CN111101300A

CN111101300A - Preparation method of artificial fur carpet

Info

Publication number: CN111101300A
Application number: CN201911340883.XA
Authority: CN
Inventors: 曹顺林
Original assignee: Kunshan Yijiaju Textile Co ltd
Current assignee: Kunshan Yijiaju Textile Co ltd
Priority date: 2019-12-23
Filing date: 2019-12-23
Publication date: 2020-05-05
Anticipated expiration: 2039-12-23
Also published as: CN111101300B

Abstract

The invention discloses a preparation method of an artificial fur carpet; selecting and using deformed chemical filament fibers with different shrinkage rates and pre-oriented filament fibers for doubling, obtaining a rib ring or zigzag yarn through network knotting or twisting and shaping, and then weaving through a weaving machine to obtain a carpet fabric in a cut pile state; then the manufactured carpet fabric is dyed and finished, the rib ring or the zigzag yarn is continuously loosened, unwound and extended, thereby forming semi-finished products of the artificial fur carpet with different specifications and styles, and finally, the artificial fur carpet is obtained through subsequent processing. Compared with the traditional preparation process of the artificial fur carpet, the same fur effect is achieved, and the process is simplified; the amount of carpet yarn used required by the present invention is significantly reduced; moreover, the fur fibers on the prepared fur carpet are not easy to tear off and fall off, and the yarn loss in the production process is greatly reduced.

Description

Preparation method of artificial fur carpet

Technical Field

The invention relates to the technical field of spinning, in particular to a preparation method of an artificial fur carpet.

Background

The artificial fur is a long-wool type fabric similar to animal fur in appearance, and is an artificial animal fur. Common manufacturing methods include knitting (weft knitting, warp knitting, stitch bonding), weaving and the like, and the weft knitting method is developed fastest and is applied most widely. Acrylic fiber, modified acrylic fiber, polyvinyl chloride fiber and the like can be used as raw materials of the artificial fur. Although the artificial fur has inferior warmth retention property to real fur, the artificial fur is soft and beautiful, can be made into overcoat, hat, collar, carpet and the like, and has wide application.

The preparation route of the traditional large fur carpet is as follows: the process proportion of medium long fiber → coloring of raw material → combing → circular knitting machine, warp knitting machine manufacturing → sizing breadth shaping → hair drawing and ironing and shearing (more than 200 ℃) to iron and shear hair tips.

The prior research project (application No. 201510205743.7) of the applicant is a processing method of a sheepskin-like carpet, which sequentially comprises the following processing steps: skein dyeing → tufting → yarn fixing → carding, ironing, shearing → compounding → cutting. The process selects the polyester long fibers with the wool thickness specification, designs the parameters of a weaving machine, fixes the yarn after tufting, combs, irones, shears and compounds TPE and suede, and automatically cuts without edge covering. Compared with the traditional preparation process of the large-fur carpet, the preparation process has the greatest advantages that three procedures of combing, ironing and shearing are omitted to obtain the same product effect, and the dyeing temperature lower than 140 ℃ is adopted, so that the production cost is greatly lower than that of the traditional process.

The Chinese invention patent application with the application number of 201710504523.3 discloses a preparation method of a simulated leather flocking carpet, which comprises the following steps: cleaning the surface of a polyvinyl chloride-based material, brushing polyvinyl acetate glue on one surface, sticking a polyester non-woven fabric, after high-temperature curing, brushing a flocking adhesive on the non-woven fabric, flocking by adopting real leather flocking short fibers, obtaining carpet grey cloth through 3-5 times of electrostatic flocking, and obtaining the required simulated real leather flocking carpet through low-temperature baking, sizing, blowing and carding; compared with the 201710504523.3 patent, the invention belongs to completely different processes, and flocking is not a weaving process, belongs to an adhesive bonding process and only uses short fibers; the pile height of the pile face manufactured by the flocking process generally cannot exceed 8mm, and the pile face is smooth and cannot achieve the hair tip effect of fur; the pile height of the suede of the imitated fur manufactured by the invention can be 5-70 mm, and the suede has the fur tip effect of fur; because the invention completely uses filament fiber, the produced product is not easy to generate natural hair loss phenomenon.

Disclosure of Invention

The invention aims to overcome the defects of complex preparation process, high cost, easy shedding of fibers and the like in the existing preparation process of the artificial fur carpet, and provides a preparation method of the artificial fur carpet.

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

the invention relates to a preparation method of an artificial fur carpet, which comprises the following steps:

s1, stranding a plurality of deformed chemical filament fibers with different shrinkage rates and pre-oriented filament fibers, and performing net knotting or twisting setting to obtain a spiral ring or zigzag yarn;

s2, weaving the rib ring or the zigzag yarn through a weaving machine to obtain a carpet fabric in a cut pile state;

s3, dyeing and finishing the carpet fabric, continuously opening the rib ring or the zigzag yarn under the scouring action of high-temperature water flow at the temperature of more than 80 ℃, and unwinding and extending the fibers of the pile face to form artificial fur carpets with different specifications.

Furthermore, the chemical deformation filament fiber is made of terylene, nylon, PBT, polypropylene and other materials.

Further, pre-oriented filament fibers are also known as spun filaments.

Further, the loom is a tufting machine, a circular machine, a warp knitting machine or the like.

Furthermore, the shrinkage rate of the chemical filament fibers which are deformed during stranding is gradually increased from the middle to the outer side.

Further, in step S1, the step of plying the plurality of textured chemical filament fibers with different shrinkage rates with the pre-oriented filament fibers comprises the following steps:

holding a plurality of deformed chemical filament fibers with different shrinkage rates together to form a deformed filament fiber bundle; stranding the textured filament fiber bundles with pre-oriented filament fibers;

or, the chemical filament textured fiber and the pre-oriented filament fiber are networked to form a thread to form a filament textured fiber bundle; stranding a plurality of deformed filament fiber bundles with different shrinkage rates;

or, the chemical filament textured fiber and the pre-oriented filament fiber are networked to form a thread to form a filament textured fiber bundle; and stranding a plurality of deformed filament fiber bundles with different shrinkage rates and deformed filament fibers.

Further, in step S1, each textured chemical filament fiber has a fineness of 40D to 1200D and is composed of several monofilaments having a fineness in the range of 0.48D to 30D.

Further, in step S1, the boiling water shrinkage of the textured chemical filament fiber is 5% to 30%.

Further, in step S1, the total fineness of the textured filament fibers in the rib-stitch or zigzag yarn is 300D to 7800D.

Further, in step S1, the ratio of the deformed filament fiber to the pre-oriented filament fiber in the rib-circle or zigzag yarn is 95 percent to 5 percent to 50 percent; the pre-oriented filament fibers are located at any position of the textured filament fibers. In the process of the present invention, the proportion of the textured filament fibers cannot be less than 50% and the proportion of the pre-oriented filament fibers (as-spun) cannot be more than 50%.

Further, in step S1, the pre-oriented filament fibers have a fineness of 48D to 600D and are composed of a plurality of monofilaments having a fineness in the range of 0.48D to 12D; the boiling water shrinkage of the pre-oriented filament fiber is 30-70%.

Further, in step S1, the twist number of the twist is 35 to 150.

Further, in the step S1, in the network knotting, the wind pressure of the network is 0.3-4 kg, the number of network nodes is 15-50/m, and the linear speed is 100-480 m/min.

Further, in step S1, the shaping temperature is 80-140 ℃ and the shaping time is 3-30 min.

Further, in step S2, the loop or zigzag yarn is adjusted to a pile height during weaving to form a carpet surface with a pile height of 5mm to 70 mm. When the rib ring or the zigzag yarn is weaved on various looms, carpet fabrics with different pile heights (lengths) of 5mm-70mm can be weaved according to different looms.

Further, in the step S3, during dyeing and finishing, the water flow of the dyeing machine is 5-40 m/min, the temperature is 80-140 ℃, and the dyeing and finishing time is 30-120 minutes.

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

1. the invention has simple process: filament fibers with different heat shrinkage → twisting (or net) + pre-oriented yarn (primary yarn) → heat setting → tufting machine or warp and weft knitting machine (or other pile cutting weaving machine) weaving → dyeing and finishing, so that the production cost can be obviously reduced;

2. most of the traditional processes use short fibers, so that a large amount of short fibers fall and are damaged in the weaving and carding processes, and the fiber consumption is increased; compared with the traditional preparation process of the fur-making carpet, the process is simple, the same fur effect is achieved, and as the continuous filament fibers are completely used, the high-temperature ironing and shearing process is not needed, the fiber loss in the production process is very little, so that the usage amount of the yarns is remarkably reduced and is only 80-90% of that of the carpet yarns in the traditional process;

3. fur of a fur carpet manufactured by the traditional process is easy to fall off: the traditional process is characterized in that short fibers are used for manufacturing fur, the important link of hair tip generation is in a carding process, the short fibers are combed into the hair tips through combing fibers, and the cohesion of each bundle of fibers actually determines that the hair tips are difficult to fall off under the action of external force;

4. the invention has small fiber damage because the high-temperature ironing, shearing and finishing at the temperature of more than 140 ℃ is not carried out, and the obtained suede effect is more flexible;

5. compared with the traditional process, the method has wider material sources, and can use long fibers with different materials and different titer, thereby imitating various fur styles.

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 illustration of a doubled flush textured chemical fiber filament tow yarn;

FIG. 2 is a schematic structural diagram of a zigzag yarn formed by twisting a filament fiber tow + pre-oriented yarn (as-spun yarn) and heating for network shaping;

FIG. 3 is a schematic illustration of a long fiber tow yarn having a shrunk tow tip formed under thermal shrinkage in a dye vat;

FIG. 4 is a schematic view showing the construction of the artificial fur carpet of example 1;

FIG. 5 is a finished view of the artificial fur carpet of example 1;

fig. 6 is a schematic structural diagram of a rib-loop yarn formed by twisting a filament fiber tow + a pre-oriented yarn (a raw yarn) and heating for setting.

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.

The principle of the invention is as follows:

① the method comprises the following steps of forming hair tips by adopting long fiber tows with different shrinkage rates and different deniers at the temperature of a dye vat:

the level yarn not before the vat is shown in figure 1; the drawing of the contracted hair tips formed under thermal contraction of the dye vat is shown in FIG. 3, and it can be seen that hair tips are formed;

② method for adjusting the loosening degree of each bundle of fiber of fur

The deformed filament fiber bundle and the pre-oriented yarn (primary yarn) are twisted with a certain degree → are heated and shaped to form a rib loop or a zigzag yarn, as shown in figure 2 or 6;

the process of the invention comprises the following steps: different shrinkage of deformed filament fibers → ply twisting (or net) + pre-oriented yarn (primary yarn) → sizing → tufting machine or warp and weft knitting machine to weave into cut pile fabric → dyeing and finishing and drying-carpet post-processing.

The dye vat in ① refers to a dye vat in dyeing and finishing, ② before the dyeing and finishing process, it can be seen that before entering the dye vat, the yarn on the fabric is in a spiral loop or a zigzag shape, and the spiral loop or the zigzag yarn is made by a twisting method, so that the fur with different styles can be dyed and finished.

③ fur height adjusting mode

During the manufacture of the yarn, the pile height is adjusted to be made into a carpet fabric with the pile height of 5mm-70mm, and a fur product with the pile height (length) of 8 mm-105 mm can be obtained after dyeing and finishing.

During dyeing and finishing, under the action of water flow and temperature of a dyeing machine, the yarns are continuously opened, unwound and extended to form fur products with different specifications and styles. Particularly, each bundle of synthesized tows can have slight lattice points which are not easy to separate in spinning and can influence the hair tip effect, so the invention adds oriented yarns to forcibly stretch and separate by heating, so that the total tows can be unwound, loosened and separated in a dye vat, and the hair tip fur product with clear layering is formed.

Specific examples are shown in the following examples:

example 1

Network method

Step one, selecting 2 FDY filaments of terylene 300D/96F with boiling water shrinkage of 17%, and combining with 1 nascent filament of terylene 72D/36F with boiling water shrinkage of 45%, and feeding the filament into a network knotter to be networked into a thread under the conditions of 0.1 kilogram of air pressure and 400 m/min of speed;

and step two, selecting 2 polyester FDY filaments with boiling water shrinkage of 12 percent and 300D/48F, and 1 polyester primary yarn with boiling water shrinkage of 50 percent and 54D/36F, feeding the filaments into a net knotter, and forming the filaments by a net at the wire running speed of 400 m/min under the air pressure of 0.1 kilogram.

Step three, doubling the two kinds of yarns which are subjected to network forming with a 300D/96F polyester FDY filament with the boiling water shrinkage rate of 20%; during doubling, the FDY filaments are held together and the shrinkage rate gradually increases from the middle to the outer side.

The yarn is fed into a network knotter again under the condition of 2KG air pressure, the number of network nodes is 30/m, the routing speed is 400 m/min, the total thickness of the network assembly is 1626D, and then loose shaping is carried out by a shaping machine, the shaping temperature is 120 ℃, the time is 4 minutes, and the yarn presents zigzag yarn;

step four, weaving the yarns by using a tufting machine with the needle pitch of 3/8 to prepare a carpet fabric with the pile height of 55 mm;

putting the carpet fabric into an overflow dye vat, reducing, cleaning and dyeing, wherein the water flow is 30 m/min, the temperature is 95 ℃, and the time is 60 min;

and step six, taking the dyed carpet fabric out of the dye vat, dehydrating and drying, scattering the top end of the fiber with the minimum shrinkage rate on the carpet fabric to form a hair tip, and shrinking and swelling the bottom end and the middle end of the fiber to form a plurality of layers of villi. Moreover, the color light and the absorption and absorption rates of different fibers are different, so that the whole carpet surface forms a color mixing effect of the same color system. Wherein the pile height of the longest hair tip fiber is 82mm, the lowest pile height is 27mm, and a plurality of different pile heights are arranged between the lowest pile height and the highest pile height, thereby forming the artificial fur carpet effect of the hair tip fur with vivid layering;

and seventhly, carrying out subsequent processing on the carpet fabric to form a finished carpet.

Example 2

Leno method

Step one, combining 1 FDY filament yarn of terylene 300D/96F with boiling water shrinkage of 20%, 2 FDY filament yarns of 300/36F with boiling water shrinkage of 12% and PBT virgin yarn of 54D/36F with boiling water shrinkage of 60% into a 954D strand;

secondly, putting the two strands 954D with the same proportion on a direct twisting machine for twisting 80 to obtain 1908D twisted strands, wherein the twisting direction of the yarns is Z twisting;

step three, putting the twisted yarn in the step two into a heat setting machine for setting, heating the yarn and then shrinking the yarn into a loop yarn, wherein the setting temperature is 140 ℃ and the setting time is 3 minutes as shown in figure 6;

fourthly, weaving the shaped yarns into carpet fabric with the height of 30mm pile by using a tufting machine with the stitch length of 3/16;

and step five, putting the woven blanket surface into a dye vat for reduction cleaning or dyeing, wherein the rib loops are completely drawn back under the action of high temperature and water flow in the dyeing and finishing processing. The dye vat water flow is 35 m/min, the temperature is 105 ℃, and the time is 90 min;

and step six, taking the dyed carpet fabric out of the dye vat, dehydrating and drying, scattering the top end of the fiber with the minimum shrinkage rate on the carpet fabric to form a hair tip, and shrinking and swelling the bottom end and the middle end of the fiber to form a plurality of layers of villi. Moreover, because the color light and the color index of several different fibers are different, the whole carpet surface forms the color mixing effect of the same color system. The pile height of the longest hair tip fiber is 45mm, the lowest pile height is 12mm, and a plurality of different pile heights are arranged between the lowest pile height and the highest pile height, so that the artificial fur carpet effect of hair tip fur with vivid layering is achieved, as shown in figure 4;

and step seven, carrying out subsequent processing on the carpet fabric to form a finished carpet, as shown in fig. 5.

Example 3

Step one, selecting 2 nylon 300D/96F deformed filaments with the boiling water shrinkage rate of 12%, combining the 2 nylon 300D/96F deformed filaments with 1 polypropylene nascent filament with the boiling water shrinkage rate of 50% and the boiling water shrinkage rate of 72D/36F, feeding the filaments into a net knotting machine, and performing net knotting to obtain 672D folded yarns under the conditions of 1 kilogram of air pressure, 15 net knots per meter and the speed of 400 m/min;

secondly, the temperature for loose setting and shaping the well-networked yarns by a setting machine is 120 ℃, the time is 4 minutes, and the yarns are zigzag yarns, as shown in figure 2;

thirdly, placing the shaped yarns on a weft knitting machine to be woven into 5mm carpet fabric;

and step four, putting the woven blanket surface into a dye vat for reduction cleaning or dyeing, wherein the rib loops are completely drawn back under the action of high temperature and water flow in the dyeing and finishing processing. The water flow of the dye vat is 25 m/min, the temperature is 135 ℃, and the time is 30 min;

taking the dyed carpet fabric out of the dye vat, dewatering and drying, continuously unwinding the fibers with the minimum shrinkage rate on the carpet fabric, scattering network knots, scattering and straightening the top ends of the fibers to form hair tips with the hair height of about 7.5mm, and shrinking and expanding the fibers at the bottom end and the middle end to form a plurality of hairs with the hair height of about 2.5 mm; moreover, the color mixing effect is formed on the whole carpet surface due to the different color lights and different color-eating rates of the 2 different fibers. Several different pile heights are formed between the lowest pile height and the highest pile height due to the slight difference of the fiber monofilaments, so that the artificial fur carpet effect of fur-tip fur with vivid layering is formed;

Performance verification

In each of examples 1 to 3, 5 sample pieces each having a diameter of 10cm were used, and the above fabrics were subjected to a fuzzing test using a YG502 circular orbit fuzzing and pilling machine. The experimental conditions were: pressure 590cN, number of fuzz 150. The experimental results are as follows: no fuzzing was observed.

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 for preparing an artificial fur carpet, characterized in that the method comprises the following steps:

2. The process for preparing artificial fur carpet as claimed in claim 1, wherein the step S1 of plying the several different shrinkage rates of the textured chemical filament fibers with the pre-oriented filament fibers comprises the following steps:

3. The process for preparing an artificial fur carpet as claimed in claim 1, wherein in the step S1, each of the textured chemical filament fibers has a fineness of 40D to 1200D and is composed of several monofilaments having a fineness ranging from 0.48D to 30D.

4. The process for preparing an artificial fur carpet as claimed in claim 1, wherein the boiling water shrinkage of the textured chemical filament fiber is 5 to 30% in step S1.

5. The process for producing an artificial fur carpet as claimed in claim 1, wherein the total fineness of the textured filament fibers in the rib-and-loop or zigzag yarn in step S1 is 300D to 7800D.

6. The process for producing an artificial fur carpet as claimed in claim 1, wherein in the step S1, the ratio of the usage amount of the textured filament fibers to the pre-oriented filament fibers in the rib-and-zigzag yarn is 95%: 5%: 50%; the pre-oriented filament fibers are located at any position of the textured filament fibers.

7. The process for producing an artificial fur carpet as claimed in claim 1, wherein in the step S1, the pre-oriented filament fibers have a fineness of 48D to 600D and are composed of a plurality of monofilaments having a fineness in the range of 0.48D to 12D; the boiling water shrinkage of the pre-oriented filament fiber is 30-70%.

8. The process for producing an artificial fur carpet as claimed in claim 1, wherein in the step S1, the twist is 35 to 150 twists; in the network knotting, the wind pressure of the network is 0.3-4 kg, the number of network nodes is 15-50/m, and the linear speed is 100-480 m/min.

9. The process for producing an artificial fur carpet as claimed in claim 1, wherein the temperature for the setting in step S1 is 80 to 140 ℃ for 3 to 30 minutes.

10. The method for manufacturing an artificial fur carpet as claimed in claim 1, wherein in the step S3, the dyeing and finishing time is 30-120 minutes at a temperature of 80-140 ℃ and a dyeing and finishing flow of 5-40 m/min.