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

Abstract

The present invention pertains to a method to manufacture a textile product, in particular a carpet product such as broadloom carpet, carpet tiles, mats and rugs, comprising a first sheet having polyamide yarns fastened to this sheet to form a pile thereon, the method comprising providing the sheet, stitching the polyamide yarns through the sheet to form the pile on a first surface of the sheet, the pile extending for a predetermined length from this first surface, and to form loops of the yarns at a second surface of the sheet, and fastening the yarns to the sheet by creating a layer of fused material on the second surface of the sheet using heat, wherein during creating the layer of fused material, at least the distal half of the length of the pile is maintained at a temperature at least 70° C. below the melting temperature of the polyamide. The invention also pertains to a method to use a textile product obtained with the new method and a device for applying the said method.

1 . A method to manufacture a textile product comprising a first sheet having polyamide yarns fastened to this sheet to form a pile thereon, the method comprising:
 providing the sheet,   stitching the polyamide yarns through the sheet to form the pile on a first surface of the sheet, the pile extending for a predetermined length from this first surface, and to form loops of the yarns at a second surface of the sheet,   fastening the yarns to the sheet by creating a layer of fused material on the second surface of the sheet using heat,   
       wherein during creating the layer of fused material, at least the distal half of the length of the pile is maintained at a temperature at least 70° C. below the melting temperature of the polyamide. 
     
     
         2 . A method according to  claim 1 , wherein the distal half of the length of the pile is maintained at a temperature at least 100° C. below the melting temperature of the polyamide. 
     
     
         3 . A method according to  claim 1 , wherein the at least distal half of the length of the pile is maintained at the temperature below the melting temperature of the polyamide using cooling means. 
     
     
         4 . A method according to  claim 1 , wherein for fastening the yarns to the sheet, the second surface of the sheet is contacted with a surface of a hot body to at least partly melt the loops of the yarns to create the mass of molten material. 
     
     
         5 . A method according to  claim 4 , wherein the surface of the hot body has a relative speed with respect to the second surface of the first sheet. 
     
     
         6 . A method according to  claim 5 , wherein the surface of the hot body is stationary, whereas the first sheet is transported along the hot body. 
     
     
         7 . A method according to  claim 1 , wherein the textile product is a laminate of the first sheet and a second sheet, wherein after the second surface of the first sheet has been processed, an adhesive is applied to this second surface to which adhesive the second sheet is adhered. 
     
     
         8 . A method according to  claim 7 , wherein the adhesive is a hot melt adhesive. 
     
     
         9 . A method according to  claim 8 , 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. 
     
     
         10 . A method according to  claim 7 , 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. 
     
     
         11 . A method according to  claim 10 , wherein the intermediate layer is a fibrous layer. 
     
     
         12 . A method according to  claim 11 , wherein the intermediate layer is a non woven layer. 
     
     
         13 . A method according to  claim 12 , wherein the intermediate layer is a knitted layer. 
     
     
         14 . Use of a textile product obtainable according to  claim 1  to cover a surface of a building or any other artificial or natural construction. 
     
     
         15 . A textile product comprising a sheet having a top surface and a bottom surface, the textile product having polyamide yarns stitched through this sheet to form a pile on the surface of the sheet, the pile extending for a predetermined length from this first surface, the yarns being fastened to the bottom surface of the sheet by forming a layer of fused polyamide material on this bottom surface, wherein the yarns in the pile have a decreased amorphous content with respect to yarns of the same polyamide annealed at a temperature of about 43° C. below the melting temperature of the polymamide for 1 hour. 
     
     
         16 . A device for use in manufacturing a textile product comprising a first sheet having polyamide 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, the pile extending for a predetermined length from this first surface, and loops of the yarns at a second surface of the sheet, the device comprising:
 heating means for heating the second surface of the sheet,   means for creating a mass of fused material on the second surface of the sheet, and   cooling means for cooling at least the distal half of the length of the pile to a temperature at least 70° C. below the melting temperature of the polyamide during creating the mass of fused material.