Lamination equipment for latex-free tufted carpet

Abstract

The present invention discloses a composite device for latex-free tufted carpet, including an unwinding device, a composite roller and a shaping device; wherein the unwinding device is used to unwind the rolled blank carpet, hot-melt fiber web and secondary cloth; the composite roller is used to laminate and composite the unrolled blank carpet, hot-melt fiber web and secondary cloth in sequence to obtain a prefabricated tufted carpet; the shaping device is used to shape the prefabricated tufted carpet at a preset temperature to obtain a finished tufted carpet. The present invention combines the hot-melt fiber web, consolidates the secondary cloth and the blank carpet by thermal bonding, and does not need to use latex for consolidation. Therefore, volatile organic compounds will not be released during production and use. At the same time, since the hot-melt fiber web is in a thin layer after hot melting, the prepared finished tufted carpet has the advantages of good elasticity, soft hand feel, and bendability.

Description

Technical Field

[0001] The invention discloses a composite device for a latex-free tufted carpet, and belongs to the technical field of tufted carpet processing equipment. Background Art

[0002] A tufted carpet is a machine-made carpet that is made by mechanically planting pile with needles on a chemical fiber fabric base to form a loop pile or cut pile carpet surface.

[0003] Traditional tufted carpets use latex backing technology to consolidate the pile, that is, relying on latex adhesive to consolidate the carpet pile and base fabric to prevent the carpet from shedding.

[0004] The latex used for carpets includes styrene-butadiene latex and vinyl acetate-acrylic latex, which are polymerized from monomers such as styrene, butyl acrylate, and vinyl acetate. During the production and use process, they will release a large amount of volatile organic compounds (VOC), resulting in poor production and use environment and serious pollution. Summary of the invention

[0005] The purpose of the present application is to provide a composite device for latex-free tufted carpets to solve the technical problems of poor production and use environment and high pollution of tufted carpets in the prior art.

[0006] The present invention provides a latex-free tufted carpet composite device, comprising an unwinding device, a composite roller and a shaping device;

[0007] The unwinding device is used to unwind the rolled blank blanket, hot-melt fiber web and secondary cloth;

[0008] The composite roller is used to laminate and composite the unreeled blank carpet, the hot-melt fiber web and the secondary cloth in sequence to obtain a prefabricated tufted carpet;

[0009] The shaping device is used to shape the prefabricated tufted carpet at a preset temperature to obtain a finished tufted carpet.

[0010] Preferably, the shaping device comprises a drying drum roller and two tenter pin plates matching the cross-sectional shape of the drying drum roller;

[0011] The two tenter pin plates are respectively arranged on both sides of the drying drum roller and are coaxially arranged with the drying drum roller.

[0012] Preferably, the shaping device further comprises a pressing unit;

[0013] The pressing unit is in contact with the drying roller and is used for pressing the prefabricated tufted carpet heated by the drying roller.

[0014] Preferably, the shaping device further comprises a cooling unit;

[0015] The cooling unit is used to cool and shape the prefabricated tufted carpet after pressing to obtain a finished tufted carpet.

[0016] Preferably, the unwinding device comprises a blanket unwinding unit, a hot-melt fiber web unwinding unit and a secondary cloth unwinding unit.

[0017] Preferably, the hot melt fiber web unwinding unit comprises an air expansion shaft;

[0018] The air inflation shaft is arranged at the center of the rolled hot-melt fiber web and is used for driving the rolled hot-melt fiber web to unwind.

[0019] Preferably, the hot melt fiber web unwinding unit further comprises a tension monitoring module;

[0020] The tension monitoring module is perpendicular to the web surface of the unrolled hot-melt fiber web and is used to monitor the tension of the hot-melt fiber web.

[0021] Preferably, the tension monitoring module comprises a distance measuring photoelectric sensor and a controller;

[0022] The distance measuring photoelectric sensor is perpendicular to the web surface of the unwound hot-melt fiber web and is used to obtain the tension of the hot-melt fiber web;

[0023] The controller is connected to the distance measuring photoelectric sensor and the air expansion shaft respectively, and is used to adjust the unwinding speed of the air expansion shaft according to the tension of the hot-melt fiber web.

[0024] Compared with the prior art, the composite equipment of the latex-free tufted carpet of the present invention has the following beneficial effects:

[0025] The present invention combines the hot-melt fiber web, consolidates the secondary cloth and the blank carpet by thermal bonding, and does not need to use latex for consolidation. Therefore, volatile organic compounds will not be released during production and use. At the same time, since the hot-melt fiber web is in a thin layer after hot melting, the prepared tufted carpet has good elasticity, soft hand feeling and can be bent, which solves the problem that the existing latex adhesive containing calcium powder is used, resulting in poor elasticity, hard hand feeling and fear of bending of the finished tufted carpet. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 It is a schematic diagram of the overall structure of a composite device for a latex-free tufted carpet according to an embodiment of the present invention;

[0027] Figure 2 It is a schematic structural diagram of a shaping device in a composite device for a latex-free tufted carpet in an embodiment of the present invention.

[0028] List of parts and reference numerals:

[0029] 101 is a blank carpet unwinding unit; 102 is a hot-melt fiber web unwinding unit; 1021 is an air expansion shaft; 1022 is a distance-measuring photoelectric sensor; 103 is a secondary cloth unwinding unit; 2 is a composite roller; 301 is a drying drum roller; 3011 is a transmission motor reducer; 302 is a pressing unit, and 303 is a cooling unit; 3041 is a needle plate; 3042 is a sprocket; 3043 is a chain; 401 is a trimming device; 402 is a waste edge collecting device; 5 is a synchronous tension frame; 6 is a carpet storage frame; 7 is a rolling car; 8 is a winder; 9 is a carpet storage box; 10 is an expansion roller; 11 is a beating and dust removal device; 12 is a vertical track; 13 is a prefabricated tufted carpet. DETAILED DESCRIPTION

[0030] In the following description, specific details such as specific system structures, technologies, etc. are provided for the purpose of illustration rather than limitation, so as to provide a thorough understanding of the embodiments of the present invention. However, it should be clear to those skilled in the art that the present invention may be implemented in other embodiments without these specific details. In other cases, detailed descriptions of well-known systems, devices, circuits, and methods are omitted to prevent unnecessary details from obstructing the description of the present invention.

[0031] like Figure 1 As shown, the composite device of the latex-free tufted carpet of the present invention comprises an unwinding device, a composite roller 2 and a shaping device;

[0032] The unwinding device is used to unwind the rolled blank blanket, hot-melt fiber web and secondary cloth;

[0033] The composite roller 2 is used to laminate and composite the unwound blank carpet, the hot-melt fiber web and the secondary cloth in sequence to obtain a prefabricated tufted carpet 13;

[0034] The shaping device is used to shape the prefabricated tufted carpet 13 at a preset temperature to obtain a finished tufted carpet.

[0035] The blank blanket in the embodiment of the present invention is a base blanket that has been flocked.

[0036] In the embodiment of the present invention, the hot-melt fiber web is combined to consolidate the secondary cloth and the blank blanket by thermal bonding, without the need to use latex for consolidation, so that volatile organic compounds will not be released during production and use.

[0037] Furthermore, since the hot-melt fiber web is in a thin layer after hot melting, the finished tufted carpet has good elasticity, soft touch and can be bent, which solves the problem that the existing latex adhesive containing calcium powder causes the finished tufted carpet to have poor elasticity, hard touch and bendability.

[0038] The preset temperature in the embodiment of the present invention is 120° C. to 200° C. Only within the above temperature range can the hot-melt fiber web be hot-melted without damaging the blank blanket and the secondary cloth.

[0039] When the prefabricated tufted carpet 13 is shaped at a preset temperature in the embodiment of the present invention, the high temperature will cause the blank carpet, the hot-melt fiber web and the secondary cloth to shrink and deform to varying degrees, resulting in wrinkles on the finished tufted carpet. To solve the above problem, the shaping device in the embodiment of the present invention includes a drying roller 301 and two tenter pin plates whose cross-sectional shapes match those of the drying roller 301, such as Figure 2 As shown;

[0040] The two tenter pin plates are respectively arranged on both sides of the drying drum roller 301 and are coaxially arranged with the drying drum roller 301 .

[0041] The two tentering pin plates in the embodiment of the present invention are arranged on both sides of the drying drum roller 301, and rotate synchronously with the drying drum roller 301, so that the prefabricated tufted carpet 13 transferred to the drying drum roller 301 can be tentered, ensuring that the grey carpet, the hot-melt fiber web and the secondary cloth will not shrink during the shaping process, and the obtained finished tufted carpet has a uniform width and a smooth surface. At the same time, the embodiment of the present invention uses the pin plate for tentering, which will not damage the grey carpet, the hot-melt fiber web and the secondary cloth.

[0042] The tenter pin plate of the embodiment of the present invention comprises a sprocket 3042, a chain 3043 sleeved on the sprocket 3042, and a pin plate 3041 fixedly connected to the chain 3043. The power device of the sprocket 3042 of the embodiment of the present invention is the same as the power device of the drying drum roller 301, so as to achieve synchronous rotation. The power device specifically comprises a transmission motor and a transmission motor reducer 3011. The sprocket 3042 and the drying drum roller 301 of the present invention are directly connected to the transmission motor reducer 3011.

[0043] In order to further improve the bonding firmness between the blank blanket and the secondary cloth, the shaping device of the embodiment of the present invention further includes a pressing unit 302;

[0044] The pressing unit 302 is in contact with the drying roller 301 and is used to press the prefabricated tufted carpet 13 heated by the drying roller 301 .

[0045] The contact surface between the pressing unit 302 and the drying drum roller 301 in the embodiment of the present invention is an arc-shaped surface, which can achieve the pressing effect while avoiding damage to the blank blanket.

[0046] Furthermore, the shaping device of the embodiment of the present invention further includes a cooling unit 303; the cooling unit 303 is arranged on the extension line of the cross section of the drying roller 301 or on the extension line of the cross section of the drying roller 301 after the pressing unit 302, that is, at the next process position of the drying roller 301, and is used to cool and shape the prefabricated tufted carpet 13 after pressing to obtain a finished tufted carpet. The finished tufted carpet after cooling and shaping has a stable shaping and will not shrink during use.

[0047] The unwinding device of the embodiment of the present invention comprises a blanket unwinding unit 101 , a hot-melt fiber web unwinding unit 102 and a secondary cloth unwinding unit 103 .

[0048] In order to prevent the hot-melt fiber web from breaking during the unwinding process, the hot-melt fiber web unwinding unit 102 of the present invention includes an air expansion shaft 1021;

[0049] The air inflation shaft 1021 is arranged at the center of the rolled hot-melt fiber web, and is used to drive the rolled hot-melt fiber web to unwind. The present invention uses the air inflation shaft 1021 to drive the rolled hot-melt fiber web to unwind, which can avoid the contact surface of the air inflation shaft 1021 and the center of the rolled hot-melt fiber web from slipping during the unwinding process, causing the hot-melt fiber web to be excessively stretched and broken.

[0050] In order to further prevent the hot melt fiber web from being broken by excessive stretching, the hot melt fiber web unwinding unit 102 of the embodiment of the present invention further includes a tension monitoring module;

[0051] The tension monitoring module is perpendicular to the web surface of the unwound hot-melt fiber web and is used to monitor the tension of the hot-melt fiber web.

[0052] The tension monitoring module in the embodiment of the present invention may be a monitoring module based on stress or a monitoring module based on photoelectric distance measurement. In a specific embodiment, the tension monitoring module includes a distance measurement photoelectric sensor 1022 and a controller;

[0053] The distance measuring photoelectric sensor 1022 is perpendicular to the web surface of the unwound hot-melt fiber web and is used to obtain the tension of the hot-melt fiber web;

[0054] The controller is connected to the distance measuring photoelectric sensor 1022 and the air expansion shaft 1021 respectively, and is used to adjust the unwinding speed of the air expansion shaft 1021 according to the tension of the hot-melt fiber web.

[0055] Exemplarily, the ranging photoelectric sensor 1022 sends the monitored distance information between it and the hot-melt fiber web to the controller. When the controller determines that the distance of the hot-melt fiber web is closer than the distance in the previous period, it controls the rotation speed of the air inflation shaft 1021 to speed up its rotation, thereby achieving tension-free unwinding of the hot-melt fiber web.

[0056] The grey blanket unwinding unit 101 and the secondary cloth unwinding unit 103 in the embodiment of the present invention can use an air inflation shaft or a conventional steel rotating shaft, and an air inflation shaft is preferred.

[0057] The composite equipment of the latex-free tufted carpet of the present invention has a simple structure and is easy to operate, and can ensure the tension-free unwinding of the hot-melt fiber web and the prepared latex-free tufted carpet is flat, uniform in width, soft and elastic.

[0058] The latex-free tufted carpet prepared by the composite equipment for the latex-free tufted carpet does not release a large amount of volatile organic compounds, and has uniform width, is soft and elastic, and has a smooth surface.

[0059] The following will take a specific latex-free tufted carpet laminating equipment as an example to explain its working process:

[0060] Step 1: unwinding the rolled blank blanket, hot-melt fiber web and secondary cloth.

[0061] In the embodiment of the present invention, the rolled blank blanket is unwound by the blank blanket unwinding unit 101 and stored in the blanket storage box 9, and then expanded by the expanding roller 10 and dusted by the beating dust removal device 11 in sequence, and then transmitted to the composite roller 2 of the next process;

[0062] The rolled hot melt fiber web is unwound without tension by the hot melt fiber web unwinding unit 102, and then expanded by an expanding roller and transferred to the composite roller 2 of the next process;

[0063] The rolled secondary cloth is unwound by the secondary cloth unwinding unit 103 , expanded by an expanding roller, and then transferred to the composite roller 2 of the next process.

[0064] Step 2, laminating and compounding the unrolled blank carpet, the hot-melt fiber web and the secondary cloth in sequence to obtain a prefabricated tufted carpet 13;

[0065] The grey carpet, the hot-melt fiber web and the secondary cloth of the embodiment of the present invention are laminated and composited from top to bottom on the composite roller 2 to obtain a prefabricated tufted carpet 13.

[0066] Step 3: shaping the prefabricated tufted carpet 13 at a preset temperature to obtain a finished tufted carpet.

[0067] In this step, the prefabricated tufted carpet 13 enters the drying drum roller 301 and is stretched by the stretching pin plates on both sides. The heated prefabricated tufted carpet 13 is pressed by the pressing unit 302 so that the blank carpet, the hot-melt fiber web and the secondary cloth are tightly connected.

[0068] Furthermore, the prefabricated tufted carpet that has passed through the laminating unit 302 is cooled through the cooling unit 303 so that the fiber web after heat melting is cooled and solidified, and the blank carpet, the heat melting fiber web and the secondary cloth are tightly bonded to obtain a finished tufted carpet.

[0069] After the finished tufted carpet is obtained, it is post-processed, specifically: the finished tufted carpet is trimmed by using the trimming device 401, and the cut waste edges are collected in the waste edge collecting device 402. The finished tufted carpet after trimming passes through the synchronous tension frame 5 and enters the carpet storage frame 6, and then passes through the rolling car 7 and is wound by the winding machine 8 to obtain the rolled finished tufted carpet.

[0070] The composite equipment for the latex-free tufted carpet of the invention has a simple structure and is easy to operate. The prepared latex-free tufted carpet does not release a large amount of volatile organic compounds and has uniform width, is soft and elastic, and has a smooth surface.

[0071] The above are only a few embodiments of the present application and do not constitute any form of limitation to the present application. Although the present application is disclosed as above with preferred embodiments, it is not intended to limit the present application. Any technician familiar with the profession, without departing from the scope of the technical solution of the present application, using the technical content disclosed above to make slight changes or modifications are equivalent to equivalent implementation cases and fall within the scope of the technical solution.

Claims

1. A composite device for latex-free tufted carpet, characterized in that: It includes an unwinding device, a composite roller and a shaping device; The unwinding device is used to unwind the rolled blank blanket, hot-melt fiber web and secondary cloth; The composite roller is used to laminate and composite the unreeled blank carpet, the hot-melt fiber web and the secondary cloth in sequence to obtain a prefabricated tufted carpet; The shaping device is used to shape the prefabricated tufted carpet at a preset temperature to obtain a finished tufted carpet; the preset temperature is 200° C.; The shaping device comprises a pressing unit, a drying drum roller and two tenter pin plates matching the cross-sectional shape of the drying drum roller; The two tenter pin plates are respectively arranged on both sides of the drying drum roller and are coaxially arranged with the drying drum roller; The prefabricated tufted carpet is wound around the drying roller at least half a turn; The pressing unit is arranged at the discharge position of the prefabricated tufted carpet on the drying drum roller; The pressing unit is in contact with the drying roller, and the contact surface between the pressing unit and the drying roller is an arc surface, and the pressing unit is used to press the prefabricated tufted carpet after being heated by the drying roller; The unwinding device comprises a grey blanket unwinding unit, a hot-melt fiber web unwinding unit and a secondary cloth unwinding unit; The hot melt fiber web unwinding unit comprises an air inflation shaft; the air inflation shaft is arranged at the center of the rolled hot melt fiber web, and is used to drive the rolled hot melt fiber web to unwind; The hot melt fiber web unwinding unit further comprises a tension monitoring module; the tension monitoring module is perpendicular to the web surface of the hot melt fiber web after unwinding, and is used to monitor the tension of the hot melt fiber web.

2. The latex-free tufted carpet composite device according to claim 1, characterized in that: The shaping device also includes a cooling unit; The cooling unit is used to cool and shape the prefabricated tufted carpet after pressing to obtain a finished tufted carpet.

3. The latex-free tufted carpet composite device according to claim 1, characterized in that: The tension monitoring module includes a distance measuring photoelectric sensor and a controller; The distance measuring photoelectric sensor is perpendicular to the web surface of the unwound hot-melt fiber web and is used to obtain the tension of the hot-melt fiber web; The controller is connected to the distance measuring photoelectric sensor and the air expansion shaft respectively, and is used to adjust the unwinding speed of the air expansion shaft according to the tension of the hot-melt fiber web.

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