High-strength lightweight tufted backing and method for the production thereof

Abstract

The invention relates to a high-strength lightweight tufted backing, particularly for use as primary or secondary carpet backing, comprising at least one ply of melt-spun synthetic filaments, which are bonded by means of high-energy water jets, characterized in that it includes a small amount of a thermally activatable binding agent, which is applied onto the ply of melt-spun filaments in the form of at least one thin layer.

1 . A high-strength lightweight tufted backing made of spunbonded non-woven, particularly for use as primary or secondary carpet backing, comprising at least one ply of melt-spun synthetic filaments bonded by means of high-energy water jets, wherein said at least one ply includes a small amount of a thermally activatable binding agent, which is applied onto the ply of melt-spun filaments in the form of at least one thin layer. 
     
     
         2 . The high-strength lightweight tufted backing according to  claim 1 , wherein said backing is configured as a 3-ply system, in which the middle ply comprises the binding agent and the two outer plies comprise synthetic filaments. 
     
     
         3 . The high-strength lightweight tufted backing according to  claim 1 , wherein the binding agent comprises a low-melting thermoplastic polymer. 
     
     
         4 . The high-strength lightweight tufted backing according to  claim 3 , wherein the low-melting thermoplastic polymer has a melting temperature that is at least 10° C. below that of the synthetic filaments. 
     
     
         5 . A high-strength lightweight tufted backing according to  claim 1 , wherein the synthetic filaments have a titer of 0.7 to 6.0 dtex. 
     
     
         6 . A high-strength lightweight tufted backing according to  claim 1 , wherein the synthetic filaments comprise polyester, polyethylene terephthalate, and/or a polyolefin. 
     
     
         7 . A high-strength lightweight tufted backing according to  claim 1 , wherein the low-melting polymer substantially comprises polyethylene, a copolymer having a proportion of polyethylene, polypropylene, a copolymer having a proportion of polypropylene, a copolyester, a polyamide, and/or a copolyamide. 
     
     
         8 . A high-strength lightweight tufted backing according to  claim 3 , wherein the low-melting polymer constitutes a weight proportion of less than 7% relative to the total weight of the tufted backing. 
     
     
         9 . A high-strength lightweight tufted backing according to  claim 3 , wherein the low-melting polymer is present in the form of spun or melt-blown fibers or fibrils. 
     
     
         10 . The high-strength lightweight tufted backing according to  claim 9 , wherein the fibers are conjugate fibers, wherein the lower-melting component constitutes the thermally activatable binding agent. 
     
     
         11 . A method for producing a high-strength lightweight tufted backing according to  claim 1 , characterized by the following steps:
 a) depositing at least one ply of synthetic filaments by means of a spun-bonded non-woven production process;   b) applying at least one thin layer of a thermally activatable binding agent.   c) hydroentangling the spunbonded non-woven filaments and distributing the binding agent by means of high-energy high-pressure water jets;   d) drying; and   e) thermal treatment in order to activate the binding agent.   
     
     
         12 . The method according to  claim 11 , wherein the drying and the thermal activation are carried out in one step. 
     
     
         13 . The method according to  claim 11 , wherein the hydroentangling is adjusted such that a specific longitudinal strength of at least 4.3 N/5 cm per g/m 2  basis weight and a specific initial modulus, measured in the longitudinal direction as tension at 5% elongation, of at least 0.45 g/5 cm per g/m 2  basis weight are achieved. 
     
     
         14 . A method according to  claim 11 , wherein the thermally activatable binding agent is applied by employing an air-laying or melt-blown method. 
     
     
         15 . Use of a high-strength lightweight tufted backing according to  claim 1  for producing three-dimensionally deformable carpets for automotive interior applications.