WO2023123990A1 - 一种无纺纱地毯及其制备方法 - Google Patents

一种无纺纱地毯及其制备方法 Download PDF

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Publication number
WO2023123990A1
WO2023123990A1 PCT/CN2022/103556 CN2022103556W WO2023123990A1 WO 2023123990 A1 WO2023123990 A1 WO 2023123990A1 CN 2022103556 W CN2022103556 W CN 2022103556W WO 2023123990 A1 WO2023123990 A1 WO 2023123990A1
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Prior art keywords
carpet
woven
woven fabric
yarn
preparation
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PCT/CN2022/103556
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English (en)
French (fr)
Inventor
曹顺林
张怡
翟梓翔
孙玉好
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昆山怡家居纺织有限公司
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Publication of WO2023123990A1 publication Critical patent/WO2023123990A1/zh

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/06—Threads formed from strip material other than paper
    • D—TEXTILES; PAPER
    • D03—WEAVING
    • D03D—WOVEN FABRICS; METHODS OF WEAVING; LOOMS
    • D03D15/00—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used
    • D03D15/40—Woven fabrics characterised by the material, structure or properties of the fibres, filaments, yarns, threads or other warp or weft elements used characterised by the structure of the yarns or threads
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04B—KNITTING
    • D04B1/00—Weft knitting processes for the production of fabrics or articles not dependent on the use of particular machines; Fabrics or articles defined by such processes
    • D04B1/14—Other fabrics or articles characterised primarily by the use of particular thread materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
    • Y02P70/62—Manufacturing or production processes characterised by the final manufactured product related technologies for production or treatment of textile or flexible materials or products thereof, including footwear

Definitions

  • the invention relates to the field of textile carpets, in particular to a non-woven yarn carpet and a preparation method thereof.
  • the invention patent with the application number: 201610493899.4 discloses a method for making a new type of non-woven hand-woven carpet, which includes the following steps: first transfer the non-woven needle-punched carpet made on the needle punching machine to the non-woven fabric cutting machine, Cut the finished non-woven fabric needle-punched carpet into two kinds of non-woven fabric strips with the same length and different widths, and then arrange the two kinds of non-woven fabric strips in the order of one wide and one narrow in the warp direction. Several loops, and then in the weft direction, one wide and one narrow cloth strip is interlaced with one wide and one narrow cloth strip in the warp direction at the same time or separately, and then circulated in this way to form interweaving Sheet rug.
  • this invention processes the non-woven fabric after it is cut into strips, the requirements for the non-woven fabric are very high, and high-quality raw materials are needed to make the non-woven fabric, which cannot be truly completely recyclable, and the recovery rate is low or even It cannot be recycled; it is difficult to carry out large-scale industrial production by hand-knitting, and the production cost cannot be reduced at this point; and the non-woven fabric cut into strips has ductility, and the tension of the strips is uneven, which affects weaving Efficiency; and the shape of the carpet made can only be a woven mat, which makes it difficult for the woven carpet to have shape and dimensional stability; the non-woven fabric cut into strips has not been twisted or added after cutting. Twist setting treatment will make fibers fall off very easily, and the resulting carpet is prone to shedding or pilling, which affects the use experience.
  • a carpet, the carpet surface layer of the carpet is made of twisted or twist-shaped cylindrical non-woven yarn, and the raw material of the non-woven yarn is virgin fiber or regenerated fiber.
  • a suede layer is formed on the upper surface of the carpet surface layer of the carpet, and the form of the suede layer is full cut, full circle, cut circle or plain weave.
  • the carpet surface layer is made by adopting tufting process, knitting process and weaving process.
  • the carpet also includes a backing layer attached to the bottom of the carpet top layer.
  • the preparation method of the carpet surface layer of described carpet comprises the steps:
  • step S2 Twisting the non-woven fabric strip obtained in step S1 to obtain a quasi-cylindrical non-woven yarn; preferably, as required, perform dry heat/moist heat setting treatment on the quasi-cylindrical non-woven yarn or wet the yarn and then Drying and setting;
  • step S3 Making the quasi-cylindrical non-woven yarn prepared in step S2 into a fabric by tufting, knitting or weaving, to obtain the carpet surface layer of the carpet.
  • step S1 the non-woven fabric is prepared by the following method:
  • the used textiles including waste yarns are collected, sorted, cleaned and disinfected in sequence, decomposed, opened, and most of the non-fibrous impurity materials are removed to obtain fiber materials, and the fiber materials are made into the non-woven fabric; or,
  • the primary or waste plastic bottle flakes are spun to produce short fibers and then further made into non-woven fabrics.
  • a variety of fibers can be fully mixed to obtain the non-woven fabric required by the present invention, and then cut into strips, twisted, and shaped to obtain non-woven yarns.
  • the fibrous material includes natural fibers, chemical fibers, or a mixture of natural fibers and chemical fibers.
  • step S1 low-melting-point fibers may be added as required during the weaving process of the non-woven fabric.
  • the low-melting fiber includes one or more of polyolefin low-melting fiber, polyamide low-melting fiber, and polyester low-melting fiber.
  • step S1 the fibrous material is shaped by wet heat setting or dry heat setting.
  • the twisting method is two-for-one twisting, double twisting or direct twisting. It is easy to twist by using a folding device (a device that can fold a strip of non-woven fabric).
  • the setting treatment method is wet heat setting or dry heat setting.
  • the twisting twist range of a single non-woven fabric strip is 50T/M-500T/M; the twisting twist range of multiple non-woven fabric strips is 30T/M-300T/M.
  • the carpet can also be made from non-waste materials, that is, raw materials, by using the above steps.
  • the carpet surface is post-processed to obtain a carpet.
  • the process of the wet heat setting treatment is to put the twisted non-cylindrical non-woven strip into a setting machine at a temperature of 70-195°C and a steam temperature of 80-180°C to make the non-cylindrical strip
  • the non-woven strip softens and holds its shape.
  • the strip cutting equipment in step S1 can use various strip cutting machines to cut strips.
  • the yarns used for weaving are made of non-woven fabric, cut into strips, single/multiple twisted or single/multiple twisted, and can be selected to be shaped or not shaped according to needs;
  • non-woven fabric made of short fibers
  • the weight range of the non-woven fabric used to make non-woven yarn is 50gsm-1000gsm;
  • the thickness range of the non-woven fabric used to make non-woven yarn is 0.5mm-15mm;
  • the width of the non-woven fabric slivers used to make the non-woven fabric used for the non-woven yarn is 5mm-50mm;
  • the non-woven yarn has a yarn count ranging from 10 to 0.25;
  • the carpet surface layer of the carpet comprises a carpet surface layer formed by weaving non-woven yarns on a tufting machine/shuttle loom/knitting machine;
  • the thickness of the carpet surface layer is 1mm-50mm.
  • the back layer of the carpet can be made of hot-melt adhesive, EVA, thermoplastic elastomer, foam latex or composite other fabrics and materials with anti-slip function for solid pile and anti-slip treatment.
  • the process route of the non-woven carpet described in one or more embodiments of the present invention is: collection of waste and old textiles—classification—cleaning (disinfection)—shredding open fibers—carding machine to remove most of the non-fibers mixed in the fibers Component materials—air-laid/multi-layer laying—adding/not adding low-melting fiber as required—making non-woven fabrics—slitting—twisting/shaping—weaving—finishing;
  • the raw materials of non-woven fabrics for the above process route are waste textiles.
  • This process does not require special classification of the collected textiles, which can contain various types of chemical fibers and natural fibers. It only needs to tear up the textiles after cleaning, loosen and decompose them. into short fibers suitable for non-woven manufacturing, and then slit and twisted to obtain non-woven yarn after making non-woven fabrics, then weaving through tufting, weaving and knitting processes, and finally finishing and processing to obtain the present invention.
  • An embodiment of the nonwoven carpet is an embodiment of the nonwoven carpet.
  • the optional process route can also be: collection of waste chemical textiles/waste plastics—sorting and cleaning—high temperature melting—making granules/chips—spinning to make short fibers—making non-woven fabrics Cloth—cutting—twisting/shaping—weaving—finishing; this process needs to classify the collected waste textiles/plastic bottles, and then produce the required short chemical fibers, and then go through non-woven fabric manufacturing and post-processing. Obtain non-woven yarn, then weave through tufting, weaving and knitting processes, and finally carry out post-finishing processing to obtain the non-woven yarn carpet of the present invention.
  • the preparation method of described carpet comprises the steps:
  • S1 Collect, classify, clean (disinfect), shred and decompose waste textiles, textile raw materials, head and tail materials in the semi-finished product manufacturing process and other available chemical fibers and natural fiber materials, and shred them into short fibers or collect chemical fiber materials, Classification, high-temperature melting, granulation, and spinning are used to obtain the non-woven fabric required for the non-woven yarn of an embodiment of the present invention, and the non-woven fabric is subjected to a sizing treatment as required;
  • step S2 putting the non-woven fabric prepared in step S1 into a slitting machine for slitting;
  • step S3 use the non-woven fabric strip that step S2 makes to use folding device (the device that can fold strip-shaped non-woven fabric) carry out twisting and setting treatment, make the quasi-cylindrical non-woven yarn required by an embodiment of the present invention ;According to the needs, the non-woven strips can also be twisted without shaping;
  • folding device the device that can fold strip-shaped non-woven fabric
  • step S4 using the non-woven yarn obtained in step S3 to weave on a tufting machine, a shuttle loom, and a knitting machine to obtain a carpet blank according to an embodiment of the present invention
  • step S5 carry out bottom-covering processing to the embryo carpet that step S4 makes, promptly use hot-melt adhesive, EVA, thermoplastic elastomer, styrofoam or composite other independent backing material or have the backing material of anti-slip treatment on the bottom of the carpet
  • the back is treated with solid fleece and anti-skid.
  • the types of low-melting-point fibers added as needed during the weaving of the non-woven fabric in step S1 include: polyolefin-based low-melting-point fibers, polyamide-based low-melting-point fibers, polyester-based low-melting-point fibers;
  • the amount of low-melting fiber added in step S1 is 0.5%-30%, by weight
  • step S1 according to the different manufacturing processes of the non-woven fabric, the non-woven fabric is divided into: needle-punched non-woven fabric, spunlace non-woven fabric;
  • the non-woven fabric can also be manufactured using long fibers.
  • a non-woven carpet prepared by one or more embodiments of the present invention can be used for secondary processing of printing and embossing to obtain new products.
  • One or more embodiments of the present invention can clean waste textiles, textile raw materials and semi-finished products, and other chemical fibers and natural fiber materials that can be used, and then remove non-fibrous materials and impurities after combing. , and then make non-woven fabrics. Due to the uniform mixing of various fibers, the obtained non-woven fabric saves a variety of high-standard classification processing requirements, simplifies the process flow, saves production costs, uses as much resources as possible, and combines the concepts of energy saving and recycling with Practical actions run through the entire production process of this invention, so a cost-effective product with low cost, low energy consumption, and low process requirements can be manufactured in a pioneering way.
  • step S1 of the preparation method of a kind of non-woven carpet of one of the embodiments of the present invention can also be:
  • the process route to realize the alternative invention is: collection of waste plastic bottles or partial plastics—cleaning and sorting—crushing—granulation—spinning—carding machine carding—multi-layer web laying—adding/not adding low-melting fiber as required—made Non-woven fabric - cutting strips - twisting and shaping - weaving - finishing;
  • the raw material of the non-woven fabric for the alternative process route is waste plastic bottles or some plastics.
  • This process needs to classify the raw materials in detail, classify the same kind of bottle flakes or plastics into one category, and then perform granulation/slicing, Spinning, in the non-woven fabric manufacturing process, a variety of fibers can be evenly mixed to obtain the non-woven fabric required by the present invention, and the non-woven yarn is obtained through post-processing, and then processed by tufting, weaving, and knitting processes. Weaving, and finally carrying out post-finishing processing to make the non-woven carpet of the present invention;
  • the steps of the preparation method of a non-woven carpet in one of the embodiments of the present invention can also be: further, the preparation method of the carpet includes the following steps:
  • step S2 putting the non-woven fabric prepared in step S1 into a slitting machine for slitting;
  • step S3 twist the non-woven fabric strip obtained in step S2 using a folding device (a device capable of folding strip-shaped non-woven fabric), to obtain the required non-woven yarn of the present invention
  • the non-woven yarn obtained after twisting in step S3 is placed in a dry heat/moist heat setting machine for steam treatment to soften the cut strips.
  • the temperature of the setting machine is 70°C-195°C, and the steam temperature is 80°C-180°C.
  • step S4 using the non-woven yarn obtained in step S3 to weave on a tufting machine, a shuttle loom, and a knitting machine to obtain the carpet blank of the present invention
  • step S5 carry out bottom-covering processing to the embryo carpet that step S4 makes, promptly use hot-melt adhesive, EVA, thermoplastic elastomer, styrofoam or composite other independent backing material or have the backing material of anti-slip treatment on the bottom of the carpet
  • the back is treated with solid fleece and anti-skid.
  • Fig. 1 non-woven yarn carpet tufting weaving process blanket face full-circle structure schematic diagram of the present invention
  • Fig. 2 is a schematic diagram of the full cut structure of the carpet surface of the non-woven carpet tuft weaving process of the present invention
  • 1- suede layer 2- base fabric layer, 3- bottom back layer;
  • Fig. 3 is the plan view of the blanket surface of the non-woven carpet flat weaving weaving process of the present invention.
  • This embodiment provides a kind of non-woven carpet and preparation method thereof
  • This embodiment adopts the tufting weaving process, and the model is a 3/8 gauge tufting machine.
  • Non-woven fabrics Use waste polyester textiles as raw materials, wash, melt at high temperature, make granules, and then pass through a spinning mechanism to obtain short fibers of 2.5DTEX+3DTEX, which are produced on a needle-punched non-woven fabric machine.
  • Non-woven fabric weighing 300gsm.
  • Cutting the non-woven fabric into strips Put the non-woven fabric prepared in 1 into a strip cutting machine to cut into strips with a width of 10mm.
  • Twisting treatment Use the strip folding device (a device capable of folding strips of nonwoven fabric) to twist the nonwoven fabric that has been cut in step 3.
  • the twist direction is S twist, and the twist is 150T/M.
  • the back yarn count is 0.3.
  • Damp heat setting treatment put the non-woven fabric strip in step 2 into a steam damp heat setting machine, the treatment temperature is 120°C, and the steam temperature is 90°C;
  • Anti-slip treatment use thermoplastic elastomer to perform solid-pile and anti-slip treatment on the back of the fabric to form the bottom layer.
  • the carpet prepared in this embodiment is shown in Figure 1; wherein, it includes a suede layer, a base cloth layer and a bottom back layer.
  • This embodiment provides a kind of non-woven carpet and preparation method thereof, and its preparation steps are as follows:
  • the present embodiment adopts the tufting weaving process, and the model is a 1/8 gauge tufting machine.
  • Twisting treatment The non-woven fabric that has been cut in step 2 is twisted using a strip folding device (a device that can fold strips of non-woven fabric), the twist direction is Z twist, and the twist is 100T/M. Yarn, the yarn count after twisting is 1.
  • Anti-slip treatment of solid fleece use thermoplastic elastomer to perform anti-slip treatment and solid fleece treatment on the back of the fabric to form the bottom layer.
  • the carpet prepared in this embodiment is shown in Figure 2, wherein it includes a suede layer, a base cloth layer and a bottom back layer.
  • This embodiment provides a kind of non-woven carpet and preparation method thereof, and its preparation steps are as follows:
  • the present embodiment adopts the knitting and weaving process, and the model is a flat knitting machine.
  • Twisting treatment Twisting the non-woven fabric that has been cut in S2 using a strip folding device (a device that can fold strips of non-woven fabric), the twist direction is Z twist, the twist is 200T/M, and the yarn is made Thread, the yarn count after twisting is 0.31.
  • Damp heat setting treatment put the non-woven fabric in step 2 into a steam damp heat setting machine, the treatment temperature is 110°C, and the steam temperature is 100°C;
  • Anti-slip treatment of solid fleece use foam latex to perform anti-slip treatment on the back of the fabric;
  • This embodiment provides a kind of non-woven carpet and preparation method thereof, and its preparation steps are as follows:
  • the present embodiment adopts the tufting weaving process, and the model is a 5/16 gauge cut-pile tufting machine.
  • Twisting treatment Twisting the 2-cut non-woven fabric with a strip folding device (a device capable of folding strip-shaped non-woven fabric), the twist direction is Z twist, the twist is 80T/M, and the yarn is made Thread, the yarn count after twisting is 0.31
  • Printing process use a digital printing machine to print the embryonic blanket.
  • Anti-skid treatment of solid pile Use styrene-butadiene latex to perform anti-slip and solid-pile treatment on the back of the carpet fabric.
  • This embodiment provides a kind of non-woven carpet and preparation method thereof, and its preparation steps are as follows:
  • the present embodiment adopts the tufting weaving process, and the model is a Dornier flat loom.
  • non-woven fabrics use waste textiles as raw materials for non-woven fabrics, remove and peel off non-fibrous materials, open and decompose them into fibers after cleaning, add 3% low-melting point fibers, and make grams on non-woven fabric equipment Non-woven fabric weighing 500gsm;
  • Non-woven fabric cutting put the non-woven fabric prepared in 1 into a strip cutting machine to cut into strips, and the width of the strips is 15mm;
  • twist treatment the non-woven fabric strip in step 2 is twisted using a strip folding device (a device capable of folding strip-shaped non-woven fabric), the twist direction is Z twist, and the twist is 70T/M to make a yarn , The yarn count after twisting is 0.13.
  • a strip folding device a device capable of folding strip-shaped non-woven fabric
  • the twist direction is Z twist
  • the twist is 70T/M to make a yarn
  • the yarn count after twisting is 0.13.
  • Moist heat setting treatment put the twisted non-woven yarn in step 3 into a steam heat setting machine for setting treatment, the treatment temperature is 120°C, and the steam temperature is 90°C;
  • Anti-slip treatment compound the back of the fabric woven in step 5 with the dotted non-woven fabric with hot melt adhesive.
  • This comparative example adopts common top to make non-woven yarn, specifically comprises the following steps:
  • This comparative example adopts the tufting weaving process, and the model is a 1/8 tufting machine
  • Anti-slip treatment use thermoplastic elastomer to carry out anti-slip treatment on the back of the fabric.
  • Test method Sampling the sample of one of the embodiments of the present invention and the existing tufted product respectively, the size is 50cmX50cm, take two pieces of 10cmX10cm black polyester cloth, press a 2KG weight on the black polyester cloth, and then pull the polyester cloth The cloth is rubbed, the pulling length is 30cm, and the number of pulling is 10 times, remove the heavy object, and count the number of broken hairs on the side where the black polyester cloth is in contact with the test sample;
  • Sampling of the present invention uses the embodiment 1 to select 1.5D native polyester staple fiber and the native polypropylene staple fiber of 2.5D to mix evenly, make the non-woven fabric that the grammage is 200gsm on the acupuncture non-woven fabric equipment, the yarn count after twisting The number is 1
  • Example 5 sample size 50cm * 50cm total 3 pieces, comparative example 1 size 50cm * 50cm total 3 pieces, carry out comparative test according to the above-mentioned experimental method, the number of times of testing is 3 times, the data are as follows:
  • the second test data is the second test data
  • one or more embodiments of the present invention show that one or more embodiments of the present invention have less hair loss in the pile of non-woven carpets
  • the embodiment 1 with a size of 30cm x 30cm was installed in the drum, put the hexapod into the drum, and took it out after 12,000 revolutions. It was found that the surface was in good condition, with slight hair loss and no serious wear and tear. The rating is level 4.
  • the embodiment 5 with a size of 30cm x 30cm was installed in the drum, put the hexapod into the drum, and took it out after 12,000 revolutions. It was found that the surface was in good condition, with slight hair loss and no serious wear. The rating is level 4.
  • the present invention can clean waste textiles, textile raw materials and semi-finished products, and other chemical fibers and natural fiber materials that can be used, and then remove non-fibrous materials and impurities after combing, and then make non-woven fabrics. cloth. Due to the uniform mixing of various fibers, the obtained non-woven fabric saves a variety of high-standard classification processing requirements, simplifies the process flow, saves production costs, and uses as many resources as possible.
  • the concepts of energy saving and recycling are combined with Practical actions run through the entire production process of this invention, so a cost-effective product with low cost, low energy consumption, and low process requirements can be manufactured in a pioneering way;
  • the wet heat setting treatment is carried out, the cohesion force between the fibers is stronger, it is not easy to shed hair, and the yarn strength is high;
  • the present invention can prepare recycled fibers into non-woven fabrics, and then into quasi-cylindrical yarns to make carpets, which simplifies the process and saves costs;
  • the present invention provides a method for preparing non-woven yarn carpets, which has high output and low requirements on fibers, and fibers of different materials, thicknesses and lengths can be mixed, and even some impurities can be contained.
  • the carpet of the present invention greatly recycles post-consumer textiles during the preparation process, and can achieve multiple recycling, which reduces production costs, solves the problem of recycling waste textiles, and makes High-quality and low-cost products, but also save resources and protect the environment.

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  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Carpets (AREA)

Abstract

本发明提供一种无纺纱地毯及其制备方法，所述地毯是使用经过处理的类圆柱形无纺纱并采用簇绒/梭织/针织等工艺制成，所述地毯面层的制备方法包括如下步骤：S1、将无纺布进行切条处理；S2、将步骤S1制得的无纺布条进行加捻定型处理，制得类圆柱形无纺纱；S3、使用步骤S2制得的类圆柱形无纺纱并采用簇绒/梭织/针织等工艺制得地毯面层。

Description

一种无纺纱地毯及其制备方法 技术领域
本发明涉及纺织地毯领域，具体涉及一种无纺纱地毯及其制备方法。
背景技术
随着全球纺织品消费市场的不断扩大，消费后的纺织品尤其是化学纤维以及混纺成分的纺织品的回收利用一直是困扰世界的一大难题，消费后的或生产过程中的边角纺织品只有极少部分单一成分的化纤纺织品经过复杂的工艺，如化学法纺丝或熔融法做成切片后纺丝再次利用。这种方法对消费后材料成分要求极高，技术难度大，设备投入资金大，成本极其昂贵，只有部分高档品牌使用这种材料，用这种再生材料做成的产品价格昂贵，从而导致市场窄小，也导致目前市面上大部分纺织品还是通过填埋或焚烧等方式处理，既破坏了环境也造成资源的极大浪费。
申请号为：201610493899.4的发明专利，公开了一种新型无纺布手编地毯的制作方法，包括如下步骤：先将针刺机上制成的无纺布针刺地毯转移到无纺布切割机上，将制成的无纺布针刺地毯分别切割成长度相同宽度不同的两种无纺布布条，然后在经向方向上将两种无纺布布条按照一条宽，一条窄的顺序排布若干个循环，然后在纬向方向上将一条宽，一条窄的布条同时或者分别与经向方向的一条宽，一条窄的布条上下交错穿插排布，并以此方法循环下去，形成交织席状地毯。此发明虽对无纺布切条后进行加工处理，但是对无纺布的要求非常高，需要用到高质量的原材料制作无纺布，无法做到真正的完全可回收利用，回收率低甚至无法回收；采用手工编织的方式，很难进行大规模工业化生产，在这一点上无法降低生产成本；并且切成条块状的无纺布具有延展性，条块状线条张力不均匀，影响织造效率；而且制成的地毯外形只能是编织后的席子状，这样使得编织后的地毯很难具有形状、尺寸的稳定性；切成条块状的无纺布切割后没有经过加捻或加捻定型处理会非常容易纤维脱落，制成的地毯容易掉毛或起球，影响使用体验。
市面上的普通无纺纱线的制备工艺路线复杂，需要对纤维进行多次梳理制作成毛条，后将浸泡于沸水后的毛条在纺纱机上反复捶打，最后烘干后制成无纺纱。这种工艺复杂，需要消耗大量水资源并产生大量污水，且产能极低，一台机一天产量不超过三百公斤，只用于高档产品中，推广价值低。本发明的技术方案如下：
一种地毯，所述地毯的毯面层为使用经过加捻或加捻定型的类圆柱形的无纺纱制成，并且所述无纺纱的原材料为原生纤维或再生纤维。
所述地毯的毯面层的上表面形成绒面层，所述绒面层形态为全割、全圈、割圈或平织。
所述毯面层为通过采用簇绒工艺、针织工艺、梭织工艺制成。
所述地毯还包括连接于毯面层底部的底背层。
所述地毯的毯面层的制备方法包括如下步骤：
S1、将无纺布进行切条，制的无纺布条；
S2、将步骤S1制得的无纺布条加捻，制得类圆柱形无纺纱；优选的，根据需要，对类圆柱形无纺纱进行干热/湿热定型处理或将纱线湿润再烘干定型；
S3、将步骤S2制得的类圆柱形无纺纱采用簇绒工艺、针织工艺或梭织工艺制成面料，制得所述地毯的毯面层。
进一步，步骤S1中，所述无纺布通过如下方法制备：
将使用后的纺织品包括废旧纱线进行收集、分类、依次进行清洗消毒、分解、开松、去除大部分非纤维成分杂质材料，获得纤维材料，将所述纤维材料制得所述无纺布；或，
将使用过后的化纤类布料及化纤废丝熔化后制成颗粒，通过纺丝机制成短纤维后进一步制成无纺布；或，
将原生或废旧塑料瓶片纺丝制得短纤维后进一步制成无纺布。在无纺布制造工序可将多种纤维进行充分混合以制得实现本发明所需的无纺布，经过切条，加捻，定型制得无纺纱。
所述纤维材料包括天然纤维、化学纤维、或天然纤维和化学纤维的混合。
步骤S1中，无纺布织造过程中可根据需要加入低熔点纤维。
所述低熔点纤维包括聚烯烃类低熔点纤维、聚酸胺类低熔点纤维、聚醋类低熔点纤维中的一种或一种以上。
步骤S1中，所述纤维材料定型处理方式为湿热定型、干热定型。
步骤S2中，所述加捻方式为倍捻、复捻或直捻。使用折条装置(能折叠条状无纺布的装置)，便于加捻。所述定型处理方式为湿热定型或干热定型。
单根无纺布切条的加捻捻度范围为50T/M-500T/M；多根无纺布切条的加捻捻度范围为30T/M-300T/M。
所述地毯还可以通过非废旧料即原生料也可以用上述步骤工艺制得。
将所述地毯面进行后加工，制得地毯。
优选的，所述湿热定型处理的工艺为将加捻后的类圆柱形无纺布条放入定型机中，温度为70-195℃，蒸汽温度为80-180℃条件下，让类圆柱形无纺布条软化并定型。
步骤S1中的切条设备可采用多种切条机进行切条。
所述一种无纺纱地毯，织造所用的纱线是经过无纺布制作、切条，单根/多根加捻或单根/多根加捻，根据需要可选择定型或不定型；
所用无纺布的种类为短纤制成的无纺布；
制成无纺纱所用的无纺布克重范围为50gsm-1000gsm；
制成无纺纱所用的无纺布厚度范围为0.5mm-15mm；
制成无纺纱所用的无纺布的无纺布切条的宽度为5mm-50mm；
所述无纺纱，成纱纱支范围为10支-0.25支；
所述地毯的毯面层包括利用无纺纱在簇绒机/梭织机/针织机上进行织造形成的地毯面层；
所述毯面层的厚度为1mm-50mm。
地毯的底背层可采用包括热熔胶、EVA、热塑弹性体、发泡乳胶或复合其他带防滑功能的面料和材料进行固绒及防滑处理。
本发明的一个或多个实施例所述无纺纱地毯的工艺路线为：废旧纺织品收集—分类—清洗(消毒)—撕碎开松纤维—梳理机梳理去除大部分混杂于纤维中的非纤维成分材料—气流成网/多层铺网—根据需要加入/不加入低熔点纤维—制成无纺布—切条—加捻/定型—织造—后整理；
上述工艺路线针对的无纺布原材料为废旧纺织品，此工艺无需将收集的纺织品进行特殊细化分类，可包含多种类的化学纤维和天然纤维，只需将纺织品清洗处理后撕碎开松并分解成适于无纺制造的短纤维，后经过无纺布制造后切条加捻制得无纺纱，再经过簇绒、梭织、针织工艺进行织造，最后进行后整理加工来制得本发明的一个实施例所述的无纺纱地毯。
作为本发明的又一实施方式，可选的工艺路线还可以为：废旧化学纺织品/废旧塑料的收集—分类清洗—高温融化—制成颗粒/切片—纺丝制成短纤维—制成无纺布—切条—加捻/定型—织造—后整理；此工艺需将收集的废旧纺织品/塑料瓶进细化分类，然后制得所需化纤短纤维，再经过无纺布制造以及后处理制得无纺纱，再经过簇绒、 梭织、针织工艺进行织造，最后进行后整理加工来制得本发明所述的无纺纱地毯。
优选的，所述地毯的制备方法包括如下步骤：
S1、把废旧纺织品、纺织品原材料和半成品制程中的头尾料及其他可以利用的化学纤维以及天然纤维材料进行收集、分类、清洗(消毒)、撕碎分解成短纤维或将化学纤维材料进行收集、分类、高温融化、造粒、纺丝制得本发明的一个实施例无纺纱所需的无纺布，并且按照需要对无纺布进行定型处理；
S2、将步骤S1制得的无纺布放入切条机进行切条处理；
S3、将步骤S2制得的无纺布条使用折条装置(能折叠条状无纺布的装置)进行加捻定型处理，制得本发明的一个实施例所需的类圆柱形无纺纱；根据需要，也可以对无纺布条只进行加捻而不需要定型；
S4、使用步骤S3制得的无纺纱在簇绒机、梭织机、针织机上进行织造，制得本发明的一个实施例的地毯胚毯；
S5、将步骤S4制得的胚毯进行覆底加工，即使用热熔胶、EVA、热塑弹性体、发泡胶或复合其他单独背衬材料或者带有防滑处理的背衬材料在地毯底背进行固绒和防滑处理。
可选的，步骤S1中无纺布织造过程中根据需要加入的低熔点纤维种类包含：聚烯烃类低熔点纤维、聚酸胺类低熔点纤维、聚醋类低熔点纤维；
步骤S1中低熔点纤维的添加量为0.5％-30％，按重量计；
步骤S1中，根据无纺布的制造工艺不同，无纺布分为：针刺无纺布、水刺无纺布；
可选的，所述无纺布还可以使用长纤进行制造。
另外，本发明的一个或多个实施例制得的一种无纺纱地毯可以用于印花、压花二次加工来获得新产品。
本发明的一个或多个实施例可以将废旧纺织品、纺织品原材料和半成品制程中的头尾料及其他可以利用的化学纤维以及天然纤维材料进行清洗、撕碎开松、梳理后去除非纤维材料以及杂质，然后制作无纺布。所得到的无纺布由于各种纤维均匀混合，省掉多种高标准的分类处理要求，简化了工艺流程、节省了生产成本，尽可能多的利用了资源，将节能、循环使用的概念以实际行动贯穿到此发明的整个生产流程当中，所以能够以开创性的方式制造一种成本低、耗能低、工艺要求低的高性价比产品。
可选的，本发明其中一个实施例的一种无纺纱地毯的制备方法的步骤S1还可以 是：
S1、把废旧塑料瓶或部分塑料收集、清洗、分类、造粒/切片、纺丝、后进行无纺布制造；
实现可替代发明的工艺路线为：废旧塑料瓶或部分塑料收集—清洗分类—粉碎——造粒—纺丝—梳理机梳理—多层铺网—根据需要加入/不加低熔点纤维—制成无纺布—切条—加捻定型—织造—后整理；
所述可替代方案工艺路线针对的无纺布原材料为废旧塑料瓶或部分塑料，此工艺需要将原料进行细化分类，将同种瓶片或塑料划为一类，然后进行造粒/切片、纺丝，在无纺布制造工序可将多种纤维进行均匀混合以制得实现本发明所需的无纺布，经过后处理制得无纺纱，再通过簇绒、梭织、针织工艺进行织造，最后进行后整理加工来制得本发明所述的无纺纱地毯；
更优选的，本发明其中一个实施例的一种无纺纱地毯的制备方法的步骤还可以是：进一步，所述地毯的制备方法包括如下步骤：
S1、把废旧纺织品、纺织品原材料和半成品制程中的头尾料及其他可以利用的化学纤维以及天然纤维材料进行收集、分类、清洗(消毒)、撕碎开松分解成短纤维；或将化学纤维材料进行收集、分类、高温融化、制成颗粒、纺丝、制成短纤维以及把废旧塑料瓶或100％化纤废旧纺织品或部分塑料收集、清洗、高标准分类、粉碎、造粒、纺丝、制成短纤维；用以上方法后制得本发明无纺纱所需的无纺布；
S2、将步骤S1制得的无纺布放入切条机进行切条处理；
S3、将步骤S2制得的无纺布条使用折条装置(能折叠条状无纺布的装置)进行加捻，制得本发明所需的无纺纱；
优选的，将步骤S3加捻后制得的无纺纱放入干热/湿热定型机中进行蒸汽处理，使切条软化。所述定型机温度为70℃—195℃，蒸汽温度为80℃—180℃。
S4、使用步骤S3制得的无纺纱在簇绒机、梭织机、针织机上进行织造，制得本发明的地毯胚毯；
S5、将步骤S4制得的胚毯进行覆底加工，即使用热熔胶、EVA、热塑弹性体、发泡胶或复合其他单独背衬材料或者带有防滑处理的背衬材料在地毯底背进行固绒和防滑处理。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本发明的其它特征、 目的和优点将会变得更明显；
图1本发明的无纺纱地毯簇绒织造工艺毯面全圈结构示意图；
图2本发明的无纺纱地毯簇绒织造工艺毯面全割结构示意图，
其中，1-绒面层，2-基布层，3-底背层；
图3本发明的无纺纱地毯平织织造工艺毯面俯视图；
其中，1-毯面层。
具体实施方式
下面结合实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明，但不以任何形式限制本发明。应当指出的是，对于本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干调整和改进；这些都属于本发明的保护范围。
实施例1
本实施例提供了一种无纺纱地毯及其制备方法，
本实施例地毯的制备步骤如下：
本实施例采用簇绒织造工艺，机型为3/8针距簇绒机，
1、制成无纺布：选用废旧涤纶纺织品为原料，经过清洗、高温融化、制成颗粒然后经过纺丝机制得2.5DTEX+3DTEX的短纤维，将其在针刺无纺布机上制得克重为300gsm的无纺布。
2、无纺布切条：把1制得的无纺布放入切条机进行切条，切条宽度为10mm。
3、加捻处理：把步骤3切完条的无纺布使用折条装置(能折叠条状无纺布的装置)进行加捻处理，捻向为S捻，捻度为150T/M，加捻后纱支支数为0.3支。
4、湿热定型处理：将步骤2中的无纺布条，放入蒸汽湿热定型机中处理温度为120℃，蒸汽温度为90℃；
5、织造：选用针距为3/8的圈绒簇绒机，毛高为15mm，将其在网络丝基布上进行簇绒，形成绒面层；
6、防滑处理：使用热塑弹性体在面料底背进行固绒和防滑处理，形成底部层。
本实施例制备的地毯如图1所示；其中，包括绒面层、基布层和底背层。
实施例2
本实施例提供了一种无纺纱地毯及其制备方法，其制备步骤如下：
本实施例采用簇绒织造工艺，机型为1/8针距簇绒机。
1、制成无纺布：选用1.5D原生涤纶短纤维和2.5D的原生丙纶短纤维均匀混合后，在针刺无纺布设备上制得克重为200gsm的无纺布。将制得的无纺布在热烫对辊上进行定型，定型温度为140℃，速度为8m/min。
2、无纺布切条：把1制得的无纺布放入切条机进行切条，切条宽度为5mm；
3、加捻处理：将步骤2切完条的无纺布使用折条装置(能折叠条状无纺布的装置)进行加捻处理，捻向为Z捻，捻度为100T/M,制成纱线,加捻后纱支支数为1支。
4、织造：选用针距为1/8针距割绒簇绒机进行织造，毛高为15mm，将其在PP基布上进行簇绒，形成绒面层；
5、固绒防滑处理：使用热塑弹性体在面料底背进行防滑处理及固绒处理，形成底部层。
本实施例制备的地毯如图2所示，其中，包括绒面层、基布层和底背层。
实施例3
本实施例提供了一种无纺纱地毯及其制备方法，其制备步骤如下：
本实施例采用针织织造工艺，机型为横机。
1、制成无纺布：选用3.5D的涤纶短纤，在针刺无纺布设备上制得克重为400gsm的无纺布。
2、无纺布切条：把1制得的无纺布放入切条机进行切条，切条宽度为8mm；
3、加捻处理：把S2切完条的无纺布使用折条装置(能折叠条状无纺布的装置)进行加捻处理，捻向为Z捻，捻度为200T/M,制成纱线，加捻后纱支支数为0.31支。
3、湿热定型处理：将步骤2中的无纺布，放入蒸汽湿热定型机中处理温度为110℃，蒸汽温度为100℃；
4、织造：选用E8横机，使用步骤3制得的无纺纱进行织造；胚毯厚度为4mm，胚毯克重为600g/㎡。
5、固绒防滑处理：使用发泡乳胶在面料底背进行防滑处理；
实施例4
本实施例提供了一种无纺纱地毯及其制备方法，其制备步骤如下：
本实施例采用簇绒织造工艺，机型为5/16针距割绒簇绒机。
1、制成无纺布：把废旧PET塑料瓶收集、清洗、高标准分类、粉碎、造粒、纺丝后，短纤为10DTEX，将其进行针刺无纺布机上制得无纺布，克重为350gsm。
2、无纺布切条：将步骤1制得的无纺布放入切条机进行切条，切条宽度为9mm；
3、加捻处理：把2切完条的无纺布使用折条装置(能折叠条状无纺布的装置)进行加捻处理，捻向为Z捻，捻度为80T/M,制成纱线，加捻后纱支支数为0.31支
4、织造：选用针距为5/16的割绒簇绒机，设定簇绒毛高为5mm，将其在长纤基布上簇绒。
5、印花工艺：将其胚毯使用数码印花机进行印花。
6、固绒防滑处理：使用丁苯乳胶在地毯面料的底背进行防滑和固绒处理。
实施例5
本实施例提供了一种无纺纱地毯及其制备方法，其制备步骤如下：
本实施例采用簇绒织造工艺，机型为多尼尔平织机。
1、制成无纺布：选用废旧纺织品为无纺布原料，清除、剥离非纤维类材质，清洗后开松处理分解成纤维，加入3％低熔点纤维，在无纺布设备上制得克重为500gsm的无纺布；
2无纺布切条：把1制得的无纺布放入切条机进行切条，切条宽度为15mm；
3、加捻处理：将步骤2的无纺布条使用折条装置(能折叠条状无纺布的装置)进行加捻处理，捻向为Z捻，捻度为70T/M,制成纱线，加捻后纱支支数为0.13支。
4、湿热定型处理：将步骤3中加捻的无纺纱线，放入蒸汽湿热定型机中定型处理，处理温度为120℃，蒸汽温度为90℃；
5、织造：多尼尔平织机进行织造，形成毯面层。
6、防滑处理：将步骤5织造好的面料底背与点塑无纺布进行热熔胶复合。
本实施例制备的地毯如图3所示。
对比例1
本对比例采用普通的毛条制成无纺纱，具体包括如下步骤：
本对比例采用簇绒织造工艺，机型为1/8簇绒机
1、选用纱线：选用新西兰羊毛进行合股，纱支为1支；捻向为S捻，捻度为80T/M。
2、织造：选用针距为1/8的割绒簇绒机，设定簇绒毛高为5mm。在PP基布上进行簇绒。
3、防滑处理：使用热塑弹性体在面料底背进行防滑处理。
性能测试
(一)绒头摩擦掉毛对比测试
测试方法：将本发明其中一个实施例的样品与现有簇绒产品分别取样，尺寸为50cmX50cm，取用两块10cmX10cm的黑色涤纶布，将2KG的重物压在黑色涤纶布上，然后拉动涤纶布进行摩擦，拉动长度为30cm，拉动次数为10次，取下重物，数黑色涤纶布与测试样接触的一面上的碎毛个数；
本发明取样使用实施例1选用1.5D原生涤纶短纤维和2.5D的原生丙纶短纤维均匀混合后，在针刺无纺布设备上制得克重为200gsm的无纺布，加捻后纱支支数为1支
对比例1取样：选用新西兰羊毛进行合股，纱支为1支。
取样：实施例5样尺寸50cmX50cm共3块，对比例1尺寸50cmX50cm共3块，按照上述实验方法进行对比测试，测试次数为3次，数据如下：
第一次测试数据：
实施例5摩擦后白色涤纶布掉毛数量：9个
对比例1摩擦后白色涤纶布掉毛数量：13个
第二次测试数据：
实施例5摩擦后白色涤纶布掉毛数量：10个
对比例1摩擦后白色涤纶布掉毛数量：14个
第三次测试数据：
实施例5摩擦后白色涤纶布掉毛数量：8个
对比例1摩擦后白色涤纶布掉毛数量：13个
综上，通过实验数据对比得出本发明的一个或多个实施例一种无纺纱地毯绒头掉毛数量更少；
(二)六足滚筒测试
1、30cm x 30cm大小的实施例1，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面外观完好，有轻微掉毛现象，没有严重磨损，等级为4级。
2、30cm x 30cm大小的现有市面上的毛条地毯并且织造参数与实施例1相同，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面严重磨损且毛条上对纤维大面积掉落，等级为3级。
3、30cm x 30cm大小的实施例5，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面外观完好，有轻微掉毛先，没有严重磨损，等级为4级。
4、30cm x 30cm大小的现有市面上的毛条平织地毯并且织造参数与实施例5相同，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面严重磨损且毛 条上对纤维大面积掉落，等级为3级。
(三)起毛起球测试
1、使用马丁代尔法，取实施例5中的无纺纱地毯，进行测试，通过不断摩擦后，表面起毛等级为4.5级。
2、使用马丁代尔法，现有市面上的新西兰羊毛平织地毯并且织造参数与实施例5相同，进行测试，通过不断摩擦后，表面起毛等级为3.5级。
3、使用马丁代尔法，取实施例3中的无纺纱地毯，进行测试，通过不断摩擦后，表面起毛等级为4.5级。
4、使用马丁代尔法，现有市面上的新西兰羊毛平织地毯并且织造参数与实施例3相同，进行测试，通过不断摩擦后，表面起毛等级为3.5级。
本发明的一个或多个实施例具有如下有益效果：
1、本发明可以将废旧纺织品、纺织品原材料和半成品制程中的头尾料及其他可以利用的化学纤维以及天然纤维材料进行清洗、撕碎开松、梳理后去除非纤维材料以及杂质，然后制作无纺布。所得到的无纺布由于各种纤维均匀混合，省掉多种高标准的分类处理要求，简化了工艺流程、节省了生产成本，尽可能多的利用了资源，将节能、循环使用的概念以实际行动贯穿到此发明的整个生产流程当中，所以能够以开创性的方式制造一种成本低、耗能低、工艺要求低的高性价比产品；
2、本发明在加捻处理后进行湿热定型处理，纤维之间的抱合力更强、不容易掉毛、纱线强度高；
3、本发明可以将回收的纤维制备成无纺布，进而制备成类圆柱形纱线，制成地毯，简化了工艺流程，节约成本；
4、本发明提供一种无纺纱地毯制备方法，产量高，对纤维要求低，可以不同材质，不同粗度、长度的纤维均可混用，甚至可以含部分的杂质。
5、本发明的地毯在制备过程中极大程度的对消费后纺织品进行二次利用，并且能够做到多次循环利用，降低了生产成本，既解决了废旧纺织品的回收难题，又做出了物美价廉的产品，同时也节省了资源，保护了环境。
以上对本发明的具体实施例进行了描述。需要理解的是，本发明并不局限于上述特定实施方式，本领域技术人员可以在权利要求的范围内做出各种变形或修改，这并不影响本发明的实质内容。

Claims (10)

  1. 一种地毯，其特征在于，地毯的毯面层为使用经过加捻或加捻定型的类圆柱形的无纺纱制成，所述无纺纱的原材料为原生纤维或再生纤维。
  2. 根据权利要求1所述的地毯，其特征在于，所述地毯的毯面层的上表面形成绒面层，所述绒面层的形态为全割、全圈、割圈或平织，所述毯面层的厚度为1mm-50mm。
  3. 根据权利要求1所述的地毯，其特征在于，所述地毯还包括连接于所述毯面层底部的底背层。
  4. 一种如权利要求1-3中任一项所述的地毯的制备方法，其特征在于，所述地毯的毯面层的制备方法包括如下步骤：
    S1、将无纺布进行切条，制得无纺布条；
    S2、将步骤S1制得的无纺布条加捻，制得类圆柱形无纺纱，所述类圆柱形无纺纱进行干热或湿热定型；
    S3、将步骤S2制得的类圆柱形无纺纱采用簇绒工艺、针织工艺或梭织工艺制成面料，进一步制得所述地毯的毯面层。
  5. 根据权利要求4所述的地毯的制备方法，其特征在于，所述的无纺布种类为短纤制成的无纺布，制成无纺纱所用的无纺布克重为50gsm-1000gsm；厚度范围为0.5mm-15mm。
  6. 根据权利要求4所述的地毯的制备方法，其特征在于，步骤S1中，无纺布条的宽度为5mm-50mm。
  7. 根据权利要求4所述的地毯的制备方法，其特征在于，步骤S2中，所述无纺纱的纱支范围为10支-0.25支。
  8. 根据权利要求4所述的地毯的制备方法，其特征在于，步骤S1中，所述无纺布通过如下方法制备：
    将使用后的纺织品包括废旧纱线进行收集、分类、依次进行清洗消毒、分解、开松、去除大部分非纤维成分杂质材料，获得纤维材料，将所述纤维材料制得所述无纺布；或，
    将使用过后的化纤类布料及化纤废丝熔化后制成颗粒，通过纺丝机制成短纤维后进一步制成无纺布；或，
    将原生或废旧塑料瓶片纺丝制得短纤维后进一步制成无纺布。
  9. 根据权利要求4所述的一种地毯的制备方法，其特征在于，所述纤维材料包括天然纤维、化学纤维、或天然纤维和化学纤维的混合。
  10. 根据权利要求1所述的一种地毯的制备方法，其特征在于：步骤S2中，所述加捻方式为倍捻、复捻或直捻。
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