EP0089018A1 - Process for continuously manufacturing fibre-reinforced fleeces - Google Patents

Abstract

1. Process for the continuous production of fibre-reinforced webs, in which a core layer of particles is placed between an under-layer and a covering layer which form outer layers, at least one of the outer layers having threads capable of being actively needled, whereby the three layers are needled together, characterised in that the core layer is formed of elastic non-foamed granular particles incapable of being penetrated by the needling needles, and that the retaining threads are applied between the granular particles.

Description

The invention relates to a method for the continuous production of fiber-reinforced webs.

Fiber-reinforced webs are made from a wide variety of elastic materials, whereby in addition to the use of raw materials, waste material is increasingly used.

From DE-OS 2.162.233 it is known to mix granulated, irreversibly crosslinked elastomers with a thermoplastic binder, to heat them to a temperature above the melting point of the binder but below the decomposition temperature of the elastomer, to extrude them as a film from a slot die and cool between cooled belts of a double belt press to a temperature below the melting point of the binder.

From DE-AS 1.089.954 a process for the production of plates or other molded products from rubber waste and textile fibers from rubber waste is known, in which pneumatic vehicle tires are cut from cord inserts by cutting, breaking and grinding these impregnated textile threads obtained with a small amount of small pieces of rubber with the addition of binders, such as natural or synthetic resins or glue, and the mixture is then hot pressed.

DE-AS 1.038.266 discloses a process for the production of porous material consisting of textile fibers, in particular textile waste, and binders, in which the textile fibers aggregate into small units in the dry state and these fiber bales are circulated in a drum with a liquid , drop-shaped binder are sprayed so that it adheres to the surface of the fiber bales in a punctiform manner, whereupon a further hardening agent is sprayed on while the resulting mass is circulated, and the mass is then shaped, dried and hardened.

It is known from rubber production to produce elastic webs in that a masticated web provided with vulcanizing agents e.g. vulcanized under the influence of steam.

All these known methods have in common that the as yet unconsolidated or not yet vulcanized web has no cohesion over its entire surface. For this reason, the elastic web must be supported by a carrier until it has hardened or vulcanized. If several such not yet hardened or not yet vulcanized webs are stored one above the other, the individual web layers must have separating layers between them, e.g. Have silicone paper. A free, unsupported movement of such tracks, even if it is e.g. is a masticated rubber skin is not possible.

The invention is therefore based on the object of a method for the continuous production of fiber-reinforced

To create webs in which the webs have their own internal cohesion, in particular also a fiber reinforcement, even in the non-set or non-vulcanized state.

This object is solved by the subject matter of claim 1. The needling process known from textile technology is used to solve this task.

In the case of so-called needling, single fibers or tufts of fibers are pierced from a fiber-containing layer placed on another layer by means of barbed needles, in which they get stuck when the needles are withdrawn and thereby bring about the connection of the fiber-containing layer with the other layer. A prerequisite for carrying out the needling technique is therefore the presence of a layer of "actively needled substances", ie a layer which is used to carry out the needling process ses retractable, fibrous structures or contains such structures. The other layer, into which the actively needled fibers are introduced, must be at least passively needable, ie, it must be able to hold the fibers inserted into it.

Such a passively needle-punched layer can itself be actively needle-punchable, but passively needle-punchable layers can also be known to be formed by woven fabrics, knitted fabrics, spunbonds, foils made of plastic or paper or the like.

Both the top layer and the underlayer can also be constructed in multiple layers. For example, the underlayer can consist of a plastic film and a non-woven fabric, e.g. the film faces the core layer.

Surprisingly, it has now been shown that elastic, non-foamed material, such as Granules made of vulcanized rubber, whether from waste rubber waste or made specially for this purpose, synthetically produced, non-foamed elastomers, granules provided with or without binders, obtained from needle felt floor coverings, or also not yet vulcanized rubber skins provided with vulcanizing aids, especially plasticizers, as lying between two outside Layers core layer between these can be needled.

By needling the webs, which have not yet set or not yet vulcanized, and which consist of the individual layers, a large number of holding fibers can be introduced into these webs in a relatively high density very quickly, as a result of which the three layers are held one below the other and the elastic materials, as well as fillers such as these, such as sand particles or the like, are prevented from entering or penetrating the outer layers.

The fiber-reinforced, elastic web formed in this way has its own internal cohesion and can now also be handled without a support and / or support surface - floating.

Such a sheet can be used as an elastic floor for sports and playgrounds, this non-set or non-vulcanized sheet being applied to the floor to be covered, which previously was e.g. has been provided with an adhesive layer to give the web adhesion to the surface. This web adhering to the ground is then coated with a liquid binder, e.g. impregnated with a two-component adhesive such as polyurethane, whereupon the actual setting takes place in the installed state of the web.

Conventional synthetic fibers made of polyester, polyamide, polypropylene or the like or natural fibers such as cotton or the like can be used as actively needled fibers. The choice here also has to be made in relation to the core layer to be needled and the properties of the web which are desired later. The second outer layer, which, as explained above, must be at least passively needled, can consist of the same fibers, but the above-mentioned webs can also be used.

The needling of the three layers means that the particles which are not connected to one another or the mass of the core layer are not only held between the two outer layers, but are also prevented from moving substantially in the plane of the web. The solid particles evenly distributed in the factory production and introduced with a constant layer thickness thus remain in their defined position even without setting or vulcanization. This also applies if openings, such as punched-out areas, slots or the like, are made in the non-set or non-vulcanized web at right angles to its plane of extent.

According to a preferred embodiment, the core layer consisting of an elastic, non-foamed material consists of a granulate which cannot be pierced when needling. The grain size is selected depending on the desired final thickness of the web, the grain size is preferably max. 5 mm. However, it is also possible to needle larger granules; then the stitch density, ie the number of needle punctures per unit area should be chosen smaller and needling should be done needles of a larger diameter are used. The needled holding fibers are then each between two or more particles. Due to the elasticity of the granulate and the internal pressure caused by needling - the layers are pressed together when needling, whereby this compression is maintained by the holding fibers - the contact areas between the granulate particles are enlarged, so that since the granulate particles have an at least rough surface, the Granulate particles can also be prevented from slipping among themselves.

In one embodiment, the granules are made from vulcanized rubber, i.e. granulated. It can be processed rubber waste, e.g. can be obtained from old car tires or the like. On the other hand, a rubber mixture specially produced for the intended use can be vulcanized and granulated. It is possible to add certain desired additives to the masticated rubber composition. A mixture of waste rubber with properties determined therefrom and properties produced separately can also be used as the core layer. The waste rubber used can also contain reinforcing fibers, such as cord inserts or the like. Before needling, fillers such as sand particles or the like can also be mixed into such a core layer, a needled web offering such a mixture a cohesion which, in a known web, can only be achieved by solidification, e.g. by vulcanizing.

The same applies in the event that the core layer consists of rubber granules and / or fillers and foamable elastomers, the foaming of the elastomers also being able to be carried out much later. Such foamable elastomers can be in granular or spherical form and e.g. rubber or plastic provided with blowing agents.

According to a preferred embodiment, the rubber particles and optionally the filler particles prior to the introduction between the two outer layers are provided with a coating has been, said _U eberzug according to an Off form consists of a binder which can be activated under heat and / or pressure and which is only activated after needling the web.

According to another embodiment, this coating consists of one component of a two-component binder, the second component of this binder being introduced into the web in liquid or powder form at the earliest after needling the web, preferably only at the point of use of the web. Such a web provided with one component of the binder can be rolled out on sports fields, whereupon the second component of the binder is then sprayed or sprinkled on.

According to a further embodiment, the coating of the particles consists of a lubricant, so that when the needling needles are inserted, they can slide along the particles more easily and these particles can evade the needles by moving them slightly to the side. After needling, this lubricant can evaporate or evaporate, in particular with the addition of heat, but such a lubricant can also cause crosslinking between the individual rubber particles or can slowly penetrate into the granulate without significantly changing its properties. Such a lubricant can e.g. Be water.

The elastic, non-foamed granulate particles can also be coated with a swelling agent, as a result of which the surface of the granulate particles swells more or less deeply. This swelling makes it easier for the needling needles to penetrate the core layer, since the surface of the granulate has not only become softer, but particles which may have got caught on the barbs of the needling needles are torn out of the granulate without the latter itself significantly changing its position. This swelling agent is preferably removed again after needling, this e.g. can be carried out under subsequent hot calendering.

A granulate that is obtained by granulating needle felt floor coverings can also be regarded as an elastic, non-foamed material that forms the core layer. In the manufacture of Needle felt floor coverings are usually cut off as a last step, the so-called edge strips, in which there are irregularities due to their edge position. Also at the beginning and at the end of a batch there are areas of the floor covering that fall below a certain quality value of the floor covering and are therefore to be regarded as waste. The _E la- elasticity to avoid such a Nadelfilzbodenbelages, which has been considered to be non-reusable waste can now be utilized by the fact that this waste strips or areas to form a granulate with a grain size of for example 2 - 5 mm pelletized and according to the invention as the core layer in the _V experienced is used. These granules are preferably in the form of fiber lumps, which are preferably at least partially bonded with a rubber latex binder. If a non-fully covering top layer with coarse, actively needled fibers, for example with a fiber titer of 100 dtex, is used, and these coarse fibers with a low basis weight are placed on the core layer, whereupon these fibers are actively needled, the granules of the core layer remain visible between these fibers. This results in a web which can in turn be used as a carpet, with an optically appealing walking side being obtained, in particular if the granules have different colors. The elastic properties of this web essentially correspond to those of the webs made of rubber granules previously written.

While in the needling of rubber granules described above, the needling offers an internal connection to the particles which are not connected to one another, when a masticated rubber skin provided with vulcanizing agents is used as the elastic, non-foamed, material forming the core layer, this has a fiber reinforcement, which also exists before the vulcanization of this rubber skin provides reinforcement. Unvulcanized rubber skins can change their shape very easily due to their plasticity, especially if they are to be handled without a support or wing. This begins with a reduction in the cross-section and leads through tearing of the skin to complete tearing. By the insertion of the needle punching needles are provided, although in the _K autschukfell weakening perforations, but since at the same time the reinforcing fibers are mechanically connected to the rubber sheet, the inherent stability of such a web will be enlarged. The perforations caused by the needles are closed again due to the plasticity of the rubber skin and the pressure exerted on the rubber skin by the two outer layers. In particular, the needled webs containing rubber or carpet granules and optionally fillers can be impregnated or acted upon with a binder, be it at the factory or at the later place of use, this binder being latex, liquid rubber, bitumen, modified polyurethane, a thermoset or even building cement . However, such a web can also be impregnated or acted on with a solvent, with crosslinking being produced between the individual rubber components.

According to one embodiment, the needled web is pressed or calendered, in particular compression-molded or calendered, this being carried out before vulcanizing or at the same time for vulcanizing the web. The vulcanization can be carried out in a known manner, for example under heat and / or pressure. At least the holding fibers connecting the two outer layers are fully integrated into the vulcanizing rubber compound during the vulcanization process. If, for example, liquid rubber has been applied to a needled web, this web is vulcanized under pressure, so at least the outer layer lying on the feed side of the liquid rubber is also incorporated into the rubber mass, so that this layer, for example fibers or a fabric, is not included in the vulcanized web is more visible. On the other hand, it is also possible to form the fiber-containing outer layer or, for example, the fabric with such a thickness that only these fibers or this fabric are visible there even after the vulcanization process, and the web thus has a textile character. An interesting one Sante structure can be achieved when the fiber layer is chosen so that, after the vulcanization process, although the _F a-fibers remain visible outside, which, rubber-containing layer but remains recognizable middle between the fibers. The same applies analogously to the web into which the textile waste has been incorporated, an interesting color effect being achieved, in particular, if differently colored textile waste is used and this still shows through after needling.

In addition to the pressing or calendering mentioned above, the needled web can also be shaped, in particular wound, after which the web is then vulcanized or set in this form.

According to a particular embodiment, shrinkable fibers are used as the actively needable fibers under the action of heat and a shrinking process is carried out after the needling of the web, whereby the core layer is further compressed.

The previously described sheets can be used as carpets. be det. Compared to conventional carpets, which are usually covered with latex or the like from the base layer, whereby the fibers are additionally bound for needling, there is now a carpet web in which the additional bond is not applied from the outside, but as a core layer before Needling is introduced.

Depending on how densely the cover layer, which generally contains the actively needled fibers, has been laid on, the core layer comprising the elastic material seems more or less through this cover layer. However, the cover layer can also be made so tight that the core layer containing the elastic material, such as rubber granulate or the like, is not visible at all, so that a web according to the invention thus gives the impression of a conventional needle felt floor covering, which, however, can be more elastic than known floor coverings.

The fibers of the cover layer, which is located on the rubber granules and which represents the walking side, provide a sliding surface for the web, which is essentially made of rubber, while the rubber core layer prevents water and dirt particles can penetrate or penetrate the web.

Further embodiments and advantages of the invention are described below on the basis of exemplary embodiments.

• Fig. 1 eine schematische Darstellung einer Anlage zur Durchführung des Verfahrens;
• Fig. 2 eine schematische Darstellung des Schnittes durch eine vernadelte, Gummipartikel und Füllstoffe aufweisende Bahn vor der Vulkanisierung;
• Fig. 3 eine schematische Darstellung eines Schnittes durch eine vernadelte, elastische Bahn, in der aufschäumbare Elastomere aufgeschäumt wurden;
• Fig. 4 eine schematische Darstellung eines Schnittes durch eine vernadelte und unter Formen vulkanisierte Bahn, und
• Fig. 5 eine vernadelte, elastische Bahn, die mit einer Nadelfilzbahn vernadelt wurde.

It shows:

• Figure 1 is a schematic representation of a plant for performing the method.
• Figure 2 is a schematic representation of the section through a needled, rubber particles and filler web before vulcanization.
• 3 shows a schematic representation of a section through a needled, elastic web in which foamable elastomers have been foamed;
• Fig. 4 is a schematic representation of a section through a needled and vulcanized under mold web, and
• Fig. 5 shows a needled, elastic web, which was needled with a needle felt web.

According to FIG. 1, a base layer 2 is placed on a conveyor device, here a conveyor belt 1, to which the core layer 4 is applied, metered here by a discharge device 3. On this core layer 4 actively needled fibers, here in the form of a fiber fleece 5, are placed, after which this three-layer system is fed to a needle machine 6.

Such needle machines 6 are known from textile needle felting technology (see, for example, Krcma, Textile Composites, pages 139 to 141). In such a needle machine 6, the system to be needled, here the three-layer system, is guided over a base plate 7 provided with bores. Above the object to be needled is a needle board 9 carrying the needling needles 8, which continuously moves up and down so far (double arrow 10) that the needle tips 11 in their lowest position have usually completely penetrated the object to be needled while they are in their have no contact with the uppermost position on the object to be needled. In this uppermost position, the one to be needled The object, here the three-layer system, is shifted cyclically in the feed direction (arrow 12), while it has to stand still during the actual needling. The needling needles 8 have at least one - here two - barbs 13 on their shank, with which they grip individual fibers or tufts of fibers and pull them into the object to be needled, or pull them through it. When the needles 8 move back, the entrained fibers or tufts of fibers detach from the barbs 13 and remain in the passively needled layer, here the base layer 2 and the core layer 4.

While now in needling in the textile industry, in the manufacture of needle felt carpets, the final thickness of z. _B. 4 - 6 mm, the needle boards 9 have a large number of needles arranged close together and this needle board can be moved, for example, at a speed of 700 strokes per minute, must be masticated when needling elastic, non-foamed materials such as rubber granules, foamable elastomers Rubber skins or carpet granules, to which fillers such as sand particles may have been added, the density of the needles 8 in the needle board 9 is increased and the number of strokes is greatly reduced.

If these criteria are met, a layer containing the aforementioned materials can also be fed to a needle process, the needles sliding along the rubber or filler particles and possibly shifting them slightly sideways. This sliding along and lateral displacement is facilitated if the particles are provided with a coating which facilitates sliding.

As can be seen from FIG. 1, the needling of the three-layer system reduces the thickness thereof, since on the one hand the layer 5 containing fibers is compressed by the needling, on the other hand this fiber layer 5 and, depending on the design, also the underlay layer 2 in the edge areas of the Core layer due to the elasticity of its material is pulled in or pressed in. In addition, the elastic material of the core layer itself is slightly compressed and ver remains under a certain tension. Due to the elasticity of these particles, the contact areas between individual particles are enlarged, since the surfaces of the same can yield. Due to this compression, the subsequent vulcanization of the web consisting of individual granules is facilitated even if liquid binders such as latex or liquid rubber are not additionally added.

According to the embodiment of the plant shown in FIG. 1 for carrying out the method according to the invention, the needled, elastic web is passed between two calender rolls 14 and 15, with which the vulcanization can be carried out, in particular if they are heated. The two calender rolls 14 and 15, pressing the web between them and exerting a pressure of 2-5 bar / cm ² on them, are pressed towards one another.

The elastic web 16 emerging from the calender rolls has a thickness which is not significantly less than the thickness of the web 16 before the calender rolls, since the elastic material expands again after calendering.

FIG. 2 now shows a needled web 16 having rubber particles 17 and filler particles 18 in an enlarged and schematic illustration, it being evident that the underlay layer 2 with the cover layer 5 over the holding fibers 19 which extend through the core layer 4. In the embodiment according to FIG. 2, an actively needled fiber fleece is used as the underlayer 2 and as the cover layer 5. The web 16 is needled here from both outer sides, which can be seen from the “fiber funnels” 20 which form at the piercing points of the needling needles 8. In these fiber funnels 20, fiber ends and fiber parts of fibers that are not gripped by barbs 13 are also partially drawn. The holding fibers 19 penetrating the web 16 are distributed unevenly over the surface of the web, which is why in practice only very few holding fibers 19 can be seen when cutting through such a web.

3 now shows a needled, elastic web in which foamable elastomers 21 and filler particles 18 have been needled, whereupon the elastomers have been foamed by activating the blowing agent. The foamed elastomers 21 not only completely fill the spaces between the filler particles 18, but also result in the fibers located in the outer layers 2 and 5 being pressed outwards, which leads to a small surface structure of the web having small curvatures. In order to prevent the web 16 from bursting apart, it is particularly advisable here to needle the web from both sides in order to maintain a sufficient mechanical connection between the two outer layers. However, the foaming process can also be carried out in a double belt press, so that the foaming of the elastomers 21 is opposed by a further, then external resistance. The foamed elastomers 21 are hatched in FIG. 3. Although this looks there, the holding fibers 19 are not passed through the elastomers 21, but they have only been completely enveloped by them during foaming.

For the manufacture of the web 16 shown in Fig. 4, rubber granule particles and filler particles 18, e.g. Beads of sand, placed between two pre-needled nonwoven webs, needled from both sides and then vulcanized in a molding press. This molding press e.g. a double belt press, had a flat, closed surface on one press side, as a result of which the lower side of the web in FIG. 4 was given a smooth surface, while the other press side had a flat surface in which a multiplicity of openings were provided at a distance from one another , so that the web was pressed less strongly in the area of these openings than in the areas adjacent to it. The vulcanized web thereby receives the knobs 22 shown in FIG. 4, which protrude beyond the surface of the web 16. In the area of these knobs 22, the web 16 is somewhat more elastic than in the adjacent areas.

Through the use of thicker, pre-needled nonwoven webs as cover layer 5 and / or as underlay layer 2, such a web 16 has a character that may be textile on both sides. If such a sheet is placed on a particularly smooth and slippery surface, there is a risk that it will slip relative to one. This can now be remedied by cutting off the upper part of a knob 22, as shown in FIG. 4 with the help of the knob on the right, as a result of which the vulcanized rubber layer emerges outwards in this region. If such a web 16 with its cut-off knobs 22 is now placed on a smooth floor in such a way that the protruding knobs come to rest on this floor, i.e. exactly the opposite, as shown in the drawing, the cut-off knobs serve as anti-slip devices.

5 now shows a needled, elastic web 16 onto which a needle felt web 23 has been needled. Holding fibers 24 removed from the needle felt web 23 were needled into the elastic web 16, as a result of which the two webs are mechanically connected to one another. This needling of the two webs 16 and 23 can be carried out both before vulcanizing the elastic web 16 and after vulcanizing the same.

According to an exemplary embodiment, not shown, a masticated rubber sheet provided with vulcanizing agents is introduced between the underlay layer and the cover layer, whereupon these three layers are needled together. Such a path can now be clear, i.e. can be handled without a base or backing layer, without the risk that the rubber skin changes in thickness, tears or tears. Instead of the discharge device 3 shown in Fig. 1, the feed then takes place, e.g. in the form of a belt conveyor or from a roll.

A further embodiment, not shown separately, but which can be produced with a system according to FIG. 1, consists in introducing and needling granules of a grain size of 2-3 mm between the two layers 2 and 5 as the core layer, which is granulated from needle felt floor covering. Such granules are in the form of fiber lumps and some still contain rubber latex. The cover layer 5 is made of coarse fibers, For example, Dorix fibers are formed, which are not deposited covering the core layer. After the needling of which consists of _{N-adelfilzbodenbelag} granule core layer through the covering layer appears. A pattern is achieved by using different colored granules, eg from different batches of carpet production. Here, too, it is possible to apply liquid rubber to such a needled web 16 in order to further solidify the granulate particles.

In the exemplary embodiments described above, inlays can also be introduced before needling. It is thus possible not to apply the core layer by means of a discharge device 4, but to provide several of them and to insert cord threads made of synthetic material or also steel threads between these discharge devices of the core layer. These threads can be needled as described above for the fillers. However, metal platelets can also be introduced as an insert, in which case care must be taken when needling that no needles are pierced in the area of these metal platelets.

The threads or the metal plates are previously processed accordingly, so that there is an adhesive effect between the rubber masses and the inserts during vulcanization.

Example:

There were two identical non-woven fabrics made of polyester fibers with 70% fibers with a titer of 6.7 dtex and 30% fibers with a titer of 17 dtex with a basis weight of 115 g / m ² and a Bafatex carrier with a basis weight of 25 g / _m ² each double-sided needling with a stitch density of 24 stitches / cm ² .

Rubber granulate with a grain size of 1 mm and a weight per unit area of 3.7 kg / m ^{2 was} placed on one of the non-woven fabrics as a base layer, covered with the other non-woven fabric and needled with a stitch density of 24 punctures / cm ² .

720 g / m ^{2 of} a 1: 1 mixture of latex 160 and water were applied to the needled web and dried at 130 ° C. for four hours.

An elastic sheet with a thickness of 4 mm was obtained.

List of the reference numerals used

• 1 conveyor belt
• 2 underlay
• 3 discharge device
• 4 core layer
• 5 fleece
• 6 needle machine
• 7 base plate
• 8 needle
• 9 needle board
• 10 double arrow
• 11 needle tip
• 12 arrow
• 13 barbs
• 14 calender roll
• 15 calender roll
• 16 lane
• 17 rubber particles
• 18 filler particles
• 19 holding fiber
• 20 fiber funnels
• 21 elastomer
• 22 knobs
• 23 needle felt web
• 24 holding fiber

Claims (28)

1. A process for the continuous production of fiber-reinforced webs, in which an elastic, non-foamed material is brought as a core layer between an underlay layer and a cover layer, of which at least one outer layer consists of actively needled fibers, after which the three layers are needled together. 2. The method according to claim 1, characterized in that the layers are needled through the cover layer and the underlayer holding fibers removed. 3. The method according to claim 1 or 2, characterized in that the elastic, unfoamed material for the core layer is used by the needling needles not penetrable granules. 4. The method according to claim 3, characterized in that the holding fibers are introduced between the granulate particles. 5. The method according to claim 3 or 4, characterized in that the granules are obtained from vulcanized rubber. 6. The method according to any one of claims 3 to 5, characterized in that fillers such as sand particles or the like are added to the core layer before needling. 7. The method according to any one of claims 3 to 6, characterized in that the core layer consists of rubber granules and / or fillers and foamable, non-pierceable elastomers, the latter being foamed after needling. 8. The method according to claim 7, characterized in that the foamable elastomers are in granular or spherical form. 9. The method according to claim 7 or 8, characterized in that a rubber or plastic provided with blowing agents is used as the foamable elastomer. 10. The method according to any one of claims 4-6, characterized in that the rubber particles and optionally the filler particles are provided with a coating before introduction between the two outer layers. 11. The method according to claim 10, characterized in that the particles are coated with a binder which can be activated under heat and / or pressure. 12. The method according to claim 11, characterized in that the binder is activated after needling the web. 13. The method according to claim 10, characterized in that the coating is the one component of a two-component binder and the second component is introduced at the earliest after needling. 14. The method according to claim 10, characterized in that the particles are coated with a lubricant. 15. The method according to claim 10, characterized in that the particles are acted upon by a swelling agent. 16. The method according to claim 15, characterized in that the swelling agent is removed again after needling, preferably under hot calenders. 17. The method according to claim 3 or 4, characterized in that the granules are obtained by granulating needle felt floor coverings. 18. The method according to claim 17, characterized in that this granulate consists of fiber lumps, which are preferably at least partially connected with a binder made of rubber latex. 19. The method according to claim 1 or 2, characterized in that a masticated rubber skin provided with vulcanization aids, in particular plasticizers, is used as the elastic, non-foamed material forming the core layer. 20. The method according to any one of the preceding claims, characterized in that a non-fully covering top layer with coarse, actively needled fibers is used and these coarse fibers are actively needled. 21. The method according to claim 20, characterized in that the coarse fibers are deposited and needled with such a low basis weight on the core layer that the core layer between these fibers are visible. 22. The method according to any one of the preceding claims, characterized in that the needled web is impregnated or acted upon with a binder. 23. The method according to claim 22, characterized in that latex, liquid rubber, a thermoplastic such as polyethylene, elastomeric bitumen or the like are used as binders. 24. The method according to any one of claims 1 to 21, characterized in that the needled web is impregnated or acted on with a solvent. 25. The method according to any one of the preceding claims, characterized in that the needled web is pressed or calendered, in particular molded or -calendered. 26. The method according to any one of the preceding claims, characterized in that the needled web is vulcanized, set or cured, in particular under heat and / or pressure. 27. The method according to any one of the preceding claims, characterized in that the needled web is shaped, in particular wound, and optionally vulcanized or sets in this form. 28. The method according to any one of the preceding claims, characterized in that shrinkable fibers are used as the active needles fibers under the action of heat and that after the needling of the web a shrinking process is carried out.

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