US 12,031,249 B2
Method for producing a needle punch velour carpet
Ralf Lehmann, Köningswartha (DE); Jochen Erhard Glass, Bad Elster (DE); Matthias Dickert, Witten (DE); and Volkmar Schulze, Schierling (DE)
Assigned to Adler Pelzer Holding GMBH, (DE)
Appl. No. 16/612,989
Filed by Adler Pelzer Holding GMBH, Hagen (DE)
PCT Filed May 15, 2018, PCT No. PCT/EP2018/062579
§ 371(c)(1), (2) Date Nov. 12, 2019,
PCT Pub. No. WO2018/210852, PCT Pub. Date Nov. 22, 2018.
Claims priority of application No. 102017208200.3 (DE), filed on May 16, 2017.
Prior Publication US 2020/0173073 A1, Jun. 4, 2020
Int. Cl. D04H 1/46 (2012.01); B60N 3/04 (2006.01); D04H 1/485 (2012.01); D05C 17/02 (2006.01); D06M 13/00 (2006.01); D06M 15/00 (2006.01)
CPC D04H 1/46 (2013.01) [D04H 1/485 (2013.01); D05C 17/026 (2013.01); D06M 13/00 (2013.01); D06M 15/00 (2013.01); B60N 3/042 (2013.01); B60N 3/048 (2013.01); D06M 2200/35 (2013.01)] 6 Claims
 
1. A process for producing a needle punch carpet having a velourized and more wear-resistant surface, comprising:
providing a bulky unstable sheet, a needling unit containing needles, and a carding machine with a carding belt;
needling the bulky unstable sheet, received from the carding belt of the carding machine, wherein the bulky unstable sheet is needled in the needling unit forming the carpet with a stitch-out side, characterized in that the stitch-out side of the carpet has a penetration depth of from 2 to 13 mm,
wherein:
a) a needle design of the needles in the needling unit is such that needle types can be used in which notches are arranged in different heights and numbers, wherein the needling unit is used for consolidation of the bulky unstable sheet;
b) a needle density of the needles in the needling unit is at least 9000/m2;
c) a fiber working weight of the carpet is from 240 to 600 g/m2;
d) only one single needling unit is employed and used for the consolidation of the bulky unstable sheet;
e) a stitch density of the carpet is from 200 to 750 stitches/cm2; and
f) the stitch-out side is brushed against a grain to erect fibers, and protruding fibers are shorn off;
wherein the carpet is velourized, and
wherein the carpet, before being subjected to a drying/cross-linking process, is coated with a wax/polymer dispersion on the stitch-out side.