A process is provided for producing a multi-layered flat fibrous structure, especially a floor covering, having a surface or wear layer, a base or carrier layer and optionally further layers. The base or carrier layer is first produced from a multi-layered non-woven fabric in a mechanical non-woven
A process is provided for producing a multi-layered flat fibrous structure, especially a floor covering, having a surface or wear layer, a base or carrier layer and optionally further layers. The base or carrier layer is first produced from a multi-layered non-woven fabric in a mechanical non-woven formation device. Elements forming the surface or wear layer are then applied to the base or carrier layer. Before application, a distribution of the elements which differ in terms of their geometrical shape is standardized in such a way that the surface or wear layer is substantially repeat-free. The elements forming the surface or wear layer are then joined at least to the base or carrier layer.
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We claim: 1. A process for producing a floor covering, which comprises: a) introducing at least two differing groups of elements with geometrically differing shapes into an applicator, equalizing the groups in the applicator, and depositing the elements in an application stream of the groups for at
We claim: 1. A process for producing a floor covering, which comprises: a) introducing at least two differing groups of elements with geometrically differing shapes into an applicator, equalizing the groups in the applicator, and depositing the elements in an application stream of the groups for at least partly forming a substantially non-repeating visible surface layer; and b) needling at least the elements forming the surface layer to a non-woven base layer. 2. The process according to claim 1, which comprises carrying out the step of introducing the elements into the applicator in accordance with at least one predetermined mixing ratio. 3. The process according to claim 1, which comprises densifying the elements in at least one section of an exit duct of the applicator to form the application stream. 4. The process according to claim 3, which comprises carrying out the densifying step in a funnel-shaped section of the exit duct. 5. The process according to claim 3, which comprises metering the elements into the section densifying the elements. 6. The process according to claim 1, which comprises at least one of laying, scattering and blowing the elements of the application stream onto the base layer. 7. The process according to claim 1, which comprises forming at least some of the elements by dividing a feed material. 8. The process according to claim 7, which comprises punching the elements out of the feed material. 9. The process according to claim 7, which comprises cutting the elements to form the feed material. 10. The process according to claim 1, which comprises forming at least some of the elements by dividing a feed material in ribbon or sheet form. 11. The process according to claim 1, which comprises forming at least some of the elements by initially dividing a feed material in sheet form in longitudinal direction and then essentially at right angles to the longitudinal direction of the feed material. 12. The process according to claim 1, which comprises forming at least some of the elements by dividing a feed material having a thickness of from 3 to 10 mm. 13. The process according to claim 1, which comprises forming at least some of the elements by dividing a feed material selected from the group consisting of a non-woven and a needle felt. 14. The process according to claim 1, which comprises forming at least some of the elements by dividing a feed material selected from the group consisting of a non-woven and a needle felt having a basis weight between 200 and 1000 gr/m2. 15. The process according to claim 7, which comprises forming at least a portion of at least one of the elements and the feed material from at least one of yarns and threads. 16. The process according to claim 15, which comprises forming at least a portion of the elements from yarn precursors. 17. The process according to claim 16, which comprises forming at least a portion of the elements from card slivers. 18. The process according to claim 16, which comprises forming at least a portion of the elements from yarn precursors having a metric count of about 0.5 to 4.0. 19. The process according to claim 15, which comprises forming at least a portion of the elements from carded yarns having a metric count between about 0.5 and 5.0. 20. The process according to claim 15, which comprises forming at least a portion of the elements from carded threads. 21. The process according to claim 20, which comprises forming at least a portion of the elements from carded threads having a metric count between about 0.5/3 and 5.0/3. 22. The process according to claim 15, which comprises forming at least a portion of the elements from semi-worsted yarns having a metric count between about 2.0 and 8.0. 23. The process according to claim 15, which comprises forming at least a portion of the elements from semi-worsted threads. 24. The process according to claim 15, which comprises forming at least a portion of the elements from semi-worsted threads having a metric count between about 2/2 and 8/2. 25. The process according to claim 1, which comprises forming at least a portion of the elements from textile pieces. 26. The process according to claim 1, which comprises forming at least a portion of the elements from woven pieces. 27. The process according to claim 1, which comprises forming the elements from at least one of natural and synthetic materials. 28. The process according to claim 1, wherein the base layer to which the elements forming the surface layer are applied, is an unconsolidated base layer. 29. The process according to claim 28, which comprises consolidating the unconsolidated base layer during the step of needling the elements to the base layer. 30. The process according to claim 1, which comprises consolidating at least one of the base layer and the surface layer by chemical binders. 31. The process according to claim 1, which comprises providing at least one further layer on a surface of the base layer remote from the surface layer.
Pickens ; Jr. Robert C. (Gurnee IL) Kirchherr Patricia R. (Grayslake IL) Thomas Reese R. (Libertyville IL), Floor covering of needled woven fabric and nonwoven batt.
Bastioli Catia (Novara ITX) Del Tredici Gianfranco (Sesto Calende ITX), Process for the continuous manufacture of thermomoldable thermoplastic composite materials.
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