High-performance carpet and preparation process thereof

Abstract

The invention belongs to the field of carpets, and discloses a high-performance carpet and a preparation process thereof.The high-performance carpet is prepared through the comprehensive process modes of fiber material mixing and twisting, annular weaving, heat setting and stretching, silver ion antibacterial treatment and the like by reasonably selecting the proportion of polyester fibers, spandex fibers, wool bundles and conductive fibers, the fabric density and the fiber spacing are optimized, and the high-performance carpet is obtained. The carpet has the advantages that by matching with mechanical and airflow stretching treatment, the best balance of high elasticity and high fluff effect of the carpet is achieved, so that the carpet has excellent elasticity recovery capability, can quickly recover form, is rich in fluff on the surface and soft in touch, and further overcomes the defects of traditional carpets in elasticity and comfort; and high fluff feeling and high anti-fouling and antibacterial properties are difficult to realize at the same time.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of carpets, in particular to a high-performance carpet and a preparation process thereof. BACKGROUND

[0002] With the continuous improvement of people's living standards, the demand for carpets in home decoration, office environment and public places is gradually increasing. As an important indoor decorative material, the performance requirements of carpets are becoming more and more diversified, especially in terms of comfort, elasticity, pile effect, durability and hygiene. Although traditional carpets can meet the basic decoration requirements, they cannot meet the multiple functional requirements of high elasticity, high pile, antibacterial and stain resistance in certain specific application environments, such as high-traffic areas, medical environments, educational institutions, etc.

[0003] At present, most of the carpets on the market use single fiber materials, such as polyester fiber, nylon fiber, etc. These carpets perform well in terms of elasticity, comfort and aesthetics, but they often have certain deficiencies in terms of elastic recovery and pile effect, and they also lack antibacterial and stain resistance. For example, some carpets are prone to deformation after being subjected to a large external force, resulting in a shortened service life. In addition, the pile layer of some carpets is relatively thin, with a hard feel, and due to the large gap between the pile, it is easy to attach dust and stains, making it difficult to clean. In addition, most of the existing carpets do not use effective antibacterial treatment, which can easily breed bacteria and mold, affecting environmental hygiene and air quality, especially in hospitals, schools and other places with high hygiene requirements. Carpets without antibacterial function cannot effectively protect the health of users.

[0004] Therefore, there is an urgent need for an improved carpet preparation process that can improve the stain resistance and antibacterial properties of carpets while ensuring high elasticity and high pile effect, solve the deficiencies of existing carpets in multiple performance aspects, and meet the market demand for high-performance carpets. SUMMARY

[0005] The present application provides a high-performance carpet and a preparation process thereof, which are used to solve the technical problems related in the background.

[0006] The technical scheme provided by the present application is as follows: a preparation process of a high-performance carpet, comprising the following steps: S1, selecting polyester fiber bundles, spandex fiber bundles, wool bundles and conductive fiber bundles to be twisted into mixed bundles, and the mass ratio is 0.4-0.6: 0.1-0.2: 0.2-0.3: 0.1-0.3; S2, using a ring weaving method to weave the mixed bundles into a preliminary carpet, the density of the preliminary carpet is 46-113 needles per square centimeter, and the spacing between the fiber bundles is 0.1-0.3 mm; S3, the primary carpet is subjected to heat setting treatment, the temperature of the treatment is 120-150 DEG C, and the duration is 5-10 minutes; S4, the carpet after heat setting is subjected to mechanical stretching and then air flow stretching; Wherein, the proportion of mechanical stretching is 8-12%, and after air flow stretching, the carpet pile increases by 30-50%; S5, the carpet is subjected to dyeing and high temperature setting after dyeing; S6, silver ion antibacterial agent is used to perform antibacterial treatment on the surface of the carpet.

[0007] In one embodiment, the fineness of the polyester fiber bundle is 1.2-2.5 dtex, the fineness of the spandex fiber bundle is 1.5-2.0 dtex, the fineness of the wool bundle is 2.0-3.0 dtex, and the fineness of the conductive fiber is 0.8-1.5 dtex.

[0008] In one embodiment, in step S5, the dyeing temperature is 80-100 DEG C, and the dyeing time is 30 minutes-1 hour.

[0009] In one embodiment, in step S5, the high temperature setting temperature is 160-180 DEG C, and the setting time is 3-5 minutes.

[0010] In one embodiment, in step S1, the polyester fiber bundle, the spandex fiber bundle and the wool bundle are first immersed in an antistatic agent and then twisted with the conductive fiber after drying.

[0011] In one embodiment, in the air flow stretching step, the air flow speed is 10-20 m / s, the air flow temperature is 80-100 DEG C, and the stretching time is 1-3 minutes.

[0012] In one embodiment, in step S6, the carpet is completely immersed in a solution containing silver ion antibacterial agent, and after soaking for 15-30 minutes, the carpet is dried by using a hot air drying device, the temperature is 50-70 DEG C, and the drying time is 30-60 minutes.

[0013] A high performance carpet is prepared according to the above preparation process.

[0014] Compared with the prior art, the present application has the following beneficial effects: (1) The preparation process of the high-performance carpet adopts a comprehensive process mode of fiber material mixed twisting, ring weaving method, heat setting and stretching process, silver ion antibacterial treatment, etc., the proportion of polyester fiber, spandex fiber, wool bundle and conductive fiber is reasonably selected, the fabric density and fiber spacing are optimized, and mechanical and airflow stretching treatment is cooperated, so that the best balance of the carpet in high elasticity and high pile effect is achieved, so that the carpet not only has excellent elastic recovery ability and can quickly recover the shape, but also has rich surface pile and soft touch, thereby solving the problems of the traditional carpet in elasticity and comfort, and the problems of difficult to simultaneously realize high pile feeling and high stain resistance and antibacterial performance. DETAILED DESCRIPTION

[0015] The application will be described in detail below with specific embodiments. The following examples will help those skilled in the art to further understand the application, but do not limit the application in any form. It should be pointed out that, for those skilled in the art, without departing from the concept of the application, a number of changes and improvements can be made. These all belong to the protection scope of the application.

[0016] The application is a preparation process of a high-performance carpet, comprising the following steps: S1, polyester fiber bundle, spandex fiber bundle and wool bundle are first immersed in an antistatic agent and dried to ensure the overall antistatic effect of the carpet; then the polyester fiber bundle, spandex fiber bundle, wool bundle and conductive fiber are twisted into a mixed wire bundle, and the mass ratio is 0.4-0.6:0.1-0.2:0.2-0.3:0.1-0.3; the fineness of the polyester fiber bundle is 1.2 dtex to 2.5 dtex; the fineness of the spandex fiber bundle is 1.5 dtex to 2.0 dtex; the fineness of the wool bundle is 2.0 dtex to 3.0 dtex; the fineness of the conductive fiber is 0.8 dtex to 1.5 dtex; this multi-fiber mixed wire bundle can realize elasticity and comfort at the same time, and ensure the density and softness of the pile, and the introduction of the conductive fiber enhances the antistatic function of the carpet. Finally, this fiber ratio provides a good foundation for the subsequent process, so that the carpet has high elasticity and rich pile effect.

[0017] S2, the mixed wire bundle is woven into a preliminary carpet by using a ring weaving method, the density of the preliminary carpet is 46 needles to 113 needles per square centimeter, and the spacing between the fiber bundles is 0.1mm-0.3mm; compared with the traditional straight-line weaving method, the ring weaving method can better maintain the shape stability of the carpet, and can effectively improve the structural strength and elasticity of the carpet, and due to the close arrangement of the fiber bundles, the surface of the carpet is more delicate, the density of the pile is higher, thereby improving the comfort and visual effect.

[0018] S3, the preliminary carpet is subjected to heat setting treatment, the treatment temperature is 120-150°C, and the duration is 5-10 minutes; the heat setting treatment ensures the overall shape and stability of the carpet.

[0019] S4, the carpet after heat setting is subjected to mechanical stretching and then airflow stretching; the mechanical stretching ratio is 8-12%, the carpet is placed in an airflow stretching machine, the airflow speed is 10-20 m / s, the airflow temperature is 80-100°C, the stretching time is 1-3 minutes, and after stretching, the carpet pile increases by 30-50%; the stretching process makes the carpet surface pile more abundant and three-dimensional through the cooperation of the mechanical and airflow stretching, thereby improving the comfort and visual effect of the carpet. Meanwhile, the stretched carpet maintains good elasticity and can effectively restore the shape, thereby ensuring the durability during long-term use.

[0020] S5, the carpet is subjected to dyeing, the dyeing temperature is 80-100°C, and the dyeing time is 30 minutes to 1 hour; after dyeing, high-temperature setting is performed, the high-temperature setting temperature is 160-180°C, and the setting time is 3-5 minutes; the mild dyeing process combined with the high-temperature setting process can ensure that the dye is firmly attached to the fiber, and after setting, the carpet can maintain color stability during use and will not fade due to repeated washing or rubbing.

[0021] S6, a silver ion antibacterial agent is used to perform antibacterial treatment on the surface of the carpet; specifically, the carpet is completely soaked in a solution containing a silver ion antibacterial agent, soaked for 15-30 minutes, and then dried by using a hot air drying device, the temperature is 50-70°C, and the drying time is 30-60 minutes; the silver ion antibacterial treatment can not only enhance the antibacterial effect of the carpet, but also prolong the service life of the carpet and maintain the hygiene of the carpet surface, thereby further improving the overall performance of the carpet. Example 1

[0022] S1: polyester fiber bundles (fineness 1.5 dtex), spandex fiber bundles (fineness 1.8 dtex), wool bundles (fineness 2.5 dtex), and conductive fibers (fineness 1.2 dtex) are selected, and twisted into mixed fiber bundles according to a mass ratio of 0.5:0.15:0.25:0.1.

[0023] S2: a preliminary carpet is woven by using a ring weaving method, the density is 75 needles per square centimeter, and the spacing between the fiber bundles is 0.2 mm.

[0024] S3: the preliminary carpet is subjected to heat setting treatment, the treatment temperature is 130°C, and the duration is 7 minutes.

[0025] S4: Mechanical stretching is performed at a stretching ratio of 10%, and then air stretching is performed at an air speed of 15 m / s, an air temperature of 90°C, and a stretching time of 2 minutes. After the air stretching, the pile of the carpet is increased by 40%.

[0026] S5: The carpet is dyed at a temperature of 90°C for 40 minutes, and then high-temperature setting is performed at a temperature of 170°C for 4 minutes.

[0027] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 20 minutes, and then drying is performed using a hot air drying apparatus at a drying temperature of 60°C for 45 minutes. Example 2

[0028] S1: Polyester fiber bundles (fineness 1.8 dtex), spandex fiber bundles (fineness 1.7 dtex), wool bundles (fineness 2.2 dtex), and conductive fibers (fineness 1.0 dtex) are selected and twisted into a mixed bundle at a mass ratio of 0.45:0.2:0.3:0.3.

[0029] S2: A primary carpet is woven using a circular weaving method at a density of 50 needles per square centimeter, and a spacing of 0.15 mm between the fiber bundles.

[0030] S3: The primary carpet is heat-set at a temperature of 140°C for 6 minutes.

[0031] S4: Mechanical stretching is performed at a stretching ratio of 9%, and then air stretching is performed at an air speed of 12 m / s, an air temperature of 85°C, and a stretching time of 2.5 minutes. After the air stretching, the pile of the carpet is increased by 35%.

[0032] S5: The carpet is dyed at a temperature of 85°C for 50 minutes, and then high-temperature setting is performed at a temperature of 165°C for 3 minutes.

[0033] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 25 minutes, and then drying is performed using a hot air drying apparatus at a drying temperature of 55°C for 50 minutes. Example 3

[0034] S1: Polyester fiber bundles (fineness 1.2 dtex), spandex fiber bundles (fineness 1.5 dtex), wool bundles (fineness 3.0 dtex), and conductive fibers (fineness 0.9 dtex) are selected and twisted into a mixed bundle at a mass ratio of 0.55:0.1:0.2:0.15.

[0035] S2: The primary carpet is woven using a circular weaving method with a density of 100 needles per square centimeter and a spacing of 0.25 mm between the fiber bundles.

[0036] S3: The primary carpet is subjected to heat setting treatment at a temperature of 120°C for 8 minutes.

[0037] S4: Mechanical stretching is performed at a ratio of 11%, followed by air stretching at a speed of 18 m / s, a temperature of 95°C, and a duration of 3 minutes. After air stretching, the pile of the carpet increases by 45%.

[0038] S5: The carpet is dyed at a temperature of 100°C for 35 minutes, followed by high-temperature setting at a temperature of 180°C for 5 minutes.

[0039] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing it in a solution containing the silver ion antibacterial agent for 30 minutes, followed by drying using a hot air drying device at a temperature of 65°C for 55 minutes. Example 4

[0040] S1: Polyester fiber bundles (fineness 1.4 dtex), spandex fiber bundles (fineness 1.6 dtex), wool bundles (fineness 2.0 dtex), and conductive fibers (fineness 0.9 dtex) are selected and twisted into mixed bundles at a mass ratio of 0.45:0.2:0.25:0.1.

[0041] S2: The primary carpet is woven using a circular weaving method with a density of 60 needles per square centimeter and a spacing of 0.18 mm between the fiber bundles.

[0042] S3: The primary carpet is subjected to heat setting treatment at a temperature of 135°C for 6 minutes.

[0043] S4: Mechanical stretching is performed at a ratio of 9%, followed by air stretching at a speed of 16 m / s, a temperature of 92°C, and a duration of 2 minutes. After air stretching, the pile of the carpet increases by 38%.

[0044] S5: The carpet is dyed at a temperature of 85°C for 45 minutes, followed by high-temperature setting at a temperature of 168°C for 4 minutes.

[0045] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing it in a solution containing the silver ion antibacterial agent for 20 minutes, followed by drying using a hot air drying device at a temperature of 58°C for 50 minutes. Example 5

[0046] S1: Selecting polyester fiber bundle (fineness 1.3 dtex), spandex fiber bundle (fineness 1.9 dtex), wool bundle (fineness 2.7 dtex), and conductive fiber (fineness 1.3 dtex), and twisting into a mixed bundle at a mass ratio of 0.5:0.15:0.25:0.1.

[0047] S2: Knitting into a preliminary carpet using a circular weaving method, with a density of 90 needles per square centimeter and a spacing of 0.2 mm between the fiber bundles.

[0048] S3: Performing heat setting treatment on the preliminary carpet, at a temperature of 145°C for 7 minutes.

[0049] S4: Performing mechanical stretching at a ratio of 10%, followed by air stretching at a speed of 18 m / s, a temperature of 95°C, and for a time of 3 minutes. After air stretching, the pile of the carpet increases by 42%.

[0050] S5: Dyeing the carpet at a temperature of 95°C for 40 minutes, followed by high-temperature setting at a temperature of 175°C for 4 minutes.

[0051] S6: Treating with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 25 minutes, followed by drying using a hot air drying device at a temperature of 62°C for 55 minutes. Example 6

[0052] S1: Selecting polyester fiber bundle (fineness 2.0 dtex), spandex fiber bundle (fineness 1.5 dtex), wool bundle (fineness 2.2 dtex), and conductive fiber (fineness 0.8 dtex), and twisting into a mixed bundle at a mass ratio of 0.4:0.1:0.3:0.2.

[0053] S2: Knitting into a preliminary carpet using a circular weaving method, with a density of 110 needles per square centimeter and a spacing of 0.3 mm between the fiber bundles.

[0054] S3: Performing heat setting treatment on the preliminary carpet, at a temperature of 125°C for 5 minutes.

[0055] S4: Performing mechanical stretching at a ratio of 8%, followed by air stretching at a speed of 14 m / s, a temperature of 85°C, and for a time of 1.5 minutes. After air stretching, the pile of the carpet increases by 30%.

[0056] S5: Dyeing the carpet at a temperature of 80°C for 35 minutes, followed by high-temperature setting at a temperature of 160°C for 3 minutes.

[0057] S6: Treatment with silver ion antibacterial agent, the carpet is completely immersed in a solution containing silver ion antibacterial agent, the soaking time is 15 minutes, and then a hot air drying equipment is used for drying, the drying temperature is 50°C, and the drying time is 40 minutes.

[0058] The following are the functional test items and test data of the high-elasticity, high-pile carpets prepared in Examples 1 to 6. We evaluate the performance of the carpets through different test items, including their elasticity, pile density, stain resistance, and antibacterial effect.

[0059] The test items are as follows: Pile density: evaluates the density of the pile on the surface of the carpet per unit area; unit: pile / cm2.

[0060] Elastic recovery rate: evaluates the ability of the carpet to return to its original shape after being stressed; unit: %.

[0061] Friction coefficient: evaluates the friction force when the surface of the carpet contacts an object; unit: friction coefficient.

[0062] Stain resistance test: evaluates the cleanliness of the carpet under specific stain conditions; unit: stain removal rate (%).

[0063] Antibacterial test: evaluates the antibacterial ability of the carpet; unit: antibacterial effect (% inhibition rate).

[0064] Tensile strength: tests the tensile strength of the carpet to determine its durability; unit: N / cm.

[0065] Color fastness test: tests the dyeing fastness of the carpet, i.e., the durability of the dye after rubbing or washing; unit: grade 1-5.

[0066] The test data is as follows: , In summary, Example 5 exhibits very balanced performance under the requirements of high elasticity and high pile preparation, not only having good elastic recovery ability and moderate pile density, but also performing excellently in functional tests such as stain resistance, antibacterial effect, and color fastness. Therefore, Example 5 is the optimal embodiment in this application, suitable for high-performance carpet applications that require long-term durability, easy cleaning, comfort, and antibacterial properties.

[0067] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. For those skilled in the art, the present application can have various modifications and changes. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A manufacturing process for a high-performance carpet, characterized in that, Includes the following steps: S1. Select polyester fiber bundles, spandex fiber bundles, wool bundles and conductive fibers and twist them together to form a mixed wire bundle with a mass ratio of 0.4-0.6:0.1-0.2:0.2-0.3:0.1-0.3; S2. The mixed yarn bundles are woven into a preliminary carpet using a loop weaving method. The density of the preliminary carpet is 46 to 113 stitches per square centimeter, and the spacing between the fiber bundles is 0.1 mm to 0.3 mm. S3. The carpet undergoes a preliminary heat setting treatment at a temperature of 120°C to 150°C for 5-10 minutes. S4. After heat setting, the carpet is first mechanically stretched, and then air-flow stretched. Among them, mechanical stretching accounts for 8%-12%, while airflow stretching increases carpet pile by 30%-50%; S5. Dye the carpet and then set it at high temperature. S6. Silver ion antibacterial agent is used to treat the carpet surface with antibacterial agents.

2. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, The polyester fiber bundle has a fineness of 1.2 dtex to 2.5 dtex; the spandex fiber bundle has a fineness of 1.5 dtex to 2.0 dtex; the wool bundle has a fineness of 2.0 dtex to 3.0 dtex; and the conductive fiber has a fineness of 0.8 dtex to 1.5 dtex.

3. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, In step S5, the staining temperature is 80℃ to 100℃, and the staining time is 30 minutes to 1 hour.

4. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, In step S5, the high-temperature setting temperature is 160℃-180℃, and the setting time is 3-5 minutes.

5. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, In step S1, polyester fiber bundles, spandex fiber bundles and wool bundles are first immersed in an antistatic agent, dried, and then twisted together with conductive fibers.

6. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, In the airflow stretching step, the airflow velocity is 10-20 m / s, the airflow temperature is 80℃-100℃, and the stretching time is 1-3 minutes.

7. The manufacturing process of a high-performance carpet as described in claim 1, characterized in that, Step S6 specifically involves: completely immersing the carpet in a solution containing silver ion antibacterial agent for 15-30 minutes, then drying it using a hot air drying device at a temperature of 50℃-70℃ for 30-60 minutes.

8. A high-performance carpet, characterized in that, Prepared according to any one of claims 1-7.