Tufted Carpet
Textile Fibers, Dyes, Finishes and Processes
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This book combines Von Moody's original work and research in the carpet industry with the well respected 1986 textile source book, Textile Fibers, Dyes, Finishes, and Processes: A Concise Guide, by Howard L. Needles to produce a unique practical guide on all aspects of the preparation, manufacture, and performance of carpet. It addresses the structure and properties of fiber, carpet construction, coatings, dyes, finishes, performance, and recycling, among other topics. This volume is an indispensable reference for all practitioners in the carpet industry.
Readership
Professionals and technicians throughout the entire carpet industry (and suppliers of the industry as well) will find this book invaluable to their activities.
Table of Contents
- Part 1: Introduction to Carpet Fiber
1. Fiber Theory and Formation
1.1 FIBER CLASSIFICATION
1.2 FIBER PROPERTIES
1.2.1 Primary Properties
1.2.2 Secondary Properties
1.2.3 Primary Fiber Properties from an Engineering Perspective
1.3 FIBER FORMATION AND MORPHOLOGY
1.3.1 Polymer Formation
1.3.2 Fiber Spinning
1.3.3 Fiber Drawing and Morphology
1.3.4 Bulking and Texturizing
1.3.5 Staple Formation
1.4 STRUCTURE PROPERTY RELATIONSHIPS
2. Fiber Indentification and Characterization
2.1 FIBER IDENTIFICATION
2.1.1 Microscopic Identification
2.1.2 Solubility
2.1.3 Heating and Burning Characteristics
2.1.4 Density or Specific Gravity
2.1.5 Staining
2.2 STRUCTURAL, PHYSICAL, and CHEMICAL CHARACTERIZATION
2.2.1 Optical and Electron Microscopy
2.2.2 Elemental and End-Group Analysis
2.2.3 Infrared Spectroscopy
2.2.4 Ultraviolet-Visible Spectroscopy
2.2.5 Nuclear Magnetic Resonance Spectroscopy
2.2.6 X-Ray Diffraction
2.2.7 Thermal Analysis
2.2.8 Molecular Weight Determination
2.2.9 Mechanical and Tensile Property Measurements
2.2.10 Specific Gravity
2.2.11 Environmental Properties
2.2.12 Chemical Properties
2.3 END-USE PROPERTY CHARACTERIZATION
2.3.1 Characteristics Related to Identity, Aesthetics and Comfort
2.3.2 Characteristics Related to Durability and Wear
2.3.3 Physical and Chemical Characteristics
3. Major Fiber and Their Properties
3.1 NYLON 6 and NYLON 6,6 FIBERS
3.1.1 Structural Properties
3.1.2 Effect of Single-Step Versus Two-Step Production of Nylon
3.1.3 Physical Properties
3.1.4 Chemical Properties
3.1.5 Nylon End-Use Properties
3.2 POLYESTER FIBERS
3.2.1 Structural Properties
3.2.2 Physical Properties
3.2.3 Chemical Properties
3.2.4 Polyester End-Use Properties
3.3 ACRYLIC FIBERS
3.3.1 Structural Properties
3.3.2 Physical Properties
3.3.3 Chemical Properties
3.3.4 Acrylic End-Use Properties
3.4 MODACRYLIC FIBERS
3.4.1 Structural Properties
3.4.2 Physical Properties
3.4.3 Chemical Properties
3.4.4 Modacrylic End-Use Properties
3.5 POLYOLEFIN FIBERS
3.5.1 Polyethylene and Polypropylene
3.5.2 Structural Properties
3.5.3 Physical Properties
3.5.4 Chemical Properties
3.5.5 Polyolefin End-Use Properties
3.6 WOOL
3.6.1 Structural Properties
3.6.2 Physical Properties
3.6.3 Chemical Properties
3.6.4 Wool End-Use Properties
Part 2: Carpet Making
4. Yarn Formation
4.1 WOOLEN AND WORSTED SYSTEMS
4.2 STAPLE SYSTEMS
4.3 FILAMENT SYSTEMS
5. Primary and Secondary Backing Construction
5.1 WOVEN
5.1.1 Woven Primary or Secondary Backing Manufacture
5.1.2 Textile Substrate Formation
5.1.3 Weaving
5.1.4 Shedding Mechanism
5.1.5 Fill Insertion
5.2 NONWOVEN
5.2.1 Nonwoven Primary or Secondary Backing Formation
5.2.2 Mechanical Bonding or Entanglement of Nonwovens
5.2.3 Stitching or Stitch Bonding
5.2.4 Self Bonding
5.2.5 Adhesive Bonding
5.3 COMPOSITE FORMATION
5.4 NEW TUFTING PRIMARY BACKINGS
6. Carpet Construction
6.1 DESCRIPTION OF LAYERS OF PILE CARPET
6.1.1 Primary Backings
6.1.2 Loop Pile Created by Tufting
6.1.3 Shearing
6.1.4 Secondary Backing
6.2 FINISHING
Part 3: Coatings, Raw Materials, and Their Processes
7. Latex Coatings
7.1 LATEX COMPOUNDS
7.1.1 Filler
7.1.2 Surfactants
7.1.3 Thickeners
7.1.4 Water
7.1.5 Flame Retardants
7.1.6 Miscellaneous
7.2 EXAMPLES OF LATEX COMPOUNDS
7.3 EFFECT OF FILLER ON LATEX COATED CARPET
7.4 EFFECT OF DENIER ON TUFTBIND
7.5 FLAME RETARDANCY
7.6 SUMMARY
Polyurethane Coating
8.1 POLYURETHANE RAW MATERIALS AND BASIC CHEMISTRY
8.2 MECHANICALLY FROTHED POLYURETHANE
8.3 WATER-BLOWN POLYURETHANE
Cushion
9.1 RESIDENTIAL
9.2 COMMERCIAL
9.3 FOAM PERFORMANCE
9.4 CUSHIONS AND PADS
10. Polyvinyl Chloride Plastisol Coating
10.1 RAW MATERIALS
10.1.1 Dispersion Resin
10.1.2 Blending Resin
10.1.3 Plasticizer
10.1.4 Stabilizers
10.1.5 Thixotropic Agents
10.1.6 Surfactants
10.1.7 Pigments
10.1.8 Fillers
10.1.9 Lubricants
10.1.10 Blowing Agents
10.1.11 Solvents or Diluents
10.2 TROUBLESHOOTING
10.3 FORMULATION
10.4 DIMENSIONAL STABILITY
10.5 FLEXIBILITY
10.6 INDENTATION
10.7 CUTTING CARPET INTO TILE
10.8 IMPERMEABILITY
10.9 SUMMARY
11. Hot Melt Coating
11.1 DISCUSSION OF HOT MELTS
11.2 INGREDIENTS
11.2.1 Polymers
11.2.2 Resins
11.2.3 Wax
11.2.4 Filler
11.2.5 Oils
11.2.6 Antioxidants
11.2.7 Flame Retardants
11.3 HOT MELT COATING PROCESS
11.4 COMPOUNDING
11.5 EXAMPLES OF HOT MELT COATING COMPOUNDS
12. Extrusion Coating Technology
12.1 EXTRUSION COATING PROCESS
12.2 THE EXTRUDER
12.3 EXTRUDER DIE
12.4 DOWNSTREAM EQUIPMENT
12.5 POLYMERS AND COMPOUNDS
12.6 EXAMPLES OF EXTRUSION COATING COMPOUNDS
13. Carpet Tile Coatings and Reinforcements
13.1 COATING SYSTEMS FOR CARPET TILE
13.1.1 Polyurethane
13.1.2 Polyvinyl Chloride (PVC)
13.1.3 Hot Melt
13.1.4 Extrusion
13.2 FIBERGLASS REINFORCEMENT
13.3 SUMMARY
Part 4: Carpet Enhancers
14. Antimicrobial Agents
14.1 USE
14.2 BACTERIAL SOURCES AND CONDITIONS FAVORABLE TO GROWTH
14.3 ANTIMICROBIAL AGENT SELECTION AND CONSIDERATION
14.4 RESIDENTIAL APPLICATIONS
14.5 PROOF OF CLAIMS
14.6 MICROORGANISM STRUCTURE
14.7 TYPES OF ANTIMICROBIAL TREATMENTS
14.8 VARIOUS ANTIMICROBIAL TREATMENTS
14.9 TESTING
14.10 PLACEMENT OF ANTIMICROBIAL AGENTS
14.11 SUMMARY
15. Color, Dyes, Dyeing, and Printing
15.1 COLOR THEORY
15.1.1 The Munsell System
15.1.2 Additive and Subractive Systems
15.1.3 Commission Internationale de l'Eclairage System
15.2 DYES AND DYE CLASSIFICATION
15.2.1 Dyes Containing Anionic Functional Groups
15.2.2 Dyes Containing Cationion Groups (Basic Dyes)
15.2.3 Special Colorant Classes
15.2.4 Dyeing of Blends
15.3 APPLICATION METHODS AND FACTORS AFFECTING DYEING
15.3.1 Dyeing Methods
15.3.2 Printing Techniques
15.3.3 Physical Factors Affecting Dyeing
15.3.4 Chemical Reagents
15.4 DYES APPLIED TO FIBER CLASSES
15.4.1 Dyes for Protein Fibers
15.4.2 Dyes for Polyamide Fibers
15.4.3 Dyes for Polyester Fibers
15.4.4 Dyes for Acrylic Fibers
15.4.5 Dyes for Polyolefin Fibers
16. Stain Blockers and Fluorochemicals
16.1 BACKGROUND
16.2 STAIN RESIST CHEMICALS FOR NYLON CARPET
16.3 TECHNOLOGY AND CHEMISTRY
16.4 FLUOROCHEMICALS
16.5 STAIN RESISTANCE TECHNOLOGY
16.6 APPLICATION OF STAIN RESIST CHEMICALS
16.6.1 Basic Information
16.6.2 Development of the Foam Application
16.7 EXAMPLES OF STAIN RESISTANT APPLICATIONS
16.7.1 Batch Exhaust
16.7.2 Continuous Exhaust
16.7.3 Use in Drying Only
16.7.4 Foam Application
16.7.5 Exhaustion of Stain Blocker on Nylon
16.8 PERFORMANCE TESTING
Part 5: Performance, Cleaning, and Recycling
17. Performance Issues
17.1 STANDARDS AND TESTS
17.1.1 Standards and Tests for Carpets
17.1.2 Standards and Tests for Backing
17.2 APPEARANCE RETENTION
17.3 FLAMMABILITY
17.3.1 Pill Test
17.3.2 Discussion of Pill Test Results
17.3.3 Radiant Panel Test
17.4 SOUND ABSORPTION
17.4.1 Testing Terminology
17.4.2 Testing of Carpet
17.4.3 Impact Sound Insulation
17.5 OTHER PERFORMANCE ISSUES
17.5.1 Butylated Hydroxy Toluene (BHT) Yellowing
17.5.2 Discoloration from Stain Blockers
17.5.3 Pile Crush or Matting
17.5.4 Shading
17.5.5 Pilling
17.5.6 Fuzzing
17.5.7 Delamination or Backing Separation
17.5.8 Indentation
17.5.9 Static
17.5.10 Grinning
18. Maintenance and Cleaning
18.1 CLEANING METHODS AND EQUIPMENT
18.2 REMOVAL OF STAINS AND CLEANING HINTS
18.3 CLEANING STAINS AND SPILLS
18.3.1 Common Spill Removal
19. Recycling
19.1 DISCUSSION
19.2 USES
19.2.1 Plastic Lumber
19.2.2 Concrete Reinforcement
19.2.3 Asphalt Modification
19.2.4 Use in Soil
19.3 RECOVERY PROCESSES
19.3.1 Individual Carpet Component Separation
19.3.2 Compatiblization of Carpet Components
19.3.3 Depolymerization
19.4 EXAMPLES OF CARPET RECYCLING
19.4.1 Carpet Used for Energy
19.4.2 Company Specific Examples of Recycli
Product details
- No. of pages: 267
- Language: English
- Copyright: © William Andrew 2004
- Published: April 1, 2000
- Imprint: William Andrew
- eBook ISBN: 9780815519409
- Hardcover ISBN: 9781884207990
About the Authors
Von Moody
Affiliations and Expertise
Auburn University