Method for producing a ductile tufted product, a ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automobile interior area

Abstract

The invention is intended to provide a simple and economical method for producing a ductile tufted product, particularly a tufted upper carpet layer that is particularly ductile, in particular for the automotive interior area. For this purpose, a melt-blown non-woven fabric is placed on a ductile polyester tufted backing and the melt-blown non-woven fabric and the polyester tufted backing are tufted together.

1 . A method for producing a ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automotive interior area, wherein a melt-blown non-woven fabric is placed on a ductile polyester tufted backing, and wherein the melt-blown non-woven fabric and the polyester tufted backing are tufted together. 
   
   
       2 . The method according to  claim 1 , wherein the tufted product is introduced in the further carpet manufacturing process solely by a thermal treatment from the tufting piercing side, particularly without latex application. 
   
   
       3 . The method according to  claim 1 , wherein a polyester spun-bond non-woven is used as the polyester tufted backing, preferably having a basis weight of 70 g/m 2  up to 140 g/m 2 , more preferred from 100 g/m 2  to 120 g/m 2 . 
   
   
       4 . A method according to  claim 1 , wherein the melt-blown non-woven fabric having a basis weight of preferably 70 g/m 2  up to 500 g/m 2  is used, more preferred from 80 g/m 2  to 200 g/m 2 , even more preferred from 80 g/m 2  to 130 g/m 2 . 
   
   
       5 . A method according to  claim 1 , wherein a thermoplastic raw material that can be spun or processed by injection molding is used as the raw material for the melt-blown non-woven fabric, particularly one selected from polyolefins, copolyolefins, polyesters, copolyesters, polyamides, and/or copolyamides having an MFI value (melt flow index) (according to DIN 1238 or ISO 1133) of 100 to 300 g/10 min. 
   
   
       6 . A method according to  claim 1 , wherein the melt-blown non-woven fabric having a thickness of 0.5 mm to 1.5 mm is used, with 0.5 mm to 1.0 mm being particularly preferred. 
   
   
       7 . A method according to  claim 1 , wherein the melt-blown non-woven fabric having a fiber titer of 0.06 dtex to 0.2 dtex, preferably of 0.06 dtex to 0.1 dtex, is used. 
   
   
       8 . A method according to  claim 1 , wherein the melt-blown non-woven fabric and the polyester tufted backing are tufted together with a tufting gauge of ⅛″ to 1/16″ without prior needling or calendaring. 
   
   
       9 . A method according to  claim 1 , wherein the melt-blown non-woven fabric is advantageously strengthened by means of an ultrasonic calendar with a bonding surface of less than 5%, preferably of less than 2%, and tufted together with the polyester tufted backing with a gauge of ⅛″ to 1/16″. 
   
   
       10 . A method according to  claim 1 , wherein the melt-blown non-woven fabric and the polyester tufted backing are strengthened together by means of an ultrasonic calendar with a bonding surface of less than 5%, preferably of less than 2%, and tufted together with a gauge of ⅛″ to 1/16″. 
   
   
       11 . A method according to  claim 2 , wherein an acoustic non-woven material and/or at least one other insulating layer is applied on the tufting piercing side of the tufted product as a further carpet manufacturing process. 
   
   
       12 . A ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automotive interior area, produced using a method according to  claim 1 , which at room temperature has:
 a maximum tensile force in the longitudinal direction (according to EN 29073-3) of 250 N/5 cm to 400 N/5 cm, preferably of 275 N/5 cm to 375 N/5 cm);   a maximum tensile force in the transverse direction (according to EN 29073-3) of 180 N/5 cm to 300 N/5 cm, preferably of 203 N/5 cm to 250 N/5 cm;   a maximum tensile elongation in the longitudinal direction (according to EN 29073-3) of 45% to 60%; and   a maximum tensile elongation in the transverse direction (according to EN 29073-3) of 42% to 55%.   
   
   
       13 . A ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automotive interior area, produced using a method according to  claim 1 , which at 140° C. has:
 a maximum tensile force in the longitudinal direction (according to EN 29073-3) of 185 N/5 cm to 200 N/5 cm;   a maximum tensile force in the transverse direction (according to EN 29073-3) of 85 N/5 cm to 120 N/5 cm;   a maximum tensile elongation in the longitudinal direction (according to EN 29073-3) of 65% to 70%; and   a maximum tensile elongation in the transverse direction (according to EN 29073-3) of 65% to 70%.   
   
   
       14 . A ductile tufted product, particularly a ductile tufted top carpet layer, particularly for the automotive interior area, produced using a method according to  claim 1 , which at room temperature has a tear propagation force in the longitudinal direction (according to DIN 53859-3) of 170 N to 240 W.