High performance carpet and process for making same

Abstract

The application belongs to the field of carpets, and discloses a high-performance carpet and a preparation process thereof. The high-performance carpet is prepared by adopting a comprehensive process mode of fiber material mixed twisting, ring weaving, heat setting and stretching process, silver ion antibacterial treatment, etc. By reasonably selecting the proportion of polyester fiber, spandex fiber, wool bundle and conductive fiber, optimizing the fabric density and fiber spacing, and cooperating with mechanical and airflow stretching treatment, the best balance of the carpet in high elasticity and high pile effect is achieved, so that the carpet not only has excellent elastic recovery capacity and can quickly recover the shape, but also has rich surface pile and soft touch, thereby solving the problems of the traditional carpet in elasticity and comfort, and the problem that it is difficult to simultaneously realize high pile feeling and high stain resistance and antibacterial performance.

Description

TECHNICAL FIELD

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

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

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

[0004] Therefore, there is an urgent need for an improved carpet preparation process to ensure high elasticity and high pile effect while improving the stain resistance and antibacterial function of the carpet, solving the deficiencies of existing carpets in multiple performance aspects, so as to meet the market demand for high-performance carpets. SUMMARY

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

[0006] The technical scheme provided by the present application is as follows: a preparation process of a high-performance carpet, comprising the following steps:

[0007] S1, selecting polyester fiber bundle, spandex fiber bundle, wool bundle and conductive fiber to twist into mixed wire bundle, the mass ratio being 0.4-0.6:0.1-0.2:0.2-0.3:0.1-0.3;

[0008] S2, using ring weaving method to weave the mixed wire bundle into a preliminary carpet, the density of the preliminary carpet being 46-113 needles per square centimeter, and the spacing between the fiber bundles being 0.1-0.3mm;

[0009] S3, the primary carpet is subjected to heat setting treatment, the temperature of the treatment is 120-150 DEG C, and the duration is 5-10 minutes;

[0010] S4, the carpet after heat setting is subjected to mechanical stretching and then air flow stretching;

[0011] The proportion of mechanical stretching is 8-12%, and after air flow stretching, the carpet pile increases by 30-50%;

[0012] S5, the carpet is subjected to dyeing and then high-temperature setting;

[0013] S6, a silver ion antibacterial agent is used to perform antibacterial treatment on the surface of the carpet.

[0014] In one embodiment, the fineness of the polyester fiber bundle is 1.2-2.5 dtex, the fineness of the spandex fiber bundle is 1.5-2.0 dtex, the fineness of the wool bundle is 2.0-3.0 dtex, and the fineness of the conductive fiber is 0.8-1.5 dtex.

[0015] In one embodiment, in step S5, the dyeing temperature is 80-100 DEG C, and the dyeing time is 30 minutes to 1 hour.

[0016] In one embodiment, in step S5, the high-temperature setting temperature is 160-180 DEG C, and the setting time is 3-5 minutes.

[0017] In one embodiment, in step S1, the polyester fiber bundle, the spandex fiber bundle and the wool bundle are first immersed in an antistatic agent and then twisted with the conductive fiber after drying.

[0018] In one embodiment, in the air flow stretching step, the air flow speed is 10-20 m / s, the air flow temperature is 80-100 DEG C, and the stretching time is 1-3 minutes.

[0019] In one embodiment, in step S6, the carpet is completely immersed in a solution containing a silver ion antibacterial agent, and after being soaked for 15-30 minutes, the carpet is dried by using a hot air drying device, the temperature is 50-70 DEG C, and the drying time is 30-60 minutes.

[0020] A high-performance carpet is prepared according to the above preparation process.

[0021] Compared with the prior art, the present application has the following beneficial effects:

[0022] (1) The preparation process of the high-performance carpet adopts a comprehensive process mode of fiber material mixed twisting, ring weaving method, heat setting and stretching process, silver ion antibacterial treatment, etc., the proportion of polyester fiber, spandex fiber, wool bundle and conductive fiber is reasonably selected, the fabric density and fiber spacing are optimized, and mechanical and airflow stretching treatment is cooperated, so that the best balance of the carpet in high elasticity and high pile effect is achieved, so that the carpet not only has excellent elastic recovery ability and can quickly recover the shape, but also has rich surface pile and soft touch, thereby solving the problems of the traditional carpet in elasticity and comfort, and the problems of difficult to simultaneously realize high pile feeling and high stain resistance and antibacterial performance. DETAILED DESCRIPTION

[0023] The application will be described in detail below with specific embodiments. The following examples will help those skilled in the art to further understand the application, but do not limit the application in any form. It should be pointed out that, for those skilled in the art, without departing from the concept of the application, a number of changes and improvements can be made. These all belong to the protection scope of the application.

[0024] The application is a preparation process of a high-performance carpet, comprising the following steps:

[0025] S1, polyester fiber bundle, spandex fiber bundle and wool bundle are first immersed in an antistatic agent and dried to ensure the overall antistatic effect of the carpet; then the polyester fiber bundle, spandex fiber bundle, wool bundle and conductive fiber are twisted into a mixed wire bundle, and the mass ratio is 0.4-0.6:0.1-0.2:0.2-0.3:0.1-0.3; the fineness of the polyester fiber bundle is 1.2 dtex to 2.5 dtex; the fineness of the spandex fiber bundle is 1.5 dtex to 2.0 dtex; the fineness of the wool bundle is 2.0 dtex to 3.0 dtex; the fineness of the conductive fiber is 0.8 dtex to 1.5 dtex; this multi-fiber mixed wire bundle can realize elasticity and comfort at the same time, and ensure the density and softness of the pile, and the introduction of the conductive fiber enhances the antistatic function of the carpet. Finally, this fiber ratio provides a good foundation for the subsequent process, so that the carpet has high elasticity and rich pile effect.

[0026] S2, the mixed wire bundle is woven into a preliminary carpet by using a ring weaving method, the density of the preliminary carpet is 46 needles to 113 needles per square centimeter, and the spacing between the fiber bundles is 0.1mm-0.3mm; compared with the traditional straight-line weaving method, the ring weaving method can better maintain the shape stability of the carpet, and can effectively improve the structural strength and elasticity of the carpet, and due to the close arrangement of the fiber bundles, the surface of the carpet is more delicate, the density of the pile is higher, thereby improving the comfort and visual effect.

[0027] S3, the preliminary carpet is subjected to heat setting treatment, the treatment temperature is 120-150°C, and the duration is 5-10 minutes; the heat setting treatment ensures the overall shape and stability of the carpet.

[0028] S4, the carpet after heat setting is subjected to mechanical stretching and then airflow stretching; the mechanical stretching ratio is 8-12%, the carpet is placed in an airflow stretching machine, the airflow speed is 10-20 m / s, the airflow temperature is 80-100°C, the stretching time is 1-3 minutes, and after stretching, the carpet pile increases by 30-50%; the stretching process makes the carpet surface pile more abundant and three-dimensional through the cooperation of the mechanical and airflow stretching, thereby improving the comfort and visual effect of the carpet. Meanwhile, the stretched carpet maintains good elasticity and can effectively restore the shape, thereby ensuring the durability during long-term use.

[0029] S5, the carpet is subjected to dyeing, the dyeing temperature is 80-100°C, and the dyeing time is 30 minutes to 1 hour; after dyeing, high-temperature setting is performed, the high-temperature setting temperature is 160-180°C, and the setting time is 3-5 minutes; the mild dyeing process combined with the high-temperature setting process can ensure that the dye is firmly attached to the fiber, and after setting, the carpet can maintain color stability during use and will not fade due to repeated washing or rubbing.

[0030] S6, a silver ion antibacterial agent is used to perform antibacterial treatment on the surface of the carpet; specifically, the carpet is completely soaked in a solution containing a silver ion antibacterial agent, soaked for 15-30 minutes, and then dried by using a hot air drying device, the temperature is 50-70°C, and the drying time is 30-60 minutes; the silver ion antibacterial treatment can not only enhance the antibacterial effect of the carpet, but also prolong the service life of the carpet and maintain the hygiene of the carpet surface, thereby further improving the overall performance of the carpet. Example 1

[0031] S1: polyester fiber bundles (fineness 1.5 dtex), spandex fiber bundles (fineness 1.8 dtex), wool bundles (fineness 2.5 dtex), and conductive fibers (fineness 1.2 dtex) are selected, and twisted into mixed fiber bundles according to a mass ratio of 0.5:0.15:0.25:0.1.

[0032] S2: a preliminary carpet is woven by using a ring weaving method, the density is 75 needles per square centimeter, and the spacing between the fiber bundles is 0.2 mm.

[0033] S3: the preliminary carpet is subjected to heat setting treatment, the treatment temperature is 130°C, and the duration is 7 minutes.

[0034] S4: Mechanical stretching is performed at a stretching ratio of 10%, and then air stretching is performed at an air speed of 15 m / s, an air temperature of 90°C, and a stretching time of 2 minutes. After the air stretching, the pile of the carpet is increased by 40%.

[0035] S5: The carpet is dyed at a temperature of 90°C for 40 minutes, and then high-temperature setting is performed at a temperature of 170°C for 4 minutes.

[0036] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 20 minutes, and then drying is performed using a hot air drying apparatus at a drying temperature of 60°C for 45 minutes. Example 2

[0037] S1: Polyester fiber bundles (fineness 1.8 dtex), spandex fiber bundles (fineness 1.7 dtex), wool bundles (fineness 2.2 dtex), and conductive fibers (fineness 1.0 dtex) are selected and twisted into a mixed bundle at a mass ratio of 0.45:0.2:0.3:0.3.

[0038] S2: A primary carpet is woven using a circular weaving method at a density of 50 needles per square centimeter, and a spacing of 0.15 mm between the fiber bundles.

[0039] S3: The primary carpet is heat-set at a temperature of 140°C for 6 minutes.

[0040] S4: Mechanical stretching is performed at a stretching ratio of 9%, and then air stretching is performed at an air speed of 12 m / s, an air temperature of 85°C, and a stretching time of 2.5 minutes. After the air stretching, the pile of the carpet is increased by 35%.

[0041] S5: The carpet is dyed at a temperature of 85°C for 50 minutes, and then high-temperature setting is performed at a temperature of 165°C for 3 minutes.

[0042] S6: The carpet is treated with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 25 minutes, and then drying is performed using a hot air drying apparatus at a drying temperature of 55°C for 50 minutes. Example 3

[0043] S1: Polyester fiber bundles (fineness 1.2 dtex), spandex fiber bundles (fineness 1.5 dtex), wool bundles (fineness 3.0 dtex), and conductive fibers (fineness 0.9 dtex) are selected and twisted into a mixed bundle at a mass ratio of 0.55:0.1:0.2:0.15.

[0044] S2: The primary carpet is woven using circular weaving method, with a density of 100 needles per square centimeter and a spacing between fiber bundles of 0.25 mm.

[0045] S3: The primary carpet is subjected to heat setting treatment at a temperature of 120°C for a duration of 8 minutes.

[0046] S4: Mechanical stretching is performed at a stretching ratio of 11%, followed by air stretching at an air speed of 18 m / s, an air temperature of 95°C, and a stretching time of 3 minutes. After air stretching, the pile of the carpet increases by 45%.

[0047] S5: The carpet is dyed at a temperature of 100°C for a duration of 35 minutes, followed by high-temperature setting at a temperature of 180°C for a duration of 5 minutes.

[0048] S6: The carpet is treated with silver ion antibacterial agent by completely immersing it in a solution containing silver ion antibacterial agent for a duration of 30 minutes, followed by drying using a hot air drying device at a temperature of 65°C for a duration of 55 minutes. Example 4

[0049] S1: Polyester fiber bundles (fineness 1.4 dtex), spandex fiber bundles (fineness 1.6 dtex), wool bundles (fineness 2.0 dtex), and conductive fibers (fineness 0.9 dtex) are selected and twisted into mixed fiber bundles in a mass ratio of 0.45:0.2:0.25:0.1.

[0050] S2: The primary carpet is woven using circular weaving method, with a density of 60 needles per square centimeter and a spacing between fiber bundles of 0.18 mm.

[0051] S3: The primary carpet is subjected to heat setting treatment at a temperature of 135°C for a duration of 6 minutes.

[0052] S4: Mechanical stretching is performed at a stretching ratio of 9%, followed by air stretching at an air speed of 16 m / s, an air temperature of 92°C, and a stretching time of 2 minutes. After air stretching, the pile of the carpet increases by 38%.

[0053] S5: The carpet is dyed at a temperature of 85°C for a duration of 45 minutes, followed by high-temperature setting at a temperature of 168°C for a duration of 4 minutes.

[0054] S6: The carpet is treated with silver ion antibacterial agent by completely immersing it in a solution containing silver ion antibacterial agent for a duration of 20 minutes, followed by drying using a hot air drying device at a temperature of 58°C for a duration of 50 minutes. Example 5

[0055] S1: Selecting polyester fiber bundle (fineness 1.3 dtex), spandex fiber bundle (fineness 1.9 dtex), wool bundle (fineness 2.7 dtex), and conductive fiber (fineness 1.3 dtex), and twisting into a mixed bundle at a mass ratio of 0.5:0.15:0.25:0.1.

[0056] S2: Knitting into a preliminary carpet using a circular weaving method, with a density of 90 needles per square centimeter and a spacing of 0.2 mm between the fiber bundles.

[0057] S3: Performing heat setting treatment on the preliminary carpet, at a temperature of 145°C for 7 minutes.

[0058] S4: Performing mechanical stretching at a ratio of 10%, followed by air stretching at a speed of 18 m / s, a temperature of 95°C, and for a time of 3 minutes. After air stretching, the pile of the carpet increases by 42%.

[0059] S5: Dyeing the carpet at a temperature of 95°C for 40 minutes; and performing high-temperature setting after dyeing, at a temperature of 175°C for 4 minutes.

[0060] S6: Treating with a silver ion antibacterial agent by completely immersing the carpet in a solution containing the silver ion antibacterial agent for 25 minutes, and then drying using a hot air drying device at a temperature of 62°C for 55 minutes. Example 6

[0061] S1: Selecting polyester fiber bundle (fineness 2.0 dtex), spandex fiber bundle (fineness 1.5 dtex), wool bundle (fineness 2.2 dtex), and conductive fiber (fineness 0.8 dtex), and twisting into a mixed bundle at a mass ratio of 0.4:0.1:0.3:0.2.

[0062] S2: Knitting into a preliminary carpet using a circular weaving method, with a density of 110 needles per square centimeter and a spacing of 0.3 mm between the fiber bundles.

[0063] S3: Performing heat setting treatment on the preliminary carpet, at a temperature of 125°C for 5 minutes.

[0064] S4: Performing mechanical stretching at a ratio of 8%, followed by air stretching at a speed of 14 m / s, a temperature of 85°C, and for a time of 1.5 minutes. After air stretching, the pile of the carpet increases by 30%.

[0065] S5: Dyeing the carpet at a temperature of 80°C for 35 minutes; and performing high-temperature setting after dyeing, at a temperature of 160°C for 3 minutes.

[0066] S6: Treatment with silver ion antibacterial agent, the carpet is completely immersed in a solution containing silver ion antibacterial agent, the soaking time is 15 minutes, and then a hot air drying equipment is used for drying, the drying temperature is 50°C, and the drying time is 40 minutes.

[0067] The following are the functional test items and test data of the high-elasticity, high-pile carpets prepared in Examples 1 to 6. We evaluate the performance of the carpets through different test items, including their elasticity, pile density, stain resistance, and antibacterial effect.

[0068] The test items are as follows:

[0069] Pile density: evaluates the density of the pile on the surface of the carpet per unit area; unit: pile / cm2.

[0070] Elastic recovery rate: evaluates the ability of the carpet to return to its original shape after being stressed; unit: %.

[0071] Friction coefficient: evaluates the friction force when the surface of the carpet contacts an object; unit: friction coefficient.

[0072] Stain resistance test: evaluates the cleanliness of the carpet under specific stain conditions; unit: stain removal rate (%).

[0073] Antibacterial test: evaluates the antibacterial ability of the carpet; unit: antibacterial effect (% inhibition rate).

[0074] Tensile strength: tests the tensile strength of the carpet to determine its durability; unit: N / cm.

[0075] Color fastness test: tests the dyeing fastness of the carpet, i.e., the durability of the dye after rubbing or washing; unit: grade 1-5.

[0076] The test data is as follows: In summary, Example 5 exhibits very balanced performance under the requirements of high elasticity and high pile preparation, not only having good elastic recovery ability and moderate pile density, but also performing excellently in functional tests such as stain resistance, antibacterial effect, and color fastness. Therefore, Example 5 is the optimal embodiment in this application, suitable for high-performance carpet applications that require long-term durability, easy cleaning, comfort, and antibacterial properties.

[0077] The above only describes the preferred embodiments of the present application and is not intended to limit the present application. Those skilled in the art can make various modifications and changes to the present application. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A process for the production of high performance carpet characterized in that, It comprises the following steps: S1, selecting polyester fiber bundle, spandex fiber bundle, wool bundle and conductive fiber to twist into mixed bundle, the mass ratio is 0.4-0.6:0.1-0.2:0.2-0.3:0.1-0.3; S2, using ring weaving method to weave the mixed bundle into preliminary carpet, the density of the preliminary carpet is 46-113 needles per square centimeter, and the spacing between the mixed bundles is 0.1-0.3 mm; S3, the preliminary carpet is subjected to heat setting treatment, the temperature of the treatment is 120-150 DEG C, and the duration is 5-10 minutes; S4, the carpet after heat setting is subjected to mechanical stretching and then airflow stretching; Wherein, the proportion of mechanical stretching is 8%-12%, and after airflow stretching, the carpet pile increases by 30%-50%; S5, the carpet is subjected to dyeing and high temperature setting after dyeing; S6, using silver ion antibacterial agent to perform antibacterial treatment on the surface of the carpet.

2. The process for preparing a high performance carpet according to claim 1, wherein, The fineness of the polyester fiber bundle is 1.2-2.5 dtex, the fineness of the spandex fiber bundle is 1.5-2.0 dtex, the fineness of the wool bundle is 2.0-3.0 dtex, and the fineness of the conductive fiber is 0.8-1.5 dtex.

3. The process for preparing a high performance carpet according to claim 1, wherein In step S5, the dyeing temperature is 80-100 DEG C, and the dyeing time is 30 minutes to 1 hour.

4. The process for preparing high performance carpet as claimed in claim 1, wherein, In step S5, the temperature of high temperature setting is 160-180 DEG C, and the setting time is 3-5 minutes.

5. The process for preparing high performance carpet as recited in claim 1, wherein, In step S1, the polyester fiber bundle, spandex fiber bundle and wool bundle are first immersed in an antistatic agent and then dried before being twisted with the conductive fiber.

6. The process for preparing high performance carpet as recited in claim 1, wherein, In the airflow stretching step, the airflow speed is 10-20 m / s, the airflow temperature is 80-100 DEG C, and the stretching time is 1-3 minutes.

7. The process for preparing high performance carpet as recited in claim 1, wherein, In step S6, the carpet is completely immersed in a solution containing silver ion antibacterial agent, and after soaking for 15-30 minutes, it is dried by using a hot air drying equipment, the temperature is 50-70 DEG C, and the drying time is 30-60 minutes.

8. A high performance carpet characterized by, Prepared according to the preparation process of any one of claims 1-7. Prepared according to the preparation process of any one of claims 1-7.

Images