Moldable, needle-punched automotive carpet

Abstract

An improved moldable, needle-punched automotive carpet of improved wear is disclosed by the invention process of combining a critical proportion of polypropylene and polyester fibers having optimal physical properties. A preferred embodiment of the invention additionally includes a binder fiber. The improved carpet comprises a blend of fibers with specific properties that, when used to manufacture the needle-punched auto carpet, produces a moldable carpet that exhibits improved wear, heretofore achieved only with more expensive tufted carpets.

1 . An integral textile composite fabric of non-woven, needled textile fibers comprising a blend of at least one polypropylene textile fiber and at least one polyester textile fiber of laid and needled textile organic fibers.  
     
     
         2 . The composite fabric of  claim 1  further comprising the addition of a binder fiber.  
     
     
         3 . The composite fabric of  claim 2  further comprising a yarn lubricant.  
     
     
         4 . The composite fabric of  claim 1  wherein the ratio of polyester to polypropylene is 60-80:40-20.  
     
     
         5 . The composite fabric of  claim 4  wherein the ratio of polyester to polypropylene is 70:30.  
     
     
         6 . The composite fabric of  claim 2  wherein the ratio of polyester to polypropylene to binder fiber is 75-55:20-35:5-10.  
     
     
         7 . The composite fabric of  claim 6  wherein the ratio of polyester to polypropylene to binder fiber is 65:28:7.  
     
     
         8 . The composite fabric of  claim 2  exhibiting a fabric loss less than 4.0 wt % after 1000 tabor cycles.  
     
     
         9 . The composite fabric of  claim 8  exhibiting a fabric loss less than 4.0 wt % after 1400 tabor cycles.  
     
     
         10 . The composite fabric of  claim 8  exhibiting a fabric loss less than 3.0 wt % after 1000 tabor cycles.  
     
     
         11 . The composite fabric of  claim 10  exhibiting a fabric loss less than 3.0 wt % after 1400 tabor cycles.  
     
     
         12 . The composite fabric of  claim 10  exhibiting a fabric loss less than 2.0 wt % after 1000 tabor cycles.  
     
     
         13 . The composite fabric of  claim 12  exhibiting a fabric loss less than 2.0 wt % after 1400 tabor cycles.  
     
     
         14 . The composite fabric of  claim 13  exhibiting a fabric loss less than 2.0 wt % after 2000 tabor cycles.  
     
     
         15 . The composite fabric of  claim 14  exhibiting a fabric loss less than 2.0 wt % after 2500 tabor cycles.