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

Abstract

The present invention provides a multi-layer, mixed-color fiber wear-resistant carpet and its preparation system, method, and application, belonging to the field of layered resin fiber carpet materials. Polyamide 6 and color masterbatches are simultaneously mixed in different screw extruders to prepare fiber filaments of different colors. After processing, mixed-color fiber bundles are prepared. Tufting is then continued to obtain a base fabric layer and a pile layer. Different functional layers are then stacked to obtain the multi-layer, mixed-color fiber wear-resistant carpet. The mixed-color fiber bundles in the present invention form a high-density cut pile structure in the carpet layer structure after tufting by a tufting machine. The expanded curled structure of the mixed-color fiber bundles can give the pile layer high resilience, making it less likely to collapse after long-term trampling, maintaining a smooth appearance, and the arrangement of different layers improves the composite strength of the carpet.

Description

Technical Field

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

[0002] In today's fiercely competitive global automotive market, the proportion of young consumers continues to rise, and their demands for personalized and upgraded automotive soft interior materials and components are becoming increasingly prominent. This has led to new technological challenges for automotive carpet materials. To enhance the competitiveness of automotive carpets in the global market and achieve sustainable development of automotive interior carpet materials, continuous innovation in design, material performance, and process technology is urgently needed to increase the technological added value of carpet materials. However, current automotive carpet materials still face numerous challenges in design, performance, and process, significantly falling short of the innovation requirements.

[0003] Currently, conventional automotive carpet materials are mostly monochromatic, manufactured from BCF fibers in dark hues such as black and gray. This traditional design is difficult to adapt to the current design concepts of personalized automotive interior materials, resulting in a gradual decline in the technical added value of automotive carpets and an inability to meet consumers' increasingly diverse aesthetic needs. Furthermore, the trend towards more diverse and intelligent vehicle usage scenarios has also raised higher standards for the functionality of carpet materials.

[0004] With the continuous innovation and maturity of autonomous driving technology, shared, unmanned autonomous vehicles are gradually entering the market, placing higher demands on the cleanability of automotive carpets. Traditional, solid-color carpets, once contaminated by dust, will clearly show stains, significantly affecting the consumer's riding experience. Furthermore, the increasing use of see-through automotive glass means that vehicles are exposed to increased operating time in high-intensity lighting environments. Existing conventional tufted carpet materials face severe color decay, making it difficult to maintain long-term aesthetics. Furthermore, the relatively simple manufacturing process for traditional automotive carpets makes it difficult to achieve complex patterns and unique textures, limiting innovative breakthroughs in product appearance and hindering further improvements in material performance.

[0005] From a material performance perspective, current automotive carpet materials mostly utilize conventional low-denier BCF monofilament designs. In actual use, this material performs poorly in resisting heel abrasion. Prolonged wear and tear during driving or pedaling can easily expose the carpet's underside and significantly alter its color, severely impacting user experience. Furthermore, high gloss in automotive interior carpets can create a negative visual experience for consumers under high-intensity lighting conditions, further reducing the product's market competitiveness.

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

[0007] In response to the above problems, the present invention provides a multi-layer mixed-color fiber wear-resistant carpet, which is prepared by synchronously mixing polyamide 6 and masterbatch in different screw extruders to prepare fiber filaments of different colors, and then preparing mixed-color fiber bundles after processing, and then further tufting to obtain a base fabric layer and a pile layer, and further stacking different functional layers to prepare the multi-layer mixed-color fiber wear-resistant carpet. The multi-layer mixed-color fiber wear-resistant carpet has good wear resistance, high dirt storage capacity, and excellent UV resistance.

[0008] The present invention provides a multi-layer mixed-color fiber wear-resistant carpet, which has a multi-layer structure and comprises, from bottom to top, a bottom layer, a first anti-breakdown layer, a reinforcing layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder.

[0009] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 8-15 mm, a pile height of 3-8 mm, and a cut pile shape;

[0010] 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 1030-1120N at room temperature, a Taber wear resistance of 3900-4000 circles without leakage, a glossiness of ≤1.5°, a grayscale level of ≥4, and good dirt-retention properties.

[0011] The shrinkage rate of the multi-layer mixed-color fiber wear-resistant carpet is 0-0.5% after being placed at 220°C for 120 seconds;

[0012] The color difference of the color space (CIELab) of the multi-layer mixed-color fiber wear-resistant carpet is lightness color difference (ΔL) ≤ 0.5, red-green axis color difference (Δa) ≤ 0.1, and yellow-blue axis color difference (Δb) ≤ 0.1.

[0013] Furthermore, the elongation at break at room temperature in the machine direction (MD) is 55-60%, and the elongation at break perpendicular to the machine direction (CD) is 50-55%.

[0014] Furthermore, the elongation at break at 130° C. in the machine direction (MD) is 115-121%, and the elongation at break perpendicular to the machine direction (CD) is 115-123%.

[0015] Furthermore, the breaking strength at room temperature in the machine direction (MD) is 1030-1105N, and the breaking strength perpendicular to the machine direction (CD) is 1050-1120N.

[0016] Furthermore, the shrinkage rate in the machine direction (MD) is 0-0.5%, and the shrinkage rate in the direction perpendicular to the machine direction (CD) is 0-0.4%.

[0017] Furthermore, the adhesive layer is compounded on the bottom of the base fabric layer by coating, and the polyethylene-polyamide-polyethylene film and the needle-punched bottom felt are compounded on the bottom of the adhesive layer by means of a laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and then the polyethylene-polyamide-polyethylene film and the non-woven base fabric are further compounded on the bottom of the reinforcing layer by means of a laminating adhesive to obtain the first anti-breakdown layer and the bottom layer.

[0018] 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 material, the preparation system includes a spinning unit, a puffing unit, a tufting unit and a compounding unit;

[0019] The spinning unit includes a screw extruder, a spinning box, an oiling device and a stretching device;

[0020] The puffing unit includes an air texturing machine, a cooling roller, a spinning net and a winder;

[0021] The tufting unit includes a tufting machine;

[0022] The composite unit includes a coating device, a laminating device and a drying machine;

[0023] The number of the screw extruders is ≥2;

[0024] The spinning box is provided with a spinneret and a tunnel, wherein the spinneret is a trilobal spinneret;

[0025] A feed port is provided above the spinning manifold, and the molten material in the screw extruder enters the spinning manifold through the feed port of the spinning manifold;

[0026] The spinning box is provided with a blowing device on the side, and a tunnel is vertically provided below. The tunnel is provided with an air inlet, and the blowing device cools the spun fiber filaments through the air inlet.

[0027] The number of the feed ports, spinnerets and corridors of the spinning manifold is consistent with the number of the screw extruders. The materials in the screw extruders enter different feed ports respectively and are spun and air-cooled through different spinnerets and corridors.

[0028] Furthermore, the screw extruder is a single-screw extruder.

[0029] Furthermore, when the number of the screw extruders is 2, it includes screw extruder 1 and screw extruder 2.

[0030] Furthermore, a metering pump is installed at the spinneret to quantify the spun material, and the speed of the metering pump is consistent.

[0031] Furthermore, the stretching device includes a primary stretching guide roller and a secondary stretching guide roller.

[0032] Furthermore, the air texturing machine is provided with a nozzle, through which low-pressure air is blown onto the fibers.

[0033] Furthermore, a guide roller is installed between the spinning network device and the cooling roller, and the guide roller is used to transport the fiber filaments, and the fiber filaments are network-processed in the spinning network device.

[0034] Furthermore, a guide roller is installed between the winder and the spinning network device, and the guide roller is used to transport the fiber filaments.

[0035] The present invention also provides a method for preparing the multi-layer mixed-color fiber wear-resistant carpet using the preparation system, comprising the following steps:

[0036] Step 1: prepare a non-woven base fabric, tuft a 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 apply water-based foamed latex to the bottom of the base fabric layer, and dry it to obtain an adhesive layer;

[0037] Step 2: After bonding the polyethylene-polyamide-polyethylene film (PEPAPE) with a laminating adhesive at the bottom of the adhesive layer, bonding the needle-punched base felt with a laminating adhesive, and after cooling, obtaining the second anti-breakdown layer and the reinforcement layer; after bonding the polyethylene-polyamide-polyethylene film (PEPAPE) with a laminating adhesive at the bottom of the reinforcement layer, bonding the non-woven base fabric with a laminating adhesive, and after cooling, obtaining the first anti-breakdown layer and the base layer; and finally obtaining the multi-layer mixed-color fiber wear-resistant carpet.

[0038] Furthermore, the preparation process of the mixed color fiber bundle includes the following steps:

[0039] S1, set up two screw extruders, divided into screw extruder 1 and screw extruder 2, add polyamide 6, black masterbatch and spinning oil into the screw extruder 1 for melt mixing, and add polyamide 6, white masterbatch and spinning oil into the screw extruder 2 for melt mixing;

[0040] S2, delivering the molten materials in S1 into a spinning manifold through different feed ports, respectively, passing through a metering pump and spinning through a dark spinneret and a light spinneret in the spinning manifold, respectively, and cooling the spun fibers through a dark channel and a light channel vertically arranged below the spinning manifold by a blowing device under cold air, respectively, to obtain solidified dark fiber fibers and light fiber fibers;

[0041] S3, oiling the dark fiber yarn and the light fiber yarn separately using an oiling device, and then stretching the oiled fiber yarns together through a stretching device to obtain stretched fiber yarns;

[0042] S4. The stretched fiber yarn is placed in an air texturing machine for air-jet puffing. The puffed fiber yarn is cooled by a cooling roller to obtain a bulked fiber yarn. The bulked fiber yarn is introduced into a spinning network device through a guide roller for knotting. The knotted bulked fiber is introduced into a winding machine through a guide roller and wound into a cylindrical yarn tube to obtain a mixed-color fiber bundle.

[0043] Furthermore, the mass ratio of the polyamide 6, the black masterbatch and the spinning oil in S1 is (95-97): (2-4): (0.5-1).

[0044] Furthermore, the mass ratio of the polyamide 6, the white masterbatch and the spinning oil in S1 is (95-97): (2-4): (0.5-1).

[0045] Furthermore, the relative viscosity of the polyamide 6 in S1 is 2.70-2.83 dl / g.

[0046] Furthermore, the processing temperature of the screw extruder 1 and the screw extruder 2 in S1 is 250-280°C, divided into four temperature zones, wherein 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.

[0047] Furthermore, the spinning speed of the metering pump in S2 is 400-500 g / min.

[0048] Furthermore, the spinneret in S2 is a trilobal spinneret, and the number of holes in the spinneret is 45-55.

[0049] Furthermore, the temperature of the spinning manifold in S2 is set to 250-270°C.

[0050] Furthermore, the spinning pressure of the spinning manifold in S2 is 60-110 bar.

[0051] Furthermore, the ambient temperature of the dark corridor and the light corridor in S2 are both 18-21° C., and the humidity is 80-85% RH.

[0052] Furthermore, the cooling air pressure of the blowing device in S2 is 4-5 mbar, and the wind speed is 0.25-0.7 m / s.

[0053] Furthermore, the oiling rate in S3 is 0.6-1.2%.

[0054] Furthermore, the stretching in S3 is divided into primary stretching and secondary stretching.

[0055] Furthermore, the temperature of the primary stretching is 80-90° C., and the stretching ratio of the primary stretching is 1.01-1.05.

[0056] Furthermore, the temperature of the secondary stretching is 170-190° C., and the stretching ratio of the secondary stretching is 2.3-2.5.

[0057] Furthermore, the puffing temperature in the air texturing machine in S4 is 170-190° C., and the nozzle pressure is 5-7 bar.

[0058] Furthermore, in S4, the rotation speed of the cooling roller is 30-60 rpm, and the temperature of the cooling roller is 20-30°C.

[0059] Furthermore, the gas pressure in the spinning network device in S4 is 4-8 bar.

[0060] Furthermore, the number of knots tied in S4 is 28-30.

[0061] Furthermore, the mixed color fiber bundle in S4 has a total curl of 15-25%, a fineness of 1500-2000D, and a number of holes of 90-110.

[0062] Furthermore, the non-woven fabric in step 1 is a polyethylene terephthalate (PET) non-woven fabric with a gram weight of 90-140 gsm.

[0063] Furthermore, the needle pitch of the tufting machine in step 1 is 1 / 10 or 5 / 64, the weft knitting density is 39.37 needles / cm or 50.39 needles / cm, and the warp knitting density is 50-60 needles / cm.

[0064] Furthermore, the wet latex weight 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.

[0065] Furthermore, the water-based foaming latex in step 1 is ethylene-vinyl acetate copolymer (EVA) water-based foaming latex.

[0066] Furthermore, the coating speed in step 1 is 4-5 m / min.

[0067] Furthermore, the drying temperature in step 1 is 130-140° C., and the drying time is 2.5-3 minutes.

[0068] Furthermore, the adhesive layer in step 1 has a gram weight of 70-100 gsm.

[0069] Furthermore, the binder in step 2 is polyethylene with a gram weight of 200-500gsm.

[0070] Furthermore, in step 2, the weight of the second anti-penetration layer is 200-500 gsm, and the weight of the reinforcement layer is 300-1000 gsm.

[0071] Furthermore, in step 2, the anti-penetration layer 1 has a gram weight of 200-500 gsm, and the bottom layer has a gram weight of 80-200 gsm.

[0072] Furthermore, the needle-punched base felt in step 2 is polyethylene terephthalate (PET) needle-punched base felt.

[0073] Furthermore, the non-woven base fabric in step 2 is a polyethylene terephthalate (PET) non-woven base fabric.

[0074] Furthermore, in step 2, the laminating speed is 3-4 m / min, and the laminating temperature is 230-240°C.

[0075] The present invention also provides a car floor mat, which is prepared from the multi-layer mixed-color fiber wear-resistant carpet.

[0076] Beneficial effects of the present invention:

[0077] 1. The present invention adopts two screw extruders to melt and mix respectively to realize the simultaneous preparation of dark and light-colored fibers. The proportion of each component can be accurately controlled by the metering pump in the spinning box. The black masterbatch of the dark fiber and the white masterbatch of the light-colored fiber are evenly dispersed in their respective screws. After being extruded through the three-leaf spinneret, the fiber color consistency is high, which meets the strict requirements of automobile interior for color uniformity. At the same time, the production efficiency of the fiber yarn is also improved through the parallel process; the present invention adopts the three-leaf spinneret for spinning, which improves the friction and cohesion of the fiber, reduces the hair removal phenomenon during tufting, and improves the pulling force of the pile. The fiber yarn spinning undergoes primary stretching to preliminarily orient the fiber molecular chain, and the secondary stretching further improves the crystallinity, enhances the bundling of the fiber bundle, and avoids the loosening of the bulked fiber during the winding process; in addition, the polyamide 6 in the present invention is spun at a specific temperature and spinning conditions, which simultaneously improves the mechanical properties of the fiber yarn such as breaking strength;

[0078] 2. The mixed-color fiber bundles in the present invention form a high-density cut pile structure in the layer structure of the carpet after tufting by a tufting machine, and the expanded curled structure of the mixed-color fiber bundles can give the pile layer high resilience, which is not easy to collapse after long-term trampling, maintaining the flatness of the appearance, and can also effectively resist high-frequency friction from soles, sand and gravel, etc. The foamed latex in the adhesive layer is water-based latex, which reduces the odor of the carpet. The second anti-penetration layer and the first anti-penetration layer are bonded by a laminating process, which can resist puncture from sharp objects and protect the base fabric from damage. The composite of the reinforcing layer and the bottom layer improves the shear strength between the layers and avoids the hidden danger of delamination. The reinforcing layer can also absorb tire noise. BRIEF DESCRIPTION OF THE DRAWINGS

[0079] Figure 1 This is a test chart of the wear resistance performance of the multi-layer mixed-color fiber wear-resistant carpet described in Example 1;

[0080] Figure 2 This is a state diagram of the surface pile layer of the multi-layer mixed-color fiber wear-resistant carpet described in Example 2;

[0081] Figure 3 This is a detailed state diagram of the surface pile layer of the multi-layer mixed-color fiber wear-resistant carpet described in Example 2;

[0082] Figure 4 This is a glossiness test chart of the tufted carpets described in Comparative Example 1 and Example 1;

[0083] Figure 5 This is a flow chart for testing the dirt-holding effect of the wear-resistant carpets described in Comparative Example 2 and Example 1;

[0084] Figure 6 This is a diagram showing the stain-holding performance of the wear-resistant carpets described in Comparative Example 2 and Example 1;

[0085] Figure 7 Schematic diagram of the structure of the system for preparing the multi-layer mixed-color fiber wear-resistant carpet of the present invention;

[0086] Figure 8 Schematic diagram of the structure of the spinning unit of the present invention;

[0087] Figure 9 Schematic diagram of the structure of the trilobal spinneret of the present invention;

[0088] Figure 10 Schematic diagram of the structure of the mixed color fiber bundle of the present invention;

[0089] Figure 11 Schematic diagram of the interlayer structure of the multi-layer mixed-color fiber wear-resistant carpet of the present invention;

[0090] The names of the numbers in the figure are: 1. Spinning unit; 2. Puffing unit; 3. Tufting unit; 4. Composite unit; 5. Screw extruder; 6. Spinning box; 7. Oiling device; 8. Stretching device; 9. Air texturing machine; 10. Cooling roller; 11. Spinning network device; 12. Winding machine; 13. Tufting machine; 14. Coating device; 15. Dryer; 16. Laminating device; 501. Screw extruder 1; 502. Screw extruder 2; 601. Feed port; 602. Spinneret; 603. Corridor; 604. Metering pump; 605. Blowing device; 801. Primary stretching guide roller; 802. Secondary stretching guide roller. DETAILED DESCRIPTION

[0091] The invention is described in detail below with reference to the embodiments:

[0092] The present invention provides a multi-layer mixed-color fiber wear-resistant carpet and a preparation system, method and application thereof. A high-performance wear-resistant multi-layer carpet is prepared by preparing mixed-color fiber bundles, which greatly improves its wear resistance, mechanical properties and aging resistance.

[0093] Example 1

[0094] The present embodiment provides a multi-layered mixed-color fiber wear-resistant carpet, which has a multi-layer structure and comprises, from bottom to top, a base layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder.

[0095] The adhesive layer is composited on the bottom of the base fabric layer by coating, a polyethylene-polyamide-polyethylene film and a needle-punched bottom felt are composited on the bottom of the adhesive layer by laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and a polyethylene-polyamide-polyethylene film and a non-woven base fabric are further composited on the bottom of the reinforcing layer by laminating adhesive to obtain the first anti-breakdown layer and the bottom layer;

[0096] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 9 mm, a pile height of 3 mm, and a cut pile shape;

[0097] The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break in the machine direction (MD) of 55% at room temperature and an elongation at break perpendicular to the machine direction (CD) of 52% at room temperature; an elongation at break in the machine direction (MD) of 115% at 130°C and an elongation at break perpendicular to the machine direction (CD) of 119% at 130°C;

[0098] The multi-layer mixed-color fiber wear-resistant carpet has a breaking strength of 1082N in the machine direction (MD) at room temperature and a breaking strength of 1112N perpendicular to the machine direction (CD) at room temperature.

[0099] The Taber wear resistance of the multi-layer mixed color fiber wear-resistant carpet is 3950 turns without leakage;

[0100] After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220° C. for 120 seconds, the shrinkage in the machine direction (MD) is 0.5%, and the shrinkage in the direction perpendicular to the machine direction (CD) is 0%;

[0101] The lightness (L) of the CIELab color space of the multi-layer mixed-color fiber wear-resistant carpet is 24.47, the red-green axis color (a) is -0.15, and the yellow-blue axis color (b) is -0.16; the grayscale level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is level 4;

[0102] The multi-layer mixed-color fiber wear-resistant carpet has a glossiness of 1.3° and good dirt-hiding property.

[0103] This embodiment also provides a method for preparing the multi-layer mixed-color fiber wear-resistant carpet using the preparation system, comprising the following steps:

[0104] S1. Two screw extruders 5 are set up, namely screw extruder 1 501 and screw extruder 2 502. Polyamide 6, black masterbatch and spinning oil in a mass ratio of 97:2.5:0.5 are added to the screw extruder 1 501 for melt mixing. At the same time, polyamide 6, white masterbatch and spinning oil in a mass ratio of 97:2.5:0.5 are added to the screw extruder 2 502 for melt mixing. The processing temperature of the screw extruder 1 501 and the screw extruder 2 502 is 250-270°C, which is divided into four temperature zones, wherein 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.

[0105] S2. The molten material in S1 is respectively delivered to the spinning manifold 6 through different feed ports 601, and the molten material is respectively spun through a 50-hole dark trilobal spinneret and a 50-hole light trilobal spinneret in the spinning manifold 6 at a speed of 500 g / min by a metering pump 604 at 250° C. and 110 bar. The spun fiber filaments are respectively cooled by a cold air of 5 mbar and 0.25 m / s at conditions of 18° C. and 85% RH through a blowing device 605 to obtain solidified dark fiber filaments and light fiber filaments.

[0106] S3, oiling the dark fiber filaments and the light fiber filaments separately using an oiling device 7, with an oiling rate of 0.6%. Then, the oiled fiber filaments are passed through a primary stretching guide roller 801 for primary stretching, wherein the temperature of the primary stretching guide roller 801 is 80° C. and the stretching ratio is 1.01. Then, the fiber filaments are passed through a secondary stretching guide roller 802 for secondary stretching, wherein the temperature of the secondary stretching guide roller 802 is 170° C. and the stretching ratio is 2.3, to obtain stretched fiber filaments;

[0107] S4. The stretched fiber filaments are placed in an air texturing machine 9 and subjected to air-jet puffing at 170° C. and a nozzle pressure of 5 bar. The puffed fiber filaments are cooled by a cooling roller 10 at a rotation speed of 30 rpm and a temperature of 20° C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning net 11 via a guide roller for knotting. The number of knots is 28±1. The air pressure in the spinning net 11 is 4 bar. The knotted bulked fiber filaments are introduced into a winder 12 via a guide roller and wound into a cylindrical bobbin to obtain a mixed-color fiber bundle.

[0108] The mixed color fiber bundle has a total curl of 15%, a fineness of 1500D, and 100 holes;

[0109] Step 1: A 90 gsm polyethylene terephthalate (PET) non-woven fabric is provided, and the mixed color fiber bundle is tufted onto the non-woven fabric through a tufting machine 13. The needle pitch of the tufting machine 13 is controlled to be 1 / 10, the weft knitting density is 39.37 needles / cm, and the warp knitting density is 50 needles / cm to obtain a cut pile layer and a base fabric layer. Ethylene vinyl acetate copolymer (EVA) water-based foamed latex (wet glue weight of 230 gsm, wet latex solid content of 40%, and foaming ratio of 2.0 times) is then applied to the bottom of the base fabric layer using a coating device 14 at a speed of 5 m / min. The layer is then placed in a dryer 15 and dried at 130° C. for 2.5 minutes to obtain a 70 gsm adhesive layer.

[0110] Step 2: Laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. using a laminating device 16, and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, to obtain a 200 gsm second anti-penetration layer and a 500 gsm reinforcement layer after cooling; laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 230° C. using a laminating device 16, and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, to obtain a 200 gsm first anti-penetration layer and a 150 gsm bottom layer after cooling; finally, the multi-layer mixed-color fiber wear-resistant carpet is obtained.

[0111] like Figure 1 This 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 chart, after the wear resistance test, the wear-resistant carpet of the present invention does not leak as the weight loss increases, indicating excellent wear resistance.

[0112] Example 2

[0113] The present embodiment provides a multi-layered mixed-color fiber wear-resistant carpet, which has a multi-layer structure and comprises, from bottom to top, a base layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder.

[0114] The adhesive layer is composited on the bottom of the base fabric layer by coating, a polyethylene-polyamide-polyethylene film and a needle-punched bottom felt are composited on the bottom of the adhesive layer by laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and a polyethylene-polyamide-polyethylene film and a non-woven base fabric are further composited on the bottom of the reinforcing layer by laminating adhesive to obtain the first anti-breakdown layer and the bottom layer;

[0115] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 8 mm, a pile height of 5 mm, and a cut pile shape;

[0116] The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 58% in the machine direction (MD) at room temperature and 51% in the direction perpendicular to the machine direction (CD) at room temperature; an elongation at break of 120% in the machine direction (MD) at 130°C and 123% in the direction perpendicular to the machine direction (CD) at 130°C;

[0117] The multi-layer mixed-color fiber wear-resistant carpet has a breaking strength of 1039N in the machine direction (MD) at room temperature and a breaking strength of 1098N perpendicular to the machine direction (CD) at room temperature.

[0118] The Taber wear resistance of the multi-layer mixed color fiber wear-resistant carpet is 4000 turns without leakage;

[0119] After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220° C. for 120 seconds, the shrinkage rate in the machine direction (MD) is 0.3%, and the shrinkage rate in the cross-machine direction (CD) is 0.2%;

[0120] The lightness (L) of the CIELab color space of the multi-layer mixed-color fiber wear-resistant carpet is 24.48, the red-green axis color (a) is -0.14, and the yellow-blue axis color (b) is -0.17; the grayscale level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is level 4;

[0121] The multi-layer mixed-color fiber wear-resistant carpet has a glossiness of 1.4° and good dirt-hiding property.

[0122] This embodiment also provides a method for preparing the multi-layer mixed-color fiber wear-resistant carpet using the preparation system, comprising the following steps:

[0123] S1. Two screw extruders 5 are set up, namely screw extruder 1 501 and screw extruder 2 502. Polyamide 6, black masterbatch and spinning oil in a mass ratio of 97:2:1 are added to the screw extruder 1 501 for melt mixing. At the same time, polyamide 6, white masterbatch and spinning oil in a mass ratio of 97:2:1 are added to 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, wherein 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.

[0124] S2. The molten material in S1 is respectively delivered to the spinning manifold 6 through different feed ports 601, and the molten material is respectively spun through a 45-hole dark trilobal spinneret and a 45-hole light trilobal spinneret in the spinning manifold 6 at a speed of 500 g / min by a metering pump 604 at 270° C. and 60 bar. The spun fiber filaments are respectively passed through a dark channel and a light channel vertically arranged below the spinning manifold 6, and are cooled by a cold air of 4 mbar and 0.5 m / s at 21° C. and 80% RH by a blowing device 605, to obtain solidified dark fiber filaments and light fiber filaments.

[0125] S3, oiling the dark fiber filaments and the light fiber filaments separately using an oiling device 7, with an oiling rate of 1%, and then passing the oiled fiber filaments together through a primary stretching guide roller 801 for primary stretching, wherein the temperature of the primary stretching guide roller 801 is 90° C. and the stretching ratio is 1.03, and then passing through a secondary stretching guide roller 802 for secondary stretching, wherein the temperature of the secondary stretching guide roller 802 is 190° C. and the stretching ratio is 2.5, to obtain stretched fiber filaments;

[0126] S4. The stretched fiber filaments are placed in an air texturing machine 9 and subjected to air-jet puffing at 180° C. and a nozzle pressure of 5 bar. The puffed fiber filaments are cooled by a cooling roller 10 at a rotation speed of 30 rpm and a temperature of 25° C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning net 11 via a guide roller for knotting. The number of knots is 28±1. The air pressure in the spinning net 11 is 6 bar. The knotted bulked fiber filaments are introduced into a winder 12 via a guide roller and wound into a cylindrical bobbin to obtain a mixed-color fiber bundle.

[0127] The mixed color fiber bundle has a total curl of 17%, a fineness of 1800D, and 90 holes;

[0128] Step 1: Prepare a 140 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 needle pitch of the tufting machine 13 to 5 / 64, the weft knitting density to 50.39 needles / cm, and the warp knitting density to 55 needles / cm, to obtain a cut pile layer and a base fabric layer, and then apply ethylene-vinyl acetate copolymer water-based foamed latex (wet glue weight of 250 gsm, wet latex solid content of 30%, and foaming ratio of 3.0 times) to the bottom of the base fabric layer using a coating device 14 at a speed of 4 m / min, and place the mixture in a dryer 15 and dry it at 140° C. for 2.5 minutes to obtain a 90 gsm adhesive layer;

[0129] Step 2: Laminating 300 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 240° C. using a laminating device 16, and then laminating 300 gsm of polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, to obtain a 300 gsm second anti-penetration layer and a 300 gsm reinforcement layer after cooling; laminating 300 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 240° C. using a laminating device 16, and then laminating 300 gsm of polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, to obtain a 300 gsm first anti-penetration layer and a 100 gsm bottom layer after cooling; finally, the multi-layer mixed-color fiber wear-resistant carpet is obtained.

[0130] like Figure 2 This is a state diagram of the surface pile layer of the multi-layer mixed-color fiber wear-resistant carpet described in this embodiment. The pile layer in the figure is arranged regularly and has uniform color.

[0131] like Figure 3 This is a detailed state diagram of the surface pile layer of the multi-layer mixed-color fiber wear-resistant carpet in Example 2. In the figure, the color contrast of the pile layer is clear.

[0132] Example 3

[0133] The present embodiment provides a multi-layered mixed-color fiber wear-resistant carpet, which has a multi-layer structure and comprises, from bottom to top, a base layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder.

[0134] The adhesive layer is composited on the bottom of the base fabric layer by coating, a polyethylene-polyamide-polyethylene film and a needle-punched bottom felt are composited on the bottom of the adhesive layer by laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and a polyethylene-polyamide-polyethylene film and a non-woven base fabric are further composited on the bottom of the reinforcing layer by laminating adhesive to obtain the first anti-breakdown layer and the bottom layer;

[0135] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 12 mm, a pile height of 8 mm, and a cut pile shape;

[0136] The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 59% in the machine direction (MD) at room temperature and 52% in the direction perpendicular to the machine direction (CD) at room temperature; an elongation at break of 121% in the machine direction (MD) at 130°C and 115% in the direction perpendicular to the machine direction (CD) at 130°C;

[0137] The multi-layer mixed-color fiber wear-resistant carpet has a breaking strength of 1104N in the machine direction (MD) at room temperature and a breaking strength of 1116N perpendicular to the machine direction (CD) at room temperature.

[0138] The Taber wear-resistant number of the multi-layer mixed-color fiber wear-resistant carpet is 3955 turns without leakage;

[0139] After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220° C. for 120 seconds, the shrinkage rate in the machine direction (MD) is 0.5%, and the shrinkage rate in the cross-machine direction (CD) is 0.4%;

[0140] The lightness (L) of 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 grayscale level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is level 4;

[0141] The multi-layer mixed-color fiber wear-resistant carpet has a glossiness of 1.3° and good dirt-hiding property.

[0142] This embodiment also provides a method for preparing the multi-layer mixed-color fiber wear-resistant carpet using the preparation system, comprising the following steps:

[0143] S1. Two screw extruders 5 are set up, namely screw extruder 1 501 and screw extruder 2 502. Polyamide 6, black masterbatch and spinning oil in a mass ratio of 95:4:1 are added to the screw extruder 1 501 for melt mixing. At the same time, polyamide 6, white masterbatch and spinning oil in a mass ratio of 95:4:1 are added to the screw extruder 2 502 for melt mixing. The processing temperature of the screw extruder 1 501 and the screw extruder 2 502 is 250-270°C, which is divided into four temperature zones, wherein 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.

[0144] S2. The molten material in S1 is respectively delivered to the spinning manifold 6 through different feed ports 601, and spun through a 55-hole dark trilobal spinneret and a 55-hole light trilobal spinneret in the spinning manifold 6 at a speed of 400 g / min by a metering pump 604 at 260° C. and 80 bar. The spun fibers are respectively cooled by a blowing device 605 at 20° C. and 85% RH using a cold air flow of 5 mbar and 0.7 m / s, to obtain solidified dark fiber fibers and light fiber fibers.

[0145] S3, oiling the dark fiber filaments and the light fiber filaments separately using an oiling device 7, with an oiling rate of 1.2%. The oiled fiber filaments are then passed through a primary stretching guide roller 801 for primary stretching, wherein the temperature of the primary stretching guide roller 801 is 85° C. and the stretching ratio is 1.05. The fiber filaments are then passed through a secondary stretching guide roller 802 for secondary stretching, wherein the temperature of the secondary stretching guide roller 802 is 180° C. and the stretching ratio is 2.4, to obtain stretched fiber filaments;

[0146] S4. The stretched fiber filaments are placed in an air texturing machine 9 and subjected to air-jet puffing at 190° C. and a nozzle pressure of 7 bar. The puffed fiber filaments are cooled by a cooling roller 10 at a rotation speed of 60 rpm and a temperature of 30° C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning net 11 via a guide roller for knotting. The number of knots is 29±1. The air pressure in the spinning net 11 is 8 bar. The knotted bulked fiber filaments are introduced into a winder 12 via a guide roller and wound into a cylindrical bobbin to obtain a mixed-color fiber bundle.

[0147] The mixed color fiber bundle has a total curl of 25%, a fineness of 2000D, and a pore count of 110;

[0148] Step 1: A 110 gsm polyethylene terephthalate non-woven base fabric is provided, and the mixed color fiber bundle is tufted onto the non-woven base fabric through a tufting machine 13. The needle pitch of the tufting machine 13 is controlled to be 5 / 64, the weft knitting density is 50.39 needles / cm, and the warp knitting density is 60 needles / cm to obtain a cut pile layer and a base fabric layer. Ethylene-vinyl acetate copolymer water-based foamed latex (wet glue weight of 330 gsm, wet latex solid content of 30%, and foaming ratio of 3.0 times) is continuously applied to the bottom of the base fabric layer using a coating device 14 at a speed of 4 m / min. The layer is then placed in a dryer 15 and dried at 140° C. for 3 minutes to obtain a 100 gsm adhesive layer.

[0149] Step 2: Laminating a 400 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 3 m / min at 235° C. using a laminating device 16, and then laminating a 400 gsm polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, to obtain a 200 gsm anti-penetration layer 2 and a 1000 gsm reinforcement layer after cooling; laminating a 400 gsm polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 4 m / min at 240° C. using a laminating device 16, and then laminating a 400 gsm polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, to obtain a 300 gsm anti-penetration layer 1 and an 80 gsm base layer after cooling; and finally obtaining the multi-layer mixed-color fiber wear-resistant carpet.

[0150] Example 4

[0151] The present embodiment provides a multi-layered mixed-color fiber wear-resistant carpet, which has a multi-layer structure and comprises, from bottom to top, a base layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder.

[0152] The adhesive layer is composited on the bottom of the base fabric layer by coating, a polyethylene-polyamide-polyethylene film and a needle-punched bottom felt are composited on the bottom of the adhesive layer by laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and a polyethylene-polyamide-polyethylene film and a non-woven base fabric are further composited on the bottom of the reinforcing layer by laminating adhesive to obtain the first anti-breakdown layer and the bottom layer;

[0153] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 10 mm, a pile height of 8 mm, and a cut pile shape;

[0154] The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 56% in the machine direction (MD) at room temperature and 55% in the direction perpendicular to the machine direction (CD) at room temperature; an elongation at break of 117% in the machine direction (MD) at 130°C and 120% in the direction perpendicular to the machine direction (CD) at 130°C;

[0155] The multi-layer mixed-color fiber wear-resistant carpet has a breaking strength of 1103N in the machine direction (MD) at room temperature and a breaking strength of 1072N perpendicular to the machine direction (CD) at room temperature.

[0156] The Taber wear resistance of the multi-layer mixed color fiber wear-resistant carpet is 3900 turns without leakage;

[0157] After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220° C. for 120 seconds, the shrinkage in the machine direction (MD) is 0.1%, and the shrinkage in the direction perpendicular to the machine direction (CD) is 0%;

[0158] The lightness (L) of the CIELab color space of the multi-layer mixed-color fiber wear-resistant carpet is 24.37, the red-green axis color (a) is -0.14, and the yellow-blue axis color (b) is -0.16; the grayscale level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is level 4;

[0159] The multi-layer mixed-color fiber wear-resistant carpet has a glossiness of 1.5° and good dirt-hiding property.

[0160] This embodiment also provides a method for preparing the multi-layer mixed-color fiber wear-resistant carpet using the preparation system, comprising the following steps:

[0161] S1. Two screw extruders 5 are set up, namely screw extruder 1 501 and screw extruder 2 502. Polyamide 6, black masterbatch and spinning oil in a mass ratio of 97:2.5:0.5 are added to the screw extruder 1 501 for melt mixing. At the same time, polyamide 6, white masterbatch and spinning oil in a mass ratio of 97:2.5:0.5 are added to the screw extruder 2 502 for melt mixing. The processing temperature of the screw extruder 1 501 and the screw extruder 2 502 is 250-270°C, which is divided into four temperature zones, wherein 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.

[0162] S2. The molten material in S1 is respectively delivered to the spinning manifold 6 through different feed ports 601, and spun through a 50-hole dark trilobal spinneret and a 50-hole light trilobal spinneret in the spinning manifold 6 at a speed of 500 g / min by a metering pump 604 at 250° C. and 110 bar. The spun fibers are respectively cooled by a blowing device 605 at 18° C. and 85% RH using a cold air flow of 5 mbar and 0.3 m / s to obtain solidified dark fiber fibers and light fiber fibers.

[0163] S3, oiling the dark fiber filaments and the light fiber filaments separately using an oiling device 7, with an oiling rate of 0.8%. Then, the oiled fiber filaments are passed through a primary stretching guide roller 801 for primary stretching, wherein the temperature of the primary stretching guide roller 801 is 80° C. and the stretching ratio is 1.01. Then, the fiber filaments are passed through a secondary stretching guide roller 802 for secondary stretching, wherein the temperature of the secondary stretching guide roller 802 is 170° C. and the stretching ratio is 2.4, to obtain stretched fiber filaments;

[0164] S4. The stretched fiber filaments are placed in an air texturing machine 9 and subjected to air-jet puffing at 190° C. and a nozzle pressure of 5 bar. The puffed fiber filaments are cooled by a cooling roller 10 at a rotation speed of 50 rpm and a temperature of 20° C. After cooling, bulked fiber filaments are obtained. The bulked fiber filaments are introduced into a spinning net 11 via a guide roller for knotting. The number of knots is 30±1. The air pressure in the spinning net 11 is 4 bar. The knotted bulked fiber filaments are introduced into a winder 12 via a guide roller and wound into a cylindrical bobbin to obtain a mixed-color fiber bundle.

[0165] The mixed color fiber bundle has a total curl of 20%, a fineness of 1800D, and 100 holes;

[0166] Step 1: Prepare 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 needle pitch of the tufting machine 13 to 1 / 10, the weft knitting density to 39.37 needles / cm, and the warp knitting density to 50 needles / cm, to obtain a cut pile layer and a base fabric layer, and then apply ethylene-vinyl acetate copolymer water-based foamed latex (wet glue weight of 300 gsm, wet latex solid content of 40%, and foaming ratio of 2.0 times) to the bottom of the base fabric layer using a coating device 14 at a speed of 5 m / min, and place the layer in a dryer 15 for drying at 130° C. for 2.5 minutes to obtain a 100 gsm adhesive layer;

[0167] Step 2: Laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 4 m / min at 230° C. using a laminating device 16, and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, to obtain a 300 gsm second anti-penetration layer and a 700 gsm reinforcement layer after cooling; laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene film (PEPAPE) at a speed of 4 m / min at 240° C. using a laminating device 16, and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, to obtain a 300 gsm first anti-penetration layer and a 200 gsm bottom layer after cooling; and finally obtaining the multi-layer mixed-color fiber wear-resistant carpet.

[0168] Comparative Example 1

[0169] This comparative example provides a commercially available ordinary tufted carpet, which is a conventional PA6 suede flat carpet manufactured by Shandong Kuntai.

[0170] like Figure 4 The gloss test chart of the carpets described in Comparative Example 1 and Example 1 shows that the gloss of the tufted carpet in Comparative Example 1 is 4.6°, while the gloss of the carpet in Example 1 is 1.3°. The low gloss gives the carpet surface a more matte texture, reducing the carpet's specular reflection. At the same time, the diffuse reflection characteristics of the low-gloss carpet also reduce surface stains and wear.

[0171] Comparative Example 2

[0172] This comparative example provides a multi-layer black fiber wear-resistant carpet, which has a multi-layer structure, from bottom to top, including a bottom layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer and a pile layer;

[0173] The multi-layer black fiber wear-resistant carpet has a thickness of 8 mm, a pile height of 3 mm, and a cut pile shape;

[0174] The multi-layer black fiber wear-resistant carpet has poor dirt-holding properties.

[0175] This comparative example also provides a method for preparing the multi-layer black fiber wear-resistant carpet, comprising the following steps:

[0176] Step 1, adding polyamide 6, black masterbatch and spinning oil in a mass ratio of 97:2.5:0.5 into a screw extruder for melt mixing, wherein the processing temperature of the screw extruder is 250-270°C, and the screw extruder is divided into four temperature zones, wherein 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;

[0177] Step 2: The molten material in Step 1 is conveyed into a spinning manifold through a feed port, and spun through a 100-hole trilobal spinneret in the spinning manifold at a speed of 500 g / min using a metering pump at 250° C. and 110 bar. The spun fiber filaments pass through a vertical channel provided below the spinning manifold and are cooled by a cold air flow of 5 mbar and 0.25 m / s at a temperature of 18° C. and 85% RH through a blowing device to obtain solidified black fiber filaments.

[0178] Step 3: The black fiber filaments are oiled using an oiling device 7 with an oiling rate of 0.6%. The oiled fiber filaments are then passed through a primary stretching guide roller 801 for primary stretching, wherein the temperature of the primary stretching guide roller 801 is 80° C. and the stretching ratio is 1.01. The fiber filaments are then passed through a secondary stretching guide roller 802 for secondary stretching, wherein the temperature of the secondary stretching guide roller 802 is 170° C. and the stretching ratio is 2.3, thereby obtaining stretched fiber filaments.

[0179] Step 4: Place the drawn fiber filaments into an air texturing machine 9 and perform air-jet puffing at 170°C and a nozzle pressure of 5 bar. The puffed fiber filaments are cooled by a cooling roller 10. The 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 network device 11 through a guide roller for knotting. The number of knots is 28±1. The gas pressure in the spinning network device 11 is 4 bar. The knotted bulked fiber is introduced into a winder 12 through a guide roller and wound into a cylindrical yarn tube to obtain a fiber bundle.

[0180] The fiber bundle has a total curl of 15%, a fineness of 1500D, and 100 holes;

[0181] Step 5: A 90 gsm polyethylene terephthalate (PET) non-woven fabric is provided, and the fiber bundle is tufted onto the non-woven fabric through a tufting machine 13. The needle pitch of the tufting machine 13 is controlled to be 1 / 10, the weft knitting density is 39.37 needles / cm, and the warp knitting density is 50 needles / cm to obtain a cut pile layer and a base fabric layer. Ethylene vinyl acetate copolymer (EVA) water-based foamed latex (wet glue weight of 230 gsm, wet latex solid content of 40%, and foaming ratio of 2.0 times) is continuously applied to the bottom of the base fabric layer using a coating device 14 at a speed of 5 m / min. The layer is then placed in a dryer 15 and dried at 130° C. for 2.5 minutes to obtain a 70 gsm adhesive layer.

[0182] Step 6: Laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene (PEPAPE) film on the bottom of the adhesive layer using a laminating device 16 at a speed of 3 m / min at 230° C., and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) needle-punched base felt, and after cooling, obtaining a 200 gsm anti-breakthrough layer 2 and a 500 gsm reinforcement layer; continuing to laminating 200 gsm of polyethylene bonded polyethylene-polyamide-polyethylene (PEPAPE) on the bottom of the reinforcement layer using a laminating device 16 at a speed of 3 m / min at 230° C., and then laminating 200 gsm of polyethylene bonded polyethylene terephthalate (PET) non-woven base fabric, and after cooling, obtaining a 200 gsm anti-breakthrough layer 1 and a 150 gsm bottom layer; finally, obtaining the multi-layer black fiber wear-resistant carpet.

[0183] like Figure 5 This is a flow chart for testing the dirt-holding effect of the wear-resistant carpets described in Comparative Example 2 and Example 1;

[0184] like Figure 6 The stain-holding effect diagram of the wear-resistant carpet described in Comparative Example 2 and Example 1 is shown. As can be seen from the figure, after the stain-holding test as shown in the figure, no obvious stains and dust are observed on the surface of the present invention, indicating good stain-holding performance.

[0185] Comparative Example 3

[0186] This comparative example provides a multi-layer mixed-color fiber wear-resistant carpet, which has a multi-layer structure, from bottom to top, including a bottom layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer;

[0187] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 9 mm, a pile height of 3 mm, and a cut pile shape;

[0188] The multi-layer mixed-color fiber wear-resistant carpet has an elongation at break of 74% in the machine direction (MD) at room temperature and 70% in the direction perpendicular to the machine direction (CD) at room temperature; an elongation at break of 128% in the machine direction (MD) at 130°C and 127% in the direction perpendicular to the machine direction (CD) at 130°C;

[0189] The multi-layer mixed-color fiber wear-resistant carpet has a breaking strength of 802N in the machine direction (MD) at room temperature and a breaking strength of 740N perpendicular to the machine direction (CD) at room temperature.

[0190] The Taber wear-resistant number of the multi-layer mixed-color fiber wear-resistant carpet is 3670 turns without leakage;

[0191] After the multi-layer mixed-color fiber wear-resistant carpet is placed at 220° C. for 120 seconds, the shrinkage in the machine direction (MD) is 0.7%, and the shrinkage in the cross-machine direction (CD) is 0.5%;

[0192] The grayscale level of the suede appearance of the multi-layer mixed-color fiber wear-resistant carpet is level 4;

[0193] The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is 1.8°.

[0194] The preparation method of the multi-layer mixed-color fiber wear-resistant carpet in this comparative example is the same as that in Example 1, except that the processing temperature of the twin-screw press machine 1 and the twin-screw press machine 2 in this comparative example is 290-330°C, divided into four temperature zones, wherein 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.

[0195] Comparative Example 4

[0196] This comparative example provides a multi-layer mixed-color fiber wear-resistant carpet, which has a multi-layer structure, from bottom to top, including a bottom layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer;

[0197] The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 9 mm, a pile height of 3 mm, and a cut pile shape.

[0198] The preparation method of the multi-layer mixed-color fiber wear-resistant carpet in this comparative example is the same as that in Example 1, except that the puffing temperature of the fiber filaments in this comparative example is 230°C.

[0199] The total curl of the mixed-color fiber bundle in this comparative example was 19%, resulting in the final prepared carpet showing obvious stripes.

[0200] The spinning oil in this embodiment is a lipid mixed oil, and its ingredients include fatty acid glyceride, alkyl phosphate potassium salt and polyethylene glycol. In addition, the spinning oil is not limited, and any commercially available lipid oil for polyamide can be used.

[0201] The preparation system used in this embodiment and comparative example includes a spinning unit 1, a bulking unit 2, a tufting unit 3 and a compounding unit 4 according to the processing direction of the material;

[0202] The spinning unit 1 includes a screw extruder 5, a spinning manifold 6, an oiling device 7 and a stretching device 8;

[0203] The puffing unit 2 includes an air texturing machine 9, a cooling roller 10, a spinning net 11 and a winder 12;

[0204] The tufting unit 3 includes a tufting machine 13;

[0205] The composite unit 4 includes a coating device 14, a drying machine 15 and a laminating device 16;

[0206] A feed port 601 is provided above the spinning manifold 6, and the molten material in the screw extruder 5 enters the spinning manifold 6 through the feed port 601 of the spinning manifold 6;

[0207] The spinning box 6 is provided with a spinneret 602, and the spinneret 602 is a trilobal spinneret;

[0208] The spinneret 602 is provided with a metering pump 604 for quantitatively measuring the spinning material, and the metering pump 604 has a consistent speed;

[0209] The spinning box 6 is provided with a blowing device 605 on the side, and a tunnel 603 is provided vertically below. The tunnel 603 is provided with an air inlet, and the blowing device 605 cools the spun fiber through the air inlet.

[0210] The number of the feed port 601, the spinneret 602 and the tunnel 603 of the spinning manifold 6 is 2. The materials in the screw extruder 5 enter different feed ports 601 respectively, and pass through different spinnerets 602 and tunnels 603 for spinning and air cooling.

[0211] The screw extruder 5 includes a screw extruder 1 501 and a screw extruder 2 502 , and the screw extruder 5 is a single screw extruder;

[0212] The stretching device 8 includes a primary stretching guide roller 801 and a secondary stretching guide roller 802;

[0213] The air texturing machine 9 is provided with a nozzle through which low-pressure air is blown onto the fibers;

[0214] A guide roller is installed between the spinning network device 11 and the cooling roller 10, and the guide roller is used to transport the fiber filaments;

[0215] A guide roller is installed between the winder 12 and the spinning net 11, and the guide roller is used to transport the fiber filaments.

[0216] The mixed color fiber bundle described in the present invention is a two-color yarn structure, and the number of holes in the mixed color fiber bundle corresponds to the number of holes in the spinneret, which is the number of holes in the spinneret*2.

[0217] Table 1 shows the properties of the carpets in this embodiment and the comparative example.

[0218]

[0219] Table 2 is the CIELab color space data of the multi-layer mixed color fiber wear-resistant carpet described in this embodiment

[0220]

[0221] As shown in Table 1 and Table 2, the multi-layer mixed-color fiber wear-resistant carpet of the present invention has good mechanical properties, high wear resistance, low gloss, and small color difference, meeting the requirements for use as a high-quality carpet.

[0222] The test standard for the elongation at break of the multi-layer mixed-color fiber wear-resistant carpet at room temperature in the present invention is ISO 13934-1, and the testing equipment is a tensile test machine;

[0223] 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 testing equipment is a hot tensile test machine;

[0224] 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 testing equipment is a tensile test machine;

[0225] The Taber abrasion test standard of the multi-layer mixed-color fiber wear-resistant carpet is "ISO 5470-1", the testing equipment is a Taber abrasion instrument, and the testing method is to use an H18 grinding wheel and a Taber abrasion instrument to polish under a load of 1000g;

[0226] The grayscale grade of the multi-layer mixed-color fiber wear-resistant carpet is compared using the GB250 gray card, which has 5 levels and 9 grades, namely 1, 2, 3, 4, and 5, with 5 being the highest and 1 being the lowest, and half a grade in between. The glossiness of the multi-layer mixed-color fiber wear-resistant carpet is tested according to ISO 2813, and the test method is based on DIN-67530.

[0227] The present invention Figure 9 The number of holes in the spinneret is only a schematic diagram and does not represent the actual number of holes.

[0228] Based on the above, it can be seen that the multi-layer mixed-color fiber wear-resistant carpet of the present invention has a wide range of uses, low cost, and extremely high market prospects.

[0229] The above description is merely a preferred embodiment of the present invention and does not constitute any other form of limitation to the present invention. Any modification or equivalent variation based on the technical essence of the present invention shall still fall within the scope of protection claimed by the present invention.

Claims

1. A multi-layer mixed-color fiber wear-resistant carpet, characterized in that: The multi-layer mixed-color fiber wear-resistant carpet has a multi-layer structure, which comprises, from bottom to top, a bottom layer, a first anti-breakdown layer, a reinforcement layer, a second anti-breakdown layer, an adhesive layer, a base fabric layer, and a pile layer. The pile layer and the base fabric layer are prepared by tufting mixed-color fiber bundles on a non-woven base fabric. The mixed-color fiber bundles are prepared by melt-spinning different-color masterbatches mixed with polyamide 6 through a synchronously arranged screw extruder. The multi-layer mixed-color fiber wear-resistant carpet has a thickness of 8-15 mm, a pile height of 3-8 mm, and a cut pile shape; 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 1030-1120N at room temperature, a Taber wear resistance of 3900-4000 circles without leakage, a glossiness of ≤1.5°, and a grayscale level of ≥4. The shrinkage rate of the multi-layer mixed-color fiber wear-resistant carpet is 0-0.5% after being placed at 220°C for 120 seconds; The color difference of the color space of the multi-layer mixed-color fiber wear-resistant carpet is ≤0.5 in lightness color difference, ≤0.1 in red-green axis color difference, and ≤0.1 in yellow-blue axis color difference; The adhesive layer is compounded on the bottom of the base fabric layer by coating, and the polyethylene-polyamide-polyethylene film and the needle-punched bottom felt are compounded on the bottom of the adhesive layer by means of a laminating adhesive to obtain the second anti-breakdown layer and the reinforcing layer, and then the polyethylene-polyamide-polyethylene film and the non-woven base fabric are further compounded on the bottom of the reinforcing layer by means of a laminating adhesive to obtain the first anti-breakdown layer and the bottom layer.

2. A system for preparing the multi-layer mixed-color fiber wear-resistant carpet according to claim 1, characterized in that: According to the processing direction of the material, the preparation system includes a spinning unit (1), a puffing unit (2), a tufting unit (3) and a compounding unit (4); The spinning unit (1) includes a screw extruder (5), a spinning manifold (6), an oiling device (7) and a stretching device (8); The puffing unit (2) includes an air texturing machine (9), a cooling roller (10), a spinning net (11) and a winder (12); The tufting unit (3) comprises a tufting machine (13); The composite unit (4) includes a coating device (14), a drying machine (15) and a laminating device (16); The number of the screw extruders (5) is ≥2; The spinning box (6) is provided with a spinneret (602) and a tunnel (603), and the spinneret (602) is a three-leaf spinneret; The number of the feed ports (601), the spinnerets (602) and the corridors (603) of the spinning box (6) is consistent with the number of the screw extruder (5). The materials in the screw extruder (5) enter different feed ports (601) respectively, and pass through different spinnerets (602) and corridors (603) for spinning and air cooling.

3. The preparation system according to claim 2, characterized in that: When the number of the screw extruders (5) is 2, it includes screw extruder 1 (501) and screw extruder 2 (502).

4. The preparation system according to claim 2, characterized in that: The spinneret (602) is provided with a metering pump (604) for quantitatively measuring the spun material, and the metering pump (604) has a consistent speed.

5. The preparation system according to claim 2, characterized in that: The stretching device (8) comprises a primary stretching guide roller (801) and a secondary stretching guide roller (802).

6. A method for preparing the multi-layer mixed-color fiber wear-resistant carpet according to claim 1 using the preparation system according to any one of claims 2 to 5, characterized in that: The following steps are involved: Step 1: prepare a non-woven base fabric, tuft a mixed color fiber bundle onto the non-woven base fabric through a tufting machine (13) to obtain a cut pile layer and a base fabric layer, and then apply water-based foamed latex to the bottom of the base fabric layer, and dry it to obtain an adhesive layer; Step 2: After bonding the polyethylene-polyamide-polyethylene film with a laminating adhesive at the bottom of the adhesive layer, continue bonding the needle-punched base felt with a laminating adhesive, and after cooling, obtain the second anti-breakdown layer and the reinforcement layer; after bonding the polyethylene-polyamide-polyethylene film with a laminating adhesive at the bottom of the reinforcement layer, continue bonding the non-woven base fabric with a laminating adhesive, and after cooling, obtain the first anti-breakdown 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: The needle pitch of the tufting machine (13) in step 1 is 1 / 10 or 5 / 64, the weft knitting density is 39.37 needles / cm or 50.39 needles / cm, and the warp knitting density is 50-60 needles / cm.

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

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

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

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