Tufted carpet blank, vehicle carpet assembly and preparation method of tufted carpet blank

Abstract

The invention provides a tufted carpet blank, a vehicle carpet assembly and a preparation method of the tufted carpet blank, the tufted carpet blank relates to the technical field of carpets for vehicles, the tufted carpet blank comprises a first non-woven fabric layer, a sizing adhesive layer, a barrier film layer and a second non-woven fabric layer which are sequentially compounded together, yarns are arranged on the surface of the first non-woven fabric layer, and the sizing adhesive layer is arranged on the surface of the second non-woven fabric layer. The yarns are woven on the non-woven fabric through a tufting process, and fluff is formed on the surface of the first non-woven fabric layer. When the tufted carpet blank is used for preparing the vehicle carpet assembly, the product quality of the prepared vehicle carpet assembly and the performance of the prepared vehicle carpet assembly can be improved.

Description

Technical Field

[0001] The present invention relates to the technical field of vehicle carpets, and in particular to a tufted carpet blank. The present invention also relates to a vehicle carpet assembly prepared by using the tufted carpet blank, and a method for preparing the vehicle carpet assembly. Background Art

[0002] With the rapid development of the automobile industry, consumers not only pay attention to the design of the car's exterior, but also have higher and higher requirements for the interior, and consumers have higher requirements for car driving comfort.

[0003] The vehicle carpet assembly is an interior decoration part installed on the sheet metal of the car cab. The quality of its performance has an important impact on the driving comfort of the car. For example, in existing vehicles, the noise mainly comes from engine noise, wind noise, road noise, etc., and engine noise is an important source of noise. If there is no barrier of the vehicle carpet assembly, these noises will enter the cab and seriously affect the driving comfort.

[0004] Existing vehicle carpet assemblies can be classified according to material into PVC synthetic resin carpets, single-layer PET flocked needle-punched carpets, PET / EVA / PET composite tufted carpet blanks, PA / PET foam carpets and single-layer PET flocked needle-punched carpets.

[0005] Among them, PVC synthetic resin carpets, the main component of its material is polyvinyl chloride, mainly including resin, plasticizer, stabilizer, talcum powder and the like.

[0006] The main component of single-layer PET flocking needle-punched carpet is polyester fiber or polyester fiber. The carpet surface with different tufted texture appearance is loosened and woven according to the needs. The middle layer is mainly a shaping glue layer and a back layer PE coating. The material is compounded by loosening, laying, needle punching and gluing.

[0007] PET / EVA / PET composite tufted carpet blanks are mainly composed of polyester fiber or polyester fiber. The middle layer is EVA to maintain the shape of the carpet. The bottom layer is a combination of PET and non-woven fabrics to slow down the molding stretch and increase the molding performance. At the same time, it plays a role in surface protection, waterproofing and anti-fouling.

[0008] Although the above-mentioned carpets are widely used in low-end and mid-range cars due to their low raw material prices and simple production processes, they are light in texture, low in strength, and poor in sound absorption, sound insulation, heat insulation, noise reduction, and vibration reduction performance, making it difficult to meet the needs of customers for exquisite perception. At the same time, these carpets will also affect driving comfort and thus driving quality, and obviously cannot meet the needs of mid-end and high-end cars. Summary of the invention

[0009] In view of this, the present invention aims to provide a tufted carpet blank, so as to improve the product quality and performance of the prepared vehicle carpet assembly.

[0010] To achieve the above object, the technical solution of the present invention is achieved as follows:

[0011] A tufted carpet blank comprises a first non-woven fabric layer, a shaping adhesive layer, a barrier film layer and a second non-woven fabric layer which are compounded in sequence;

[0012] Yarns are arranged on the surface of the first non-woven fabric layer. The yarns are woven on the non-woven fabric by a tufting process, so that fluff is formed on the surface of the first non-woven fabric layer.

[0013] Further, the yarn comprises PA6 yarn;

[0014] The first non-woven fabric layer and the second non-woven fabric layer are made of PET non-woven fabric;

[0015] The setting glue comprises acrylic latex, and the barrier film is a PE / PA / PE co-extruded film.

[0016] Furthermore, the height of the villi is between 1.8 mm and 2.2 mm;

[0017] The acrylic latex has a gram weight between 70g / ㎡ and 120g / ㎡;

[0018] The thickness of the PE / PA / PE co-extruded film is between 0.15 mm and 2 mm;

[0019] The gram weight of the PET non-woven fabric is between 100g / ㎡ and 120g / ㎡.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] The tufted carpet blank of the present invention, because it is provided with a barrier film layer and a second non-woven fabric layer, can help improve the product quality and performance of the prepared vehicle carpet assembly during the preparation of the vehicle carpet assembly. The barrier film layer can play a barrier and isolation role. When preparing the vehicle carpet assembly, it can better prevent the foaming material in the foaming process from penetrating into the surface of the tufted carpet blank, that is, prevent the foaming material from penetrating into the fluff made of yarn, which is beneficial to improving the appearance quality of the prepared vehicle carpet assembly.

[0022] Another object of the present invention is to provide a vehicle carpet assembly, comprising the tufted carpet blank as described above;

[0023] In the front-rear direction of the vehicle, the front part of the tufted carpet blank is compounded with a sound insulation layer and a first sound absorbing layer arranged in sequence, and the rear part of the tufted carpet blank is compounded with a second sound absorbing layer.

[0024] Furthermore, a pad is embedded in the first sound-absorbing layer, and the pad is made of EPP.

[0025] Further, the front portion of the vehicle carpet assembly has a treading area, and the pad is provided at the treading area; and / or,

[0026] The front part of the carpet assembly is provided with a treading area and an upward warping area, and the pad is arranged at the connection part between the treading area and the upward warping area.

[0027] Furthermore, the treading area is provided with an anti-skid pad, and the thickness of the anti-skid pad is between 0.8mm and 1.2mm.

[0028] Furthermore, the sound insulation layer is made of EVA rubber sheet, and the sound absorption layer is made of polyurethane foam material; and / or,

[0029] The thickness of the sound insulation layer is between 1.3 mm and 1.7 mm, and the thickness of the sound absorption layer is between 5 mm and 50 mm.

[0030] The vehicle carpet assembly described in the present invention has the functions of sound insulation, sound absorption, heat insulation, dust prevention, waterproofing, flame retardancy and decoration. The sound insulation layer prepared by the EVA rubber board can achieve a good sound insulation effect. The sound absorption layer prepared by the polyurethane foam material has fine pores and a high open porosity, and can achieve a good sound absorption and noise reduction effect.

[0031] In addition, another object of the present invention is to provide a method for preparing a vehicle carpet assembly, the method comprising:

[0032] preparing a tufted carpet blank;

[0033] A sound insulation layer is compounded on the front of the tufted carpet blank;

[0034] The first sound absorbing layer is compounded on the sound insulation layer, and the second sound absorbing layer is compounded on the rear of the tufted carpet blank to form the vehicle carpet assembly.

[0035] Furthermore, the preparation method of the tufted carpet blank comprises:

[0036] The yarn is knitted on the non-woven fabric by a tufting process, and a first non-woven fabric layer with fluff is formed on the molded surface;

[0037] The first non-woven fabric layer, the shaping adhesive layer, the barrier film layer and the second non-woven fabric layer are compounded together in sequence to form the tufted carpet blank.

[0038] The method for preparing the vehicle carpet assembly of the present invention has the same beneficial effects as the aforementioned vehicle carpet assembly relative to the prior art, and will not be described in detail herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The accompanying drawings constituting a part of the present invention are used to provide a further understanding of the present invention. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the accompanying drawings:

[0040] Figure 1 It is a schematic cross-sectional structure diagram of the tufted carpet blank according to the first embodiment of the present invention;

[0041] Figure 2 This is a schematic structural diagram of a vehicle carpet assembly according to a second embodiment of the present invention;

[0042] Figure 3 For along Figure 2 Sectional view along line AA;

[0043] Figure 4 It is a structural schematic diagram of the vehicle carpet assembly according to the second embodiment of the present invention from another viewing angle;

[0044] Figure 5 for Figure 4 Exploded diagram.

[0045] Description of reference numerals:

[0046] 1. Sound insulation layer; 2. Tufted carpet blank; 3. Pad; 4. Sound absorption layer; 5. Footrest card; 6. Footrest; 7. Anti-slip mat; 8. Buckle;

[0047] 201, yarn; 202, first non-woven fabric layer; 203, shaping adhesive layer; 204, barrier film layer; 205, second non-woven fabric layer; 206, upturned area; 207, treading area;

[0048] 401, a first sound absorbing layer; 402, a second sound absorbing layer. DETAILED DESCRIPTION

[0049] It should be noted that, in the absence of conflict, the embodiments of the present invention and the features in the embodiments may be combined with each other.

[0050] In the description of the present invention, the orientation or positional relationship shown in the drawings is only for the convenience of describing the present invention and simplifying the description, and does not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are only used for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0051] In addition, in the description of the present invention, unless otherwise clearly defined, the terms "installation", "connection", "connection", and "connector" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood in combination with specific circumstances.

[0052] like Figure 4 As shown, the front-to-back direction is the front-to-back direction of the vehicle, usually refers to the length direction of the vehicle, the left-to-right direction is the left-to-right direction of the vehicle, usually refers to the width direction of the vehicle, and the up-down direction is the height direction of the vehicle. In the accompanying drawings: the front arrow points to the head of the vehicle, the back arrow points to the tail of the vehicle, the up arrow points to the top of the vehicle, and the down arrow points to the bottom of the vehicle.

[0053] Sitting in the driver's seat facing the front of the car, the side where your left hand is is the left side, and the side where your right hand is is the right side. Figure 4 The left arrow in the middle points to the left side of the vehicle, and the right arrow points to the right side of the vehicle. The terms "inside" and "outside" are relative, where "inside" refers to the interior space of the vehicle, and "outside" refers to the outside of the vehicle body, that is, a position away from the interior space of the vehicle.

[0054] The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with embodiments.

[0055] Embodiment 1

[0056] The present embodiment relates to a tufted carpet blank 2, which, when used in preparing a vehicle carpet assembly, is beneficial to improving the quality and performance of the prepared vehicle carpet assembly.

[0057] Based on the above design concept, an exemplary cross-sectional schematic diagram of the tufted carpet blank 2 of this embodiment is shown as follows: Figure 2 As shown, in terms of overall structure, the tufted carpet blank 2 includes a first non-woven fabric layer 202, a shaping adhesive layer 203, a barrier film layer 204 and a second non-woven fabric layer 205 which are compounded in sequence.

[0058] The surface of the first non-woven fabric layer 202 is provided with yarns 201 , and the yarns 201 are woven on the non-woven fabric by a tufting process, so that the surface of the first non-woven fabric layer 202 is formed with fluff.

[0059] It should be noted that the yarn 201 of the tufted carpet blank 2 is generally made of nylon or polyester, so that the carpet surface of the tufted carpet blank 2 is dense and beautiful, and is used in mid-to-high-end car models. It has intricate fiber filaments, so that the prepared tufted carpet blank 2 has a sound-absorbing effect, and can absorb and seal the floating dust in the car, prevent dust particles from flying in the air in the car, and help keep the air in the car fresh.

[0060] Therefore, as a preferred embodiment, the yarn 201 in this embodiment is PA6 yarn. In the tufted carpet blank 2 made of PA6 yarn, the gram weight of the PA6 pile surface is generally 350g / ㎡-550g / ㎡, and the height of the pile formed by the yarn 201 is generally between 1.8mm-2.2mm, such as 1.8mm, 2.0mm and 2mm. It should be understood that the yarn 201 includes not only PA6 yarn, but also yarn 201 of other materials.

[0061] Preferably, the first non-woven fabric layer 202 is made of PET non-woven fabric. PET non-woven fabric is used as the base fabric of PA6 yarn, and plays a weaving role of the yarn 201 material. Preferably, the gram weight of PET non-woven fabric is generally between 100g / ㎡-120g / ㎡, such as 100g / ㎡, 120g / ㎡, and 120g / ㎡, and the thickness is about 1mm.

[0062] In this embodiment, the material used for the shaping glue layer 203 preferably includes acrylic latex, which mainly plays a role in shaping materials and parts, and its gram weight is generally between 70g / ㎡-120g / ㎡, such as 70g / ㎡, 100g / ㎡, and 120g / ㎡. It should be understood that the shaping glue layer 203 may include other types of shaping glue in addition to acrylic latex.

[0063] Preferably, the aforementioned barrier film layer 204 is made of PE / PA / PE film. The PE / PA / PE film is a co-extruded film with good toughness, good wear resistance, high melting point and certain flame retardancy. In the process of preparing the vehicle carpet assembly, the PE / PA / PE film can play a barrier and isolation role. The PE / PA / PE film is not easy to break during the heating process, and can better prevent the following PU foam material from penetrating into the surface of the tufted carpet blank 2, that is, prevent the PU foam material from penetrating into the fluff made of yarn 201, which is beneficial to improving the appearance quality of the manufactured vehicle carpet assembly.

[0064] The gram weight of PE / PA / PE film is generally 170g / ㎡-250g / ㎡, such as 170g / ㎡, 190g / ㎡, 220g / ㎡, 250g / ㎡, and its thickness is generally between 0.15mm-0.2mm, such as 0.15mm, 0.17, 0.19mm, 0.2mm.

[0065] In this embodiment, the second non-woven fabric layer 205 is preferably PET non-woven fabric. The gram weight, thickness, etc. of the PET non-woven fabric can be referred to the above description and will not be described in detail here. The second non-woven fabric layer 205 is conveniently combined with the sound insulation layer 1 and the sound absorption layer 4 described below.

[0066] The tufted carpet blank 2 of the present invention, because it is provided with the barrier film layer 204 and the second non-woven fabric layer 205, can help improve the product quality and performance of the prepared vehicle carpet assembly during the process of preparing the vehicle carpet assembly.

[0067] Embodiment 2

[0068] This embodiment relates to a vehicle carpet assembly, such as Figures 2 to 5 As shown, the vehicle carpet assembly of this embodiment mainly includes the tufted carpet blank 2 as in the first embodiment, and also includes a sound insulation layer 1 and a sound absorption layer 4, which is beneficial to improving the sound insulation and sound absorption, and can improve driving comfort.

[0069] Specifically, Figure 5 As shown, in the front-rear direction of the vehicle, the front part of the tufted carpet 2 is compounded with the sound insulation layer 1 and the first sound absorbing layer 401 arranged in sequence, and the rear part of the tufted carpet 2 is compounded with the second sound absorbing layer 402 .

[0070] It should be noted that the main function of the sound insulation layer 1 is sound insulation, which is to block the sound waves and make them attenuate. The main function of the sound absorption layer 4 is sound absorption, which is to continuously reflect the sound waves through the sound absorption layer 4 and reduce the frequency of the sound waves to achieve the sound absorption effect.

[0071] In this embodiment, the sound insulation layer 1 is only provided at the front of the vehicle carpet assembly, mainly considering that the noise at the front of the vehicle is relatively large, while the sound insulation layer 1 is not provided at the rear of the vehicle carpet assembly, mainly considering that the noise at the rear is relatively small. Omitting the sound insulation layer 1 will have less impact on the NVH performance of the vehicle and meet the lightweight requirements of the vehicle.

[0072] Still refer to Figures 2 to 5 As shown, as a preferred embodiment, the first sound absorbing layer 401 is embedded with a pad 3, such as Figure 2 and Figure 5 In this embodiment, there are four pads 3, and the pads 3 are made of EPP, which is made of polyacrylimide foam.

[0073] Polyacrylimide foam is a microporous material. The pad 3 made of this material is composed of countless bubbles inside. It has the functions of light weight, heat insulation and good cushioning. When used in automobiles, it can better improve the overall NVH performance of the automobile.

[0074] In this embodiment, the weight of the pad 3 is generally 25 kg / m 3 -35kg / m 3 If it is 25kg / m 3 、30kg / m 3 、35kg / m 3 The thickness of the pad 3 is between 10 mm and 20 mm, such as 10 mm, 15 mm, 20 mm, etc.

[0075] It should be noted that in the area where the pad 3 needs to be embedded, the thickness of the pad 3 should not be less than 1 / 3 of the thickness of the foam layer. The vehicle carpet assembly made in this way was tested with a φ80mm pressure plate and a pressure of 70N, and its deformation was less than 6mm, proving that the area where the pad 3 is embedded can effectively improve the overall rigidity and thickness of the vehicle carpet assembly, which is conducive to satisfying the stepping comfort of the occupants in the cab.

[0076] Specifically, the front portion of the vehicle carpet assembly has a treading area 207, and a cushion block 3 is provided at the treading area 207. As in this embodiment, the front treading area 207 is used for people in the front left driver seat and the front right co-driver seat to step on.

[0077] More specifically, two pads 3 are embedded in the first sound absorbing layer 401 corresponding to the pedaling area 207 , and the two pads 3 are arranged at intervals in the left and right directions of the vehicle to correspond to the pedaling positions of the persons in the front left driving seat and the front right co-pilot seat respectively.

[0078] The two pads 3 arranged at the treading area 207 are specifically in the form of plates. Both are long strips with their length directions extending along the left and right directions of the vehicle. Each pad 3 is provided with a plurality of openings, and the axial direction of the openings is consistent with the thickness direction of the vehicle carpet assembly, which is beneficial to improving the reliability of the composite.

[0079] It should be noted that, in addition to the treading area 207, the front part of the carpet assembly is also provided with an upturned area 206, which is located at the front end of the vehicle carpet assembly and is warped upward to better isolate the noise of the engine. Preferably, a pad 3 is provided at the connection between the upturned area 206 and the treading area 207 of the vehicle carpet assembly. Specifically, a pad 3 is embedded in the first sound absorbing layer corresponding to the connection between the treading area 207 and the upturned area 206.

[0080] In a preferred embodiment, the pad 3 on the right side of the connection between the upward area 206 and the treading area 207 is plate-shaped and has multiple openings. The pad 3 on the left side of the connection between the upward area 206 and the treading area 207 includes a first pad and a second pad formed as one piece.

[0081] The length direction of the first pad is bent along the connection between the upturned area 206 and the treading area 207, and the cross section is roughly triangular. The second pad is located on the inner side of the first pad, that is, on the side close to the middle of the left-right direction of the vehicle. The length direction of the second pad extends along the left-right direction of the vehicle. The first pad and the second pad are both provided with a plurality of openings, and the axial direction of the openings is consistent with the thickness direction of the vehicle carpet assembly, which can better ensure the reliability of the pad 3 being embedded in the vehicle carpet assembly.

[0082] As a preferred embodiment, the treading area 207 is provided with an anti-skid pad 7. For example, in this embodiment, the anti-skid pad 7 is provided at a portion of the treading area 207 corresponding to the main driver. Preferably, the thickness of the anti-skid pad 7 is between 0.8 mm and 1.2 mm, such as 0.8 mm, 1 mm, or 2 mm.

[0083] The material of the anti-skid pad 7 is PVC (polyvinyl chloride), and the anti-skid pad 7 is specifically welded on the upper surface of the vehicle carpet assembly. During the driving process of the vehicle, the anti-skid pad 7 can effectively avoid the friction between the driver's heel and the vehicle carpet assembly, improve the wear resistance of the carpet, and help ensure driving safety. It should be understood that it is also feasible to set the anti-skid pad 7 at the position of the tread area 207 corresponding to the co-pilot.

[0084] It should be noted that the vehicle carpet assembly of this embodiment is also provided with a buckle 8, and the installation position can refer to the existing structure. The buckle 8 is an existing structure, and the material is PA6+30% GF, which is formed by injection molding. Structurally, the buckle 8 is divided into a buckle cover and a buckle seat. There are fine threads inside the buckle seat cover, which can be clamped on the front and back of the semi-finished carpet blank by a cylinder. The buckle 8 can cooperate with the installation of the anti-skid pad 7. A layer of anti-skid pad 7 is laid on the vehicle carpet assembly, which can improve the comfort of the carpet, relieve the fatigue of the feet and joints, and reduce noise pollution.

[0085] As a preferred embodiment, the sound insulation layer 1 is made of EVA rubber sheet, and the thickness of the sound insulation layer 1 is between 1.3 mm and 1.7 mm, such as 1.3 mm, 1.5 mm, 1.7 mm, etc. The material of the EVA rubber sheet is ethylene-vinyl acetate copolymer.

[0086] As a preferred embodiment, the sound absorbing layer 4 is made of polyurethane foam material (PU foam material), and its material is polyether polyol and isocyanate, and is made by mixing the two.

[0087] Specifically, the foam cells in the polyurethane foam layer are fine and have a high open porosity, which makes it have a good sound absorption effect and can effectively absorb and reduce the noise inside the car. Among them, polyether polyol (POLY) is also called A material and white material. Its components include 35%-40% of combined polyether, 20%-30% of catalyst, 15%-20% of foaming agent, 5%-8% of stabilizer, 3%-5% of flame retardant, 3%-5% of formaldehyde remover, and 1%-2% of chain extender by weight. Among them, the catalyst is foaming amine and gel amine, the foaming agent is water, the stabilizer is silicone oil, the flame retardant is ammonium phosphate, and the chain extender is triethanolamine.

[0088] Isocyanate (ISO) is also called B material or black material, and its component is isocyanate. The foaming process of the polyurethane foam layer mainly includes mixing, milky whitening, rising, drawing, shrinking, etc. It should be noted that when the thickness of the polyurethane foam layer is ≥30mm, the aforementioned pad 3 needs to be pre-buried.

[0089] Specifically, the weight of the polyurethane foam layer is generally 50kg / m 3 -120kg / m 3 Between, such as 50kg / m 3 、80kg / m 3 , 100kg / m 3 , 120kg / m 3 The thickness of the polyurethane foam layer is between 5 mm and 50 mm, for example, it can be 5 mm, 10 mm, 20 mm, 30 mm, 40 mm, or 50 mm.

[0090] The vehicle carpet assembly of this embodiment has the functions of sound insulation, sound absorption, heat insulation, dust prevention, waterproofing, flame retardancy and decoration.

[0091] In addition, continue to refer to Figure 2 and Figure 5 As shown, the vehicle carpet assembly of this embodiment further includes a footrest 6 and a footrest card 5. The footrest 6 is arranged at a position close to the left side of the upturned area 206, so that the footrest 6 is used to place the driver's left foot when driving, which is conducive to ensuring driving comfort. The footrest 6 is provided with small ribs arranged horizontally, which is not easy to be bent, and the sole of the foot will not slip due to the large downward pressure.

[0092] Preferably, the footrest 6 is made of PP+EPDM-TD20, which can be used to prepare leather grain parts with high appearance quality. These materials are both elastic and highly wear-resistant, have a long service life, and can be formed in one step using a mold, which is convenient and quick to manufacture.

[0093] The vehicle carpet assembly of this embodiment can effectively improve the NVH (Noise, Vibration, Harshness) performance and VOC (volatile organic compounds) performance of the cab, providing users with a quiet and comfortable use environment.

[0094] At the same time, the present embodiment also relates to a method for preparing the vehicle carpet assembly, which comprises: preparing a tufted carpet blank 2, and compounding a sound insulation layer 1 on the front of the tufted carpet blank 2, compounding a first sound absorbing layer 401 on the sound insulation layer 1, and compounding a second sound absorbing layer 402 on the rear of the tufted carpet blank 2. Specifically, the sound insulation layer 1 and the second sound absorbing layer 402 are both compounded on the second non-woven fabric layer 205 in the tufted carpet blank 2.

[0095] In brief, the preparation method of the aforementioned tufted carpet blank 2 includes weaving the yarn 201 on the non-woven fabric through a tufting process, forming a first non-woven fabric layer 202 with fluff on the surface, and compounding the first non-woven fabric layer 202, the shaping glue layer 203, the barrier film layer 204 and the second non-woven fabric layer 205 in sequence to form the tufted carpet blank 2.

[0096] Specifically, relative to the side of the first non-woven fabric layer 202 provided with the fluff, a shaping adhesive layer 203 is coated on the other side of the first non-woven fabric layer 202, and then a barrier film layer 204 and a second non-woven fabric layer 205 are sequentially compounded on the shaping adhesive layer 203. The specific parameters of the yarn 201, the first non-woven fabric layer 202, the shaping adhesive layer 203, the barrier film layer 204 and the second non-woven fabric layer 205 refer to the description of the first embodiment, and will not be described in detail here.

[0097] The specific method for producing the tufted carpet blank 2 includes the following steps: preparing the yarn 201 and the first non-woven fabric layer 202, tufting, gluing, cutting, compounding the barrier film layer 204, compounding the second non-woven fabric layer 205, rolling, and cutting, and existing production equipment can be used.

[0098] Tufting is to mechanically plant pile (yarn 201) on a chemical fiber fabric base (such as the PET non-woven fabric in this embodiment) with a needle to form a loop pile or cut pile carpet surface. The tufted carpet blank 2 prepared by the tufting process has a full and elastic appearance and has good tensile resistance, wear resistance, light aging resistance, abrasion color fastness, corrosion resistance, aging resistance, mildew resistance and flame retardancy.

[0099] More specifically, the main processing methods for tufted carpets are:

[0100] 1. Material preparation

[0101] In this embodiment, it is necessary to prepare PA6 yarn, PET non-woven fabric (upper base fabric, lower base fabric), acrylic latex (setting adhesive layer 203), and PE / PA / PE film.

[0102] Second, tufting is performed using a tufting machine, that is, the yarn 201 is mechanically guided by a needle row to tuft the base fabric in a row at a high speed to form neat and dense pile on the blanket surface, and then the pile is cut to form the first non-woven fabric layer 202.

[0103] 3. Apply acrylic latex on the side of the PET non-woven fabric without fluff, and stick the upper base fabric and the ends of the fluff into a firm whole.

[0104] 4. Use existing equipment to laminate PE / PA / PE film, PET non-woven fabric (lower base fabric) and other back materials.

[0105] Fifth, the processed product is rolled up, and then cut into pieces by a cutting device to make a tufted carpet blank 2 for standby use.

[0106] The method for preparing the automotive carpet of this embodiment further includes:

[0107] S1. Pressing

[0108] This step mainly includes the steps of preparing the tufted carpet blank 2 and the EVA rubber sheet, heating with a heating plate, infrared heating, and material compression molding. More specifically, the preparation method includes the following steps.

[0109] S101, placing the tufted carpet blank 2 and the EVA rubber sheet in the loading area of ​​the loading station of the carpet heating and compression molding equipment respectively, wherein the carpet heating and compression molding equipment is an existing equipment.

[0110] The loading station mainly includes the main frame, transfer lifting and suction mechanism, material correction platform, loading trolley, conveyor line, visual inspection system, protective net, safety grating and other mechanisms. The material picking mechanism mainly includes aluminum profiles, vacuum suction cups, acupuncture mechanisms, gear racks, linear guides and tank chains. Among them, the vacuum suction cup assembly and acupuncture mechanism can be manually adjusted in length and width, and the vacuum suction cup has a partition function to better adapt to materials of different specifications.

[0111] The material correction platform mainly includes a servo correction mechanism, a linear guide rail and a fan, etc. The fan can be used to blow the floating material to make the correction smoother. The correction of the material is completed by the servo motor, which can ensure the correction speed and accuracy.

[0112] After the equipment is started, the needle punching mechanism in the feeding area needle punches the tufted carpet blank 2 in the material-fixing platform, and the centering mechanism in the material-fixing platform fixes the tufted carpet blank 2 to a preferred position, and then the needle punching mechanism takes the tufted carpet out of the material-fixing platform and places it on the conveyor belt to wait. At the same time, the vacuum adsorption mechanism adsorbs the EVA rubber sheet in the material-fixing platform, and the centering mechanism in the material-fixing platform fixes the EVA rubber sheet to a preferred position, and then the vacuum suction cup mechanism takes the EVA rubber sheet out of the material-fixing platform, and stacks it on the tufted carpet blank 2 to align with it, and finally conveys it to the contact heating station by the conveyor belt.

[0113] S102, the tufted carpet blank 2 and the EVA rubber sheet enter the contact heating station of the carpet heating and compression molding equipment.

[0114] The contact press station mainly includes a mold temperature controller, an upper heating plate, a lower heating plate, a lifting cylinder and a synchronous lifting mechanism, a main frame, a Teflon cloth transmission mechanism, etc. The lower heating plate is fixed, and the upper heating plate is movable and lifted. The hot oil is introduced into the mold temperature controller for heating. The oil guide pipes are evenly distributed inside, and the heating is stable and uniform. The temperature can be adjusted and it is compatible with a variety of materials.

[0115] Each heating plate has its own chain structure and integrated transport platform function, making the overall structure simpler and more efficient. The heating temperature is controlled between 220℃-240℃, such as 220℃, 230℃, 240°C, and the heating time is controlled between 50 seconds and 70 seconds, such as 50 seconds, 60 seconds, 70 seconds, etc. At the same time, the contact press applies a certain pressure, and the tufted carpet blank 2 and the EVA rubber sheet are bonded together under high temperature. After the heating and baking is completed, the material dragging claws will carry it to the infrared heating area for heating.

[0116] It should be noted that if the heating temperature is too high or the heating time is too long, the tufted carpet will be burnt and the EVA rubber sheet will melt, causing the product to be scrapped. On the contrary, if the heating temperature is too low or the heating time is too short, the EVA rubber sheet may not be baked through and softened, and insufficiently stretched during molding, causing the product to tear and break. Therefore, the heating temperature and heating time are limited in this embodiment.

[0117] S103, the tufted carpet blank 2 and the EVA rubber sheet enter the infrared heating station of the carpet heating and compression molding equipment.

[0118] The infrared heating station is mainly equipped with an infrared heating oven, which includes an upper heating plate, a material dragging claw, a material support lifting platform, and a main frame. The infrared heater is the heat source element of the infrared heating machine and is the core component of the infrared heating machine. The heating uses a halogen tube heating lamp, which is more energy-efficient.

[0119] These lamps are arranged in a staggered manner to ensure uniform heating. Partition control is adopted and can be adjusted according to materials of different specifications to ensure heating efficiency and energy saving. The heating temperature of the infrared zone is between 180℃-190℃, such as 180℃, 185℃, 190℃, and the heating time is controlled between 35 seconds and 45 seconds, such as 35 seconds, 40 seconds, 45 seconds, etc.

[0120] After the infrared heating and baking is completed, the electric feeding clamps on both sides of the forming mold will deliver it to the top of the lower mold of the carpet forming mold. Among them, the electric feeding clamps include feeding clamp transfer rails, feeding clamp mechanisms, width adjustment mechanisms, lifting servo electric cylinders, width adjustment mechanisms and other parts.

[0121] S104, the tufted carpet blank 2 and the EVA rubber sheet enter the molding press station of the carpet heating molding equipment.

[0122] The forming press station is equipped with a forming press, which includes the forming press body, front and rear lifting claw mechanism, upper platform, peripheral guardrail, servo hydraulic station and other parts. This forming press is driven by a servo hydraulic station to effectively control the lifting of the slide. The use of a mold changing trolley with an electric winch to change the mold makes mold changing more labor-saving and convenient.

[0123] After the feeding jaws of the press are tightened, the tufted carpet blank 2 and the EVA rubber sheet are tightly attached to the lower mold surface of the forming mold. The forming press drives the upper mold downward to close the mold, and the holding pressure is between 6Mpa-10Mpa, such as 6Mpa, 8Mpa, 10Mpa, and the holding time is between 50 seconds and 70 seconds, such as 50 seconds, 60 seconds, and 70 seconds.

[0124] There are cold water pipes in the upper and lower molds of the forming mold, and cooling water is passed through them for cooling. The temperature of the chiller is set between 10℃-20℃, such as 10℃, 15℃, and 20℃. Excessive holding pressure, too long holding time, and too low cold water temperature will cause waste of production cycle and production energy. Insufficient holding pressure and holding time, high cold water temperature is not conducive to the cooling and shaping of the blanket, and there is a risk of deformation of the semi-finished blanket after compression molding.

[0125] S105, placing the pressed carpet blank semi-finished product into the unloading station of the carpet heating molding equipment.

[0126] The unloading station includes an unloading fixed frame, an unloading tray, an unloading tray transfer frame, an unloading tray turning mechanism, an unloading conveyor belt, an unloading conveyor belt frame, etc. After the holding time is over, the press is lifted up, the needle punching mechanism in the upper mold takes out the semi-finished blanket blank, the unloading tray is moved in, and then the upper mold needle is retracted, and the semi-finished blanket blank falls on the unloading tray.

[0127] Then, the unloading tray is moved out and turned over, and the semi-finished blanket is placed on the conveyor belt. The conveyor belt rotates to send the semi-finished blanket to the high-frequency heat sealing station, and finally the operator places the semi-finished blanket on the heat sealing tooling.

[0128] S2, high frequency heat welding forming

[0129] This step is carried out using a double-press head-automatic slide high-frequency heat sealing machine, which is an existing mechatronics device controlled by an industrial computer. It mainly includes a high-power high-frequency oscillator, a servo hydraulic press and pneumatic system, a high-frequency power output matching and automatic tracking system, a high-frequency automotive carpet mold, a PLC control and a touch screen operation display system.

[0130] The working principle of the high-frequency heat sealing machine is that under the action of the high-frequency electric field, the positive and negative charges of the molecules of the heated material will be displaced to form electric dipoles. The electric dipoles are repeatedly polarized, causing intense friction between the molecules to generate heat. In this way, the electric field energy absorbed by the material is converted into heat energy, which can achieve the purpose of heating.

[0131] Heat sealing tooling is required during the heat sealing process. The heat sealing tooling consists of a fiberglass support, a base plate, a positioning groove, a welding copper mold, a copper mold base, a snap cover insert, a forklift groove, an aviation plug, a water joint, a gas joint, an induction device, etc.

[0132] The high-frequency heat sealing machine is mainly used to install the buckle 8 on the vehicle carpet assembly, and can also be used to weld the PVC anti-skid pad 7. The operator places the buckle cover in the heat sealing tool insert, places the anti-skid pad 7 on the welding copper mold, and presses the adsorption button to adsorb the anti-skid pad 7 on the copper mold; then the semi-finished carpet blank is placed on the heat sealing tool.

[0133] Press the start button with both hands, the pulley in the equipment with the heat-sealing tooling enters the equipment workbench and is positioned, the shielding door is closed, and the buckle 8 is installed and the anti-slip pad 7 is welded.

[0134] The welding time is between 10 seconds and 15 seconds, such as 10 seconds, 12 seconds, and 15 seconds. The welding pressure is between 6Mpa and 8Mpa, such as 6Mpa, 7Mpa, and 8Mpa. The welding current is between 1.0A and 2.0A, such as 1.0A, 1.5A, and 2.0A. The cooling time is between 5 seconds and 8 seconds, such as 5 seconds, 7 seconds, and 8 seconds. The gas pressure is between 0.5Mpa and 0.8Mpa, such as 0.5Mpa, 0.6Mpa, and 0.8Mpa.

[0135] If the welding time is too long, the welding pressure and the welding current are too high, it is easy to cause the anti-skid pad 7 and the semi-finished blanket to be welded at the edge and then break down. On the contrary, if the parameters are too low, it will cause the welding to be weak and the anti-skid pad 7 to fall off.

[0136] At the same time, the buckle seat in the barrel of the equipment is sent to the linear feeding tray through the vibration plate, and the linear feeding tray sends the buckle seat to the bottom of the pressing cylinder. The lower end of the pressing cylinder is equipped with a vacuum suction cup, which first sucks up the buckle seat, moves the linear feeding tray out, and the pressing cylinder descends to install the buckle seat on the semi-finished blanket.

[0137] The air pressure is between 0.6Mpa and 0.8Mpa, such as 0.6Mpa, 0.7Mpa, and 0.8Mpa. If the air pressure of the cylinder is too high, the buckle 8 is easy to crack during installation. Otherwise, the buckle 8 is not installed firmly and is easy to fall off, which affects the quality of the vehicle carpet assembly.

[0138] S3, Foaming

[0139] In this process, carpet closed mold foaming equipment is required. Carpet closed mold foaming equipment includes wet system and dry system. The wet system includes material tank, heat exchanger, low pressure filter, flow meter, high and low pressure switching valve, hydraulic station, mixing head, metering pump, suction pump, stirring kettle, etc. The dry system includes equipment frame, press, foaming mold, hydraulic station, loading trolley, vacuum device, servo device, power unit, guide unit, electrical unit, control unit, alarm unit, safety protection unit, EPP detection unit, etc.

[0140] The carpet foaming mold includes the upper mold core, the lower mold core, the upper mold bottom plate, the lower mold bottom plate, the limit block, the guide column, the locking mold plate, the forklift slot, the air joint, the vacuum joint, the exhaust cylinder, the hand valve, etc. The foaming support includes the glass fiber reinforced plastic surface, the profile bracket, the bottom plate, the positioning plate, the positioning column, etc.

[0141] During foaming, press the origin return button, the upper platform of the press moves upward and opens, the lower platform turns 90° and stands upright, and the loading trolley returns to the initial loading position. The operator places the semi-finished carpet blank after high-frequency heat sealing on the foaming support of the loading trolley. Another operator evenly sprays the release agent on the lower mold of the carpet foaming mold, and places a pad 3 on the front row of the lower mold.

[0142] Press the start button, the trolley moves to the working area, the upper mold has adsorption holes, and the semi-finished blanket in the foam tray is adsorbed by the vacuum system, and then the loading trolley returns to the initial loading position. The visual inspection system detects whether there is a pad 3 in the lower mold. If there is no pad 3, the equipment stops running. If there is a pad 3, the lower mold is turned over and laid flat. After it is in place, the upper platform of the press machine descends with the upper mold to close the mold.

[0143] After the mold is in place, the polyurethane foam material is drawn from the two material tanks by the metering pump, sent to the mixing gun head through the high-pressure injection system, and injected into the closed mold cavity. The foam material begins to foam and form in the mold cavity. When the pressure holding time is up, the upper platform of the press moves upward with the upper mold. After the upward movement is in place, the lower mold is turned 90 degrees and stands up, and the operator takes out the product.

[0144] During this process, the temperature of the foaming material is controlled between 22°C and 28°C, such as 22°C, 25°C, and 28°C. The temperature of the lower mold is between 60°C and 70°C, such as 60°C, 65°C, and 70°C. The injection pressure of material A in the polyurethane foam material is between 120Bar and 160Bar, such as 120Bar, 140Bar, and 160Bar. The injection pressure of material B is between 120Bar and 150Bar, such as 120Bar, 135Bar, and 150Bar. The pouring flow rate is between 380g / s and 420g / s, such as 380g / s, 400g / s, and 420g / s.

[0145] In the lower model cavity, four injection guns can be used to inject AB materials. The gram weight of each injection gun is between 700g-900g, such as 700g, 800g, and 900g. The ratio of A material to B material is between 100:50-100:60, such as 100:50, 100:55, and 100:60. The holding pressure is between 10Mpa-13Mpa, such as 10Mpa, 11.5Mpa, and 13Mpa. The holding time is between 70 seconds and 90 seconds, such as 70 seconds, 80 seconds, and 90 seconds.

[0146] Too much injection foaming material is prone to overflow, resulting in waste. On the contrary, the foaming is not full, and local shortages will affect the final product quality of the vehicle carpet assembly. If the holding pressure and holding time are too low, the foaming is not easy to form, resulting in product deformation. On the contrary, it will cause low production efficiency and energy waste. Incorrect injection pressure and ratio will cause the foaming to be too soft or too hard, affecting product quality.

[0147] S4, cutting and forming

[0148] This step is specifically carried out using carpet water cutting equipment, which includes an industrial robot, an ultra-high pressure water jet pump, a robot actual pipeline, an ultra-high pressure main pipeline, a manual unloading valve group, a single workbench, a negative pressure adsorption system, a fast rolling door, a control system, a safety protection system, a mold identification system, a chiller, a softening water unit, a steel structure platform, a residual material cleaning air gun, an MES system reserved interface, an equipment reserved interface, etc.

[0149] The water jet cutting tooling includes a cast aluminum tooling body, welding profiles, base plate, aviation plug, air joint, flip cylinder, pressure clamp, etc.

[0150] Place the foamed semi-finished blanket on the water jet tooling, the foamed layer of the semi-finished blanket fits tightly with the surface of the water jet tooling, the adsorption pressure is between -5Kpa--1Kpa, such as -5Kpa, -3Kpa, -1Kpa, the high pressure of water jet is between 3000Bar-4000Bar, such as 3000Bar, 3500Bar, 4000Bar. The air pressure of the water jet high pressure robot is controlled between 0.5Mpa-0.8Mpa, such as 0.5Mpa, 0.6Mpa, 0.7Mpa, 0.8Mpa.

[0151] According to the set cutting program, along a certain trajectory path, cutting is performed (three arms cutting simultaneously) to remove the edge and hole excess of the semi-finished carpet. It should be noted that if the above adsorption pressure is too high or too low, the carpet cutting size will be unstable, and low water pressure in water cutting will cause the problem of not being able to cut the semi-finished carpet blank.

[0152] S5, footrest 6 assembly

[0153] This step requires the use of the existing carpet footrest 6 installation tooling, which includes an equipment frame, forklift holes, nylon support blocks, cylinders, clamping blocks, sensors, air joints, aviation plugs, touch screens, PLCs, etc.

[0154] During assembly, the cut blanket semi-finished product is placed on the footrest 6 tooling with the PU foam layer facing upwards. The operator positions the footrest 6 in the nylon support block on the tooling, and the boss columns on the footrest 6 extend to the back of the blanket along the cut holes.

[0155] Then place each footrest card 5 on the boss column of the footrest 6 from the back side of the semi-finished blanket (the side without fluff). When the induction switch on the footrest 6 tooling detects the presence of the semi-finished blanket, the footrest 6, and the footrest card 5, press the start button with both hands, and the cylinder pushes out the clamping block for pressing.

[0156] The pressure holding pressure is between 0.5Mpa and 0.8Mpa, such as 0.5Mpa, 0.6Mpa, 0.7Mpa, and 0.8Mpa, and the pressure holding time is between 4 seconds and 6 seconds, such as 4 seconds, 5 seconds, and 6 seconds. In this process, low pressure and short pressure holding time will cause the footrest 6 to be unsecured, easy to loosen, and not fit the surface of the carpet, affecting the appearance quality.

[0157] S6. Image detection

[0158] This step is performed by existing carpet image detection equipment, which includes an equipment frame, a workbench, a camera, a carpet mold, an electrical cabinet, a display unit, an alarm unit, a start button, a lighting lamp, etc.

[0159] During the inspection, the finished product of the vehicle carpet assembly is placed on the image inspection tooling, and the carpet image inspection equipment is used to detect whether the carpet accessories such as buckles 8, anti-slip pads 7, and footrests 6 are missing, whether there is excess material in the surrounding holes, and whether the holes are missed.

[0160] If accessories are missing or there is excess material or a hole is missed, the corresponding position on the carpet will be shown on the display screen of the carpet image detection equipment, and the buzzer will sound an alarm to indicate that the product is unqualified. The product will then be sent to the unqualified product area by the operator; if it is qualified, the operator will send the finished vehicle carpet assembly to the finished product tooling truck.

[0161] The vehicle carpet assembly prepared by the method of this embodiment has good sound insulation, sound absorption, environmental protection, and noise reduction, which can bring users a quiet and comfortable use environment and improve the NVH performance in the car. In the vehicle carpet assembly, the sound insulation layer 1 prepared by the EVA rubber sheet can play a good sound insulation effect, and the sound absorption layer 4 prepared by the polyurethane foam material has fine pores and a high open porosity, which can play a good sound absorption and noise reduction effect.

[0162] The above are only preferred embodiments of the present invention and are 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 tufted carpet blank, characterized in that: It comprises a first non-woven fabric layer (202), a shaping adhesive layer (203), a barrier film layer (204) and a second non-woven fabric layer (205) which are compounded in sequence; Yarns (201) are provided on the surface of the first non-woven fabric layer (202); the yarns (201) are woven on the non-woven fabric by a tufting process, so that fluff is formed on the surface of the first non-woven fabric layer (202).

2. The tufted carpet blank according to claim 1, characterized in that: The yarn (201) comprises PA6 yarn (201); The first non-woven fabric layer (202) and the second non-woven fabric layer (205) are made of PET non-woven fabric; The setting glue comprises acrylic latex, and the barrier film is a PE / PA / PE co-extruded film.

3. The tufted carpet blank according to claim 1 or 2, characterized in that: The height of the villi is between 1.8 mm and 2.2 mm; The acrylic latex has a gram weight between 70g / ㎡ and 120g / ㎡; The thickness of the PE / PA / PE co-extruded film is between 0.15 mm and 2 mm; The gram weight of the PET non-woven fabric is between 100g / ㎡ and 120g / ㎡.

4. A vehicle carpet assembly, characterized in that: A tufted carpet blank (2) comprising any one of claims 1 to 3; In the front-to-rear direction of the vehicle, the front part of the tufted carpet blank (2) is compounded with a sound insulation layer (1) and a first sound absorbing layer (401) arranged in sequence, and the rear part of the tufted carpet blank (2) is compounded with a second sound absorbing layer (402).

5. The vehicle carpet assembly according to claim 4, characterized in that: A cushion block (3) is embedded in the first sound-absorbing layer (401), and the cushion block (3) is made of EPP.

6. The vehicle carpet assembly according to claim 5, characterized in that: The front part of the vehicle carpet assembly has a treading area (207), and the pad (3) is provided at the treading area (207); and / or, The front part of the carpet assembly comprises a treading area (207) and an upward warping area (206), and the pad (3) is provided at the connection part between the treading area (207) and the upward warping area (206).

7. The vehicle carpet assembly according to claim 6, characterized in that: The treading area (207) is provided with an anti-skid pad (7), and the thickness of the anti-skid pad (7) is between 0.8 mm and 1.2 mm.

8. The vehicle carpet assembly according to any one of claims 4 to 7, characterized in that: The sound insulation layer (1) is made of EVA rubber sheet, and the sound absorption layer (4) is made of polyurethane foam material; and / or, The thickness of the sound insulation layer (1) is between 1.3 mm and 1.7 mm, and the thickness of the sound absorption layer (4) is between 5 mm and 50 mm.

9. A method for preparing a vehicle carpet assembly, characterized in that: The preparation method comprises: Preparing a tufted carpet blank (2); A sound insulation layer (1) is compounded on the front of the tufted carpet blank (2); The first sound absorbing layer (401) is compounded on the sound insulation layer (1), and the second sound absorbing layer (402) is compounded on the rear of the tufted carpet blank (2) to form the vehicle carpet assembly.

10. The method for preparing a vehicle carpet assembly according to claim 9, characterized in that: The preparation method of the tufted carpet blank (2) comprises: The yarn (201) is knitted onto the non-woven fabric by a tufting process, so that a first non-woven fabric layer (202) with fluff is formed on the surface of the molded fabric; The first non-woven fabric layer (202), the shaping adhesive layer (203), the barrier film layer (204) and the second non-woven fabric layer (205) are sequentially compounded together to form the tufted carpet blank (2).

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