CN114645389A

CN114645389A - Tufted carpet

Info

Publication number: CN114645389A
Application number: CN202210259875.8A
Authority: CN
Inventors: 曹顺林; 张怡; 翟梓翔; 孙玉好
Original assignee: Kunshan Yijia Ju Textile Co ltd
Current assignee: Kunshan Yijia Ju Textile Co ltd
Priority date: 2022-03-16
Filing date: 2022-03-16
Publication date: 2022-06-21
Anticipated expiration: 2042-03-16
Also published as: CN114645389B

Abstract

The present invention relates to a tufted carpet. The tufted carpet comprises a pile surface layer, a base cloth layer and an anti-slip layer, wherein the pile surface layer is obtained by tufting primary yarns or mixed yarns containing the primary yarns on the front surface of the base cloth layer; the anti-slip layer is compounded on the back of the base fabric layer. The invention utilizes the combination of the primary yarn and the tufting technology to prepare the carpet with adjustable pile height, the pile height can be lower than 3mm, and the carpet with low pile height forms the plain weave carpet style after high-temperature expansion and shrinkage, thereby achieving the low pile high effect which can not be achieved by the common tufted carpet, and compared with the plain weave carpet, the tufting weaving efficiency greatly exceeds the weaving efficiency of the plain weave carpet. Meanwhile, the carpet disclosed by the invention is simple in process, low in cost and high in environmental friendliness, and the hand feeling and the water absorption of the prepared carpet are close to those of a cotton carpet.

Description

Tufted carpet

Technical Field

The invention relates to the field of carpets in the textile industry, in particular to a tufted carpet.

Background

The tufted carpet is a carpet which is manufactured efficiently and becomes the most popular product in the carpet industry, but the tufted carpet on the market is manufactured by weaving after being manufactured into finished yarn by spinning staple fibers or drawing, deforming and bulking filaments, and the traditional spinning process has long manufacturing process, complex process and large loss, so that the cost is high; meanwhile, a large amount of oiling agent and other chemical additives are needed to be added in the spinning process, and the oiling agent and the chemical additives need to be removed in the subsequent working procedures of the carpet made of the yarn, so that certain influence is caused on the environment. In addition, the light and thin carpet is more and more popular in the market at present, the light and thin carpet in the market is almost manufactured by a shuttle weaving or warp and weft weaving process, the efficiency is low, the cost is high, the limit of tufting equipment and the limit of the traditional yarn process are met, the minimum pile height of the traditional tufted carpet is not less than 3mm, and the light and thin carpet is not suitable for places needing the light and thin carpet with low pile height.

The application number is CN201911114344.4 a method for manufacturing a pattern yarn carpet, which utilizes the extremely strong thermal shrinkage rate and boiling water shrinkage rate before the orientation of the primary yarn to be mixed with other draw textured fibers (DTY/BCF/FDY/ATY), and the mixture is cut by a cutting loom after being meshed (a net machine) or twisted to be made into 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. Although the fancy yarn carpet can be doubled with DTY, BCF, FDY and ATY, the proportion of the inventive primary yarn is 4-15%, so that the tufting is an effect that plain weaving cannot be woven, and most of the invention uses the drawn yarn, so large-scale cost saving cannot be realized, and the used chemicals are much higher than those of primary yarn weaving alone.

DTY (draw texturing yarn): POY (similar to FDY in spinning process but higher in elongation) is generally used as a yarn raw material, and through the processes of lapping, false twisting and double twisting, fibers of the yarn are separated, bulkiness and irregular in section are achieved, the air permeability is better than that of FDY, and the hand feeling is softer than that of FDY (common conventional yarn types).

POY: pre-oriented yarn, full name: PRE-ORIENTED YARN or PARTIALLY ORIENTED YARN. The chemical fiber filament is not completely stretched and has an orientation degree between an unoriented filament and a stretched filament. It has a certain degree of orientation, good stability and high shrinkability as compared with undrawn yarn, and is often used as a special yarn for drawing false twist textured yarn (DTY).

FDY: fully drawn yarn, full name: FULL DRAW YARN. And spinning and stretching to obtain the synthetic fiber filament. The fibers are fully drawn and can be used directly in textile processing.

UDY: undrawn yarn, the fiber molecules have substantially no orientation, and are not crystallized. The yarn has low strength, large elongation, poor dimensional stability and no direct use value.

The existing rib plain-woven carpet has low weaving efficiency, high cost and poor dimensional stability. Aiming at some limitations of the traditional tufted carpet, the tufted carpet with simple process, low cost and high environmental protection is prepared by combining the primary yarn and the tufting technology, has the effect of rib plain weaving, and has the hand feeling and the water absorption of the prepared carpet close to those of a cotton carpet.

Disclosure of Invention

The invention aims to provide a preparation method of a tufted carpet, aiming at the problem that the primary yarn is not used for direct weaving.

The loop pile carpet surface prepared by the primary yarn is subjected to high-temperature shrinkage to form the appearance effect of a plain weave carpet.

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

the invention provides a tufted carpet with plain weaving effect, which comprises a pile surface layer and a base cloth layer; the pile surface layer is obtained by tufting and carrying out heat treatment on a base fabric layer by using a primary yarn and/or a mixed yarn containing the primary yarn; the boiling water shrinkage of the as-spun yarn is 35-70%; the tufting process comprises one of loop pile, high-low loop pile, cut pile, high-low cut pile, high-cut low loop and high-loop low cut. The suede layer comprises one of a loop suede layer, a high-low loop suede layer, a cut suede layer, a high-low cut suede layer, a high-cut low loop layer and a high-loop low cut layer

As one embodiment of the invention, the as-spun yarn is formed by doubling twisting or knotting a plurality of as-spun yarns; the mixed yarn is formed by doubling, twisting or netting the as-spun yarn and the drawn yarn. The twisting degree of doubling twisting is 40-360T/m, and the twisting direction is S or Z twisting. The doubling and netting process is to make the primary yarn into non-twisted netting yarn with 20-300 net knots per meter. Twisting and netting are carried out to facilitate high-efficiency weaving. The yarns only containing the primary yarns are twisted or meshed, and then are subjected to high-temperature shrinkage crystallization to ensure the shrinkage consistency, the carpet surface pile is high and uniform, and a good appearance effect of the plain-weave carpet is achieved. The primary yarn in the mixed yarn is crystallized through high-temperature shrinkage, and because the primary yarn has more content, the primary yarn can drive the stretching yarn to lower the suede one time, the appearance effect of the plain-weave carpet can be formed, and meanwhile, the shrinkage of the primary yarn can cause the stretching yarn to expand transversely to form a yarn napping state, so that the multicolor color mixing effect is realized, and the carpet surface coverage is better.

In one embodiment of the present invention, the blend yarn contains more than 50% of the spun yarn. The primary yarn has unchanged water absorption after high-temperature shrinkage, but is easier to dry due to the increase of gaps. When the mixed yarn shrinks and the primary yarn is more, the drawn yarn is shrunk together, so that the effect of low pile height and plain weaving is achieved. If the content of the used primary yarn is less than 50 percent, the carpet surface can keep the original state of loop pile or cut pile and can not be attached to the base cloth, and the plain weaving effect can not be formed.

In one embodiment of the present invention, the blend yarn contains more than 50% of the spun yarn. The raw silk has unchanged water absorption after high-temperature shrinkage, but is easier to dry due to the increase of gaps. When the mixed yarn shrinks and the primary yarn is more, the drawn yarn is shrunk together, so that the effect of low pile height and plain weaving is achieved. If the content of the used primary yarn is less than 50 percent, the carpet surface can keep the original cut pile state and can not be attached to the base cloth, and the flat weaving effect with the pile feeling can not be formed.

As an embodiment of the invention, the primary silk comprises one or more of UDY, MOY, POY, HOY.

As an embodiment of the invention, the drawn yarn comprises one or more of ATY, FDY, DTY.

As an embodiment of the invention, the total thickness of the as-spun yarn or hybrid yarn is from 300D to 15000D. The monofilament thickness of the primary yarn is 0.1D-600D.

As an embodiment of the invention, the pile height of the pile face layer is 1.5mm to 5 mm. The height of the pile is preferably 1.5mm-3 mm. The height of the cut velvet layer is 1.5mm-5mm, and the height of the velvet is preferably 1.5mm-3 mm. The pile height of the traditional tufted carpet can not be lower than 3mm, and the traditional tufted carpet is fluffy and does not have the effect of plain weaving. The height of the pile after the primary yarn tufting reaches 5mm-3mm at the lowest, but after high-temperature shrinkage, the height of the pile on the carpet surface can reach 1.5mm-5mm, particularly 1.5mm-3mm, and the pile has the effect of plain weaving.

In one embodiment of the present invention, the base fabric layer is formed by a knitted or woven fabric and a needle-punched chemical fiber non-woven fabric.

As an embodiment of the present invention, the carpet further comprises a non-slip layer; the anti-slip layer is compounded on the back of the base fabric layer.

As an embodiment of the invention, the material of the anti-slip layer comprises one of thermoplastic elastomer, hot melt adhesive, foamed adhesive and anti-slip fabric.

The invention also provides a preparation method of the tufted carpet with the plain weaving effect, which comprises the following steps: after tufting is carried out on the base cloth layer, the tufted embryonic carpet is subjected to heat treatment setting through a mesh belt or a roller, and the primary yarn yarns can be quickly shrunk after high temperature, so that the tufted carpet with the plain weaving effect is obtained. The anti-slip layer is compounded on the back of the base fabric layer.

As an embodiment of the present invention, the heat treatment setting is one of high temperature setting, steam setting and high temperature falling water treatment.

As an embodiment of the invention, the temperature of the high-temperature shaping is 80-200 ℃. The high-temperature shaping is carried out by using an oven.

As an embodiment of the present invention, the steam-setting temperature is 80 ℃ to 188 ℃.

As an embodiment of the invention, the temperature of the high-temperature water falling treatment is 80-140 ℃.

As an embodiment of the invention, the speed of the mesh belt or roller is 1m/min to 15 m/min.

Compared with the existing woven carpet, the invention has the following beneficial effects:

1. the loop pile carpet prepared by the invention can achieve the effect similar to rib plain weaving, and the carpet with low pile height forms the plain weaving carpet style after high-temperature expansion and shrinkage, thereby achieving the effect of low pile height which can not be achieved by the common loop pile carpet. The carpet has the advantages of high weaving efficiency and low cost, the abrasion resistance of the carpet surface is better, and the hemispherical plain-woven carpet formed on the fabric can not be woven by the primary yarn.

2. The cut pile carpet prepared by the invention can achieve the effect of plain weaving with pile feeling, and the carpet with low pile height forms the style of plain weaving carpet after high-temperature expansion and shrinkage, thereby achieving the effect of the common cut pile carpet which needs plain hair. The carpet disclosed by the invention has the advantages of high weaving efficiency and low cost, the abrasion resistance of the carpet surface is better, and the yarn tows are gathered together and the hair tips are scattered.

3. Compared with the plain weave carpet, the weaving efficiency of the primary silk carpet greatly exceeds that of the plain weave carpet, and the weaving efficiency is more than 5 times. And because the spinning step of the raw silk is few, the cost is low, the process route is short, so the carpet woven by the raw silk has higher efficiency than the flat-woven carpet in the view of the whole production flow. The used chemicals (such as oil) of the primary silk are less than those of DTY and FDY, so that the secondary recycling is facilitated, and the pollution to the environment is reduced.

4. The yarns are mixed to form loop pile, cut pile or loop cut pile with different heights, so that the yarn has stereoscopic impression and can form patterns.

5. The primary yarn of the carpet has gaps after shrinkage, and the finished carpet made of the primary yarn under the same condition has faster dehydration and better quick drying compared with a conventional plain woven carpet due to the increase of the gaps among fibers.

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 primary loop pile tufted carpet;

FIG. 2 is a high and low loop pile tufted carpet of as-spun yarn;

FIG. 3 is a raw filament cut pile tufted carpet;

wherein, 1, looping a velvet layer; 2. the base fabric layer, 3, the anti-slip layer, 4, the cut pile layer, 5 and the high-low loop pile layer.

Detailed Description

The invention is described in detail below with reference to the figures and specific embodiments. The following examples, which are set forth to provide a detailed description of the invention and a detailed description of the operation, will help those skilled in the art to further understand the present invention. It should be noted that the scope of the present invention is not limited to the following embodiments, and that several modifications and improvements made on the premise of the idea of the present invention belong to the scope of the present invention.

The invention provides a preparation method of a tufted carpet, which comprises the following steps:

1) and (3) doubling: the as-spun yarn is subjected to doubling twisting using a two-for-one twister, the twist being 40 to 360T/m. The twisting direction is S or Z twisting, or the net knot is made into net yarn without twisting direction for single use, or the net yarn is doubled or knotted with ATY, FDY and DTY. The ratio of the primary yarn to FDY is 50-1%, the ratio of the primary yarn to DTY is 50-1%, and the ratio of the primary yarn to ATY doubling is 50-1%.

2) Weaving: and carrying out tufting process on the upper part and the lower part of a tufting loom by using the prepared primary yarn. The height of the velvet is 3mm-5 mm. Wherein the base cloth of the tufting process is chemical fiber base cloth. Wherein the tufting process comprises loop pile and high-low loop.

3) And (3) heat treatment: conveying the tufted carpet blank, namely a carpet blank body to an oven through a mesh belt or a roller or carrying out high-temperature water falling and steam setting,

the traction speed of the mesh belt or the roller is 5m/min-10 m/min;

the temperature of the oven is 80-200 ℃,

the setting temperature of the steam is 80-105 ℃,

the high-temperature falling water temperature is 80-105 ℃.

The as-spun yarn can be rapidly shrunk at a shrinkage rate of 15-70% after being subjected to high temperature.

4) Anti-skid treatment: performing covering processing on the blank blanket after heat treatment; namely, the carpet bottom is backed and anti-skid treated by hot melt adhesive, thermoplastic elastomer, foamed adhesive or other fabrics and materials with anti-skid function.

5) Cutting: and cutting the antiskid-treated embryonic blanket according to the size.

6) Edge sewing: and (5) performing a hemming process on the cut embryo blanket.

Specific application examples are shown in the following examples:

example 1

The embodiment relates to a tufted carpet, which comprises a loop pile layer 1, a base fabric layer 2 and an anti-slip layer 3, as shown in figure 1. The preparation of the tufted carpet comprises the following steps:

1) and (3) doubling: and (3) using polyester UDY yarns to perform net knot tying on a net knot tying machine without twisting direction, wherein the total D number is 3000D.

2) Weaving: the tufting machine adopts a loop tufting machine with 1/10 needle pitches, and yarns penetrate into a needle of the tufting machine to be tufted on the long-fiber base cloth; the height of the machine pile is 6 mm.

3) And (3) heat treatment: conveying the tufted carpet blank into an oven through a mesh belt, wherein the speed of steam shaping of the carpet blank is 5 m/min; the steam oven temperature was 102 ℃. The UDY yarn shrank rapidly in the oven, with a wool height of 2.1 mm.

4) Printing: and (4) carrying out a digital printing process on the blank blanket after the heat treatment.

5) Anti-skid treatment: the carpet bottom is subjected to anti-skid treatment by using foamed natural latex, and the gram weight of the foamed natural latex is 650 g/square meter.

6) Cutting: and cutting the antiskid-treated embryonic blanket according to the size.

7) Edge sewing: and (5) carrying out a seaming process on the cut embryo blanket.

Example 2

The present embodiments relate to a tufted carpet. The preparation of the tufted carpet comprises the following steps:

1) and (3) doubling: and doubling and knotting the polyester POY yarns on a knotting machine, wherein the twisting direction is a non-twisting direction, and the total D number is 3600D.

2) Weaving: the tufting machine adopts a loop tufting machine with 1/10 needle pitches, and yarns penetrate into a needle of the tufting machine to be tufted on the long-fiber base cloth; the height of the pile is 5 mm.

3) And (3) heat treatment: and (3) performing high-temperature water falling on the tufted carpet blank through an overflow cylinder, wherein the high-temperature water falling temperature of the carpet blank is 100 ℃. The POY yarns are quickly shrunk through high-temperature water falling yarns, and the wool height is changed into 1.8 mm.

4) Printing: the blank blanket after heat treatment is subjected to a digital printing process,

5) anti-skid treatment: the carpet bottom is subjected to anti-skid treatment by using foamed natural latex, and the gram weight of the foamed natural latex is 600 g/square meter.

7) Edge covering: and (5) edge wrapping the cut embryonic blanket.

Example 3

The embodiment relates to a tufted carpet, which comprises a high-low loop pile layer 5, a base fabric layer 2 and an anti-slip layer 3, as shown in figure 2. The preparation of the tufted carpet comprises the following steps

1) Doubling and twisting: twisting polyester POY and polyester FDY in a plying way, wherein the twisting direction is Z twisting, and the ratio of the POY to the FDY is 7: 3, the total D number is 4000D;

2) weaving: the tufting machine adopts a loop tufting machine with 1/10 needle pitches, POY and the yarns are penetrated into a needle of the tufting machine to be tufted on the long-fiber base cloth according to a needle penetrating mode of 1: 1; the height of the pile is 5 mm.

3) And (3) heat treatment: conveying the tufted carpet blank into an oven through a mesh belt, wherein the speed of the carpet blank for high-temperature shaping is 4 m/min; the steam oven temperature was 110 ℃. The yarn shrinks rapidly in the oven, the pure POY wool height becomes 1.5mm, and the wool height of the POY and DTY ply becomes 3 mm. The blanket surface is shaped like a stereo high-low ring.

4) Anti-skid treatment: the carpet bottom is subjected to anti-skid treatment by using foamed natural latex, and the gram weight of the foamed natural latex is 600 g/square meter.

6) Edge covering: and (5) edge wrapping the cut embryonic blanket.

Example 4

1) and (3) doubling: twisting the terylene HOY on a two-for-one twister, wherein the twisting direction is S twisting, and the total D number is 5000D.

2) Weaving: the tufting machine adopts a loop tufting machine with 1/8 needle pitches, and yarns penetrate into a needle of the tufting machine to be tufted on the long-fiber base cloth; the height of the machine pile is 4 mm.

3) And (3) heat treatment: conveying the tufted carpet blank into an oven through a mesh belt, wherein the speed of steam shaping of the carpet blank is 5 m/min; the steam oven temperature was 102 ℃. The HOY yarn shrank rapidly in the oven, with a wool height of 2.4 mm.

5) Anti-slip treatment: the carpet bottom is subjected to anti-slip treatment by using a thermoplastic elastomer and a film coating process.

Example 5

The present embodiment relates to a tufted carpet, as shown in fig. 1, a loop pile layer 1, a base fabric layer 2 and an anti-slip layer 3. The preparation of the tufted carpet comprises the following steps:

1) and (3) doubling: the polyester POY yarns and the polyester DTY yarns are doubled and knotted on a knotting machine in a ratio of 70 percent to 30 percent, the twisting direction is a non-twisting direction, and the total D number is 3600D.

2) Weaving: the tufting machine adopts a loop tufting machine with 1/10 needle pitches, and yarns penetrate into a needle of the tufting machine to be tufted on the long-fiber base cloth; the height of the pile is 8 mm.

3) And (3) heat treatment: and (3) performing high-temperature water falling on the tufted carpet blank through an overflow cylinder, wherein the high-temperature water falling temperature of the carpet blank is 100 ℃. The POY yarns are quickly shrunk through high-temperature water falling yarns, and the wool height is changed into 1.6 mm.

4) The printing process comprises the following steps: and (4) carrying out a digital printing process on the blank blanket after the heat treatment.

Example 6

The present embodiment relates to a tufted carpet, as shown in fig. 3, comprising a cut pile layer 4, a base fabric layer 2 and an anti-slip layer 3. The preparation of the tufted carpet comprises the following steps:

1) and (3) doubling: twisting polyester POY yarn on a two-for-one twister, wherein the twisting direction is Z twisting, and the total D number is 3000D.

2) Weaving: the tufting machine adopts a tufting machine with 1/10 needle pitches, and yarns penetrate into a needle of the tufting machine to be tufted on the long-fiber base cloth; the height of the machine velvet is 5 mm.

3) And (3) heat treatment: conveying the tufted carpet blank into an oven through a mesh belt, wherein the speed of steam shaping of the carpet blank is 5 m/min; the steam oven temperature was 102 ℃. The POY yarn shrank rapidly in the oven, with a wool height of 1.5 mm.

5) Anti-slip treatment: the carpet bottom is subjected to anti-slip treatment by using a thermoplastic elastomer.

7) Edge sewing: and (5) carrying out a serging process on the cut embryonic blanket.

Comparative example 1

1) and (3) doubling: the polyester POY yarns and the polyester DTY yarns are doubled and knotted on a knotting machine in a ratio of 30 percent to 70 percent, the twisting direction is a non-twisting direction, and the total D number is 3600D.

2) Weaving: the tufting machine adopts a loop tufting machine with 1/10 needle pitches, and yarns penetrate through the tufting machine and are tufted on the long-fiber base cloth; the height of the pile is 10 mm.

3) And (3) heat treatment: and (3) performing high-temperature water falling on the tufted carpet blank through an overflow cylinder, wherein the high-temperature water falling temperature of the carpet blank is 100 ℃. The POY yarns are quickly shrunk through high-temperature water falling yarns, and the wool height is changed into 7 mm.

Verification of performance comparison test

First, dehydration test

The tufted carpet of the invention in example 1 was taken at 40cm x 40cm and the gram weight was 600gsm, placed in water and wetted completely for 5 minutes and then taken out, placed on an electronic scale and weighed at 1032gsm, placed in a household washing machine and dewatered for 10 minutes and then placed on an electronic scale and weighed at 790 gsm.

The tufted carpet of the invention in example 5 was taken at 40cm x 40cm and the gram weight was 600gsm, placed in water for 5 minutes to completely soak it, taken out, placed on an electronic scale and weighed at 1331gsm, placed in a household washing machine for dewatering for 10 minutes, and placed on an electronic scale and weighed at 942 gsm.

The tufted carpet of the invention of comparative example 1 was taken at 40cm x 40cm and the gram weight was 600gsm, placed in water for 5 minutes to completely wet it, removed, placed on an electronic scale and weighed at 1456gsm, placed in a domestic washing machine for dewatering for 10 minutes, and placed on an electronic scale and weighed at 1100 gsm.

The DTY carpet on the market is taken to be 40cm x 40cm, the gram weight is 600gsm, the DTY carpet is taken out after being put into water and completely soaked for 5 minutes, an electronic scale is placed to weigh the weight to be 1594gsm, the DTY carpet is put into a household washing machine to be dehydrated for 10 minutes, and then the DTY carpet is placed on the electronic scale and the weight to be 1323 gsm.

Taking a plain-woven carpet on the market 40cm x 40cm, taking out the carpet with the gram weight of 600gsm after putting the carpet into water to be completely soaked for 5 minutes, placing an electronic scale to weigh the carpet with the gram weight of 1089gsm, placing the carpet into a household washing machine to be dehydrated for 10 minutes, and placing the carpet on the electronic scale to weigh the carpet with the gram weight of 856 gsm.

In summary, the tufted carpets of the present invention dewater better than existing products.

Two, six foot roller test

1. Example 3, 30cm x 30cm, was mounted in a rotating drum, six feet were placed in the drum, and after 12000 revolutions, the surface was found to be intact with no severe wear.

2. The existing high-cut low-circle carpet with the size of 30cm x 30cm on the market is installed in a rotary drum, six feet are placed in the rotary drum, and the carpet is taken out after 12000 turns, and the surface is found to be seriously worn and cannot be used.

3. Example 2, 30cm x 30cm, was mounted in a rotating drum, and six feet were placed in the drum and taken out after 12000 revolutions, and it was found that the surface appearance was intact and not severely worn.

4. The existing loop carpet on the market with the size of 30cm x 30cm is arranged in a rotary drum, six feet are placed in the rotary drum, and the loop carpet is taken out after 12000 turns, and the surface is found to be seriously abraded and cannot be used.

5. Example 6, 30cm x 30cm, was mounted in a rotating drum, and six feet were placed in the drum and taken out after 12000 revolutions, and it was found that the surface appearance was intact and not severely worn.

4. The existing commercial cut pile carpet process of 30cm x 30cm is similar to that of example 6, the carpet is installed in a rotary drum, six feet are placed in the rotary drum, and the carpet is taken out after 12000 turns, and the surface is found to be seriously abraded and cannot be used.

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 tufted carpet, characterized in that the carpet comprises a pile face layer, a base layer; the pile surface layer is obtained by tufting and carrying out heat treatment on a base fabric layer by using a primary yarn and/or a mixed yarn containing the primary yarn; the boiling water shrinkage of the as-spun yarn is 35-70%; the tufting process comprises one of loop pile, high-low loop pile, cut pile, high-low cut pile, high-cut low loop and high-loop low cut.

2. The tufted carpet of claim 1, wherein the as-spun yarns are formed by doubling twisting or knotting a plurality of as-spun yarns; the mixed yarn is formed by doubling, twisting or netting the as-spun yarn and the drawn yarn.

3. Tufted carpet according to claim 2, characterized in that the number of primary filaments in the hybrid yarn is over 50%.

4. Tufted carpet according to claim 1, wherein the as-spun filaments comprise one or several of UDY, MOY, POY, HOY.

5. Tufted carpet according to claim 1, characterized in that the total thickness of the as-spun yarns or hybrid yarns is 300D-15000D.

6. Tufted carpet according to claim 1, wherein the pile height of the pile face layer is 1.5mm-5 mm.

7. The tufted carpet of claim 1, wherein the base layer is a base layer formed of a knitted or woven fabric and a needled chemical fiber non-woven fabric.

8. The tufted carpet of claim 1, wherein the carpet further comprises a non-slip layer; the anti-slip layer is compounded on the back of the base fabric layer.

9. The tufted carpet of claim 8 wherein the material of the anti-slip layer comprises one of a thermoplastic elastomer, a hot melt adhesive, a foam adhesive, an anti-slip fabric.

10. A method of making the carpet of claim 1, comprising the steps of: after tufting is carried out on the base cloth layer, the tufted embryonic carpet is subjected to heat treatment setting through a mesh belt or a roller, and the primary yarn yarns can be quickly shrunk after high temperature, so that the tufted carpet with the plain weaving effect is obtained.