Anti-hair-slip carpet with silky hand feeling and manufacturing method of anti-hair-slip carpet
By using 200F-300F nylon glossy yarn and acrylic coating, combined with softening treatment, a lint-resistant carpet with a silky feel is formed, solving the problems of lint shedding and rough feel of traditional nylon carpets and improving product quality.
Patent Information
- Application Number
- CN202510863669.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-26
- Publication Date
- 2025-10-28
AI Technical Summary
Traditional nylon carpets suffer from shedding and pile problems, have a rough feel, lack silky smoothness, and conventional processes cannot solve the risk of shedding caused by poor latex penetration.
Made with 200F-300F nylon glossy yarn, the base fabric layer is formed by weaving or tufting, an acrylic coating is applied and dried and cured, then softened, and finally a backing fabric layer and an adhesive layer are laminated on the back to form a lint-resistant carpet with a silky feel.
It effectively reduces shedding, improves the feel, and gives the carpet a silky and soft touch, solving the problems of shedding and rough feel of traditional nylon carpets and enhancing the product's market competitiveness.
Smart Images
Figure CN120840193A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of carpet manufacturing technology, and specifically relates to a lint-resistant carpet with a silky smooth feel and a method for manufacturing it. Background Technology
[0002] Traditional carpets, especially those made with conventional nylon yarns (such as 60F, 128F, 144F, 1 / 4 or 1 / 2 matte), often face the following problems: 1. Shedding: During use, due to the large number of fibers, especially in new carpets or after cutting, fibers are prone to shedding, affecting the user experience and environmental hygiene. 2. Rough feel: Conventional nylon carpets tend to be hard and rough, lacking the silky smoothness of high-end fabrics, making it difficult to meet consumers' demands for a high-quality feel, similar to silk or natural materials (such as rayon). 3. Process limitations: Conventional processes involve directly applying adhesive after tufting, resulting in poor latex penetration, which cannot fully penetrate the fibers, increasing the risk of shedding. Current technologies often use post-treatment adhesive application or increasing the thickness of the backing adhesive to try to solve the shedding problem, but this often leads to the carpet becoming harder, losing elasticity, and further deteriorating the feel. Summary of the Invention
[0003] To overcome the shortcomings of the prior art, the present invention provides a lint-resistant carpet with a silky smooth feel and a method for manufacturing it.
[0004] This invention is achieved through the following technical solution: A lint-resistant carpet with a silky smooth feel includes a base fabric layer and an adhesive backing layer, characterized in that: a glossy nylon fiber layer is attached above the base fabric layer, an acrylic coating is provided between the base fabric layer and the adhesive backing layer, and a bottom fabric layer is provided below the adhesive backing layer.
[0005] A method for manufacturing a lint-resistant carpet with a silky smooth feel, characterized by the following steps: (1) Use 200F-300F nylon glossy yarn to tie onto the base fabric layer through weaving or tufting process to form a carpet substrate consisting of a base fabric layer and a glossy nylon fiber layer. (2) Apply an acrylic coating to the back of the carpet substrate; (3) Dry and cure the carpet substrate with acrylic coating applied; (4) Soften the dried and cured carpet substrate and then dry it. (5) Apply acrylic calcium powder mixed latex to the back of the carpet substrate after softening and drying to form a backing layer, and then laminate a base fabric layer on the back of the backing layer. After curing, a carpet is formed. (6) Cut the carpet into carpet blocks; (7) Apply fabric strips or sew the edges of block carpet products.
[0006] Preferably, in step (1), 256F nylon bright yarn is used.
[0007] Preferably, in step (2), a pattern is printed on the front side of the carpet substrate using an inkjet printer.
[0008] Preferably, in step (2), the acrylic coating is formed by mixing water-based acrylic emulsion with calcium powder, adding crosslinking agent and penetrant, and applying it evenly by roller coating and scraping. The amount of acrylic coating is 600-800g / ㎡.
[0009] Preferably, in step (2), the water-based acrylic emulsion has a solid content of 50%, the calcium powder is 400 mesh, the water-based acrylic emulsion and calcium powder are mixed at a mass ratio of 1:1, and 1% of the mass of the mixture of crosslinking agent and 0.5% of the mass of the mixture of penetrant are added to the mixture, and the amount of acrylic coating is 700g / ㎡.
[0010] Preferably, in step (3), the carpet substrate is placed in an oven and dried at 120-140°C for 5-7 minutes.
[0011] Preferably, in step (3), the product is dried at 130°C for 6 minutes.
[0012] Preferably, in step (4), the carpet substrate is immersed in a mixed solution of 15 g / l softener and 1 g / l citric acid at a speed of 0.7-0.9 m / min. After vacuum dewatering, the liquid content of the carpet is controlled at 30%-50%, and then it is put into an oven for drying at a temperature of 80-90℃ for 8-10 min.
[0013] Preferably, in step (4), the vehicle speed is 0.8 m / min, the liquid content of the blanket surface is controlled at 40%, the drying temperature is 85℃, and the drying time is 9 min.
[0014] Preferably, in step (5), the acrylic calcium powder mixed latex is made by mixing acrylic latex with 50% solid content with 400 mesh calcium powder, the mass ratio of acrylic latex to calcium powder is 1:2.5, the amount of adhesive applied to the backing layer is 1300-1400g / ㎡, and then it is cured at 130-150℃ for 4-6min.
[0015] Preferably, in step (5), the amount of adhesive applied to the backing layer is 1350 g / m², and then cured at 140°C for 5 min.
[0016] The beneficial effects of this invention are: the acrylic pre-coating process fully penetrates the root of the carpet fibers to form an effective bond, which consolidates the fibers from the source, greatly reducing the problem of shedding and lint during carpet use and cutting, and solving the industry's pain point.
[0017] The softer nylon (200F-300F) yarn, combined with a high-gloss finish, provides a basic sheen and softness. In particular, the key softening process effectively improves the hand feel that may become stiff after acrylic pre-coating, ultimately giving the carpet a unique, high-end silky and soft touch similar to real silk or rayon, which is something that conventional nylon carpets cannot achieve.
[0018] First, pre-coating addresses the shedding issue, then softening addresses the feel issue. The order of these two steps cannot be reversed. The softening treatment is performed after the pre-coating has cured, ensuring that the softening effect can directly act on the carpet fibers and is not affected by the subsequent hardening of the backing adhesive.
[0019] Acrylic pre-coating is mainly applied to the back side. With proper control of the coating amount, it does not affect the high gloss effect brought by the carpet surface gloss process.
[0020] The resulting carpet products have distinctive features (anti-shedding + silky smooth feel + high gloss), giving them high recognition and competitiveness in the market. Attached Figure Description
[0021] The invention will now be further described with reference to the accompanying drawings.
[0022] Appendix Figure 1 It is a structural schematic diagram of the present invention; Appendix Figure 2 This is a process flow diagram of the present invention; In the diagram, 1 is the base fabric layer, 2 is the adhesive backing layer, 3 is the glossy nylon fiber layer, 4 is the acrylic coating, and 5 is the bottom fabric layer. Detailed Implementation
[0023] Example 1: 1. Yarn preparation: Select 200F nylon ply-set yarn as the blanket yarn. The yarn spinning fineness is 1200DTEX, the 2 plies are Z twist, and the twist after heat setting is 210 twists / m. The nylon yarn is treated with a bright yarn process.
[0024] 2. Weaving / Tufting: Using the nylon yarn treated above, a carpet substrate is formed by weaving or tufting on the base fabric.
[0025] 3. Printing: The pattern is printed using a 12-color inkjet printer. If it is a colored yarn product, it will be directly transferred to the next process.
[0026] 4. Pre-coating with acrylic mixed latex: Apply an acrylic coating to the back of the carpet substrate. Use a roller coating and scraper coating method to evenly apply water-based acrylic emulsion (50% solid content) and calcium powder (400 mesh). Mix the two in a 1:1 mass ratio, then add 1% crosslinking agent and 0.5% penetrant. Control the coating amount to 600g / m².
[0027] 5. Pre-coating, drying and curing: Dry or cure the carpet substrate with acrylic coating. Place the coated carpet in an oven and dry at 120°C for 5 minutes to allow the acrylic coating to fully cure.
[0028] 6. Softening treatment: The carpet substrate that has undergone the above treatment is softened. The carpet is soaked in a mixed solution of 15g / l softener and 1g / l citric acid at a speed of 0.7m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 30%. Then it is dried in an oven at 80℃ for 8min.
[0029] 7. Backing Adhesive: A backing fabric is laminated onto the back of the softened carpet substrate (i.e., the side pre-coated with acrylic), and an acrylic-calcium powder mixed latex adhesive is applied to form a stable carpet structure. The latex is prepared by mixing acrylic latex (50% solid content) and calcium powder (400 mesh) in a 1:2.5 mass ratio. A cotton backing fabric is laminated onto the back of the softened carpet using the mixed latex, with an adhesive application rate of 1300 g / m², and then cured at 130°C for 4 minutes.
[0030] 8. Cutting: Cut the carpet into pieces of the required size after backing and adhesive application.
[0031] 9. Finishing: Apply fabric strips or machine-sewn edges to the carpet.
[0032] Example 2: 1. Yarn preparation: 256F nylon ply-set yarn is selected as the blanket yarn. The yarn spinning fineness is 1300DTEX, the 2 plies are Z twist, and the twist after heat setting is 220 twists / m. The nylon yarn is treated with a bright yarn process.
[0033] 2. Weaving / Tufting: Using the nylon yarn treated above, a carpet substrate is formed by weaving or tufting on the base fabric.
[0034] 3. Printing: The pattern is printed using a 12-color inkjet printer. If it is a colored yarn product, it will be directly transferred to the next process.
[0035] 4. Acrylic mixed latex pre-coating: Apply an acrylic coating to the back of the carpet substrate. Use a roller coating and scraper coating method to evenly apply water-based acrylic emulsion (50% solid content) and calcium powder (400 mesh). Mix the two in a 1:1 mass ratio, then add 1% crosslinking agent and 0.5% penetrant. The coating amount is controlled at 700g / m².
[0036] 5. Pre-coating, drying and curing: Dry or cure the carpet substrate with acrylic coating. Place the coated carpet in an oven and dry at 130°C for 6 minutes to allow the acrylic coating to fully cure.
[0037] 6. Softening treatment: The carpet substrate that has undergone the above treatment is softened. The carpet is soaked in a mixed solution of 15g / l softener and 1g / l citric acid at a speed of 0.8m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 40%. Then it is dried in an oven at 85℃ for 9min.
[0038] 7. Backing Adhesive: A backing fabric is laminated onto the back of the softened carpet substrate (i.e., the side pre-coated with acrylic), and an acrylic-calcium powder mixed latex adhesive is applied to form a stable carpet structure. The latex is prepared by mixing acrylic latex (50% solid content) and calcium powder (400 mesh) in a 1:2.5 mass ratio. A cotton backing fabric is laminated onto the back of the softened carpet using the mixed latex, with an adhesive application rate of 1350 g / m², and then cured at 140°C for 5 minutes.
[0039] 8. Cutting: Cut the carpet into pieces of the required size after backing and adhesive application.
[0040] 9. Finishing: Apply fabric strips or machine-sewn edges to the carpet.
[0041] Example 3: 1. Yarn preparation: Select 300F nylon ply-set yarn as the blanket yarn. The yarn spinning fineness is 1400DTEX, the 2 plies are Z twist, and the twist after heat setting is 230 twists / m. The nylon yarn is treated with a bright yarn process.
[0042] 2. Weaving / Tufting: Using the nylon yarn treated above, a carpet substrate is formed by weaving or tufting on the base fabric.
[0043] 3. Printing: The pattern is printed using a 12-color inkjet printer. If it is a colored yarn product, it will be directly transferred to the next process.
[0044] 4. Acrylic mixed latex pre-coating: Apply an acrylic coating to the back of the carpet substrate. Use a roller coating and scraper coating method to evenly apply water-based acrylic emulsion (50% solid content) and calcium powder (400 mesh). Mix the two in a 1:1 mass ratio, then add 1% crosslinking agent and 0.5% penetrant. The coating amount is controlled at 800g / m².
[0045] 5. Pre-coating, drying and curing: Dry or cure the carpet substrate with acrylic coating. Place the coated carpet in an oven and dry at 140°C for 7 minutes to allow the acrylic coating to fully cure.
[0046] 6. Softening treatment: The carpet substrate that has undergone the above treatment is softened. The carpet is soaked in a mixed solution of 15g / l softener and 1g / l citric acid at a speed of 0.9m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 50%. Then it is dried in an oven at 90℃ for 10min.
[0047] 7. Backing Adhesive: A backing fabric is laminated onto the back of the softened carpet substrate (i.e., the side pre-coated with acrylic), and an acrylic-calcium powder mixed latex adhesive is applied to form a stable carpet structure. The latex is prepared by mixing acrylic latex (50% solid content) and calcium powder (400 mesh) in a 1:2.5 mass ratio. A cotton backing fabric is laminated onto the back of the softened carpet using the mixed latex, with an adhesive application rate of 1400 g / m², and then cured at 150°C for 6 minutes.
[0048] 8. Cutting: Cut the carpet into pieces of the required size after backing and adhesive application.
[0049] 9. Finishing: Apply fabric strips or machine-sewn edges to the carpet.
[0050] Example 4: 1. Yarn preparation: Select 200F nylon ply-set yarn as the blanket yarn. The yarn spinning fineness is 1200DTEX, the 2 plies are Z twist, and the twist after heat setting is 210 twists / m. The nylon yarn is treated with a bright yarn process.
[0051] 2. Weaving / Tufting: Using the nylon yarn treated above, a carpet substrate is formed by weaving or tufting on the base fabric.
[0052] 3. Printing: The pattern is printed using a 12-color inkjet printer. If it is a colored yarn product, it will be directly transferred to the next process.
[0053] 4. Acrylic mixed latex pre-coating: Apply an acrylic coating to the back of the carpet substrate. Use a roller coating and scraper coating method to evenly apply water-based acrylic emulsion (50% solid content) and calcium powder (400 mesh). Mix the two in a 1:1 mass ratio, then add 1% crosslinking agent and 0.5% penetrant. The coating amount is controlled at 800g / m².
[0054] 5. Pre-coating, drying and curing: Dry or cure the carpet substrate with acrylic coating. Place the coated carpet in an oven and dry at 120°C for 7 minutes to allow the acrylic coating to fully cure.
[0055] 6. Softening treatment: The carpet substrate that has undergone the above treatment is softened. The carpet is soaked in a mixed solution of 15g / l softener and 1g / l citric acid at a speed of 0.7m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 30%. Then it is dried in an oven at 80℃ for 10min.
[0056] 7. Backing Adhesive: A backing fabric is laminated onto the back of the softened carpet substrate (i.e., the side pre-coated with acrylic), and an acrylic-calcium powder mixed latex adhesive is applied to form a stable carpet structure. The latex is prepared by mixing acrylic latex (50% solid content) and calcium powder (400 mesh) in a mass ratio of 1:2.5. A cotton backing fabric is laminated onto the back of the softened carpet using the mixed latex, with an adhesive application rate of 1300 g / m², and then cured at 130°C for 6 minutes.
[0057] 8. Cutting: Cut the carpet into pieces of the required size after backing and adhesive application.
[0058] 9. Finishing: Apply fabric strips or machine-sewn edges to the carpet.
[0059] Example 5: 1. Yarn preparation: Select 300F nylon ply-set yarn as the blanket yarn. The yarn spinning fineness is 1400DTEX, the 2 plies are Z twist, and the twist after heat setting is 230 twists / m. The nylon yarn is treated with a bright yarn process.
[0060] 2. Weaving / Tufting: Using the nylon yarn treated above, a carpet substrate is formed by weaving or tufting on the base fabric.
[0061] 3. Printing: The pattern is printed using a 12-color inkjet printer. If it is a colored yarn product, it will be directly transferred to the next process.
[0062] 4. Pre-coating with acrylic mixed latex: Apply an acrylic coating to the back of the carpet substrate. Use a roller coating and scraper coating method to evenly apply water-based acrylic emulsion (50% solid content) and calcium powder (400 mesh). Mix the two in a 1:1 mass ratio, then add 1% crosslinking agent and 0.5% penetrant. Control the coating amount to 600g / m².
[0063] 5. Pre-coating, drying and curing: Dry or cure the carpet substrate with acrylic coating. Place the coated carpet in an oven and dry at 140°C for 5 minutes to allow the acrylic coating to fully cure.
[0064] 6. Softening treatment: The carpet substrate that has undergone the above treatment is softened. The carpet is soaked in a mixed solution of 15g / l softener and 1g / l citric acid at a speed of 0.9m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 50%. Then it is dried in an oven at 90℃ for 8min.
[0065] 7. Backing Adhesive: A backing fabric is laminated onto the back of the softened carpet substrate (i.e., the side pre-coated with acrylic), and an acrylic-calcium powder mixed latex adhesive is applied to form a stable carpet structure. The latex is prepared by mixing acrylic latex (50% solid content) and calcium powder (400 mesh) in a 1:2.5 mass ratio. A cotton backing fabric is laminated onto the back of the softened carpet using the mixed latex, with an adhesive application rate of 1400 g / m², and then cured at 150°C for 4 minutes.
[0066] 8. Cutting: Cut the carpet into pieces of the required size after backing and adhesive application.
[0067] 9. Finishing: Apply fabric strips or machine-sewn edges to the carpet.
[0068] The 200F-300F yarn used in this invention has lower rigidity and softer properties compared to conventional nylon yarn (1 / 4 or 1 / 2, matte 60F-144F). After being treated with a high-gloss process, it has a high gloss. The acrylic coating can penetrate and solidify the roots and ends of the carpet yarns, forming an adhesive layer that effectively prevents shedding during subsequent use. Drying or curing the carpet substrate with the acrylic coating allows the acrylic coating to set and perform its adhesive function. The softening treatment improves the feel of the carpet fibers, making them silky and soft, simulating the touch of silk or rayon carpets. The acrylic coating application rate is 600-800g / ㎡, which effectively solidifies the fibers to prevent shedding without excessively penetrating the carpet surface and affecting the feel and gloss. The finished carpet of this invention is subjected to a shedding test (vacuuming the carpet surface five times and weighing the fallen fibers) and a feel evaluation (blind test by a professional touch evaluation team). Results: The shedding rate was reduced by more than 80% compared to uncoated regular nylon 60F carpets; the hand feel evaluation was over 100% "very silky and soft", close to the feel of real silk or rayon carpets.
[0069] The comparison charts of the effects are as follows: As shown in the table above, the softening treatment was performed first, followed by acrylic pre-coating and backing adhesive. Results: After softening, the latex did not adhere well to the fibers, resulting in severe linting; the softening effect was compromised in the subsequent pre-coating and backing processes, ultimately leading to minimal improvement in the hand feel. Therefore, this invention utilizes the basic softening effect of 256F nylon yarn, the crucial role of acrylic latex pre-coating in preventing linting, and the decisive role of the softening treatment in improving the hand feel. The necessity of the pre-coating followed by softening sequence is evident.
Claims
1. A lint-resistant carpet with a silky feel, comprising a base fabric layer (1) and an adhesive backing layer (2), characterized in that: A glossy nylon fiber layer (3) is attached above the base fabric layer (1), an acrylic coating (4) is provided between the base fabric layer (1) and the adhesive backing layer (2), and a bottom fabric layer (5) is provided below the adhesive backing layer (2).
2. A method for manufacturing a lint-resistant carpet with a silky smooth feel, characterized in that: Includes the following steps: (1) Use 200F-300F nylon glossy yarn to tie onto the base fabric layer (1) through weaving or tufting process to form a carpet substrate consisting of the base fabric layer (1) and the glossy nylon fiber layer (3); (2) Apply an acrylic coating to the back of the carpet substrate (4); (3) The carpet substrate with acrylic coating (4) is dried and cured. (4) Soften the dried and cured carpet substrate and then dry it. (5) Apply acrylic calcium powder mixed latex to the back of the carpet substrate after softening and drying to form a backing layer (2), and then composite the backing fabric layer (5) on the back of the backing layer (2). After curing, a carpet is formed. (6) Cut the carpet into carpet blocks; (7) Apply fabric strips or sew the edges of block carpet products.
3. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 2, characterized in that: in In step (1), 256F nylon glossy yarn is used; in step (2), the pattern is printed on the front side of the carpet substrate using an inkjet printer. The acrylic coating is made by mixing water-based acrylic emulsion with calcium powder, adding crosslinking agent and penetrant, and applying it evenly by roller coating and scraping. The amount of acrylic coating is 600-800g / ㎡.
4. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 3, characterized in that: in In step (2), the solid content of the water-based acrylic emulsion is 50%, the calcium powder is 400 mesh, and the water-based acrylic emulsion and calcium powder are mixed at a mass ratio of 1:
1. 1% of the mass of the mixture is added to the mixture as a crosslinking agent and 0.5% of the mass of the mixture as a penetrant. The amount of acrylic coating is 700 g / m².
5. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 2, characterized in that: in In step (3), the carpet substrate is placed in an oven and dried at 120-140℃ for 5-7 minutes.
6. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 5, characterized in that: In step (3), the product is dried at 130°C for 6 minutes.
7. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 2, characterized in that: in In step (4), the carpet substrate is immersed in a mixed solution of 15 g / l softener and 1 g / l citric acid at a speed of 0.7-0.9 m / min. After vacuum dewatering, the liquid content of the carpet surface is controlled at 30%-50%. Then, it is put into an oven for drying at a temperature of 80-90℃ for 8-10 min.
8. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 7, characterized in that: in In step (4), the vehicle speed is 0.8 m / min, the liquid content on the carpet surface is controlled at 40%, the drying temperature is 85℃, and the drying time is 9 min.
9. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 2, characterized in that: In step (5), the acrylic calcium powder mixed latex is made by mixing acrylic latex with 50% solid content with 400 mesh calcium powder. The mass ratio of acrylic latex to calcium powder is 1:2.
5. The amount of adhesive applied to the backing layer is 1300-1400g / ㎡. Then it is cured at 130-150℃ for 4-6min.
10. The method for manufacturing a silky-smooth, lint-resistant carpet according to claim 9, characterized in that: In step (5), the amount of adhesive applied to the backing layer is 1350 g / m², and then cured at 140°C for 5 min.