Tufted Carpet. Textile Fibers, Dyes, Finishes, and Processes

1076_fm.pdf......Page 1
Bibliography......Page 0
Preface......Page 4
1076_fm_2.pdf......Page 7
Preface......Page 10
Table of Contents......Page 13
Part I. Introduction to Carpet Fiber......Page 21
1. Fiber Theory and Formation......Page 22
1.1 Fiber Classification......Page 23
1.2 Fiber Properties......Page 24
1.2.1 Primary Properties......Page 25
1.2.2 Secondary Properties......Page 26
1.2.3 Primary Fiber Properties from an Engineering Perspective......Page 29
1.3.1 Polymer Formation......Page 30
1.3.2 Fiber Spinning......Page 32
1.3.3 Fiber Drawing and Morphology......Page 35
1.3.4 Bulking and Texturizing......Page 37
1.3.5 Staple Formation......Page 39
1.4 Structure-Property Relationships......Page 40
2.1.1 Microscopic Identification......Page 41
2.1.5 Staining......Page 42
2.2.2 Elemental and End-Group Analysis......Page 43
2.2.5 Nuclear Magnetic Resonance Spectroscopy......Page 44
2.2.7 Thermal Analysis......Page 45
2.2.9 Mechanical and Tensile Property Measurements......Page 46
2.2.11 Environmental Properties......Page 47
2.2.12 Chemical Properties......Page 48
2.3.1 Characteristics Related to Identity, Aesthetics, and Comfort......Page 49
2.3.3 Physical and Chemical Characteristics and Response of Fiber to Its Environmental Surroundings......Page 51
3.1 Nylon 6 and Nylon 6,6 Fibers......Page 53
3.1.1 Structural Properties......Page 54
3.1.2 Effect of Single-Step versus Two-Step Production of Nylon......Page 55
3.1.3 Physical Properties......Page 56
3.1.5 Nylon End-Use Properties......Page 57
3.2.1 Structural Properties......Page 58
3.2.4 Polyester End-Use Properties......Page 60
3.3 Acrylic Fibers......Page 61
3.3.3 Chemical Properties......Page 62
3.3.4 Acrylic End-Use Properties......Page 64
3.4.2 Physical Properties......Page 65
3.4.4 Modacrylic End-Use Properties......Page 67
3.5.2 Structural Properties......Page 68
3.5.3 Physical Properties......Page 69
3.5.5 Polyolefin End-Use Properties......Page 70
3.6.1 Structural Properties......Page 71
3.6.2 Physical Properties......Page 74
3.6.3 Chemical Properties......Page 75
3.6.4 Wool End-Use Properties......Page 76
Part II. Carpet Making......Page 78
4. Yarn Formation......Page 79
4.1 Woolen and Worsted Systems......Page 80
4.3 Filament Systems......Page 81
5.1 Woven......Page 82
5.1.1 Woven Primary or Secondary Backing Manufacture......Page 83
5.1.2 Textile Substrate Formation......Page 84
5.1.3 Weaving......Page 85
5.1.4 Shedding Mechanisms......Page 87
5.1.5 Fill Insertion......Page 88
5.2.1 Nonwoven Primary or Secondary Backing Formation......Page 91
5.2.2 Mechanical Bonding or Entanglement of Nonwovens......Page 93
5.2.4 Self Bonding......Page 94
5.3 Composite Formation......Page 95
5.4 New Tufting Primary Backings......Page 96
6.1.1 Primary Backings......Page 97
6.1.2 Loop Pile Created by Tufting......Page 98
6.1.4 Secondary Backing......Page 103
6.2 Finishing......Page 104
Part III. Coatings, Raw Materials, and their Processes......Page 106
7.1 Latex Compounds......Page 107
7.1.2 Surfactants......Page 110
7.2 Examples of Latex Compounds......Page 111
7.4 Effect of Denier on Tuftbind......Page 113
7.5 Flame Retardancy......Page 115
7.6 Summary......Page 116
8.1 Polyurethane Raw Materials and Basic Chemistry......Page 117
8.2 Mechanically Frothed Polyurethane......Page 118
8.3 Water-Blown Polyurethane......Page 119
9.1 Residential......Page 121
9.2 Commercial......Page 122
9.3 Foam Performance......Page 123
9.4 Cushions and Pads......Page 124
10.1 Raw Materials......Page 126
10.1.3 Plasticizer......Page 127
10.1.7 Pigments......Page 128
10.2 Troubleshooting......Page 129
10.4 Dimensional Stability......Page 132
10.5 Flexibility......Page 133
10.9 Summary......Page 134
11.1 Discussion of Hot Melts......Page 135
11.2.4 Filler......Page 137
11.3 Hot Melt Coating Process......Page 138
11.5 Examples of Hot Melt Coating Compounds......Page 140
12.1 Extrusion Coating Process......Page 142
12.3 Extruder Die......Page 143
12.4 Downstream Equipment......Page 144
12.6 Examples of Extrusion Coating Compounds......Page 145
13. Carpet Tile Coatings and Reinforcements......Page 148
13.1.3 Hot Melt......Page 149
13.3 Summary......Page 150
Part IV. Carpet Enhancers......Page 152
14.1 Use......Page 153
14.2 Bacterial Sources and Conditions Favorable To Growth......Page 154
14.3 Antimicrobial Agent Selection and Consideration......Page 155
14.5 Proof of Claims......Page 156
14.7 Types of Antimicrobial Agents......Page 157
14.8 Various Antimicrobial Treatments......Page 158
14.9 Testing......Page 160
14.11 Summary......Page 161
15.1 Color Theory......Page 162
15.1.1 The Munsell System......Page 166
15.1.2 Additive and Subtractive Systems......Page 167
15.1.3 Commission Internationale de l'Eclairage System......Page 168
15.2.1 Dyes Containing Anionic Functional Groups......Page 169
15.2.3 Special Colorant Classes......Page 172
15.2.4 Dyeing of Blends......Page 173
15.3 Application Methods and Factors Affecting Dyeing......Page 174
15.3.1 Dyeing Methods......Page 175
15.3.2 Printing Techniques......Page 176
15.3.4 Chemical Reagents......Page 179
15.4.2 Dyes for Polyamide Fibers......Page 180
15.4.4 Dyes for Acrylic Fibers......Page 181
15.4.5 Dyes for Polyolefin Fibers......Page 182
16.1 Background......Page 183
16.2 Stain Resist Chemicals for Nylon Carpet......Page 184
16.3 Technology and Chemistry......Page 185
16.4 Fluorochemicals......Page 186
16.5 Stain Resistance Technology......Page 187
16.6 Application of Stain Resist Chemicals......Page 189
16.6.2 Development of the Foam Application......Page 190
16.7.3 Use in Drying Only......Page 194
16.7.5 Exhaustion of Stain Blocker on Nylon......Page 195
16.8 Performance Testing......Page 197
Part V. Performance, Cleaning, and Recycling......Page 198
17.1 Standards And Tests......Page 199
17.2 Appearance Retention......Page 200
17.3 Flammability......Page 201
17.3.1 Pill Test......Page 203
17.3.2 Discussion of Pill Test Results......Page 204
17.3.3 Radiant Panel Test......Page 208
17.4 Sound Absorption......Page 211
17.4.2 Testing of Carpet......Page 213
17.4.3 Impact Sound Insulation......Page 214
17.5.4 Shading......Page 215
17.5.7 Delamination or Backing Separation......Page 216
17.5.10 Grinning......Page 217
18.1 Cleaning Methods and Equipment......Page 218
18.2 Removal of Stains and Cleaning Hints......Page 219
18.3.1 Common Spill Removal......Page 220
19.1 Discussion......Page 222
19.2.2 Concrete Reinforcement......Page 223
19.3 Recovery Processes......Page 224
19.4.1 Carpet Used for Energy......Page 225
19.4.2 Company Specific Examples of Recycling......Page 226
Appendix: Carpet Test Methods......Page 228
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Bibliography......Page 239
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