Mica cool fiber printed carpet, preparation method and printing device

Abstract

The application discloses a mica cool fiber printed carpet, a preparation method and a printing device, and belongs to the technical field of carpets. The mica cool fiber printed carpet comprises the following steps: S1, mica powder is mixed with a dyeable polymer matrix at a mass ratio of 3.5%-4.5%, and after slicing and granulation, the mica cool fiber bulk filament is prepared by using a high-swelling porous high-speed spinning process; the mica cool fiber bulk filament is twisted and compounded with a basic textile fiber to obtain a blended yarn; S2, tufted base cloth weaving, the blended yarn prepared in S1 is woven into a carpet base cloth by using a four-square tufting weaving process; in the four-square tufting weaving process, the same process parameters are adopted for needle pitch and needle density, so that the pile on the carpet surface is uniformly distributed; and S3, digital positioning and zoned printing. The mica cool fiber printed carpet, the preparation method and the printing device realize high-precision zoned three-dimensional printing and support small-batch flexible customized production while realizing stable cool feeling, deodorization and antistatic functions of the carpet.

Description

Technical Field

[0001] This invention specifically relates to a mica cooling fiber printed carpet, its preparation method, and its printing device, belonging to the field of carpet technology. Background Technology

[0002] As consumers' demands for home comfort continue to increase, home textile products that combine practicality and functionality are increasingly favored by the market. Traditional carpets are mostly made of ordinary polyester, nylon and other chemical fibers. In high-temperature environments, they are prone to problems such as stuffiness, lack of breathability and poor temperature sensitivity, which greatly reduces the summer user experience. To this end, Chinese Patent Publication No. CN106942983A discloses a method for processing straw mat carpets, including the following steps: (1) Carpet weaving: The fabric is made of 150D high-quality cold silk and is woven by a multi-arm double-layer jacquard loom; (2) In the finishing step: Printing: Flat screen mechanical printing is used; (3) Composite; (4) Sewing Manufacturing and inspection; (5) Packaging; The beneficial effects of the present invention: The structure is compact, with no exposed fluff, and high-quality cooling silk is used as raw material. The carpet structure is compact, beautiful, environmentally friendly and durable. The temperature difference is 4-5 degrees Celsius, which makes it comfortable to use in summer. It is beautiful and environmentally friendly. The printing and processing of existing functional cooling carpets mostly adopt traditional flat screen and rotary screen batch printing processes. On the one hand, there are shortcomings such as low positioning accuracy and large pattern alignment deviation, which makes it difficult to adapt to the three-dimensional printing needs of carpets with different loop pile structures. On the other hand, small batch customization costs are high and the pattern adjustment flexibility is poor, which makes it impossible to quickly respond to the market's personalized customization needs. In addition, existing cooling carpets are prone to local heat accumulation and short duration of cooling. Summary of the Invention

[0003] To address the aforementioned issues, this invention proposes a mica cooling fiber printed carpet, its preparation method, and a printing device. This enables the carpet to maintain a stable cooling sensation, deodorize, and resist static electricity, while simultaneously achieving high-precision zoned three-dimensional printing and supporting small-batch flexible customized production.

[0004] The method for preparing mica cooling fiber printed carpet of the present invention includes the following steps: Preparation of S1 blended yarn: Mica powder and dyeable polymer matrix are mixed at a mass ratio of 3.5%-4.5%, and after slicing and granulation, mica cooling fiber bulked filaments with a linear density of 1200-3600 dtex are produced by high-expansion multi-porous high-speed spinning process; the mica cooling fiber bulked filaments are twisted and compounded with basic textile fibers to obtain blended yarn; S2 Tufted Fabric Weaving: The blended yarn obtained in S1 is woven into carpet fabric using a square tufting weaving process; in the square tufting weaving process, the needle spacing and needle density are the same process parameters to ensure that the carpet pile is evenly distributed. S3 Digital Positioning and Zoning Printing: The carpet fabric is fed into the digital printing equipment, and the surface of the fabric is photographed by a high-speed area array imaging acquisition device set at the front of the printer head under high-energy illumination. The three-dimensional pattern intelligent recognition system identifies the cut pile area and loop pile area on the surface of the fabric, and matches independent printing parameters for the cut pile area and loop pile area respectively to complete the positioning and zoning printing. After printing, a finishing process is carried out.

[0005] The cooling effect of the mica cooling fiber carpet prepared by this invention is not active cooling, but rather passive cooling achieved through the intrinsic material properties of delaminated nano-mica. This is achieved through the dual physical effects of rapid heat dissipation due to high thermal conductivity of the crystals and heat absorption by interfacial hydration phase change. Furthermore, the square tufted weave structure homogenizes the heat conduction path and enhances the contact heat transfer effect, ultimately resulting in a lasting and uniform cooling sensation. The details are as follows: Firstly, the delaminated nanosheet mica possesses a dual cooling effect. The first effect is the high thermal conductivity of its layered crystals, which rapidly dissipates heat upon contact, eliminating localized heat buildup. This is the core of the instantaneous cooling sensation. Furthermore, by utilizing the difference in thermal conductivity between mica and the polymer matrix, heat is rapidly conducted and diffused from the hot skin to the blanket surface. Mica is a natural layered silicate crystal, with silicon-oxygen tetrahedra and aluminum-oxygen octahedrons connected by strong covalent and ionic bonds within its layers, resulting in a regular and orderly atomic arrangement. In contrast, ordinary polyester (PET), nylon, and other textile matrices are amorphous and semi-crystalline polymers with disordered molecular chain arrangements and numerous defects. The core carrier of solid heat conduction is lattice vibration waves (phonons): crystalline structures exhibit less phonon scattering and a larger mean free path, resulting in high heat conduction efficiency; amorphous polymers, lacking molecular chain defects... The trapping effect leads to frequent phonon scattering, significantly weakening thermal conductivity. For example, the thermal conductivity of PET is only 0.03, while that of sheet mica can be more than 5 times that of PET. Simultaneously, mica exhibits significant anisotropy in thermal conductivity: when the thickness of the mica sheet is reduced to the nanometer level, the boundary scattering effect on vertical thermal conductivity becomes increasingly significant, resulting in a decrease in the thermal conductivity coefficient perpendicular to the film direction. However, the thermal conductivity coefficient in the transverse direction of the film gradually increases. This characteristic enables the formation of a uniform temperature structure in the transverse direction of the blanket surface. Secondly, it forms a nano-delamination and continuous thermal conductivity network. When ordinary thick sheet mica powder is directly added, it is isolated by the polymer matrix, failing to form a continuous thermal conductivity pathway, thus limiting the improvement in cooling sensation. This invention uses delamination nano-mica, peeling thick mica sheets into single sheets of nanometer thickness, increasing the specific surface area to 450 m². 2At a concentration of 3.5%-4.5% by mass, the mica is uniformly dispersed in nylon or modified polyester melt. When the amount of mica added reaches the thermal conductivity percolation threshold, the nano-mica sheets are oriented and overlapped along the fiber axis under the action of spinning and stretching, forming a continuous inorganic thermally conductive network inside the fiber. When the human body comes into contact with the carpet surface, the heat of the skin will not accumulate at the contact point, but will quickly diffuse to the surrounding fibers and the deep layers of the carpet surface through the mica thermally conductive network, and the temperature of the contact area will drop rapidly, thus producing a direct cool touch.

[0006] The second effect is the surface hydration phase change endothermic effect, which achieves continuous interfacial heat absorption and prolongs the cooling sensation. This effectively solves the problem of carpets feeling cool upon initial contact but becoming stuffy after prolonged contact. Specifically, the delaminated nano-mica surface carries a large number of negative charges and hydroxyl groups, possessing extremely strong polar hydration capabilities. It can adsorb water molecules from the air, forming a stable bound hydration film on the surface of the sheets. In other words, the nano-mica surface is charged, has strong hydration, and high water content. This bound water requires temperatures above 500℃ to be completely removed, therefore it will not disappear due to evaporation at room temperature and pressure, and can last for a long time. To maintain the stability of the cooling performance; when the skin comes into contact with the carpet, the body surface temperature (about 32-34℃) is higher than the initial temperature of the fiber. Heat is transferred to the surface of the mica, breaking the binding balance of the hydration film: some bound water molecules gain energy and undergo desorption and phase change. This process absorbs a large amount of latent heat of vaporization and continuously draws heat from the skin side; at the same time, water molecules in the environment will continuously replenish and adsorb onto the surface of the mica, forming a dynamic cycle of adsorption, desorption, and re-adsorption. Under normal environmental humidity conditions, it can continuously play a role in absorbing heat and cooling down, avoiding a stuffy feeling after prolonged contact.

[0007] In addition, the present invention employs a four-sided tufted weaving process, which can amplify and homogenize the cooling effect, as detailed below: The equidistant dot matrix arrangement achieves uniform cooling across the entire carpet surface: Traditional tufting processes have inconsistent needle spacing and needle density parameters, resulting in uneven density of the pile and discontinuous heat conduction paths, which can easily lead to localized heat accumulation and uneven distribution of cooling sensation. This invention uses a square weaving method, strictly controlling the needle spacing and needle density to use the same process parameters, so that the pile on the carpet surface is evenly distributed in a square dot matrix. The heat conduction path length of each pile is consistent, and the overall thermal conductivity of the carpet surface is uniform. When in contact with the skin, the entire area dissipates heat synchronously, completely eliminating the feeling of localized coolness or stuffiness. This makes the distribution of the pile on the carpet surface more uniform and the heat conduction effect more significant.

[0008] The differentiated adaptation of cut pile and loop pile structures creates layers of cooling sensation: For different carpet surface structures such as high-cut low-loop, flat-cut flat-loop, and Oganic, the cooling experience naturally differs: In cut pile areas, the pile ends are cut and spread out, resulting in a larger fiber surface area and more contact points with the skin, leading to a larger area for heat conduction and hydration, and a more direct and gentle cooling sensation; In loop pile areas, the structure is compact, the pile ends are strongly supported, heat conduction is more direct, and the cooling sensation is more refreshing; The partitioned digital printing process of this invention, combined with these structural characteristics, achieves a visually three-dimensional printing effect while preserving the tactile cooling sensation layers of different pile structures, giving the carpet both decorative and cooling functions.

[0009] Further, in step S1, the dyeable polymer matrix is ​​nylon or modified polyester; the basic textile fiber is nylon filament or modified polyester filament; and the mica powder is delaminated nanosheet mica with a specific surface area of ​​not less than 450 m². 2 / g; In step S2, the carpet fabric has a carpet surface structure of any one of high cut low loop, flat cut flat loop or Oganic structure; In the blended yarn, the mass percentage of mica cooling fiber bulked filament is 40%-70%, and the mass percentage of basic textile fiber is 30%-60%.

[0010] Further, in step S1, the mica powder is vacuum dried to a moisture content ≤200ppm after delamination and peeling, and then mixed with a dyeable polymer matrix for extrusion granulation; in the high-expansion multi-porous high-speed spinning process, the spinneret has 120-240 holes, the main drawing ratio is 2.8-3.5, and after spinning, it is expanded by an air deformation nozzle with a working air pressure of 0.6-0.9Mpa; during the spinning and drawing process, the delaminated mica flakes constituting the mica powder are oriented along the fiber axis with an orientation degree ≥75%; the delaminated mica is vacuum dried to control the moisture content, avoiding bubbles and fiber breakage in the melt during spinning, and ensuring the stability of multi-porous spinning; the 120-240 hole spinneret is matched with the coarse denier yarn of tufted carpet, and the main drawing ratio is 2.8-3.5 times, so that the delaminated mica flakes are oriented along the fiber axis, forming a continuous heat conduction path, while improving the antistatic properties of the fiber.

[0011] Furthermore, in step S2, the pile density of the square tufting weaving process is 40-80 piles / cm. 2 The height deviation of a single pile head should be ≤ ±0.5mm; when using a high-cut, low-loop structure, the ratio of cut pile height to loop pile height should be (1.8-2.5):1, forming a gradient cooling contact layer on the blanket surface; 40-80 piles / cm are required. 2The pile density and pile height deviation within ±0.5mm ensure uniform distribution of heat-conducting units on the blanket surface, eliminating local heat accumulation dead zones; a pile height ratio of 1.8-2.5:1 is set for the high-cut, low-loop structure to form a gradient contact structure with a soft and cool surface and a supportive and heat-dissipating bottom layer, taking into account both tactile comfort and continuous coolness.

[0012] Further, in step S3, before printing, the digital printing equipment matches the width and weave texture of the carpet fabric using customized positioning calibration parameters to ensure high-precision alignment between the pattern and the fabric structure; the high-speed area array imaging acquisition device is set with its shooting direction perpendicular to the carpet surface; the three-dimensional pattern intelligent recognition system identifies cut pile and loop pile areas using two methods: pile height difference and texture grayscale. The height difference recognition threshold is 2-5mm, and the grayscale difference recognition threshold is 15-30 levels; after recognition, a partitioned printing mask file is generated to control the printing parameter output of the cut pile area and the loop pile area respectively; wherein, customized positioning calibration... Parameter matching specifically involves adjusting the positioning control parameters of the printing equipment before the actual width and weave texture of the carpet fabric to be processed. This ensures precise alignment between the designed printed pattern and the physical structure of the carpet surface (pile matrix, loop pile boundaries) to prevent misalignment or offset. Specifically, the following steps are performed: First, width parameters are matched: Different specifications of carpet fabric have different widths (total widths), and the fabric may experience slight stretching and shrinkage during transport. The horizontal starting position of the print head, effective printing width, and horizontal scaling factor are calibrated to ensure the pattern is aligned horizontally. The boundaries precisely align with the edges of the raw fabric, preventing issues such as patterns printing off-center or uneven white space on both sides. It can adapt to tufted carpet raw fabrics of varying widths, supporting multi-specification production from narrow rugs to wide wall-to-wall carpets. Secondly, it performs weave texture parameter matching, specifically: Matching reference: directly using the original weave texture of the raw fabric as the positioning reference, eliminating the need for additional printed positioning marks; Calibration units: Lateral: matching the stitch length cycle of the carpet surface (the lateral pile spacing of the four-sided tufted pile); Vertical: matching the fabric feed step length of the equipment (the distance the raw fabric is fed forward after each printed row); ensuring the repeat cycle of the printed pattern... The partition boundaries correspond precisely to an integer number of knitting stitch cycles, ensuring complete alignment between the pattern and the pile dot matrix. This prevents issues such as misalignment between the pattern and the pile, or misalignment during the printing of cut pile sections. During printing, a front-mounted high-speed area array camera and a 3D pattern intelligent recognition system complete the process: first, the actual texture data of the fabric is captured, and the true stitch length and width deviation are calculated. Then, the horizontal coordinates and vertical stepping parameters are dynamically corrected to complete the dynamic calibration of the entire width line by line. Ultimately, a high-precision effect with a printing alignment deviation of ≤0.5mm can be achieved, ensuring accurate independent printing of cut pile / loop pile sections in subsequent printing processes.

[0013] The intelligent recognition system for 3D patterns uses two methods to identify patterns: pile height difference and texture grayscale. Specifically: First, pile height difference: This is achieved by differentiating between cut pile and loop pile in terms of their 3D height. For example, in a high-cut, low-loop structure, the cut pile tip is significantly higher than the loop pile, with a height difference typically between 2-5mm. In a flat-cut, flat-loop structure, the effective height and contour undulations of the cut pile tip after it is cut and spread out also have a stable height difference compared to the regular annular protrusions of the loop pile. During recognition, a high-energy illumination source is arranged at an angle, and a high-speed area array camera captures images of the carpet surface with light and shadow. A photometric 3D vision algorithm is used to reconstruct the relative height distribution of the pile surface, quantifying the height difference between different areas. A 2-5mm recognition threshold filters out interference from normal pile height fluctuations and slight wrinkles on the carpet surface, identifying only significant structural height differences as cut-loop pile boundaries. Second, texture grayscale dimension: This is achieved by differentiating between cut pile and loop pile based on their light reflection characteristics. Cut pile consists of cut, fluffy fiber ends, which, after being illuminated, primarily exhibit diffuse reflection, resulting in an overall darker grayscale. The texture is fine and disordered; loop pile consists of closed, smooth fiber loops with stronger specular reflection, resulting in a brighter overall grayscale and a regular, periodic circular texture. During recognition, features such as the average grayscale value, texture period, and edge density of the region are extracted from the grayscale image captured by a high-speed area array camera to quantify the grayscale difference between the two types of pile. A recognition threshold of 15-30 levels (256 grayscale levels) can filter out grayscale interference caused by uneven whiteness of the fabric and slight stains, identifying only stable reflectivity differences as structural partitions. Both pile height difference and texture grayscale are used for recognition to avoid misjudgment caused by a single method: if only the height difference is used, carpet wrinkles and pile height tolerances will be misidentified as loop pile boundaries; if only the grayscale difference is used, stains and fiber color differences will be misidentified as structural partitions. The two methods are combined, requiring both the height difference threshold and the grayscale difference threshold to be met for the corresponding area to be identified, which can significantly improve the recognition accuracy, ensure the accuracy of the partition printing mask, and ultimately achieve a three-dimensional effect of independent parameter printing for cut pile and loop pile areas.

[0014] The cut pile area uses large-diameter ink droplets for printing, with a single droplet volume of 30-50pl and a printing pass count of 4-6 passes; the loop pile area uses small-diameter ink droplets for printing, with a single droplet volume of 10-20pl and a printing pass count of 2-4 passes. During the positioning and partitioning printing, positioning calibration is first performed. This calibration uses the original weave texture of the fabric as the positioning reference, with the transverse stitch period and longitudinal fabric step length as the calibration units, completing a full-width, row-by-row dynamic calibration. The finishing process... The mica undergoes steaming, washing, and low-temperature heat setting in sequence. The low-temperature heat setting temperature is 110-130℃, and the setting time is 2-3 minutes. No silicone softener is added during the entire finishing process to avoid film-forming substances from coating the surface of the mica sheets and clogging the pores, thus ensuring that the high specific surface area of ​​the mica is not damaged and that its deodorizing and adsorption capabilities and hydration cooling effect are retained for a long time. The low-temperature heat setting at 110-130℃ prevents the mica sheets from agglomerating and the polymer matrix from shrinking excessively at high temperatures, thus ensuring the integrity of the internal thermal conductivity network of the fiber.

[0015] The system employs a combination of height and grayscale differences for identification, avoiding misjudgments that can occur with single identification methods, and accurately delineates the boundaries between cut pile and loop pile. Independent control of printing parameters for the two zones is achieved through a partitioned mask file. Large ink droplets with multiple passes adapt to the fluffy structure of the cut pile zone, ensuring rich color penetration; small ink droplets with fewer passes adapt to the compact structure of the loop pile zone, ensuring sharp edges on the patterns, ultimately creating a differentiated three-dimensional visual effect. The system uses the original weave texture of the raw fabric as a positioning reference, eliminating the need for pre-printed positioning marks and saving the previous marking process, while also avoiding the impact of positioning marks on the finished product's aesthetics. Line-by-line calibration, based on stitch length cycles, can compensate for fabric feeding tension deviations in real time, ensuring printing alignment accuracy for large-format carpets.

[0016] Further, in step S2, after the four-sided tufting weaving process is completed, the carpet surface enters a gradient hot-pressing and setting process: the carpet surface is hot-pressed at low temperature and low pressure, causing the upper 1 / 3-1 / 2 of the pile to be flattened and compacted, forming a transverse uniform temperature layer, while the lower part of the pile remains upright and fluffy, forming a retaining layer; the mica flakes in the transverse uniform temperature layer are arranged in a transverse orientation along the carpet surface; the hot-pressing and setting temperature is 110-120℃, the hot-pressing pressure is 0.2-0.4MPa, and the hot-pressing time is 10-20s; after hot pressing, the flatness deviation of the carpet surface pile is ≤0.2mm, and the pile fluffiness retention rate of the bottom layer is ≥85%; based on the uniform weaving of the four-sided tufting, the low-temperature and low-pressure surface hot-pressing and setting process forms a double-layer gradient structure of a transverse uniform temperature layer on the surface and a functional retaining layer on the bottom layer; the transverse uniform temperature layer on the surface... Temperature Equalizing Layer: After the upper part of the pile is hot-pressed and compacted, the mica sheets inside the fibers follow the pile's orientation and are arranged parallel to the transverse direction of the carpet surface. This fully utilizes the high transverse thermal conductivity of the mica sheets, forming a continuous planar heat-conducting network on the carpet surface. When the human body comes into contact with the carpet, the heat at the contact point can quickly diffuse to the surroundings along the carpet surface, preventing heat accumulation in local areas and avoiding heat buildup from prolonged walking, thus extending the duration of the cooling sensation. The bottom layer forms a lasting layer, with the lower part of the pile remaining upright and fluffy, and the mica sheets maintaining their axial orientation. This preserves sufficient specific surface area and porous structure, continuously performing hydration heat absorption and odor adsorption functions, providing continuous cooling support for the surface temperature equalizing layer, while ensuring long-term stable deodorization performance. Through a gradient structure, the high transverse thermal conductivity and axial functional properties of mica are utilized in different areas, achieving rapid heat dissipation and a continuous cooling sensation.

[0017] A mica cooling fiber carpet printing device is disclosed, which is used for the preparation of mica cooling fiber printed carpets. The device includes a printing machine body, a printer head, an imaging acquisition unit, and an intelligent recognition control unit mounted on the printing machine body. The imaging acquisition unit is located at the front end of the printer head's feed side and includes a high-energy illumination source and a high-speed area array high-definition camera. The intelligent recognition control unit is connected to both the imaging acquisition unit and the printer head. The intelligent recognition control unit has a built-in two-mode recognition module, a partition mask generation module, and a texture positioning calibration module connected in sequence. The printer head has variable droplet output, capable of independently outputting two droplet sizes: 10-20pl small droplets and 30-50pl large droplets.

[0018] Furthermore, it also includes a tension linkage control unit, which is connected to the intelligent recognition control unit via signal.

[0019] A mica cooling fiber printed carpet is prepared using a mica cooling fiber printed carpet preparation method.

[0020] Compared with the prior art, the mica cooling fiber printed carpet, preparation method and printing apparatus of the present invention have the following advantages: 1. Stable and lasting cooling sensation with significantly improved thermal conductivity: Through pretreatment with delaminated mica, axially oriented spinning, and four-sided tufting, a continuous axial heat-conducting network is formed within the fibers, resulting in a uniform and densely distributed pile on the blanket surface. The finished product has a contact cooling coefficient Qmax ≥ 0.22 W / cm². 2 Combined with low-temperature finishing without softener, the mica functional surface is not covered. After 50 washes, the cooling sensation is retained at ≥90%, and the deodorizing performance is retained at ≥85%.

[0021] 2. Multifunctional synergy: Based on 450m of delaminated mica 2 With a high specific surface area of ​​over / g, it can achieve natural deodorization without the need for additional additives, with an ammonia removal rate of ≥70%; the axial orientation of mica also gives the fibers antistatic properties, reducing the surface resistivity of the carpet by 1-2 orders of magnitude, thus reducing dust accumulation and electrostatic adsorption problems.

[0022] 3. Outstanding three-dimensional printing effect and high positioning accuracy: Through intelligent recognition and variable ink droplet partition printing in two ways, the loop pile area presents differentiated color texture and three-dimensional layering, solving the problems of uneven color and blurry pattern of traditional loop pile printing; the original texture dynamic positioning technology makes the alignment deviation of large-format carpet printing ≤0.5mm, eliminating the need for additional marking process and increasing production efficiency by more than 15%.

[0023] 4. Gradient structure enhances uniform temperature dissipation: The double-layer gradient carpet surface, constructed based on the anisotropic thermal conductivity of mica, increases the lateral thermal conductivity of the surface layer by more than 40%, allowing heat to dissipate quickly without heat accumulation and extending the duration of continuous coolness by more than 30%, thus avoiding the problem of localized stuffiness after prolonged walking.

[0024] 5. Adaptable to flexible production: The entire process from spinning and weaving to printing is digitally controlled. Pattern adjustments can be made without the need for plate making. It supports flexible production from sampling to small-batch, multi-variety production, which greatly shortens the production cycle of customized products and reduces the cost of small-batch production. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the overall process for preparing a mica cooling fiber printed carpet according to an embodiment of the present invention.

[0026] Figure 2 This is a schematic diagram of the overall process for preparing a mica cooling fiber printed carpet according to another embodiment of the present invention.

[0027] Figure 3 This is a schematic diagram of the structure of a mica cooling fiber carpet printing device according to an embodiment of the present invention.

[0028] Figure 4 This is a schematic diagram of the structure of a mica cooling fiber carpet printing device according to another embodiment of the present invention. Detailed Implementation

[0029] like Figures 1 to 4 The method for preparing mica cooling fiber printed carpet shown includes the following steps: Preparation of S1 blended yarn: Mica powder and dyeable polymer matrix are mixed at a mass ratio of 3.5%-4.5%, and after slicing and granulation, mica cooling fiber bulked filaments with a linear density of 1200-3600 dtex are produced by high-expansion multi-porous high-speed spinning process; the mica cooling fiber bulked filaments are twisted and compounded with basic textile fibers to obtain blended yarn; S2 Tufted Fabric Weaving: The blended yarn obtained in S1 is woven into carpet fabric using a square tufting weaving process; in the square tufting weaving process, the needle spacing and needle density are the same process parameters to ensure that the carpet pile is evenly distributed. S3 Digital Positioning and Zoning Printing: The carpet fabric is fed into the digital printing equipment, and the surface of the fabric is photographed by a high-speed area array imaging acquisition device set at the front of the printer head under high-energy illumination. The three-dimensional pattern intelligent recognition system identifies the cut pile area and loop pile area on the surface of the fabric, and matches independent printing parameters for the cut pile area and loop pile area respectively to complete the positioning and zoning printing. After printing, a finishing process is carried out.

[0030] The cooling effect of the mica cooling fiber carpet prepared by this invention is not active cooling, but rather passive cooling achieved through the intrinsic material properties of delaminated nano-mica. This is achieved through the dual physical effects of rapid heat dissipation due to high thermal conductivity of the crystals and heat absorption by interfacial hydration phase change. Furthermore, the square tufted weave structure homogenizes the heat conduction path and enhances the contact heat transfer effect, ultimately resulting in a lasting and uniform cooling sensation. The details are as follows: Firstly, the delaminated nanosheet mica possesses a dual cooling effect. The first effect is the high thermal conductivity of its layered crystals, which rapidly dissipates heat upon contact, eliminating localized heat buildup. This is the core of the instantaneous cooling sensation. Furthermore, by utilizing the difference in thermal conductivity between mica and the polymer matrix, heat is rapidly conducted and diffused from the hot skin to the blanket surface. Mica is a natural layered silicate crystal, with silicon-oxygen tetrahedra and aluminum-oxygen octahedrons connected by strong covalent and ionic bonds within its layers, resulting in a regular and orderly atomic arrangement. In contrast, ordinary polyester (PET), nylon, and other textile matrices are amorphous and semi-crystalline polymers with disordered molecular chain arrangements and numerous defects. The core carrier of solid heat conduction is lattice vibration waves (phonons): crystalline structures exhibit less phonon scattering and a larger mean free path, resulting in high heat conduction efficiency; amorphous polymers, lacking molecular chain defects... The trapping effect leads to frequent phonon scattering, significantly weakening thermal conductivity. For example, the thermal conductivity of PET is only 0.03, while that of sheet mica can be more than 5 times that of PET. Simultaneously, mica exhibits significant anisotropy in thermal conductivity: when the thickness of the mica sheet is reduced to the nanometer level, the boundary scattering effect on vertical thermal conductivity becomes increasingly significant, resulting in a decrease in the thermal conductivity coefficient perpendicular to the film direction. However, the thermal conductivity coefficient in the transverse direction of the film gradually increases. This characteristic enables the formation of a uniform temperature structure in the transverse direction of the blanket surface. Secondly, it forms a nano-delamination and continuous thermal conductivity network. When ordinary thick sheet mica powder is directly added, it is isolated by the polymer matrix, failing to form a continuous thermal conductivity pathway, thus limiting the improvement in cooling sensation. This invention uses delamination nano-mica, peeling thick mica sheets into single sheets of nanometer thickness, increasing the specific surface area to 450 m². 2 At a concentration of 3.5%-4.5% by mass, the mica is uniformly dispersed in nylon or modified polyester melt. When the amount of mica added reaches the thermal conductivity percolation threshold, the nano-mica sheets are oriented and overlapped along the fiber axis under the action of spinning and stretching, forming a continuous inorganic thermally conductive network inside the fiber. When the human body comes into contact with the carpet surface, the heat of the skin will not accumulate at the contact point, but will quickly diffuse to the surrounding fibers and the deep layers of the carpet surface through the mica thermally conductive network, and the temperature of the contact area will drop rapidly, thus producing a direct cool touch.

[0031] The second effect is the surface hydration phase change endothermic effect, which achieves continuous interfacial heat absorption and prolongs the cooling sensation. This effectively solves the problem of carpets feeling cool upon initial contact but becoming stuffy after prolonged contact. Specifically, the delaminated nano-mica surface carries a large number of negative charges and hydroxyl groups, possessing extremely strong polar hydration capabilities. It can adsorb water molecules from the air, forming a stable bound hydration film on the surface of the sheets. In other words, the nano-mica surface is charged, has strong hydration, and high water content. This bound water requires temperatures above 500℃ to be completely removed, therefore it will not disappear due to evaporation at room temperature and pressure, and can last for a long time. To maintain the stability of the cooling performance; when the skin comes into contact with the carpet, the body surface temperature (about 32-34℃) is higher than the initial temperature of the fiber. Heat is transferred to the surface of the mica, breaking the binding balance of the hydration film: some bound water molecules gain energy and undergo desorption and phase change. This process absorbs a large amount of latent heat of vaporization and continuously draws heat from the skin side; at the same time, water molecules in the environment will continuously replenish and adsorb onto the surface of the mica, forming a dynamic cycle of adsorption, desorption, and re-adsorption. Under normal environmental humidity conditions, it can continuously play a role in absorbing heat and cooling down, avoiding a stuffy feeling after prolonged contact.

[0032] In addition, the present invention employs a four-sided tufted weaving process, which can amplify and homogenize the cooling effect, as detailed below: The equidistant dot matrix arrangement achieves uniform cooling across the entire carpet surface: Traditional tufting processes have inconsistent needle spacing and needle density parameters, resulting in uneven density of the pile and discontinuous heat conduction paths, which can easily lead to localized heat accumulation and uneven distribution of cooling sensation. This invention uses a square weaving method, strictly controlling the needle spacing and needle density to use the same process parameters, so that the pile on the carpet surface is evenly distributed in a square dot matrix. The heat conduction path length of each pile is consistent, and the overall thermal conductivity of the carpet surface is uniform. When in contact with the skin, the entire area dissipates heat synchronously, completely eliminating the feeling of localized coolness or stuffiness. This makes the distribution of the pile on the carpet surface more uniform and the heat conduction effect more significant.

[0033] The differentiated adaptation of cut pile and loop pile structures creates layers of cooling sensation: For different carpet surface structures such as high-cut low-loop, flat-cut flat-loop, and Oganic, the cooling experience naturally differs: In cut pile areas, the pile ends are cut and spread out, resulting in a larger fiber surface area and more contact points with the skin, leading to a larger area for heat conduction and hydration, and a more direct and gentle cooling sensation; In loop pile areas, the structure is compact, the pile ends are strongly supported, heat conduction is more direct, and the cooling sensation is more refreshing; The partitioned digital printing process of this invention, combined with these structural characteristics, achieves a visually three-dimensional printing effect while preserving the tactile cooling sensation layers of different pile structures, giving the carpet both decorative and cooling functions.

[0034] In step S1, the dyeable polymer matrix is ​​nylon or modified polyester; the basic textile fiber is nylon filament or modified polyester filament; and the mica powder is delaminated nanosheet mica with a specific surface area of ​​not less than 450 m². 2 / g; In step S2, the carpet fabric has a carpet surface structure of any one of high cut low loop, flat cut flat loop or Oganic structure; In the blended yarn, the mass percentage of mica cooling fiber bulked filament is 40%-70%, and the mass percentage of basic textile fiber is 30%-60%.

[0035] In step S1, the mica powder is delaminated and then vacuum dried to a moisture content ≤200ppm, before being mixed with a dyeable polymer matrix and extruded into granules. In the high-expansion, multi-porous, high-speed spinning process, the spinneret has 120-240 holes, the main drawing ratio is 2.8-3.5, and after spinning, it is expanded by an air deformation nozzle with a working air pressure of 0.6-0.9 MPa. During the spinning and drawing process, the delaminated mica flakes constituting the mica powder are oriented along the fiber axis with an orientation degree ≥75%. The delaminated mica is vacuum dried to control the moisture content, avoiding bubbles and fiber breakage in the melt during spinning and ensuring the stability of multi-porous spinning. The 120-240 hole spinneret is matched with the coarse denier yarn of tufted carpet, and the 2.8-3.5 times main drawing ratio makes the delaminated mica flakes oriented along the fiber axis, forming a continuous heat conduction path and improving the antistatic properties of the fiber.

[0036] In step S2, the pile density of the square tufting weaving process is 40-80 piles / cm. 2 The height deviation of a single pile head should be ≤ ±0.5mm; when using a high-cut, low-loop structure, the ratio of cut pile height to loop pile height should be (1.8-2.5):1, forming a gradient cooling contact layer on the blanket surface; 40-80 piles / cm are required. 2 The pile density and pile height deviation within ±0.5mm ensure uniform distribution of heat-conducting units on the blanket surface, eliminating local heat accumulation dead zones; a pile height ratio of 1.8-2.5:1 is set for the high-cut, low-loop structure to form a gradient contact structure with a soft and cool surface and a supportive and heat-dissipating bottom layer, taking into account both tactile comfort and continuous coolness.

[0037] In step S3, before printing, the digital printing equipment matches the width and weave texture of the carpet fabric using customized positioning calibration parameters to ensure high-precision alignment between the pattern and the fabric structure. The high-speed area array imaging acquisition device is set with its shooting direction perpendicular to the carpet surface. The three-dimensional pattern intelligent recognition system identifies cut pile and loop pile areas using two methods: pile height difference and texture grayscale. The height difference recognition threshold is 2-5mm, and the grayscale difference recognition threshold is 15-30 levels. After recognition, a partitioned printing mask file is generated to control the printing parameter output of the cut pile area and the loop pile area respectively. The customized positioning calibration parameters match... Specifically, before the digital printing process, the positioning control parameters of the printing equipment are adjusted based on the actual width and weave texture of the carpet fabric to be processed. This ensures that the designed printed pattern is precisely aligned with the physical structure of the carpet surface (pile matrix, loop pile boundaries), preventing misalignment or offset. Specifically: First, width parameters are matched: different specifications of carpet fabric have different widths (total widths), and the fabric will experience slight stretching and shrinkage deviations during transport. The lateral starting position of the print head, effective printing width, and lateral scaling factor are calibrated to ensure that the left and right boundaries of the pattern are aligned with the carpet surface. The fabric edges are precisely aligned, preventing issues such as patterns printing off-center or uneven white space on both sides. It can adapt to tufted carpet fabrics of varying widths, supporting multi-specification production from narrow rugs to wide wall-to-wall carpets. Secondly, it performs weave texture parameter matching, specifically: Matching reference: directly using the original weave texture of the fabric as the positioning reference, eliminating the need for additional printed positioning marks; Calibration units: Lateral: matching the stitch length cycle of the carpet surface (the lateral pile spacing of the four-sided tufted pile); Vertical: matching the fabric feed step length of the equipment (the distance the fabric is fed forward for each printed row); ensuring the repeat cycle and spacing of the printed pattern are consistent. The zone boundaries correspond precisely to an integer number of weaving stitch cycles, ensuring complete alignment between the pattern and the pile dot matrix. This prevents issues such as misalignment between the pattern and the pile, or misalignment during the printing of cut pile sections. During printing, a front-mounted high-speed area array camera and a 3D pattern intelligent recognition system complete the process: first, the actual texture data of the fabric is captured, and the true stitch length and width deviation are calculated. Then, the horizontal coordinates and vertical stepping parameters are dynamically corrected to complete the dynamic calibration of the entire width line by line. Ultimately, a high-precision effect with a printing alignment deviation of ≤0.5mm can be achieved, ensuring accurate independent printing of cut pile / loop pile sections in subsequent printing processes.

[0038] The intelligent recognition system for 3D patterns uses two methods to identify patterns: pile height difference and texture grayscale. Specifically: First, pile height difference: This is achieved by differentiating between cut pile and loop pile in terms of their 3D height. For example, in a high-cut, low-loop structure, the cut pile tip is significantly higher than the loop pile, with a height difference typically between 2-5mm. In a flat-cut, flat-loop structure, the effective height and contour undulations of the cut pile tip after it is cut and spread out also have a stable height difference compared to the regular annular protrusions of the loop pile. During recognition, a high-energy illumination source is arranged at an angle, and a high-speed area array camera captures images of the carpet surface with light and shadow. A photometric 3D vision algorithm is used to reconstruct the relative height distribution of the pile surface, quantifying the height difference between different areas. A 2-5mm recognition threshold filters out interference from normal pile height fluctuations and slight wrinkles on the carpet surface, identifying only significant structural height differences as cut-loop pile boundaries. Second, texture grayscale dimension: This is achieved by differentiating between cut pile and loop pile based on their light reflection characteristics. Cut pile consists of cut, fluffy fiber ends, which, after being illuminated, primarily exhibit diffuse reflection, resulting in an overall darker grayscale. The texture is fine and disordered; loop pile consists of closed, smooth fiber loops with stronger specular reflection, resulting in a brighter overall grayscale and a regular, periodic circular texture. During recognition, features such as the average grayscale value, texture period, and edge density of the region are extracted from the grayscale image captured by a high-speed area array camera to quantify the grayscale difference between the two types of pile. A recognition threshold of 15-30 levels (256 grayscale levels) can filter out grayscale interference caused by uneven whiteness of the fabric and slight stains, identifying only stable reflectivity differences as structural partitions. Both pile height difference and texture grayscale are used for recognition to avoid misjudgment caused by a single method: if only the height difference is used, carpet wrinkles and pile height tolerances will be misidentified as loop pile boundaries; if only the grayscale difference is used, stains and fiber color differences will be misidentified as structural partitions. The two methods are combined, requiring both the height difference threshold and the grayscale difference threshold to be met for the corresponding area to be identified, which can significantly improve the recognition accuracy, ensure the accuracy of the partition printing mask, and ultimately achieve a three-dimensional effect of independent parameter printing for cut pile and loop pile areas.

[0039] The cut pile area uses large-diameter ink droplets for printing, with a single droplet volume of 30-50pl and a printing pass count of 4-6 passes; the loop pile area uses small-diameter ink droplets for printing, with a single droplet volume of 10-20pl and a printing pass count of 2-4 passes. During the positioning and partitioning printing, positioning calibration is first performed. This calibration uses the original weave texture of the fabric as the positioning reference, with the transverse stitch period and longitudinal fabric step length as the calibration units, completing a full-width, row-by-row dynamic calibration. The finishing process... The mica undergoes steaming, washing, and low-temperature heat setting in sequence. The low-temperature heat setting temperature is 110-130℃, and the setting time is 2-3 minutes. No silicone softener is added during the entire finishing process to avoid film-forming substances from coating the surface of the mica sheets and clogging the pores, thus ensuring that the high specific surface area of ​​the mica is not damaged and that its deodorizing and adsorption capabilities and hydration cooling effect are retained for a long time. The low-temperature heat setting at 110-130℃ prevents the mica sheets from agglomerating and the polymer matrix from shrinking excessively at high temperatures, thus ensuring the integrity of the internal thermal conductivity network of the fiber.

[0040] The system employs a combination of height and grayscale differences for identification, avoiding misjudgments that can occur with single identification methods, and accurately delineates the boundaries between cut pile and loop pile. Independent control of printing parameters for the two zones is achieved through a partitioned mask file. Large ink droplets with multiple passes adapt to the fluffy structure of the cut pile zone, ensuring rich color penetration; small ink droplets with fewer passes adapt to the compact structure of the loop pile zone, ensuring sharp edges on the patterns, ultimately creating a differentiated three-dimensional visual effect. The system uses the original weave texture of the raw fabric as a positioning reference, eliminating the need for pre-printed positioning marks and saving the previous marking process, while also avoiding the impact of positioning marks on the finished product's aesthetics. Line-by-line calibration, based on stitch length cycles, can compensate for fabric feeding tension deviations in real time, ensuring printing alignment accuracy for large-format carpets.

[0041] In step S2, after the four-sided tufting weaving process is completed, the carpet surface enters the gradient hot-pressing and setting process: The carpet surface is hot-pressed at low temperature and low pressure, causing the upper 1 / 3-1 / 2 of the pile to be flattened and compacted, forming a transverse uniform temperature layer, while the lower pile remains upright and fluffy, forming a retaining layer; the mica flakes in the transverse uniform temperature layer are arranged transversely along the carpet surface; the hot-pressing and setting temperature is 110-120℃, the hot-pressing pressure is 0.2-0.4MPa, and the hot-pressing time is 10-20s; after hot pressing, the flatness deviation of the carpet surface pile is ≤0.2mm, and the pile fluffiness retention rate of the bottom layer is ≥85%; based on the uniform four-sided tufting weaving, the low-temperature and low-pressure surface hot-pressing and setting process creates a double-layer gradient structure of a transverse uniform temperature layer on the surface and a functional retaining layer on the bottom; the transverse uniform temperature layer... Layer 1: After the upper part of the pile is hot-pressed and compacted, the mica sheets inside the fibers follow the pile's orientation and are arranged parallel to each other in the transverse direction of the carpet surface. This fully utilizes the high transverse thermal conductivity of the mica sheets, forming a continuous planar heat-conducting network on the carpet surface. When the human body comes into contact with the carpet, the heat at the contact point can quickly diffuse outwards along the carpet surface, preventing heat accumulation in localized areas and avoiding heat buildup from prolonged walking, thus extending the duration of the cooling sensation. Layer 2: The bottom layer forms a lasting layer. The lower part of the pile remains upright and fluffy, and the mica sheets maintain their axial orientation, retaining sufficient specific surface area and pore structure to continuously perform hydration heat absorption and odor adsorption functions, providing continuous cooling support for the surface temperature uniform layer, while ensuring long-term stable deodorization performance. Through a gradient structure, the high transverse thermal conductivity and axial functional properties of mica are utilized in different areas, achieving rapid heat dissipation and a continuous cooling sensation.

[0042] A mica cooling fiber carpet printing device is disclosed, which is used for the preparation of mica cooling fiber printed carpets. The device includes a printing machine body, a printer head, an imaging acquisition unit, and an intelligent recognition control unit mounted on the printing machine body. The imaging acquisition unit is located at the front end of the printer head's feed side and includes a high-energy illumination source and a high-speed area array high-definition camera. The intelligent recognition control unit is connected to both the imaging acquisition unit and the printer head. The intelligent recognition control unit has a built-in two-mode recognition module, a partition mask generation module, and a texture positioning calibration module connected in sequence. The printer head has variable droplet output, capable of independently outputting two droplet sizes: 10-20pl small droplets and 30-50pl large droplets.

[0043] It also includes a tension linkage control unit, which is connected to the intelligent recognition control unit via signal.

[0044] A mica cooling fiber printed carpet is prepared using a mica cooling fiber printed carpet preparation method.

[0045] Example 1: The specific steps of the mica cooling fiber printed carpet preparation method in this embodiment are as follows: Preparation of blended yarn: Selected delaminated nanosheet mica powder (specific surface area 480m²) 2 The mica-modified masterbatch was obtained by vacuum drying to a moisture content of 180 ppm and uniformly mixing it with nylon 6 chips at a mass ratio of 4%. The mixture was then granulated using a twin-screw extruder. The masterbatch was fed into a spinning machine using a 192-hole spinneret with a main draw ratio of 3.2. The masterbatch was then expanded using an air-deformation nozzle at a pressure of 0.75 MPa to produce a mica-cooling fiber bulked filament with a linear density of 2400 dtex and a mica axial orientation of 78%. This mica-cooling fiber bulked filament was then twisted with ordinary nylon 6 filaments of the same linear density at a mass ratio of 6:4, with a twist coefficient set to 320, to produce a blended yarn. The mica-cooling fiber accounted for 60% of the total mass of the blended yarn. Tufted fabric weaving: Using the blended yarn prepared in the previous step, a flat-cut, flat-loop carpet fabric is woven on a tufting loom using a four-way weaving process. During the weaving process, the needle spacing and needle density are both set to 5mm, the pile density is 60 threads / cm², and the pile height deviation is controlled within ±0.3mm. After weaving, the fabric is sizing and set to obtain an off-white carpet fabric with a width of 2m.

[0046] Digital positioning and zone printing: The carpet fabric is fed into the digital positioning and printing device. The front end of the printer head on the feed side of the device is equipped with a diffused high-energy LED surface light source and a high-speed area array high-definition camera. During the fabric transport process, the surface light source evenly illuminates the carpet surface, and the camera captures surface images perpendicular to the carpet surface. Positioning calibration uses the original 5mm stitch pitch texture of the fabric as a benchmark, and performs dynamic calibration line by line. After calibration, the printing alignment deviation is 0.3mm. The image data is transmitted to the 3D pattern intelligent recognition system, which distinguishes between flat cut areas and flat loop areas through a 3mm height difference and a 20-level grayscale difference, generating a zone printing mask. Acid dye ink is used, and the printing resolution is set to 720dpi. The cut pile area uses 40pl ink droplets and 4-pass printing, while the loop pile area uses 15pl ink droplets and 3-pass printing. The ink volume ratio of the two areas is 1.3:1, completing independent zone printing.

[0047] Post-processing: After printing, the carpet is placed in a steaming machine and steamed at 105℃ for 10 minutes to fully fix the dye; then it is washed with water to remove surface loose dye. No silicone softener is added during the washing process; finally, it is heat-set at 120℃ for 2.5 minutes to obtain the finished printed carpet.

[0048] According to testing, the contact cooling coefficient Qmax of the finished carpet in this embodiment is 0.28 W / cm². 2 Ammonia removal rate can reach 72%; color fastness to rubbing reaches level 4; after 50 water washes, the coolness retention rate is 92% and the deodorization retention rate is 88%.

[0049] Example 2: The difference between the preparation method of the mica cooling fiber printed carpet in this embodiment and that in Embodiment 1 is as follows: In the preparation of the blended yarn, the dyeable polymer matrix uses modified polyester chips, mica powder accounts for 3.8% by mass, the spinneret has 144 holes, the main draw ratio is 3.0, and the nozzle air pressure is 0.7 MPa, resulting in mica cooling fiber bulked filaments with a linear density of 3000 dtex. The mica cooling fiber bulked filaments are then twisted and compounded with ordinary modified polyester filaments at a mass ratio of 5:5, with the cooling fiber accounting for 50% of the total mass of the blended yarn. The tufted fabric is woven with a high-cut, low-loop structure. The four-way process parameters are 6mm for both needle spacing and needle density, and 48 fibers / cm² for pile density. The cut pile height is 8mm, the loop pile height is 4mm, and the cut pile to loop pile height ratio is 2:1, forming a gradient cool-feeling contact layer.

[0050] The printing uses disperse dye ink, and the printing resolution is set to 360dpi. The intelligent recognition system identifies the high cut pile and low loop pile areas through a 4mm height difference. The cut pile area uses 45pl ink droplets and 6-pass printing, while the loop pile area uses 12pl ink droplets and 2-pass printing. The ink volume-to-mass ratio is 1.4:1, achieving a layered three-dimensional printing effect.

[0051] In the finishing process, the steaming temperature is 108℃ and the steaming time is 12min; the heat setting temperature is 125℃ and the setting time is 2min, and no softener is added throughout the process.

[0052] Tests showed that the finished carpet in this embodiment had a cooling coefficient Qmax of 0.25W / cm², with a significant instantaneous cooling sensation on the surface and continuous heat dissipation in the bottom layer; the printing alignment deviation was 0.4mm, the color fastness to soap washing reached level 4, and the three-dimensional printing with a high-cut, low-circle structure had distinct layers.

[0053] Example 3: The difference between the preparation method of the mica cooling fiber printed carpet in this embodiment and that in Embodiment 1 is as follows: In the preparation of blended yarn, mica powder accounts for 4.5% of the mass and has a specific surface area of ​​520 m² / g; mica cool fiber bulked filaments account for 70% of the total mass of the blended yarn, and basic nylon filaments account for 30%; the main spinning draw ratio is 3.5 and the nozzle air pressure is 0.85 MPa to ensure spinning stability under high addition levels.

[0054] The tufted fabric is woven using the Oganic structure, with a four-way needle spacing and needle density of 4.5mm, a pile density of 75 threads / cm², and a pile height of 5mm. This results in a denser blanket surface and a larger contact area for cooling and deodorization.

[0055] The printing process uses full-width, uniform, high-precision printing with a resolution of 720dpi. The inkjet parameters are optimized for the uniform velvet surface of the Oganic to ensure the fineness of the pattern.

[0056] The finishing process involves low-temperature setting at 115℃, with no softener used throughout, to preserve the porous structure of the mica surface to the greatest extent possible.

[0057] Tests showed that the finished carpet in this embodiment achieved a cooling coefficient (Qmax) of 0.31 W / cm², an ammonia removal rate of 78%, and an antistatic surface resistivity of 8 × 10⁻⁶. 9 Ω significantly improves cooling, deodorizing, and antistatic properties.

[0058] Example 4: The mica cooling fiber carpet printing device of this embodiment includes a printing machine body, a printer head, an imaging acquisition unit and an intelligent recognition control unit disposed on the printing machine body; the imaging acquisition unit is fixedly installed at the front end of the feed side of the printer head and moves synchronously with the printer head, including a set of diffuse high-energy LED surface light sources and a high-speed area array high-definition camera; the light emission direction of the surface light source is tilted at 45° toward the surface of the fabric, and the camera lens is set perpendicular to the surface of the fabric, and the imaging range covers a 2m wide fabric printing area; The intelligent recognition control unit incorporates a dual-dimensional recognition module, a partition mask generation module, and a texture positioning calibration module. The input end connects to the image output end of the camera, while the output end connects to the control module of the print head. The dual-dimensional recognition module automatically divides the pile area and loop pile area using height difference and grayscale difference algorithms. The partition mask generation module outputs independent printing parameter commands for the two areas. The texture positioning calibration module uses the original weave stitch length of the fabric as a reference to correct the fabric offset in real time. The print head supports variable droplet output, independently outputting two droplet sizes: 10-20pl small droplets and 30-50pl large droplets, adapting to the printing needs of different pile structures.

[0059] Example 5: This embodiment, based on embodiment 1, also includes a gradient hot pressing and shaping process, as detailed below: The preparation of blended yarn and the four-sided tufted weaving steps are the same as in Example 1, and a flat-cut loop fabric with a pile height of 6mm is woven. Gradient hot pressing and setting: After weaving, the greige fabric is fed into a continuous hot pressing and setting machine. The hot pressing temperature is set to 115℃, the hot pressing pressure is 0.3MPa, and the hot pressing time is 15s. The pressure rollers only act on the surface of the blanket, so that the upper 2mm area of ​​the pile is flattened and compacted to form a transverse uniform temperature layer, while the lower 4mm pile remains upright and fluffy to form a functional retention layer. Post-hot pressing inspection: the surface pile flatness deviation was 0.15mm, and the bottom pile fluffiness retention rate was 88%; the lateral orientation ratio of the surface mica sheet layer reached 65%, and the in-plane thermal conductivity was increased by 45% compared with the unpressed sample.

[0060] The digital positioning printing and finishing steps are the same as in Example 1. Before printing, the imaging system automatically identifies the texture of the velvet surface after hot pressing and calibrates the positioning parameters.

[0061] Tests showed that the cooling coefficient Qmax of the finished carpet in this embodiment reached 0.30 W / cm²; after continuous contact for 30 minutes, the temperature at the contact point of the carpet surface was 1.8°C lower than that in Example 1, and the duration of cooling effect was increased by 35%; the ammonia removal rate was 73%, which was basically the same as the basic solution, achieving a significant upgrade in cooling effect duration.

[0062] Example 6: This embodiment, based on embodiment 2, adopts a zoned printing process, as detailed below: The preparation of blended yarn and the tufted weaving steps are the same as in Example 2, and a high-cut, low-loop fabric is obtained. Zoned printing: Low film-forming disperse dye ink with a film-forming aid ratio of 1.2% is used; during the printing process, the fabric conveying tension is controlled at 0.4 N / cm, the cut pile area uses 35pl ink droplets and 5 passes for printing, and the loop pile area uses 15pl ink droplets and 3 passes for printing; after testing, the ink penetration depth in the cut pile area is 2 / 5 of the pile height, and the penetration depth in the loop pile area is 1 / 3 of the pile height; the finishing steps are the same as in Example 2.

[0063] Tests showed that the rubbing fastness of the printed carpet in this embodiment reached level 4, and the color saturation was no different from that of ordinary printing schemes; the cooling coefficient Qmax after printing was 0.24W / cm², which was only 4% lower than that of the unprinted fabric, and the cooling function retention rate reached 96%; the ammonia removal rate was 70%, and the deodorization function retention rate reached 92%, thus achieving the simultaneous combination of printing aesthetics, cooling sensation and deodorization function in the carpet.

[0064] The above embodiments are merely preferred embodiments of the present invention. Therefore, all equivalent changes or modifications made to the structure, features and principles described in the claims of the present invention are included within the scope of the present invention.

Claims

1. A method for preparing a mica cooling fiber printed carpet, characterized in that, Includes the following steps: Preparation of S1 blended yarn: Mica powder and dyeable polymer matrix are mixed at a mass ratio of 3.5%-4.5%, and after slicing and granulation, mica cooling fiber bulked filaments with a linear density of 1200-3600 dtex are produced by high-expansion multi-porous high-speed spinning process; the mica cooling fiber bulked filaments are twisted and compounded with basic textile fibers to obtain blended yarn; S2 Tufted Fabric Weaving: The blended yarn obtained in S1 is woven into carpet fabric using a square tufting weaving process; in the square tufting weaving process, the needle spacing and needle density are the same process parameters to ensure that the carpet pile is evenly distributed. S3 Digital Positioning and Zoning Printing: The carpet fabric is fed into the digital printing equipment, and the surface of the fabric is photographed by a high-speed area array imaging acquisition device set at the front of the printer head under high-energy illumination. The three-dimensional pattern intelligent recognition system identifies the cut pile area and loop pile area on the surface of the fabric, and matches independent printing parameters for the cut pile area and loop pile area respectively to complete the positioning and zoning printing. After printing, a finishing process is carried out.

2. The method for preparing mica cooling fiber printed carpet according to claim 1, characterized in that: In step S1, the dyeable polymer matrix is ​​nylon or modified polyester; the basic textile fiber is nylon filament or modified polyester filament; and the mica powder is delaminated nanosheet mica with a specific surface area of ​​not less than 450 m². 2 / g; In step S2, the carpet fabric has a carpet surface structure of any one of high cut low loop, flat cut flat loop or Oganic structure; In the blended yarn, the mass percentage of mica cooling fiber bulked filament is 40%-70%, and the mass percentage of basic textile fiber is 30%-60%.

3. The method for preparing mica cooling fiber printed carpet according to claim 2, characterized in that: In step S1, the mica powder is delaminated and then vacuum dried to a moisture content of ≤200ppm, and then mixed with a dyeable polymer matrix and extruded into granules. In the high-expansion multi-porous high-speed spinning process, the spinneret has 120-240 holes, the main drawing ratio is 2.8-3.5, and after spinning, it is expanded by an air deformation nozzle with a working air pressure of 0.6-0.9 MPa. During the spinning and drawing process, the delaminated mica flakes constituting the mica powder are oriented along the fiber axis with an orientation degree of ≥75%.

4. The method for preparing mica cooling fiber printed carpet according to claim 1, characterized in that: In step S2, the pile density of the square tufting weaving process is 40-80 piles / cm. 2 The height deviation of a single pile head is ≤ ±0.5mm; when using a high-cut, low-loop structure, the ratio of cut pile height to loop pile height is 1.8-2.5:1, forming a gradient cool-feeling contact layer on the blanket surface.

5. The method for preparing mica cooling fiber printed carpet according to claim 1, characterized in that: In step S3, before printing, the digital printing equipment matches the width and weave texture of the carpet fabric with customized positioning calibration parameters to ensure high-precision alignment between the pattern and the fabric structure; the high-speed area array imaging acquisition device is set with its shooting direction perpendicular to the carpet surface; the three-dimensional pattern intelligent recognition system identifies cut pile and loop pile areas through two methods: pile height difference and texture grayscale. The height difference recognition threshold is 2-5mm, and the grayscale difference recognition threshold is 15-30 levels; after recognition, a partitioned printing mask file is generated to control the printing parameter output of the cut pile area and the loop pile area respectively.

6. The method for preparing mica cooling fiber printed carpet according to claim 5, characterized in that: The cut pile area uses large-diameter ink droplets for printing, with a single droplet volume of 30-50pl and a printing pass count of 4-6 passes; the loop pile area uses small-diameter ink droplets for printing, with a single droplet volume of 10-20pl and a printing pass count of 2-4 passes. During the positioning and partitioning printing, positioning calibration is first completed. The positioning calibration uses the original weave texture of the fabric as the positioning reference, and uses the horizontal stitch period and the vertical fabric step length as the calibration units to complete the full-width row-by-row dynamic calibration. The finishing process consists of steaming, washing, and low-temperature heat setting in sequence. The low-temperature heat setting temperature is 110-130℃, and the setting time is 2-3 minutes.

7. The method for preparing mica cooling fiber printed carpet according to claim 1, characterized in that: In step S2, after the four-sided tufting weaving process is completed, the carpet surface enters the gradient hot pressing and setting process: the carpet surface is hot-pressed at low temperature and low pressure, so that the upper 1 / 3-1 / 2 area of ​​the pile is flattened and compacted to form a transverse uniform temperature layer, while the lower part of the pile remains upright and fluffy to form a durable layer; the mica flakes in the transverse uniform temperature layer are arranged in a transverse orientation along the carpet surface; the hot pressing and setting temperature is 110-120℃, the hot pressing pressure is 0.2-0.4MPa, and the hot pressing time is 10-20s; after hot pressing, the flatness deviation of the pile on the carpet surface is ≤0.2mm, and the pile fluffiness retention rate of the bottom layer is ≥85%.

8. A mica cooling fiber carpet printing apparatus, used in the method for preparing mica cooling fiber printed carpets according to any one of claims 1 to 7, characterized in that: The device includes a printing machine body, a print head, an imaging acquisition unit, and an intelligent recognition control unit mounted on the printing machine body. The imaging acquisition unit is located at the front end of the feed side of the print head and includes a high-energy illumination source and a high-speed area array high-definition camera. The intelligent recognition control unit is connected to both the imaging acquisition unit and the print head. The intelligent recognition control unit has built-in two recognition modules, a partition mask generation module, and a texture positioning calibration module connected in sequence. The print head has variable droplet output and can independently output two droplet sizes: 10-20pl small droplets and 30-50pl large droplets.

9. The mica cooling fiber carpet printing device according to claim 8, characterized in that, It also includes a tension linkage control unit, which is connected to the intelligent recognition control unit via signal.

10. A mica cooling fiber printed carpet, characterized in that: The mica cooling fiber printed carpet was prepared using any one of the methods described in claims 1 to 7.

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