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CN117944335A - Multilayer carpet and preparation method thereof - Google Patents

Multilayer carpet and preparation method thereof Download PDF

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Publication number
CN117944335A
CN117944335A CN202410203090.8A CN202410203090A CN117944335A CN 117944335 A CN117944335 A CN 117944335A CN 202410203090 A CN202410203090 A CN 202410203090A CN 117944335 A CN117944335 A CN 117944335A
Authority
CN
China
Prior art keywords
layer
carpet
mute
blanket
microfiber
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN202410203090.8A
Other languages
Chinese (zh)
Inventor
曹顺林
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kunshan Yijia Ju Textile Co ltd
Original Assignee
Kunshan Yijia Ju Textile Co ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kunshan Yijia Ju Textile Co ltd filed Critical Kunshan Yijia Ju Textile Co ltd
Priority to CN202410203090.8A priority Critical patent/CN117944335A/en
Publication of CN117944335A publication Critical patent/CN117944335A/en
Pending legal-status Critical Current

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Classifications

    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B32B2262/0284—Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/10—Properties of the layers or laminate having particular acoustical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/554—Wear resistance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets

Landscapes

  • Carpets (AREA)

Abstract

The invention discloses a multilayer carpet and a preparation method thereof. The multi-layer carpet comprises an upper layer carpet and a lower layer carpet, wherein the upper layer carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, the lower layer carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper layer carpet and the lower layer carpet are detachably bonded and connected through the carpet back layer and the carpet surface layer 2; when the blanket back layer is a mute single-filament bundle layer, the blanket surface layer 2 is a mute microfiber layer; or when the blanket back layer is a mute microfiber layer, the blanket surface layer 2 is a mute monofilament bundle layer. According to the invention, after chemical processing or physical processing is carried out on the bottom back of the upper blanket and the surface of the lower blanket, the mute microfiber layer distributed with superfine fiber bundles and the mute monofilament bundle layer distributed with monofilament bundles are overlapped together, and electrostatic adsorption effect is generated under the action of gravity and external force, so that the mute microfiber layer and the mute monofilament bundle layer can be mutually bonded to form a relatively thick sound-insulation blanket; meanwhile, the upper layer carpet and the lower layer carpet can be separated and can be used independently.

Description

Multilayer carpet and preparation method thereof
Technical Field
The invention belongs to the technical field of detachable carpets, and relates to a multilayer carpet and a preparation method thereof.
Background
The detachable and washable two-in-one carpet has been popular with most consumers in the market because of the advantages of washability, replaceability, convenient storage and the like, but the traditional installation method of the carpet layer and the anti-slip layer is generally realized by combining the traditional magic tape or the singeing non-woven fabric or the singeing barb fabric with the hair-catching knitted fabric. Certain disadvantages exist in the use process, such as loud noise when tearing, hand pricking on the hook surface, easy damage to clothes, easy ash storage, easy damage to the suede surface, shortened service life and the like. Therefore, it is necessary to utilize a textile fabric that is soft and has good adhesion force and does not rely on chemical adhesives to bond to replace the traditional magic tape, singed non-woven fabrics and singed barb cloth to improve the disassembly and assembly of the two-in-one carpet, thereby improving the use feeling of the carpet and prolonging the service life of the carpet.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a multilayer carpet and a preparation method thereof, wherein a soft textile fabric with mute opening and closing and good adhesive force is used for replacing the traditional magic tape/singed non-woven fabric/singed barb cloth to improve the disassembly and assembly of the carpet and the two-in-one carpet, and the problems mentioned in the technical background are solved.
The aim of the invention can be achieved by the following scheme:
in the technical scheme provided by the invention, the blanket mute single filament bundle layer and the mute microfiber layer are arranged on the blanket back of the upper blanket and the blanket face of the lower blanket and are overlapped together to generate electrostatic adsorption effect under the action of external force, so that the disassembly/combination installation of the multi-layer blanket can be completed, and therefore, all household functions of the free combination type blanket, namely, the blanket face is attractive, the water-washable and foldable, the replacement is convenient, the storage is convenient, the three-purpose cost performance function of one blanket (namely, the double-layer mute blanket, the upper blanket can be independently used as a blanket/sofa cover/bedspread and the like, and the lower blanket can be independently used as a blanket) and the like are realized.
The invention provides a multi-layer carpet, which comprises an upper layer carpet and a lower layer carpet, wherein the upper layer carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, the lower layer carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper layer carpet and the lower layer carpet are detachably bonded and connected through the carpet back layer and the carpet surface layer 2;
When the blanket back layer is a mute single-filament bundle layer, the blanket surface layer 2 is a mute microfiber layer;
or when the blanket back layer is a mute microfiber layer, the blanket surface layer 2 is a mute monofilament bundle layer.
In the invention, the upper blanket and the lower blanket are overlapped together through the blanket back layer and the blanket surface layer 2 to generate electrostatic adsorption effect under the action of external force so as to obtain detachable connection.
As an embodiment of the present invention, the carpet surface layer 1 includes any one or a combination of several of tufted surface layer, woven pile surface layer, knitted pile surface layer, and needle punched pile surface layer.
As one embodiment of the present invention, the pile surface state of the carpet surface layer 1 comprises at least one or a combination of several of cut pile, loop pile and flat fabric; the pile cutting process comprises at least one of tufting, knitting, tatting and non-weaving.
In the invention, the blanket surface layer 1 of the upper blanket can be printed with various patterns or decorated by using the same fabric to embroider.
As one embodiment of the invention, the material of the silent monofilament bundle layer comprises at least one of composite tows, animal wool fibers, and blend fibers of natural fibers and chemical fibers. The composite tow is in a loose, inclined, curved configuration.
As one embodiment of the present invention, the composite tow includes at least one of a chemical filament composite tow, a spun staple fiber yarn.
Further, the chemical filament composite tow comprises at least one of terylene, polypropylene and nylon, and the filament type of the chemical filament composite tow comprises at least one of FDY, DTY, BCF, POY.
Further, the spun yarn is spun yarn of short fibers or yarn blended by a plurality of short fibers.
Further, the natural fibers include animal wool fibers including wool fibers.
As one embodiment of the present invention, the silent filament bundle layer is a filament bundle layer in which filament bundles are distributed; the monofilament bundles are formed by sharing a plurality of monofilaments, and the top ends of the monofilaments are provided with dispersed inclined or bent structures. The multiple filaments together form a base with a greater surface density and higher horizontal bond pull and durability than conventional filaments (monofilament).
As an embodiment of the present invention, the fineness of the monofilaments is 1.04-60DPF. Below 1.04D, the monofilaments are too soft and are not easy to be inserted into fiber bundles of the mute microfiber layer to form entanglement, the mute adsorption effect is reduced, and the horizontal adhesive force is reduced; the spinning process of the composite fiber bundle with the monofilament larger than 60D is difficult, and the monofilament is hard.
As one embodiment of the present invention, the silent filament bundle layer has a filament density of 1200 to 180000 filaments/square inch. The density is lower than 1200 roots/square inch, the adhesive force is low, the bottom exposing phenomenon exists, the appearance is poor, and the use value is low; and the weaving difficulty is high and the efficiency and the economic value are low, wherein the weaving difficulty is high and the weaving efficiency is higher than 180000 pieces per square inch.
As an embodiment of the present invention, the thickness of the silent filament bundle layer is 1 to 15mm. The high-pile adhesion effect is best in this thickness range.
As one embodiment of the invention, the material of the mute microfiber layer comprises at least one of high shrinkage tows and microfiber tows. In the invention, the mute microfiber layer is made of microfiber tows or composite tows of high-shrinkage tows and microfiber tows, wherein the mass ratio of the high-shrinkage tows to the microfiber tows in the composite tows is 1:1-1:3.
Further, the material of the superfine fiber tows comprises at least one of sea-island filaments, bicomponent filaments and modified superfine chemical fiber filaments.
As one embodiment of the present invention, the silent microfiber layer is a tuft layer in which microfiber tufts are distributed.
Further, the fineness of the monofilaments in the ultra-fine fiber bundles is 0.05-2.08D.
As an embodiment of the present invention, the thickness of the mute microfiber layer is 1 to 15mm.
In the invention, the superfine fiber bundles are a plurality of fine and smooth superfine fiber bundles.
As an embodiment of the present invention, the multi-layered carpet further includes an intermittent anti-slip layer provided on the tuft surface in the silent microfiber layer, i.e., the intermittent anti-slip layer may be selectively provided on the tuft surface in the silent microfiber layer.
Further, the intermittent anti-slip layer comprises intermittent anti-slip resin or intermittent anti-slip glue; the intermittent anti-slip layer comprises at least one of TPE/PU, PUR, hot melt adhesive, acrylic adhesive and EVA adhesive.
As one embodiment of the present invention, the anti-slip layer is a material layer having an anti-slip function.
Further, the anti-slip layer comprises any one of a TPE layer, a latex layer, PVC, PU, PUR, hot melt adhesive, acrylic adhesive, EVA adhesive layer, SBR adhesive layer and other anti-slip materials.
In the invention, the upper blanket and the lower blanket can be mutually adhered or separated through the two layers of the fabric of the mute monofilament bundle layer and the mute microfiber layer, and the traditional magic tape is not required to be additionally arranged on the fabric, or the upper blanket surface and the lower blanket surface are disassembled, assembled and installed and the anti-skid function is realized through singed non-woven fabrics.
In the invention, the mute monofilament bundle layer and the mute microfiber layer can be respectively positioned at the bottom of the upper blanket and the upper part of the lower blanket, and the positions of the two contact layers can be freely selected, so that the main functions of the invention are not affected due to position inversion.
In a second aspect, the present invention provides a method of making a multi-layer carpet, the method comprising the steps of:
S1, preparing a mute monofilament bundle layer: preparing a cut velvet fabric from composite tows or animal plush fibers or blend fibers of natural fibers and chemical fibers, carding or thermally processing the cut velvet fabric, and separating to obtain a monofilament bundle layer distributed with monofilament bundles, namely a silent monofilament bundle layer;
S2, preparing a mute microfiber layer: doubling the high-shrinkage tows and the superfine fiber tows, or doubling, texturing and networking, and then forming (many ultra-fine) fiber tows after high-temperature dyeing and degreasing, so as to obtain a tows layer distributed with superfine fiber tows, namely a mute microfibers layer;
or, tatting, knitting or needling fabric made of a plurality of superfine fiber tows, grinding and napping the fabric, and performing high-temperature treatment to obtain a tows layer distributed with superfine fiber tows, namely a mute microfibers layer;
s3, preparing a multi-layer carpet: compounding the blanket surface layer 1 with a mute monofilament bundle layer to form an upper blanket, and compounding a mute microfiber layer with an anti-slip layer to form a lower blanket;
Or, compounding the blanket surface layer 1 with the mute microfiber layer to form an upper blanket, and compounding the mute monofilament bundle layer with the anti-slip layer to form a lower blanket;
(the upper and lower layers are attracted to each other by static electricity) to give the multi-layered carpet.
As an embodiment of the present invention, in step S1, the method for producing a cut pile fabric includes at least one of weaving, knitting, tufting, non-woven needling, and flocking.
As an embodiment of the present invention, step S1 further comprises dyeing and finishing the cut pile fabric before carding or thermal processing. Dyeing and finishing is aimed at removing part of the spin oil/spin oil.
As one embodiment of the invention, step S1 further comprises adding a stiffening agent to the cut pile fabric prior to carding or thermal processing, wherein the stiffening agent has a concentration of 10-30g/L and is used in an amount of 30-500gsm. The addition of stiffening agents can increase the horizontal bonding tension of the carpet.
As an embodiment of the invention, the stiffening agent comprises at least one of TF-639B, mo Jiangjian up to 2195.
As one embodiment of the invention, the step S1 further comprises adding an electrostatic reinforcing agent to the cut velvet fabric during carding or hot processing, wherein the concentration of the electrostatic reinforcing agent is 10-50g/L, and the use amount of the electrostatic reinforcing agent is 20-300gsm. An electrostatic enhancer (also called an electrostatic cleaner) is added to enhance the electrostatic adsorption effect to enhance the horizontal adhesion between the upper and lower blanket layers.
As one embodiment of the present invention, the static enhancer comprises jieskino 4957758.
As an embodiment of the present invention, in step S1, carding includes at least one of roughening, carding, cutting, ironing processes; the hot processing comprises the step of carrying out hot blowing process or ironing process or other processes equivalent to hot blowing on the cut velvet fabric.
In the invention, the filament bundles or fibers on the surface of the fabric are dispersed by carding or hot working to form monofilaments with dispersed inclined or bent structures at the top ends, and the prepared mute monofilament layer has electrostatic accumulation.
In step S2, as an embodiment of the present invention, the manner of making the fabric includes at least one of knitting, tatting, and needling.
In step S2, as an embodiment of the present invention, the fineness of the monofilaments in the plurality of ultrafine fiber bundles is 2.08DPF or less.
As an embodiment of the present invention, in step S2, the high temperature dyeing degreasing temperature is 60-230 ℃.
In the invention, the high shrinkage tows of the mute microfiber layer and the superfine fiber tows with different shrinkage rates are mutually wound together to form a gap, so that the monofilaments of the mute monofilament bundle layer are inserted/mutually entangled/electrostatically adsorbed together to generate electrostatic adsorption effect, thereby forming an adhesive effect.
As an embodiment of the present invention, step S2 further comprises performing brushing, roughening, or brushing after the high temperature dyeing degreasing.
As an embodiment of the present invention, step S2 further comprises dyeing and finishing and drying the fabric before the sanding and napping. Dyeing and finishing aims at removing part of spinning oil.
In the invention, static accumulation exists on the surface of the hair bundle layer treated in the step S2.
As an embodiment of the present invention, step S2 further includes coating the surface of the ultra fine fiber bundle with an intermittent anti-slip resin or an intermittent anti-slip adhesive.
As an embodiment of the present invention, in step S3, the compounding manner includes at least one of glue compounding, hot melt compounding, flame compounding.
Compared with the prior art, the invention has the following beneficial effects:
1. According to the invention, the problems of insufficient horizontal bonding tension and wear resistance of the traditional carpet are solved under the monofilament fineness and the corresponding monofilament density of the silent monofilament bundle layer, so that the obtained multilayer carpet has excellent horizontal bonding tension and wear resistance (namely durability).
2. Unlike traditional pile loop and hook structure, the present invention has superfine fiber bundles distributed on the surface and static accumulation on the surface, and has high electrostatic adsorption effect, high horizontal adhesion tension, high adhesion effect and high durability.
3. The multilayer carpet prepared by the invention is detachably bonded, wherein the mute microfiber layer can be used independently or can be matched with other carpets; the folding type portable storage rack is foldable, can be replaced conveniently and can be stored conveniently; meanwhile, the carpet can be split into a plurality of small blocks, and the misplacement infinite extension splicing is realized, so that the carpet has rich application scenes.
4. According to the invention, by adding a proper amount of stiffening agent into the processing method of the cut velvet silence layer fabric, the horizontal bonding tension of the carpet can be improved, and the service scene of the carpet can be enlarged.
5. According to the invention, a proper amount of electrostatic reinforcing agent (electrostatic dust collector) is added in the processing step of the mute monofilament bundle layer, so that the horizontal bonding tension of the upper and lower carpets is further enhanced, and a better carpet bonding effect is achieved.
6. The monofilament fineness of the mute monofilament bundle layer is large, the material selection range of the mute monofilament bundle layer is wide, the filament fiber bundles can be selected, yarns made of short fibers (including chemical fibers, wool fibers, fibrilia and the like) can be selected, and the mute monofilament bundle layer has excellent practical industrial application value.
7. Compared with the traditional hook density and loop density of the magic tape, the pile density of the textile fabric of the mute monofilament bundle layer and the mute microfiber layer is higher, the structure of the textile fabric is tighter, the cohesive energy is higher, a stronger electrostatic adsorption effect is easy to generate under the action of gravity and external force, and a stronger bonding effect is achieved; the textile fabric related to the mute monofilament bundle layer and the mute microfiber layer in the embodiment of the invention has better self-attaching effect than a magic tape. Meanwhile, the carpet within the monofilament density range has stronger durability, is more durable and is more solid. The disassembly and assembly are mute, and the noise is not very large. In particular, the anti-skid effect, especially the lateral anti-skid effect is very excellent.
8. The textile fabric adopted by the mute monofilament bundle layer and the mute microfiber layer in the invention can not damage any surface due to long-term open and close use, and greatly prolongs the service life, thereby easily realizing the blanket function in the blanket.
Drawings
Other features, objects and advantages of the present invention will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:
FIG. 1 is a schematic view of a carpet construction; wherein, 1 is blanket surface layer 1,2 is blanket back layer, 3 is upper blanket, 4 is blanket surface layer 2,5 is anti-slip layer, 6 is lower blanket;
FIG. 2 is a schematic diagram of the upper blanket structure in embodiment 1; wherein 7 is a monofilament bundle;
FIG. 3 is a schematic view of the lower blanket structure in example 1; wherein 8 is a high shrinkage filament bundle, and 9 is a superfine fiber filament bundle.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The following examples, which are presented to provide those of ordinary skill in the art with a detailed description of the invention and to provide a further understanding of the invention, are presented in terms of implementation and operation. It should be noted that the protection scope of the present invention is not limited to the following embodiments, and several adjustments and improvements made on the premise of the inventive concept are all within the protection scope of the present invention.
Stiffening agent manufacturers used in the embodiments of the present invention: zhejiang Zhi community of stock parts of Limited company, model: TF-639B (English: TRANSPEC STF TF-639B).
Example 1
The carpet structure of this embodiment is shown in fig. 1, and the upper carpet and the lower carpet structure are shown in fig. 2 and 3, respectively.
1. The carpet surface is selected to be 250GSM nylon BCF flat cut tufting printing, the pile height is 4mm, and the tufting base cloth is 100GSM filament non-woven fabric base cloth. And (3) the tufted carpet surface printed with the flowers is fixed with EVA glue for later use.
2. The pile-fastened carpet surface and 150GSM non-woven fabric are compounded together by a flame compounding method with the weight of 20 g/square meter to form the carpet surface layer 1 (1). The purpose of the composite non-ballistic cloth is to better maintain post-wash appearance and post-wash dimensions.
3. Polyester DTY150D/36F (about 4.17DPF for single filaments) is selected to be woven into a fabric on a single-bed knitting machine, and then the fabric is subjected to brushing, velvet cutting, dyeing and hot blowing treatment to obtain a mute single-filament bundle layer with single-filament bundles (7), namely a carpet back layer (2), wherein the gram weight is about 200 grams per square meter, the length of the velvet is about 2.5mm, and the single-filament density is 174960 per square inch. And (3) compositing the mute monofilament bundle layer and the blanket surface layer 1 in the step (2) to obtain an upper blanket (3).
4. And (3) doubling and texturing the sea-island fibers of the 75D/200F island and the 75D polyester high stretch yarns, then performing weft knitting (knitting) to obtain weft-knitted ant cloth (i.e. knitted fabric), and then adding a 32% NaOH solution with mass concentration into a dye vat at 130 ℃ to perform degreasing alkali reduction (i.e. high-temperature dyeing degreasing) to obtain a mute microfiber layer with high shrinkage tows (8) and superfine fiber tows (9), namely a carpet surface layer 2 (4), wherein the pile height (i.e. thickness) is 1.5mm, and the monofilament fineness of the superfine fiber part is 0.375D.
5. And (3) compounding the mute microfiber layer fabric prepared in the step (4) with 700 g/square meter point plastic non-woven fabric, namely an anti-slip layer (5), by using PUR thermosol to obtain the lower blanket (6) of the invention.
6. And finishing cutting, packaging and shipping.
Example 2
1. The carpet face was 360GSM printed flannel as the carpet face.
2. And (3) compounding the 500GSM printed flannelette blanket surface and the 200GSM non-woven fabric together by using PUR glue to form a blanket surface layer 1, wherein the pile height is 5mm.
3. And (3) combining 105D/36Fx37 polyester-nylon composite spinning and 100D high-shrinkage yarns, and taking the combined yarns as warp yarns and 150D/14F polyester filaments as weft yarns, preparing 180GSM warp-wise superfine fiber fabric according to plain weave, dyeing and degreasing at high temperature (at 130 ℃), drying and shaping, and then carrying out high-speed picking/roughening on the fabric to obtain the mute superfine fiber layer. Wherein the DPF of the superfine fiber part is about 0.08DPF, and the mute superfine fiber layer and the blanket surface layer 1 of the step 2 are compounded together to form an upper blanket.
4. The 1800D/144F black polypropylene BCF yarn is selected to be manufactured into a cut pile carpet surface with the row spacing of about 12.70 needles/inch on a tufting machine with the 1/12 needle pitch, the pile height is 3.5 mm, a stiffening agent (model TF-639B, the proportion is 30 g/L) of 200GSM is sprayed on the carpet surface, and then the blank carpet is fed into an oven to be subjected to hot air treatment, and the top end of the BCF monofilament bundle is in a bending and diverging state to form the carpet surface 2 of the mute monofilament bundle layer. The monofilament fineness in the monofilament bundles is about 12.50DPF and the density is about 21946 filaments per square inch.
5. And coating 500GSM TPE anti-slip adhesive on the back of the silent monofilament layer fabric, and blowing hot air to the carpet surface by an air heater at 120 ℃ during coating to further enable the monofilaments of the carpet surface to be in a divergent inclined state, so that the lower carpet disclosed by the invention is obtained.
And 6, finishing cutting, and packaging.
Example 3
1. The carpet surface is 700GSM jacquard fabric as the carpet surface and is used as the carpet surface layer 1.
2. The grey cloth is obtained by weaving 215D/36Fx37 sea island yarn DTY serving as a pile yarn and 150D/72F terylene DTY serving as a base yarn on a warp knitting machine, and the grey cloth is prepared by using 2g/L of YZ-101 fiber opener and 100%6g/L of caustic soda according to the bath ratio of 1:15, carrying out fiber opening and oil removal. The fiber opening temperature is controlled to be about 95 ℃ for 30 minutes, then dyeing, drying and shaping are carried out, and finally high-speed brushing/brushing is carried out to obtain the mute microfiber layer. The fiber of the microfiber portion of the surface of the silent microfiber layer was 0.16DPF.
3. Compounding the blanket surface layer 1 in the step 1 and the mute microfiber layer in the step 2 into the upper blanket of the invention.
4. Selecting 1800D/30F terylene BCF monofilament bundle yarns and 120GSM terylene viscose-like non-woven fabrics as base cloth, weaving the yarns on a 1/6 tufting machine to prepare a blanket, spraying 300GSM Jiesheno electrostatic dust collector (i.e. electrostatic reinforcing agent) on the prepared blanket, wherein the model number 4957758 is 30g/L, coating SBR glue on the back of the blanket, and drying and shaping the blanket in a hot air oven to form a blanket surface layer 2. The stitch was about 10 needles/inch, the fleece was 5mm in height, and the filament density was about 1800 filaments/square inch. The drying and shaping temperature is 160 ℃, and the end of the monofilament of the shaped monofilament bundle presents a slightly-curved shape.
5. And (3) compounding the PUR glue for the fabric prepared in the step (4) with 3D mesh cloth to obtain the lower blanket. The back of the 3D mesh cloth is coated with 30GSM SEBS hot-melt anti-slip adhesive.
6. And (5) finishing cutting, and packaging.
Comparative example 1
The preparation of this comparative example was essentially the same as example 1, except that the quiet monofilament bundle layer fabric was replaced with a barbed mesh having 300D filaments as the base filaments and 450D filaments as the barbs. The multilayer carpet obtained in example 1 was used as an experimental example, and the multilayer carpet obtained in comparative example 1 was used as a comparative example, and the following experiment was performed (the experimental bonding area was 13cm×19 CM).
Experiment one: the carpets of the experimental example and the comparative example are respectively fixed on the same wood grain floor, then the middle part on the right side of the upper carpet surface is hooked by a chest expander and pulled slowly until the upper carpet surface and the lower carpet surface are separated and the tensile force reading at that moment is recorded, and the horizontal bonding tensile force is tested, and the result is as follows:
Experimental example = 121 newtons;
Comparative example = 87 newtons.
Experiment II: the test example and the comparative example are respectively pulled open rapidly and then closed, pulled open again and closed again, repeated 1000 times, the appearance condition of the four fabrics of the comparative example is seen, and the durability is tested, and the result is as follows:
experimental example = almost no change
Comparative example = ultrafine fiber bundle layer a lot of broken fluff appears, and a lot of broken barbed black filaments remain on the ultrafine fiber bundle layer.
Comparative example 2
The preparation of this comparative example was essentially the same as example 1, except that the silent monofilament layer facing was replaced with singeing fibers (6dx51mm+2.5dx51mm needle punched into an orbital nonwoven felt followed by a thermal singeing treatment). The multilayer carpet obtained in example 1 was used as an experimental example, and the multilayer carpet obtained in comparative example 2 was used as a comparative example, and the following experiment was performed (the experimental bonding area was 13cm×19 CM).
Experiment one: the experimental example and the comparative example are respectively fixed on the same wood grain floor, then the middle part on the right side of the upper blanket surface is hooked by a chest expander and is pulled slowly until the upper blanket surface and the lower blanket surface are separated and the tension reading at that moment is recorded, and the horizontal bonding tension is tested, and the result is as follows:
Experimental example = 121 newtons;
comparative example = 85 newtons.
Experiment II: the test example and the comparative example are respectively pulled open rapidly and then closed, pulled open again and closed again, repeated 1000 times, the appearance condition of the four fabrics of the comparative example is seen, and the durability is tested, and the result is as follows:
Experimental example = little change;
Comparative example = a number of black dots and broken fibers were attached to the microfiber bundle layer.
Comparative example 3
The preparation method of this comparative example was basically the same as example 1, except that the silent monofilament layer was changed to singeing felt sub-fibers, 6dx51mm+2.5dx51mm was needled into a rail nonwoven felt, and then subjected to a thermal singeing treatment, and the ultra fine fiber bundle layer was changed to 300D/48F weft knitted terry cloth. The following experiment (experimental bonding area 13cm×19 CM) was performed using the multilayer carpet obtained in example 1 as an experimental example and the multilayer carpet obtained in comparative example 3 as a comparative example.
Experiment one: the experimental example and the comparative example are respectively fixed on the same wood grain floor, then the middle part on the right side of the upper blanket surface is hooked by a chest expander and is pulled slowly until the upper blanket surface and the lower blanket surface are separated and the tension reading at that moment is recorded, and the horizontal bonding tension is tested, and the result is as follows:
Experimental example = 121 newtons;
Comparative example = 23 newtons.
Experiment II: the test example and the comparative example are respectively pulled open rapidly and then closed, pulled open again and closed again, repeated 1000 times, the appearance condition of the four fabrics of the comparative example is seen, and the durability is tested, and the result is as follows:
Experimental example = little change;
comparative example = many black broken felt fibers appear on the microfiber bundle layer, and some of the fleece of the weft-knitted fleece is pulled open to reveal the bottom.
Comparative example 4
The preparation method of the comparative example is basically the same as that of the example 2, except that in the step 3, 105D/36Fx37 polyester-nylon composite spinning and 100D high shrinkage yarn are dyed and dried by a weft knitting machine to form 180gsm terry cloth, and then the terry cloth is compounded with a blanket surface to form an upper blanket, and the lower blanket is the same as that of the example 2;
The following experiment (experimental bonding area 13cm×19 CM) was performed using the multilayer carpet obtained in example 2 as an experimental example and the multilayer carpet obtained in comparative example 4 as a comparative example.
Experiment one: the experimental example and the comparative example are respectively fixed on the same wood grain floor, then the middle part on the right side of the upper blanket surface is hooked by a chest expander and is pulled slowly until the upper blanket surface and the lower blanket surface are separated and the tension reading at that moment is recorded, and the horizontal bonding tension is tested, and the result is as follows:
Experimental example = 91 newtons;
Comparative example = 72 newtons.
Experiment II: the test example and the comparative example are respectively pulled open rapidly and then closed, pulled open again and closed again, repeated 5000 times, the appearance condition of the four fabrics of the comparative example is seen, and the durability is tested, and the result is as follows:
Experimental example = substantially unchanged;
Comparative example = terry with slight damage.
Example 4
The preparation method of this example is substantially the same as that of example 2, except that no stiffening agent is added in step 3. The multi-layered carpets obtained in example 2 and example 4 were subjected to the following experiment (the experimental bonding area was 13cm×19 CM).
Experiment one: example 2 and example 4 were placed on the same wood grain floor, respectively, and then the middle portion of the right side of the upper carpet face was hooked with a chest expander and pulled slowly until the upper and lower carpet faces were separated and the tension readings at that moment were recorded, and the horizontal adhesion tension was measured, with the following results:
example 2 = 91 newtons;
Example 4 = 83 newtons.
Experiment II: example 2 and example 4 were pulled rapidly and then closed, pulled again and closed again, and repeated 1000 times to see the appearance of the four fabrics of the comparative example, and the durability was tested as follows:
Example 2 = little change;
Example 4 = little change.
Example 5
The preparation method of this example is basically the same as that of example 3, except that no electrostatic enhancer is added to the silent monofilament layer fabric. The multi-layered carpets obtained in example 3 and example 5 were subjected to the following experiment (the experimental bonding area was 13cm×19 CM).
The multi-layered carpets obtained in example 3 and example 5 were fixed to the same wood grain floor, respectively, and then the right middle portion of the upper carpet surface was hooked by a chest expander and pulled slowly until the upper and lower carpet surfaces were separated and the tension readings at that moment were recorded, and the horizontal adhesion tension was measured, as follows:
Example 3 = 109 newtons;
Example 5 = 92 newtons.
Experiment II: example 3 and example 5 were pulled rapidly and then closed, pulled again and closed again, and repeated 1000 times to see the appearance of the four fabrics of the comparative example, and the durability was tested as follows:
Example 3 = little change;
Example 5 = little change.
In summary, the multilayer carpet obtained by the method has excellent horizontal bonding tension, durability and economic value under the fineness of the monofilaments and the density of the monofilaments of the silent monofilament bundles. In addition, the stiffening agent is generally applied to the plane fabric to stiffen the fabric, and a small amount of stiffening agent is added in the processing step of the silent monofilament bundle layer by creatively using the stiffening agent, so that the horizontal bonding tension of the carpet can be improved, the service scene of the carpet is enlarged, and the durability of the carpet is enhanced. Meanwhile, a small amount of electrostatic reinforcing agent (electrostatic dust collector) is creatively added in the processing step of the silent single-filament bundle layer, so that the horizontal bonding tension of the upper carpet and the lower carpet is further enhanced. More importantly, compared with the hook connection and adhesion of the traditional loop and the hook structure, the mute microfiber layer has the advantages that superfine fiber bundles are distributed on the surface of the mute microfiber layer, a strong electrostatic adsorption effect is easy to generate under the action of gravity and external force, and strong horizontal adhesion tensile force is achieved after the mute microfiber bundles are adhered to the mute monofilament bundle layer, so that a strong adhesion effect is achieved, and the mute monofilament bundle layer has higher durability.
The foregoing describes specific embodiments of the present invention. It is to be understood that the invention is not limited to the particular embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the claims without affecting the spirit of the invention.

Claims (10)

1. The multi-layer carpet is characterized by comprising an upper layer carpet and a lower layer carpet, wherein the upper layer carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, the lower layer carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper layer carpet and the lower layer carpet are detachably bonded and connected through the carpet back layer and the carpet surface layer 2;
the blanket back layer is a mute single-filament bundle layer, and the blanket surface layer 2 is a mute microfiber layer;
or, the blanket back layer is a mute microfiber layer, and the blanket surface layer 2 is a mute monofilament bundle layer.
2. The multi-layer carpet of claim 1, wherein the material of the silent filament bundle layer comprises at least one of composite filament bundles, animal wool fibers, blends of natural fibers and chemical fibers.
3. The multi-layer carpet of claim 1, wherein the silent filament bundle layer is a filament bundle layer having a plurality of filament bundles distributed therein; the monofilament bundles are formed by sharing a plurality of monofilaments, and the top ends of the monofilaments are provided with dispersed inclined or bent structures.
4. A multi-layered carpet according to claim 3, wherein the fineness of the monofilaments is 1.04-60DPF; the silent filament bundle layer has a filament density of 1200-180000 filaments/square inch.
5. The multi-layer carpet of claim 1, wherein the material of the silent microfiber layer comprises at least one of high shrinkage tows and microfiber tows.
6. The multi-layer carpet of claim 5, wherein the silent microfiber layer is a tuft layer having a plurality of microfiber tufts distributed therein.
7. The multi-layered carpet of claim 6, wherein the fineness of the monofilaments in the ultra fine fiber bundles is 0.05 to 2.08D.
8. A method of making a multi-layer carpet as claimed in any one of claims 1 to 7, comprising the steps of:
S1, preparing a mute monofilament bundle layer: preparing a cut velvet fabric from composite tows or animal plush fibers or blend fibers of natural fibers and chemical fibers, carding or thermally processing the cut velvet fabric, and separating to obtain a monofilament bundle layer distributed with monofilament bundles, namely a silent monofilament bundle layer;
s2, preparing a mute microfiber layer: doubling the high-shrinkage tows and the superfine fiber tows, or doubling and texturing and networking, and then forming the fiber tows after high-temperature dyeing and degreasing to obtain a tows layer distributed with superfine fiber tows, namely a mute microfiber layer;
Or, tatting or knitting or needling fabric made of a plurality of superfine fiber tows, grinding and napping the fabric, and performing high-temperature treatment to obtain a tows layer distributed with superfine fiber tows, namely a mute microfibers layer;
s3, preparing a multi-layer carpet: compounding the blanket surface layer 1 with a mute monofilament bundle layer to form an upper blanket, and compounding a mute microfiber layer with an anti-slip layer to form a lower blanket;
Or, compounding the blanket surface layer 1 with the mute microfiber layer to form an upper blanket, and compounding the mute monofilament bundle layer with the anti-slip layer to form a lower blanket;
The multilayer carpet is obtained.
9. The method of claim 8, wherein step S1 further comprises adding a stiffening agent to the cut pile fabric prior to carding or thermal processing, wherein the stiffening agent has a concentration of 10-30g/L and is used in an amount of 30-500gsm; the carding comprises at least one of the processes of roughening, carding, cutting silk and ironing; the hot processing comprises at least one of a hot blowing process and an ironing process.
10. The method of claim 8, wherein step S1 further comprises adding an electrostatic enhancer to the cut pile fabric of the silent monofilament layer before carding or hot working, wherein the electrostatic enhancer has a concentration of 10-50g/L and is used in an amount of 20-300gsm.
CN202410203090.8A 2024-02-23 2024-02-23 Multilayer carpet and preparation method thereof Pending CN117944335A (en)

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CN202410203090.8A CN117944335A (en) 2024-02-23 2024-02-23 Multilayer carpet and preparation method thereof

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Application Number Priority Date Filing Date Title
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