to Figure 3, non-twisted
strands 15 are also passively needle-processed through connecting fibers 16 onto
a carrier layer 17, the connecting fibers 16 having their origin in the fibrous
material 18 of the carrier layer 17. The actively needle-processed carrier
layer 17 is therefore connected to the strands 15. The connecting fibers 16
have penetrated again into the strands 15 at most up to a surface 19 thereof,
which faces away from the carrier layer 13, without thefiber material 20 of
the strands 15 in any way having been used for the needle process. This results
in turn in the floor covering 14 being free on its upper side 21, or substan-
tially free from any connecting fibers 16 projecting therefrom. To the lower
side 22 of the carrier layer 17 there is connected a covering layer 23. The
strands 15 consisting of non-twisted fiber material 21 are surrounded or wound
around by a binding thread 24, so that each has its own cohesiveness.
Figure 4 shows a top side 25 of a floor covering 26, including
strands 27 which, not visible, but as has been described in the versions illus-
trated in Figures 1 and 2, are passively needle-processed through a fibrous
carrier layer, and wherein connecting fibers of the carrier layer merely
penetrate the strands 27 and are therefore passively needle processed thereto.
The strands 27 are composed of nontwisted fiber material 28 and a binding thread
30 is wound therearound in such a fashion that the strands 27 are drawn together
along the longitudinal direction and have constrictions 29; this makes it
appear that the binding thread passes near or through the center of the strand
as it is not visible. As can be seen, the floor covering gives the appearance
of a tufting loop imitation.
Figure 5 shows one of the strands 27 pulled apart along a longi-
tudinal direction E, so that the respective entwining of the binding thread 30
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and the strands 27 can be recognized. On releasing the tension, the binding
thread 30 under tension constricts the strand 27 in such a manner that, for
example its constricted portions appear in a pearl-like manner, as if strung
along a string ~Figure 4). The strand 27 therefore is elastic along its longi-
tudinal direction E, its elasticity being dependent upon the tension applied
to the binding thread 30 during manufacture of the strands 27, and the resulting
apparent excessive twist thereof.
I wish it to be understood that I do not desire to be limited to
the exact details of construction shown and described, for obvious modifications
will occur to a person skilled in the art.
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