Antiskid carpet for vehicle and production process and equipment set thereof

Abstract

The invention relates to an automotive antiskid carpet and a production process and equipment set thereof. The anti-skid carpet for the vehicle comprises a tufted carpet layer, a lamination bonding layer and an anti-skid base cloth layer which are sequentially arranged from top to bottom, the anti-skid base cloth layer comprises a non-woven fabric layer and a warp and weft barb set embedded in the non-woven fabric layer, and the warp and weft barb set comprises a plurality of parallel wefts and a plurality of barb warps perpendicular to the wefts. And the anti-skid barbs of the barbed warps protrude out of the non-woven fabric layer. The preparation process at least comprises the steps of preparation of the anti-skid base cloth, preparation of the tufting layer and film spraying. According to the anti-skid carpet for the vehicle, the wefts and the barb warps are directly woven on the non-woven fabric base cloth, so that the peel strength of the anti-skid carpet for the vehicle is greatly improved. In addition, the anti-slip base cloth, the lamination bonding layer and the tufted carpet layer are compounded by adopting a lamination process, and an adhesive is not needed, so that the carpet is green and environment-friendly.

Description

Technical Field

[0001] The invention relates to the technical field of anti-skid carpets, and in particular to an anti-skid carpet for vehicles and a production process and equipment group thereof. Background Art

[0002] Most of the anti-skid carpets for cars are tufted carpets. Tufted carpets are machine-made carpets that are mechanically piled on a chemical fiber fabric base cloth with a needle arrangement to form a loop pile or cut pile carpet surface. Anti-skid carpets for cars generally have an anti-skid layer added to the bottom of the tufted carpet, while ordinary anti-skid carpets for cars generally have barbs or anti-skid rubber particles on the lower surface of the anti-skid layer to enhance friction. However, since ordinary anti-skid carpets for cars place pre-woven mesh barbs directly on the outer surface of the anti-skid layer, and then use a needle punching process to pierce it into the anti-skid layer, and the barbs are generally made of nylon plastic wire, when the anti-skid carpets for cars are taken and put in many times, the barbs are easily peeled off from the anti-skid layer due to multiple forces. The anti-skid rubber particles are mostly glued to the bottom of the anti-skid layer with glue, and the glue is easy to oxidize, causing the anti-skid rubber particles to fall off, and then the anti-skid carpets for cars move due to the loss of anti-skid function, reducing the safety of driving. Summary of the invention

[0003] The purpose of the present invention is to solve the deficiencies of the prior art. The first purpose of the present invention is to provide a production process for anti-skid carpet for vehicles. By adopting this process, the warp and weft barb groups can be directly woven on the non-woven base fabric to improve its peel strength.

[0004] The second object of the present invention is to provide an anti-skid carpet for a vehicle, in which the barbed warp threads are woven together with a non-woven fabric layer, and are fixed by weft threads crisscrossing the barbed warp threads. This not only improves the peeling strength between the warp and weft barb groups and the non-woven fabric layer, but also effectively prevents the barbed warp threads from deforming after weaving.

[0005] The third object of the present invention is to provide a production device for anti-skid carpet for vehicles, the key of which is to weave the barbed warp and weft threads on the non-woven fabric layer through a sewing machine to form the above-mentioned warp and weft barb groups.

[0006] The technical solution adopted by the first invention object of the present invention is: a production process of anti-skid carpet for vehicles, comprising at least the following steps:

[0007] S1. Preparation of anti-slip base fabric: weaving warp and weft barb groups on the formed non-woven fabric, specifically including:

[0008] S11, preparation of non-woven fabric layer: non-woven fabric fibers of different colors are mixed evenly, and then combed, combed, and stacked to form a non-woven fabric base fabric, which is directly sent to the next process or rolled up for standby use;

[0009] S12, weaving of warp and weft barbed groups: firstly, heat-press one side surface of the non-woven base fabric, then atomize to remove static electricity, lay weft on the heat-pressed surface of the non-woven base fabric, and then drop the warp to make the warp perpendicular to the weft, so that the warp and weft are staggered to prevent the warp from being deformed after weaving; use a sewing machine to weave the warp on the non-woven fabric, and use the needle punching mechanism of the sewing machine to form a non-slip ring on the warp while weaving;

[0010] S13, after weaving is completed, high temperature shaping is performed, and then the anti-skid ring on the warp is cut open by a shearing machine, so that the outer end surface of the warp forms a barb fork; the outer end surface of the barb fork is burned by a flame spray gun device to form anti-skid barbs, and an anti-skid base fabric is made, and the fabric is rolled up for standby use or directly enters the next process;

[0011] S2, preparation of tufting layer: first weave the base fabric, then tuft the base fabric through a tufting machine to form a tufted carpet, and then roll it up for standby use or directly enter the next process;

[0012] S3. Laminating: Use a laminating machine to heat and extrude the laminating adhesive layer. The two sides of the laminating adhesive layer are respectively laminated and calendered with the anti-slip base fabric and the tufted carpet. The side of the anti-slip base fabric with anti-slip burrs faces outwards, and the pile side of the tufted carpet faces outwards. Finally, it is cooled and rolled up to make an anti-slip carpet for vehicles.

[0013] Preferably, the specific steps for preparing the S11 non-woven fabric layer include: mixing non-woven staple fibers of different colors evenly, then entering into a combing machine for combing, then combing a net to form a thin layer of mesh fibers, then stacking and laying them into a desired thickness through a web laying machine, using a needle punching machine to firmly form the non-woven fabric, and then winding them up through a first winding device for standby use or directly entering into the next process.

[0014] Preferably, in the step S11, the mixing of the non-woven staple fibers includes firstly mechanically stirring and mixing the staple fibers using a fiber mechanical mixer, and then further mixing and stirring them using a fiber air-blowing mixer.

[0015] Preferably, the thickness of the nonwoven fabric in S11 is 400 g / m2.

[0016] Preferably, in step S3, the laminating machine uses PE or TPR material to extrude the laminating adhesive layer.

[0017] Preferably, the drawn wire in S12 is made of PET, PP or nylon by extrusion and drawing.

[0018] Preferably, the drawn wire in S12 is composed of 1-4 strands of nylon wire.

[0019] Preferably, the drawing wire in S12 is composed of three strands of nylon wire.

[0020] The technical solution adopted for the above-mentioned second invention object of the present invention is: an anti-skid carpet for a vehicle, which is made by the above-mentioned production process, and includes a tufted carpet layer, a laminated adhesive layer and an anti-skid base fabric layer arranged in sequence from top to bottom, the anti-skid base fabric layer includes a non-woven fabric layer and a warp and weft barb group embedded in the non-woven fabric layer, the warp and weft barb group includes a plurality of parallel wefts and a plurality of barbed warp threads perpendicular to the weft threads, and the anti-skid barbs of the barbed warp threads protrude outside the non-woven fabric layer.

[0021] Preferably, the barbed warp threads include braided warp threads and barbed drawn wires clustered on the braided warp threads, and the barbed drawn wires are clustered on the braided warp threads in a "V" shape.

[0022] The technical solution adopted by the third invention object of the present invention is: an equipment group for producing anti-skid carpet for vehicles, including an anti-skid base fabric production part, a tufting part and a coating part; wherein,

[0023] The production part of the anti-slip base fabric includes, in the order of production, a fiber mechanical mixer, a fiber air-blowing mixer, a combing machine, a web laying machine, an atomizing machine, a hot pressing device, a sewing machine, a drying device, a shearing machine, a flame spray gun device, and a second winding device;

[0024] The tufting part includes a braiding machine, a tufting machine, and a third winding device in the order of production;

[0025] The coating part includes, in order of production sequence, an anti-slip base fabric unwinding device, a tufted carpet unwinding device, an extrusion device, a composite calendering device, a cooling device, and a fourth winding device.

[0026] Compared with the prior art, the present invention has the following advantages:

[0027] 1. The anti-skid carpet for vehicles of the present invention has an anti-skid base fabric layer comprising a non-woven fabric layer and a warp and weft barb group embedded in the non-woven fabric layer. The barbed warp threads of the warp and weft barb group are woven into one body with the non-woven fabric layer, and are fixed by weft threads crisscrossing with the barbed warp threads. This can not only improve the peeling strength between the warp and weft barb group and the non-woven fabric layer, but also effectively prevent the barbed warp threads from deforming after weaving.

[0028] 2. The production process of the anti-skid carpet for vehicles of the present invention is simple in process flow, and the warp and weft threads do not need to be woven in advance. Instead, the weft threads and barbed warp threads are directly woven on the non-woven base fabric, which can also greatly improve its peel strength. In addition, the anti-skid base fabric, the mulching adhesive layer and the tufted carpet layer are composited by the laminating process, and no adhesive is needed, which is green and environmentally friendly.

[0029] 3. The vehicle anti-skid carpet production equipment of the present invention weaves the barbed warp and weft threads on the non-woven fabric layer through a sewing machine to form the warp and weft barb groups. The fiber network structure of the non-woven staple fibers is firmly combined with the weaving structure of the warp and weft barb groups to improve the peel strength of the vehicle anti-skid carpet. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a structural schematic diagram of the anti-skid carpet for vehicle of the present invention.

[0031] Figure 2 The figure is a schematic diagram of the bottom structure of the anti-skid carpet for vehicle of the present invention.

[0032] Figure 3 It is a schematic diagram of the structure of the barbed warp thread.

[0033] Figure 4 It is a process flow chart of the present invention.

[0034] Figure 5 This is a flow chart of the coating process in step S3 of the present invention.

[0035] The numbers in the figure show:

[0036] 1-tufted carpet layer, 11-pile layer, 12-base fabric layer, 2-laminated adhesive layer, 3-anti-slip base fabric layer, 31-non-woven fabric layer, 32-warp and weft barb group, 321-weft, 322-barb warp, 3221-anti-slip barb, 3222-woven warp, 3223-barb drawing wire;

[0037] 001-fiber mechanical mixer, 002-fiber air-blowing mixer, 003-combing machine, 004-net laying machine, 005-needling machine, 006-hot pressing device, 007-atomizing machine, 008-edge sewing machine, 009-drying device, 010-wool shearing machine, 011-flame spray gun device, 012-second winding device, 013-weaving machine, 014-tufting machine, 015-third winding device, 016-anti-slip base cloth unwinding device, 017-tufted carpet unwinding device, 018-extrusion device, 019-composite calendering device, 020-cooling device, 021-fourth winding device, 022-first winding device. DETAILED DESCRIPTION

[0038] In order to deepen the understanding of the present invention, the present invention will be further described in detail below in conjunction with implementation examples and drawings. The present invention can be implemented in the following manner:

[0039] Example 1

[0040] Reference Figure 1-3 The anti-skid carpet for vehicle of this embodiment comprises a tufted carpet layer 1, a laminated adhesive layer 2 and an anti-skid base fabric layer 3 which are arranged in sequence from top to bottom.

[0041] The anti-skid bottom fabric layer 3 includes a non-woven fabric layer 31 and a warp and weft barb group 32 embedded in the non-woven fabric layer 31, the warp and weft barb group 32 includes a plurality of parallel wefts 321 and a plurality of barbed warp lines 322 perpendicular to the wefts 321, and the anti-skid barbs 3221 of the barbed warp lines 322 protrude outside the anti-skid layer. The wefts 321 and barbed warp lines 322 of this embodiment are crisscrossed to form a grid, the barbed warp lines 322 are woven into one body with the non-woven fabric layer 31, and are fixed by the wefts 321 crisscrossed with the barbed warp lines 322, which can not only improve the peeling strength between the warp and weft barb group 32 and the non-woven fabric layer 31, but also effectively prevent the barbed warp lines 322 from deforming after weaving.

[0042] In this embodiment, the barbed warp 322 includes a braided warp 3222 and a barbed wire 3223 clustered on the braided warp 3222. The braided warp 3222 is directly braided in the non-woven fabric layer 31. During the braiding process, the barbed wire 3223 is clustered in a "V" shape on the braided warp 3222. The anti-slip barbs 3221 are arranged at the free ends of the barbed wire 3223. The outer end surface of the anti-slip barbs 3221 is a smooth surface to prevent scratching. This design allows the braided warp 3222 to firmly embed the barbed wire 3223 in the non-woven fabric layer 31, greatly improving its peel strength.

[0043] In order to improve the anti-skid ability of the barbed wire drawing line 3223, the barbed wire drawing line 3223 is a nylon, PET or PP extruded wire drawing line. The barbed wire drawing line 3223 is composed of 1-4 strands of nylon wire. In this embodiment, the barbed wire drawing line 3223 is composed of 3 strands of nylon wire. This design makes the barbed wire drawing line 3223 claw-shaped and evenly distributed on the entire barbed warp 322, further improving its anti-skid ability.

[0044] In this embodiment, the coating adhesive layer 2 is a PE or TPR coating adhesive layer. The coating process is used to composite the anti-slip base fabric layer 3, the coating adhesive layer 2 and the tufted carpet layer 1, without the need for adhesives, which is green and environmentally friendly. In addition, it can also play a waterproof role.

[0045] In this embodiment, the tufted carpet layer 1 includes a base fabric layer 12 and a pile layer 11 tufted on the base fabric layer 12. The base fabric layer 12 is close to the film bonding layer 2, and the pile layer 11 is PP, PET, PA long fiber bulked fiber or twisted and plied fiber, wool twisted yarn, or other materials can be used as needed.

[0046] Reference Figure 4The production process of the above-mentioned anti-skid carpet for automobile includes the preparation of anti-skid base fabric, the preparation of tufting layer and lamination. By adopting this process, the above-mentioned carpet can be produced, and the peeling strength of the anti-skid base fabric layer 3 can be improved.

[0047] In this embodiment, at least the following steps are included:

[0048] S1. Preparation of anti-slip base fabric: weaving warp and weft barb groups 32 on the formed non-woven fabric, specifically including:

[0049] S11, preparation of non-woven fabric layer 31: non-woven fabric fibers of different colors are mixed evenly, and then combed, combed, and stacked to form a non-woven base fabric, which is directly put into the next process or rolled up for standby use. Specifically, the short fibers are first mechanically stirred and mixed using a fiber mechanical mixer 001, and then further mixed and mixed using a fiber air-blown mixer 002. Non-woven staple fibers are used because they have better drafting properties and lower costs. In addition, the rough and fluffy surface can increase the contact area between the non-woven surface and the laminated adhesive layer 2, making it easier and more secure to fit with the laminated adhesive layer 2 later. When the non-woven staple fibers of different colors are evenly mixed, they enter the combing machine 003 for combing, and then the combing net forms a thin layer of mesh fibers, which is then laid layer by layer by the web laying machine 004 to the required thickness. The thickness of this embodiment is 400g / square meter. Finally, the needle punching machine 005 is used to form a non-woven fabric layer 31, which can directly enter the next process or be rolled up by the first winding device 022 for standby use.

[0050] S12, weaving of warp and weft barbed group 32: firstly, heat press one side surface of non-woven base fabric, the upper surface of non-woven base fabric after heat pressing is relatively flat, which is conducive to subsequent weaving operation. Then, use atomizer 003 to atomize and remove static electricity, then lay weft 321 on the surface of non-woven base fabric after heat pressing, and then drop warp to make the warp perpendicular to weft 321. The warp and weft 321 are interlaced to prevent the warp from deforming after weaving; use sewing machine 008 to weave the warp on non-woven fabric to form the above-mentioned weaving warp 3222, and use the needle punching mechanism of sewing machine 008 to form anti-skid rings on the warp while weaving, at this time, a row of annular anti-skid rings will be formed on the weaving warp 3222; this process can make weft 321, barbed warp 322 and non-woven fabric layer 31 weave together, greatly improving the peeling strength between warp and weft barbed group 32 and non-woven fabric layer 31. In addition, the wire drawing wire of this embodiment is made by extruding and drawing nylon material, and has a strong anti-slip ability.

[0051] S13, after weaving is completed, the drying device 009 is used for high temperature setting, and then the shearing machine 010 is used to cut the anti-skid ring on the warp line, so that the outer end surface of the warp line forms a barb fork; because the barb fork will prick the hand, the safety is low. In order to solve the problem of the barb fork pricking the hand, the flame spray gun device 011 is used to burn the outer end surface of the barb fork to form the anti-skid barb 3221 (such as Figure 3 As shown in the figure, the anti-skid base fabric can be rolled up by the second rolling device 012 for standby use or directly enter the next process; the anti-skid barbs 3221 can hook the car interior to achieve the purpose of fixing and preventing skidding. During the burning process, the flame tail sprayed by the flame spray gun device is mainly used to sweep the surface of the barb fork, so that the outer end surface of the anti-skid barb 3221 shrinks to a smooth surface, thereby solving the problem of pricking the hand.

[0052] S2, preparation of tufted layer: firstly, the base fabric is woven by the weaving machine 013, and then tufted by the tufting machine 014 on the base fabric to form a tufted carpet, which can be rolled up by the third winding device 015 for standby use or directly enter the next process;

[0053] S3, coating: The extrusion device 018 of the coating machine is used to heat and extrude the coating adhesive layer 2. The extrusion material can be PE or TPR material. The two sides of the coating adhesive layer 2 are respectively laminated and calendered with the anti-skid base fabric and the tufted carpet, wherein the side of the anti-skid base fabric with anti-skid burrs faces outward, and the side of the tufted carpet faces outward. Finally, it is cooled and rolled up to form a car anti-skid carpet. The coating process is used to laminate the anti-skid base fabric, the coating adhesive layer 2 and the tufted carpet layer 1, without the need for adhesives, which is green and environmentally friendly.

[0054] Reference Figure 4 ,The above production process requires the following equipment groups, including the anti-slip base fabric production part, the tufting part and the laminating part;

[0055] The production part of the anti-skid base fabric includes, in the order of production, a fiber mechanical mixer 001, a fiber air-blowing mixer 002, a combing machine 003, a web laying machine 004, a needle punching machine 005, a hot pressing device 006, an atomizing machine 007, a sewing machine 008, a drying device 009, a shearing machine 010, a flame spray gun device 011, and a second winding device 012; wherein, a first winding device 022 may also be provided behind the needle punching machine 005 so as to wind up the non-woven base fabric that cannot be woven in time. The barbed warp 322 and the weft 321 are woven on the non-woven fabric layer 31 by the sewing machine 008, thereby forming the above-mentioned warp and weft barb group 32. The fiber network structure of the non-woven staple fiber is firmly combined with the woven structure of the warp and weft barb group 32 to improve the peeling strength of the anti-skid carpet for vehicles. In addition, the fuel used by the flame spray gun device 011 is natural gas. When a combustion failure occurs, the pressure roller originally used to press the anti-skid base cloth down to the tail of the flame will bounce up, so that the anti-skid base cloth will immediately move away from the flame spray gun device 011, thereby reducing the probability of safety accidents.

[0056] The tufting part includes a weaving machine 013, a tufting machine 014, and a third winding device 015 in the order of production; the weaving machine 013 is used to weave the base fabric, and then the tufting machine 014 is used to tuft the base fabric to form a tufted carpet.

[0057] Reference Figure 5 The laminating part is mainly a laminating machine, which includes, in order of production, an anti-slip base fabric unwinding device 016, a tufted carpet unwinding device 017, an extrusion device 018, a composite calendering device 019, a cooling device 020, and a fourth winding device 021. The equipment used in the laminating part is conventional equipment, and in order to achieve the principle of economy in the review procedure, it will not be repeated in this embodiment.

[0058] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A production process for anti-skid carpet for vehicles, It is characterized in that At least the following steps are included: S1. Preparation of anti-slip base fabric: weaving a warp and weft barb group (32) on a formed non-woven fabric, specifically comprising: S11, preparation of non-woven fabric layer (31): non-woven fabric fibers of different colors are mixed evenly, and then combed, combed, and stacked to form a non-woven fabric base fabric, which is directly sent to the next process or rolled up for standby use; S12, weaving of the warp and weft barbed wire group (32): firstly, heat-pressing one side surface of the non-woven fabric base fabric, then atomizing to remove static electricity, laying the weft wire (321) on the heat-pressed surface of the non-woven fabric base fabric, then dropping the warp wire so that the warp wire and the weft wire (321) are perpendicular, and using a sewing machine (008) to weave the warp wire on the non-woven fabric, and while weaving, using the needle punching mechanism of the sewing machine (008) to form a non-slip ring on the warp wire; S13, after weaving is completed, high temperature shaping is performed, and then the anti-skid ring on the warp is cut by a shearing machine (010), so that the outer end surface of the warp forms a barb fork; then the outer end surface of the barb fork is burned by a flame spray gun device (011) to form anti-skid barbs (3221), and the anti-skid base fabric is made, and rolled up for standby use or directly enters the next process; S2, preparation of tufting layer: first weave the base fabric, then tuft the base fabric through a tufting machine to form a tufted carpet, and then roll it up for standby use or directly enter the next process; S3, laminating: using a laminating machine to heat and extrude the laminating adhesive layer (2), and the two sides of the laminating adhesive layer (2) are respectively laminated and calendered with the anti-skid base fabric and the tufted carpet, wherein the side of the anti-skid base fabric with anti-skid burrs faces outwards, and the pile side of the tufted carpet faces outwards, and finally cooled and rolled up to form the anti-skid carpet for vehicles.

2. A process for producing a non-slip carpet for a vehicle according to claim 1, It is characterized in that The specific steps for preparing the S11 non-woven fabric layer (31) include: mixing non-woven fabric staple fibers of different colors evenly, and then entering the combing machine (003) for combing, and then combing the net to form a thin layer of mesh fibers, and then using a web laying machine (004) to stack and lay the layers to the required thickness, and using a needle punching machine (005) to form a non-woven fabric, and then winding it up by a first winding device (022) for standby use or directly entering the next process.

3. A process for producing a non-slip carpet for a vehicle according to claim 2, It is characterized in that In the step S11, the mixing of the non-woven fabric staple fibers includes firstly using a fiber mechanical mixer (001) to mechanically stir and mix the staple fibers, and then using a fiber air-blowing mixer (002) to further mix and evenly mix the staple fibers.

4. The process for producing a non-slip carpet for a vehicle according to claim 1, It is characterized in that The thickness of the nonwoven fabric in S11 is 400 g / m2.

5. The process for producing a non-slip carpet for a vehicle according to claim 1, It is characterized in that The wire drawing wire in S12 is made of PET, PP or nylon by extrusion and drawing.

6. The process for producing a non-slip carpet for a vehicle according to claim 5, It is characterized in that The wire drawing wire in S12 is composed of 1 to 4 strands of nylon wire.

7. The process for producing a non-slip carpet for a vehicle according to claim 1, It is characterized in that In the step S3, the laminating machine uses PE or TPR material to extrude the laminating adhesive layer (2). 8.An anti-slip carpet for cars, It is characterized in that The method is manufactured by the production process described in any one of claims 1 to 8, comprising a tufted carpet layer (1), a laminated adhesive layer (2) and an anti-skid base fabric layer (3) arranged in sequence from top to bottom, wherein the anti-skid base fabric layer (3) comprises a non-woven fabric layer (31) and a warp and weft barb group (32) embedded in the non-woven fabric layer (31), wherein the warp and weft barb group (32) comprises a plurality of parallel wefts (321) and a plurality of barbed warp threads (322) perpendicular to the weft threads (321), and the anti-skid barbs (3221) of the barbed warp threads (322) protrude outside the non-woven fabric layer (31).

9. The process for producing a non-slip carpet for a vehicle according to claim 8, It is characterized in that The barbed warp threads (322) include braided warp threads (3222) and barbed wire drawing threads (3223) clustered on the braided warp threads (3222); the barbed wire drawing threads (3223) are clustered on the braided warp threads (3222) in a "V" shape.

10. An equipment set for producing anti-skid carpet for vehicles, It is characterized in that It includes the anti-slip base fabric production part, tufting part and laminating part; among which, The anti-slip base fabric production part includes, in order of production sequence, a fiber mechanical mixer (001), a fiber air-blowing mixer (002), a carding machine (003), a web laying machine (004), a needle punching machine (005), a hot pressing device (006), an atomizing machine (007), a sewing machine (008), a drying device (009), a shearing machine (010), a flame spray gun device (011), and a second winding device (012); The tufting part includes a knitting machine (013), a tufting machine (014), and a third winding device (015) in the order of production; The coating part includes, in order of production sequence, an anti-slip base fabric unwinding device (016), a tufted carpet unwinding device (017), an extrusion device (018), a composite calendering device (019), a cooling device (020), and a fourth winding device (021).

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