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.

1 - 11 . (canceled)  
     
     
         12 . A method for preparing a poly(trimethylene terephthalate) carpet, comprising the steps of: 
 (A) cabling poly(trimethylene terephthalate) yarns;    (B) heat-setting cabled poly(trimethylene terephthalate) yarns by use of a heat-setting device at a main tunnel temperature of 120 to 160° C. and a band speed of 4 to 9 m/min, wherein 200 to 240 g of the yarns are put on each meter of a metal plate of the heat-setting device;    (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) backing a dyed carpet; and    (F) shearing the resulting carpet.    
     
     
         13 . The method according to  claim 12 , 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.  
     
     
         14 . The method according to  claim 12 , further comprising the step of frieze processing before heat-setting.  
     
     
         15 . The method according to  claim 12 , 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.  
     
     
         16 . The method according to  claim 12 , 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.  
     
     
         17 . The method according to  claim 12 , 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 backing.  
     
     
         18 . The method according to  claim 12 , 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°.  
     
     
         19 . A method for preparing a poly(trimethylene terephthalate) carpet, comprising the steps of: 
 (A) cabling poly(trimethylene terephthalate) dope dyed yarns;    (B) heat-setting the cabled poly(trimethylene terephthalate) dope dyed yarns by use of a heat-setting device at a main tunnel temperature of 120 to 160° C. and a band speed of 4 to 9 m/min, wherein 200 to 240 g of the yarns are put on each meter of a metal plate of the heat-setting device;    (C) tufting the heat-set poly(trimethylene terephthalate) dope dyed yarns at 5 to 15 stitches/inch;    (D) backing a tufted carpet; and    (E) shearing the resulting carpet.    
     
     
         20 . The method according to  claim 19 , 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.  
     
     
         21 . The method according to  claim 19 , further comprising the step of frieze processing before heat-setting.  
     
     
         22 . The method according to  claim 19 , 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.  
     
     
         23 . The method according to  claim 19 , 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 backing.  
     
     
         24 . The method according to  claim 19 , 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°.  
     
     
         25 . A method for preparing a poly(trimethylene terephthalate) carpet, comprising the steps of: 
 (A) cabling poly(trimethylene terephthalate) yarns;    (B) space dyeing the cabled poly(trimethylene terephthalate) yarns in a single color or in six or fewer colors with a multi color dyeing machine;    (C) heat-setting the dyed poly(trimethylene terephthalate) yarns by use of a heat-setting device at a main tunnel temperature of 120 to 160° C. and a band speed of 4 to 9 m/min, wherein 200 to 240 g of the yarns are put on each meter of a metal plate of the heat-setting device;    (D) tufting heat-set poly(trimethylene terephthalate) yarns at 5 to 15 stitches/inch;    (E) backing a tufted carpet; and    (F) shearing the resulting carpet.