Tufted Carpet

Part 1: Introduction to Carpet Fiber

1. Fiber Theory and Formation

2. 1 FIBER CLASSIFICATION

3. 2 FIBER PROPERTIES

4. 2.1 Primary Properties

5. 2.2 Secondary Properties

6. 2.3 Primary Fiber Properties from an Engineering Perspective

7. 3 FIBER FORMATION AND MORPHOLOGY

8. 3.1 Polymer Formation

9. 3.2 Fiber Spinning

10. 3.3 Fiber Drawing and Morphology

11. 3.4 Bulking and Texturizing

12. 3.5 Staple Formation

13. 4 STRUCTURE PROPERTY RELATIONSHIPS

14. Fiber Indentification and Characterization

15. 1 FIBER IDENTIFICATION

16. 1.1 Microscopic Identification

17. 1.2 Solubility

18. 1.3 Heating and Burning Characteristics

19. 1.4 Density or Specific Gravity

20. 1.5 Staining

21. 2 STRUCTURAL, PHYSICAL, and CHEMICAL CHARACTERIZATION

22. 2.1 Optical and Electron Microscopy

23. 2.2 Elemental and End-Group Analysis

24. 2.3 Infrared Spectroscopy

25. 2.4 Ultraviolet-Visible Spectroscopy

26. 2.5 Nuclear Magnetic Resonance Spectroscopy

27. 2.6 X-Ray Diffraction

28. 2.7 Thermal Analysis

29. 2.8 Molecular Weight Determination

30. 2.9 Mechanical and Tensile Property Measurements

31. 2.10 Specific Gravity

32. 2.11 Environmental Properties

33. 2.12 Chemical Properties

34. 3 END-USE PROPERTY CHARACTERIZATION

35. 3.1 Characteristics Related to Identity, Aesthetics and Comfort

36. 3.2 Characteristics Related to Durability and Wear

37. 3.3 Physical and Chemical Characteristics

38. Major Fiber and Their Properties

39. 1 NYLON 6 and NYLON 6,6 FIBERS

40. 1.1 Structural Properties

41. 1.2 Effect of Single-Step Versus Two-Step Production of Nylon

42. 1.3 Physical Properties

43. 1.4 Chemical Properties

44. 1.5 Nylon End-Use Properties

45. 2 POLYESTER FIBERS

46. 2.1 Structural Properties

47. 2.2 Physical Properties

48. 2.3 Chemical Properties

49. 2.4 Polyester End-Use Properties

50. 3 ACRYLIC FIBERS

51. 3.1 Structural Properties

52. 3.2 Physical Properties

53. 3.3 Chemical Properties

54. 3.4 Acrylic End-Use Properties

55. 4 MODACRYLIC FIBERS

56. 4.1 Structural Properties

57. 4.2 Physical Properties

58. 4.3 Chemical Properties

59. 4.4 Modacrylic End-Use Properties

60. 5 POLYOLEFIN FIBERS

61. 5.1 Polyethylene and Polypropylene

62. 5.2 Structural Properties

63. 5.3 Physical Properties

64. 5.4 Chemical Properties

65. 5.5 Polyolefin End-Use Properties

66. 6 WOOL

67. 6.1 Structural Properties

68. 6.2 Physical Properties

69. 6.3 Chemical Properties

70. 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

11. 1 RAW MATERIALS

12. 1.1 Dispersion Resin

13. 1.2 Blending Resin

14. 1.3 Plasticizer

15. 1.4 Stabilizers

16. 1.5 Thixotropic Agents

17. 1.6 Surfactants

18. 1.7 Pigments

19. 1.8 Fillers

20. 1.9 Lubricants

21. 1.10 Blowing Agents

22. 1.11 Solvents or Diluents

23. 2 TROUBLESHOOTING

24. 3 FORMULATION

25. 4 DIMENSIONAL STABILITY

26. 5 FLEXIBILITY

27. 6 INDENTATION

28. 7 CUTTING CARPET INTO TILE

29. 8 IMPERMEABILITY

30. 9 SUMMARY

31. Hot Melt Coating

32. 1 DISCUSSION OF HOT MELTS

33. 2 INGREDIENTS

34. 2.1 Polymers

35. 2.2 Resins

36. 2.3 Wax

37. 2.4 Filler

38. 2.5 Oils

39. 2.6 Antioxidants

40. 2.7 Flame Retardants

41. 3 HOT MELT COATING PROCESS

42. 4 COMPOUNDING

43. 5 EXAMPLES OF HOT MELT COATING COMPOUNDS

44. Extrusion Coating Technology

45. 1 EXTRUSION COATING PROCESS

46. 2 THE EXTRUDER

47. 3 EXTRUDER DIE

48. 4 DOWNSTREAM EQUIPMENT

49. 5 POLYMERS AND COMPOUNDS

50. 6 EXAMPLES OF EXTRUSION COATING COMPOUNDS

51. Carpet Tile Coatings and Reinforcements

52. 1 COATING SYSTEMS FOR CARPET TILE

53. 1.1 Polyurethane

54. 1.2 Polyvinyl Chloride (PVC)

55. 1.3 Hot Melt

56. 1.4 Extrusion

57. 2 FIBERGLASS REINFORCEMENT

58. 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

16. 1 COLOR THEORY

17. 1.1 The Munsell System

18. 1.2 Additive and Subractive Systems

19. 1.3 Commission Internationale de l'Eclairage System

20. 2 DYES AND DYE CLASSIFICATION

21. 2.1 Dyes Containing Anionic Functional Groups

22. 2.2 Dyes Containing Cationion Groups (Basic Dyes)

23. 2.3 Special Colorant Classes

24. 2.4 Dyeing of Blends

25. 3 APPLICATION METHODS AND FACTORS AFFECTING DYEING

26. 3.1 Dyeing Methods

27. 3.2 Printing Techniques

28. 3.3 Physical Factors Affecting Dyeing

29. 3.4 Chemical Reagents

30. 4 DYES APPLIED TO FIBER CLASSES

31. 4.1 Dyes for Protein Fibers

32. 4.2 Dyes for Polyamide Fibers

33. 4.3 Dyes for Polyester Fibers

34. 4.4 Dyes for Acrylic Fibers

35. 4.5 Dyes for Polyolefin Fibers

36. Stain Blockers and Fluorochemicals

37. 1 BACKGROUND

38. 2 STAIN RESIST CHEMICALS FOR NYLON CARPET

39. 3 TECHNOLOGY AND CHEMISTRY

40. 4 FLUOROCHEMICALS

41. 5 STAIN RESISTANCE TECHNOLOGY

42. 6 APPLICATION OF STAIN RESIST CHEMICALS

43. 6.1 Basic Information

44. 6.2 Development of the Foam Application

45. 7 EXAMPLES OF STAIN RESISTANT APPLICATIONS

46. 7.1 Batch Exhaust

47. 7.2 Continuous Exhaust

48. 7.3 Use in Drying Only

49. 7.4 Foam Application

50. 7.5 Exhaustion of Stain Blocker on Nylon

51. 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

19. 1 CLEANING METHODS AND EQUIPMENT

20. 2 REMOVAL OF STAINS AND CLEANING HINTS

21. 3 CLEANING STAINS AND SPILLS

22. 3.1 Common Spill Removal

23. Recycling

24. 1 DISCUSSION

25. 2 USES

26. 2.1 Plastic Lumber

27. 2.2 Concrete Reinforcement

28. 2.3 Asphalt Modification

29. 2.4 Use in Soil

30. 3 RECOVERY PROCESSES

31. 3.1 Individual Carpet Component Separation

32. 3.2 Compatiblization of Carpet Components

33. 3.3 Depolymerization

34. 4 EXAMPLES OF CARPET RECYCLING

35. 4.1 Carpet Used for Energy

36. 4.2 Company Specific Examples of Recycli

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.

Professionals and technicians throughout the entire carpet industry (and suppliers of the industry as well) will find this book invaluable to their activities.