Method for producing textile products, products obtainable therefrom and method to reclaim the products

Abstract

The present invention discloses a method for manufacturing an optionally laminated textile product, the method comprising the steps of: a) providing a first sheet with yarns fastened thereto where the first sheet has a first surface and a second surface and the yarns extend from the first surface of the first sheet, b) heating the second surface of the first sheet thereby at least partly melting the yarns fastened to the first sheet to bond the yarns to the first sheet; c) exposing the second surface of the first sheet to pressure; d) optionally imparting a mechanical force on the molten fraction of the yarns in a direction parallel to the surface of the first sheet; e) applying hot melt adhesive to the second surface of the first sheet; and f)optionally applying a dimensionally stable second sheet to the second surface of the first sheet; with the proviso that where the optional step (f) is absent then step (d) is not optional.

1 . A method for manufacturing a textile product, the method comprising the steps of:
 a) providing a first sheet with yarns fastened thereto where the first sheet has a first surface and a second surface and the yarns extend from the first surface of the first sheet,   b) heating the second surface of the first sheet thereby at least partly melting the yarns fastened to the first sheet to bond the yarns to the first sheet;   c) exposing the second surface of the first sheet to pressure;   d) optionally imparting a mechanical force on the molten fraction of the yarns in a direction parallel to the surface of the first sheet; wherein the method further comprises   e) applying hot melt adhesive to the second surface of the first sheet; and   f) optionally applying a dimensionally stable second sheet to the second surface of the first sheet;   
       with the proviso that where the optional step (f) is absent then step (d) is not optional. 
     
     
         2 . A method according to  claim 1 , the method comprising the steps of:
 a) providing a first sheet with yarns fastened thereto where the first sheet has a first surface and a second surface and the yarns extend from the first surface of the first sheet,   b) heating the second surface of the first sheet thereby at least partly melting the yarns fastened to the first sheet to bond the yarns to the first sheet;   c) exposing the second surface of the first sheet to pressure;   d) imparting a mechanical force on the molten fraction of the yarns preferably in a direction parallel to the surface of the first sheet; wherein the method further comprises   e) applying hot melt adhesive to the second surface of the first sheet; and   f) optionally applying a dimensionally stable second sheet to the second surface of the first sheet.   
     
     
         3 . A method according to  claim 1 , where in step (a) the yarns are fastened to the first sheet temporarily. 
     
     
         4 . A method according to  claim 1 , in which the yarns of the first sheet also additionally extend from the second surface of the first sheet. 
     
     
         5 . A method according to  claim 1 , in which the second surface of the first sheet is calendered in whole or in part and adhesive is provided by applying molten adhesive on the calendered second surface of the first sheet, and where the calendered second surface of the first sheet has a temperature above the melting temperature of the hot melt adhesive when the adhesive is applied. 
     
     
         6 . A method according to  claim 1 , in which the hot melt adhesive is provided as a layer having a thickness of less than 1 mm, preferably less than 0.5 mm. 
     
     
         7 . A method according to  claim 1 , in which the hot melt adhesive has a melting point lower than each of the yarn, the first sheet and the second sheet where present. 
     
     
         8 . A method according to  claim 1 , in which
 the hot melt adhesive comprises a Polymer P in an amount of at least 50% by weight of the hot melt adhesive composition and/or   where the yarn, the first sheet and the second sheet (where present) each independently comprise at least one Polymer R;   where Polymer P and/or any of Polymer(s) R is independently obtained and/or obtainable by polycondensation, a ring opening polymerisation of cyclic monomers, a step-growth polymerisation method and/or is a recycled polycondensate.   
     
     
         9 . A method according to  claim 8 , where any of the Polymer(s) R for each of the yarn, the first sheet and the second sheet where present comprises substantially the same material. 
     
     
         10 . A method according to  claim 8 , in which the Polymer P and/or any of the Polymer(s) R comprises one or more polymer and/or copolymer selected from the group consisting of: (co)polyurethane(s); (co)polycarbonate(s); (co)polyester(s), (co)polyamide(s);(co)poly(ester-amide(s); mixtures thereof and/or copolymers thereof. 
     
     
         11 . A method according to  claim 10 , in which the Polymer P and/or any of the Polymer(s) R is a (co)polyester, a (co)polyamide and/or a poly(ester-amide). 
     
     
         12 . A method according to  claim 11 , in which the Polymer P and/or any of the Polymer(s) R is a (co)polyester. 
     
     
         13 . A method according to  claim 8 , in which the Polymer P has a melt viscosity at 150° C. of <500 Pa·s. 
     
     
         14 . A method according to  claim 1 , in which the hot melt adhesive is a thermoplastic adhesive. 
     
     
         15 . A textile product, comprising:
 I) a first sheet with yarns fastened thereto by
 (i) a first fastener where the first sheet has a first surface and a second surface and the yarns extend from the first surface of the first sheet; and 
 (ii) a second fastener where the yarns have been fused at least in part to the first sheet and/or each other optionally by heat and/or pressure; 
 (iii) a third fastener, characterized in that the third fastener comprising a hot melt adhesive (HMA) substantially located on the second surface of the first sheet; 
   II) optionally a dimensionally stable second sheet attached to the second surface of the first sheet optionally attached by the hot melt adhesive;   
       with the provisos that if the second sheet is absent then
 (A) the HMA (component (a) (iii)) substantially comprises, preferably consists of non-embedded HMA; and 
 (B) in the second fastener (component (I)(ii)) the yarns have been fused at least in part to the first sheet and/or each other by a mechanical force imparted to a molten fraction of the yarns in a direction parallel to the surface of the first sheet; 
 
     
     
         16 . A textile product as claimed in  claim 15 , in which the HMA comprises a Polymer P and/or the yarn, the first sheet and the second sheet where present comprise at least one Polymer R. 
     
     
         17 . A textile product as claimed in  claim 15  which comprises a carpet, carpet tile, rug and/or mat. 
     
     
         18 . A textile product according to  claim 15 , in which the first sheet, the second sheet (where present) and optionally the hot melt adhesive are substantially the same type of polymer. 
     
     
         19 . A textile product as claimed in  claim 15  which is a polyester carpet tile 
     
     
         20 . A textile product as claimed in  claim 15  which is an optionally laminated polyester loom carpet comprising at least one, preferably at least two polyester layers (optionally each layer comprising the first and second sheets). 
     
     
         21 . A textile product as claimed in  claim 15  which is a laminated loom carpet comprising a nylon layer (optionally comprising the second sheet) and a polyester layer (optionally comprising the first sheet). 
     
     
         22 . A method to reclaim a textile product comprising taking a used textile product according to  claim 15 , wherein the method comprises heating the hot melt adhesive to allow the first sheet to de-connect from the second sheet (where present), collecting the first sheet and/or the second sheet (where present) for reuse. 
     
     
         23 . A method according to  claim 22 , wherein the method comprises heating the hot melt adhesive to allow the first sheet to de-connect from the second sheet, collecting the first sheet and the second sheet in two separate streams, and further heating the separate streams above their melting temperature to obtain recycled polymer and re-using the obtained polymer. 
     
     
         24 . A method to reclaim a textile product comprising taking a used textile product according to  claim 15 , wherein the method comprises heating the product as a whole, thereby melting the polymer comprised in the yarns, the backing (where present), the sheet and the hot melt adhesive and re-using the obtained polymer. 
     
     
         25 . A method according to  24 , wherein the melting is effected in one melting step and the method is effected without a separation step between the melting and the re-using. 
     
     
         26 . A method according to  claim 22 , wherein the polymer of the textile product is a polycondensate. 
     
     
         27 . A textile product comprising unmodified or chemically modified and/or mechanically modified recycled polycondensate obtained in the method of  claim 26 . 
     
     
         28 . Use of a hot melt adhesive to produce a textile product of  claim 15 . 
     
     
         29 . Use of a textile product as claimed in  claim 15  as a floor covering. 
     
     
         30 . A method of applying a textile product to a floor comprising the steps of:
 applying to a floor a textile product as claimed in  claim 15  and   fastening the textile product to the floor.   
     
     
         31 . A floor covered with a textile product as claimed in  claim 15 . 
     
     
         32 . A device for manufacturing a textile product as claimed in  claim 15  having as a characterising feature a head to apply hot melt adhesive.