Method for preparing poly (trimethylene terephthalate) carpet

Abstract

Disclosed is a method for preparing a poly(trimethylene terephthalate) carpet, in which the poly(trimethylene terephthalate) carpet is prepared from poly(trimethylene terephthalate) yarns through the post-processes comprising cabling, heat setting, tufting, dyeing, becking, and shearing. The poly(trimethylene terephthalate) yarns have advantages of improved quality, functionality, and workability by optimizing operating conditions of the steps.

What is claimed is:  
     
         1 . A method for preparing a poly(trimethylene terephthalate) carpet, comprising the steps of: 
 (A) cabling poly(trimethylene terephthalate) yarns;    (B) heat-setting twisted poly(trimethylene terephthalate) yarns with a density of 200 to 240 g/m by use of a Superba at a main tunnel temperature of 120 to 160° C. and a band speed of 4 to 9 m/min;    (C) tufting heat-set poly(trimethylene terephthalate) yarns at 5 to 15 stitches/inch;    (D) beck-dyeing a tufted carpet without carriers by use of a disperse dye under conditions of atmospheric pressure and a dyeing temperature of 90 to 100° C.;    (E) becking a dyed carpet; and    (F) shearing the resulting carpet.    
     
     
         2 . The method according to  claim 1 , wherein poly(trimethylene terephthalate) dope dyed yarns are used.  
     
     
         3 . The method according to  claim 1  or  2 , wherein the cabling step is carried out by Z-twisting the yarns at 180 to 250 twists/m to a two- or three-ply cable.  
     
     
         4 . The method according to  claim 1  or  2 , comprising the step of condensing poly(trimethylene terephthalate) yarns with the use of an intermingle machine at 400 to 1000 m/min under a air pressure of 4 to 8 bars without a heat-setting step.  
     
     
         5 . The method according to  claim 1  or  2 , further comprising the step of frieze processing before heat-setting.  
     
     
         6 . The method according to  claim 1  or  2 , wherein a pile height ranges from 4 to 18 mm for a cut pile style carpet and from 2.5 to 15 mm for a loop pile style carpet.  
     
     
         7 . The method according to  claim 1  or  2 , wherein the tufted carpet is dyed under conditions of OWF (an amount of an added dye based on the carpet) of 0.01 to 3%, a liquid ratio of 10:1 to 25:1, and a dispersing agent of 0.25 to 1.0 g/l.  
     
     
         8 . The method according to  claim 1  or  2 , further comprising the step of space dyeing the poly(trimethylene terephthalate) yarns in a single color or in six or fewer colors with the use of a multi color dyeing machine before the heat-setting step.  
     
     
         9 . The method according to  claim 1  or  2 , wherein said dyed carpet is coated with a latex composition consisting of base latex of 30 to 50%, CaCO 3  of 50 to 70%, dispersing agent, and viscosity enhancing agent, followed by being adhered to a second foundation cloth in the step of becking.  
     
     
         10 . The method according to  claim 1  or  2 , wherein the poly(trimethylene terephthalate) carpet is prepared from poly(trimethylene terephthalate) yarns spun through a nozzle having 40 or more holes with a Y-shaped cross section, a modification ratio of 1.5 to 3.5, and an arm angle of 5 to 40°.  
     
     
         11 . A poly(trimethylene terephthalate) carpet prepared by the method according to  claim 1 , having pile yarns with drawing strength of 2.0 kg or more, bonded fabric with peeling strength of 2.0 kg or more, and color fastness to washing, color fastness to rubbing, and color fastness to light of grade  4  or more with respect to Korean Industrial Standards.