Environment-friendly fancy yarn tufted carpet and preparation method thereof

Abstract

The invention provides an environment-friendly fancy yarn tufted carpet and a preparation method thereof, and relates to the technical field of household textile manufacturing, and the preparation method is characterized by comprising the following steps: preparing environment-friendly yarns: blending wool and synthetic fibers to prepare white main yarns, and preparing pre-colored fancy yarns through a color master batch spinning or space dyeing washing-free process; the method has the advantages that dyeing wastewater is thoroughly eradicated, and a traditional high-water-consumption dyeing link is omitted through the color master batch spinning and space dyeing washing-free process; indoor air pollution is completely eradicated, and VAE odorless latex is adopted to replace petroleum-based gum, so that the release amount of TVOC is extremely low, and'odorless and ready-to-use 'is realized; the natural and random color artistic effect is achieved, and the handicraft texture is presented through physical twisting; meanwhile, excellent comprehensive performance is achieved, wool provides comfortable foot feeling and flame retardance, synthetic fiber enhances wear resistance, and excellent tufting locking force and dimensional stability are guaranteed through combination of the VAE gum and the cotton base cloth.

Description

Technical Field

[0001] This invention relates to the field of home textile manufacturing technology, and in particular to an environmentally friendly fancy yarn tufted carpet and its preparation method. Background Technology

[0002] Tufted carpets are one of the most widely used flooring materials in modern interior decoration. They are highly efficient to produce and can meet diverse needs through pattern design. However, as consumers' demands for health, environmental protection, and personalized aesthetics continue to rise, the technical contradictions exposed in the manufacturing and use of traditional tufted carpets are becoming increasingly prominent.

[0003] Currently, there is a significant conflict between aesthetic richness and production pollution. To achieve colorful patterns, the industry commonly adopts a "spinning first, then dyeing" or blank printing process. This route consumes enormous amounts of water and energy, with up to 10 tons of water consumed per ton of dyed yarn, and discharges difficult-to-treat wastewater containing heavy metals and auxiliaries. Furthermore, post-dyed products have limited colorfastness, with wet rubbing colorfastness mostly around level 3, making them prone to fading and staining, affecting aesthetic durability. Secondly, functional necessity coexists with health risks. To lock in the pile yarn, mainstream processes use petroleum-based adhesives such as carboxylated styrene-butadiene latex (XSBR). These adhesives continuously release volatile organic compounds (VOCs) such as benzene series compounds during curing and the initial stages of use, leading to indoor air pollution. Long-term exposure harms the respiratory system, limiting their application in sensitive locations such as kindergartens and hospitals. Moreover, existing improvement solutions struggle to balance overall performance. While using solid colors or recycled materials to make yarn reduces emissions, it sacrifices decorative value; hot melt adhesive reduces VOCs but makes carpets feel harder and less resilient; pre-dyed fiber solutions face the problem of limited color gradation or complex processes.

[0004] Therefore, the industry urgently needs to break through the path dependence of "rich visual effects relying on highly polluting dyeing" and "stable structure accompanied by the release of harmful substances" and develop a new type of tufted carpet that combines high-level aesthetics, clean production throughout the entire process, health and safety throughout the entire life cycle, and does not sacrifice comfort and durability. This has become a key technical problem that needs to be solved in this field. Summary of the Invention

[0005] The purpose of this invention is to provide an environmentally friendly fancy yarn tufted carpet and its preparation method, which solves the contradiction in the existing tufted carpet technology that "rich visual effects inevitably rely on high-pollution dyeing" and "stable tufted structure inevitably involves the release of harmful substances (VOCs)". It achieves a unique fancy effect with a handcrafted texture and excellent physical properties while eliminating water and air pollution.

[0006] To achieve the above-mentioned objectives, the technical solution adopted by this invention is as follows:

[0007] An environmentally friendly fancy yarn tufted carpet, characterized in that it comprises:

[0008] Fleece yarn, base fabric, adhesive backing layer, and cotton base fabric;

[0009] The tufted yarn is on the base fabric, the adhesive layer is coated on the back of the base fabric, and the cotton base fabric is laminated below the adhesive layer.

[0010] The yarn is formed by physically twisting and plying at least one basic white main yarn and at least one pre-dyed fancy yarn.

[0011] The main white yarn is a blended yarn containing 20% ​​to 100% (by weight) wool;

[0012] The pre-dyed fancy yarn is a colored yarn made by masterbatch spinning process or section dyeing no-wash process.

[0013] The adhesive backing layer is formed by curing odorless VAE (vinyl acetate-ethylene copolymer) latex.

[0014] The cotton base fabric is a cotton-like material.

[0015] As an improvement, the main white yarn, excluding wool, contains one or more fibers selected from nylon, polyester, and polypropylene.

[0016] As an improvement, the raw material fibers of the pre-dyed fancy yarn are selected from polyester, nylon or polypropylene; wherein, when using masterbatch spinning process, the color originates from the fiber itself; when using section dyeing no-wash process, the color is fixed by microwave or steam non-water washing method.

[0017] As an improvement, the twisting method of the yarn is two-ply, three-ply, or four-ply twisting, with the twist controlled between 60 and 150 twists per meter, so that the color of the pre-dyed fancy yarn is revealed on the carpet surface in a random, discontinuous, or natural gradient manner.

[0018] As an improvement, the solid content of the VAE odorless latex layer is 45% to 60%, and the dry coating weight on the back of the carpet is 300 g / m² to 600 g / m².

[0019] As an improvement, the tufting spacing of the carpet is selected from 1 / 4 inch, 1 / 2 inch, 5 / 32 inch, 1 / 8 inch, 1 / 10 inch or 1 / 12 inch; the total volatile organic compound (TVOC) emission of the carpet is less than 0.05 mg / m³.

[0020] As an improvement, the cotton-based backing fabric is pure cotton or a cotton blend, which has moisture-wicking and breathable properties and provides dimensional stability after being laminated with the VAE adhesive layer.

[0021] A method for preparing an environmentally friendly fancy yarn tufted carpet, characterized by comprising:

[0022] Environmentally friendly yarn preparation: wool and synthetic fibers are blended to make a white base yarn, and pre-dyed fancy yarn is prepared by masterbatch spinning or section dyeing no-wash process. Then the two are twisted together with a twist of 60-150 twists / meter.

[0023] Cleaning tufting: The prepared ply yarn is used as the face yarn and tufted on the base fabric;

[0024] Harmless gluing and lamination: Apply VAE odorless latex to the back of the tufted carpet and immediately laminate the cotton backing fabric to the glued surface.

[0025] Low-temperature drying and curing: Dry and cure the laminated carpet at 100℃ to 150℃ for 8 to 12 minutes;

[0026] Post-processing: After the carpet has been cured and set, it is trimmed, scraped, edged, and inspected.

[0027] As an improvement, during the drying and curing process, the moisture in the VAE emulsion evaporates, and the polymer chains fuse and cross-link with each other to form a strong adhesive film that tightly bonds the root of the yarn, the base fabric, and the cotton backing fabric.

[0028] As an improvement, if a section dyeing no-wash process is used to prepare pre-dyed fancy yarn, then after the yarn is partially dyed, it can be quickly fixed by microwave or steam without water washing, thus achieving zero wastewater discharge.

[0029] The beneficial effects of this invention are as follows: Complete elimination of dyeing wastewater: By employing masterbatch spinning and section dyeing without washing to prepare fancy yarns, the traditional water- and energy-intensive yarn dyeing process is completely eliminated. Based on an annual production scale of thousands of tons, tens of thousands of tons of industrial water can be saved annually, and the generation and treatment of corresponding dye wastewater are eliminated.

[0030] Eliminate indoor air pollution sources: Utilizing VAE water-based odorless latex instead of petroleum-based adhesives such as carboxylated styrene-butadiene rubber, the product eliminates the introduction of VOCs such as formaldehyde and benzene compounds at the source. Tested by authoritative institutions, the product's TVOC emission level is close to the detection limit, providing the market with a truly "odorless, ready-to-use" healthy carpet option.

[0031] The art of natural, random colors: The combination of off-white wool yarn and colored fancy yarn through physical twisting results in a color distribution that is naturally determined by the randomness of the twisting, creating a color effect that is full of variation and rhythm that cannot be achieved by mechanical printing, and has the feel of high-end custom-made handcraftsmanship.

[0032] Superior overall performance: Wool provides luxurious comfort, warmth, and flame retardancy; synthetic fibers ensure yarn strength and abrasion resistance; multi-ply twisting enhances yarn cohesion and blanket fullness; the combination of VAE backing and cotton backing ensures excellent tufting retention (laboratory tufting pull-out force tests generally exceed 30N) and product dimensional stability. All performance aspects are comprehensively guaranteed and synergistically enhanced while prioritizing environmental protection.

[0033] The carpet of this invention, due to its superior environmental and health properties, is particularly suitable for places with extremely high requirements for indoor environmental quality, such as residential bedrooms, children's rooms, hospital wards, nursing homes, schools, and kindergartens. Its widespread use will effectively reduce indoor air pollution levels, improve public health, and has positive social benefits. Attached Figure Description

[0034] Figure 1 This is a cross-sectional view of an environmentally friendly fancy yarn tufted carpet according to the present invention.

[0035] Figure 2 This is a flowchart of a method for preparing an environmentally friendly fancy yarn tufted carpet according to the present invention.

[0036] In the diagram: 1. Fleece yarn; 2. Base fabric; 3. Adhesive backing layer; 4. Cotton base fabric. Detailed Implementation

[0037] To make the content of this invention easier to understand, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Identical components are represented by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "inner" and "outer" refer to directions toward or away from the geometric center of a specific component, respectively.

[0038] like Figure 1 As shown, an environmentally friendly fancy yarn tufted carpet is characterized by comprising: tufted yarn 1, base fabric 2, adhesive backing layer 3, and cotton backing fabric 4; the tufted yarn 1 is tufted on the base fabric 2, the adhesive backing layer 3 is coated on the back of the base fabric 2, and the cotton backing fabric 4 is laminated below the adhesive backing layer 3; the tufted yarn 1 is formed by physically twisting and plying at least one basic white main yarn and at least one pre-dyed fancy yarn; the basic white main yarn is a blended yarn containing 20% ​​to 100% (by weight) wool; the pre-dyed fancy yarn is a colored yarn made using a masterbatch spinning process or a section dyeing no-wash process; the adhesive backing layer 3 is formed by curing odorless VAE (vinyl acetate-ethylene copolymer) latex; and the cotton backing fabric 4 is a cotton fabric material.

[0039] In the main white yarn, the fiber components other than wool are selected from one or more of nylon, polyester, and polypropylene. The raw materials for the pre-dyed fancy yarn are selected from polyester, nylon, or polypropylene; when using masterbatch spinning technology, the color originates from the fiber itself; when using space dyeing no-wash technology, the color is fixed by microwave or steam non-water washing. The ply twisting method of the pile yarn 1 is two-ply, three-ply, or four-ply twisting, and its twist is controlled between 60 and 150 twists per meter, so that the color of the pre-dyed fancy yarn is revealed on the carpet surface in a random, discontinuous, or naturally gradual manner.

[0040] Furthermore, the VAE odorless latex layer has a solid content of 45% to 60%, and the dry weight of the coating on the carpet backing is 300 g / m² to 600 g / m². The tufting spacing of the carpet is selected from 1 / 4 inch, 1 / 2 inch, 5 / 32 inch, 1 / 8 inch, 1 / 10 inch, or 1 / 12 inch; the total volatile organic compound (TVOC) emission of the finished carpet is less than 0.05 mg / m³. The cotton backing fabric 4 is pure cotton or a cotton blend, which has moisture absorption and breathability and provides dimensional stability when laminated with the VAE backing layer 3.

[0041] like Figure 2 As shown, a method for preparing an environmentally friendly fancy yarn tufted carpet is characterized by the following steps: Environmental yarn preparation: Wool and synthetic fibers are blended to produce a white base yarn, and a pre-dyed fancy yarn is prepared using masterbatch spinning or section dyeing without washing. The two yarns are then twisted together at a twist of 60-150 twists / meter. Clean tufting: The prepared tufted yarn 1 is used as the face yarn and tufted onto a base fabric 2. Harmless adhesive application and lamination: VAE odorless latex is applied to the back of the tufted carpet, and a cotton base fabric is immediately laminated to the coated surface. Low-temperature drying and curing: The laminated carpet is dried and cured at 100℃ to 150℃ for 8 to 12 minutes. Finishing: The cured carpet is sheared, scraped, cut, edged, and inspected.

[0042] Secondly, during the drying and curing process, the moisture in the VAE emulsion evaporates, and the polymer chains fuse and cross-link to form a strong adhesive film that tightly bonds the root of the yarn 1, the base fabric 2, and the cotton backing fabric 4. If a section dyeing no-wash process is used to prepare pre-dyed fancy yarn, after the yarn is partially dyed, it can be directly fixed with microwave or steam for rapid color fixing without a water washing process, achieving zero wastewater discharge.

[0043] Example 1: In making a random polka dot style home carpet, the yarn is first prepared: a blend of 50% Australian Merino wool and 50% recycled polyester staple fiber is used to produce a 2.4 Nm / 2 double-ply white base yarn; simultaneously, using masterbatch spinning technology, a 2.3 Nm / 1 polyester fancy yarn containing evenly dispersed dark camel, light camel, and gray is produced. Then, one fancy yarn and two base white yarns are twisted together at an S-direction twist of 80 twists / meter, making the colored spots appear and disappear. For the tufting stage, 100 g / m² PP woven fabric is used as the base fabric 2, and a 1 / 4-inch spacing tufting machine is used, setting the pile height to 8 mm. In the gluing and laminating stage, 50% solids content VAE odorless latex is applied to the back, controlling the dry glue amount to approximately 480 g / m², and then bonded to a pure cotton plain weave fabric. It is then placed in a circulating hot air oven and dried and cured at 125°C for 8 minutes. Finally, the carpet is cooled, sheared at a uniform speed until the pile height is consistent, and then cut and hand-edged as needed. The resulting carpet has a soft and rustic color with randomly distributed camel-gray speckles. The TVOC emission level is only 0.028mg / m³, no formaldehyde was detected, and the tufting pull-out force reaches 48N. It also has excellent wet rubbing color fastness, combining environmental protection, health, durability, and beauty.

[0044] Example 2: In the production of a variegated abstract-style commercial corridor carpet, a natural white base yarn blended with 60% New Zealand wool and 40% nylon is selected, paired with three variegated patterned yarns in light blue, beige, and light gray, produced using a variegated, wash-free process (microwave color fixing, zero wastewater discharge). One patterned yarn and two natural white base yarns are twisted together at a Z-direction twist of 80 twists / meter to create a random and natural gradient effect. For the tufting stage, 103g polypropylene base fabric 2 is used, with medium-density tufting at 1 / 4-inch spacing, and a pile height of 8mm to create a soft feel underfoot. During adhesive application and lamination, 50% VAE odorless latex is evenly applied to the back of the carpet, controlling the dry adhesive amount to approximately 400g / m², and then bonded with a moisture-wicking and breathable pure cotton backing fabric 4 to improve dimensional stability and comfort. Subsequently, it is cured in a 120℃ oven for 10 minutes to ensure a strong bond between the layers. Finally, fine shearing and finishing are performed to make the carpet surface smooth and soft. The finished carpet has a natural color transition like a hand-painted design, with a TVOC emission level of less than 0.01 mg / m³, no odor, and the wool component gives it excellent flame retardancy (B1 grade) and a warm feel, making it very suitable for use in bedrooms and children's rooms.

[0045] The above embodiments are merely preferred implementations of the present invention and are not intended to limit the scope of protection of the present invention. Any adjustments to relevant process parameters (such as wool ratio, synthetic fiber type, twist, backing adhesive content and coating amount, drying temperature and time, etc.) made by those skilled in the art without departing from the design concept of the present invention should be considered to fall within the scope of protection of the present invention. For example, the base yarn can be 100% wool, the fancy yarn can be spun from polypropylene masterbatch, the backing adhesive content can be selected as 45%, the coating amount can be selected as 350 g / m², and the drying temperature can be selected as 100℃, etc.

[0046] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An environmentally friendly fancy yarn tufted carpet, characterized in that, include: Velvet yarn (1), base fabric (2), adhesive backing layer (3) and cotton base fabric (4); The tufted yarn (1) is tufted on the base fabric (2), the adhesive layer (3) is coated on the back of the base fabric (2) (1), and the cotton base fabric (4) is laminated below the adhesive layer (3); The yarn (1) is formed by physically twisting and plying at least one basic white main yarn and at least one pre-dyed fancy yarn; The main white yarn is a blended yarn containing 20% ​​to 100% (by weight) wool; The pre-dyed fancy yarn is a colored yarn made by masterbatch spinning process or section dyeing no-wash process. The adhesive backing layer (3) is formed by curing odorless VAE (vinyl acetate-ethylene copolymer) latex; The cotton base fabric (4) is a cotton fabric material.

2. The environmentally friendly fancy yarn tufted carpet according to claim 1, characterized in that, In the main white yarn, the fiber components other than wool are selected from one or more of nylon, polyester, and polypropylene.

3. The environmentally friendly fancy yarn tufted carpet according to claim 2, characterized in that, The raw materials for the pre-dyed fancy yarn are selected from polyester, nylon, or polypropylene; when using masterbatch spinning process, the color originates from the fiber itself; when using section dyeing no-wash process, the color is fixed by microwave or steam non-water washing method.

4. The environmentally friendly fancy yarn tufted carpet according to claim 3, characterized in that, The twisting method of the yarn (1) is two-ply, three-ply or four-ply twisting, and its twist is controlled between 60 twists and 150 twists per meter, so that the color of the pre-dyed fancy yarn is revealed on the carpet surface in a random, discontinuous or natural gradient manner.

5. The environmentally friendly fancy yarn tufted carpet according to claim 4, characterized in that, The solid content of the VAE odorless latex layer is 45% to 60%, and the dry coating weight on the back of the carpet is 300 g / m² to 600 g / m².

6. The environmentally friendly fancy yarn tufted carpet according to claim 5, characterized in that, The tufting spacing of the carpet is selected from 1 / 4 inch, 1 / 2 inch, 5 / 32 inch, 1 / 8 inch, 1 / 10 inch or 1 / 12 inch; the total volatile organic compound (TVOC) emission of the carpet is less than 0.05 mg / m³.

7. The environmentally friendly fancy yarn tufted carpet according to claim 1, characterized in that, The cotton-based backing fabric (4) is pure cotton or cotton blended fabric, which has moisture absorption and breathability and provides dimensional stability when combined with the VAE backing layer (3).

8. The method for preparing an environmentally friendly fancy yarn tufted carpet according to claim 1, characterized in that, include: Environmentally friendly yarn preparation: wool and synthetic fibers are blended to make a white base yarn, and pre-dyed fancy yarn is prepared by masterbatch spinning or section dyeing no-wash process. Then the two are twisted together with a twist of 60-150 twists / meter. Cleaning tufting: The prepared ply yarn (1) is used as the face yarn and tufted on the base fabric (2); Harmless gluing and lamination: Apply VAE odorless latex to the back of the tufted carpet and immediately laminate the cotton backing fabric to the glued surface. Low-temperature drying and curing: Dry and cure the laminated carpet at 100℃ to 150℃ for 8 to 12 minutes; Post-processing: After the carpet has been cured and set, it is trimmed, scraped, edged, and inspected.

9. The method for preparing an environmentally friendly fancy yarn tufted carpet according to claim 8, characterized in that, During the drying and curing process, the moisture in the VAE emulsion evaporates, and the polymer chains fuse and cross-link with each other to form a strong adhesive film that tightly bonds the root of the yarn (1), the base fabric (2), and the cotton backing fabric (4).

10. The method for preparing an environmentally friendly fancy yarn tufted carpet according to claim 8, characterized in that, If a section dyeing process without washing is used to prepare pre-dyed fancy yarn, then after the yarn is partially dyed, it can be quickly fixed by microwave or steam without a water washing process, thus achieving zero wastewater discharge.

Images