CN114587128A

CN114587128A - Carpet

Info

Publication number: CN114587128A
Application number: CN202210258898.7A
Authority: CN
Inventors: 曹顺林; 张怡; 翟梓翔; 孙玉好
Original assignee: Kunshan Yijia Ju Textile Co ltd
Current assignee: Kunshan Yijia Ju Textile Co ltd
Priority date: 2022-03-16
Filing date: 2022-03-16
Publication date: 2022-06-07
Also published as: WO2023173724A1

Abstract

The invention relates to a carpet, which comprises a carpet surface layer and a bottom surface layer, wherein the carpet is prepared by putting a blank carpet into a dry and wet blank cloth shaping device and rubbing the carpet surface layer with the inner wall of a box body and the carpet surface layer. Placing the blank blanket into a rolling or shaking wet and hot box body for rolling and shaping, wherein the suede of the blanket surface layer is rubbed with the inner wall of the box body and the box body, and simultaneously, under the action of centrifugal force, the root of the tows of the suede is shaped and each tow is upright, so that the tows are prevented from being agglomerated; the topmost end of each tow forms a slightly curved, shed pile under the action of friction and high temperature, giving the appearance of a cotton fibre. The surface of the carpet can keep the surface shape after being washed and dried for a plurality of times within 100 ℃.

Description

Carpet

Technical Field

The invention belongs to the field of carpets, and particularly relates to a carpet. The invention designs a carpet preparation process.

Background

Carpets have long entered every family as a popular floor covering. There are many materials used for carpets, and among them, cotton carpets are widely favored by consumers due to their comfortable touch, high moisture absorption, and excellent dyeing properties.

However, the cotton carpet on the market at present is easy to absorb moisture and absorb humidity due to the characteristics of the short lignin fibers of cotton, and is easy to mildew if being stored improperly: when the cotton carpet is put into a washing machine for washing, the short fibers are easy to fall off and take a long time for dehydration, drying or sun drying; if the cotton fiber is contacted with sunlight and dried for a long time, the cotton fiber can generate yellowing and crispness phenomena. According to the investigation of the inventor, many consumers in the market at present urgently desire a carpet which not only has the appearance and the touch of a cotton carpet and excellent water absorption performance, but also can avoid the defects of more fluff falling, easy aging, easy mildew generation, difficult dehydration and drying and the like of the existing cotton carpet.

Disclosure of Invention

The present invention provides a carpet to solve the above technical problems.

The purpose of the invention can be realized by the following scheme:

in a first aspect, the present invention provides a carpet comprising a pile face layer and a base layer; the velvet surface layer is obtained by weaving on base cloth; the carpet is prepared by placing a base cloth layer woven with a velvet surface layer into a dry, wet and hot blank cloth shaping device for rolling and shaping, and enabling the velvet surface layer to rub against the inner wall of a box body and the inner wall of the box body and the base cloth layer to enable tows of the velvet surface layer to be shaped; the dry and wet hot grey cloth shaping device is a dry and wet hot box body processing device with rolling and/or shaking functions.

Further, the carpet also comprises a bottom back layer compounded on the bottom of the base cloth layer. The back of the bottom back layer can be treated with anti-skid treatment.

When the carpet is placed into a rolling or shaking dry-wet hot-blank cloth shaping device for rolling shaping processing, the suede of the carpet surface layer is rubbed with the inner wall of the box body and the carpet surface layer, and simultaneously, the root of the tows of the suede is shaped and each tow stands upright under the action of centrifugal force, so that the tows are prevented from being agglomerated; the top end of each tow forms a slightly bent and sporadic pile under the action of friction force and high temperature, so that the appearance of the tow presents the appearance of cotton fiber, the root parts of the tows on the carpet surface after the rolling and shaping processing are upright, the tows are not easy to be entangled with each other, and the top end of the tows generates the sporadic and slightly bent pile. The yarns are softened and easily bundled through humidification treatment, and then are subjected to heating treatment and shaping, so that the surface morphology of the suede of the carpet can be well kept after the suede is washed and dried for multiple times within 100 ℃.

Furthermore, the dry, wet and hot blank cloth shaping device comprises one of a ball rolling machine, an overflow cylinder, an industrial washing machine and a flat washing and drying integrated machine. The dry and wet heat blank cloth shaping device carries out dry and wet heat treatment, including one of dry heat treatment, wet heat treatment and dry and wet heat treatment,

further, the heating temperature of the dry, wet and hot blank cloth shaping device is 45-160 ℃.

Further, the pile surface layer is woven on the base fabric through a tufting process.

Furthermore, the yarns used by the carpet surface layer are single-strand or multi-strand extinction or semi-extinction DTY tows, are doubled and folded, and are made into extinction or semi-extinction DTY strands through twisting or net tying.

Further, the dull or semi-dull DTY tows are obtained by texturing, stretching and deforming the primary yarns or FDY tows.

Preferably, a plurality of DTY tows are twisted by plying to make a DTY strand. The twisted direction of the plied and twisted compound yarn is S or Z twist, and the two-for-one twist is 35T/M-150T/M. Preferably, the DTY tows are polyester or nylon tows in an S + Z twisted form.

Further, the linear Density (DPF) of the single filaments in the delustered or semi-delustered DTY tow is 0.40 deier-5.00 deier.

Further, the linear density of the extinction or semi-extinction DTY strands is 75D-12000D.

Further, the extinction or semi-extinction DTY plied yarns are subjected to heat setting treatment in a yarn setting machine, and the setting temperature of the yarn setting machine is 80-190 ℃.

Furthermore, the extinction or semi-extinction DTY tows can be firstly subjected to net tying and then are plied to form the plied yarns on a yarn net machine. The knotting net knots are a medium net and a heavy net, so that the yarns are prevented from being scattered in the subsequent process.

Optionally, the material of the bottom and back layers comprises one of a thermoplastic elastomer, natural rubber, a hot melt adhesive and a fabric with an anti-slip function or a hooking function.

In a second aspect, the present invention also relates to a process for preparing a carpet, said process comprising the steps of:

s1, preparing yarns: selecting primary yarns or drawn yarn tows, performing elastication and drawing deformation to prepare DTY tows, doubling and plying single-strand or multi-strand DTY tows, and twisting or netting to prepare folded yarns;

s2, weaving process: weaving the DTY plied yarn prepared in the step S1 on a base fabric layer by using a tufting process to obtain a embryonic carpet;

s3, rolling and shaping: putting the carpet face fabric woven in the step S2 into a dry-wet-hot grey cloth shaping device for rolling shaping processing, and rubbing the carpet face with a box body or a cylinder body and the carpet face to obtain a cotton-style carpet face;

s4, preparing a bottom back layer: and (5) preparing a bottom back layer on the back surface of the carpet blank by using the carpet surface processed in the step S3 to obtain the carpet.

Further, the yarn selected in step S1 may be regenerated dull and semi-dull polyester or nylon yarn.

Optionally, after the weaving of the embryonic blanket in step S2 is completed, a pile fixing process is performed. The pile fixing treatment comprises one of glue pile fixing and flame composite pile fixing.

Further, the step S3 may be a rolled carpet or a sheet carpet. When the sheet blanket is subjected to dry-wet heat treatment, the sheet blanket compounded with the bottom layer and the back layer can also be subjected to rolling and shaping treatment.

Compared with the prior art, the invention has the following beneficial effects:

1. after the product uses the delustering and semi-delustering yarns to pass through the dry and wet heat box body, the top end of each tow forms a shed-shaped bent pile, so that the product has the effect similar to cotton hand feeling and the luster of the carpet surface is more like a cotton carpet, and the carpet surface layer made of the tows formed by a plurality of 0.4D-5D fine denier DTY has excellent water absorption performance;

2. compared with the existing polyester carpet, the polyester carpet can be washed repeatedly, has small appearance change, and is not easy to agglomerate in the long-time normal use process.

3. Compared with cotton carpets, the cotton carpet has the advantages of long service durability, no short fiber falling phenomenon and better dewatering performance than cotton carpets.

4. The carpet of the invention does not need to add any auxiliary agent in the preparation process, thereby avoiding environmental pollution; even if the water flow cylinder is used for production, the water inside the water flow cylinder can be recycled for many times. In the process of the dry and wet box body, the carpet blank blanket rolls along with a machine and is rubbed at high temperature to form upright tows under the action of centrifugal force, and the upright bunched roots and piles are slightly sporadically bent.

Drawings

Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:

FIG. 1 is a schematic view of a carpet of example 1 of the present invention;

FIG. 2 is a side view of the carpet of example 1 before and after a wet and dry heat treatment; wherein, a is a side view before dry and wet heat treatment, and b is a side view before dry and wet heat treatment;

FIG. 3 is a top plan view of the carpet of example 1 before and after the dry and wet heat treatment; wherein a is a top view before dry-wet heat treatment, and b is a top view before dry-wet heat treatment;

FIG. 4 is a schematic view of a carpet of example 4 of the present invention;

wherein, 1, a velvet surface layer, 2, a base cloth layer, 3 and a bottom back layer.

Detailed Description

The invention is described in detail below with reference to the figures and specific embodiments. The following examples, which are set forth to provide a detailed description of the invention and a detailed description of the operation, will help those skilled in the art to further understand the present invention. It should be noted that the protection scope of the present invention is not limited to the following embodiments, and several modifications and improvements made on the premise of the idea of the present invention belong to the protection scope of the present invention.

Example 1

The embodiment relates to a carpet, as shown in fig. 1, comprising a base fabric layer 2, a suede layer 1 woven on the base fabric layer 2, and a bottom back layer 3 compounded at the bottom of the base fabric layer 2. The carpet preparation comprises the following steps:

step one, preparing yarns: selecting 300D/192F terylene primary raw silk tows, manufacturing the draw textured tows by using a draw texturing process, doubling and twisting 6 tows in S + Z form into a folded yarn with the twist of 50T/m and the total D number of 1800D, wherein the form of a single tow is the false twist form of S + Z. Then putting the folded yarn on a loose forming machine for forming treatment, wherein the forming temperature is 150 ℃;

step two, manufacturing process: the yarn obtained in step 1 was tufted on a long fiber base fabric using a cut pile tufting machine at a gauge of 3/16.

Step three, a velvet fixing process: and (3) fixing the blank blanket woven in the step (2) on the blanket back by using hot melt adhesive, wherein the melting temperature of the hot melt adhesive is 180 ℃.

Step four, rolling and shaping processing: putting the fabric subjected to the pile fixing in the step 3 into a ball rolling machine for dry-wet heat treatment, so that the pile face of the carpet face is subjected to rolling friction with the inner wall of the box body and the fabric; the internal temperature of the ball rolling machine box body is 120 ℃, and the steam temperature is 100 ℃; the steam consumption is 2 kg;

step five, preparing a bottom back layer: and (3) carrying out anti-skid treatment on the back of the carpet surface layer prepared in the step 4) by using TPE.

Example 2

This example relates to a carpet, which was prepared by the following steps:

step one, preparing yarns: selecting 300D/288F nylon DTY light net tows, and then using a heavy net process to ply 4 tows, wherein the total D number is 1200D, the number of net knots is 50/m, and the twist is 40T/m.

Step two, manufacturing process: the yarn from step 1 was tufted on a interlaced yarn substrate using an 1/10 cut tufting machine.

Step three, a velvet fixing process: and (3) fixing the pile on the back of the blanket surface layer of the embryonic blanket woven in the step (2) by using EVA water-based adhesive, wherein the drying temperature is 130 ℃.

Step four, rolling and shaping processing: and (4) putting the blank blanket subjected to the pile fixing in the step (3) into an industrial washing machine to enable the pile surface of the blanket surface to rub against water flow, the inner wall of the cylinder body and the blanket. The water temperature in the cylinder is 80 ℃.

Step five, dehydrating and drying the shaped blanket surface layer;

step six, preparing a bottom back layer: the back of the carpet is subjected to anti-slip treatment by using foaming latex.

Example 3

The invention relates to a carpet, which is prepared by the following steps:

1) preparing yarns: the waste plastic bottles are collected, cleaned, classified at a high standard, sliced, granulated, spun, elasticated, stretched and deformed to be prepared into DTY multi-strand tows, and the DTY multi-strand tows are doubled and twisted to be prepared into folded yarns, wherein the total D number is 4500D, the twisting direction is S twist, and the twist degree is 90T/m.

2) The manufacturing process comprises the following steps: and (3) weaving the yarns in the step (1) by using a rapier loom.

3) And (3) rolling and shaping processing: putting the fabric prepared in the step 2 into an industrial washing machine, and enabling the carpet surface to roll with the inner wall of the machine and water flow to rub; the water temperature was 100 ℃.

4) The composite process comprises the following steps: and (4) compounding the fabric prepared in the step (3) with non-woven fabric by using a hot melt adhesive machine.

5) Preparing a bottom back layer: styrene-butadiene latex is used for anti-skid treatment on the carpet back.

Example 4

The invention relates to a carpet, which comprises a base fabric layer 2 and a suede layer 1 woven on the base fabric layer 2, as shown in figure 4. The carpet preparation comprises the following steps:

1) preparing yarns: selecting 300D/48F terylene primary raw silk tows, manufacturing the tensile deformation tows in the shape of S + Z by using a tensile deformation process, doubling and twisting 8 strands of S + Z tows into folded yarns, wherein the twist is 50T/m, and the total D number is 2400D. Then putting the folded yarn on a loose forming machine for forming treatment, wherein the forming temperature is 150 ℃;

2) the manufacturing process comprises the following steps: the yarn obtained in step 1 was tufted on a polypropylene base fabric using a cut pile tufting machine with a gauge of 1/4.

3) The composite process comprises the following steps: compounding the embryo blanket weaved in the step 2) with 180 g/square meter terylene napping cloth on the back of the blanket by using PUR hot melt adhesive, wherein the melting temperature of the hot melt adhesive is 180 ℃.

4) And (3) rolling and shaping processing: putting the fabric subjected to the pile fixing in the step 3 into a ball rolling machine to perform dry, wet and hot box body, and enabling the pile face of the carpet face to be in rolling friction with the inner wall of the box body and the fabric; the internal temperature of the ball rolling machine box body is 120 ℃, and the steam temperature is 100 ℃; the amount of steam used was 1.80 kg.

Verification of performance contrast test

Water washing test

The carpet in example 1 with the size of 30x30cm was taken, a household washing machine with 130W power was used, the water temperature was 45 ℃, and the surface fluff was not obviously linned and agglomerated after one 30-minute water washing, and the surface fluff was not obviously linned and agglomerated after 15 water washing.

The carpet in example 3 with the size of 30x30cm was taken, a household washing machine with 130W power was used, the water temperature was 45 ℃, and the surface fluff was found not to have obvious fluff falling and agglomeration after one 30-minute water washing, and the surface fluff was found not to have obvious fluff falling and agglomeration after 15 water washing.

The preparation method of the material is basically the same as that of example 1 in size of 30x30cm, except that the material is cotton fiber, the material is not subjected to wet heat treatment, a household washing machine with 130W power is used, the water temperature is 45 ℃, obvious drop signs of surface fluff are found after one 30-minute water washing, and the drop signs of the surface fluff are found to be more obvious after 15 times of water washing.

The preparation method of 30x30cm is basically the same as that of example 3, except that the method is characterized in that the method does not adopt damp heat treatment, uses 130W power of a household washing machine, has the water temperature of 45 ℃, and shows that the surface fluff has obvious agglomeration after one 30-minute water washing, and the surface fluff is mostly agglomerated after 15 times of water washing.

Pilling test

The carpet of example 1 was tested using the martindale method and after passing constant rubbing the surface fuzz and pilling rating was 4.

The Martindale method is used, the preparation method of the embodiment 1 is basically the same, the difference is that the material used is cotton fiber, the test is carried out, and after continuous friction, the surface fluffing and pilling grade is 3 grade.

The carpet of example 3 was tested using the martindale method and after passing constant rubbing the surface fuzzing and pilling rating was 4.

The Martindale method is used, the preparation method of the embodiment 3 is basically the same, the difference is that the used material is cotton fiber, the test is carried out, and after continuous friction, the surface fuzzing and pilling grade is 3 grade.

Six-foot roller test

1. In example 1 having a size of 30cm × 30cm, six feet were placed in a rotating drum, and after 12000 rotations, the surface was found to be intact, to have a slight linting phenomenon, and to be not severely worn.

2. The 30x30cm size measurement of 30cm x30cm size was substantially the same as the example 1 preparation method except that the material used was cotton fiber and was not subjected to wet heat treatment, it was mounted in a rotating drum, six feet were put into the rotating drum, and after 12000 cycles, it was taken out, and it was found that the surface was severely worn and the fall of the face yarn was significant.

3. Example 4, which is 30cm x30cm, was mounted in a rotating drum, and six feet were placed in the rotating drum and taken out after 12000 revolutions, and it was found that the surface appearance was intact, had slight linting first, and was not severely worn.

4. The preparation method of 30x30cm was substantially the same as that of example 4, except that the used material was cotton fiber and was not subjected to wet heat treatment, the cotton fiber was mounted in a rotating drum, six feet were put into the rotating drum, and after 12000 cycles, the surface was found to be severely worn and the fall of the face yarn was evident.

From the test data, the carpet disclosed by the invention has better upright property than cotton carpets and common polyester and nylon carpets, greatly reduces the hair loss rate, and is convenient for daily household cleaning.

The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention.

Claims

1. A carpet, characterized in that the carpet comprises a pile layer and a base layer; the velvet surface layer is obtained by weaving on base cloth; the carpet is prepared by placing a base cloth layer woven with a velvet surface layer into a dry, wet and hot blank cloth shaping device for rolling and shaping, and enabling the velvet surface layer to rub against the inner wall of a box body and the inner wall of the box body and the base cloth layer to enable tows of the velvet surface layer to be shaped; the dry and wet hot grey cloth shaping device is a dry and wet hot box body processing device with rolling and/or shaking functions.

2. The carpet of claim 1, further comprising a backing layer laminated to the bottom of the backing layer.

3. The carpet of claim 1, wherein the dry, wet and hot grey fabric setting device comprises one of a ball rolling machine, an overflow cylinder, an industrial washing machine and a flat washing and drying integrated machine.

4. The carpet of claim 1, wherein the heating temperature of the dry and wet hot blank setting device is 45 ℃ to 160 ℃.

5. The carpet of claim 1, characterized in that the yarns used in the pile face layer are single or multi-ply matted or semi-matted DTY tow doubled and matted or semi-matted DTY strands made by twisting or knotting.

6. The carpet of claim 5, wherein the matt or semi-matt DTY tow is obtained by texturing, draw texturing a virgin or FDY tow.

7. The carpet of claim 5, characterized in that the linear density of the individual filaments in the matted or semi-matted DTY tow is 0.40DENIER-5.00 DENIER.

8. The carpet of claim 5, wherein the linear density of the matte or semi-matte DTY strands is 75D to 12000D.

9. The carpet of claim 5, wherein the matte or semi-matte DTY strands are heat-set in a yarn setter having a setting temperature of 80 ℃ to 190 ℃.

10. A method of preparing a carpet, comprising the steps of:

s1, preparing yarns: selecting primary yarns or drawn yarn tows, performing elasticizing and drawing deformation to prepare DTY tows, doubling and plying single-strand or multi-strand DTY tows, and twisting or netting to prepare dull or semi-dull DTY plied yarns;

s2, weaving process: weaving the DTY plied yarn prepared in the step S1 on a base cloth layer by using a tufting process to obtain a embryonic carpet;