WO2023173724A1 - 一种地毯 - Google Patents

一种地毯 Download PDF

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Publication number
WO2023173724A1
WO2023173724A1 PCT/CN2022/123305 CN2022123305W WO2023173724A1 WO 2023173724 A1 WO2023173724 A1 WO 2023173724A1 CN 2022123305 W CN2022123305 W CN 2022123305W WO 2023173724 A1 WO2023173724 A1 WO 2023173724A1
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Prior art keywords
carpet
matt
dty
layer
dry
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PCT/CN2022/123305
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English (en)
French (fr)
Inventor
曹顺林
张怡
翟梓翔
孙玉好
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昆山怡家居纺织有限公司
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Publication of WO2023173724A1 publication Critical patent/WO2023173724A1/zh

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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/08—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
    • B32B3/085—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts spaced apart pieces on the surface of a layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • 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
    • B32B5/18—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 features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • 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
    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G1/00—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics
    • D02G1/02—Producing crimped or curled fibres, filaments, yarns, or threads, giving them latent characteristics by twisting, fixing the twist and backtwisting, i.e. by imparting false twist
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J1/00—Modifying the structure or properties resulting from a particular structure; Modifying, retaining, or restoring the physical form or cross-sectional shape, e.g. by use of dies or squeeze rollers
    • D02J1/22—Stretching or tensioning, shrinking or relaxing, e.g. by use of overfeed and underfeed apparatus, or preventing stretch
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02J—FINISHING OR DRESSING OF FILAMENTS, YARNS, THREADS, CORDS, ROPES OR THE LIKE
    • D02J13/00—Heating or cooling the yarn, thread, cord, rope, or the like, not specific to any one of the processes provided for in this subclass
    • 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
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C7/00—Heating or cooling textile fabrics
    • D06C7/02—Setting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0207—Materials belonging to B32B25/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/726—Permeability to liquids, absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2471/00—Floor coverings
    • B32B2471/02—Carpets

Definitions

  • the invention belongs to the field of carpets, and specifically relates to a carpet.
  • the invention designs a carpet preparation process.
  • carpet As a popular floor decoration material, carpet has already entered thousands of households. There are many materials used for carpets, among which cotton carpets are widely loved by consumers for their comfortable touch, high moisture absorption properties and excellent dyeing properties.
  • the cotton carpets currently on the market are prone to moisture absorption due to the characteristics of cotton's own lignin short fibers. If stored improperly, they are prone to mildew: and when the cotton carpets are put into the washing machine for cleaning, the short fibers are prone to It will fall off, and it will take a long time to dehydrate or dry in the sun; if it is exposed to sunlight for a long time and dried, the cotton fiber will turn yellow and become brittle.
  • According to the inventor's investigation there are currently many consumers on the market who are eager to have a carpet that not only has the appearance and feel of cotton carpets as well as excellent water absorption properties, but at the same time can avoid the excessive lint loss and easy aging of existing cotton carpets. , easy to mold, difficult to dehydrate and dry and other shortcomings.
  • the present invention provides a carpet.
  • embodiments of the present invention provide a carpet, which includes a suede layer and a base fabric layer; the suede layer is woven on a base fabric; and the carpet is made by woven pile
  • the base fabric layer of the surface layer is put into a dry and wet heat gray fabric shaping device for tumbling and shaping processing, so that the suede layer rubs against the inner wall of the box and itself to shape the tows of the suede layer; the dry and wet heat gray cloth
  • the shaping device is a dry and wet heat box processing device with rolling and/or shaking functions.
  • the carpet further includes a backing layer compounded at the bottom of the base fabric layer.
  • the back of the bottom back layer can also be treated with anti-slip treatment.
  • the dry and wet heat gray fabric shaping device includes one of a rolling ball machine, an overflow cylinder, an industrial washing machine, and an integrated flat washing and drying machine.
  • the dry and wet heat gray fabric shaping device performs dry and wet heat treatment, including one of dry heat, moist heat, and dry and wet heat treatment.
  • the heating temperature of the dry and wet heat gray cloth shaping device is 45-160°C.
  • the suede layer is woven on the base fabric through a tufting process.
  • the yarn used in the carpet surface layer is a matte or semi-dull DTY strand made of single or multiple strands of matt or semi-matt DTY filaments that are stranded and twisted or knotted.
  • the matt or semi-matt DTY filament bundle is obtained by texturing and stretching deformation of virgin filament or FDY filament bundle.
  • DTY filament bundles are combined and twisted to obtain DTY strands.
  • the twist direction of the combined and twisted strands is S or Z twist, and the double twist twist is 35T/M-150T/M.
  • the DTY tow is polyester or nylon tow in the form of S+Z twist.
  • the linear density (DPF) of a single filament in the matte or semi-matte DTY filament bundle is 0.40DENIER-5.00DENIER.
  • linear density of the matt or semi-matt DTY strands is 75D-12000D.
  • the matt or semi-matt DTY strands are heat-set in a yarn setting machine, and the setting temperature of the yarn setting machine is 80-190°C.
  • the matt or semi-matt DTY filaments can also be tied into network knots on the yarn network machine and then plied into strands.
  • the netting knots are medium and heavy netting to prevent the yarn from unraveling in subsequent processes.
  • the material of the bottom back layer includes one of thermoplastic elastomer, natural rubber, hot melt adhesive, and fabric with anti-slip function or hooking function.
  • the present invention also relates to a method for preparing a carpet, which method includes the following steps:
  • Preparation of yarn Select virgin silk or drawn silk tows, and make DTY tows through elasticity and stretching deformation. After merging single or multiple DTY tows, they are twisted or knotted. made into strands;
  • step S2 Use the DTY strands prepared in step S1 to weave on the base fabric layer using the tufting process to obtain an embryo blanket;
  • Tumbling and shaping processing Put the carpet surface fabric woven in step S2 into a dry and wet heat gray fabric shaping device for tumbling and shaping processing, and let the carpet surface rub against the box or cylinder and itself to produce a cotton-style blanket. noodle;
  • Step S4 Prepare the backing layer: use the carpet surface processed in step S3 to prepare the backing layer on the back of the embryonic carpet to obtain the carpet.
  • the yarn selected in step S1 can also be regenerated matt or semi-matt polyester or nylon yarn.
  • a pile fixing process is performed.
  • the fixing treatment includes one of glue fixing and flame composite fixing.
  • the embryo blanket placed in step S3 can be a roll blanket or a sheet blanket.
  • the carpet with the combined bottom and back layer can also be tumbling and shaped.
  • Figure 1 is a schematic diagram of a carpet according to Embodiment 1 of the present invention.
  • Figure 2 is a side view of the carpet in Example 1 before and after dry and wet heat treatment; wherein, a is a side view before dry and wet heat treatment, and b is a side view before dry and wet heat treatment;
  • Figure 3 is a top view of the carpet in Example 1 before and after dry and wet heat treatment; where a is a top view before dry and wet heat treatment, and b is a top view before dry and wet heat treatment;
  • Figure 4 is a schematic diagram of a carpet according to Embodiment 4 of the present invention.
  • This embodiment relates to a carpet, as shown in Figure 1, including a base fabric layer 2, a suede layer 1 woven on the base fabric layer 2, and a backing layer 3 compounded at the bottom of the base fabric layer 2.
  • the carpet preparation includes the following steps:
  • Step 1 prepare the yarn: select 300D/192F polyester virgin silk tow, and use the stretching and deformation process to make the stretched and deformed tow.
  • the shape of the single tow is S+Z false twist form, and then 6 strands of S
  • the +Z-shaped filament bundles are paralleled and twisted into strands, the twist degree is 50T/m, and the total D number is 1800D.
  • the shaping temperature is 150°C;
  • Step 2 manufacturing process: use a cut pile tufting machine with a gauge of 3/16 to tuft the yarn produced in step 1 on a long fiber base fabric.
  • Step 3 Fixing process: Use hot-melt adhesive to fix the velvet on the back of the carpet woven in step 2.
  • the melting temperature of the hot-melt adhesive is 180°C.
  • Step 4 tumbling and shaping processing: Put the fabric that has been piled in step 3 into a rolling ball machine for dry and wet heat treatment, so that the suede surface of the carpet surface rolls and rubs against the inner wall of the box and itself; the internal temperature of the rolling ball machine box is 120 °C, the steam temperature is 100°C; the steam consumption is 2 kg;
  • Step 5 Prepare the bottom back layer: Use TPE to perform anti-slip treatment on the back of the carpet surface layer prepared in step 4).
  • This embodiment relates to a carpet, and the carpet preparation includes the following steps:
  • Step 1 prepare the yarn: select 300D/288F nylon DTY light mesh tows, and then use the heavy mesh process to combine the four tows.
  • the total number of D is 1200D
  • the number of network knots is 50/meter
  • the twist is 40T /m.
  • Step two manufacturing process: use a 1/10 cut pile tufting machine to tuft the yarn in step 1 on the network silk base fabric.
  • Step 3 Fixing process: Use EVA water-based glue on the embryo blanket woven in step 2 to fix the texture on the back of the blanket surface layer.
  • the drying temperature is 130°C.
  • Step four, tumbling and shaping processing Put the embryo blanket that has been fixed in step 3 into an industrial washing machine to rub the suede surface of the carpet surface with the water flow, the inner wall of the cylinder and the carpet itself.
  • the water temperature inside the cylinder is 80°C.
  • Step 5 Dehydrate and dry the shaped carpet surface layer
  • Step 6 Prepare the backing layer: Use foamed latex to perform anti-slip treatment on the back of the blanket.
  • the invention relates to a carpet.
  • the preparation of the carpet includes the following steps:
  • Tumbling and shaping processing Put the fabric prepared in step 2 into an industrial washing machine, so that the carpet surface rubs against the inner wall of the machine and the water flow; the water temperature is 100°C.
  • the present invention relates to a carpet, as shown in Figure 4, including a base fabric layer 2 and a suede layer 1 woven on the base fabric layer 2.
  • the carpet preparation includes the following steps:
  • step 2) The embryo blanket woven in step 2) is compounded with 180 g/m2 polyester fleece fabric on the back of the blanket using PUR hot melt adhesive.
  • the melting temperature of the hot melt adhesive is 180°C.
  • Tumbling and shaping processing Put the fabric that has been piled in step 3 into the rolling ball machine to dry and wet heat the box, so that the pile surface of the carpet surface rolls and rubs against the inner wall of the box and itself; the internal temperature of the ball rolling machine box is 120°C, steam temperature is 100°C; steam consumption is 1.80 kg.
  • Example 1 Take a 30x30cm carpet in Example 1, use a household washing machine with a power of 130W and a water temperature of 45°C. After one 30-minute washing, it is found that the surface fluff has no obvious lint loss or clumping. After 15 times of washing, it is found that the surface fluff has no obvious lint loss. , agglomeration phenomenon.
  • Example 3 Take a 30x30cm carpet in Example 3, use a household washing machine with a power of 130W and a water temperature of 45°C. After one 30-minute water washing, it is found that there is no obvious lint loss or clumping on the surface. After 15 times of washing, it is found that there is no obvious lint loss on the surface. , agglomeration phenomenon.
  • the 30x30cm size is basically the same as the preparation method in Example 1. The difference is that the material used is cotton fiber and has not been subjected to moisture heat treatment. A household washing machine with a power of 130W and a water temperature of 45°C was used. After a 30-minute wash, it was found that the surface fluff was obviously lost. There are no signs of falling off. After washing for 15 times, it is found that the fluff on the surface is falling off more obviously.
  • the 30x30cm size is basically the same as the preparation method in Example 3. The difference is that there is no moist heat treatment.
  • a household washing machine with a power of 130W and a water temperature of 45°C is used. After a 30-minute water washing, it is found that the surface fluff has obvious agglomeration. After 15 times of washing, it is found that the surface has agglomeration. The villi are mostly clumped together.
  • Example 1 Using the Martindale method, the preparation method of Example 1 is basically the same. The difference is that the material used is cotton fiber. After testing, the surface fuzzing and pilling grade is level 3 after constant friction.
  • Example 3 Using the Martindale method, the preparation method of Example 3 is basically the same. The difference is that the material used is cotton fiber. After testing, the surface fuzzing and pilling grade is level 3 after constant friction.
  • Embodiment 1 with a size of 30cm x 30cm was installed in the drum, put the six legs into the drum, and took it out after 12,000 revolutions. It was found that the surface appearance was intact, with slight lint loss, and no serious wear.
  • Example 4 Take a 30x30cm size and the preparation method is basically the same as in Example 4. The difference is that the material used is cotton fiber and has not been subjected to moisture heat treatment. Install it in the rotating drum, put the six legs into the rotating drum, and pass through After taking it out after 12,000 revolutions, it was found that the surface was severely worn and the blanket yarn threads had dropped significantly.
  • the carpet of the present invention has better uprightness than cotton carpets and ordinary polyester and nylon carpets, has a significantly reduced lint loss rate, and is convenient for daily cleaning at home.
  • the present invention has the following beneficial effects:
  • This product uses matt and semi-matt yarns. After passing through the dry and wet heat box, the top of each filament bundle forms a radiating and curved pile, giving it a cotton-like feel and a carpet surface luster more like cotton. Similar to carpets, the carpet surface layer made of multiple tows of fine denier DTY of 0.4D-5D also has excellent water absorption properties;
  • the present invention can be washed multiple times with little change in appearance, and is not prone to clumping during long-term normal use.
  • the present invention Compared with cotton carpets, the present invention has long-term durability and no short fiber falling phenomenon. At the same time, it has better dehydration performance than cotton carpets.
  • the carpet of the present invention does not need to add any additives during the preparation process to avoid environmental pollution; even if it is produced using a water tank, the water inside can be recycled multiple times.
  • the carpet embryos are rolled by the machine and subjected to high-temperature friction, forming upright filament bundles under the action of centrifugal force.
  • the hair roots are upright and bundled, and the piles are slightly scattered and bent.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Carpets (AREA)

Abstract

本发明涉及一种地毯，本发明的地毯包括毯面层和底面层，所述地毯是将胚毯放入干湿热坯布定型装置中，让毯面层与箱体的内壁及自身相互摩擦制得。将胚毯放入滚动或抖动的湿热箱体进行翻滚定型加工，毯面层的绒面与箱体的内壁及自身相互摩擦，同时在离心力的作用下，绒面的丝束根部定形且每股丝束挺立，避免了丝束之间互相结团；每根丝束的最顶端在摩擦力和高温的作用下形成轻微弯曲的散发状的绒头，使其外观呈现棉质纤维的外观。

Description

一种地毯 技术领域
本发明属于地毯领域，具体涉及一种地毯。本发明设计一种地毯制备工艺。
背景技术
地毯作为一种广受欢迎的地面装饰材料早已进入千家万户。用于地毯的材料有多种，其中棉质地毯因其舒适的触感、高吸湿性能及其优良染色性能广受消费者喜爱。
但目前市面上的棉质地毯由于棉花本身的木质素短纤维的特性导致棉质地毯容易吸湿吸潮，如果存放不当易发生霉变：而且将棉质地毯的放入洗衣机清洗时，短纤维容易脱落，而且需要花很长时间脱水烘干或晒干；如长时间与阳光接触晒干，棉纤维会产生黄变和发脆现象。根据本发明人调查，目前市场上有许多消费者急迫希望有一种地毯，既具有棉质地毯的外观及触感以及优良的吸水性能，同时又能避免现有棉质地毯的掉绒多，易老化，易发霉，不易脱水烘干等缺点。
发明内容
本发明为了解决上述技术问题，本发明提供一种地毯。
本发明的目的可以通过以下方案来实现：
第一方面，本发明的实施例提供了一种地毯，所述地毯包括绒面层和基布层；所述绒面层是在基布上进行织造所得；所述地毯是通过将织有绒面层的基布层放入干湿热坯布定型装置中翻滚定型加工，让绒面层与箱体的内壁及自身相互摩擦，使绒面层的丝束定型制得；所述干湿热坯布定型装置为具备滚动和/或抖动功能的干湿热箱体加工装置。
进一步的，所述地毯还包括复合在基布层底部的底背层。底背层的背部还可进行防滑处理。
本发明地毯放入滚动或抖动的干湿热坯布定型装置中进行翻滚定型加工时，毯面层的绒面与箱体的内壁及自身相互摩擦，同时在离心力的作用下，绒面的丝束根部定形且每股丝束挺立，避免了丝束之间互相结团；每根丝束的最顶端在摩擦力和高温的作用下形成轻微弯曲的散发状的绒头，使其外观呈现棉质纤维的外观，且经过翻滚定型加工后的毯面的丝束根部挺立，丝束之间不容易相互纠缠，丝束最顶端产生散发性轻微弯曲的绒头。通过加湿处理使纱线软化、容易集束，再通过加热处理定型，这样的地毯的绒面 经过100℃以内的多次水洗烘干后依然较好地保持表面形态。
进一步的，所述干湿热坯布定型装置包括滚球机、溢流缸、工业洗衣机、平洗烘干一体机中的一种。干湿热坯布定型装置进行干湿热处理，包括干热、湿热、干湿热处理中的一种，
进一步的，所述干湿热坯布定型装置的加热温度为45-160℃。
进一步的，所述绒面层通过簇绒工艺在基布上进行织造所得。
进一步的，所述毯面层所使用的纱线为单股或多股的消光或半消光DTY丝束并线合股，通过加捻或打网络结制成的消光或半消光DTY股线。
进一步的，所述消光或半消光DTY丝束是将初生丝或FDY丝束后经过加弹、拉伸变形所得。
优选地，将多根DTY丝束通过合股加捻制得DTY股线。合股加捻后的股线捻向为S或Z捻，倍捻捻度为35T/M-150T/M。优选的，DTY丝束为S+Z加捻形态的涤纶或尼龙丝束。
进一步的，所述消光或半消光的DTY丝束中的单根丝的线密度(DPF)为0.40DENIER-5.00DENIER。
进一步的，所述消光或半消光DTY股线的线密度为75D-12000D。
进一步的，所述消光或半消光DTY股线在纱线定型机中进行热定型处理，纱线定型机的定型温度为80-190℃。
进一步的，还可以将消光或半消光DTY丝束在纱线网络机上先打网络结后再合股成股线。所述打网络结为中、重网，防止纱线在后工序中散开。
可选的，所述底背层的材料包括热塑弹性体、天然橡胶、热熔胶、具有防滑功能或有勾连作用的面料中的一种。
第二方面，本发明还涉及一种地毯的制备方法，所述方法包括如下步骤：
S1、制备纱线：选取初生丝或拉伸丝丝束，经过加弹、拉伸变形制成DTY丝束，将单股或多股DTY丝束并线合股后，通过加捻或打网络结制成股线；
S2、织造工艺：使用步骤S1制得的DTY股线使用簇绒工艺在基布层上进行织造，得胚毯；
S3、翻滚定型加工：将步骤S2中织造好的毯面面料，放入干湿热坯布定型装置中翻滚定型加工，让毯面与箱体或缸体及自身摩擦，制得棉质风格的毯面；
S4、制得底背层：将步骤S3中处理好的毯面，在胚毯背面制得底背层，得所述地 毯。
进一步的，步骤S1中的选用纱线还可以是由再生的消光及半消光涤纶、尼龙纱线。
可选的，步骤S2中胚毯织造完成后，进行固绒处理。所述固绒处理包括胶类固绒、火焰复合固绒中的一种。
进一步的，步骤S3中放入胚毯可以为卷毯或片毯。所述片毯进行干湿热处理时，也可以可将复合好底背层的片毯进行翻滚定型处理。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本发明的其它特征、目的和优点将会变得更明显：
图1为本发明的实施例1地毯的示意图；
图2为实施例1地毯干湿热处理前后的侧视图；其中，a为干湿热处理前的侧视图，b为干湿热处理前的侧视图；
图3为实施例1地毯干湿热处理前后的俯视图；其中，a为干湿热处理前的俯视图，b为干湿热处理前的俯视图；
图4为本发明的实施例4地毯的示意图；
其中，1、绒面层，2、基布层，3、底背层。
具体实施方式
下面结合附图和具体实施例对本发明进行详细说明。以下实例在本发明技术方案的前提下进行实施，提供了详细的实施方式和具体的操作过程，将有助于本领域的技术人员进一步理解本发明。需要指出的是，本发明的保护范围不限于下述实施例，在本发明的构思前提下做出的若干调整和改进，都属于本发明的保护范围。
实施例1
本实施例涉及一种地毯，如图1所示，包括，基布层2，在基布层2上织造所得的绒面层1，在基布层2底部复合的底背层3。该地毯制备包括如下步骤：
步骤一，制备纱线：选用300D/192F的涤纶初生丝丝束，使用拉伸变形工艺制作拉伸变形的丝束，单根丝束形态为S+Z的假捻形态，再将6股S+Z形态的丝束并线、加捻成股线，捻度为50T/m，总D数为1800D。然后将股线放入将松式定型机上进行定型处理，定型温度为150℃；
步骤二，制造工艺：将步骤1制得的纱线使用针距3/16的割绒簇绒机，在长纤基布上进行簇绒。
步骤三，固绒工艺：将步骤2织造好的胚毯使用热熔胶在毯背上进行固绒处理,热熔胶熔化温度为180℃。
步骤四，翻滚定型加工：将步骤3中固绒后的面料放入滚球机中进行干湿热处理，使毯面的绒面与箱体内壁及自体滚动摩擦；滚球机箱体内部温度为120℃，蒸汽温度为100℃；蒸汽用量2公斤；
步骤五，制得底背层：使用TPE在步骤4)制得的毯面层背部进行防滑处理。
实施例2
本实施例涉及一种地毯，该地毯制备包括如下步骤：
步骤一，制备纱线：选用300D/288F的尼龙DTY轻网丝束，再使用重网工艺将4根丝束合股，总D数为1200D，网络结个数为50个/米，捻度为40T/m。
步骤二，制造工艺：将步骤1中的纱线使用1/10割绒簇绒机在网络丝基布上进行簇绒。
步骤三，固绒工艺：将步骤2织造好的胚毯使用EVA水性胶在毯面层背部上进行固绒处理，烘干温度为130℃。
步骤四，翻滚定型加工：将步骤3中固绒好的胚毯，放入工业洗衣机中进行使毯面的绒面与水流，缸体内壁及地毯自身摩擦。缸体内部水温温度为80℃。
步骤五，将定型后的毯面层脱水烘干；
步骤六，制得底背层：使用发泡乳胶在毯背进行防滑处理。
实施例3
本发明涉及一种地毯，该地毯制备包括如下步骤：
1)制备纱线：将废旧塑料瓶收集、清洗、高标准分类、切片、造粒、纺丝后加弹、拉伸变形制成DTY多股丝束并线加捻制成股线，总D数为4500D，捻向为S捻，捻度为90T/m。
2)制造工艺：将步骤1中的纱线，使用剑杆织机进行织造。
3)翻滚定型加工：将步骤2中制好的面料放入工业洗衣机中，使毯面与机器内壁及水流滚动进行摩擦；水温为100℃。
4)复合工艺：将步骤3中制好的面料使用热熔胶机复合无纺布。
5)制得底背层：使用丁苯乳胶在毯背上进行防滑处理。
实施例4
本发明涉及一种地毯，如图4所示，包括，基布层2，在基布层2上织造所得的绒 面层1。该地毯制备包括如下步骤：
1)制备纱线：选用300D/48F的涤纶初生丝丝束，使用拉伸变形工艺制作拉伸变形的丝束，形态为S+Z，再将8股S+Z的丝束并线、加捻成股线，捻度为50T/m，总D数为2400D。然后将股线放入将松式定型机上进行定型处理，定型温度为150℃；
2)制造工艺：将步骤1制得的纱线使用针距1/4的割绒簇绒机，在丙纶基布上进行簇绒。
3)复合工艺：将步骤2)织好的胚毯使用PUR热熔胶在毯背上复合180克/平方米的涤纶起绒布,热熔胶熔化温度为180℃。
4)翻滚定型加工：将步骤3中固绒后的面料放入滚球机中进行干湿热箱体，使毯面的绒面与箱体内壁及自体滚动摩擦；滚球机箱体内部温度为120℃，蒸汽温度为100℃；蒸汽用量1.80公斤。
性能对比试验验证
水洗测试
取30x30cm大小的实施例1中的地毯，使用家用洗衣机130W功率，水温为45℃，经过一次30分钟水洗发现表面绒毛未见明显掉毛、结团，水洗15次发现表面绒毛未见明显掉毛，结团现象。
取30x30cm大小的实施例3中的地毯，使用家用洗衣机130W功率，水温为45℃，经过一次30分钟水洗发现表面绒毛未见明显掉毛、结团，水洗15次发现表面绒毛未见明显掉毛，结团现象。
取30x30cm大小与实例1制备方法基本相同，不同之处在其使用的材质为棉纤维且未经过湿热处理，使用家用洗衣机130W功率，水温为45℃，经过一次30分钟水洗发现表面绒毛有明显掉落迹象，水洗15次发现表面绒毛掉落更加明显。
取30x30cm大小与实例3制备方法基本相同，不同之处在没有经过湿热处理，使用家用洗衣机130W功率，水温为45℃，经过一次30分钟水洗发现表面绒毛有明显结团现象，水洗15次发现表面绒毛大部分结团在一块。
起毛起球测试
使用马丁代尔法，取实施例1中的地毯，进行测试，通过不断摩擦后，表面起毛起球等级为4级。
使用马丁代尔法，取实施例1制备方法基本相同，不同之处在其使用的材质为棉纤维，进行测试，通过不断摩擦后，表面起毛起球等级为3级。
使用马丁代尔法，取实施例3的地毯，进行测试，通过不断摩擦后，表面起毛起球等级为4级。
使用马丁代尔法，取实施例3制备方法基本相同，不同之处在其使用的材质为棉纤维，进行测试，通过不断摩擦后，表面起毛起球等级为3级。
六足滚筒测试
1、30cm x 30cm大小的实施例1，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面外观完好，有轻微掉毛现象，没有严重磨损。
2、30cm x 30cm大小的取30x30cm大小与实例1制备方法基本相同，不同之处在其使用的材质为棉纤维且未经过湿热处理，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面严重磨损且毯面纱线掉落明显。
3、30cm x 30cm大小的实施例4，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面外观完好，有轻微掉毛先，没有严重磨损。
4、取30x30cm大小与实施例4制备方法基本相同，不同之处在其使用的材质为棉纤维且未经过湿热处理，将其安装在转鼓内，将六足放入转鼓内，进过12000转后取出，发现表面严重磨损且毯面纱线掉落明显。
由综上试验数据可得，本发明中的地毯比棉质地毯及普通涤纶、尼龙地毯直立性更好，掉毛率大幅度减少，且方便家庭日常清洗。
与现有技术相比，本发明具有如下有益效果：
1、本产品使用消光及半消光的纱线经过干湿热箱体后，每根丝束的顶端形成呈散发状弯曲的绒头，使其具有类似棉手感的效果并且毯面光泽更像棉类地毯，而用由多根0.4D-5D的细旦DTY构成的丝束制得的毯面层同样具有优异的吸水性能；
2、本发明与现有涤纶地毯相比可多次水洗并且外观变化小，并且长时间正常使用过程中不容易结团。
3、本发明与棉类地毯相比长时间的使用耐久性、无短纤维掉落现象，同时比棉质地毯具有更优的脱水性能。
4、本发明的地毯在制备过程中无需添加任何的助剂从而避免造成环境污染；即便使用水流缸时生产，内部的水可以多次循环使用。在干湿热箱体过程中地毯胚毯随着机器滚动、高温摩擦，在离心力的作用下形成挺立的丝束，直立集束的毛根且绒头呈轻微的散发性弯曲。
以上对本发明的具体实施例进行了描述。需要理解的是，本发明并不局限于上述特 定实施方式，本领域技术人员可以在权利要求的范围内做出各种变形或修改，这并不影响本发明的实质内容。

Claims (10)

  1. 一种地毯，其特征在于，所述地毯包括绒面层和基布层；所述绒面层是在基布上进行织造所得；所述地毯是通过将织有绒面层的基布层放入干湿热坯布定型装置中翻滚定型加工，让绒面层与箱体的内壁及自身相互摩擦，使绒面层的丝束定型制得；所述干湿热坯布定型装置为具备滚动和/或抖动功能的干湿热箱体加工装置。
  2. 根据权利要求1所述的地毯，其特征在于，所述地毯还包括复合在基布层底部的底背层。
  3. 根据权利要求1所述的地毯，其特征在于，所述干湿热坯布定型装置包括滚球机、溢流缸、工业洗衣机、平洗烘干一体机中的一种。
  4. 根据权利要求1所述的地毯，其特征在于，所述干湿热坯布定型装置的加热温度为45℃-160℃。
  5. 根据权利要求1所述的地毯，其特征在于，所述绒面层所使用的纱线为单股或多股的消光或半消光DTY丝束并线合股，通过加捻或打网络结制成的消光或半消光DTY股线。
  6. 根据权利要求5所述的地毯，其特征在于，所述消光或半消光DTY丝束是将初生丝或FDY丝束后经过加弹、拉伸变形所得。
  7. 根据权利要求5所述的地毯，其特征在于，所述消光或半消光的DTY丝束中的单根丝的线密度为0.40DENIER-5.00DENIER。
  8. 根据权利要求5所述的地毯，其特征在于，所述消光或半消光DTY股线的线密度为75D-12000D。
  9. 根据权利要求5所述的地毯，其特征在于，所述消光或半消光DTY股线在纱线定型机中进行热定型处理，纱线定型机的定型温度为80℃-190℃。
  10. 一种地毯的制备方法，其特征在于，所述方法包括如下步骤：
    S1、制备纱线：选取初生丝或拉伸丝丝束，经过加弹、拉伸变形制成DTY丝束，将单股或多股DTY丝束并线合股后，通过加捻或打网络结制成消光或半消光DTY股线；
    S2、织造工艺：使用步骤S1制得的DTY股线使用簇绒工艺在基布层上进行织造，得胚毯；
    S3、翻滚定型加工：将步骤S2中织造好的毯面面料，放入干湿热坯布定型装置中翻滚定型加工，让毯面与箱体或缸体及自身摩擦，制得棉质风格的毯面；
    S4、制得底背层：将步骤S3中处理好的毯面，在胚毯背面制得底背层，得所述地毯。
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