Multi-layer carpet and preparation method thereof

Abstract

The present invention discloses a multi-layer carpet and a preparation method thereof. The multi-layer carpet comprises an upper carpet and a lower carpet, wherein the upper carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, and the lower carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper carpet and the lower carpet are connected by detachable bonding of the carpet back layer and the carpet surface layer 2; when the carpet back layer is a silent single-filament bundle layer, the carpet surface layer 2 is a silent ultra-fiber layer; or, when the carpet back layer is a silent ultra-fiber layer, the carpet surface layer 2 is a silent ultra-fiber bundle layer. The present invention chemically or physically processes the back of the upper carpet and the surface of the lower carpet, so that the silent ultra-fiber layer with ultra-fine fiber bundles and the silent monofilament bundle layer with monofilament bundles are superimposed together, and an electrostatic adsorption effect is generated under the action of gravity and external force, so that they can be bonded together to form a relatively thick sound insulation carpet; at the same time, the upper and lower carpets can be disassembled and used separately.

Description

Technical Field

[0001] The invention belongs to the technical field of detachable carpets and relates to a multi-layer carpet and a preparation method thereof. Background Art

[0002] Since its birth, the detachable and washable two-in-one carpet has been loved by most consumers in the market due to its advantages such as washability, replaceability, and convenient storage. However, the traditional installation method of the carpet layer and the anti-slip layer is generally achieved by the combination of traditional Velcro or singed non-woven fabric or singed barbed fabric and fleece knitted fabric. There are certain disadvantages during use, such as loud noise when tearing, the hook surface is prickly, it is easy to hook clothes, it is easy to hide dust, it is easy to pull the suede and shorten the service life, etc. Therefore, it is necessary to use a textile fabric with electrostatic adsorption, softness and good adhesion, and does not rely on chemical glue for bonding to replace the traditional Velcro, singed non-woven fabric, and singed barbed fabric to improve the disassembly and assembly of the two-in-one carpet, thereby improving the use experience of the carpet and increasing the service life of the carpet. Summary of the invention

[0003] The purpose of the present invention is to address the deficiencies of the prior art and provide a multi-layer carpet and a preparation method thereof, using a silent opening and closing, soft and highly adhesive textile fabric to replace the traditional Velcro / singed non-woven fabric / singed barbed fabric to improve the assembly and disassembly of carpets and two-in-one carpets, and solve the problems mentioned in the technical background.

[0004] The purpose of the present invention can be achieved by the following scheme:

[0005] In the technical solution provided by the present invention, by arranging a carpet silent monofilament bundle layer and a silent microfiber layer on the carpet back of the upper carpet and the carpet surface of the lower carpet and superimposing them together to generate electrostatic adsorption under the action of external force, the multi-layer carpet can be disassembled / assembled and installed, thereby conveniently realizing all the household functions of this free combination carpet - beautiful carpet surface, washable, foldable, easy to replace, easy to store and cost-effective function of one carpet with three uses (i.e., a double-layer silent carpet, the upper carpet can be used as a carpet / sofa cover / bed cover, etc., and the lower carpet can be used as a carpet alone), etc.

[0006] The present invention provides a multi-layer carpet, the multi-layer carpet comprises an upper carpet and a lower carpet, the upper carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, the lower carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, the upper carpet and the lower carpet are connected by detachably bonding the carpet back layer and the carpet surface layer 2;

[0007] When the blanket back layer is a silent monofilament bundle layer, the blanket surface layer 2 is a silent microfiber layer;

[0008] Or, when the blanket back layer is a silent ultra-fiber layer, the blanket surface layer 2 is a silent monofilament bundle layer.

[0009] In the present invention, the upper blanket and the lower blanket are superimposed together by the blanket back layer and the blanket surface layer 2 to generate an electrostatic adsorption effect under the action of external force, thereby obtaining a detachable connection.

[0010] As an embodiment of the present invention, the carpet surface layer 1 includes any one or a combination of a tufted surface layer, a woven suede surface layer, a knitted suede surface layer, and a needle-punched suede surface layer.

[0011] As an embodiment of the present invention, the pile state of the carpet surface layer 1 includes at least one of cut pile, loop pile, and flat fabric or a combination of several thereof; the process of the cut pile includes at least one of tufting, knitting, weaving, and non-woven.

[0012] In the present invention, the blanket surface layer 1 of the upper blanket can be printed with various patterns, or decorated with patches and embroidery of the same fabric.

[0013] As an embodiment of the present invention, the material of the silent monofilament bundle layer includes at least one of composite filament bundles, animal hair fibers, and blended fibers of natural fibers and chemical fibers. The composite filament bundles are in a scattered, inclined and curved shape.

[0014] As an embodiment of the present invention, the composite yarn bundle includes at least one of a chemical filament composite yarn bundle and a short-spun chemical fiber yarn.

[0015] Furthermore, the chemical filament composite tow includes at least one of polyester, polypropylene, and nylon, and the types of filaments of the chemical filament composite tow include at least one of FDY, DTY, BCF, and POY.

[0016] Furthermore, the short-staple chemical fiber yarn is a yarn spun from short fibers or a yarn blended from multiple short fibers.

[0017] Furthermore, the natural fibers include animal hair fibers, and the animal hair fibers include wool fibers.

[0018] As an embodiment of the present invention, the silent monofilament bundle layer is a monofilament bundle layer with distributed monofilament bundles; the monofilament bundle is composed of multiple monofilaments with a common bottom, and the top end of the monofilament has a dispersed inclined or curved structure. Compared with ordinary monofilaments (monofilament), multiple monofilaments with a common bottom have a higher surface density of the fabric, and higher horizontal bonding tension and durability.

[0019] As an embodiment of the present invention, the fineness of the monofilament is 1.04-60DPF. If the monofilament is less than 1.04D, the monofilament is too soft and is not easy to be inserted into the fiber bundle of the silent microfiber layer to form entanglement, the silent adsorption effect is reduced, and the horizontal bonding force becomes smaller; the spinning process of the composite fiber bundle with a monofilament greater than 60D is difficult, and the monofilament is relatively hard.

[0020] As an embodiment of the present invention, the monofilament density of the silent monofilament bundle layer is 1200-180000 strands / square inch. If it is lower than 1200 strands / square inch, the density is too low, the bonding force is small, the bottom is exposed, the appearance is poor, and the use value is low; if it is higher than 180000 strands / square inch, the weaving difficulty is large, the efficiency is low, and the economic value is low.

[0021] As an embodiment of the present invention, the thickness of the silent filament bundle layer is 1-15 mm. The bonding effect of the pile height within this thickness range is the best.

[0022] As an embodiment of the present invention, the material of the silent microfiber layer includes at least one of a high shrinkage tow and a microfiber tow. In the present invention, the material of the silent microfiber layer is a microfiber tow, or a composite tow of a high shrinkage tow and a microfiber tow, and the mass ratio of the high shrinkage tow to the microfiber tow in the composite tow is 1:1-1:3.

[0023] Furthermore, the material of the ultrafine fiber bundle includes at least one of sea-island fibers, bicomponent filaments, and modified ultrafine chemical fiber filaments.

[0024] As an embodiment of the present invention, the silent microfiber layer is a tuft layer in which microfiber tufts are distributed.

[0025] Furthermore, the fineness of the monofilament in the ultrafine fiber bundle is 0.05-2.08D.

[0026] As an embodiment of the present invention, the thickness of the silent ultra-fiber layer is 1-15 mm.

[0027] In the present invention, the ultrafine fiber bundles are a plurality of fine and uniform ultrafine fiber bundles.

[0028] As an embodiment of the present invention, the multi-layer carpet also includes an intermittent anti-slip layer, which is arranged on the surface of the hair bundles in the silent microfiber layer, that is, the intermittent anti-slip layer can be selectively arranged on the surface of the hair bundles in the silent microfiber layer.

[0029] Furthermore, the intermittent anti-slip layer includes intermittent anti-slip resin or intermittent anti-slip glue; the intermittent anti-slip layer includes at least one of TPE / PU, PUR, hot melt glue, acrylic glue, and EVA glue.

[0030] As an embodiment of the present invention, the anti-slip layer is a material layer with an anti-slip function.

[0031] Furthermore, the anti-slip layer includes any one of a TPE layer, a latex layer, PVC, PU, ​​PUR, hot melt adhesive, acrylic adhesive, an EVA adhesive layer, an SBR adhesive layer and other anti-slip materials.

[0032] In the present invention, the upper blanket and the lower blanket can be bonded or separated to each other by two layers of fabric, namely, the silent monofilament bundle layer and the silent microfiber layer. There is no need to install traditional Velcro on the fabric, or to install singed non-woven fabric to achieve the disassembly and installation of the upper and lower blanket surfaces and the anti-slip function.

[0033] In the present invention, the silent monofilament bundle layer and the silent ultra-fiber layer can be located at the bottom of the upper blanket and the top of the lower blanket respectively, and the positions of the two contact layers can be freely selected without affecting the main functions of the present invention due to position reversal.

[0034] In a second aspect, the present invention provides a method for preparing a multi-layer carpet, the method comprising the following steps:

[0035] S1. Preparing a silent monofilament bundle layer: preparing a composite yarn bundle, or animal hair fiber, or a blended fiber of natural fiber and chemical fiber into a cut pile-like fabric, combing or heat-processing the cut pile-like fabric, and separating a monofilament bundle layer with monofilament bundles distributed therein, i.e., a silent monofilament bundle layer;

[0036] S2. Preparation of a silent ultra-fine fiber layer: a knitted or woven fabric is made by paralleling high-shrinkage tows and ultra-fine fiber tows or paralleling and stretching or paralleling and stretching and forming a network, and then high-temperature dyeing and degreasing are performed to form (many ultra-fine) fiber tows to obtain a bundle layer with ultra-fine fiber bundles distributed thereon, i.e., a silent ultra-fine fiber layer;

[0037] Or, a woven, knitted or needle-punched fabric made of multiple microfiber bundles is subjected to sanding and high-temperature treatment to obtain a bundle layer with microfiber bundles distributed thereon, i.e., a silent microfiber layer;

[0038] S3, preparing a multi-layer carpet: compounding the carpet surface layer 1 and the silent monofilament bundle layer to form an upper carpet, and compounding the silent microfiber layer and the anti-slip layer to form a lower carpet;

[0039] Or, the carpet surface layer 1 is compounded with the silent microfiber layer to form an upper carpet, and the silent monofilament bundle layer is compounded with the anti-slip layer to form a lower carpet;

[0040] (The upper and lower layers are attracted to each other by static electricity) to obtain the multi-layer carpet.

[0041] As an embodiment of the present invention, in step S1, the method of making the cut pile fabric includes at least one of weaving, knitting, tufting, non-woven needle punching, and flocking.

[0042] As an embodiment of the present invention, step S1 further comprises dyeing and finishing the cut pile fabric before combing or heat treatment. The purpose of dyeing and finishing is to remove part of the spinning oil / spinning oil.

[0043] As an embodiment of the present invention, step S1 further comprises adding a stiffener to the cut pile fabric before carding or heat treatment, wherein the concentration of the stiffener is 10-30 g / L and the amount used is 30-500 gsm. Adding the stiffener can increase the horizontal bonding tension of the carpet.

[0044] As an embodiment of the present invention, the stiffening agent includes at least one of TF-639B and Wanjiang Jianda 2195.

[0045] As an embodiment of the present invention, step S1 further comprises adding an electrostatic enhancer to the cut pile fabric during carding or heat processing, wherein the concentration of the electrostatic enhancer is 10-50 g / L and the amount used is 20-300 gsm. The electrostatic enhancer (also known as an electrostatic dust absorber) is added to enhance the electrostatic adsorption effect to enhance the horizontal bonding force between the upper and lower blanket layers.

[0046] As an embodiment of the present invention, the electrostatic enhancer includes Jieshengnuo 4957758.

[0047] As an embodiment of the present invention, in step S1, combing includes at least one of sanding, combing, cutting and ironing processes; the thermal processing includes subjecting the cut pile fabric to a hot blowing process or an ironing process or other processes equivalent to hot blowing.

[0048] In the present invention, the tows or fibers on the surface of the fabric are spread out by combing or heat processing to form monofilaments with dispersed inclined or curved structures at the top, and the obtained silent monofilament layer has static electricity accumulation.

[0049] As an embodiment of the present invention, in step S2, the fabric is made by at least one of knitting, weaving and needle punching.

[0050] As an embodiment of the present invention, in step S2, the fineness of single filaments in the plurality of ultrafine fiber bundles is less than or equal to 2.08 DPF.

[0051] As an embodiment of the present invention, in step S2, the temperature of the high temperature dyeing and degreasing is 60-230°C.

[0052] In the present invention, the high shrinkage bundles and ultrafine fiber bundles of the silent microfiber layer have different shrinkage rates, and the bundles with different shrinkage rates are entangled with each other to form gaps, so that the monofilaments of the silent monofilament bundle layer are inserted / entangled with each other / electrostatically adsorbed together to produce electrostatic adsorption and thus form a bonding effect.

[0053] As an embodiment of the present invention, step S2 further comprises scratching, sanding, or brushing after high-temperature dyeing and degreasing.

[0054] As an embodiment of the present invention, step S2 further includes dyeing and drying the fabric before sanding and fleece. The purpose of dyeing and finishing is to remove part of the spinning oil.

[0055] In the present invention, static electricity is deposited on the surface of the hair bundle layer after being treated in step S2.

[0056] As an embodiment of the present invention, step S2 further comprises coating the surface of the microfiber bundles with intermittent anti-skid resin or intermittent anti-skid glue.

[0057] As an embodiment of the present invention, in step S3, the compounding method includes at least one of glue compounding, hot melt compounding and flame compounding.

[0058] Compared with the prior art, the present invention has the following beneficial effects:

[0059] 1. The fineness of the single filaments and the corresponding single filament density of the silent single filament bundle layer in the present invention solve the problem of insufficient horizontal bonding tension and wear resistance of traditional carpets, so that the obtained multi-layer carpet has both excellent horizontal bonding tension and wear resistance (i.e. durability).

[0060] 2. Different from the traditional hook-and-loop bonding of terry loops and hooks, the surface of the silent microfiber layer of the present invention is distributed with microfiber bundles, and there is static electricity accumulation on the surface. It is easy to produce a strong electrostatic adsorption effect under the action of gravity and external force. After bonding with the silent monofilament bundle layer, it has a strong horizontal bonding tension, achieving a strong bonding effect and having higher durability.

[0061] 3. The multi-layer carpet prepared by the present invention is detachably bonded, and the silent microfiber layer can be used alone or in combination with other carpets; it is foldable, easy to replace, and easy to store; at the same time, the carpet can be disassembled into several small pieces and can be infinitely extended and spliced ​​in an offset manner, and has a wide range of application scenarios.

[0062] 4. The present invention unexpectedly found that the horizontal bonding tension of the carpet can be improved and the application scenarios of the carpet can be expanded by adding an appropriate amount of stiffener to the processing method of the cut pile silent layer fabric.

[0063] 5. The present invention further enhances the horizontal bonding tension of the upper and lower carpets by adding a proper amount of electrostatic enhancer (electrostatic dust absorber) in the processing step of the silent monofilament bundle layer, thereby achieving a better carpet bonding effect.

[0064] 6. The single filament fineness range of the silent single filament bundle layer of the present invention is relatively large, and the material selection range of the silent ultra-fiber layer is relatively wide. Filament fiber bundles or yarns made of short fibers (including chemical fibers, wool fibers, hemp fibers, etc.) can be selected, which has excellent practical industrial application value.

[0065] 7. The plush density of the textile fabrics of the silent monofilament bundle layer and the silent microfiber layer in the present invention is higher than the hook density and loop density of the traditional Velcro. The tighter the structure of the fabric, the higher the cohesive energy, and it is easy to produce a strong electrostatic adsorption effect under the action of gravity and external force, and has a strong bonding effect; and the textile fabrics involving the silent monofilament bundle layer and the silent microfiber layer in the embodiment of the present invention have a better self-adhesive effect than "Velcro". At the same time, the carpet within the monofilament density range of the present invention is more durable, more durable, and more solid. It is quiet to disassemble and assemble, and there is no loud noise. In particular, the anti-slip effect, especially the lateral anti-slip effect is very outstanding.

[0066] 8. The textile fabrics used in the silent monofilament bundle layer and the silent microfiber layer of the present invention will not cause any side to be damaged due to long-term opening and closing use, which greatly improves the service life, thereby making the blanket-in-blanket function easily realized. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0068] Figure 1 Schematic diagram of the carpet structure; 1 is the carpet surface layer 1, 2 is the carpet back layer, 3 is the upper carpet, 4 is the carpet surface layer 2, 5 is the anti-slip layer, and 6 is the lower carpet;

[0069] Figure 2 Schematic diagram of the upper blanket structure in Example 1; wherein 7 is a monofilament bundle;

[0070] Figure 3 Schematic diagram of the structure of the lower blanket in Example 1; wherein 8 is a high shrinkage tow and 9 is an ultrafine fiber tow. DETAILED DESCRIPTION

[0071] The present invention is described in detail below in conjunction with the accompanying drawings and specific embodiments. The following examples are implemented on the premise of the technical solution of the present invention, provide detailed implementation methods and specific operation processes, and will help those skilled in the art to further understand the present invention. It should be pointed out that the protection scope of the present invention is not limited to the following embodiments, and several adjustments and improvements made under the premise of the concept of the present invention all belong to the protection scope of the present invention.

[0072] The manufacturer of the stiffening agent used in the embodiments of the present invention is Zhejiang Transpec Zhilian Co., Ltd., model: TF-639B (English: TRANSPEC STF TF-639B).

[0073] Example 1

[0074] The carpet structure of this embodiment is as follows Figure 1As shown, the upper blanket and the lower blanket structures are as follows Figure 2 , 3 shown.

[0075] 1. Choose a 250GSM nylon BCF flat-cut tufted printed blanket with a pile height of 4 mm and a 100GSM filament non-woven fabric as the tufted base fabric. Use EVA glue to fix the tufted and printed blanket for later use.

[0076] 2. The carpet surface with fixed pile and 150GSM non-woven fabric are flame-laminated at 20g / m2 to form a carpet surface layer 1 (1). The purpose of laminating the non-woven fabric is to better maintain the appearance and size after washing.

[0077] 3. Polyester DTY150D / 36F (monofilament 4.17DPF or so) is selected and knitted into fabric on a single needle bed knitting machine, and then brushed, cut, dyed, and hot blown to obtain a silent monofilament bundle layer with monofilament bundles (7), i.e., a blanket backing layer (2), with a gram weight of about 200 grams per square meter, a pile length of about 2.5 mm, and a monofilament density of 174960 strands per square inch. The silent monofilament bundle layer and the blanket surface layer 1 of step 2 are compounded together to obtain an upper blanket (3).

[0078] 4. The sea-island fiber of 75D / 200F and 75D polyester high elastic yarn are paralleled and stretched, and then weft knitted (knitted) to obtain a weft-knitted ant cloth (i.e., knitted fabric). At 130°C, a NaOH solution with a mass concentration of 32% is added to a dyeing tank for degreasing and alkali reduction (i.e., high-temperature dyeing and degreasing) to obtain a silent ultra-fine fiber layer with high shrinkage bundles (8) and ultra-fine fiber bundles (9), i.e., a blanket surface layer 2 (4), with a pile height (i.e., thickness) of 1.5 mm and a single filament fineness of 0.375D in the ultra-fine fiber part.

[0079] 5. The sound-proof microfiber layer fabric prepared in step 4 is compounded with 700 g / m2 dot-molded non-woven fabric, i.e., the anti-slip layer (5), using PUR hot melt adhesive to obtain the lower blanket (6) of the present invention.

[0080] 6. Complete cutting, finishing, packaging and shipment.

[0081] Example 2

[0082] 1. Choose 360GSM printed flannel as the blanket surface.

[0083] 2. The 500GSM printed flannel blanket surface and the 200GSM non-woven fabric are compounded together with PUR glue to form a blanket surface layer 1 with a pile height of 5mm.

[0084] 3. The 105D / 36Fx37 polyester-nylon composite spinning and 100D high shrinkage yarn are combined and tied into a heavy network knot as the warp, and the 150D / 14F polyester filament is used as the weft to make a 180GSM warp microfiber fabric according to the plain weave, and then dyed and degreased at high temperature (at 130°C), and then dried and shaped, and the fabric is high-speed fleece / sanded to obtain a silent microfiber layer. The DPF of the microfiber part is about 0.08DPF, and the silent microfiber layer is compounded with the blanket surface layer 1 of step 2 to form an upper blanket.

[0085] 4. 1800D / 144F black polypropylene BCF yarn was selected and made into a cut pile carpet surface with a row spacing of about 12.70 needles / inch and a pile height of 3.5 mm on a tufting machine with a needle spacing of 1 / 12. 200GSM stiffening agent (model TF-639B, ratio of 30g / L) was sprayed on the carpet surface. Then, the blank carpet was sent into an oven for hot air treatment, and the top of the BCF monofilament bundle was in a bent and divergent state, forming the carpet surface 2 of the silent monofilament bundle layer of the present invention. The monofilament fineness in the monofilament bundle was about 12.50DPF, and the density was about 21946 strands per square inch.

[0086] 5. Coat the back of the silent monofilament layer fabric with 500GSM TPE anti-slip glue. During coating, a hot air blower blows hot air to the blanket surface at a temperature of 120 degrees Celsius, further making the monofilaments on the blanket surface divergently inclined to obtain the lower blanket of the present invention.

[0087] 6. Complete cutting, finishing and packaging.

[0088] Example 3

[0089] 1. Choose 700GSM jacquard fabric as the blanket surface, as the blanket surface layer 1.

[0090] 2. The grey fabric was woven on a warp knitting machine using 215D / 36Fx37 island yarn DTY as the fleece yarn and 150D / 72F polyester DTY yarn as the base yarn. The fabric was opened and degreased with YZ-101 fiber opening agent 2g / L, caustic soda 100% 6g / L, and bath ratio 1:15. The opening temperature was controlled at about 95 degrees for 30 minutes, followed by dyeing, drying and shaping, and finally high-speed brushing / grabbing to obtain a silent microfiber layer. The microfiber part of the surface of the silent microfiber layer has a fiber content of 0.16DPF.

[0091] 3. The carpet surface layer 1 in step 1 and the silent microfiber layer in step 2 are compounded into the upper carpet of the present invention.

[0092] 4. 1800D / 30F polyester BCF monofilament yarn and 120GSM polyester imitation bonded non-woven fabric as base fabric were woven on a 1 / 6 tufting machine to form a blanket. 300GSM of Jieshengnuo electrostatic dust absorber (i.e., electrostatic enhancer), model 4957758, with a ratio of 30g / L, was sprayed on the finished blanket. Then, SBR glue was coated on the back of the blanket and dried in a hot air oven to form a blanket surface layer 2. The stitches were about 10 needles / inch, the pile height was 5mm, and the monofilament density was about 1800 strands / square inch. The drying and shaping temperature was 160 degrees Celsius. After shaping, the ends of the monofilaments of the monofilament bundle showed a diffused micro-bend shape.

[0093] 5. Compound the fabric prepared in step 4 with 3D mesh cloth using PUR adhesive to obtain the lower layer carpet of the present invention. 30GSM SEBS hot melt anti-slip adhesive is coated on the back of the 3D mesh cloth.

[0094] 6. Complete cutting, finishing and packaging.

[0095] Comparative Example 1

[0096] The preparation method of this comparative example is basically the same as that of Example 1, except that the mute monofilament bundle layer fabric is replaced with a barbed mesh fabric with a base yarn of 300D monofilament and barbs of 450D monofilament. The multi-layer carpet obtained in Example 1 is used as an experimental example, and the multi-layer carpet obtained in Comparative Example 1 is used as a comparative example, and the following experiment is carried out (the experimental bonding area is 13CM×19CM).

[0097] Experiment 1: Fix the experimental and comparative carpets on the same wood-grain floor, then use a tensioner to hook the middle right part of the upper carpet surface and slowly pull it until the upper and lower carpet surfaces separate and record the tension reading at that moment to test the horizontal bonding tension. The results are as follows:

[0098] Experimental example = 121 Newtons;

[0099] Comparative = 87 Newtons.

[0100] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0101] Experimental example = Almost no change

[0102] Comparative Example = The ultra-fine fiber bundle layer has a lot of damaged fluff, and many black barbed wires are broken and left on the ultra-fine fiber bundle layer.

[0103] Comparative Example 2

[0104] The preparation method of this comparative example is basically the same as that of Example 1, except that the mute monofilament layer fabric is replaced with singed felt sub-fiber (6DX51MM+2.5DX51MM needle-punched into track non-woven felt and then subjected to heat processing and singeing treatment). The multi-layer carpet obtained in Example 1 is used as an experimental example, and the multi-layer carpet obtained in Comparative Example 2 is used as a comparative example, and the following experiment is carried out (the experimental bonding area is 13CM×19CM).

[0105] Experiment 1: Fix the experimental example and the comparative example on the same wood grain floor, then use a tensioner to hook the middle part of the right side of the upper carpet surface and slowly pull it until the upper and lower carpet surfaces are separated and record the tension reading at that moment to test the horizontal bonding tension. The results are as follows:

[0106] Experimental example = 121 Newtons;

[0107] Comparative = 85 Newtons.

[0108] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0109] Experimental case = almost no change;

[0110] Comparative Example = Many black spots and broken fibers were attached to the ultrafine fiber bundle layer.

[0111] Comparative Example 3

[0112] The preparation method of this comparative example is basically the same as that of Example 1, except that the mute monofilament layer fabric is replaced with a singed felt fiber, 6DX51MM+2.5DX51MM is needle-punched into a track non-woven felt and then subjected to a heat-processed singeing treatment, and the ultrafine fiber bundle layer is replaced with a 300D / 48F weft-knitted raised cloth. The multi-layer carpet obtained in Example 1 is used as an experimental example, and the multi-layer carpet obtained in Comparative Example 3 is used as a comparative example, and the following experiment is conducted (the experimental bonding area is 13CM×19CM).

[0113] Experiment 1: Fix the experimental example and the comparative example on the same wood grain floor, then use a tensioner to hook the middle part of the right side of the upper carpet surface and slowly pull it until the upper and lower carpet surfaces are separated and record the tension reading at that moment to test the horizontal bonding tension. The results are as follows:

[0114] Experimental example = 121 Newtons;

[0115] Comparative = 23 Newtons.

[0116] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0117] Experimental case = almost no change;

[0118] Comparative Example = Many black broken felt fibers appeared on the ultrafine fiber bundle layer, and some of the weft-knitted brushed fabric was broken and exposed.

[0119] Comparative Example 4

[0120] The preparation method of this comparative example is basically the same as that of Example 2, except that in step 3, 105D / 36Fx37 polyester-nylon composite spinning and 100D high shrinkage yarn are used to form 180gsm terry cloth by weft knitting machine, dyed, dried and shaped, and then compounded with the blanket surface to form an upper blanket, and the lower blanket is the same as that of Example 2;

[0121] The multi-layer carpet obtained in Example 2 was used as an experimental example, and the multi-layer carpet obtained in Comparative Example 4 was used as a comparative example to conduct the following experiment (the experimental bonding area was 13CM×19CM).

[0122] Experiment 1: Fix the experimental example and the comparative example on the same wood grain floor, then use a tensioner to hook the middle part of the right side of the upper carpet surface and slowly pull it until the upper and lower carpet surfaces are separated and record the tension reading at that moment to test the horizontal bonding tension. The results are as follows:

[0123] Experimental example = 91 Newtons;

[0124] Comparative = 72 Newtons.

[0125] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 5000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0126] Experimental example = basically no change;

[0127] Comparative = Slight damage to the loops.

[0128] Example 4

[0129] The preparation method of this embodiment is basically the same as that of embodiment 2, except that no stiffening agent is added in step 3. The multi-layer carpets obtained in embodiments 2 and 4 were subjected to the following experiment (the experimental bonding area is 13CM×19CM).

[0130] Experiment 1: Place Example 2 and Example 4 on the same wood grain floor, then use a tensioner to hook the middle part of the right side of the upper carpet surface and slowly pull until the upper and lower carpet surfaces are separated and record the tension reading at that moment to test the horizontal bonding tension. The results are as follows:

[0131] Example 2 = 91 Newtons;

[0132] Example 4 = 83 Newtons.

[0133] Experiment 2: Example 2 and Example 4 were quickly opened and closed, opened again, and closed again, and repeated 1000 times to observe the appearance of the four fabrics of the comparative example and test the durability. The results are as follows:

[0134] Example 2 = Almost no change;

[0135] Example 4 = Almost no change.

[0136] Example 5

[0137] The preparation method of this embodiment is basically the same as that of embodiment 3, except that no static enhancer is added to the mute monofilament layer fabric. The multi-layer carpets obtained in embodiments 3 and 5 were subjected to the following experiment (the experimental bonding area is 13CM×19CM).

[0138] The multi-layer carpets obtained in Example 3 and Example 5 were fixed on the same wood-grain floor, and then a tensioner was hooked on the middle part of the right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces were separated and the tension reading at that moment was recorded to test the horizontal bonding tension. The results were as follows:

[0139] Example 3 = 109 Newtons;

[0140] Example 5 = 92 Newtons.

[0141] Experiment 2: Example 3 and Example 5 were quickly opened and closed, opened again, and closed again, and repeated 1000 times to observe the appearance of the four fabrics of the comparative example and test the durability. The results are as follows:

[0142] Example 3 = Almost no change;

[0143] Example 5 = Almost no change.

[0144] In summary, it can be seen that under the filament fineness and filament density of the silent filament bundle layer of the present invention, the obtained multi-layer carpet has excellent horizontal bonding tension, durability and economic value. In addition, stiffeners are usually used for flat fabrics to make the fabrics more stiff. The present invention creatively uses stiffeners to add a small amount of stiffeners in the processing steps of the silent filament bundle layer, and unexpectedly finds that the horizontal bonding tension of the carpet can be improved, the use scenarios of the carpet can be expanded, and the durability of the carpet can be enhanced. At the same time, the present invention creatively adds a small amount of electrostatic enhancer (electrostatic dust absorber) in the processing steps of the silent filament bundle layer to further enhance the horizontal bonding tension of the upper and lower carpets. More importantly, unlike the hook-and-loop bonding of the traditional loop and hook structure, the surface of the silent ultra-fiber layer of the present invention is distributed with ultra-fine fiber bundles, which can easily produce a strong electrostatic adsorption effect under the action of gravity and external force, and has a strong horizontal bonding tension after bonding with the silent filament bundle layer, achieving a strong bonding effect, and having higher durability.

[0145] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art may make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A multi-layer carpet, characterized in that: The multi-layer carpet comprises an upper carpet and a lower carpet, wherein the upper carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, and the lower carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper carpet and the lower carpet are connected by detachably bonding the carpet back layer and the carpet surface layer 2; The blanket back layer is a silent monofilament bundle layer, and the blanket surface layer 2 is a silent microfiber layer; Or, the blanket back layer is a silent microfiber layer, and the blanket surface layer 2 is a silent monofilament bundle layer; The silent monofilament bundle layer is a monofilament bundle layer with a plurality of monofilament bundles distributed thereon, wherein the monofilament bundle is composed of a plurality of monofilaments on the bottom, and the fineness of the monofilaments is 1.04-60DPF; the monofilament density of the silent monofilament bundle layer is 1200-180000 strands / square inch; The material of the silent monofilament bundle layer includes at least one of composite tow, animal hair fiber, and blended fiber of natural fiber and chemical fiber; The material of the silent microfiber layer includes at least one of a high shrinkage tow and a microfiber tow; The silent ultra-fine fiber layer is a bundle layer on which a plurality of ultra-fine fiber bundles are distributed.

2. The multi-layer carpet according to claim 1, characterized in that: The top end of the monofilament has a dispersed inclined or curved structure.

3. The multi-layer carpet according to claim 1, characterized in that: The fineness of the monofilament in the microfiber bundle is 0.05-2.08D.

4. A method for preparing a multi-layer carpet as claimed in any one of claims 1 to 3, characterized in that: The preparation method comprises the following steps: S1. Preparing a silent monofilament bundle layer: preparing a composite yarn bundle, or animal hair fiber, or a blended fiber of natural fiber and chemical fiber into a cut pile-like fabric, combing or heat-processing the cut pile-like fabric, and separating a monofilament bundle layer with monofilament bundles distributed therein, i.e., a silent monofilament bundle layer; S2. Preparation of a silent microfiber layer: knitting or woven fabrics made by paralleling high shrinkage tows and microfiber tows, or paralleling and stretching, or paralleling and stretching to form a network, and then high-temperature dyeing and degreasing to form fiber tows to obtain a hair bundle layer with microfiber hair bundles distributed thereon, i.e., a silent microfiber layer; the temperature of the high-temperature dyeing and degreasing is 60-230°C; S3, preparing a multi-layer carpet: compounding a carpet surface layer 1 with a silent monofilament bundle layer to form an upper carpet, and compounding a silent microfiber layer with an anti-slip layer to form a lower carpet; Or, the first carpet surface layer is compounded with the silent microfiber layer to form an upper carpet, and the silent monofilament bundle layer is compounded with the anti-slip layer to form a lower carpet; The multi-layer carpet is obtained.

5. The preparation method according to claim 4, characterized in that: Step S1 also includes adding a stiffener to the cut pile fabric before combing or heat processing, wherein the concentration of the stiffener is 10-30g / L and the usage amount is 30-500gsm; the combing includes at least one of sanding, combing, silk cutting and ironing processes; the heat processing includes at least one of hot blowing process and ironing process.

6. The preparation method according to claim 4, characterized in that: Step S1 also includes adding an electrostatic dust absorber to the cut pile fabric of the silent monofilament layer before combing or heat processing, wherein the concentration of the electrostatic dust absorber is 10-50 g / L and the usage amount is 20-300 gsm.

Images