Method of obtaining tufting coating

FIELD: manufacturing process.

SUBSTANCE: invention relates to the textile industry, in particular to a method for manufacturing tufted material, used as flooring, as well as for interior decoration. The method consists in applying a binder - fine hot melt polyethylene powder, on the secondary synthetic non-woven substrate. The binder while heated turns into a plastic condition. Then under pressure it connects the secondary substrate with a primary polypropylene woven substrate, stitched with pile of synthetic yarn. The application of the binder is carried out on the secondary substrate, while its progress and effect of temperature on top. The connection of the primary substrate and the secondary substrate with a binder in a plastic condition is carried out under a pressure of 0.3-0.7 MPa, while the impact of the temperature of the lower calender of 130°-150° C and the temperature of the upper calender of 50°-80° C. The primary substrate is fed directly into the joint area of layers, at a rate of admission of the secondary substrate with the binder. In the result manufacturability of the carpet is improved due to separation of stages of the binder melting and the layers connecting.

EFFECT: increased strength of binding of substrates across the surface while maintaining the appearance of the pile layer.

2 tbl, 6 ex, 2 dwg

 

The invention relates to the textile industry, in particular to a method of production of tufted material used as a floor covering, as well as for interior decoration.

The known method of production of tufted carpet, which is to promote primary substrate, stitched pile threads over the bath of molten thermoplastic binder, which is applied to the underside of the primary backing through the shaft, partially immersed in a bath of molten binder, with further advancement of the primary substrate and its connection with the second substrate through the pressure calenders. The disadvantages of this method is the uncontrolled application of thermoplastic binder and its long-term growth to areas of the joints, which leads to an excess or lack of binders for bonding, as well as partial hardening binders until the area of the joints that affects the quality of the adhesive joint (U.S. patent 5612113, CL VV 27/12, D06N 7/00, WV 003/02).

A known method of making tufted carpets, described in the book Enersave, HEPSERA "non-Woven rugs" (M: Legprombytizdat, 1986, p.66-69), which is applied on the wrong side of the primary backing, stitched pile yarn, La is exnovo compound, connection with a secondary substrate, the supply of the drying section. The disadvantages of this method is the formation of voids between the pile yarn on the wrong side of the primary substrate and the secondary substrate, resulting in embrittlement of the binder layer and its partial spalling when exposed to dynamic loads. For maintenance of the production line requires a separate chemical station for the preparation of the latex compound. The length of the drying section, which takes up to 20 meters, that is almost 1/3 of the entire production line. Carpet material obtained in this way, rather rigid and limited in use on raised surfaces.

The closest analogue of the claimed invention is a method for tufting coverage, outlined in the journal "Design. Materials. Technology" (Antonomasia, Avipoxviruses. Optimization of process duplication tufted carpet using hot melt powder. The study of strength properties of the resulting material, No. 3, 2009, p.27-30). The method of manufacture is to smooth the coating over the entire surface of the secondary substrate of polyethylene fine powder, the connection of the primary substrate, sewn cloth, with a secondary substrate with the binder, promotion and fixation layer between a through h is cut calenders, which affect the layers of the pressure and temperature of 130°C for 30 seconds. Carpeted floor, made this way, provides strength, flexibility carpet material, which allows its use on raised surfaces. The disadvantage of affecting the quality of the carpet material, is that when the connection of the primary substrate, stitched pile yarn with the second substrate, a shift caused binders and uneven redistribution. The influence of temperature on the stage of fixation leads to damage of the pile layer and affect the appearance of the carpet material.

The technical result of the created solution is to eliminate these disadvantages, namely: improving the manufacturability of the carpet due to the separation stages: melting a binder, and a connection layer, while enhancing the bonding strength over the entire surface due to the uniform distribution of the binder on the secondary substrate, preserving the appearance of the pile layer by connecting the primary and secondary substrates with different temperatures: lower calender 130-150°C, the upper calender 50-80°C.

This object is achieved in that in a method of producing tufted coating, coating binders, melkodispersnoj the hot-melt polyethylene powder occurs on the secondary synthetic non-woven substrate with a transition binder in a plastic state when heated, the connection under the pressure of the secondary substrate with a woven polypropylene primary backing, stitched pile of synthetic yarn, characterized in that the deposition of fine thermoplastic polyethylene powder is carried out on the secondary synthetic nonwoven substrate while it is progress and the impact of the above temperature, and the connection woven polypropylene primary backing, stitched synthetic pile, and secondary synthetic non-woven substrate with a binder in a plastic state carried out under a pressure of 0.3-0.7 MPa, while the influence of the temperature of the lower calender 130-150°C, and temperature the upper calender 50°-80°C, and the primary substrate is fed directly into the zone of connection layers, with the arrival rate of the secondary polozhki with the binder.

Significant indicators established technology are: the separation stages of the melt on the secondary substrate and further submission layers under pressure in the connection zone under pressure with exposure to different temperatures, which ensures the achievement of the technical result, in conjunction with other distinctive features of the solution.

Only h is discontinuous use of these techniques provides the achievement of the technical result only the stated set of actions with the regime indicators allows to make a conclusion about the significance of the differences.

The figure 1 presents schematic tufted cover, 1 - pile, 2 - primary substrate, 3 - binder, 4 - secondary substrate. The figure 2 presents a method of obtaining a tufted cover, where 5 - fine polyethylene hot-melt powder, 6 - dosing shaft, 7 - oscillating brush, 8 - vibrating screen, 9 - secondary substrate 10 to the primary backing, sewn cloth, 11 - impact zone temperature, 12 - upper nip calender, 13 - lower the presser calender, 14 - cooling zone, 15 - area of the winding of the finished tufted material.

The method of obtaining comprises several stages:

The source materials are:

Woven polypropylene primary backing, weighing 100-120 g/m2with a softening temperature not less than 150°C, stitched pile polyamide, polyester yarns, continuous hinges, the linear density of the pile threads 200-500 Tex, with the number of beams 10 cm on a duck and on the basis of from 35 to 50 loops, the pile height of up to 4.5 mm, the softening temperature of the pile should not be less than 100°C.

The secondary substrate, which is a non-woven needle-punched polypropylene or polyester with a surface density of 150-350 g/m2then what woman 2,0-2,8 mm, nerovnoi by weight not more than 8%, a breaking load along the length and width of not less than 180 H, with a softening temperature of not less than 155°C.

Binder, which is a hot-melt fine polyethylene powder, made in the form of separate particles by size of 40-200 μm, a softening temperature of 90-120°C, with a density applied on the secondary substrate 110 g/m2.

Technological process is modeled on the equipment presented on figure 2, which shows that the secondary synthetic nonwoven substrate 9, which moves with uniform velocity in the range of 5-20 m/min using a metering shaft 6, the oscillating brush 7 and shakers 8, evenly fine hot melt polyethylene powder with a density of deposition from 110 g/m2. Thermoplastic powder is fed through the mesh shaft over the entire width of the secondary substrate. With continued movement of the secondary substrate, coated with a binder, gets 20-30 seconds in the impact zone temperature 11, the polyethylene powder is transferred into a plastic state when heated and enters the upper layers of the secondary substrate. The longer the area softening of the binder, the higher the speed the manufacture of tufted carpets. Further, the material moves towards the area connected to the tion, at the same time with the same speed in the connection zone enters the primary backing, stitched pile. In the connection zone through calenders on layers simultaneously operates a pressure of 0.3-0.7 MPa and a temperature of 130-150°C. the temperature of the lower calender equal to the temperature in the zone of influence of temperature and the upper calender equal to 50-80°C, in order not to smooth over the pile, not to let any of the prints, and allows you to preserve original appearance. At the moment the connection is deep penetration of the binder into the secondary substrate, and the pile tufts located on the reverse side of the primary substrate, filling the space between the beams. The separation of the stages of melting the binder and the connection layers enables you to evenly distribute the glue over the entire surface of the tufted material. After the connection zone material enters the cooling zone cold air and then enters the wound. The technical result is achieved in that the binder in the form of hot-melt plastic binders come in a plastic state, penetrates the upper layers of the secondary substrate, pile yarn tufts and between them is located on the reverse side of the primary substrate, thus forming cell (hole) structure that completely surrounds the bundle of cloth on the reverse is the primary side of the substrate, bonding the pile is not only with the secondary substrate, but also with each other. Due to the applied pressure is obtained to achieve sufficient penetration of the binder into the secondary substrate, and the beams of cloth on the reverse side of the primary substrate. Thus, there is a single system that helps boost the strength of the tufted carpet material, as well as to give flexibility to the canvas.

Table 1 - Modal indices
Plot softening binderPressure calenders
The temperature in the area of heating, °CTime delay,The feed speed, m/sThe temperature of the lower calender, °CThe temperature of the upper calender, °CPressure calenders, MPa
130-15020-305-20130-15050-800,3-0,7

Table 2 - Quality indicators
Plot softening binderPressure calendersQuality indicators
The temperature in the area of heating, °CTime delay,The feed speed, m/sThe temperature of the lower calender, °CThe temperature of the upper calender, °CPressure calenders, MPaStrength, mnRigidity, MKN·cm2
1502020150800,725300345576
1503020150800,728500345527
1303020130800,722800345535
1503020150800,320600345498
150305150800,728100345583
1503020150500,728000345551

It has been experimentally confirmed that the material maintains flexibility and strength and can be used as a floor material for cut surfaces with heavy wear. Below is an example implementation of a technology with application of regime indicators and indicators of quality, durability, table 1, 2.

Tests tufted material was carried out according to GOST 14217-87 (ST SEV 5578-86) "textile Materials. Floor coverings. The method of determining the strength of fixing of the pile", GOST 15902.3-79 "non-woven Cloth. Strength determination methods", GOST 10550-93 "textile" Fabric. The method of determining the stiffness when the technology is baie", GOST 21530-76 "Carpets and rugs. Method for determining the resistance to abrasion pile surface, GOST 25191-82 Coatings and products carpet machinemade. The method of determining the thickness change under dynamic loading", European standard EN 985:1994 - test roller chair.

The analysis of the table of results shows that by using the separation stages of the melt binder on the secondary substrate and the future supply of primary and secondary substrates in the connection zone in conjunction with the actions of certain operational parameters improves the strength of the carpet material, at the same time maintains the flexibility of the tufted carpet material, which allows its use on raised surfaces and terrain, due to the properties of the polyethylene, as well as the applied pressure and the method of application of fine polyethylene binder. In addition, depending on the process parameters, for example, when the temperature of extrusion, the amount of binder, the exposure time under pressure, there is a possibility of regulation of economic indicators of production of tufted carpet, its properties of hardness and strength. Thus, the strength of the proposed material meets the requirements of TH IS T 28867-90 Coatings and products carpet nonwoven machinemade. General technical conditions".

The technological process is accelerated due to the fact that it requires time for drying binder that is quicker to carry out the step of hardening the binder and to avoid possible visible and invisible defects in material during application and hardening of the binder.

The melting point of the thread should be above the melting temperature of the binder.

The method of obtaining tufted coverings, consisting in the application of binder: fine hot melt polyethylene powder in the secondary synthetic non-woven substrate with a transition binder in a plastic state when heated, the connection under the pressure of the secondary substrate with a woven polypropylene primary backing, stitched pile of synthetic yarn, characterized in that the deposition of fine thermoplastic polyethylene powder is carried out on the secondary synthetic nonwoven substrate while it is progress and the impact of the above temperature, and the connection woven polypropylene primary backing, stitched synthetic pile, and secondary synthetic non-woven substrate with a binder in a plastic condition perform under pressure 0,3-0,7 MPa under the simultaneous effect of the rate is atural lower calender 130-150°C and the temperature of the upper calender 50-80°C, and the primary substrate is fed directly into the zone of connection of the layers with the arrival rate of the secondary substrate with the binder.



 

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