Multi-layer carpet and preparation method therefor

Abstract

Disclosed in the present invention are a multi-layer carpet and a preparation method therefor. The multi-layer carpet comprises an upper-layer carpet and a lower-layer carpet, the upper-layer carpet comprising from top to bottom a first carpet surface layer 1 and a carpet back layer, and the lower-layer carpet comprising from top to bottom a second carpet surface layer 2 and an anti-skid layer, the upper-layer carpet and the lower-layer carpet being connected by means of detachably bonding the carpet back layer and the carpet surface layer 2; when the carpet back layer is a silencing monofilament bundle layer, the carpet surface layer 2 is a silencing microfibre layer, or when the carpet back layer is a silencing microfibre layer, the carpet surface layer 2 is a silencing monofilament bundle layer. In the present invention, after chemical or physical processing of the back of the upper-layer carpet and the surface of the lower-layer carpet, the silencing microfiber layer provided with ultra-fine fiber bundles and the silencing monofilament bundle layer provided with monofilament bundles are stacked together, and an electrostatic adsorption effect is produced under the action of gravity and external force, so that the layers can be bonded together to form a relatively thick sound insulation carpet; in addition, the upper-layer carpet and the lower-layer carpet can be separated and used independently.

Description

Multi-layer carpet and preparation method thereof Technical Field

[0001] The invention belongs to the technical field of detachable carpets and relates to a multi-layer carpet and a preparation method thereof. Background Art

[0002] Since its introduction, removable and washable two-in-one carpets have gained widespread popularity due to their washability, replaceability, and convenient storage. However, traditional methods for installing the carpet layer and anti-slip layer typically rely on traditional Velcro, singed non-woven fabric, or a combination of singed barbed and fleece knitted fabric. This has drawbacks during use, such as loud noise when ripping, prickly hooks that can easily damage clothing, dust collection, and damage to the suede, shortening its lifespan. Therefore, a textile fabric with electrostatic adsorption, softness, and good adhesion, and independent of chemical adhesives, is needed to replace traditional Velcro, singed non-woven fabric, and singed barbed fabric to improve the assembly and disassembly of two-in-one carpets, thereby enhancing the user experience and extending their lifespan.

[0003] Summary of the Invention

[0004] The purpose of the present invention is to address the shortcomings of the existing technology and provide a multi-layer carpet and a preparation method thereof, using a silent opening and closing, soft and adhesive textile fabric to replace the traditional Velcro / singed non-woven fabric / singed barbed fabric to improve the disassembly and assembly of carpets and two-in-one carpets, and solve the problems mentioned in the technical background.

[0005] The purpose of the present invention can be achieved by the following solutions:

[0006] In the technical solution provided by the present invention, by arranging a silent single-filament bundle layer and a silent microfiber layer on the back of the upper carpet and the surface of the lower carpet, and stacking them together to generate electrostatic adsorption under the action of external force, the multi-layer carpet can be disassembled / assembled and installed, thereby conveniently realizing all the household functions of this free combination carpet - beautiful carpet surface, washable, foldable, easy to replace, easy to store and cost-effective function of one carpet for three uses (that is, a double-layer silent carpet, the upper carpet can be used as a carpet / sofa cover / bed cover, etc., and the lower carpet can be used as a carpet alone), etc.

[0007] The present invention provides a multi-layer carpet, comprising an upper carpet and a lower carpet, wherein the upper carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, and the lower carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper carpet and the lower carpet are connected by detachably bonding the carpet back layer and the carpet surface layer 2;

[0008] When the blanket back layer is a silent monofilament bundle layer, the blanket surface layer 2 is a silent microfiber layer;

[0009] Alternatively, when the blanket back layer is a silent microfiber layer, the blanket surface layer 2 is a silent monofilament bundle layer.

[0010] In the present invention, the upper blanket and the lower blanket are detachably connected by stacking the blanket back layer and the blanket surface layer 2 together to generate an electrostatic adsorption effect under the action of external force.

[0011] As an embodiment of the present invention, the carpet surface layer 1 includes any one or a combination of tufted surface layer, woven pile surface layer, knitted pile surface layer, and needle punched pile surface layer.

[0012] As an embodiment of the present invention, the pile surface state of the carpet surface layer 1 includes at least one of cut pile, loop pile, and flat fabric, or a combination thereof; the process of the cut pile includes at least one of tufting, knitting, weaving, and non-woven.

[0013] In the present invention, the carpet surface layer 1 of the upper carpet can be printed with various patterns, or decorated with patches and embroidery made of the same material.

[0014] As an embodiment of the present invention, the material of the silent monofilament bundle layer includes at least one of composite yarn bundle, animal hair fiber, and blended fiber of natural fiber and chemical fiber. The composite yarn bundle is in a loose, inclined and curved shape.

[0015] As an embodiment of the present invention, the composite yarn bundle includes at least one of a chemical filament composite yarn bundle and a staple-spun chemical fiber yarn.

[0016] Furthermore, the chemical filament composite yarn bundle includes at least one of polyester, polypropylene, and nylon, and the type of filaments of the chemical filament composite yarn bundle includes at least one of FDY, DTY, BCF, and POY.

[0017] Furthermore, the short-staple chemical fiber yarn is a yarn spun from short fibers or a yarn blended from multiple short fibers.

[0018] Furthermore, the natural fibers include animal hair fibers, and the animal hair fibers include wool fibers.

[0019] In one embodiment of the present invention, the silent monofilament bundle layer comprises a monofilament bundle layer distributed with monofilament bundles; the monofilament bundles are composed of multiple monofilaments with a common base, and the top ends of the monofilaments have dispersed inclined or curved structures. Compared to ordinary monofilaments, the multi-filament common base fabric has a higher surface density, higher horizontal bonding strength, and greater durability.

[0020] In one embodiment of the present invention, the monofilament has a fineness of 1.04-60 DPF. A monofilament with a fineness below 1.04 DPF is too soft and difficult to insert into the fiber bundle of the silent microfiber layer, resulting in entanglement, reduced silent adsorption effect, and decreased horizontal bonding strength. A monofilament with a fineness greater than 60 DPF is difficult to spin and the monofilament tends to be stiff.

[0021] In one embodiment of the present invention, the monofilament density of the silent monofilament bundle layer is 1,200 to 180,000 strands per square inch. Below 1,200 strands per square inch, the density is too low, resulting in weak adhesion, exposed base, poor appearance, and low usability. Above 180,000 strands per square inch, weaving becomes difficult, inefficient, and economically unsuitable.

[0022] As an embodiment of the present invention, the thickness of the silent monofilament bundle layer is 1-15 mm. The bonding effect of the pile height within this thickness range is the best.

[0023] As one embodiment of the present invention, the material of the silent microfiber layer includes at least one of a high-shrinkage tow and a microfiber tow. In the present invention, the material of the silent microfiber layer is a microfiber tow, or a composite tow of a high-shrinkage tow and a microfiber tow, wherein the mass ratio of the high-shrinkage tow to the microfiber tow in the composite tow is 1:1-1:3.

[0024] Furthermore, the material of the ultrafine fiber tow includes at least one of sea-island filaments, bicomponent filaments, and modified ultrafine chemical fiber filaments.

[0025] As an embodiment of the present invention, the silent microfiber layer is a tuft layer in which microfiber tufts are distributed.

[0026] Furthermore, the fineness of the monofilament in the microfiber bundle is 0.05-2.08D.

[0027] As an embodiment of the present invention, the thickness of the silent ultra-fiber layer is 1-15 mm.

[0028] In the present invention, the ultrafine fiber bundles are a plurality of fine and uniform ultrafine fiber bundles.

[0029] As an embodiment of the present invention, the multi-layer carpet also includes an intermittent anti-slip layer, which is arranged on the surface of the hair bundles in the silent microfiber layer, that is, the intermittent anti-slip layer can be selectively arranged on the surface of the hair bundles in the silent microfiber layer.

[0030] Furthermore, the intermittent anti-slip layer includes intermittent anti-slip resin or intermittent anti-slip glue; the intermittent anti-slip layer includes at least one of TPE, PU, ​​PUR, hot melt adhesive, acrylic adhesive, and EVA adhesive.

[0031] As an embodiment of the present invention, the anti-slip layer is a material layer with an anti-slip function.

[0032] Furthermore, the anti-slip layer includes any one of a TPE layer, a latex layer, PVC, PU, ​​PUR, hot melt adhesive, acrylic adhesive, EVA adhesive layer, SBR adhesive layer and other anti-slip materials.

[0033] In the present invention, the upper blanket and the lower blanket can be bonded or separated with each other by the two layers of fabric, the silent monofilament bundle layer and the silent microfiber layer, without the need to install traditional Velcro on the fabric or to install singed non-woven fabric to achieve the disassembly and installation and anti-slip function of the upper and lower blanket surfaces.

[0034] In the present invention, the silent monofilament bundle layer and the silent microfiber layer can be located at the bottom of the upper blanket and the top of the lower blanket respectively. The positions of the two contact layers can be freely selected and the main functions of the present invention will not be affected by position reversal.

[0035] In a second aspect, the present invention provides a method for preparing a multi-layer carpet, the method comprising the following steps:

[0036] S1. Preparing a silent monofilament bundle layer: preparing a cut pile fabric from a composite yarn bundle, or animal hair fiber, or a blend of natural fiber and chemical fiber, and combing or heat-treating the cut pile fabric to obtain a monofilament bundle layer with distributed monofilament bundles, i.e., the silent monofilament bundle layer;

[0037] S2. Preparation of a silent microfiber layer: a knitted or woven fabric is made by paralleling high shrinkage tows and microfiber tows or paralleling and stretching or paralleling and stretching and forming a network, and then high-temperature dyeing and degreasing are performed to form (many super-fine) fiber tows to obtain a bundle layer with microfiber bundles distributed thereon, i.e., a silent microfiber layer;

[0038] Alternatively, a woven, knitted or needle-punched fabric made of multiple microfiber bundles is subjected to sanding and high-temperature treatment to obtain a bundle layer with microfiber bundles distributed thereon, namely, a silent microfiber layer;

[0039] S3. Preparing a multi-layer carpet: Compounding the carpet surface layer 1 with the silent monofilament bundle layer to form an upper carpet layer, and compounding the silent microfiber layer with the anti-slip layer to form a lower carpet layer;

[0040] Alternatively, the carpet surface layer 1 is compounded with the silent microfiber layer to form an upper carpet layer, and the silent monofilament bundle layer is compounded with the anti-slip layer to form a lower carpet layer;

[0041] (The upper and lower layers are attracted to each other by static electricity) to obtain the multi-layer carpet.

[0042] As an embodiment of the present invention, in step S1, the method of making the cut pile fabric includes at least one of weaving, knitting, tufting, non-woven needle punching, and flocking.

[0043] As an embodiment of the present invention, step S1 further includes dyeing and finishing the cut pile fabric before carding or heat treatment. The purpose of dyeing and finishing is to remove part of the spinning oil.

[0044] As one embodiment of the present invention, step S1 further includes adding a stiffening agent to the cut pile fabric before carding or heat treatment, wherein the stiffening agent has a concentration of 10-30 g / L and an amount of 30-500 gsm. Adding the stiffening agent can increase the horizontal bonding strength of the carpet.

[0045] As an embodiment of the present invention, the stiffening agent includes at least one of TF-639B and Wanjiang Jianda 2195.

[0046] As one embodiment of the present invention, step S1 further includes adding an electrostatic enhancer to the cut pile fabric during the carding or heat treatment, wherein the concentration of the electrostatic enhancer is 10-50 g / L and the amount used is 20-300 gsm. The addition of the electrostatic enhancer (also known as an electrostatic dust absorber) enhances the electrostatic adsorption effect and strengthens the horizontal adhesion between the upper and lower layers of the carpet.

[0047] As an embodiment of the present invention, the electrostatic enhancer includes Jieshengnuo 4957758.

[0048] As an embodiment of the present invention, in step S1, combing includes at least one of sanding, combing, shearing, and ironing processes; the thermal processing includes subjecting the cut pile fabric to a hot blowing process or an ironing process or other processes equivalent to hot blowing.

[0049] In the present invention, the tows or fibers on the surface of the fabric are spread out by carding or heat treatment to form monofilaments with dispersed inclined or curved structures at the top, and the obtained silent monofilament layer has static accumulation.

[0050] As an embodiment of the present invention, in step S2, the fabric is made by at least one of knitting, weaving, and needle punching.

[0051] As an embodiment of the present invention, in step S2, the fineness of single filaments in the plurality of ultrafine fiber bundles is less than or equal to 2.08 DPF.

[0052] As an embodiment of the present invention, in step S2, the temperature of the high-temperature dyeing and degreasing is 60-230°C.

[0053] In the present invention, the high shrinkage tows and the ultrafine fiber tows of the silent microfiber layer have different shrinkage rates, and the tows with different shrinkage rates are entangled with each other to form gaps, so that the monofilaments of the silent monofilament bundle layer are inserted / entangled with each other / electrostatically adsorbed together to produce electrostatic adsorption, thereby forming a bonding effect.

[0054] As an embodiment of the present invention, step S2 further comprises scratching, sanding, or brushing after high-temperature dyeing and degreasing.

[0055] As an embodiment of the present invention, step S2 further includes dyeing and finishing the fabric and drying it before sanding and fleece production. The purpose of dyeing and finishing is to remove part of the spinning oil.

[0056] In the present invention, static electricity is accumulated on the surface of the hair bundle layer after the treatment in step S2.

[0057] As an embodiment of the present invention, step S2 further comprises coating the surface of the microfiber bundles with intermittent anti-slip resin or intermittent anti-slip glue.

[0058] As an embodiment of the present invention, in step S3, the compounding method includes at least one of glue compounding, hot melt compounding, and flame compounding.

[0059] Compared with the prior art, the present invention has the following beneficial effects:

[0060] 1. The fineness of the single filaments and the corresponding single filament density of the silent single filament bundle layer in the present invention solve the problems of insufficient horizontal bonding tension and wear resistance of traditional carpets, so that the obtained multi-layer carpet has both excellent horizontal bonding tension and wear resistance (i.e., durability).

[0061] 2. Different from the traditional hook-and-loop bonding structure, the surface of the silent microfiber layer of the present invention is distributed with microfiber bundles, and there is static electricity accumulation on the surface. It is easy to produce a strong electrostatic adsorption effect under the action of gravity and external force. After bonding with the silent monofilament bundle layer, it has a strong horizontal bonding tension, achieving a strong bonding effect and higher durability.

[0062] 3. The multi-layer carpet prepared by the present invention is detachably bonded, and the silent microfiber layer can be used alone or in combination with other carpets; it is foldable, easy to replace, and easy to store; at the same time, the carpet can be disassembled into several small pieces and can be infinitely extended and spliced, which has a wide range of application scenarios.

[0063] 4. The present invention unexpectedly discovered that the horizontal bonding tension of the carpet can be improved by adding an appropriate amount of stiffener to the processing method of the cut pile silent layer fabric, thereby expanding the use scenarios of the carpet.

[0064] 5. The present invention further enhances the horizontal bonding tension of the upper and lower carpet layers by adding an appropriate amount of electrostatic enhancer (electrostatic dust absorber) during the processing of the silent monofilament bundle layer, thereby achieving a better carpet bonding effect.

[0065] 6. The fineness of the single filaments in the silent monofilament bundle layer of the present invention is relatively large, and the material selection range of the silent microfiber layer is relatively wide. Filament fiber bundles or yarns made of short fibers (including chemical fibers, wool fibers, hemp fibers, etc.) can be selected, which has excellent practical industrial application value.

[0066] 7. The pile density of the textile fabrics used in the silent monofilament bundle layer and silent microfiber layer of the present invention is higher than the hook and loop density of traditional Velcro. The denser the fabric structure, the higher the cohesive energy, which easily generates a stronger electrostatic adsorption effect under the action of gravity and external forces, resulting in a strong adhesive effect. Furthermore, the textile fabrics used in the silent monofilament bundle layer and silent microfiber layer of the embodiments of the present invention exhibit better self-adhesion than Velcro. Furthermore, carpets within the monofilament density range of the present invention are more durable, more durable, and more solid. They are also quiet during assembly and disassembly, without any loud noise. They are particularly effective in preventing slipping, especially in lateral directions.

[0067] 8. The textile fabrics used in the silent monofilament bundle layer and the silent microfiber layer of the present invention will not cause any side to be damaged due to long-term opening and closing use, which greatly improves the service life, thereby making the blanket-in-blanket function easily realized. BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Other features, objects and advantages of the present invention will become more apparent upon reading the detailed description of non-limiting embodiments with reference to the following drawings:

[0069] Figure 1 is a schematic diagram of the carpet structure; wherein 1 is the carpet surface layer 1, 2 is the carpet back layer, 3 is the upper carpet, 4 is the carpet surface layer 2, 5 is the anti-slip layer, and 6 is the lower carpet;

[0070] FIG2 is a schematic diagram of the upper blanket structure in Example 1; wherein 7 is a monofilament bundle;

[0071] FIG3 is a schematic diagram of the structure of the lower blanket in Example 1; wherein 8 is a high shrinkage tow and 9 is an ultrafine fiber tow. DETAILED DESCRIPTION

[0072] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. The following examples are implemented under the premise of the technical solution of the present invention, provide detailed implementation methods and specific operating procedures, and will help those skilled in the art to further understand the present invention. It should be pointed out that the scope of protection of the present invention is not limited to the following embodiments, and a number of adjustments and improvements made under the premise of the concept of the present invention all fall within the scope of protection of the present invention.

[0073] The stiffening agent used in the embodiments of the present invention is manufactured by: Zhejiang Transpec Zhilian Co., Ltd., model: TF-639B (English: TRANSPEC STF TF-639B).

[0074] Example 1

[0075] The carpet structure of this embodiment is shown in FIG1 , and the structures of the upper carpet and the lower carpet are shown in FIG2 and FIG3 respectively.

[0076] 1. Choose a 250GSM nylon BCF flat-cut tufted printed blanket with a pile height of 4mm and a 100GSM filament non-woven base fabric. Use EVA glue to secure the tufted and printed blanket.

[0077] 2. The blanket surface with the fixed pile and the 150GSM non-woven fabric are flame-laminated to form a blanket surface layer 1 (1). The purpose of laminating the non-woven fabric is to better maintain the appearance and size after washing.

[0078] 3. Polyester DTY150D / 36F (monofilament yarn of approximately 4.17 DPF) is selected and knitted on a single needle bed knitting machine to form a fabric. The fabric is then brushed, cut, dyed, and then subjected to a heat-blown treatment to obtain a silent monofilament bundle layer having monofilament bundles (7), i.e., the blanket backing layer (2). The weight is approximately 200 grams per square meter, the pile length is approximately 2.5 mm, and the monofilament density is 174,960 strands per square inch. The silent monofilament bundle layer is combined with the blanket surface layer 1 obtained in step 2 to obtain the upper blanket layer (3).

[0079] 4. The sea island fibers of 75D / 200F island and 75D polyester high elastic yarn are paralleled and stretched, and then weft knitted (knitted) to obtain weft knitted ant cloth (i.e. knitted fabric). At 130°C, the fibers are degreased by alkali reduction (i.e. high temperature dyeing and degreasing) with a NaOH solution having a mass concentration of 32% and added to a dyeing vat to obtain a silent microfiber layer having high shrinkage tows (8) and microfiber tows (9), i.e., a blanket surface layer 2 (4), with a pile height (i.e., thickness) of 1.5 mm and a microfiber part with a single filament fineness of 0.375D.

[0080] 5. The silent microfiber layer fabric prepared in step 4 is compounded with 700 g / m2 dot-molded non-woven fabric, i.e., the anti-slip layer (5), using PUR hot melt adhesive to obtain the lower blanket (6) of the present invention.

[0081] 6. Complete cutting, finishing, packaging and shipping.

[0082] Example 2

[0083] 1. Choose 360GSM printed flannel as the blanket surface.

[0084] 2. 500GSM printed flannel blanket surface and 200GSM non-woven fabric are compounded together with PUR glue to form blanket surface layer 1 with a pile height of 5mm.

[0085] 3. 105D / 36F*37 polyester-nylon composite yarn and 100D high-shrinkage yarn are combined and tied with a heavy network knot as the warp, and 150D / 14F polyester filament is used as the weft to form a 180GSM warp microfiber fabric in a plain weave. After high-temperature dyeing and degreasing (at 130°C), the fabric is dried and shaped, and then high-speed fleece / sanded to obtain a silent microfiber layer. The DPF of the microfiber part is approximately 0.08DPF. The silent microfiber layer is composited with the blanket surface layer 1 in step 2 to form the upper blanket.

[0086] 4. 1800D / 144F black polypropylene BCF yarn was selected and tufted on a 1 / 12 gauge tufting machine to produce a cut pile carpet surface with a row spacing of approximately 12.70 needles / inch and a pile height of 3.5 mm. 200gsm of a stiffening agent (model TF-639B, ratio 30g / L) was sprayed on the carpet surface. The carpet was then placed in an oven for hot air treatment, causing the top ends of the BCF filament bundles to bend and diverge, forming carpet surface 2 of the present invention, comprising a silent filament bundle layer. The filaments in the filament bundles had a fineness of approximately 12.50 DPF and a density of approximately 21,946 strands per square inch.

[0087] 5. The back of the silent monofilament layer fabric is coated with 500GSM TPE anti-slip glue. During the coating, a hot air blower blows hot air to the blanket surface at a temperature of 120 degrees Celsius, further making the monofilaments on the blanket surface divergent and inclined, thereby obtaining the lower blanket of the present invention.

[0088] 6. Complete cutting, finishing and packaging.

[0089] Example 3

[0090] 1. Choose 700GSM jacquard fabric as the blanket surface, as the blanket surface layer 1.

[0091] 2. Greige fabric was woven on a warp knitting machine using 215D / 36F*37 island-in-the-sea yarn (DTY) as the pile yarn and 150D / 72F polyester DTY as the base yarn. The fabric was then opened and degreased using 2g / L YZ-101 fiber opener and 6g / L 100% caustic soda at a bath ratio of 1:15. The opening temperature was controlled at approximately 95°C for 30 minutes. The fabric was then dyed, dried, and set, and finally high-speed brushed / fleeced to produce the silent microfiber layer. The microfiber portion of the surface of the silent microfiber layer had a fiber density of 0.16 DPF.

[0092] 3. The carpet surface layer 1 in step 1 and the silent microfiber layer in step 2 are compounded to form the upper carpet of the present invention.

[0093] 4. 1800D / 30F polyester BCF monofilament yarn and 120GSM polyester imitation bonded nonwoven fabric were woven on a 1 / 6 tufting machine to create a blanket. The blanket was then sprayed with 300GSM of JISUNO electrostatic dust absorber (i.e., static enhancer), model 4957758, at a ratio of 30g / L. SBR adhesive was then applied to the back of the blanket and dried in a hot air oven to form blanket surface layer 2. The stitch count was approximately 10 stitches / inch, the pile height was 5mm, and the monofilament density was approximately 1800 strands / square inch. The drying and setting temperature was 160°C. After setting, the monofilament ends of the monofilament bundle exhibited a slightly curved shape.

[0094] 5. The fabric prepared in step 4 is compounded with a 3D mesh cloth using PUR adhesive to obtain the lower layer carpet of the present invention. The back of the 3D mesh cloth is coated with 30GSM SEBS hot melt anti-slip adhesive.

[0095] 6. Complete cutting, finishing and packaging.

[0096] Comparative Example 1

[0097] The preparation method for this comparative example is essentially the same as that for Example 1, differing only in that the silent monofilament bundle layer fabric is replaced with a barbed mesh fabric with a 300D monofilament base yarn and 450D monofilament barbs. The multi-layer carpet obtained in Example 1 was used as an experimental example, and the multi-layer carpet obtained in Comparative Example 1 was used as a comparative example. The following experiment was conducted (the experimental bonding area was 13 cm x 19 cm).

[0098] Experiment 1: The experimental and comparative carpets were fixed to the same wood-grain floor. A tensioner was then hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal adhesion tension. The results are as follows:

[0099] Experimental example = 121 Newtons;

[0100] Comparative = 87 Newtons.

[0101] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four pieces of comparative example fabric was observed and the durability was tested. The results are as follows:

[0102] Experimental example = Almost no change

[0103] Comparative Example = The microfiber bundle layer had a lot of damaged hairs, and many black barbed wires were broken and left on the microfiber bundle layer.

[0104] Comparative Example 2

[0105] The preparation method of this comparative example is essentially the same as that of Example 1, except that the silent monofilament layer is replaced with singed felt fibers (6x51mm + 2.5x51mm needle-punched into a nonwoven track mat and then heat-singed). The multi-layer carpet obtained in Example 1 was used as an experimental example, and the multi-layer carpet obtained in Comparative Example 2 was used as a comparative example. The following experiment was conducted (the experimental bonding area was 13cm x 19cm).

[0106] Experiment 1: The experimental example and comparative example were fixed on the same wood-grain floor. Then, a tensioner was hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal bonding tension. The results are as follows:

[0107] Experimental example = 121 Newtons;

[0108] Comparative = 85 Newtons.

[0109] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four pieces of comparative example fabric was observed and the durability was tested. The results are as follows:

[0110] Experimental case = almost no change;

[0111] Comparative Example = The ultrafine fiber bundle layer had many black spots and broken fibers attached.

[0112] Comparative Example 3

[0113] The preparation method for this comparative example is essentially the same as that for Example 1, differing only in that the silent monofilament layer is replaced with a singed felt sub-fiber. A 6DX51mm + 2.5DX51mm track nonwoven felt is needle-punched and then heat-singed. The microfiber bundle layer is replaced with a 300D / 48F weft-knitted fleece. The multi-layer carpet obtained in Example 1 was used as an experimental example, and the multi-layer carpet obtained in Comparative Example 3 was used as a comparative example. The following experiments were conducted (the experimental bonding area was 13 cm × 19 cm).

[0114] Experiment 1: The experimental example and comparative example were fixed on the same wood-grain floor. Then, a tensioner was hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal bonding tension. The results are as follows:

[0115] Experimental example = 121 Newtons;

[0116] Comparative = 23 Newtons.

[0117] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four pieces of comparative example fabric was observed and the durability was tested. The results are as follows:

[0118] Experimental case = almost no change;

[0119] Comparative Example = Many black broken felt fibers appeared on the microfiber bundle layer, and some of the hairs of the weft-knitted terry cloth were pulled apart, exposing the bottom.

[0120] Comparative Example 4

[0121] The preparation method of this comparative example is basically the same as that of Example 2, except that, in step 3, 105D / 36Fx37 polyester-nylon composite yarn and 100D high shrinkage yarn are spun into 180gsm terry cloth using a weft knitting machine, dyed, dried and shaped, and then composited with the blanket surface to form the upper blanket. The lower blanket is the same as that in Example 2.

[0122] The multi-layer carpet obtained in Example 2 was used as an experimental example, and the multi-layer carpet obtained in Comparative Example 4 was used as a comparative example to conduct the following experiment (the experimental bonding area was 13CM×19CM).

[0123] Experiment 1: The experimental example and comparative example were fixed on the same wood-grain floor. Then, a tensioner was hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal bonding tension. The results are as follows:

[0124] Experimental example = 91 Newtons;

[0125] Comparative = 72 Newtons.

[0126] Experiment 2: The experimental example and the comparative example were quickly opened and closed, opened again, and closed again, and repeated 5000 times. The appearance of the four pieces of comparative example fabric was observed and the durability was tested. The results are as follows:

[0127] Experimental example = basically no change;

[0128] Comparative = Slightly damaged loops.

[0129] Example 4

[0130] The preparation method of this embodiment is basically the same as that of embodiment 2, except that no stiffening agent is added in step 3. The multi-layer carpets obtained in embodiments 2 and 4 were subjected to the following experiment (the experimental bonding area was 13 cm x 19 cm).

[0131] Experiment 1: Example 2 and Example 4 were placed on the same wood-grain floor. A tensioner was then hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal bonding tension. The results are as follows:

[0132] Example 2 = 91 Newtons;

[0133] Example 4 = 83 Newtons.

[0134] Experiment 2: Example 2 and Example 4 were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0135] Example 2 = almost no change;

[0136] Example 4 = Almost no change.

[0137] Example 5

[0138] The preparation method of this embodiment is basically the same as that of embodiment 3, except that no static enhancer is added to the silent monofilament fabric. The multi-layer carpets obtained in embodiments 3 and 5 were subjected to the following experiment (the experimental bonding area was 13 cm x 19 cm).

[0139] The multi-layer carpets obtained in Example 3 and Example 5 were respectively fixed on the same wood-grain floor. Then, a tensioner was hooked on the middle right side of the upper carpet surface and slowly pulled until the upper and lower carpet surfaces separated. The tension reading at that moment was recorded to test the horizontal adhesion tension. The results are as follows:

[0140] Example 3 = 109 Newtons;

[0141] Example 5 = 92 Newtons.

[0142] Experiment 2: Example 3 and Example 5 were quickly opened and closed, opened again, and closed again, and repeated 1000 times. The appearance of the four fabrics of the comparative example was observed and the durability was tested. The results are as follows:

[0143] Example 3 = almost no change;

[0144] Example 5 = Almost no change.

[0145] In summary, it can be seen that under the filament fineness and filament density of the silent monofilament bundle layer of the present invention, the obtained multi-layer carpet has excellent horizontal bonding tension, durability and economic value. In addition, stiffeners are usually used on flat fabrics to make the fabric more stiff. The present invention creatively uses stiffeners to add a small amount of stiffeners in the processing steps of the silent monofilament bundle layer, and unexpectedly finds that the horizontal bonding tension of the carpet can be improved, the use scenarios of the carpet can be expanded, and the durability of the carpet can be enhanced. At the same time, the present invention creatively adds a small amount of electrostatic enhancer (electrostatic dust absorber) in the processing steps of the silent monofilament bundle layer to further enhance the horizontal bonding tension of the upper and lower carpets. More importantly, unlike the hook-and-hook bonding of the traditional loop and hook structure, the surface of the silent microfiber layer of the present invention is distributed with microfiber bundles, which easily generate a strong electrostatic adsorption effect under the action of gravity and external force. After bonding with the silent monofilament bundle layer, it has a strong horizontal bonding tension, achieves a strong bonding effect, and has higher durability.

[0146] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art may make various variations or modifications within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A multi-layer carpet, characterized in that: The multi-layer carpet comprises an upper carpet and a lower carpet, wherein the upper carpet is provided with a carpet surface layer 1 and a carpet back layer from top to bottom, and the lower carpet is provided with a carpet surface layer 2 and an anti-slip layer from top to bottom, and the upper carpet and the lower carpet are connected by detachably bonding the carpet back layer and the carpet surface layer 2; The blanket back layer is a silent monofilament bundle layer, and the blanket surface layer 2 is a silent microfiber layer; Alternatively, the blanket back layer is a silent microfiber layer, and the blanket surface layer 2 is a silent monofilament bundle layer.

2. The multi-layer carpet according to claim 1, characterized in that The material of the silent monofilament bundle layer includes at least one of composite yarn bundles, animal hair fibers, and blended fibers of natural fibers and chemical fibers.

3. The multi-layer carpet according to claim 1, characterized in that The silent monofilament bundle layer is a monofilament bundle layer in which a plurality of monofilament bundles are distributed; the monofilament bundle is composed of a plurality of monofilaments with a common bottom, and the top end of the monofilament has a dispersed inclined or curved structure.

4. The multi-layer carpet according to claim 3, characterized in that The fineness of the monofilament is 1.04-60DPF; the monofilament density of the silent monofilament bundle layer is 1200-180000 strands / square inch.

5. The multi-layer carpet according to claim 1, characterized in that The material of the silent microfiber layer includes at least one of a high shrinkage tow and an ultrafine fiber tow.

6. The multi-layer carpet according to claim 5, characterized in that The silent microfiber layer is a tuft layer on which a plurality of microfiber tufts are distributed.

7. The multi-layer carpet according to claim 6, characterized in that The fineness of the monofilament in the microfiber bundle is 0.05-2.08D.

8. A method for preparing a multi-layer carpet according to any one of claims 1 to 7, characterized in that: The preparation method comprises the following steps: S1. Preparing a silent monofilament bundle layer: preparing a cut pile fabric from a composite yarn bundle, or animal hair fiber, or a blend of natural fiber and chemical fiber, and combing or heat-treating the cut pile fabric to obtain a monofilament bundle layer with distributed monofilament bundles, i.e., the silent monofilament bundle layer; S2. Preparation of a silent microfiber layer: knitting or woven fabrics made by paralleling high shrinkage tows and microfiber tows, or paralleling and stretching them, or paralleling and stretching them and forming a network, and then high-temperature dyeing and degreasing them to form fiber tows to obtain a bundle layer with microfiber bundles distributed thereon, i.e., a silent microfiber layer; Alternatively, a woven, knitted or needle-punched fabric made of multiple microfiber bundles is subjected to sanding and high-temperature treatment to obtain a bundle layer with microfiber bundles distributed thereon, namely, a silent microfiber layer; S3. Preparing a multi-layer carpet: Compounding the carpet surface layer 1 with the silent monofilament bundle layer to form an upper carpet layer, and compounding the silent microfiber layer with the anti-slip layer to form a lower carpet layer; Alternatively, the carpet surface layer 1 is compounded with the silent microfiber layer to form an upper carpet layer, and the silent monofilament bundle layer is compounded with the anti-slip layer to form a lower carpet layer; The multi-layer carpet is obtained.

9. The preparation method according to claim 8, characterized in that Step S1 also includes adding a stiffener to the cut pile fabric before combing or heat processing, wherein the concentration of the stiffener is 10-30 g / L and the usage amount is 30-500 gsm; the combing includes at least one of sanding, combing, shearing, and ironing processes; and the heat processing includes at least one of hot blowing process and ironing process.

10. The preparation method according to claim 8, characterized in that Step S1 further comprises adding an electrostatic enhancer to the cut pile fabric of the silent monofilament layer before carding or heat treatment, wherein the concentration of the electrostatic enhancer is 10-50 g / L and the usage amount is 20-300 gsm.

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