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Title:
FIBRE CARPET BASE USED IN CARPET PRODUCTION
Document Type and Number:
WIPO Patent Application WO/2021/061062
Kind Code:
A1
Abstract:
The invention is related to a fibre carpet base using in the production of carpets that have been produced with the fibre carpet fabric production method. In the reinforced carpet base subject to the invention, a reinforcing intermediate mesh layer (3) has been used that is formed of polypropylene strips, between the base fabric (1) located at the lowermost section and the muslin reinforcement layer (2) that has been formed following the blending of polypropylene or polyester material. This intermediate mesh layer (3) is used as the second reinforcement layer (3) that is produced by means of the weaving system made of polypropylene strips. Alternatively, the reinforced carpet base subject to the invention comprises a base fabric (1) located at the lowermost section and a muslin reinforcement layer (2) at the top section, that has been formed following the blending of polypropylene or polyester material, and an intermediate reinforcing mesh layer (3) that is made from the same material as the base fabric but having a different weight basis, located between said two layers (1,2). The base fabric at the lowermost section is used as the UV protection base fabric (2) in order to provide UV protection for the produced base fabric.

Inventors:
GÜNDÜZ İBRAHIM ONUR (TR)
GÜNDÜZ ALI (TR)
Application Number:
TR2020/050118
Publication Date:
April 01, 2021
Filing Date:
February 17, 2020
Export Citation:
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Assignee:
INOVA PAZARLAMA ANONIM SIRKETI (TR)
International Classes:
E01C13/08
Download PDF:
Claims:
CLAIMS

1. The invention is a fibre carpet base used in manufacturing of carpets, characterized by comprising a base fabric (1) woven from polypropylene strips, a reinforcing muslin layer (2) formed by the mixture of polypropylene or polyester material at different ratios and different amounts and a carding process and needle punching said material onto the base fabric (1).

2. A fibre carpet base according to claim 1 , characterized in that the base fabric (1 ) located at the lowermost section is made of a UV protection material.

3. A fibre carpet base according to claim 1 , characterized by comprising a reinforcing intermediate mesh layer (3) formed of polypropylene strips, that is located between the base fabric (1 ) located at the lowermost section and the muslin reinforcement layer (2).

4. A fibre carpet base according to claim 1 , characterized by comprising, a base fabric (1) located at the lowermost section and a muslin reinforcement layer (2) at the top section, that has been formed following the blending of polypropylene or polyester material, and an intermediate reinforcing mesh layer (3) that is made from the same material as the base fabric but having a different weight basis, located between said two layers (1 ,2).

5. A fibre carpet base according to claim 4, characterized in that the base fabric at the lowermost section is a UV protection base fabric (1).

Description:
Fibre Carpet Base Used In Carpet Production

Technical Field of the Invention: The invention is related to a fibre carpet base that is used in the production of carpets that have been produced by means of the fibre carpet fabric production method.

Prior Art:

In the prior art, after the pile yarns are sewn onto a non-reinforced base fabric during carpet manufacturing, chemical agents or adhesive agents are applied onto the bottom surface of the base fabric for fixation and a further thermal process is applied. Melting is experienced on the base following the application of a thermal process during the production of a carpet base fabric, and the molten material that is formed after the thermal process coats the entire base surface. After the molten material is subjected to the cooling process, the material is hardened and fixation is enabled or a fixing process is carried out. After the fixation or fixing process of the carpet that is produced by sewing pile yarns onto the non- reinforced base fabric, holes need to be opened for discharging rainwater from the carpet. The opening of such holes causes an extra amount of effort and time and leads to an increase in floor coating expenses. The problem of size change is experienced at the carpet fabric base due to temperature differences in such products where fixation or fixing process to the base is carried out. In order to prevent size changes that may arise due to temperature differences, base fabrics that are formed of glass fibre as reinforcement, are adhered with an adhesive to the base fabric, thereby incorporating said fibre to the base fabric. The post-adhesion of the woven fabric made of glass fibre also leads to higher costs.

One of the documents in the literature of the prior art that is related to a carpet base is the document disclosing the invention of a fibre reinforced carpet base used in producing carpets, that is protected within the scope of the utility model document numbered TR 2010 01641 Y. In this document, a base fabric that is used for reinforcement is disclosed. This base fabric is the carpet base fabric that is to be used in order to obtain a final carpet that is used for example as a football field carpet etc., by utilizing a muslin that is formed of polyester fibres that can melt at low temperatures. When the carpet is subjected to a thermal process which enables fixation or fixing, the muslin used as a reinforcement material, formed of polyester fibre that melts at low temperatures melts and fixing is l provided. By means of the invention described in this document, the consumption of external chemical agent used for fixation and adhesive is reduced and the costs are reduced. Moreover in this invention, it is described that the changes of sizes of the carpet due to temperature differences can be prevented by the addition of felt that is formed of glass fibre for reinforcement in accordance with the usage area of the final carpet. In this document it is disclosed that the felt formed of glass fibre is mechanically coupled by means of a single needle punching process in a single step to the base together with the reinforcement fibre muslin, thereby eliminating the need to use an adhesive or an adhesion process.

One of the most important parts of this product is the reinforcement structure having a muslin form, formed of polyester that can melt at low temperatures. After the carpet is obtained by sewing of pile yarns onto the base fabric, this reinforcement structure melts when it is subjected to a thermal process for fixation, and following this, the melted material fills into the holes opened into the base fabric by the tufting needles at the sewing points of the pile loops that have been sewn onto the base fabric. The holes are closed partially such that small openings are available for both providing sufficient fixation or fixing and for enabling the discharging of rainwater out of the carpet from under the carpet by allowing small-sized openings to remain at the points where the pile yarns are sewn onto the base fabric.

Technical Problems that are Faced:

In the utility model document numbered TR 2010 01641 Y of the prior art, a carpet base that is reinforced with glass fibre onto the base fabric is disclosed. As it is known, glass fibre contains asbestos. When users step on this carpet base, they are subjected to the hazardous effects of asbestos. Allergic conditions and redness occurs in users in connection with the itching of their body. In the prior art, a cloud of dust is discharged into the air while it is passing through the drums during the process of converting glass fibre into muslin, and the operator(s) inhale this glass fibre powder and experience health problems. Moreover as the glass fibre that is added for reinforcement to the base fabric breaks during fixation with glass fibre needle punching, resilience losses are encountered.

In order to ensure that users do not face any health problems, in our invention polypropylene, polyester and a fibre mix formed of a mixture of both are used instead of glass fibre in the fibre carpet base when producing carpets. As glass fibre is not used in our invention, users no longer encounter health problems arising from glass fibre.

In our invention, as polypropylene, polyester or a fibre mix formed of a mixture of both is used instead of glass fibre, breakages do not occur such as the breaks that used to occur during needle punching of glass fibre and the loss of resilience that is encountered due to such breakages during the production of the base fabric is eliminated. During the production of a base fabric the mechanical connections that enable connection are ensured to be stronger by means of the needle punching process.

In the prior art, the deficiency of basis weight per metre square that occurs due to the breakages in glass fibre disrupts the homogenous distribution of glass fibre inside the muslin. This leads to distortion of the structure of the carpet base and reduces quality and causes the standard features of the product to be lost.

As a result of the search carried out on the general properties of fibres, it has been noticed that the tensile strength of the polyester fibre is 18 newtons g/den for conditioned and 45 newtons for wet g/den. The polypropylene tensile strength of polypropylene is 70 newtons g/den for conditioned and 90 newtons for wet g/den. The tensile strength of glass fibre used in the prior art is 3 newtons g/den for conditioned and 4 newtons for wet g/den. When the tensile strength values of the materials are taken into consideration, it can be noticed that the tensile strength of the polypropylene used in our invention is much higher than the tensile strength of glass fibre. A base fabric that is much more resilient than before has been obtained by means of our invention by using polypropylene.

In our carpet base subject to the invention, polypropylene or polyester has been used instead of glass fibre and a tufting process is carried out on the carpet base, thereby the gripping strength of artificial grass is increased and while the problem of separation or detachment of the fibres from the carpet base is minimized the gripping strength is increased.

Moreover, the recycling of glass fibre is very difficult, costly and time-consuming, whereas the recycling of polypropylene or polyester is much cheaper and easier. A carpet base having high resilience that is reinforced with recyclable and environmentally friendly materials is produced by means of our invention through the usage of such recyclable materials.

The carpet bases used in the prior art lose their properties quickly when they are subjected to sunlight and when they are used outdoors, and as a result, some parts of the carpet may come apart. Our carpet base subject to the invention comprises the usage of UV base fabric so that it does not get damaged when subjected to sunlight. The UV base fabric prevents the fabric from coming apart or from being damaged due to sunlight.

In the prior art, a glass fibre formed of a single type or a polyester material that melts at lower pressures was used as the second reinforcement layer. In this technique a mixing process is not carried out, coating onto the base fabric is performed by producing a muslin for reinforcement using a single type of fibre. As the secondary layer is separate from the first layer, two separate production techniques are used. An additional muslin layer production needs to be carried out in order to produce a reinforcement muslin layer, and following this, the muslin that is produced needs to be coated onto the base fabric with another technique. These processes increase costs and also leads to poor adhesion of the base fabric to the reinforcement muslin.

Different types of fibres are brought together at the area where the mixing is to be carried out and the fibre types having different properties are mixed with each other in a single place, at different ratios and numbers, during the production of the carpet base subject of our invention. After the mixing is carried out the mixture is blended. This mixture is brought into a reinforcement muslin layer with carders and the muslin is laid over the base fabric. By this means the positive synergic effect of different fibre types is transferred onto the base fabric as a reinforced single muslin layer.

Pressure or tension applied onto the floor is increased in game-fields such as handball or football that are played with several players. In such cases, the resilience of the carpet base is reduced and changes and deteriorations occur in the structure thereof, and the carpet base is deformed in a shorter period of time. In order to eliminate this disadvantage, an intermediate reinforcing mesh layer is used between the muslin made of a fibre mix which is placed between the fabric base and the muslin, wherein said reinforcing mesh layer is formed again of polypropylene, made of strips that increases resilience, usage life and prevents rapid deformation. This intermediate mesh layer is used as the second layer that is produced by means of the weaving system made of polypropylene strips.

Description of the Figures:

Figure-1 : View of the base and muslin layer of the carpet base subject of our invention Figure-2: View of the manufactured base carpet base subject of our invention

Figure-3: View of the base and muslin layer of the manufactured carpet base subject of our invention

Figure-4: View of the base, muslin layer and the intermediate reinforcing mesh layer of the carpet base subject of our invention Figure-5: View of the manufactured base carpet base subject of our invention having two reinforcement layers

Figure-6: View of the base, muslin layer and the intermediate reinforcing mesh layer of the manufactured carpet base subject of our invention Figure-7: The view of the base fabric (1) having different basis weight, used as the second intermediate layer for reinforcement of the carpet base subject of our invention

Figure-8: The view of the manufactured base fabric (1) having different basis weight, used as the second intermediate layer for reinforcement of the carpet base subject of our invention

Figure-9: The view of all of the layers of the manufactured base fabric (1) having different basis weight, used as the second intermediate layer for reinforcement of the carpet base subject of our invention

Brief definitions of the part numbers illustrated in the Figures: 1 - Base fabric

2- Muslin layer

3- Intermediate reinforcing mesh layer

Detailed Description of the Invention: After the different types of fibres and brought together at different ratios and after they are blended together in the carpet base subject of our invention, the fibres are combed to the same length with the carding machine and are spread over the base fabric with a spreading machine. After the fibres are spread over the base fabric (1) as a muslin layer (2) that is spread onto the base fabric (1), these layers (1 , 2) are mechanically coupled to each other with the use of a needle punching machine. Thereby a reinforced carpet base fabric is produced that has been formed as a single carpet base. Polypropylene material is used as the base fabric of the carpet base subject of the invention Polypropylene material can be found in the base fabric as strips.

Different types of fibres are blended at different ratios and the synergic effect of each fibre type is transferred onto the base fabric.

The type of fibres used in our invention is formed of polypropylene or polyester or a mixture of both. Polypropylene or polyester materials are fibre types having different properties and different ratios. In our invention, a UV protected base fabric (1) is used as the base fabric (1). By this means, the usage life of the carpet has been extended, even if the carpet is exposed to sunlight.

In the carpet base subject to the invention, a reinforcing intermediate mesh layer (3) has been used that is formed of polypropylene strips in order to extend the usage life and prevent rapid deformation of the carpet and increase its resilience, wherein said mesh has been placed between the base fabric (1) and the muslin reinforcement layer (2) that has been formed following the blending of polypropylene or polyester material. This intermediate mesh layer (3) is used as the second reinforcement layer (3) that is produced by means of the weaving system made of polypropylene strips. The base fabric (1) and the first and second reinforcement layers (2,3) are fixed to each other by means of needle punching.

In the carpet base subject to the invention a base fabric (3) that has a different basis weight but that is made of the same material as the reinforcement base fabric (1) is used between the base fabric (1) and the muslin reinforcement layer (2). Moreover in this base fabric, while resilience has been increased using a base fabric (3) having a different basis weight without UV protection on the UV protected base fabric (1) located at the lowermost section, UV protection is provided by means of the UV protected base fabric (1) located at the lowermost section.

The carpet base described in detail above is formed of a base fabric (1) and a muslin layer

(2) provided for reinforcement, which is formed following the mixing of polypropylene or polyester material at different ratios and amounts and the carding process and needle punching said material onto the base fabric (1).

A UV protected material is used in the base fabric (1) located at the lowermost section of the reinforced carpet base subject to the invention.

In the reinforced carpet base subject to the invention, a reinforcing intermediate mesh layer

(3) has been used that is formed of polypropylene strips, between the base fabric (1) located at the lowermost section and the muslin reinforcement layer (2) that has been formed following the blending of polypropylene or polyester material. This intermediate mesh layer (3) is used as the second reinforcement layer (3) that is produced by means of the weaving system made of polypropylene strips.

Alternatively, the reinforced carpet base subject to the invention comprises a base fabric (1) located at the lowermost section and a muslin reinforcement layer (2) at the top section, that has been formed following the blending of polypropylene or polyester material, and an intermediate reinforcing mesh layer (3) that is made from the same material as the base fabric but having a different weight basis, located between said two layers (1 ,2). The base fabric at the lowermost section is used as the UV protection base fabric (2) in order to provide UV protection for the produced base fabric.