Tufted carpet

Polypropylene fibers are used for face pile of needle felt, tufted carpets, upholstery fabrics, etc. 

To make cut pile carpets, two strands of BCF yarns are twisted together and heat-set with steam using a Superba heat setting machine at 135-145 °C or at 175-195 °C when heat-set with super-heated steam in a Suessen. An experimental design experiment [94] showed the higher the heat set temperature, then the lower is the bulk of the final carpet, but there is an increase in the tip definition and walk performance. The tufted carpets are then dyed with disperse dyes at atmospheric boil [95] in a continuous or a batch process. PTT carpets showed excellent resiliency in walk test experiments, equivalent to a nylon and much better than both PET and polypropylene, had lower static charge of <3.5 kV, and were resistant to coffee, mustard, betadine, red acid dyes and other stains [96],... 

The types of textile structures that lend themselves to continuous dyeing methods are woven and tufted carpets. Continuous dyeing is designed for long runs of similar product it is a high-output method of dye application. 

ALCOGUM 9635 is a sodium polyacrylate thickener suitable for use in latex adhesives for the tufted carpet industry. 

Coating compound for hand-tufted carpets, ready for use. 

Another area where emulsion polymers have found broad acc tance is in the bonding of fibers. These fibers can all he of the same material, as in nonwoven-type structures or of different materials, such as in the woven and nonwoven composites utilized in tufted carpets. Optimized deposition of the polmer at fiber intersections rather than overall fiber coating and in some instances the copious use of inert fillers represent the art involved in developing properties at minimum cost. 

Polyethylene and polypropylene fibres are both used as fibre-forming for textile purposes. They are widely used in industrial fabrics. These two fibres can be bonded into non-woven fabric form and used as the base for tufted carpeting. Olefin fibres are relatively low in cost, but both the fibres have low melting points, low glass-transition temperatures and poor dyeability. 

Stabilization of Carboxylated Styrene Butadiene (X-SBR) Latices Carboxylated SBR latices are used as adhesives in applications where durability and flexibility are desired. Some of the major uses for X-SBR latex are in tufted carpet backing, paper coatings, wall and vinyl floor tile adhesives, and pressure-sensitive adhesives. Typically, discoloration is the first measure of the degradation of an X-SBR latex. Discoloration of a dried latex film can often be related to a loss of the physical properties and subsequently, to inferior performance in an adhesive formulation. Figure 9 illustrates the effects of adding an effective antioxidant system to an X-SBR latex on the level of discoloration as a result of static oven aging at 150°C (300°F). The addition of AO-4 alone... 

The consumption of polypropylene carpet in West Europe is about 0.5 MT, which is about 50% of all flooring materials for 2.6 billion sq.m. It is second to 3.6 billion sq.m, for nylon, whereas polyester is only used for bathroom rugs. Among the flooring materials used in West Europe, tufted carpet accounts for 60%. Among 500,000 tons of polypropylene carpet, tufted carpet accounts for 150 KT, machine woven, 130 KT, needle-punched, 100 KT, and carpet backing, 100 KT. 

As there are many textile products ranging from yams to carpets which have to be processed, many different drying processes are used by the textile industry. To complicate things further, various processes are used for the same product. Typical drying systems used by the textile industry for drying fabrics and tufted carpets are discussed in this chapter. 

Suction or perforated drum dryers are often used to dry fabrics, particularly nonwovens, and sometimes unbacked tufted carpets. These dryers usually consist of two or more perforated drums mounted horizontally in a compartment (Figure 38.8). Several two-drum compartments are typically linked together to form a complete machine. Fans draw air from the interior of the drums producing suction on the surface area in contact with the material. This suction holds the material to the surface of the drum permitting hot air to pass through the material being dried. A portion of the drum has no suction, which permits the material to transfer to the next drum without interference. 

The second type of through-air dryer commonly used to dry fabrics and unbacked tufted carpets is shown schematically in Figure 38.9. It is a convection oven with a tenter frame that controls the transverse dimension of the product... 

The bicomponent fibres are suitable for felts, needle-punched carpets and tiles and upholstery fabrics the appearance of these products is more pleasant than that of uncrimped fibres owing to the absence of gloss and they have a bulkier, softer handle. Continuous crimped yams could be suitable for certain types of stretch fabrics or knitted products but so far these products have not reached the commercial stage. Attempts to use the bicomponent fibres for tufted carpets have not been satisfactory so far for two reasons. One reason is that the resilience of the piles is less than that of wool or nylon. Another reason is that fibrillated fibres may show a tendency towards a further fibrillation under severe wear or abuse. 

Fig. 11.4 Schematic of (a) an automotive floor composite (500-900gsm) comprising an upper tufted carpet structure, back-coated scrim, and lower, thermoformable low density polyethylene (LDPE) acoustic layer (b) a boot sideliner comprising a preformed composite faced with a textile.

Uses Cement admixture elastomeric textile thread adhesives (cold-sealable pkg., selfsealing envelopes, leather/tile adhesives, pressure-sensitive) binder for tufted carpet anchor coatings, flock attachment, nonwoven fabrics carpet foam backings dampproofing formulations latex dipping compds. (gloves, contraceptives, balloons) molded latex foam natural rubber castings rubberized hair prods. in food-pkg. adhesives and pressure-sensitive adhesives... 

Carrageenan (Chondrus crispus) Sodium magnesium silicate binder, tufted carpet anchor coatings Natural rubber latex binder, uncoated tablets PEG-125... 

Carpet is a complex, multicomponent system. The tufted carpet, the most common type (90%) as shown in Figure 16.1, typically consists of two layers of backing (mostly polypropylene fabrics), joined by CaCOs-filled styrene-butadiene latex mbber (SBR), and face fibers (majority being nylon 6 and nylon 6,6 textured yams) tufted into the primary backing. The SBR adhesive is a thermoset material, which cannot be remelted or reshaped. The waste containing the SBR (postconsumer and some industrial waste) has not found suitable uses, and it forms the major part of the carpet waste going into the landfills. Figure 16.2 shows the typical masses for the various components [13]. 

Adhesives are used in tufted carpets to anchor and stabilize the yarns they can also be used to attach a foam backing or a laminated secondary backing. Latices predominate with SBR (cross-linked) being the most widely used EVA latex (see Ethylene-vinyl acetate copolymers) is cheaper but has lower bond strength and is water sensitive. Other adhesives used are PVC plastisols in carpet tiles and hot melts and two-component polyurethanes in top-quality products (because hot melts and polyurethanes are relatively expensive). 

Carpet backing n. A primary backing through which the carpet tuffs are inserted is always required for tufted carpets. The backing is usually made of woven jute or non-woven manufactured fiber fabrics. A secondary backing, again made of jute or manufactured fibers, is normally added at... 

Dynapoint process n. A continuous computer-controlled process for manufacturing tufted carpets with intricate patterns from undyed yarn. The carpet is dyed as it is tufted and the colors and pattern are clearly visible through the primary backing of the carpet. 

Extended length n. The length of a face pile yarn required to produce 1 in. of tufted carpet. 

Shag carpet n. A loosely tufted carpet construction with cut pile 1-5 in. in length and with greater than normal spacing between tufts. 

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