Tufted Carpet
1st Edition
Textile Fibers, Dyes, Finishes and Processes
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Table of Contents
Part 1: Introduction to Carpet Fiber
Fiber Theory and Formation
1 FIBER CLASSIFICATION
2 FIBER PROPERTIES
2.1 Primary Properties
2.2 Secondary Properties
2.3 Primary Fiber Properties from an Engineering Perspective
3 FIBER FORMATION AND MORPHOLOGY
3.1 Polymer Formation
3.2 Fiber Spinning
3.3 Fiber Drawing and Morphology
3.4 Bulking and Texturizing
3.5 Staple Formation
4 STRUCTURE PROPERTY RELATIONSHIPS
Fiber Indentification and Characterization
1 FIBER IDENTIFICATION
1.1 Microscopic Identification
1.2 Solubility
1.3 Heating and Burning Characteristics
1.4 Density or Specific Gravity
1.5 Staining
2 STRUCTURAL, PHYSICAL, and CHEMICAL CHARACTERIZATION
2.1 Optical and Electron Microscopy
2.2 Elemental and End-Group Analysis
2.3 Infrared Spectroscopy
2.4 Ultraviolet-Visible Spectroscopy
2.5 Nuclear Magnetic Resonance Spectroscopy
2.6 X-Ray Diffraction
2.7 Thermal Analysis
2.8 Molecular Weight Determination
2.9 Mechanical and Tensile Property Measurements
2.10 Specific Gravity
2.11 Environmental Properties
2.12 Chemical Properties
3 END-USE PROPERTY CHARACTERIZATION
3.1 Characteristics Related to Identity, Aesthetics and Comfort
3.2 Characteristics Related to Durability and Wear
3.3 Physical and Chemical Characteristics
Major Fiber and Their Properties
1 NYLON 6 and NYLON 6,6 FIBERS
1.1 Structural Properties
1.2 Effect of Single-Step Versus Two-Step Production of Nylon
1.3 Physical Properties
1.4 Chemical Properties
1.5 Nylon End-Use Properties
2 POLYESTER FIBERS
2.1 Structural Properties
2.2 Physical Properties
2.3 Chemical Properties
2.4 Polyester End-Use Properties
3 ACRYLIC FIBERS
3.1 Structural Properties
3.2 Physical Properties
3.3 Chemical Properties
3.4 Acrylic End-Use Properties
4 MODACRYLIC FIBERS
4.1 Structural Properties
4.2 Physical Properties
4.3 Chemical Properties
4.4 Modacrylic End-Use Properties
5 POLYOLEFIN FIBERS
5.1 Polyethylene and Polypropylene
5.2 Structural Properties
5.3 Physical Properties
5.4 Chemical Properties
5.5 Polyolefin End-Use Properties
6 WOOL
6.1 Structural Properties
6.2 Physical Properties
6.3 Chemical Properties
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
Polyvinyl Chloride Plastisol Coating
1 RAW MATERIALS
1.1 Dispersion Resin
1.2 Blending Resin
1.3 Plasticizer
1.4 Stabilizers
1.5 Thixotropic Agents
1.6 Surfactants
1.7 Pigments
1.8 Fillers
1.9 Lubricants
1.10 Blowing Agents
1.11 Solvents or Diluents
2 TROUBLESHOOTING
3 FORMULATION
4 DIMENSIONAL STABILITY
5 FLEXIBILITY
6 INDENTATION
7 CUTTING CARPET INTO TILE
8 IMPERMEABILITY
9 SUMMARY
Hot Melt Coating
1 DISCUSSION OF HOT MELTS
2 INGREDIENTS
2.1 Polymers
2.2 Resins
2.3 Wax
2.4 Filler
2.5 Oils
2.6 Antioxidants
2.7 Flame Retardants
3 HOT MELT COATING PROCESS
4 COMPOUNDING
5 EXAMPLES OF HOT MELT COATING COMPOUNDS
Extrusion Coating Technology
1 EXTRUSION COATING PROCESS
2 THE EXTRUDER
3 EXTRUDER DIE
4 DOWNSTREAM EQUIPMENT
5 POLYMERS AND COMPOUNDS
6 EXAMPLES OF EXTRUSION COATING COMPOUNDS
Carpet Tile Coatings and Reinforcements
1 COATING SYSTEMS FOR CARPET TILE
1.1 Polyurethane
1.2 Polyvinyl Chloride (PVC)
1.3 Hot Melt
1.4 Extrusion
2 FIBERGLASS REINFORCEMENT
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
Color, Dyes, Dyeing, and Printing
1 COLOR THEORY
1.1 The Munsell System
1.2 Additive and Subractive Systems
1.3 Commission Internationale de l'Eclairage System
2 DYES AND DYE CLASSIFICATION
2.1 Dyes Containing Anionic Functional Groups
2.2 Dyes Containing Cationion Groups (Basic Dyes)
2.3 Special Colorant Classes
2.4 Dyeing of Blends
3 APPLICATION METHODS AND FACTORS AFFECTING DYEING
3.1 Dyeing Methods
3.2 Printing Techniques
3.3 Physical Factors Affecting Dyeing
3.4 Chemical Reagents
4 DYES APPLIED TO FIBER CLASSES
4.1 Dyes for Protein Fibers
4.2 Dyes for Polyamide Fibers
4.3 Dyes for Polyester Fibers
4.4 Dyes for Acrylic Fibers
4.5 Dyes for Polyolefin Fibers
Stain Blockers and Fluorochemicals
1 BACKGROUND
2 STAIN RESIST CHEMICALS FOR NYLON CARPET
3 TECHNOLOGY AND CHEMISTRY
4 FLUOROCHEMICALS
5 STAIN RESISTANCE TECHNOLOGY
6 APPLICATION OF STAIN RESIST CHEMICALS
6.1 Basic Information
6.2 Development of the Foam Application
7 EXAMPLES OF STAIN RESISTANT APPLICATIONS
7.1 Batch Exhaust
7.2 Continuous Exhaust
7.3 Use in Drying Only
7.4 Foam Application
7.5 Exhaustion of Stain Blocker on Nylon
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
Maintenance and Cleaning
1 CLEANING METHODS AND EQUIPMENT
2 REMOVAL OF STAINS AND CLEANING HINTS
3 CLEANING STAINS AND SPILLS
3.1 Common Spill Removal
Recycling
1 DISCUSSION
2 USES
2.1 Plastic Lumber
2.2 Concrete Reinforcement
2.3 Asphalt Modification
2.4 Use in Soil
3 RECOVERY PROCESSES
3.1 Individual Carpet Component Separation
3.2 Compatiblization of Carpet Components
3.3 Depolymerization
4 EXAMPLES OF CARPET RECYCLING
4.1 Carpet Used for Energy
4.2 Company Specific Examples of Recycli
Description
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.
Details
- No. of pages:
- 267
- Language:
- English
- Copyright:
- © William Andrew 2004
- Published:
- 28th September 2004
- Imprint:
- William Andrew
- Hardcover ISBN:
- 9781884207990
- eBook ISBN:
- 9780815519409
Ratings and Reviews
About the Authors
Von Moody
Affiliations and Expertise
Auburn University
Howard L. Needles
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