Multi-layer color-mixed fiber wear-resistant carpet and preparation system, method and application of multi-layer color-mixed fiber wear-resistant carpet

Abstract

The invention provides a multilayer mixed-color fiber wear-resistant carpet as well as a preparation system, method and application thereof, and belongs to the field of layered resin fiber carpet materials. Polyamide 6 and color master batch are synchronously mixed in different screw extruders to prepare fiber yarns with different colors, the fiber yarns are processed to prepare color-mixed fiber bundles, tufting is continued to obtain a base cloth layer and a pile layer, and different functional layers are continued to be overlaid to prepare the multilayer color-mixed fiber wear-resistant carpet. The mixed-color fiber bundles in the layer structure of the carpet form a high-density cut pile structure after being tufted by a tufting machine, the bulked crimp structure of the mixed-color fiber bundles can endow pile layers with high resilience, the pile layers are not prone to collapse after being treaded for a long time, the appearance flatness is kept, and the composite strength of the carpet is improved through arrangement of different layers.

Description

Technical Field

[0001] The present invention relates to the field of laminated resin fiber carpet materials, and particularly to a multi-layer mixed-color fiber wear-resistant carpet and a preparation system, method and application thereof. Background Art

[0002] At present, with the fierce competition in the global automotive market, the proportion of the young consumer group is increasing continuously. Their personalized needs for automotive soft interior materials and components and the demand for product quality upgrading are becoming increasingly prominent. The field of automotive carpet materials has also faced new technical challenges. To enhance the competitiveness of automotive carpets in the global market and achieve the sustainable development of automotive interior carpet materials, it is urgent to carry out continuous innovation from dimensions such as appearance design, material performance and process technology, and improve the technical added value of carpet materials. However, there are still many problems in the design, performance and process of current automotive carpet materials, and there is a large gap from the innovation requirements.

[0003] Currently, conventional automotive carpet materials mostly adopt a single-color design style and are made of dark-colored BCF fibers such as black and gray. This traditional design is difficult to meet the current design concept of personalized automotive interior materials, resulting in a gradual decrease in the technical added value of automotive carpets and being unable to meet the increasingly diverse aesthetic needs of consumers. Moreover, the diversification and intelligentization trends of automotive usage scenarios also put forward higher standards for the functionality of carpet materials.

[0004] With the continuous innovation and maturity of autonomous driving technology, shared driverless autonomous vehicles are gradually entering the market, which puts forward higher requirements for the cleanliness of automotive carpets. After traditional ordinary solid-color carpets are contaminated with dust, stains will be clearly highlighted, greatly affecting the riding experience of consumers. At the same time, with the increase in the usage area of see-through automotive glass, the running time of automobiles in high-intensity light environments increases. Existing conventional tufted carpet materials face serious problems of color decay and are difficult to maintain long-term beauty. In addition, at the process technology level, the traditional automotive carpet manufacturing process is relatively single, and it is difficult to present complex patterns and special textures, which limits the innovation breakthrough in appearance and also affects the further improvement of material performance.

[0005] From the perspective of material performance, current automotive carpet materials mostly adopt the design of conventional low-denier BCF monofilaments. In actual use, this material performs poorly in resisting heel wear. During the driving or stepping process of consumers, long-term wear is likely to cause the carpet to show the bottom layer and a significant change in the appearance color, seriously affecting the use experience. Moreover, in high-intensity light environments, if the automotive interior carpet has a high gloss, it will bring an unpleasant visual experience to consumers and further reduce the market competitiveness of the product.

[0006] In summary, most of the existing automotive carpets are in a single-color style. However, with the continuous development of automobiles, defects such as poor cleaning ability and obvious stains caused by single-color carpets have gradually emerged. At the same time, problems such as poor wear resistance, poor aging resistance under light conditions, and single process technology of the existing automotive carpets still need to be solved urgently. Summary of the Invention

[0007] In view of the above problems, the present invention provides a multi-layer mixed-color fiber wear-resistant carpet. Different-colored fiber filaments are prepared by mixing polyamide 6 and color masterbatch synchronously in different screw extruders, and after processing, they are made into mixed-color fiber bundles, and then tufted continuously to obtain a base cloth layer and a pile layer. After continuously stacking different functional layers, the multi-layer mixed-color fiber wear-resistant carpet is prepared. The multi-layer mixed-color fiber wear-resistant carpet has good wear resistance, high dirt hiding property, and excellent ultraviolet resistance.

[0008] The present invention provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which is composed of a bottom layer, a first anti-puncture layer, a reinforcement layer, a second anti-puncture layer, an adhesive layer, a base cloth layer, and a pile layer from bottom to top. The pile layer and the base cloth layer are prepared by tufting mixed-color fiber bundles on a non-woven base cloth. The mixed-color fiber bundles are prepared by melt mixing and spinning polyamide 6 with different-color masterbatch through synchronously arranged screw extruders; The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 8-15 mm, the pile height is 3-8 mm, and the shape of the pile is cut pile; The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 50-60% at room temperature, an elongation at break of 115-123% at 130 °C, a breaking strength of 1030-1120 N at room temperature, the number of Taber wear-resistant cycles is 3900-4000 cycles without bottom leakage, the glossiness ≤ 1.5 °, the gray scale level ≥ 4 levels, and good dirt hiding property; The multi-layer mixed-color fiber wear-resistant carpet has a shrinkage rate of 0-0.5% after being placed at 220 °C for 120 s; The color difference of the multi-layer mixed-color fiber wear-resistant carpet in the color space (CIELab) is the lightness color difference (ΔL) ≤ 0.5, the red-green axis color difference (Δa) ≤ 0.1, and the yellow-blue axis color difference (Δb) ≤ 0.1.

[0009] Furthermore, the elongation at break in the machine direction (MD) of the elongation at break at room temperature is 55-60%, and the elongation at break perpendicular to the machine direction (CD) is 50-55%.

[0010] Furthermore, the elongation at break in the machine direction (MD) of the elongation at break at 130 °C is 115-121%, and the elongation at break perpendicular to the machine direction (CD) is 115-123%.

[0011] Further, the breaking strength at normal temperature in the machine direction (MD) is 1030 - 1105 N, and the breaking strength perpendicular to the machine direction (CD) is 1050 - 1120 N.

[0012] Further, the shrinkage rate in the machine direction (MD) is 0 - 0.5%, and the shrinkage rate perpendicular to the machine direction (CD) is 0 - 0.4%.

[0013] Further, the adhesive layer is compounded at the bottom of the base fabric layer by coating, and the polyethylene - polyamide - polyethylene film and the needle - punched bottom felt are compounded at the bottom of the adhesive layer by means of a film - casting binder to obtain the second anti - penetration layer and the reinforcing layer. Then, the polyethylene - polyamide - polyethylene film and the non - woven bottom cloth are compounded at the bottom of the reinforcing layer by means of a film - casting binder to obtain the first anti - penetration layer and the bottom layer.

[0014] The present invention also provides a preparation system for the multi - layer mixed - color fiber wear - resistant carpet. According to the processing direction of the materials, the preparation system includes a spinning unit, a texturing unit, a tufting unit, and a compounding unit; The spinning unit includes a screw extruder, a spinning box, an oiling device, and a stretching device; The texturing unit includes an air - texturing machine, a cooling roller, a spinning networker, and a winding machine; The tufting unit includes a tufting machine; The compounding unit includes a coating device, a film - casting device, and a dryer; The number of the screw extruders ≥ 2; The spinning box is provided with a spinneret plate and a channel. The spinneret plate is a three - lobe spinneret plate; An inlet is arranged above the spinning box, and the molten material in the screw extruder enters the spinning box through the inlet of the spinning box; A blowing device is installed on the side of the spinning box, and a channel is vertically arranged below. An air inlet is arranged on the channel, and the blowing device cools the fiber filaments after spinning through the air inlet; The number of the inlets, the spinneret plates, and the channels of the spinning box is the same as the number of the screw extruders. The materials in the screw extruders enter different inlets respectively, and are spun and air - cooled through different spinneret plates and channels.

[0015] Further, the screw extruder is a single - screw extruder.

[0016] Further, when the number of the screw extruders is 2, it includes a first screw extruder and a second screw extruder.

[0017] Further, a metering pump is installed at the spinneret to quantify the materials for spinning, and the speeds of the metering pumps are consistent.

[0018] Further, the drawing device includes a primary drawing roller and a secondary drawing roller.

[0019] Further, a nozzle is provided on the air texturing machine, and low-pressure air is blown through the nozzle to the fibers.

[0020] Further, a guide roller is installed between the spinning networker and the cooling roller, and the guide roller is used to convey the fiber filaments, and the fiber filaments are subjected to network processing in the spinning networker.

[0021] Further, a guide roller is installed between the winding machine and the spinning networker, and the guide roller is used to convey the fiber filaments.

[0022] The present invention also provides a preparation method for preparing the multi-layer mixed-color fiber wear-resistant carpet with the preparation system, including the following steps: Step 1: Set up a non-woven base fabric, tuft the mixed-color fiber bundle onto the non-woven base fabric through a tufting machine to obtain a cut pile layer and a base fabric layer, and then continue to coat the bottom of the base fabric layer with aqueous foamed latex, and obtain an adhesive layer after drying; Step 2: After coating the bottom of the adhesive layer with a binder to bond a polyethylene-polyamide-polyethylene film (PEPAPE), continue to coat the binder to bond a needled bottom felt, and obtain an anti-penetration layer II and a reinforcing layer after cooling; continue to coat the bottom of the reinforcing layer with a binder to bond a polyethylene-polyamide-polyethylene film (PEPAPE), and then continue to coat the binder to bond a non-woven bottom cloth, and obtain an anti-penetration layer I and a bottom layer after cooling; finally, obtain the multi-layer mixed-color fiber wear-resistant carpet.

[0023] Further, the preparation process of the mixed-color fiber bundle includes the following steps: S1: Set up two screw extruders, namely screw extruder I and screw extruder II, add polyamide 6, a black masterbatch and a spinning oil agent to the screw extruder I for melting and mixing, and at the same time add polyamide 6, a white masterbatch and a spinning oil agent to the screw extruder II for melting and mixing; S2: Respectively convey the molten materials in S1 to the spinning box through different feed ports, and respectively spin the materials through a dark spinneret and a light spinneret in the spinning box through a metering pump. After spinning, the fiber filaments respectively pass through a dark channel and a light channel vertically arranged below the spinning box and are respectively cooled by a blowing device under cold air to obtain solidified dark fiber filaments and light fiber filaments; S3: Respectively oil the dark fiber filaments and the light fiber filaments with an oiling device, and then jointly pass the oiled fiber filaments through a drawing device for drawing to obtain drawn fiber filaments; S4. Place the drawn fiber filaments into an air texturing machine for jet bulking. The bulked fiber filaments are cooled by a cooling roller, and after cooling, bulked continuous-filament yarns are obtained. Introduce the bulked continuous-filament yarns into a spinning networker through a guide roller for knotting. After knotting, the bulked continuous-filament yarns are introduced into a winding machine through a guide roller and wound into a cylindrical yarn bobbin to obtain a mixed-color fiber bundle.

[0024] Further, in S1, the mass ratio of the polyamide 6, the black masterbatch, and the spinning finish is (95 - 97):(2 - 4):(0.5 - 1).

[0025] Further, in S1, the mass ratio of the polyamide 6, the white masterbatch, and the spinning finish is (95 - 97):(2 - 4):(0.5 - 1).

[0026] Further, in S1, the relative viscosity of the polyamide 6 is 2.70 - 2.83 dl / g.

[0027] Further, in S1, the processing temperatures of the first screw extruder and the second screw extruder are 250 - 280 °C, divided into four temperature zones. The temperature of the first temperature zone is 250 °C, the temperature of the second temperature zone is 260 - 270 °C, the temperature of the third temperature zone is 270 - 280 °C, and the temperature of the fourth temperature zone is 260 - 270 °C.

[0028] Further, in S2, the spinning speed of the metering pumps is 400 - 500 g / min.

[0029] Further, in S2, the spinneret plate is a three-lobed spinneret plate, and the number of holes in the spinneret plate is 45 - 55.

[0030] Further, in S2, the temperature of the spinning box is set to 250 - 270 °C.

[0031] Further, in S2, the spinning pressure of the spinning box is 60 - 110 bar.

[0032] Further, in S2, the ambient temperatures of the dark channel and the light channel are both 18 - 21 °C, and the humidity is 80 - 85%RH.

[0033] Further, in S2, the air-cooling wind pressure of the blowing device is 4 - 5 mbar, and the wind speed is 0.25 - 0.7 m / s.

[0034] Further, in S3, the oiling rate of the oiling is 0.6 - 1.2%.

[0035] Further, in S3, the drawing is divided into primary drawing and secondary drawing.

[0036] Further, the temperature of the first-stage stretching is 80 - 90°C, and the stretching ratio of the first-stage stretching is 1.01 - 1.05.

[0037] Further, the temperature of the second-stage stretching is 170 - 190°C, and the stretching ratio of the second-stage stretching is 2.3 - 2.5.

[0038] Further, the temperature of the bulking in the air texturing machine in S4 is 170 - 190°C, and the nozzle pressure is 5 - 7 bar.

[0039] Further, the rotational speed of the cooling roller in S4 is 30 - 60 rpm, and the temperature of the cooling roller is 20 - 30°C.

[0040] Further, the gas pressure in the spinning networker in S4 is 4 - 8 bar.

[0041] Further, the number of knots in S4 is 28 - 30.

[0042] Further, the total crimp of the blended fiber bundle in S4 is 15 - 25%, the fineness is 1500 - 2000 D, and the number of holes is 90 - 110.

[0043] Further, the non-woven base fabric in Step 1 is a polyethylene terephthalate (PET) non-woven base fabric with a grammage of 90 - 140 gsm.

[0044] Further, the stitch density of the tufting machine in Step 1 is 1 / 10 or 5 / 64, the weft knitting density is 39.37 stitches / cm or 50.39 stitches / cm, and the warp knitting density is 50 - 60 stitches / cm.

[0045] Further, the wet glue grammage of the water-based foamed latex in Step 1 is 230 - 330 gsm, the wet latex solid content is 30 - 40%, and the foaming ratio is 2.0 - 3.0 times.

[0046] Further, the water-based foamed latex in Step 1 is an ethylene-vinyl acetate copolymer (EVA) water-based foamed latex.

[0047] Further, the coating speed in Step 1 is 4 - 5 m / min.

[0048] Further, the drying temperature in Step 1 is 130 - 140°C, and the drying time is 2.5 - 3 min.

[0049] Further, the grammage of the adhesive layer in Step 1 is 70 - 100 gsm.

[0050] Further, the binders in step 2 are all polyethylene with a grammage of 200 - 500 gsm.

[0051] Further, the grammage of the second anti-breakthrough layer in step 2 is 200 - 500 gsm, and the grammage of the reinforcing layer is 300 - 1000 gsm.

[0052] Further, the grammage of the first anti-breakthrough layer in step 2 is 200 - 500 gsm, and the grammage of the bottom layer is 80 - 200 gsm.

[0053] Further, the needle-punched base felt in step 2 is a polyethylene terephthalate (PET) needle-punched base felt.

[0054] Further, the non-woven base fabric in step 2 is a polyethylene terephthalate (PET) non-woven base fabric.

[0055] Further, the film laminating speed in step 2 is 3 - 4 m / min, and the film laminating temperature is 230 - 240 °C.

[0056] The present invention also provides an automotive floor mat, which is prepared from the multi-layer mixed-color fiber wear-resistant carpet.

[0057] Advantages of the present invention: 1. In the present invention, two screw extruders are used to melt and mix respectively to realize the synchronous preparation of dark and light fibers. Continuing, the metering pumps in the spinning box can accurately control the proportion of each component. The black masterbatch of the dark fibers and the white masterbatch of the light fibers are evenly dispersed in their respective screws. After being extruded through a trilobal spinneret, the fiber color consistency is high, meeting the stringent requirements of automotive interior for color uniformity. At the same time, the production efficiency of the fiber filaments is improved through the parallel process; in the present invention, a trilobal spinneret is used for spinning, which improves the friction and cohesion of the fibers, reduces the hair loss phenomenon during tufting, and improves the pulling force of the pile. The fiber filaments are spun and the fiber molecular chains are initially oriented through the first-stage stretching, and the crystallinity is further improved through the second-stage stretching, enhancing the bundling property of the fiber bundle and avoiding the loosening of the bulked fibers during winding; in addition, polyamide 6 in the present invention is spun under specific temperature and spinning conditions, simultaneously improving the mechanical properties such as the breaking strength of the fiber filaments. 2. In the carpet's layer structure, the blended fiber bundle in the present invention forms a high-density cut pile structure after tufting by a tufting machine. The bulking crimp structure of the blended fiber bundle can endow the pile layer with high resilience, making it not easy to collapse after long-term trampling, maintaining the appearance flatness, and also effectively resisting high-frequency friction from soles, sand and gravel, etc. The foamed latex in the adhesive layer is water-based latex, reducing the odor of the carpet. The anti-puncture layer II and the anti-puncture layer I are bonded by a film laminating process, which can resist the puncture of sharp objects, protect the base fabric from damage, and enhance the compounding of the reinforcing layer and the bottom layer, improving the interlayer shear strength, avoiding the hidden danger of delamination, and the reinforcing layer can also absorb tire noise. BRIEF DESCRIPTION OF THE DRAWINGS

[0058] Figure 1 It is a test chart of the wear resistance of the multi-layer blended fiber wear-resistant carpet described in Example 1; Figure 2 It is a state chart of the surface pile layer of the multi-layer blended fiber wear-resistant carpet described in Example 2 of the present embodiment; Figure 3 It is a detailed state chart of the surface pile layer of the multi-layer blended fiber wear-resistant carpet described in Example 2 of the present embodiment; Figure 4 It is a test chart of the glossiness of the tufted carpets described in Comparative Example 1 and Example 1; Figure 5 It is a flow chart of the dirt retention effect test of the wear-resistant carpets described in Comparative Example 2 and Example 1; Figure 6 It is an effect chart of the dirt retention of the wear-resistant carpets described in Comparative Example 2 and Example 1; Figure 7 It is a schematic structural diagram of the preparation system of the multi-layer blended fiber wear-resistant carpet described in the present invention; Figure 8 It is a schematic structural diagram of the spinning unit described in the present invention; Figure 9 It is a schematic structural diagram of the trilobal spinneret described in the present invention; Figure 10 It is a schematic structural diagram of the blended fiber bundle described in the present invention; Figure 11 It is a schematic diagram of the interlayer structure of the multi-layer blended fiber wear-resistant carpet described in the present invention; The names of each label in the figure are as follows: 1. Spinning unit; 2. Bulking unit; 3. Tufting unit; 4. Composite unit; 5. Screw extruder; 6. Spinning box; 7. Oil application device; 8. Drawing device; 9. Air texturing machine; 10. Cooling roller; 11. Spinning networker; 12. Winder; 13. Tufting machine; 14. Coating device; 15. Dryer; 16. Film laminating device; 501. Screw extruder 1; 502. Screw extruder 2; 601. Feed inlet; 602. Spinneret; 603. Channel; 604. Metering pump; 605. Blowing device; 801. Primary drawing guide roller; 802. Secondary drawing guide roller. Detailed implementation mode

[0059] The following is a detailed description of the invention in combination with embodiments: The present invention provides a multi-layer mixed-color fiber wear-resistant carpet and a preparation system, method and application thereof. By preparing a mixed-color fiber bundle, a high-performance wear-resistant multi-layer carpet is prepared, greatly improving its wear resistance, mechanical properties, aging resistance and the like.

[0060] Embodiment 1 This embodiment provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which is composed of a bottom layer, a first anti-penetration layer, a reinforcement layer, a second anti-penetration layer, an adhesive layer, a base cloth layer and a pile layer from bottom to top. The pile layer and the base cloth layer are prepared by tufting a mixed-color fiber bundle on a non-woven base cloth. The mixed-color fiber bundle is prepared by melting and mixing polyamide 6 with different-color masterbatches through a synchronously arranged screw extruder for spinning. The adhesive layer is compounded at the bottom of the base cloth layer by coating. A polyethylene-polyamide-polyethylene film and a needle-punched bottom felt are compounded at the bottom of the adhesive layer by means of film laminating adhesive to obtain the second anti-penetration layer and the reinforcement layer. Then, a polyethylene-polyamide-polyethylene film and a non-woven bottom cloth are compounded at the bottom of the reinforcement layer by means of film laminating adhesive to obtain the first anti-penetration layer and the bottom layer. The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 9 mm, the pile height is 3 mm, and the pile form is cut pile. The elongation at break of the multi-layer mixed-color fiber wear-resistant carpet in the machine direction (MD) at room temperature is 55%, and the elongation at break perpendicular to the machine direction (CD) at room temperature is 52%; the elongation at break in the machine direction (MD) at 130 °C is 115%, and the elongation at break perpendicular to the machine direction (CD) at 130 °C is 119%. The breaking strength of the multi-layer mixed-color fiber wear-resistant carpet in the machine direction (MD) at room temperature is 1082 N, and the breaking strength perpendicular to the machine direction (CD) at room temperature is 1112 N. The number of Taber abrasion resistance cycles of the multi-layer mixed-color fiber wear-resistant carpet is 3950 cycles without bottom leakage. After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220 °C for 120 s, the shrinkage rate in the machine direction (MD) is 0.5%, and the shrinkage rate perpendicular to the machine direction (CD) is 0%; The lightness (L) of the multi-layer mixed-color fiber wear-resistant carpet in the CIELab color space is 24.47, the color on the red-green axis (a) is -0.15, and the color on the yellow-blue axis (b) is -0.16; the gray level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is 4; The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is 1.3°, and it has good dirt resistance.

[0061] This embodiment also provides a preparation method for preparing the multi-layer mixed-color fiber wear-resistant carpet with the preparation system, including the following steps: S1. Set two screw extruders 5, namely screw extruder one 501 and screw extruder two 502. Add polyamide 6, black masterbatch, and spinning oil agent with a mass ratio of 97:2.5:0.5 into the screw extruder one 501 for melt mixing, and at the same time add polyamide 6, white masterbatch, and spinning oil agent with a mass ratio of 97:2.5:0.5 into the screw extruder two 502 for melt mixing; the processing temperature of the screw extruder one 501 and the screw extruder two 502 is 250-270 °C, which is divided into four temperature zones, where the temperature of the first temperature zone is 250 °C, the temperature of the second temperature zone is 265 °C, the temperature of the third temperature zone is 270 °C, and the temperature of the fourth temperature zone is 270 °C; S2. Respectively convey the molten materials in S1 to the spinning box 6 through different feeding ports 601, and both at a speed of 500 g / min by the metering pump 604, and respectively carry out spinning through the 50-hole dark three-lobed spinneret and the 50-hole light three-lobed spinneret in the spinning box 6 at 250 °C and 110 bar. After spinning, the fiber filaments respectively pass through the dark channel and the light channel vertically arranged below the spinning box 6 and are cooled by the blowing device 605 with cold air at 18 °C and 85% RH under the conditions of 5 mbar and 0.25 m / s to obtain solidified dark fiber filaments and light fiber filaments; S3. Respectively oil the dark fiber filaments and the light fiber filaments with the oiling device 7, and the oiling rate is 0.6%. Then, the oiled fiber filaments jointly pass through the first-stage stretching guide roller 801 for first-stage stretching. The temperature of the first-stage stretching guide roller 801 is 80 °C, and the stretching ratio is 1.01. Then, it passes through the second-stage stretching guide roller 802 for second-stage stretching. The temperature of the second-stage stretching guide roller 802 is 170 °C, and the stretching ratio is 2.3 to obtain stretched fiber filaments; S4. Place the drawn fiber filaments into an air texturing machine 9, and perform jet bulking at 170 °C and a nozzle pressure of 5 bar. The bulked fiber filaments are cooled by a cooling roller 10. The rotational speed of the cooling roller 10 is 30 rpm, and the temperature is 20 °C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning networker 11 through guide rollers for knotting. The number of knots is 28 ± 1. The gas pressure inside the spinning networker 11 is 4 bar. The bulked fiber after knotting is introduced into a winding machine 12 through guide rollers and wound into a cylindrical yarn bobbin to obtain a mixed-color fiber bundle; The total crimp of the mixed-color fiber bundle is 15%, the fineness is 1500 D, and the number of holes is 100; Step 1. Set up a 90 gsm polyethylene terephthalate (PET) non-woven base fabric. Tuft the mixed-color fiber bundle onto the non-woven base fabric through a tufting machine 13. Control the stitch density of the tufting machine 13 to be 1 / 10, the weft knitting density to be 39.37 stitches / cm, and the warp knitting density to be 50 stitches / cm to obtain a cut pile layer and a base fabric layer. Then continue to coat an ethylene-vinyl acetate copolymer (EVA) aqueous foaming latex (wet glue weight per unit area is 230 gsm, wet latex solid content is 40%, and foaming ratio is 2.0 times) on the bottom of the base fabric layer with a coating device 14 at a speed of 5 m / min, and place it in a dryer 15 to dry at 130 °C for 2.5 min to obtain a 70 gsm adhesive layer; Step 2. At the bottom of the adhesive layer, use a film laminating device 16 to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at 230 °C at a speed of 3 m / min, and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) needle-punched bottom felt. After cooling, a 200 gsm anti-puncture layer II and a 500 gsm reinforcing layer are obtained; continue to use the film laminating device 16 at the bottom of the reinforcing layer to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at 230 °C at a speed of 3 m / min, and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) non-woven bottom cloth. After cooling, a 200 gsm anti-puncture layer I and a 150 gsm bottom layer are obtained; finally, the multi-layer mixed-color fiber wear-resistant carpet is obtained.

[0062] As Figure 1 It is a wear resistance test chart of the multi-layer mixed-color fiber wear-resistant carpet described in Example 1. As can be seen from the figure, after the wear-resistant carpet of the present invention undergoes a wear resistance test, with the increase of weight loss, no bottom leakage phenomenon occurs, and the wear resistance is excellent.

[0063] Example 2 This embodiment provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a first anti-penetration layer, a reinforcement layer, a second anti-penetration layer, an adhesive layer, a base cloth layer and a pile layer. The pile layer and the base cloth layer are prepared by tufting mixed-color fiber bundles on a non-woven base cloth. The mixed-color fiber bundles are prepared by melt spinning of polyamide 6 mixed with different-color masterbatches through a synchronously set screw extruder; The adhesive layer is compounded at the bottom of the base cloth layer by coating. A polyethylene-polyamide-polyethylene film and a needled bottom felt are compounded at the bottom of the adhesive layer by means of a film laminating binder to obtain the second anti-penetration layer and the reinforcement layer. Then, a polyethylene-polyamide-polyethylene film and a non-woven bottom cloth are compounded at the bottom of the reinforcement layer by means of a film laminating binder to obtain the first anti-penetration layer and the bottom layer; The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 8 mm, the pile height is 5 mm, and the shape of the pile is cut pile; The elongation at break in the machine direction (MD) of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is 58%, and the elongation at break perpendicular to the machine direction (CD) at room temperature is 51%; the elongation at break in the machine direction (MD) at 130 °C is 120%, and the elongation at break perpendicular to the machine direction (CD) at 130 °C is 123%; The breaking strength of the multi-layer mixed-color fiber wear-resistant carpet in the machine direction (MD) at room temperature is 1039 N, and the breaking strength perpendicular to the machine direction (CD) at room temperature is 1098 N; The number of Taber abrasion cycles of the multi-layer mixed-color fiber wear-resistant carpet is 4000 cycles without bottom leakage; After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220 °C for 120 s, the shrinkage rate in the machine direction (MD) is 0.3%, and the shrinkage rate perpendicular to the machine direction (CD) is 0.2%; The lightness (L) of the multi-layer mixed-color fiber wear-resistant carpet in the CIELab color space is 24.48, the red-green axis color (a) is -0.14, and the yellow-blue axis color (b) is -0.17; the gray level of the pile surface appearance of the multi-layer mixed-color fiber wear-resistant carpet is 4; The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is 1.4°, and it has good soil resistance.

[0064] This embodiment also provides a preparation method for preparing the multi-layer mixed-color fiber wear-resistant carpet with the preparation system, including the following steps: S1. Set up two screw extruders 5, namely screw extruder 1 501 and screw extruder 2 502. Add polyamide 6, masterbatch black, and spinning finish in a mass ratio of 97:2:1 into the screw extruder 1 501 for melt mixing. At the same time, add polyamide 6, masterbatch white, and spinning finish in a mass ratio of 97:2:1 into the screw extruder 2 502 for melt mixing. The processing temperature of the screw extruder 1 501 and the screw extruder 2 502 is 250 - 280 °C, which is divided into four temperature zones. The temperature of the first temperature zone is 250 °C, the temperature of the second temperature zone is 270 °C, the temperature of the third temperature zone is 280 °C, and the temperature of the fourth temperature zone is 260 °C. S2. Convey the molten materials in S1 to the spinning box 6 through different feed ports 601 respectively, and both at a speed of 500 g / min by the metering pump 604, and carry out spinning through the 45-hole dark three-lobed spinneret and the 45-hole light three-lobed spinneret in the spinning box 6 respectively at 270 °C and 60 bar. After spinning, the fiber filaments respectively pass through the dark duct and the light duct vertically arranged below the spinning box 6 and are cooled by the blowing device 605 with cold air at 4 mbar and 0.5 m / s under the conditions of 21 °C and 80% RH to obtain solidified dark fiber filaments and light fiber filaments. S3. Oil the dark fiber filaments and the light fiber filaments respectively with the oiling device 7, and the oiling rate is 1%. Then, the oiled fiber filaments are jointly stretched by the first-stage stretching roller 801. The temperature of the first-stage stretching roller 801 is 90 °C, and the stretching ratio is 1.03. Then, it passes through the second-stage stretching roller 802 for secondary stretching. The temperature of the second-stage stretching roller 802 is 190 °C, and the stretching ratio is 2.5 to obtain stretched fiber filaments. S4. Put the stretched fiber filaments into the air texturing machine 9 and carry out jet bulking at 180 °C and a nozzle pressure of 5 bar. The bulked fiber filaments are cooled by the cooling roller 10. The rotation speed of the cooling roller 10 is 30 rpm, and the temperature is 25 °C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into the spinning networker 11 through the guide roller for knotting, and the number of knots is 28 ± 1. The gas pressure in the spinning networker 11 is 6 bar. The bulked fiber after knotting is introduced into the winding machine 12 through the guide roller and wound into a cylindrical yarn bobbin to obtain a mixed-color fiber bundle. The total crimp of the mixed-color fiber bundle is 17%, the fineness is 1800 D, and the number of holes is 90. Step 1: Set up a 140 gsm polyethylene terephthalate non-woven base fabric. Tuft the mixed fiber bundle onto the non-woven base fabric through a tufting machine 13. Control the stitch density of the tufting machine 13 to be 5 / 64, the weft knitting density to be 50.39 stitches / cm, and the warp knitting density to be 55 stitches / cm to obtain a cut-pile surface layer and a base fabric layer. Then, continue to coat the bottom of the base fabric layer with ethylene-vinyl acetate copolymer water-based foaming latex (wet glue weight: 250 gsm, wet latex solid content: 30%, foaming ratio: 3.0 times) using a coating device 14 at a speed of 4 m / min, and place it in a dryer 15 to dry at 140°C for 2.5 min to obtain a 90 gsm adhesive layer; Step 2: At the bottom of the adhesive layer, use a film laminating device 16 to laminate a 300 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at 240°C at a speed of 3 m / min, and then continue to laminate a 300 gsm polyethylene-bonded polyethylene terephthalate (PET) needle-punched bottom felt. After cooling, obtain a 300 gsm anti-breakthrough layer two and a 300 gsm reinforcement layer. Then, continue to use the film laminating device 16 to laminate a 300 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcement layer at 240°C at a speed of 3 m / min, and then continue to laminate a 300 gsm polyethylene-bonded polyethylene terephthalate (PET) non-woven bottom cloth. After cooling, obtain a 300 gsm anti-breakthrough layer one and a 100 gsm bottom layer. Finally, obtain the multi-layer mixed fiber wear-resistant carpet.

[0065] As Figure 2 This is the state diagram of the surface pile layer of the multi-layer mixed fiber wear-resistant carpet in this embodiment. In the figure, the arrangement of the pile layer is regular and the color is uniform.

[0066] As Figure 3 This is the detailed state diagram of the surface pile layer of the multi-layer mixed fiber wear-resistant carpet in Embodiment 2. In the figure, the colors of the pile layer are in sharp contrast.

[0067] Embodiment 3 This embodiment provides a multi-layer mixed fiber wear-resistant carpet. The multi-layer mixed fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, an anti-breakthrough layer one, a reinforcement layer, an anti-breakthrough layer two, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed fiber bundles onto a non-woven base fabric. The mixed fiber bundles are prepared by melt mixing and spinning polyamide 6 with different color masterbatches through a synchronously set screw extruder. The adhesive layer is compounded at the bottom of the base fabric layer by coating. The polyethylene-polyamide-polyethylene film and the needle-punched bottom felt are compounded at the bottom of the adhesive layer by pouring adhesive, obtaining the second anti-penetration layer and the reinforcing layer. Then, the polyethylene-polyamide-polyethylene film and the non-woven bottom cloth are compounded at the bottom of the reinforcing layer by pouring adhesive, obtaining the first anti-penetration layer and the bottom layer; The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 12 mm, the pile height is 8 mm, and the pile head form is cut pile; The elongation at break in the machine direction (MD) of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is 59%, and the elongation at break perpendicular to the machine direction (CD) at room temperature is 52%; the elongation at break in the machine direction (MD) at 130 °C is 121%, and the elongation at break perpendicular to the machine direction (CD) at 130 °C is 115%; The breaking strength in the machine direction (MD) of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is 1104 N, and the breaking strength perpendicular to the machine direction (CD) at room temperature is 1116 N; The number of Taber abrasion resistance cycles of the multi-layer mixed-color fiber wear-resistant carpet is 3955 cycles without showing the bottom layer; After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220 °C for 120 s, the shrinkage rate in the machine direction (MD) is 0.5%, and the shrinkage rate perpendicular to the machine direction (CD) is 0.4%; The lightness (L) in the CIELab color space of the multi-layer mixed-color fiber wear-resistant carpet is 24.46, the red-green axis color (a) is -0.15, and the yellow-blue axis color (b) is -0.17; the gray scale level of the pile surface appearance of the multi-layer mixed-color fiber wear-resistant carpet is 4; The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is 1.3°, and it has good soil hiding property.

[0068] This embodiment also provides a preparation method for preparing the multi-layer mixed-color fiber wear-resistant carpet with the preparation system, including the following steps: S1. Set two screw extruders 5, namely screw extruder one 501 and screw extruder two 502. Add polyamide 6, black masterbatch, and spinning oil agent with a mass ratio of 95:4:1 into the screw extruder one 501 for melting and mixing. At the same time, add polyamide 6, white masterbatch, and spinning oil agent with a mass ratio of 95:4:1 into the screw extruder two 502 for melting and mixing; the processing temperature of the screw extruder one 501 and the screw extruder two 502 is 250 - 270 °C, which is divided into four temperature zones, where the temperature of the first temperature zone is 250 °C, the temperature of the second temperature zone is 265 °C, the temperature of the third temperature zone is 270 °C, and the temperature of the fourth temperature zone is 270 °C; S2. Feed the molten materials in S1 into the spinning box 6 through different feed ports 601 respectively, at a speed of 400 g / min by the metering pump 604, and carry out spinning through the 55-hole dark three-lobed spinneret plate and the 55-hole light three-lobed spinneret plate in the spinning box 6 respectively at 260 °C and 80 bar. After spinning, the fiber filaments pass through the dark duct and the light duct vertically arranged below the spinning box 6 respectively, and are cooled by the blowing device 605 with cold air at 20 °C and 85% RH under the conditions of 5 mbar and 0.7 m / s respectively to obtain solidified dark fiber filaments and light fiber filaments; S3. Oil the dark fiber filaments and the light fiber filaments respectively with the oiling device 7, and the oiling rate is 1.2%. Then, the oiled fiber filaments are stretched together through the primary stretching roller 801. The temperature of the primary stretching roller 801 is 85 °C, and the stretching ratio is 1.05. Then, it passes through the secondary stretching roller 802 for secondary stretching. The temperature of the secondary stretching roller 802 is 180 °C, and the stretching ratio is 2.4 to obtain stretched fiber filaments; S4. Put the stretched fiber filaments into the air texturing machine 9 and carry out jet bulking at 190 °C and a nozzle pressure of 7 bar. The bulked fiber filaments are cooled by the cooling roller 10. The rotation speed of the cooling roller 10 is 60 rpm, and the temperature is 30 °C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into the spinning networker 11 through the guide roller for knotting, and the number of knots is 29 ± 1. The gas pressure in the spinning networker 11 is 8 bar. The bulked fiber filaments after knotting are introduced into the winding machine 12 through the guide roller and wound into a cylindrical yarn bobbin to obtain a mixed-color fiber bundle; The total crimp of the mixed-color fiber bundle is 25%, the fineness is 2000 D, and the number of holes is 110; Step 1. Set up a 110 gsm polyethylene terephthalate non-woven base fabric, and tuft the mixed-color fiber bundle onto the non-woven base fabric through the tufting machine 13. Control the stitch density of the tufting machine 13 to be 5 / 64, the weft knitting density to be 50.39 stitches / cm, and the warp knitting density to be 60 stitches / cm to obtain a cut-pile pile layer and a base fabric layer. Then, continue to coat the bottom of the base fabric layer with ethylene-vinyl acetate copolymer water-based foaming latex (wet glue weight is 330 gsm, wet latex solid content is 30%, and foaming ratio is 3.0 times) by the coating device 14 at a speed of 4 m / min, and put it into the dryer 15 to be dried at 140 °C for 3 min to obtain a 100 gsm adhesive layer; Step 2: At the bottom of the bonding layer, use a film laminating device 16 to laminate a polyethylene-polyamide-polyethylene film (PEPAPE) with a weight of 400 gsm polyethylene at a speed of 3 m / min at 235°C, and then continue to laminate a polyethylene-bonded polyethylene terephthalate (PET) needle punched base fabric with a weight of 400 gsm. After cooling, a puncture-proof layer two with a weight of 200 gsm and a reinforcing layer with a weight of 1000 gsm are obtained; continue to use the film laminating device 16 at the bottom of the reinforcing layer to laminate a polyethylene-polyamide-polyethylene film (PEPAPE) with a weight of 400 gsm polyethylene at a speed of 4 m / min at 240°C, and then continue to laminate a polyethylene-bonded polyethylene terephthalate (PET) non-woven base fabric with a weight of 400 gsm. After cooling, a puncture-proof layer one with a weight of 300 gsm and a bottom layer with a weight of 80 gsm are obtained; finally, the multi-layer mixed-color fiber wear-resistant carpet is obtained.

[0069] Example 4 This example provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a puncture-proof layer one, a reinforcing layer, a puncture-proof layer two, a bonding layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting a mixed-color fiber bundle on a non-woven base fabric. The mixed-color fiber bundle is prepared by melt spinning of polyamide 6 mixed with different color masterbatches through a synchronously arranged screw extruder. The bonding layer is compounded at the bottom of the base fabric layer by coating. The polyethylene-polyamide-polyethylene film and the needle punched base fabric are compounded at the bottom of the bonding layer by film laminating the binder to obtain the puncture-proof layer two and the reinforcing layer. Then, continue to compound the polyethylene-polyamide-polyethylene film and the non-woven base fabric at the bottom of the reinforcing layer by film laminating the binder to obtain the puncture-proof layer one and the bottom layer. The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 10 mm, the pile height is 8 mm, and the pile form is cut pile. The elongation at break in the machine direction (MD) of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is 56%, and the elongation at break perpendicular to the machine direction (CD) at room temperature is 55%; the elongation at break in the machine direction (MD) at 130°C is 117%, and the elongation at break perpendicular to the machine direction (CD) at 130°C is 120%. The breaking strength in the machine direction (MD) of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is 1103 N, and the breaking strength perpendicular to the machine direction (CD) at room temperature is 1072 N. The number of cycles of Taber abrasion of the multi-layer mixed-color fiber wear-resistant carpet is 3900 cycles without bottom leakage. After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220°C for 120 s, the shrinkage rate in the machine direction (MD) is 0.1%, and the shrinkage rate perpendicular to the machine direction (CD) is 0%. The lightness (L) in the CIELab color space of the multi-layer mixed-color fiber wear-resistant carpet is 24.37, the color on the red-green axis (a) is -0.14, and the color on the yellow-blue axis (b) is -0.16; the gray scale level of the surface appearance of the multi-layer mixed-color fiber wear-resistant carpet is 4; The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is 1.5°, and it has good dirt resistance.

[0070] This embodiment also provides a preparation method for preparing the multi-layer mixed-color fiber wear-resistant carpet with the preparation system, including the following steps: S1. Set two screw extruders 5, namely screw extruder 1 501 and screw extruder 2 502. Add polyamide 6, black masterbatch and spinning oil agent with a mass ratio of 97:2.5:0.5 to the screw extruder 1 501 for melting and mixing. At the same time, add polyamide 6, white masterbatch and spinning oil agent with a mass ratio of 97:2.5:0.5 to the screw extruder 2 502 for melting and mixing; the processing temperature of the screw extruder 1 501 and the screw extruder 2 502 is 250 - 270°C, which is divided into four temperature zones, where the temperature of the first temperature zone is 250°C, the temperature of the second temperature zone is 265°C, the temperature of the third temperature zone is 270°C, and the temperature of the fourth temperature zone is 270°C; S2. Respectively convey the molten materials in S1 to the spinning box 6 through different feed ports 601, and both at a speed of 500 g / min by the metering pump 604, and respectively carry out spinning through the 50-hole dark three-lobed spinneret and the 50-hole light three-lobed spinneret in the spinning box 6 at 250°C and 110 bar. After spinning, the fiber filaments respectively pass through the dark channel and the light channel vertically arranged below the spinning box 6, and are respectively cooled by the blowing device 605 with cold air at 1 mbar and 0.3 m / s under the conditions of 18°C and 85% RH to obtain solidified dark fiber filaments and light fiber filaments; S3. Respectively oil the dark fiber filaments and the light fiber filaments with the oiling device 7, and the oiling rate is 0.8%. Then, the oiled fiber filaments jointly pass through the first-stage stretching guide roller 801 for first-stage stretching. The temperature of the first-stage stretching guide roller 801 is 80°C, and the stretching ratio is 1.01. Then, pass through the second-stage stretching guide roller 802 for second-stage stretching. The temperature of the second-stage stretching guide roller 802 is 170°C, and the stretching ratio is 2.4 to obtain stretched fiber filaments; S4. Place the drawn fiber filaments into an air texturing machine 9, and perform jet bulking at 190°C and a nozzle pressure of 5 bar. The bulked fiber filaments are cooled by a cooling roller 10 with a rotation speed of 50 rpm and a temperature of 20°C. After cooling, bulked fiber filaments are obtained. Introduce the bulked fiber filaments through a guide roller into a spinning networker 11 for knotting, and the number of knots is 30 ± 1. The gas pressure inside the spinning networker 11 is 4 bar. Introduce the bulked fiber after knotting through a guide roller into a winding machine 12 and wind it into a cylindrical yarn bobbin to obtain a mixed-color fiber bundle; The total crimp of the mixed-color fiber bundle is 20%, the fineness is 1800 D, and the number of holes is 100; Step 1. Set up a 90 gsm polyethylene terephthalate non-woven base fabric. Tuft the mixed-color fiber bundle onto the non-woven base fabric through a tufting machine 13. Control the stitch density of the tufting machine 13 to be 1 / 10, the weft knitting density to be 39.37 stitches / cm, and the warp knitting density to be 50 stitches / cm to obtain a cut-pile pile layer and a base fabric layer. Then continue to coat the bottom of the base fabric layer with ethylene-vinyl acetate copolymer water-based foaming latex (wet glue weight is 300 gsm, wet latex solid content is 40%, and foaming ratio is 2.0 times) using a coating device 14 at a speed of 5 m / min, and place it in a dryer 15 to dry at 130°C for 2.5 min to obtain a 100 gsm adhesive layer; Step 2. At the bottom of the adhesive layer, at a speed of 4 m / min, at 230°C, use a film laminating device 16 to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE), and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) needle-punched bottom felt. After cooling, obtain a 300 gsm anti-penetration layer two and a 700 gsm reinforcement layer. Then continue to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at the bottom of the reinforcement layer at a speed of 4 m / min at 240°C using a film laminating device 16, and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) non-woven bottom cloth. After cooling, obtain a 300 gsm anti-penetration layer one and a 200 gsm bottom layer. Finally, obtain the multi-layer mixed-color fiber wear-resistant carpet.

[0071] Comparative Example 1 This comparative example provides a commercially available ordinary tufted carpet, which is a conventional PA6 suede flat carpet produced by Shandong Kuntai.

[0072] As Figure 4This is the glossiness test chart of the carpets described in Comparative Example 1 and Example 1. As can be seen from the figure, the glossiness of the tufted carpet in Comparative Example 1 is 4.6°, while the glossiness of the carpet in Example 1 is 1.3°. The low glossiness makes the carpet surface closer to a matte texture, reducing the specular reflection of the carpet. At the same time, the diffuse reflection characteristics of the low-gloss carpet also weaken the stains and wear on the surface.

[0073] Comparative Example 2 This comparative example provides a multi-layer black fiber wear-resistant carpet. The multi-layer black fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a first anti-penetration layer, a reinforcement layer, a second anti-penetration layer, an adhesive layer, a base fabric layer, and a pile layer respectively; The thickness of the multi-layer black fiber wear-resistant carpet is 8 mm, the pile height is 3 mm, and the shape of the pile is cut pile; The multi-layer black fiber wear-resistant carpet has poor dirt retention.

[0074] This comparative example also provides a preparation method of the multi-layer black fiber wear-resistant carpet, including the following steps: Step 1: Add polyamide 6, black masterbatch, and spinning oil agent with a mass ratio of 97:2.5:0.5 into a screw extruder press for melt mixing. The processing temperature of the screw extruder is 250 - 270 °C, which is divided into four temperature zones. The temperature of the first temperature zone is 250 °C, the temperature of the second temperature zone is 265 °C, the temperature of the third temperature zone is 270 °C, and the temperature of the fourth temperature zone is 270 °C; Step 2: Convey the molten material in Step 1 to the spinning box through the feed port, and spin at a speed of 500 g / min by a metering pump through a 100-hole trilobal spinneret in the spinning box at 250 °C and 110 bar. After spinning, the fiber filaments pass through a vertical channel below the spinning box and are cooled by a blowing device with cold air at 18 °C and 85% RH under the conditions of 5 mbar and 0.25 m / s to obtain solidified black fiber filaments; Step 3: Oil the black fiber filaments with an oiling device 7, and the oiling rate is 0.6%. Then, the oiled fiber filaments are subjected to primary stretching through a primary stretching guide roller 801. The temperature of the primary stretching guide roller 801 is 80 °C, and the stretching ratio is 1.01. Then, it passes through a secondary stretching guide roller 802 for secondary stretching. The temperature of the secondary stretching guide roller 802 is 170 °C, and the stretching ratio is 2.3 to obtain stretched fiber filaments; Step 4: Put the drawn fiber filaments into an air texturing machine 9, and perform jet bulking at 170°C and a nozzle pressure of 5 bar. The bulked fiber filaments are cooled by a cooling roller 10. The rotational speed of the cooling roller 10 is 30 rpm, and the temperature is 20°C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning networker 11 through a guide roller for knotting. The number of knots is 28 ± 1. The gas pressure inside the spinning networker 11 is 4 bar. The bulked fiber after knotting is introduced into a winding machine 12 through a guide roller and wound into a cylindrical yarn bobbin to obtain a fiber bundle; The total crimp of the fiber bundle is 15%, the fineness is 1500 D, and the number of holes is 100; Step 5: Set up a 90 gsm polyethylene terephthalate (PET) non-woven base fabric. The fiber bundle is tufted onto the non-woven base fabric by a tufting machine 13. Control the stitch density of the tufting machine 13 to be 1 / 10, the weft knitting density to be 39.37 stitches / cm, and the warp knitting density to be 50 stitches / cm to obtain a cut pile layer and a base fabric layer. Then, continue to coat an ethylene-vinyl acetate copolymer (EVA) water-based foaming latex (wet glue weight is 230 gsm, wet latex solid content is 40%, and foaming ratio is 2.0 times) on the bottom of the base fabric layer at a speed of 5 m / min using a coating device 14, and put it into a dryer 15 to be dried at 130°C for 2.5 min to obtain a 70 gsm bonding layer; Step 6: At the bottom of the bonding layer, at a speed of 3 m / min, use a film laminating device 16 to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene film (PEPAPE) at 230°C, and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) needle-punched bottom felt. After cooling, a 200 gsm anti-puncture layer II and a 500 gsm reinforcing layer are obtained; continue to use the film laminating device 16 at the bottom of the reinforcing layer at a speed of 3 m / min to laminate a 200 gsm polyethylene-bonded polyethylene-polyamide-polyethylene (PEPAPE) at 230°C, and then continue to laminate a 200 gsm polyethylene-bonded polyethylene terephthalate (PET) non-woven bottom cloth. After cooling, a 200 gsm anti-puncture layer I and a 150 gsm bottom layer are obtained; finally, the multi-layer black fiber wear-resistant carpet is obtained.

[0075] As Figure 5 This is the flowchart for testing the soil hiding effect of the wear-resistant carpets in Comparative Example 2 and Example 1; As Figure 6 This is the soil hiding effect diagram of the wear-resistant carpets in Comparative Example 2 and Example 1. It can be seen from the figure that after the soil hiding experiment as shown, no obvious stains and dust can be observed on the surface, and the soil hiding property is good.

[0076] Comparative Example 3 This comparative example provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a first anti-puncture layer, a reinforcement layer, a second anti-puncture layer, an adhesive layer, a base fabric layer, and a pile layer; The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 9 mm, the pile height is 3 mm, and the pile form is cut pile; The elongation at break of the multi-layer mixed-color fiber wear-resistant carpet in the machine direction (MD) at room temperature is 74%, and the elongation at break perpendicular to the machine direction (CD) at room temperature is 70%; the elongation at break in the machine direction (MD) at 130 °C is 128%, and the elongation at break perpendicular to the machine direction (CD) at 130 °C is 127%; The breaking strength of the multi-layer mixed-color fiber wear-resistant carpet in the machine direction (MD) at room temperature is 802 N, and the breaking strength perpendicular to the machine direction (CD) at room temperature is 740 N; The number of Taber abrasion cycles of the multi-layer mixed-color fiber wear-resistant carpet is 3,670 cycles without bottom leakage; After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220 °C for 120 s, the shrinkage rate in the machine direction (MD) is 0.7%, and the shrinkage rate perpendicular to the machine direction (CD) is 0.5%; The gray scale grade of the pile surface appearance of the multi-layer mixed-color fiber wear-resistant carpet is 4; The gloss of the multi-layer mixed-color fiber wear-resistant carpet is 1.8°.

[0077] In this comparative example, the preparation method of the multi-layer mixed-color fiber wear-resistant carpet is the same as that in Example 1. The difference is that the processing temperature of the first twin-screw extruder press and the second twin-screw extruder press in this comparative example is 290 - 330 °C, which is divided into four temperature zones, where the temperature of the first temperature zone is 290 °C, the temperature of the second temperature zone is 320 °C, the temperature of the third temperature zone is 330 °C, and the temperature of the fourth temperature zone is 300 °C.

[0078] Comparative Example 4 This comparative example provides a multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a first anti-puncture layer, a reinforcement layer, a second anti-puncture layer, an adhesive layer, a base fabric layer, and a pile layer; The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 9 mm, the pile height is 3 mm, and the pile form is cut pile.

[0079] In this comparative example, the preparation method of the multi-layer mixed-color fiber wear-resistant carpet is the same as that in Example 1. The difference is that the puffing temperature of the fiber filaments in this comparative example is 230 °C.

[0080] The total crimp of the mixed-color fiber bundle in this comparative example is 19%, resulting in obvious stripes in the finally prepared carpet.

[0081] In this embodiment, the spinning finish is a lipid mixed spinning finish, and its components include fatty acid glyceride, potassium alkyl phosphate, and polyethylene glycol. In addition, the spinning finish is not limited, and commercially available lipid polyamide spinning finishes can all be used.

[0082] The preparation system used in this embodiment and the comparative example includes a spinning unit 1, a texturing unit 2, a tufting unit 3, and a composite unit 4 according to the processing direction of the materials. The spinning unit 1 includes a screw extruder 5, a spinning box 6, an oiling device 7, and a stretching device 8. The texturing unit 2 includes an air texturing machine 9, a cooling roller 10, a spinning networker 11, and a winding machine 12. The tufting unit 3 includes a tufting machine 13. The composite unit 4 includes a coating device 14, a dryer 15, and a film laminating device 16. A feed inlet 601 is provided above the spinning box 6, and the molten material in the screw extruder 5 enters the spinning box 6 through the feed inlet 601 of the spinning box 6. A spinneret plate 602 is provided in the spinning box 6, and the spinneret plate 602 is a three-lobed spinneret plate. A metering pump 604 is installed at the spinneret plate 602 to quantify the material for spinning, and the speeds of the metering pumps 604 are the same. A blowing device 605 is installed on the side of the spinning box 6, and a duct 603 is vertically provided below. An air inlet is provided on the duct 603, and the blowing device 605 cools the spun fiber filaments through the air inlet. The numbers of the feed inlet 601, the spinneret plate 602, and the duct 603 of the spinning box 6 are 2. The materials in the screw extruder 5 enter different feed inlets 601 respectively, and are spun and air-cooled through different spinneret plates 602 and ducts 603. The screw extruder 5 includes a first screw extruder 501 and a second screw extruder 502, and the screw extruder 5 is a single-screw extruder. The stretching device 8 includes a primary stretching guide roller 801 and a secondary stretching guide roller 802. A nozzle is provided on the air texturing machine 9, and low-pressure air is blown on the fiber through the nozzle. A guide roller is installed between the spinning networker 11 and the cooling roller 10, and the guide roller is used to convey the fiber filaments. A guide roller is installed between the winding machine 12 and the spinning networker 11, and the guide roller is used to convey the fiber filaments.

[0083] In the present invention, the mixed-color fiber bundle has a two-color filament structure, and the number of holes thereof corresponds to the number of holes in the spinneret plate, which is the number of holes in the spinneret plate * 2.

[0084] Table 1 shows the performance of the carpets described in this embodiment and the comparative example.

[0085] Table 2 shows the CIELab color space data of the multi-layer mixed-color fiber wear-resistant carpet described in this embodiment.

[0086] As shown in Table 1 and Table 2, the multi-layer mixed-color fiber wear-resistant carpet described in the present invention has good mechanical properties, high wear resistance, low gloss, and small color difference, meeting the use requirements of high-quality carpets.

[0087] The test standard for the elongation at break of the multi-layer mixed-color fiber wear-resistant carpet described in the present invention at room temperature is "ISO13934-1", and the test equipment is a tensile machine; The test standard for the elongation at break of the multi-layer mixed-color fiber wear-resistant carpet at 130 °C is "ISO 13934-1", and the test equipment is a hot tensile machine; The test standard for the breaking strength of the multi-layer mixed-color fiber wear-resistant carpet at room temperature is "ISO 13934-1", and the test equipment is a tensile machine; The test standard for the Taber abrasion resistance of the multi-layer mixed-color fiber wear-resistant carpet is "ISO 5470-1", the test equipment is a Taber abrasion instrument, and the test method is to polish with a H18 grinding wheel under a 1000 g load using the Taber abrasion instrument; The gray scale level of the multi-layer mixed-color fiber wear-resistant carpet is tested by comparing with a GB250 gray scale card. There are a total of 5 levels and 9 grades for the gray scale card; they are 1, 2, 3, 4, and 5 levels respectively, where level 5 is the highest and level 1 is the lowest, and intermediate half levels can be evaluated; the test standard for the gloss of the multi-layer mixed-color fiber wear-resistant carpet is "ISO 2813", and the test method refers to "DIN-67530".

[0088] The present invention Figure 9 The number of holes in the spinneret plate shown in the figure is only a schematic diagram, and the number of holes in the figure does not represent the actual number of holes.

[0089] Based on the above, the multi-layer mixed-color fiber wear-resistant carpet described in the present invention has a very wide range of applications, low cost, and extremely high market prospects.

[0090] The above description is only a preferred embodiment of the present invention, and does not limit the present invention in any other form. Any modification or equivalent change made based on the technical essence of the present invention still falls within the scope of protection required by the present invention.

Claims

1. A multi-layered mixed-color fiber wear-resistant carpet, characterized in that, The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which from bottom to top are a bottom layer, a first anti-penetration layer, a reinforcement layer, a second anti-penetration layer, an adhesive layer, a base cloth layer and a pile layer. The pile layer and the base cloth layer are prepared by tufting a mixed-color fiber bundle on a non-woven base cloth. The mixed-color fiber bundle is prepared by melt mixing and spinning polyamide 6 with different color masterbatches through a synchronously set screw extruder. The thickness of the multi-layer mixed-color fiber wear-resistant carpet is 8 - 15 mm, the pile height is 3 - 8 mm, and the shape of the pile is cut pile. The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 50 - 60% at room temperature, an elongation at break of 115 - 123% at 130 °C, a breaking strength of 1030 - 1120 N at room temperature, the number of Taber abrasion resistance cycles is 3900 - 4000 cycles without bottom leakage, the glossiness ≤ 1.5°, the gray scale level ≥ 4 levels, and good soil hiding property. The multi-layer mixed-color fiber wear-resistant carpet has a shrinkage rate of 0 - 0.5% after being placed at 220 °C for 120 s. The color difference in the color space of the multi-layer mixed-color fiber wear-resistant carpet is that the lightness color difference ≤ 0.5, the red-green axis color difference ≤ 0.1, and the yellow-blue axis color difference ≤ 0.

1.

2. A preparation system for the multi-layer mixed-color fiber wear-resistant carpet according to claim 1, characterized in that, According to the processing direction of the materials, the preparation system includes a spinning unit (1), an inflation unit (2), a tufting unit (3) and a composite unit (4). The spinning unit (1) includes a screw extruder (5), a spinning box (6), an oiling device (7) and a stretching device (8). The inflation unit (2) includes an air texturing machine (9), a cooling roller (10), a spinning networker (11) and a winding machine (12). The tufting unit (3) includes a tufting machine (13). The composite unit (4) includes a coating device (14), a dryer (15) and a film laminating device (16). The number of the screw extruders (5) ≥ 2. A spinneret plate (602) and a channel (603) are arranged in the spinning box (6), and the spinneret plate (602) is a three-lobed spinneret plate. The number of the feed inlet (601) of the spinning box (6), the spinneret plate (602) and the channel (603) is the same as the number of the screw extruders (5). The materials in the screw extruders (5) respectively enter different feed inlets (601), and are spun and air-cooled through different spinneret plates (602) and channels (603).

3. The preparation system according to claim 2, characterized in that, When the number of the screw extruders (5) is 2, it includes a first screw extruder (501) and a second screw extruder (502).

4. The preparation system according to claim 2, characterized in that, A metering pump (604) is installed at the spinneret plate (602) to quantify the spinning materials, and the speeds of the metering pumps (604) are the same.

5. The preparation system according to claim 2, wherein The stretching device (8) includes a first-stage stretching guide roller (801) and a second-stage stretching guide roller (802).

6. A method for preparing the multi-layer color-mixed fiber wear-resistant carpet according to claim 1 by using the preparation system according to any one of claims 2-5, characterized in that, It includes the following steps: Step 1: Set a non-woven base cloth, tuft the mixed-color fiber bundle onto the non-woven base cloth through a tufting machine (13) to obtain a cut pile layer and a base cloth layer, and then continue to coat the bottom of the base cloth layer with aqueous foaming latex, and obtain an adhesive layer after drying. Step 2: Apply a binder by curtain coating at the bottom of the adhesive layer to bond a polyethylene-polyamide-polyethylene film, then continue to apply the binder by curtain coating to bond the needle punched base fabric, and after cooling, obtain the second anti-penetration layer and the reinforcement layer; continue to apply a binder by curtain coating at the bottom of the reinforcement layer to bond a polyethylene-polyamide-polyethylene film, then continue to apply the binder by curtain coating to bond the non-woven base fabric, and after cooling, obtain the first anti-penetration layer and the bottom layer; finally, obtain the multi-layer mixed-color fiber wear-resistant carpet.

7. The preparation method according to claim 6, characterized in that, In step 1, the stitch density of the tufting machine (13) is 1 / 10 or 5 / 64, the weft knitting density is 39.37 stitches / cm or 50.39 stitches / cm, and the warp knitting density is 50 - 60 stitches / cm.

8. The preparation method according to claim 6, characterized in that, In step 1, the drying temperature is 130 - 140 °C, and the drying time is 2.5 - 3 min.

9. The preparation method according to claim 6, characterized in that, In step 2, the curtain coating speed is 3 - 4 m / min, and the curtain coating temperature is 230 - 240 °C.

10. An automotive floor mat, characterized in that, The automotive floor mat is prepared from the multi-layer mixed-color fiber wear-resistant carpet according to claim 1.

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