Anti-skid carpet rubber pad

Abstract

The present invention discloses an anti-skid carpet rubber pad layer; the anti-skid carpet rubber pad layer comprises an anti-skid water-repellent layer of a bottom layer and a bonding layer of an upper layer, and the bonding layer is a single-sided fabric with a plurality of monofilament protrusions. The bonding layer is a single-sided fabric with protrusions made of monofilaments above 20D, or a single-sided structural layer formed by cutting open the middle of a three-dimensional mesh structure layer; the three-dimensional mesh structure layer is composed of two layers of warp knitted mesh cloth and a plurality of polyester, polypropylene or nylon monofilaments arranged vertically in the middle connecting the two layers of warp knitted mesh cloth. The anti-skid carpet rubber pad layer of the present invention can be used in combination with a variety of carpet surfaces, and has moderate bonding strength; the carpet surface will not be damaged during disassembly due to excessive bonding force, nor will the carpet surface be easily displaced or warped due to excessively low bonding force; it also has the advantages of being rollable and foldable, machine washable, easy to lay, and easy to transport.

Description

Technical Field

[0001] The invention relates to a carpet in the textile industry, in particular to an anti-skid carpet rubber pad layer. Background Art

[0002] There are two ways to design a standard bath mat: the first is to design it like a towel, so it can be washed. However, this mat is not slip-resistant and poses a safety hazard; the other method is to bond a non-slip material to the back of the carpet. This carpet is claimed to be washable, but once washed in the machine, it will separate or break, or the upper fabric and lower backing will separate. Moreover, the cumbersome design and manufacturing of traditional carpets and the high price hinder the versatility of such carpets. For example, it does not allow users to change carpets seasonally and as needed. Therefore, a carpet is needed that has the functions of a conventional carpet and allows users to separate the surface material of the carpet from the backing layer with non-slip and water-repellent properties, and remove and wash the surface material of the carpet.

[0003] Through searching the existing patent documents, it is found that the Chinese utility model patent with application number 201520843605.7 discloses a detachable anti-slip carpet; wherein, a plurality of evenly distributed and retractable sockets are provided on the top surface of the base layer; a plug corresponding to the sockets is provided on the bottom surface of the connecting layer; and the woolen layer is woven and fixed on the top surface of the connecting layer. The base layer is equivalent to a rubber cushion layer. However, the base layer can only be used in conjunction with a specific connecting layer; and the connection between the top surface of the base layer and the bottom surface of the connecting layer is inelastic, and there is an echo when people walk on it, and the sound insulation effect is poor; at the same time, when connecting, the plug and the socket must be completely aligned to be plugged in, which is inconvenient to operate and often requires professional construction personnel to operate; in addition, the plug is easily damaged during disassembly and cleaning, which seriously affects the service life.

[0004] CN 102711563 A provides a carpet with a cushion portion; the carpet is constructed by attaching a cover and a non-slip and non-absorbent cushion below to each other through a loop on the cover and a hook on the cushion through an interlocking mechanical connection. The interlocking mechanical connection is formed by VELCRO in the first embodiment. When the rubber cushion layer is used in combination with a soft carpet surface, a large force is likely to cause damage to the carpet, and it is not very convenient to disassemble. In the second embodiment, the interlocking mechanical connection is formed by a granular material layer on the cushion. The cover is made of velvet cloth, and the loops on it are fine and difficult to see with the naked eye; and the granular material layer on the rubber cushion layer is a gravel layer formed by heat-treating the short fibers of 3D-18D on the cushion; the connection strength between the gravel layer and the carpet cover is poor, and the carpet surface is easily displaced and warped; and because the granular material layer on the cushion is a gravel layer formed by heat-treating the fibers on the cushion, it cannot be curled or folded, and transportation is extremely inconvenient. Summary of the invention

[0005] The purpose of the present invention is to overcome the defects of the above-mentioned existing anti-slip carpet rubber pad layer, such as the excessively high bonding force when used in combination with the carpet surface, which easily damages the carpet surface during disassembly, the low bonding force affecting the use effect, the carpet surface is easily displaced and warped, and the rubber pad layer cannot be curled or folded, and provide an anti-slip carpet rubber pad layer.

[0006] The objective of the present invention is achieved through the following technical solutions:

[0007] The present invention relates to an anti-skid carpet rubber pad layer.

[0008] The anti-skid carpet rubber pad layer includes a bottom anti-skid water-repellent layer and an upper bonding layer, wherein the bonding layer is a warp-knitted mesh cloth with a plurality of polyester, polypropylene or nylon monofilament protrusions; or a single-sided tufted fabric or a single-sided flocked fabric with a plurality of polyester, polypropylene or nylon monofilament protrusions.

[0009] As an embodiment of the present invention, the angles between the polyester, polypropylene or nylon monofilament protrusions and the warp knitted mesh fabric, single-sided tufted fabric or single-sided flocked fabric are all 40° to 90°.

[0010] As an embodiment of the present invention, the height of the protrusions of the polyester or nylon monofilament on the bonding layer is 1.5 mm to 10 mm.

[0011] As an embodiment of the present invention, the bonding layer is a single-sided structural layer formed by cutting open the middle of a three-dimensional sandwich mesh cloth.

[0012] The three-dimensional sandwich mesh fabric is composed of upper and lower layers of warp knitted mesh fabric and a plurality of polyester, polypropylene or nylon monofilaments vertically arranged in the middle and connecting the upper and lower layers of warp knitted mesh fabric.

[0013] The three-dimensional sandwich mesh fabric is woven from 20D to 120D polyester, polypropylene or nylon monofilaments. More specifically, it is woven from 20D to 120D polyester monofilament yarns. When the polyester monofilament is lower than 20D, the polyester monofilament protrusions formed on the bonding layer are too soft, which will affect the bonding effect with the carpet.

[0014] The thickness of the three-dimensional sandwich mesh cloth is 2 mm to 20 mm. The area of ​​a single mesh on the upper and lower layers of the warp knitted mesh cloth is 0.2 square millimeters to 100 square millimeters.

[0015] As an embodiment of the present invention, the anti-slip and water-repellent layer is a foamed latex layer, a thermoplastic elastomer material layer, an acrylic resin layer, an EVA foam layer, a polyurethane foam layer, an XPE foam layer or an IXPE foam layer.

[0016] As an embodiment of the present invention, the anti-skid carpet rubber pad layer can be used in combination with a carpet surface.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] 1. The bonding surface of the anti-slip carpet rubber pad layer of the present invention adopts a single-sided structural layer formed by cutting open the middle of a three-dimensional sandwich mesh cloth. The polyester monofilament on the single-sided structural layer is integrated with the warp-knitted mesh cloth, which is not easy to fall off, thereby increasing the service life;

[0019] 2. The 20D-120D polyester monofilaments on the bonding surface of the anti-slip carpet rubber pad layer of the present invention can form thick, hard, and stiff protrusions, which can be easily inserted into the gaps of various carpet surfaces, and can also be easily and arbitrarily disassembled, and can be repeatedly disassembled for many times without damage;

[0020] 3. The anti-skid carpet rubber pad layer of the present invention can be used in combination with a variety of carpet surfaces, and the bonding strength is moderate; it will not damage the carpet surface during disassembly due to excessive bonding strength, nor will it cause the carpet surface to shift or warp easily due to too low bonding strength;

[0021] 4. The rubber cushion layer of the anti-skid carpet of the present invention can be rolled and folded, so it is convenient to transport. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Other features, objects and advantages of the present invention will become more apparent from the detailed description of non-limiting embodiments made with reference to the following drawings:

[0023] Figure 1 It is a structural schematic diagram of the anti-skid carpet rubber pad layer of the present invention;

[0024] Figure 2 It is a schematic diagram of the anti-skid carpet rubber pad layer of the present invention being used in combination with a carpet surface having a 3D mesh cloth bottom layer;

[0025] Among them, 1 is the surface layer, 2 is the adhesive layer, 3 is the 3D mesh cloth, 4 is the bonding layer, and 5 is the anti-slip and water-repellent layer. DETAILED DESCRIPTION

[0026] The present invention is described in detail below in conjunction with embodiments. The following embodiments will help those skilled in the art to further understand the present invention, but are not intended to limit the present invention in any form. It should be noted that, for those of ordinary skill in the art, some adjustments and improvements can also be made without departing from the concept of the present invention. These all belong to the protection scope of the present invention.

[0027] Example 1

[0028] This embodiment relates to an anti-slip carpet rubber pad layer, such as Figure 1 As shown, including:

[0029] The bottom layer is a non-slip and water-repellent layer 5 (foamed latex layer);

[0030] The upper bonding layer 4 is a warp-knitted mesh fabric with a plurality of polyester monofilament protrusions.

[0031] The bonding layer is a single-sided structural layer formed by cutting open a three-dimensional sandwich mesh fabric consisting of two layers of warp knitted mesh fabric and a plurality of polyester monofilaments arranged vertically in the middle and connecting the two layers of warp knitted mesh fabric; the three-dimensional sandwich mesh fabric is specifically formed by integrally weaving 80D polyester monofilament yarns.

[0032] The angle between the polyester monofilament protrusion and the warp knitted mesh cloth is between 40° and 60°; the height of the polyester monofilament protrusion is 5 mm. The size of a single mesh on the warp knitted mesh cloth of the bonding layer is: an area of ​​20 square millimeters.

[0033] The anti-slip carpet rubber pad layer of this embodiment can be used in combination with a carpet with a flannel layer or a 3D mesh cloth bottom layer on the bottom surface. When used in combination with a carpet surface with a 3D mesh cloth (thickness of 5 mm, mesh size of: area 20 square millimeters) on the bottom surface, such as Figure 2 As shown, the carpet surface is composed of a surface layer 1, a bottom layer of 3D mesh cloth 3, and an adhesive layer 2 arranged between the two layers; when used together, the monofilament protrusions on the bonding layer of the anti-skid carpet adhesive pad layer are inserted into the mesh of the 3D mesh cloth. In addition, since the bonding surface of the 3D mesh cloth and the anti-skid pad is made of the same material; and since the three-dimensional mesh cloth structure layer has a certain thickness, when the protrusions on the bonding surface are inserted into the mesh, the protrusions are also inserted into the gaps connecting the polyester monofilaments in the middle of the three-dimensional mesh cloth structure layer; these two points make the carpet surface and the anti-skid pad have high bonding strength when used in combination, and are not easy to move in the use environment, and will not curl up around, and have good comfort.

[0034] Example 2

[0035] This embodiment relates to an anti-slip carpet rubber pad layer, such as Figure 1 As shown, including:

[0036] The bottom layer is a non-slip and water-repellent layer 5 (thermoplastic elastomer material layer);

[0037] The upper bonding layer 4 is a warp-knitted mesh fabric with a plurality of polyester monofilament protrusions.

[0038] The bonding layer is a single-sided structural layer formed by cutting open a three-dimensional mesh structural layer consisting of two layers of warp knitted mesh cloth and a plurality of polyester monofilaments arranged vertically in the middle and connecting the two layers of warp knitted mesh cloth; the three-dimensional mesh structural layer is specifically formed by integrally weaving 20D polyester monofilament yarns.

[0039] The angle between the polyester monofilament protrusion and the warp knitted mesh cloth is between 50° and 70°; the height of the polyester monofilament protrusion is 1.5 mm. The area of ​​a single mesh on the warp knitted mesh cloth of the bonding layer is 0.2 square millimeters.

[0040] The anti-skid carpet rubber pad layer of this embodiment can be used in combination with a carpet whose bottom surface is a flannel layer or a carpet having a 3D mesh cloth bottom layer.

[0041] Example 3

[0042] This embodiment relates to an anti-slip carpet rubber pad layer, such as Figure 1 As shown, including:

[0043] The bottom layer is a non-slip and water-repellent layer 5 (acrylic resin layer);

[0044] The upper bonding layer 4 is a warp-knitted mesh fabric with a plurality of polyester monofilament protrusions.

[0045] The bonding layer is a single-sided structural layer formed by cutting open a three-dimensional mesh structural layer consisting of two layers of warp knitted mesh cloth and a plurality of polyester monofilaments vertically arranged in the middle and connecting the two layers of warp knitted mesh cloth; the three-dimensional mesh structural layer is specifically formed by integrally weaving 120D polyester monofilament yarns.

[0046] The angle between the polyester monofilament protrusion and the warp knitted mesh cloth is between 40° and 60°; the height of the polyester monofilament protrusion is 10 mm. The area of ​​a single mesh on the warp knitted mesh cloth of the bonding layer is 100 square millimeters.

[0047] The anti-skid carpet rubber pad layer of this embodiment can be used in combination with a carpet whose bottom surface is a flannel layer or a carpet having a 3D mesh cloth bottom layer.

[0048] Example 4

[0049] This embodiment relates to an anti-slip carpet rubber pad layer, comprising:

[0050] The bottom layer is non-slip and water-repellent (foamed latex layer);

[0051] The upper bonding layer is a single-sided flocking fabric with a plurality of polyester monofilament protrusions arranged thereon; the bonding layer is formed by integrated weaving and flocking of 80D polyester monofilament yarns.

[0052] The angle between the polyester monofilament protrusion and the single-sided flocking fabric is between 50° and 60°; the height of the polyester monofilament protrusion is 8 mm. The area of ​​a single mesh on the warp-knitted mesh fabric of the bonding layer is 36 square millimeters.

[0053] Performance Verification

[0054] There is a carpet with a cushion portion in the prior art; constructed of a cover and an underlying non-slip, non-absorbent pad attached to each other by an interlocking mechanical connection of loops on the cover and hooks on the pad.

[0055] The interlocking mechanical connection is formed by VELCRO in the first embodiment. This VELCRO has a Velcro effect. However, the loops and hooks are damaged after being disassembled many times, such as after 10 times, the suede surface is damaged, resulting in insufficient bonding strength.

[0056] In the second embodiment, the interlocking mechanical connection is formed by the granular material layer on the pad. The cover is made of fleece cloth, and the loops on it are very fine and difficult to see with the naked eye. The granular material layer on the pad is formed by heat-treating the 3D-18D short fibers on the pad to form a gravel layer. Therefore, the interlocking connection strength is poor. In addition, the surroundings of the cover will be warped during use, affecting the user experience. In addition, because the granular material layer on the pad is formed by heat-treating the fibers on the pad to form a gravel layer, it cannot be curled or folded.

[0057] The interlocking mechanical connection is formed in the third embodiment by a resin material having protrusions that interlock with the bottom surface of the cover. However, the bonding strength of this interlocking mechanical connection of the cover and the pad is very poor.

[0058] The anti-slip carpet rubber pad layer of Example 1 was used in combination with a carpet surface having a 3D mesh cloth (thickness of 5 mm, mesh size of 20 square millimeters) on the bottom surface, which was recorded as Experimental Group 1;

[0059] The second embodiment described above is used as control group 1;

[0060] The bottom surface of the cushion layer with the granular material layer in the second solution is combined with a carpet surface of 3D mesh cloth (thickness of 5 mm, mesh size: area of ​​20 square millimeters), which is recorded as comparison group 2;

[0061] The following experiment was conducted on the detachable carpets of control group 1, control group 2 and embodiment 1:

[0062] 1. Bonding strength test

[0063] Experimental equipment: Computerized desktop tensile testing machine

[0064] 1) Take the carpet surface and cushion layer of the control group 1 with a size of 5cmx20cm, overlap each other, roll it twice with a 6kg roller, and perform three average peeling force tests with a tensile testing machine. The test results are: 0.576 Newton, 0.453 Newton, and 0.321 Newton; it can be seen that the peeling force gradually weakens.

[0065] The carpet surface and cushion layer of the control group 2 with a size of 5 cm x 20 cm were overlapped with each other. Since there was almost no adhesion between the carpet surface and the cushion layer, the peeling force could not be tested by the above method.

[0066] The carpet surface and the anti-slip bonding layer of the detachable carpet of Example 1 with a size of 5 cm x 20 cm were overlapped, rolled twice with a 6 kg roller, and tested for average peeling force three times with a tensile testing machine. The results after the test were: 1.387 Newtons, 1.325 Newtons, and 1.467 Newtons; it can be seen that the peeling force remained basically unchanged and was significantly better than that of the control group 1;

[0067] 2) Take the carpet surface and cushion layer of the control group 1 with a size of 5cmx20cm, overlap each other, roll them twice with a 6kg roller, and perform three average lateral separation force tests with a tensile testing machine. The test results are: 26.551 Newtons, 11.575 Newtons, and 6.230 Newtons. It can be seen that the lateral separation force is greatly weakened;

[0068] The carpet surface and the anti-slip bonding layer of the detachable carpet of Example 1 with a size of 5 cmx20 cm were overlapped with each other, rolled twice with a 6 kg roller, and tested for the average lateral separation force three times with a tensile testing machine. The test results were: 52.128 Newtons; 52.128 Newtons, 53.252 Newtons; it can be seen that the lateral separation force remained basically unchanged and was significantly better than that of the control group 1.

[0069] 2. Disassembly life test:

[0070] The carpet surface and cushion layer of the control group 1 with a size of 5cmx20cm were overlapped, rolled twice with a 6kg roller, and separated 20 times in the longitudinal and transverse directions using a tensile testing machine. It was found that the loop pile of the bottom layer of the carpet surface was severely damaged, the gravel layer was partially damaged, and the broken gravel particles were stuck to the velvet cloth of the bottom layer of the carpet surface, which seriously affected the appearance. In addition, the final adhesion strength could not be tested by the tensile testing machine for peeling strength;

[0071] The carpet surface and the anti-slip bonding layer of the detachable carpet of Example 1 with a size of 5 cm x 20 cm were overlapped with each other, rolled twice with a 6 kg roller, and subjected to 20 longitudinal and transverse separation tests using a tensile testing machine. The result showed that the peeling force was 1.335 Newtons.

[0072] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art may make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A non-slip carpet rubber pad, characterized in that: The anti-skid carpet rubber pad layer includes a bottom anti-skid water-repellent layer and an upper bonding layer, wherein the bonding layer is a warp-knitted mesh cloth with a plurality of raised polyester, polypropylene or nylon monofilaments, and is a single-sided structural layer formed by cutting the middle of a three-dimensional sandwich mesh cloth; The three-dimensional sandwich mesh fabric is composed of two layers of warp knitted mesh fabric and a plurality of polyester, polypropylene or nylon monofilaments arranged vertically in the middle and connecting the two layers of warp knitted mesh fabric, and is woven integrally with 20D to 120D polyester monofilament yarns; the angle between the protrusions of the polyester, polypropylene or nylon monofilament and the warp knitted mesh fabric is 40 to 70 degrees; The anti-skid carpet rubber pad layer is used in combination with a carpet surface; the carpet surface has a 3D mesh cloth bottom layer.

2. The anti-slip carpet rubber pad layer according to claim 1, characterized in that: The height of the polyester or nylon monofilament protrusions on the bonding layer is 1.5 mm to 10 mm.

3. The anti-slip carpet rubber pad layer according to claim 1, characterized in that: The thickness of the three-dimensional sandwich mesh cloth is 2 mm to 20 mm.

4. The anti-slip carpet rubber pad layer according to claim 3, characterized in that: The area of ​​a single mesh on the upper and lower layers of the warp knitted mesh fabric is 0.2 square millimeters to 100 square millimeters.

5. The anti-slip carpet rubber pad layer according to claim 1, characterized in that: The anti-skid and water-repellent layer is a foamed latex layer, an acrylic resin layer, an EVA foamed layer, a polyurethane foamed layer, an XPE foamed layer or an IXPE foamed layer.

6. The anti-skid carpet rubber pad layer according to claim 1, characterized in that: The anti-slip and water-repellent layer is a thermoplastic elastomer material layer.

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