CN110846760B

CN110846760B - Manufacturing method of patterned yarn carpet

Info

Publication number: CN110846760B
Application number: CN201911114344.4A
Authority: CN
Inventors: 曹顺林
Original assignee: Kunshan Yijia Ju Textile Co ltd
Current assignee: Kunshan Yijia Ju Textile Co ltd
Priority date: 2019-11-14
Filing date: 2019-11-14
Publication date: 2022-04-01
Anticipated expiration: 2039-11-14
Also published as: CN110846760A

Abstract

The invention discloses a manufacturing method of a flower type yarn carpet; mixing the super-strong thermal shrinkage and boiling water shrinkage before the primary yarn orientation with other draw textured fibers (DTY/BCF/FDY/ATY), and cutting by a cutting loom after a net (a net machine) or twisting to obtain a carpet surface; when the back of the carpet surface is glued, the carpet with high elasticity and different styles is automatically formed by shrinkage molding by using the temperature of the carpet gluing machine during gluing. The manufacturing process is simple; in the manufacturing process, the pattern yarn carpet with various styles can be prepared by adjusting different proportions of the primary yarn and other draw textured fibers DTY/BCF/FDY/ATY, the wind pressure of a network, the linear speed of the network, the tension of the fibers, the gum temperature and the like.

Description

Manufacturing method of patterned yarn carpet

Technical Field

The invention relates to the technical field of spinning, in particular to a manufacturing method of a patterned yarn carpet.

Background

The primary yarn is the yarn spun from direct melt and not subjected to drawing and yarn changing, belongs to an intermediate in polyester spinning, and is basically used for producing DTY (draw textured yarn) and FDY (fully drawn yarn) yarns and is rarely used for manufacturing finished products. The raw yarn is generally classified into undrawn yarn (UDY), semi-pre-oriented yarn (MOY), pre-oriented yarn (POY), and Highly Oriented Yarn (HOY) according to the difference in spinning speed.

Wherein undrawn yarn (UDY): the fiber molecules of the yarn have no orientation basically and are not crystallized, and the yarn has low strength, large elongation and poor dimensional stability and can not be directly applied generally. Semi-oriented yarn (MOY): the fiber molecules of the fiber have a small amount of orientation, the orientation degree is higher than UDY and lower than that of pre-oriented yarns, and the structural state of the yarns is still not stable enough and cannot be directly applied. Pre-oriented yarn (POY): the fiber itself has been moderately drawn, has a degree of orientation, has a small number of crystallites, and is still below the finished yarn requirements. The yarn has low strength and high elongation, is not suitable for being directly used for processing fabrics generally, but can be used for meeting the weaving requirement by producing composite yarns by compounding with other fibers, so that the fabrics have special styles. Highly Oriented Yarn (HOY): the fiber is prepared by one-step ultrahigh-speed spinning, has high fiber molecular orientation degree and good fiber dyeing performance, but has larger elongation and thermal shrinkage, and can not meet the general use requirements.

The conventional carpet yarn manufacturing procedure is: spinning DTY/BCF/FDY/ATY → piecing together network → twisting → sizing (traditional carpet yarn is divided into two types of white yarn and colored spun yarn, white yarn is generally sized in dyeing, colored spun yarn is sized on a special sizing machine) → carpet manufacturing. Wherein DTY is a draw textured yarn, FDY is a fully drawn yarn (spinning and drawing one-step method), BCF is a bulked continuous yarn (a textured yarn with higher linear density), and ATY is an air textured yarn.

Through the search of the existing patent documents, the Chinese patent application with the application number of 201811229275.7 discloses a preparation method of a polyester twisting and shaping wool-like carpet yarn; the preparation method comprises the following steps: mixing, melting and spinning and stretching the high-shrinkage polyester of the polyester color master batch to obtain Bulked Continuous Filament (BCF) → cooling and shaping → twisting → shaping, and obtaining carpet yarn → manufacturing the carpet. The chinese patent application No. 201210541684.7 discloses a method for manufacturing carpet yarn; the preparation method comprises the following steps: spinning to obtain two bundles of flame-retardant nylon-6 fibers and one bundle of antistatic fibers → collecting the three bundles of fibers to form a fiber bundle → stretching the fiber bundle by a stretching roller and then entering a bulking deformer to form bulked yarns → cooling, shaping and networking the bulked yarns to generate network knots for periodically binding the yarns on the surfaces of the yarns → winding the bulked yarns into cone yarns by a winding machine to prepare carpet yarns → manufacturing the carpet. The two schemes are both traditional carpet yarn manufacturing procedures, and the working procedures are complex.

The Chinese invention patent application with the application number of 201811479947.X discloses a multifunctional terylene fancy yarn and a preparation method thereof; the yarn is formed by compounding four different spinning threads, namely fine denier porous flame-retardant POY (pre-oriented yarn) yarns, cationic MOY (polyester) yarns and full-dull FDY (fully drawn yarn) yarns with two different specifications; the preparation process comprises the following steps: the cation MOY filament, the fine denier porous flame-retardant POY filament and the full-dull FDY filament are converged at a roller; then the multifunctional fancy polyester yarn is obtained after the processes of drafting, deforming (the resultant is the textured yarn after converging, drafting and deforming), cooling, twisting, network compounding, sizing and winding. The carpet yarn is different from the traditional carpet yarn in that: the method is characterized in that a positive ion MOY filament, a fine denier porous flame-retardant POY filament and a full-dull FDY filament composite filament are adopted, and fancy carpet yarns are prepared through the working procedures of drafting, deformation, twisting, network compounding, sizing and the like, so that the carpet is manufactured; in the composite yarn, a full-dull FDY yarn is a main yarn and is in a straight state, a cation MOY yarn and two fine-denier porous flame-retardant POY yarns are wound on the full-dull FDY yarn, the fine-denier porous flame-retardant POY yarns are uniformly wound, the cation MOY yarns are wound in a density interval manner, in the finally obtained yarn, the winding effect of the MOY on the FDY is distributed in a density interval manner and a sparse interval manner, the POY yarns float on the surface of the yarn, but the POY is a pre-oriented yarn and can play a fluffy effect only by being subjected to texturing → DTY; however, the preparation process still belongs to the traditional carpet yarn manufacturing procedure and is complex.

Disclosure of Invention

The invention aims to overcome the defects of complex process and the like in the conventional carpet yarn manufacturing process, and provides a method for manufacturing a patterned yarn carpet. The preparation process of the carpet comprises the following steps: spinning DTY/BCF/FDY/ATY + as-spun filament (oriented filament/semi-oriented filament) → web → carpet manufacture. The invention utilizes the extremely strong thermal shrinkage and boiling water shrinkage before the orientation of the primary yarn, mixes with other fibers (spinning DTY/BCF/FDY/ATY), and cuts off the mixture by a carpet pile cutting loom (including a circular loom, a warp knitting machine, a tufting machine and the like) after a network (a network machine) or twisting to prepare a carpet surface; when the back glue is applied to the back of the carpet surface, the temperature of the back glue of the carpet back glue machine is utilized, the radial strong heat shrinkage force of the primary raw silk is utilized, other fibers are stretched to the required shape, and therefore fluffy and high-strength elasticity is generated, and the automatic shrinkage molding is further realized to form the carpet with different high elasticity and styles.

The purpose of the invention is realized by the following technical scheme:

the invention relates to a manufacturing method of a patterned yarn carpet, which comprises the following steps:

s1, mixing the draw textured fiber with the primary yarn to form a mixed yarn;

s2, the mixed yarns are networked, and network knots for periodically tightening the yarns are generated on the surfaces of the mixed yarns; or twisting the hybrid yarn;

s3, cutting the mixed yarn after the net or twisting treatment in the step S2 by a pile cutting loom to manufacture a carpet surface;

and S4, back gluing is carried out on the back of the carpet surface, and the yarn on the carpet surface is automatically shrunk and formed into the fancy yarn carpet with different high elasticity and styles at the temperature when the back gluing is carried out on the carpet back gluing machine.

The primary yarn in the mixed yarn does not need to be positioned, and the yarn on the carpet surface can be automatically shrunk and formed into the fancy yarn carpet with high elasticity and different styles by subsequently printing network points with specified strength according to the process requirement during back gluing.

In step S1, the draw textured fiber is one or more of DTY, BCF, FDY, and ATY.

In step S1 and step S1, the raw silk has a heat shrinkage of 15% to 50% measured by boiling in boiling water at 100 ℃ for 10 minutes.

In one embodiment of the present invention, the fineness of the raw silk is 45D to 300D in step S1.

As one embodiment of the present invention, in step S1, the as-spun filaments are pre-oriented filaments or semi-oriented filaments.

In one embodiment of the present invention, in step S1, the total fineness of the draw textured fibers in the hybrid yarn is 300D to 5000D.

In one embodiment of the present invention, in step S1, the spun yarn is 4 to 15% and the draw textured fiber is 96 to 85% in terms of the ratio of the number D of the different fibers in the mixed yarn. If the proportion of the primary yarns is lower than 4 percent, the tensile force generated after the primary yarns are heated is not easy to pull other deformed yarns to generate an elbow effect, and an inverted U shape cannot be formed, so that the fluffiness of the suede of the carpet is poor, and the hair surface is uneven; if the percentage of the primary yarn is higher than 15%, the primary yarn generates excessive contraction force after being heated to drive other deformed yarns to be seriously bent, so that the false circle phenomenon is formed on the pile surface of the carpet, and the surface is disordered.

In step S2, the wind pressure of the network is 2.5kg to 6kg and the linear velocity is 20 m/S to 480 m/S. If the wind pressure is lower than 2.5kg, the network points are easy to disperse through external force friction; the existing equipment does not support the wind pressure higher than 6 kg; if the linear velocity is lower than 20 m/s, the production efficiency is low and the cost is high; if the linear velocity is higher than 480 m/s, the formed network points are loose and are easy to fall off and scatter.

In an embodiment of the present invention, in step S2, the back-adhesive temperature is 80 ℃ to 190 ℃. If the temperature is too low and the primary yarn is not heated enough, the primary yarn still keeps larger elasticity and cannot form an elbow effect and an inverted U character, so that the fluffiness of the carpet suede is poor; if the temperature is higher than 190 ℃, the primary yarn can be strongly shrunk, and other deformed yarns can be secondarily deformed, so that the texture of the carpet becomes disordered.

Compared with the prior art, the invention has the following beneficial effects:

1. the process is simple: spinning DTY/BCF/FDY/ATY + as-spun filament (oriented filament/semi-oriented filament) → web → carpet manufacture; the production cost can be obviously reduced;

2. the carpet pattern yarns with various styles can be prepared by adjusting the gum temperature and the like according to different proportions of the primary yarns and the spinning DTY/BCF/FDY/ATY fibers, the wind pressure of a network, the linear speed of the network and the tension of the fibers (which refers to the tension of the fibers when the fibers are networked on a network machine, wherein all the tensions are based on the drafting force borne by the primary yarns, and other textured yarns and the primary yarns keep the same horizontal line, in the invention, the drafting force borne by the primary yarns cannot be used for drafting deformation under the condition that the drafting force borne by the primary yarns is within the range of 1-5 Newton, and the uneven yarn count can be caused by overlarge and undersize drafting forces), for example: zigzag yarns, chenille flower-shaped yarns, necklace bead-shaped flower-shaped yarns, U-shaped bent yarns, and the like;

3. the amount of yarn used for carpet is square meter per gram weight, another index uses the pile volume to measure the thickness of the carpet; the carpet with the same fancy yarn carpet surface is prepared, the carpet yarn produced by the method of the invention has greatly increased stacking volume, thereby reducing the square meter/gram weight of the carpet yarn, achieving the purpose of saving materials, and saving the usage amount by 20-40% compared with the traditional carpet yarn; thereby remarkably reducing the production cost and greatly improving the market competitiveness.

Drawings

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

FIG. 1 is a schematic structural view of a composite filament; wherein, 1 is pre-oriented yarn, 2 is draw textured fiber;

FIG. 2 is a schematic structural view of a U-bend yarn carpet of example 1;

FIG. 3 is a schematic structural view of a chenille flower yarn-like carpet of example 2;

FIG. 4 is a schematic view of the structure of the necklace bead type lace carpet of example 3;

figure 5 is a schematic of the construction of the zigzag yarn carpet of example 4.

Detailed Description

The present invention will be described in detail with reference to examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be apparent to those skilled in the art that several modifications and improvements can be made without departing from the inventive concept. All falling within the scope of the present invention.

Example 1

The embodiment relates to a manufacturing method of a pattern yarn carpet, which comprises the following steps:

1. mixing the draw textured fiber FDY and the pre-oriented yarn according to the thickness (D number) ratio of 11:1 to form a mixed yarn (it is to be noted that the FDY and the pre-oriented yarn have the same length before being heated; the mixed yarn is also called a composite yarn, and the structure after being heated is shown in figure 1); wherein the pre-oriented yarn has a fineness of 100D (1 100D of the as-spun yarn) and a heat shrinkage (measured by boiling in 100 ℃ boiling water for 10 minutes) of 45%; taking 11 FDY yarns of 100D, wherein the total D number of the mixed yarns is 1200D;

2. the mixed yarns are subjected to network, and network knots for periodically binding the yarns are generated on the surfaces of the mixed yarns; the wind pressure of the network is 4kg, the linear velocity is 350 m/s, and the carpet yarn is prepared;

3. the carpet yarn is cut off by a tufting machine to form a carpet surface;

4. carrying out back gluing on the back of the carpet surface by using a carpet back gluing machine, wherein the back gluing temperature is 150 ℃; this back glue temperature causes the yarns on the face of the carpet to automatically shrink to shape, forming a carpet with U-turn yarns as shown in fig. 2.

During production, in the step 1, the pre-oriented yarns can be cold-drawn to various required radial thermal shrinkage rates and fineness according to the design requirements, so that various styles of carpet pattern yarns can be obtained.

Example 2

The present embodiment relates to a method of manufacturing a carpet, comprising:

1. mixing the tensile deformation fiber BCF and the semi-oriented yarn according to the thickness (D number) ratio of 9:1 to form mixed yarn; the semi-oriented yarn had a fineness of 300D (2 pieces 150D) and a heat shrinkage (measured by boiling in 100 ℃ boiling water for 10 minutes) of 24%; taking 2700D BCF 1 yarns, wherein the total D number of the mixed yarns is 3000D;

2. the mixed yarns are subjected to network, and network knots for periodically binding the yarns are generated on the surfaces of the mixed yarns; the wind pressure of the network is 6kg, the linear velocity is 200 m/s, and the carpet yarn is prepared;

3. the carpet yarn is cut off by a warp and weft knitting machine to form a carpet surface;

4. carrying out back gluing on the back of the carpet surface by using a carpet back gluing machine, wherein the back gluing temperature is 170 ℃; this back-glue temperature causes the carpet yarns on the carpet face to automatically shrink to shape, forming a carpet having a chenille flower type yarn as shown in fig. 3.

Example 3

1. mixing the draw textured fiber DTY and the pre-oriented yarn according to the thickness (D number) ratio of 6:1 to form a mixed yarn; the fineness of the pre-oriented yarn is 50D 1, and the thermal shrinkage (measured by boiling in 100 ℃ boiling water for 10 minutes) is 25%; the D number of DTY is 300D (taking 1 DTY of 300D);

2. the mixed yarns are subjected to network, and network knots for periodically binding the yarns are generated on the surfaces of the mixed yarns; the wind pressure of the network is 2.5kg, the linear velocity is 20 m/s, and the carpet yarn is prepared;

3. the carpet yarn is cut off by a tufting machine to form a carpet surface;

4. carrying out back gluing on the back of the carpet surface by using a carpet back gluing machine, wherein the back gluing temperature is 85 ℃; the temperature of the gum enables the yarn on the carpet surface to automatically shrink and form, and the carpet with the flower type yarn like necklace beads is formed as shown in figure 4.

Example 4

1. mixing the mixed fiber of the draw textured fiber FDY and the pre-oriented yarn according to the thickness (D number) ratio of 6:1 to form mixed yarn; the pre-oriented yarn had a fineness of 100D and a heat shrinkage (measured by boiling in 100 ℃ boiling water for 10 minutes) of 35%; the total D number of the hybrid yarn is 700D, wherein the FDY hybrid fiber is specifically 100D of FDY 6);

2. the mixed yarns are subjected to network, and network knots for periodically binding the yarns are generated on the surfaces of the mixed yarns; the wind pressure of the network is 3.5kg, the linear velocity is 480 m/s, and the carpet yarn is prepared;

4. carrying out back gluing on the back of the carpet surface by using a carpet back gluing machine, wherein the back gluing temperature is 110 ℃; this back glue temperature causes the yarns on the face of the carpet to automatically shrink to shape, forming a carpet with zigzag yarns as shown in figure 5.

Comparative example 1

This comparative example provides a conventional method of weaving fancy carpet yarn prior to making a carpet comprising the steps of:

1. as in example 1, the draw textured fiber FDY and the pre-oriented yarn were mixed in a ratio of thickness (D number) of 11:1 to form a mixed yarn; wherein the pre-oriented yarn has a fineness of 100D (1 100D of the as-spun yarn) and a heat shrinkage (measured by boiling in 100 ℃ boiling water for 10 minutes) of 45%; taking 11 FDY yarns of 100D, wherein the total D number of the mixed yarns is 1200D;

2. twisting by a two-for-one twister in a twisting direction Z, wherein the twist is 120 twists/m;

3. preparing U-shaped bent yarns by using a continuous yarn heat-setting machine, wherein the setting temperature is 140 ℃, and the setting time is 20 minutes;

4. cutting the U-shaped elbow yarn by a tufting machine to obtain a carpet surface; and (4) carrying out gum application on the back of the carpet surface to obtain the carpet.

The carpet yarn made in this comparative example has a yarn usage of 1100g per gram of square weight, while the carpet yarn made in example 1 has a yarn usage of 620g per gram of square weight, which achieves the same carpet pile volume as in comparative example 1, saving 43.6% of the yarn usage.

In summary, the preparation process of the carpet of the present invention comprises: spinning DTY/BCF/FDY/ATY + as-spun filament (oriented filament/semi-oriented filament) → web → carpet manufacture. The invention utilizes the extremely strong thermal shrinkage and boiling water shrinkage before the orientation of the primary yarn, mixes with other materials (spinning DTY/BCF/FDY), and cuts off the network (network machine) or the cutting loom (including circular machine, warp knitting machine, tufting machine and other fabric looms) after twisting to make carpet surface; the back of the carpet surface is glued, and the carpet with high elasticity and different styles is automatically formed by shrinkage molding by using the temperature of the back gluing machine for the carpet.

The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention.

Claims

1. A method of making a patterned yarn carpet, comprising the steps of:

s1, mixing the draw textured fiber with the primary yarn to form a mixed yarn;

s4, carrying out gum application on the back of the carpet surface, wherein the yarn on the carpet surface is automatically shrunk and formed into the fancy yarn carpet at the temperature when the gum application of the carpet gum application machine is carried out;

in the step S1, in the mixed yarn, according to the proportion of D numbers of different fibers, the proportion of the primary yarn is 4-15%, and the proportion of the draw textured fiber is 96-85%;

in step S4, the temperature of the gum is 80-190 ℃;

the heat shrinkage rate of the as-spun silk is 15-50% when the as-spun silk is boiled in boiling water at 100 ℃ for 10 minutes;

the fineness of the primary raw silk is 45D-300D;

in step S2, the wind pressure of the network is 2.5 kg-6 kg, and the linear velocity is 20 m/S-480 m/S.

2. The method for manufacturing fancy yarn carpet of claim 1, wherein in the step S1, the draw textured fiber is one or more of DTY, BCF, FDY, ATY.

3. The method for manufacturing fancy yarn carpet of claim 1, wherein the primary yarns are pre-oriented yarns or semi-oriented yarns in the step S1.

4. The method for manufacturing a fancy yarn carpet of claim 1, wherein the total fineness of the draw textured fibers in the mixed yarn is 300D to 5000D in step S1.