WO2021184406A1 - 一种利用回收纱线制备的软底地毯及其制造方法 - Google Patents

一种利用回收纱线制备的软底地毯及其制造方法 Download PDF

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Publication number
WO2021184406A1
WO2021184406A1 PCT/CN2020/081288 CN2020081288W WO2021184406A1 WO 2021184406 A1 WO2021184406 A1 WO 2021184406A1 CN 2020081288 W CN2020081288 W CN 2020081288W WO 2021184406 A1 WO2021184406 A1 WO 2021184406A1
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WIPO (PCT)
Prior art keywords
carpet
recycled
fiber
layer
woven fabric
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PCT/CN2020/081288
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English (en)
French (fr)
Inventor
郑寿全
Original Assignee
苏州东帝士纤维地毯有限公司
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Publication date
Application filed by 苏州东帝士纤维地毯有限公司 filed Critical 苏州东帝士纤维地毯有限公司
Priority to JP2022527754A priority Critical patent/JP2022547343A/ja
Priority to EP20926045.4A priority patent/EP4111915A4/en
Priority to AU2020436828A priority patent/AU2020436828B2/en
Priority to US17/403,320 priority patent/US11668046B2/en
Publication of WO2021184406A1 publication Critical patent/WO2021184406A1/zh

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
    • D06N7/0065—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the pile
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0212—Carpets; Stair runners; Bedside rugs; Foot mats to support or cushion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
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    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J11/00—Features of adhesives not provided for in group C09J9/00, e.g. additives
    • C09J11/02—Non-macromolecular additives
    • C09J11/04—Non-macromolecular additives inorganic
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • D—TEXTILES; PAPER
    • D05—SEWING; EMBROIDERING; TUFTING
    • D05C—EMBROIDERING; TUFTING
    • D05C17/00—Embroidered or tufted products; Base fabrics specially adapted for embroidered work; Inserts for producing surface irregularities in embroidered products
    • D05C17/02—Tufted products
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
    • D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
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    • D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
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    • D06N7/0081—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by their backing, e.g. pre-coat, back coating, secondary backing, cushion backing with at least one extra fibrous layer at the backing, e.g. stabilizing fibrous layer, fibrous secondary backing
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
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    • D—TEXTILES; PAPER
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Definitions

  • the invention belongs to the technical field of carpet manufacturing, and specifically relates to a soft-bottom carpet prepared by using recycled yarns and a manufacturing method thereof.
  • the technical problem to be solved by the present invention is to provide a carpet made from recycled yarns to reduce energy consumption and secondary pollution in the process of yarn recycling, and at the same time have soft material, high comfort, good elasticity, Stable physical properties, good temperature insulation effect, etc.;
  • the technical problem to be solved by the present invention is to provide the method for preparing the carpet prepared by using recycled yarn.
  • a soft-bottom carpet prepared from recycled yarns The carpet includes a carpet fiber layer and a recycled fiber layer from top to bottom.
  • the carpet fiber layer includes carpet fibers and a first long-fiber non-woven fabric. Tufted on the first long-fiber non-woven fabric, the recycled fiber layer includes recycled fibers and a second long-fiber non-woven fabric, and the recycled fiber is tufted on the second long-fiber non-woven fabric; a carpet fiber layer and Recycled fiber layer, the tufted pile surface includes a variety of loop pile, cut pile and loop cut pile mixed style.
  • the carpet fiber layer and the recycled fiber layer are fixedly bonded.
  • the material of the carpet fiber is PP, PET, PTT, nylon, PO or wool, preferably nylon or PP.
  • the first long-fiber non-woven fabric and the second long-fiber non-woven fabric are 70-150 g/m 2 , preferably 90-100 g/m 2 .
  • the carpet fiber layer and the recycled fiber layer are bonded by an adhesive.
  • the material of the adhesive is PVC, asphalt, PO, PU, PE or EVA, preferably PO.
  • a latex layer is arranged between the carpet fiber layer and the recycled fiber layer.
  • the material of the latex layer is EVA, water-based PU, acrylic or SBR, preferably SBR.
  • a non-woven fabric layer is provided under the recycled fiber layer.
  • the recycled fiber layer and the non-woven fabric layer are connected by an adhesive.
  • the basis weight of the non-woven fabric layer is 50-1200 g/m 2 , preferably 50-300 g/m 2 .
  • the heat shrinkage rate of the non-woven fabric layer is less than 2%.
  • the piles of the pile surface in the recycled fiber layer are not less than 100,000/m 2 .
  • the above-mentioned manufacturing method of soft carpet made from recycled yarn includes the following steps:
  • Pre-coating and drying of latex Mix the water-based latex SBR, antibacterial agent, calcium carbonate, and foaming agent in a mass ratio of 62-100:0-1:0-35:0-2, preferably 65-70: 0 ⁇ 1:28 ⁇ 35:0 ⁇ 1, using a foaming machine for air foaming, the foaming ratio is 1.2-10 times, preferably 1.5-3 times, uniformly coated on the back of the carpet fiber layer, the coating amount is 50 ⁇ 800g/m 2 , preferably 80 ⁇ 350g/m 2 dry glue amount, dried to obtain the latex layer;
  • Recycled fiber tufting the recycled fibers are classified, the recycled fibers are combined into 850D-4000D coarse recycled fibers, and the coarse recycled fibers are tufted on the second long-fiber non-woven fabric to obtain a recycled fiber layer.
  • the pile density of the pile surface on the fiber layer is specifically 100,000 fibers/m 2 to 450,000 fibers/m 2
  • the pile height is specifically 2.5 mm to 12 mm, preferably 3.5 mm to 6.5 mm, to obtain a recycled fiber layer;
  • Recycled fiber tufted soft bottom PO and calcium carbonate are fed in a mass ratio of 20 ⁇ 45:55 ⁇ 80, then heated and melted and stirred uniformly.
  • the mass ratio of PO and calcium carbonate is preferably 20 ⁇ 30:70 ⁇ 80.
  • On the suede surface of the recycled fiber layer scrape with a spatula to a height of 0.5mm-1.0mm, preferably 0.5mm-0.8mmPO, and the amount of calcium carbonate binder is 150-2000g/m 2 per square meter, preferably 500-800g/ m 2 , combine the recycled fiber tufted layer with the non-woven fabric layer, press it with a roller, and cool at 5-30°C to form a recycled fiber tufted soft bottom layer;
  • Carpet fiber layer and recycled fiber layer bonding PO and calcium carbonate are heated and melted in a mass ratio of 25-50:50-75, and the mass ratio of PO and calcium carbonate is preferably 25-35:65-75, and cooled , Granulate to obtain PO-calcium carbonate binder particles;
  • the PO-calcium carbonate binder particles are fed into the carpet tile bonding machine, heated and melted at 130-220°C, and then smoothly coated on the tufted back of the recycled fiber tufted soft bottom layer with an extruder , Use a scraper to scrape off the excess part and bond it with the latex surface of the carpet fiber tufted layer.
  • the amount of PO-calcium carbonate adhesive is controlled at 500g/m 2 ⁇ 2500g/m 2 per square meter, and the thickness is 0.8mm ⁇ 1.5mm; After bonding, it is pressed by rollers and put in a cooling box at 5-30°C for cooling.
  • step (2) the drying conditions are as follows: the drying temperature is 140-200°C, and the drying time is 2-8 minutes.
  • the recycled yarn needs to be classified, recycled and produced according to the material of the yarn fiber.
  • the recycled fiber of the same material needs to be classified according to the fiber thickness (Denny number D). Fibers with the same or close Deny number can be classified Together, fibers with different denier numbers or large differences in denier numbers need to be managed separately. According to the fiber thickness requirements during tufting, the finer fibers can be plied to reach or close to the thickness of the tufted fiber.
  • the pile is on the second long-fiber non-woven fabric.
  • the heat shrinkage rate of the fibers used in the same roll of recycled fiber layers must be consistent, and the heat shrinkage rate must be within ⁇ 3%.
  • the recycled fiber described in the present invention is such color deviation, physical property deviation, and color change transition.
  • Fiber used In the prior art, it is directly discarded or cut and recycled. If it is discarded directly, raw materials will be wasted and the production cost will increase.
  • the present invention classifies recycled fibers according to their different materials, and divides them into PP, nylon, PET, PTT, PO, wool and other categories, and then classifies the defective products according to the fiber thickness and heat shrinkage rate. Recycled fibers of the same material need to be classified according to fiber thickness (Denny number D). Fibers with the same or close Denny numbers can be grouped together.
  • Fibers with different Denny numbers or large differences in Denny numbers need to be made. Differentiate management. According to the fiber thickness requirements during tufting, the finer fibers can be twisted to reach or close to the thickness of the tufted fiber, and the tufting is on the second long-fiber non-woven fabric. For example, using nylon recycled fiber, the 1100D yarn is double-twisted into 2200D, and the 680D yarn is twisted into 2040D yarn and used separately. The heat shrinkage rate of the fibers used in the same roll of recycled fiber layers must be consistent, and the heat shrinkage rate must be within ⁇ 3%.
  • This classification is to ensure that the raw materials, thickness, height, and density of the fibers are uniform and consistent during the entire production process.
  • it is necessary to strictly control the height of the pile during the carpet weaving process, and the height must be within plus or minus 2mm; to ensure that the comfort and softness of the entire batch of products tend to be consistent.
  • the invention is based on the concept of green and environmental protection, and on the basis of the traditional carpet production process, the usage of PVC and asphalt is reduced as much as possible, and these materials can even be used without these materials to create a more green, environmentally friendly, safe and comfortable carpet.
  • the invention has the advantages of soft material, high comfort, good elasticity, stable physical properties, and good temperature insulation effect.
  • the invention can not only prevent the output and waste of its own defective fiber, but also absorb the defective products produced by other manufacturers. It can use the existing equipment in the industry without adding other equipment and directly use it in the carpet. To maximize energy saving and emission reduction;
  • FIG. 1 Schematic diagram of the structure of the present invention.
  • FIG. 1 Schematic diagram of the preparation process of the present invention.
  • FIG. 3 Schematic diagram of the preparation process of the present invention.
  • 1 is the carpet fiber
  • 2 is the first long-fiber non-woven fabric
  • 3 is the first resin bonding layer
  • 4 is the second long-fiber non-woven fabric
  • 5 is the recycled fiber
  • 6 is the second resin bonding Layer 7 is a latex layer and 8 is a non-woven fabric.
  • a soft-bottom carpet prepared by using recycled yarns.
  • the carpet includes a carpet fiber layer and a recycled fiber layer sequentially arranged from top to bottom.
  • the carpet fiber layer includes carpet fibers and a first long-fiber non-woven fabric.
  • the fiber is tufted on the first long-fiber non-woven fabric, the recycled fiber layer includes recycled fibers and the second long-fiber non-woven fabric, and the recycled fiber is tufted on the second long-fiber non-woven fabric;
  • the carpet fiber layer And the recycled fiber layer, the tufted pile surface includes a variety of loop pile, cut pile and mixed style of loop pile and cut pile.
  • the material of the carpet fiber is PP, PET, PTT, nylon, PO or wool.
  • the first long-fiber non-woven fabric and the second long-fiber non-woven fabric have a grammage of 70-150 g/m 2 , a thickness of 1.2 mm or less, a strength of 10 kgf or more, and a heat shrinkage rate of less than 0.9%.
  • Non-woven fabric is a high-quality non-woven fabric material, which is characterized by strong strength and can ensure that the horizontal dimension is always stable; the material of the first long-fiber non-woven fabric and the second long-fiber non-woven fabric is polyester.
  • the carpet fiber layer and the recycled fiber layer are bonded by an adhesive.
  • the material of the adhesive is PVC, asphalt, PO, PU, PE or EVA.
  • the adhesive is used to bond the carpet fiber layer and the recycled fiber layer, and the adhesive can also be used to bond the recycled fiber layer to the non-woven fabric layer.
  • the preferred material of the adhesive is PO, and PO and calcium carbonate are mixed in a mass ratio of 25-50:50-75.
  • the ratio can be modified or other additives can be added as required; first, PO and calcium carbonate are fed at a ratio of 25-50:50-75 and then heated and melted. After the PO is melted, the calcium carbonate is stirred evenly to ensure the dispersion of calcium carbonate. After the performance is good, it is cooled and granulated. Then it is fed to the carpet tile bonding machine. After heating and melting the raw materials at 130-220°C, feed them into the feeding port of the carpet tile bonding machine for extrusion coating, and then use a spatula to smoothly coat them on the back of the tufted soft bottom layer of recycled fiber tufts, and Remove the excess and make it adhere to the latex surface of the carpet fiber layer.
  • the dosage is controlled at 500 ⁇ 2500g/m 2 .
  • the thickness is controlled within 0.8mm ⁇ 1.5mm according to the actual needs of production. After coating, put it into a cooling box at 5-30°C for smooth cooling, ensuring that the product is flat during the cooling process. After cooling, the finished product is cut and produced.
  • a latex layer is provided between the carpet fiber layer and the recycled fiber layer, and the material of the latex layer is EVA, water-based PU, acrylic or SBR, preferably SBR. Adding a latex layer can make the carpet more elastic and softer.
  • the coating amount of EVA water-based PU, acrylic or SBR is Dry50g/m 2 ⁇ 800g/m 2 , and the coating method is foaming and glueing.
  • the latex layer preferably adopts the following formula: the mass ratio of SBR, antibacterial agent, calcium carbonate and foaming agent is 62-100:0 ⁇ 1:0 ⁇ 35:0 ⁇ 2, antibacterial agent, calcium carbonate, foaming agent are optional The components.
  • the material preparation method of the latex layer Put SBR, antibacterial agent, calcium carbonate, and foaming agent into the mixing tank according to the proportion, and after stirring, use a foaming machine to foam, uniformly coat the back of the carpet fiber layer, and scrape off The extra part.
  • the coating amount is 50g/m 2 ⁇ 800g/m 2 , in order to play the role of fiber reinforcement, avoid falling off and cause appearance defects; after coating, enter the 140 ⁇ 200°C oven at a speed of 5m/min for 2 ⁇ 8 minutes drying Dry, roll the blanket and set aside after the latex is dry.
  • a non-woven fabric layer is provided under the recycled fiber layer, and the heat shrinkage rate of the non-woven fabric is less than 2%; the weight range: 50-1200 g/m 2 .
  • the non-woven fabric layer is a non-essential structure. This non-woven fabric layer can be added in order to be beautiful or to further improve the stability of the carpet.
  • the material of the non-woven fabric layer can be polyester or nylon.
  • the heat shrinkage rate is less than 2% to ensure that it is not easy to fluff. No stratification, the weight is between 50 ⁇ 1200g/m 2 .
  • Example 1 The above-mentioned method for manufacturing a soft carpet made from recycled yarn includes the following steps:
  • the nylon fiber is tufted on the first long-fiber non-woven fabric by the tufting carpet loom equipment to become a carpet fiber layer, which is ready for use in rolls.
  • One side of the carpet fiber layer with piles is the carpet pile surface, and the other side is the tufted back surface, which is to be pre-coated with latex.
  • Control the coating amount to be 50-800g/m 2 , preferably 80-350g/m 2 dry glue amount. After coating, dry it in an oven at 140-200°C at a speed of 5m/min for 2-8 minutes, and the latex is dried into a roll spare;
  • the recycled fiber adopts nylon crude fiber of about 850D ⁇ 4000D after plying. Select fibers of similar thickness to be directly tufted on the second long-fiber non-woven fabric through the tufting carpet loom equipment to make a recycled fiber layer and roll it for use. .
  • the pile density of the pile surface is specifically 100,000 roots/m 2 to 450,000 roots/m 2
  • the pile height is specifically 2.5 mm to 12 mm.
  • the scraper 10 is used to make it evenly coated on the suede surface of the recycled fiber layer and scraped out
  • the suitable height is 0.5mm-1.0mm (preferably 0.5mm-0.8mm)
  • the dosage is controlled at 150-2000g/m 2 (preferably 500-800g/m 2 ) per square meter
  • the recycled fiber layer is combined with the non-woven fabric layer. It is compacted by rollers to perform stable cooling at 5 to 30°C. During the cooling process, the product is ensured to be flat, forming a soft tufted bottom layer of recycled fibers, which is rolled into a roll for later use.
  • the dosage is controlled at 500g/m 2 ⁇ 2500g/m 2 (preferably 600 ⁇ 1200g/m 2 ) per square meter, and the thickness is controlled at 0.8mm ⁇ 1.5mm in height.
  • test data of the above-mentioned soft carpet manufacturing method prepared from recycled yarn is as follows:
  • Example 1 Refer to the method of Example 1 to produce recycled yarn soft carpets and recycled yarn soft carpets that do not contain unnecessary structures.
  • the size of the finished carpet tile is 500mm*500mm, and 25 sampling points are planned on average.
  • the data of each sampling point is measured and recorded with a hardness tester in a fixed sequence. Finally, the effective detection data is obtained with the average value of the 25 sampling points.

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Abstract

一种利用回收纱线制备的软底地毯，由上至下依次为地毯纤维层、回收纤维层，地毯纤维层包括地毯纤维（1）和第一长纤无纺布（2），地毯纤维（1）簇绒在第一长纤无纺布（2）上，回收纤维层包括回收纤维（5）和第二长纤无纺布（4），回收纤维（5）簇绒在第二长纤无纺布（4）上；地毯纤维层、回收纤维层之间固定粘合。该地毯具有材质柔软、舒适度高、弹性佳、物性稳定、具有良好的隔温效果等优势。

Description

一种利用回收纱线制备的软底地毯及其制造方法 技术领域
本发明属于地毯制造技术领域，具体涉及一种利用回收纱线制备的软底地毯及其制造方法。
背景技术
目前国内地毯大多采用地毯毯面簇绒后附着PVC或者沥青作为地毯的底材，中间可加入玻璃纤维层以提高地毯尺寸稳定性，或者在地毯毯面簇绒后附着无纺布类的底材。但是，PVC底材用于地毯上使用，通常质地较硬，舒适度不佳，各大厂商一直都在试图寻找一种新的材料以替代PVC作为地毯底材；而无纺布类的底材，虽然较PVC材质相比，相对柔软，但是由于其尺寸的不稳定性、容易翘曲的物性，继而在使用中品质弊端不断显现。因此，我们一直致力于创造一种兼具PVC/沥青类的稳定性和软底的舒适性，并且融入绿色再生环保的科学理念的底材。
我们发现，纤维在生产和加工的过程中会因为颜色偏差、物性异常、换色过渡产生一部分瑕疵品，这部分瑕疵品在生产正常的地毯时是无法使用的，因此常规做法是予以丢弃或者是做切割回收。切割回收即是纤维割断后进行高温熔化继而造粒，再进行高温熔化根据需要制成其他相应产品。但是这种回收方法需要利用切割、熔融、造粒、成型等设备，这些大功率设备需要消耗大量的能源，高频率的作业同样消耗着大量的人力，并且在切割纤维的过程中，会产生大量的毛屑、粉尘，进一步造成作业人员的身体损害，其产生的二次污染以及对能源的大量消耗对环境造成不可逆转的影响。
发明内容
发明目的：本发明要解决的技术问题是提供一种利用回收纱线制备的地毯，以减少纱线回收过程中的能源消耗以及二次污染，同时兼具材质柔软、舒适度高、弹性佳、物性稳定、具有良好的隔温效果等优点；
本发明还要解决的技术问题是提供上述利用回收纱线制备的地毯的制备方法。
技术方案：
一种利用回收纱线制备的软底地毯，该地毯包括由上至下依次为地毯纤维层、回收纤维层，所述地毯纤维层包括地毯纤维和第一长纤无纺布，所述地毯纤维簇绒在第一长纤无纺布上，所述回收纤维层包括回收纤维和第二长纤无纺布，所述的回收纤维簇绒在第二长纤无纺布上；地毯纤维层和回收纤维层，经簇绒后的绒面包括了各种圈绒、割绒以及圈割绒混合风格。
所述的地毯纤维层、回收纤维层之间固定粘合。
其中，所述的地毯纤维的材质为PP、PET、PTT、尼龙、PO或羊毛，优选尼龙或PP。
其中，所述的第一长纤无纺布和第二长纤无纺布为70～150g/m 2，优选90-100g/m 2。
其中，所述地毯纤维层、回收纤维层之间通过粘合剂粘合。
其中，所述粘合剂的材质为PVC、沥青、PO、PU、PE或EVA，优选PO。
其中，所述的地毯纤维层、回收纤维层之间设有乳胶层。
其中，所述的乳胶层的材质为EVA、水性PU、亚克力或SBR，优选SBR。
其中，所述回收纤维层下设有无纺布层。
其中，所述回收纤维层与无纺布层之间用粘合剂连接。
其中，所述无纺布层克重为50～1200g/m 2，优选50～300g/m 2。
其中，所述无纺布层的热缩率小于2％。
其中，所述的回收纤维层中绒面的绒头不低于100000根/m 2。
上述利用回收纱线制备的软底地毯的制造方法，包括如下步骤：
(1)地毯纤维簇绒：将地毯纤维簇绒在第一长纤无纺布上，得到地毯纤维层，所述的地毯纤维的材质为PP、PET、PTT、尼龙、PO或羊毛；
(2)乳胶预涂烘干：将水性乳胶SBR、抗菌剂、碳酸钙、发泡剂按照质量比为62～100:0～1:0～35:0～2混合均匀，优选65～70：0～1：28～35:0～1，利用发泡机进行空气发泡，发泡倍率为1.2～10倍，优选1.5～3倍，均匀涂布于地毯纤维层的背面，涂布量为50～800g/m 2，优选80～350g/m 2干胶量，烘干，得到乳胶层；
(3)回收纤维簇绒：对回收纤维进行分类，将回收纤维合股为850D～4000D粗回收纤维，将粗回收纤维簇绒在第二长纤无纺布上，得到回收纤维层，所述回收纤维层上 绒面的绒头密度具体为100000根/m 2～450000根/m 2，绒头高度具体为2.5mm～12mm，优选3.5mm～6.5mm，得到回收纤维层；
(4)回收纤维簇绒软底：将PO、碳酸钙按照质量比为20～45：55～80，的比例投料后加热熔融，搅拌均匀，PO、碳酸钙质量比优选20～30：70～80，冷却，造粒，得到PO-碳酸钙粘合剂颗粒；PO-碳酸钙粘合剂颗粒投料到方块地毯粘合机中，130～220℃加热熔融，再用挤压机平整的涂布在回收纤维层的绒面上，用刮刀刮至高度为0.5mm-1.0mm，优选0.5mm～0.8mmPO、碳酸钙粘合剂用量为每平方米150～2000g/m 2，优选500～800g/m 2，将回收纤维簇绒层与无纺布层结合，通过滚轮压紧，在5-30℃下冷却形成回收纤维簇绒软底层；
(5)地毯纤维层与回收纤维层粘合：将PO、碳酸钙按照质量比为25～50：50～75的比例加热熔融，PO、碳酸钙质量比优选25～35：65～75，冷却，造粒，得到PO-碳酸钙粘合剂颗粒；
将PO-碳酸钙粘合剂颗粒投料到方块地毯粘合机的中，采用130-220℃对其进行加热熔融，再用挤压机平整的涂布在回收纤维簇绒软底层的簇绒背面，用刮刀刮除多余的部分，并与地毯纤维簇绒层的乳胶面粘合，PO-碳酸钙粘合剂用量控制在每平方米500g/m 2～2500g/m 2，厚度为0.8mm～1.5mm；粘合后通过滚轮压紧，并投入到5～30℃的冷却箱冷却。
步骤(2)中，所述的烘干条件如下：烘干温度140～200℃，烘干时间2～8分钟。
所述回收纱线需要根据纱线纤维的材质进行分类回收和生产，同种材质的回收纤维，还需要按照纤维粗细(丹尼数D)进行分类，丹尼数相同或是接近的纤维可以归在一起，不同丹尼数或丹尼数差异较大的纤维需要做区分管理，根据簇绒时纤维的粗细需求，可以将较细的纤维通过合股的方式达到或接近簇绒纤维的粗细，簇绒在第二长纤无纺布上。同卷回收纤维层所使用的纤维热缩率需趋于一致，并且确保热缩率在±3％以内。
在纱线纤维的生产过程中会因为产品的颜色偏差、物性偏差、换色过渡等情况而产生瑕疵品，本发明中所述的回收纤维就是这种颜色偏差、物性偏差、换色过渡而无法使用的纤维。现有技术中采用的是直接丢弃或者是做切割回收，若直接丢弃则造成原料浪费，增加生产成本。本发明根据回收纤维的材质不同，对其进行分类，将其分为：PP、尼龙、PET、PTT、PO、羊毛等类别，再根据瑕疵品的纤维粗细以及热缩率，进行分类。 同种材质的回收纤维，还需要按照纤维粗细(丹尼数D)进行分类，丹尼数相同或是接近的纤维可以归在一起，不同丹尼数或丹尼数差异较大的纤维需要做区分管理，根据簇绒时纤维的粗细需求，可以将较细的纤维通过合股的方式达到或接近簇绒纤维的粗细，簇绒在第二长纤无纺布上。例如采用尼龙回收纤维，将1100D的纱线双股加撚成2200D，680D纱线三股加撚成2040D纱线，分别使用。同卷回收纤维层所使用的纤维热缩率需趋于一致，并且确保热缩率在±3％以内。
这样分类的目的在于，确保整幅生产过程中纤维的原料、粗细、高度、密度均匀保持一致。为了确保回收纤维层在使用中的平整性，需要严格控制织毯过程中绒头的高度保持一致，高度要求正负2mm以内；以确保整批产品的舒适感、柔软度趋于一致。
有益效果：
本发明基于绿色环保的理念，在传统的地毯生产工艺基础上尽可能的减少PVC和沥青的使用量，甚至可以不使用这些原料，创造出更为绿色环保、安全舒适的地毯。
本发明除了具有材质柔软、舒适度高、弹性佳、物性稳定、具有良好的隔温效果等优势。本发明不但可以杜绝自身不良品纤维的产出废弃，还可以吸收其他厂商生产的不良品，利用本行业既有设备，无需增加其他设备的前提下，将其直接使用在地毯中，真正的做到最大限度的节能减排；
本发明将回收纤维簇绒到长纤无纺布上，采用立体纤维结构，减少现有无纺布底材生产技术中横向或纵向织造，对于热胀冷缩环境的剧烈影响，该立体结构作为地毯的底材具有良好的稳定性，提高了柔软度及回弹性，进一步提高地毯整体的稳定效果。
附图说明
图1本发明结构示意图。
图2本发明制备过程示意图。
图3本发明制备过程示意图。
具体实施方式
下面结合附图对本发明的技术方案作进一步说明。
图1中，1为地毯纤维，2为第一长纤无纺布，3为第一树脂粘合层，4为第二长纤无纺布，5为回收纤维，6为第二树脂粘合层，7为乳胶层，8为无纺布。
一种利用回收纱线制备的软底地毯，该地毯包括由上至下依次设置的地毯纤维层、回收纤维层，所述地毯纤维层包括地毯纤维和第一长纤无纺布，所述地毯纤维簇绒在第一长纤无纺布上，所述回收纤维层包括回收纤维和第二长纤无纺布，所述的回收纤维簇绒在第二长纤无纺布上；地毯纤维层和回收纤维层，经簇绒后的绒面包括了各种圈绒、割绒以及圈割绒混合风格等。
所述的地毯纤维层、回收纤维层之间固定粘合。
其中，所述的地毯纤维的材质为PP、PET、PTT、尼龙、PO或羊毛。
其中，所述的第一长纤无纺布和第二长纤无纺布的克重为70～150g/m 2，厚度1.2mm以下，强度10kgf以上，热缩率低于0.9％，长纤无纺布是一种高品质的无纺布材料，其特点为强度强，同时可以确保横向的尺寸始终保持稳定；第一长纤无纺布和第二长纤无纺布的材质为涤纶。
其中，所述地毯纤维层、回收纤维层之间通过粘合剂粘合。
其中，所述粘合剂的材质为PVC、沥青、PO、PU、PE或EVA。粘合剂用于粘合地毯纤维层和回收纤维层，粘合剂也可以用于将回收纤维层与无纺布层贴合。粘合剂首选材质为PO，将PO与碳酸钙按照质量比为25～50：50～75比例混合。
按照需要可修改配比或添加其他助剂；先将PO及碳酸钙，按照25～50：50～75的比率投料后加热熔融，让PO融化后和碳酸钙进行搅拌均匀，确保碳酸钙的分散性良好之后，冷却造粒。之后投料到方块地毯粘合机。采用130～220℃对原料进行加热熔融后，投料到方块地毯粘合机的投料口中挤压涂布，再用刮刀使其平整的涂布在回收纤维簇绒软底层的簇绒背面上，并去除多余的部分，使其与地毯纤维层的乳胶面粘合。根据生产的实际需要，用量控制在500～2500g/m 2。厚度根据生产的实际需要，控制在0.8mm～1.5mm。涂布后、投入到5～30℃的冷却箱平稳的冷却，冷却过程中确保产品平整。冷却后进行成品裁切制作。
作为优选，所述地毯纤维层、回收纤维层之间设有乳胶层，所述乳胶层的材质为EVA、水性PU、亚克力或SBR，优选SBR。加入乳胶层可以使地毯弹性更高、柔软度 更好。EVA水性PU、亚克力或SBR涂布量Dry50g/m 2～800g/m 2，涂布方式发泡上胶。
乳胶层优选采用如下配方：SBR、抗菌剂、碳酸钙、发泡剂的质量比为62～100:0～1:0～35:0～2，抗菌剂、碳酸钙、发泡剂为可选择的组分。
乳胶层的材料制备方法：按配比将SBR、抗菌剂、碳酸钙、发泡剂投入搅拌槽，搅拌均匀后，使用发泡机进行发泡，均匀的涂布在地毯纤维层的背面，刮除多余部分。涂布量为50g/m 2～800g/m 2，以起到纤维加固的作用，避免脱落而造成外观的瑕疵；涂布后以5m/分钟速度进入140～200℃烘箱进行2～8分钟烘干，乳胶干透后卷毯备用.
其中，所述回收纤维层下设有无纺布层，所述无纺布的热缩率小2％；克重区间：50～1200g/m 2。无纺布层为非必须结构,为了美观或进一步提高地毯的稳定性可以增加这层无纺布层，无纺布层的材质可为涤纶或尼龙，热缩率小于2％，确保不易起毛，不分层，克重在50～1200g/m 2之间。
实施例1：上述利用回收纱线制备的软底地毯制造方法，包括如下步骤：
(1)地毯纤维簇绒
利用簇绒织毯机设备将尼龙纤维簇绒在第一长纤无纺布上，成为地毯纤维层，成卷备用。地毯纤维层有绒头的一面为地毯绒面，另一面为簇绒背面，待乳胶预涂。
(2)乳胶预涂烘干
采用水性环保乳胶SBR，配比为SBR：抗菌剂：碳酸钙：发泡剂＝62～100:0～1:0～35:0～2，优选65-70：0～1：28～35:0～1，其中，抗菌剂和发泡剂的含量可以为0，将上述原料按配比投入搅拌槽中，搅拌均匀后，使用发泡机进行空气发泡，发泡倍率为1.2～10倍，优选1.5～3.0倍，均匀的涂布在地毯纤维层的簇绒背面，用刮刀刮除多余的乳胶。控制涂布量为50～800g/m 2，优选80～350g/m 2干胶量，涂布后以5m/分钟速度在140～200℃烘箱进行2～8分钟烘干，乳胶干燥后成卷备用；
(3)回收纤维簇绒
回收纤维采用合股后850D～4000D左右的尼龙粗纤维，选择粗细较为接近的的纤维直接通过簇绒织毯机设备簇绒在第二长纤无纺布上，制成回收纤维层，成卷备用。绒面的绒头密度具体为100000根/m 2～450000根/m 2，绒头高度具体为2.5mm～12mm。
特别说明：回收纤维层可以根据需求切换贴合面的方向。即可以用回收纤维层的背 面与无纺布层粘合，而回收纤维层的绒面与地毯纤维层的乳胶面贴合。
(4)PO粘合层(第二树脂粘合层为非必须结构)
将PO及碳酸钙，按照20～45：55～80(优选20～30：70～80)的比率投料后加热熔融(温度130～220℃)，让PO融化后和碳酸钙进行搅拌均匀，确保碳酸钙良好的分散性之后，冷却(温度5～30℃)造粒(粒径小于4～40目)，确保熔融情况可确保均匀。采用130～220℃对原料进行加热熔融后，投料到方块地毯粘合机的投料口11中挤压涂布，再用刮刀10使其平整的涂布在回收纤维层的绒面上，刮出适合的高度0.5mm～1.0mm(优选0.5mm～0.8mm)，用量控制在每平方米150～2000g/m 2(优选500～800g/m 2)，将回收纤维层与无纺布层结合。通过滚轮压紧，进行5～30℃平稳的冷却，冷却过程中确保产品平整，形成回收纤维簇绒软底层，成卷备用。
(5)PO粘合层
将PO及碳酸钙，按照25～50：50～75的比率投料后加热熔融(温度130～220℃)，让PO融化后和碳酸钙进行搅拌均匀，确保碳酸钙良好的分散性之后，冷却(温度5～30℃)造粒粒径小于4～40目。采用130～220℃对原料进行加热熔融后，投料到方块地毯粘合机的投料口11中挤压涂布，再用刮刀10使其平整的涂布在回收纤维簇绒软底层的簇绒背面上，并去除多余的部分，使其与地毯纤维层的乳胶面粘合。用量控制在每平方米500g/m 2～2500g/m 2(优选600～1200g/m 2)，厚度控制在高度0.8mm～1.5mm。粘合后通过滚轮压紧，并投入到5～30℃的冷却箱平稳的冷却，冷却过程中确保产品平整。根据实际需求，将成品软底地毯裁切成一定的尺寸。
上述利用回收纱线制备的软底地毯制造方法，检测数据如下：
实施例2：轮椅实验的回弹性比率
取成品方块毯尺寸为500mm*500mm，使用测厚仪对样品进行全厚测量，记录有效数据。将测量过的地毯放置于脚轮椅测试仪的底板上予以固定，将负重90kg的模拟轮椅脚放在毯面上，设置转动次数2000转，开动仪器。转动结束后，取出样毯，水平静置24小时。以上步骤完成后，再次使用测厚仪对样品进行全厚测量，取得有效数据。比对有效数据后计算回弹性比率。
参照实施例1的方法制造回收纱线的软底地毯和不含非必须结构的回收纱线软底地毯。
结论：百分比高则回弹性高，弹性佳
表1本发明与竞品的轮椅试验的回弹性比率
Figure PCTCN2020081288-appb-000001
表2本发明与不含非必须结构的地毯的轮椅试验的回弹性比率
Figure PCTCN2020081288-appb-000002
2六足滚桶实验回弹性比率---针对弹性佳的补充数据
取成品方块毯，使用测厚仪对样品进行全厚测量，记录有效数。裁切尺寸后贴合在滚筒内壁上，放入六足滚轮测试仪器内，设置12000转，开动仪器。转动结束后，取出样毯，水平静置24小时。以上步骤完成后，再次使用测厚仪对样品进行全厚测量，取得有效数据。比对有效数据后计算回弹性比率。
结论：百分比高则回弹性高，弹性佳
表3本发明与竞品地毯的六足滚筒实验回弹性比率
Figure PCTCN2020081288-appb-000003
表4本发明与不含非必须结构的地毯的的六足滚筒回弹性比率
Figure PCTCN2020081288-appb-000004
3软硬度测试---针对材质柔软，舒适度高的补充数据
取成品方块毯尺寸为500mm*500mm，平均规划25个取样点，按照固定顺序使用硬度计测量各取样点数据并予以记录，最终以25个取样点平均值取得有效检测数据。
结论：数值低则软度高，柔软度佳
表5本发明与竞品地毯的软硬度测试
Figure PCTCN2020081288-appb-000005
表6本发明与不含非必须结构地毯的软硬度测试
Figure PCTCN2020081288-appb-000006
4地毯隔温效果--针对良好的隔温效果的补充数据
取成品方块毯裁切至同铁板完全一致的大小，并覆盖设备铁板。将设备温度设置到80℃并维持此温度至测试结束。成品方块地毯块放在80℃设备铁板后，立即测量其毯面正中央位置初始温度并记录有效数据，而后计时，每6分钟进行一次毯面导热性温 度测试，记录有效数据。
结论：表面温度低则导热性差，隔温效果佳
表7本发明与竞品地毯的隔温效果测试
Figure PCTCN2020081288-appb-000007
表8本发明与不含非必须结构地毯的格温效果测试
Figure PCTCN2020081288-appb-000008

Claims (10)

  1. 一种利用回收纱线制备的软底地毯，其特征在于，该地毯包括地毯纤维层、回收纤维层，所述地毯纤维层包括地毯纤维(1)和第一长纤无纺布(2)，所述地毯纤维(1)簇绒在第一长纤无纺布(2)上，所述回收纤维层包括回收纤维(5)和第二长纤无纺布(4)，所述的回收纤维(5)簇绒在第二长纤无纺布(4)上；
    所述的地毯纤维层、回收纤维层之间固定粘合。
  2. 根据权利要求1所述的利用回收纱线制备的软底地毯，其特征在于，所述的地毯纤维(1)的材质为PP、PET、PTT、尼龙、PO或羊毛；
    所述的第一长纤无纺布(2)和第二长纤无纺布(4)的克重分别为70～150g/m 2。
  3. 根据权利要求1所述的利用回收纱线制备的软底地毯，其特征在于，所述地毯纤维层、回收纤维层之间通过粘合剂粘合。
  4. 根据权利要求1所述的利用回收纱线制备的软底地毯，其特征在于，所述粘合剂的材质为PVC、沥青、PO、PU、PE或EVA。
  5. 根据权利要求1所述的用回收纱线制备的软底地毯，其特征在于，所述的地毯纤维层、回收纤维层之间设有乳胶层。
  6. 根据权利要求5所述的利用回收纱线制备的软底地毯，其特征在于，所述的乳胶层的材质为EVA、水性PU、亚克力或SBR。
  7. 根据权利要求1所述的利用回收纱线制备的软底地毯，其特征在于，所述回收纤维层下设有无纺布层；所述回收纤维层与无纺布层之间用粘合剂连接。
  8. 根据权利要求7所述的利用回收纱线制备的软底地毯，其特征在于，所述无纺布层克重为50～1200g/m 2，所述无纺布层的热缩率小于2％。
  9. 根据权利要求1所述的利用回收纱线制备的软底地毯，其特征在于，所述的回收纤维层中绒面的绒头不低于100000根/m 2，绒头高度高于2.5mm低于12mm。
  10. 权利要求1～9所述利用回收纱线制备的软底地毯的制造方法，其特征在于，包括如下步骤：
    (1)地毯纤维簇绒：将地毯纤维簇绒在第一长纤无纺布上，得到地毯纤维层；
    (2)乳胶预涂烘干：将水性乳胶SBR、抗菌剂、碳酸钙、发泡剂按照质量比为(62～100):(0～1):(0～35):(0～2)混合均匀，使用发泡机进行空气发泡，发泡倍率为1.2～10倍，均匀涂布于地毯纤维层的背面，涂布量为50～800g/m 2干胶量，烘干，得到乳胶层；
    (3)回收纤维簇绒：对回收纤维进行分类，将回收纤维合股为850D～4000D粗回收纤维，将粗回收纤维簇绒在第二长纤无纺布上，得到回收纤维层；
    (4)回收纤维簇绒软底：将PO、碳酸钙按照质量比为(20～45)：(55～80)的比例投料后加热熔融，搅拌均匀，冷却，造粒，得到PO-碳酸钙粘合剂颗粒；PO-碳酸钙粘合剂颗粒投料到方块地毯粘合机中130～220℃加热熔融，再用挤压机平整的涂布在回收纤维层的绒面上，再用刮刀刮至高度为0.5mm～1.0mm，PO、碳酸钙粘合剂用量为每平方米150～2000g/m 2，将回收纤维簇绒层与无纺布层结合，通过滚轮压紧，在5～30℃下冷却形成回收纤维簇绒软底层；
    (5)地毯纤维层与回收纤维层粘合：将PO、碳酸钙按照质量比为25～50：50～75的比例混合，加热熔融，冷却，造粒，得到PO-碳酸钙粘合剂颗粒；
    将PO-碳酸钙粘合剂颗粒投料到方块地毯粘合机的中，采用130～220℃对其进行加热熔融，再用挤压机平整的涂布在回收纤维簇绒软底层的簇绒背面，用刮刀刮除多余的部分，并与地毯纤维层的乳胶面粘合，PO-碳酸钙粘合剂用量控制在每平方米500g/m 2～2500g/m 2，厚度为0.8mm～1.5mm；粘合后通过滚轮压紧，并投入到5～30℃的冷却箱冷却；
    步骤(2)中，所述的烘干条件如下：烘干温度140～200℃，烘干时间2～8分钟。
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