A method to manufacture a textile product, a use thereof and a device for applying the method

Abstract

The invention pertains to a method to manufacture a textile product comprising a first sheet having polyester yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polyester yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, contacting the second surface of the sheet with a surface of a hot body to at least partly melt the loops of the yarns to fasten the yarns to the sheet, wherein the second surface is actively cooled to force the temperature to be below the glass transition temperature of the polyester yarns within 60 seconds after the contacting of the second surface with the hot body. The invention also pertains to a device for applying this method.

1 . A method to manufacture a textile product comprising a first sheet having polyester yarns fastened to this sheet to form a pile thereon, the method comprising:
 providing the sheet,   stitching the polyester yarns through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet,   contacting the second surface of the sheet with a surface of a hot body to at least partly melt the loops of the yarns to fasten the yarns to the sheet,   characterised in that the second surface is cooled to force the temperature to be below the glass transition temperature of the polyester yarns within 60 seconds after the contacting of the second surface with the hot body.   
     
     
         2 . A method according to  claim 1 , wherein the second surface is actively cooled. 
     
     
         3 . A method according to  claim 1 , wherein the second surface is cooled to force the temperature to be below the glass transition temperature of the polyester yarns within 30 seconds after the contacting of the second surface with the hot body. 
     
     
         4 . A method according to  claim 1 , wherein the surface is actively cooled by contacting the second surface with a cold body. 
     
     
         5 . A method according to  claim 4 , wherein the cold body is a stationary beam having a contacting surface that runs in essence parallel to the second surface. 
     
     
         6 . A method according  claim 4 , wherein the cold body is maintained at a temperature below the glass transition temperature of the polyester yarns by actively cooling the body using convection and/or conduction. 
     
     
         7 . A method according to  claim 1 , wherein the surface of the hot body has a relative speed with respect to the second surface of the first sheet. 
     
     
         8 . A method according to  claim 7 , wherein the surface of the hot body is stationary, whereas the first sheet is transported along the hot body. 
     
     
         9 . A method according to  claim 1 , wherein the textile product is a laminate of the first sheet and a second sheet, characterised in that after the second surface of the first sheet has been processed according to any of the preceding claims, an adhesive is applied to this second surface to which adhesive the second sheet is adhered. 
     
     
         10 . A method according to  claim 9 , wherein the adhesive is a hot melt adhesive. 
     
     
         11 . A method according to  claim 10 , wherein the hot melt adhesive comprises at least 50% by weight of a polymer chosen from the group consisting of polyurethane, polycarbonate, polyester, polyamide, poly(ester-amide), polyolefine, mixtures thereof and/or copolymers thereof. 
     
     
         12 . A method according to  claim 9 , wherein an intermediate layer is provided between the first sheet and the second sheet wherein the intermediate layer is resilient to allow local deformation of this layer along the second surface of the first sheet or along the surface of the second sheet adjacent to the intermediate layer. 
     
     
         13 . A method according to  claim 12 , wherein the intermediate layer is a knitted layer. 
     
     
         14 . A method according to  claim 9 , wherein each of the first sheet, the second sheet, the adhesive and resilient layer are made of polyester. 
     
     
         15 . Use of a textile product obtainable according to  claim 1  to cover a surface of a building or any other artificial or natural construction. 
     
     
         16 . A device for use in manufacturing a textile product comprising a first sheet having polyester yarns fastened to this sheet to form a pile thereon, the yarns being stitched through the sheet to form the pile on a first surface of the sheet and loops of the yarns at a second surface of the sheet, the device comprising:
 a hot body that can be heated to above a melting temperature of the polyester yarns,   means for contacting the second surface of the sheet with the hot body,   transport means for transporting the sheet along the hot body while the second surface is in contact therewith, and   cooling means for cooling the second surface to a temperature below the glass transition temperature of the polyester yarns within 60 seconds after the second surface is in contact with the hot body, and   downstream of the cooling means, a means for applying a layer of adhesive to the second surface.   
     
     
         17 . A device according to  claim 16 , wherein the cooling means is an active cooling means.