Square carpet and manufacturing method thereof

Abstract

The square carpet comprises a base, a panel is clamped to the top of the base, clamping frames are fixedly installed on the opposite sides of the base and the panel, a buckle is fixedly installed on the right side of the panel, two clamping grooves are formed in the left side of the panel, a non-woven fabric layer is fixedly installed in the base, and the non-woven fabric layer is fixedly installed in the non-woven fabric layer. A glass fiber layer is attached to the top of the non-woven fabric layer, a polyolefin hot melt adhesive layer is attached to the top of the glass fiber layer, an EVA coating is attached to the top of the polyolefin hot melt adhesive layer, and a glue surface layer is attached to the top of the EVA coating. According to the technical scheme, the extrusion stretchability of the carpet can be effectively improved, the service life of the carpet is prolonged, the carpet has the advantages of high rebound resilience, water resistance, excellent weather resistance, heat insulation, heat preservation, ultraviolet resistance, aging resistance and capability of preventing moisture from being accumulated in the carpet, and the square carpet is more comfortable, higher in rebound resilience, better in waterproofness and better in service life. And the requirements of users are met.

Description

Technical Field

[0001] The invention relates to the field of carpets, in particular to a square carpet and a manufacturing method thereof. Background Art

[0002] Square carpet is a kind of high-end low-carbon decorative material that has become popular in recent years. It is not used alone as a mat in a specific location in the room. It is usually laid by splicing a large number of pieces. It is small in shape, usually 50x50cm or 60x60cm. Square splicing carpet is mainly used in offices, business meetings and other places. It is easy to install and the pattern combination is random. The common square splicing carpets on the market are divided into two types: polypropylene and nylon.

[0003] A new type of warp knitted spliced ​​square carpet and its continuous production method disclosed by searching 20211162859.9 have excellent wear resistance. In the castor chair test, under a load of 90kg, there is no damage after 3,000 laps. The waterproof and anti-fouling properties are strong: the upper surface of the carpet has been specially treated, which can play a good waterproof and anti-fouling effect. Water droplets dripping on the carpet surface are completely spherical, and will not wet the carpet or penetrate into the carpet structure. In addition, the continuous production method effectively improves production efficiency and is conducive to large-scale production.

[0004] However, the flexibility of the above-mentioned carpet is too hard due to the special processing technology, and the surface comfort is poor. Users cannot experience the comfort of the carpet when lying on it, and it does not have a rebound effect. After sitting on it, the carpet will be compressed together and has no fluffy feeling. The overall user experience is poor and it is difficult to meet the growing needs of users. Summary of the invention

[0005] The main purpose of the present invention is to provide a carpet tile and a method for manufacturing the same, aiming to improve the comfort and / or elasticity of existing carpets.

[0006] To achieve the above-mentioned purpose, the present invention proposes a square carpet, including a base, a panel is clamped on the top of the base, a clamping frame is fixedly installed on the opposite sides of the base and the panel, a buckle is fixedly installed on the right side of the panel, and two clamping slots are provided on the left side of the panel, a non-woven fabric layer is fixedly installed inside the base, a glass fiber layer is bonded to the top of the non-woven fabric layer, a polyolefin hot melt adhesive layer is bonded to the top of the glass fiber layer, an EVA coating is bonded to the top of the polyolefin hot melt adhesive layer, and a glue surface layer is bonded to the top of the EVA coating.

[0007] In one embodiment, the base and the panel are both plush blanket blanks, the snap-fit ​​frame is a rubber frame, and the base, the snap-fit ​​frame and the panel are spliced ​​together by a hot-melt process.

[0008] In one embodiment, the inner diameter of the slot is adapted to the buckle and is arranged bilaterally symmetrically.

[0009] In one embodiment, the non-woven fabric layer is made of the following raw materials in parts by weight: 40-50 parts of polypropylene resin, 10-18 parts of polyester fiber, 8-15 parts of polyester fiber; The nonwoven fabric layer is produced by using the above materials through a spunbonding process.

[0010] In one embodiment, the glass fiber layer is made of the following raw materials in parts by weight: 20-40 parts of pyrophyllite, 10-15 parts of quartz sand, 2-4 parts of limestone, 0.5-3 parts of dolomite, 1-3 parts of colemanite, 2-7 parts of boraxite; The glass fiber layer is manufactured by the processes of high-temperature melting, wire drawing, yarn winding and weaving of the above materials.

[0011] In one embodiment, the polyolefin hot melt adhesive layer is made of the following raw materials in parts by weight: 20-35 parts of amorphous propylene, 10-18 parts of amorphous propylene-ethylene, 5-11 parts of amorphous propylene-butene, 2-8 parts of amorphous propylene-hexene, 10-15 parts of amorphous propylene-ethylene-butene, 3-12 parts of tackifier, 2-5 parts of wax and 1-3 parts of plasticizer.

[0012] In one embodiment, the EVA coating is made of the following raw materials in parts by weight: 3-5 parts of maleic anhydride graft compatibilizer, 10-25 parts of thermoplastic polyolefin elastomer, 2-5 parts of wax, 2-5 parts of tackifying resin, 50-70 parts of filler and 3-8 parts of reinforcing agent; The EVA coating is a polyolefin elastomer hot melt adhesive.

[0013] In one embodiment, the plush blanket blanks used for the base and the panel are fixedly installed on the top and bottom of the snap-fit ​​frame, and the non-woven fabric layer, glass fiber layer, polyolefin hot melt adhesive layer, EVA coating and glue surface layer are all inside the snap-fit ​​frame.

[0014] A method for manufacturing a carpet tile, comprising any one of the above methods for manufacturing a carpet tile, wherein the manufacturing method is as follows: Step 1: Appearance manufacturing: hot press the rubber raw material into a square frame of 50cm×50cm×1cm, and glue the plush blanket blank to the bottom of the square frame with industrial glue; Step 2: Filling layer manufacturing: ① Taking the above-mentioned raw materials in parts by weight of polypropylene resin, polyester fiber and polyester fiber, a non-woven fabric layer is made by a spunbond process; ② Take the above raw materials in parts by weight, such as pyrophyllite, quartz sand, limestone, dolomite, colemanite and magnesia stone, and make them into glass fiber layers through high temperature melting, wire drawing, yarn winding and weaving; ③ Taking the above-mentioned raw materials in parts by weight, amorphous propylene, amorphous propylene-ethylene, amorphous propylene-butene, amorphous propylene-hexene, amorphous propylene-ethylene-butene, tackifier, wax and plasticizer, and mixing them to make a polyolefin hot melt adhesive layer; ④ Take the maleic anhydride graft compatibilizer, thermoplastic polyolefin elastomer, wax, tackifying resin, filler and reinforcing agent of the above raw materials in parts by weight and mix them to make EVA coating through hot melting; Step 3: Carpet assembly: stack the above filling layers in sequence, heat-press them, and then apply a layer of glue on the surface. Put the finished filling layers into the snap-fit ​​frame to ensure that the four sides are completely in contact with the snap-fit ​​frame. Step 4: Carpet packaging: Inject industrial glue into the interior of the snap-fit ​​frame, adhere the top layer of carpet plush to the top of the snap-fit ​​frame, and squeeze the square carpet to a size of 60cm×60cm×2cm.

[0015] In one embodiment, each filling layer in step 2 is made into a block with a size of 48cm×48cm×0.8cm, and the filling layers in step 3 are arranged from bottom to top in the order of non-woven fabric layer, glass fiber layer, polyolefin hot melt adhesive layer and EVA coating.

[0016] The technical solution of the present invention uses a non-woven fabric layer, a glass fiber layer, a polyolefin hot melt adhesive layer, and an EVA coating as the filling inner layer. The non-woven fabric has the advantages of being moisture-proof, breathable, flexible, thin and flame-retardant. It can be used in carpets to increase the air permeability and flexibility of the carpet. The glass fiber has high tensile strength, high elastic coefficient, large elongation within the elastic limit and high tensile strength, large impact energy absorption, and good processability. It can be made into products in different forms such as strands, bundles, felts, and woven fabrics, and is not easy to burn. It can effectively improve the extrusion and stretchability of the carpet and increase the service life of the carpet. The polyolefin hot melt adhesive has good barrier properties and can effectively isolate sweat and moisture from entering the interior of the carpet. The EVA coating has the advantages of high resilience, excellent water resistance and weather resistance, heat insulation, UV resistance, anti-aging, and the ability to prevent moisture from accumulating inside the carpet, making the square carpet more comfortable, more resilient, and more waterproof, and more in line with user needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0018] Figure 1 It is a structural exploded diagram of the present invention; Figure 2 is a schematic diagram of an assembly embodiment of the present invention; Figure 3 It is a flow chart of the manufacturing method of the present invention.

[0019] The following are the descriptions of the reference numerals: 1. Base; 2. Panel; 3. Snap-on frame; 4. Buckle; 5. Slot; 6. Non-woven fabric layer; 7. Glass fiber layer; 8. Polyolefin hot melt adhesive layer; 9. EVA coating; 10. Glue surface layer. Implementation

[0020] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] It should be noted that if the embodiments of the present invention involve directional indications (such as up, down, left, right, front, back, etc.), the directional indications are only used to explain the relative position relationship, movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly.

[0022] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" 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 an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0023] In addition, if there are descriptions involving "first", "second", etc. in the embodiments of the present invention, the descriptions of "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying their relative importance or implicitly indicating the number of technical features indicated. Therefore, the features defined as "first" and "second" may explicitly or implicitly include at least one of the features. In addition, the meaning of "and / or" appearing in the full text includes three parallel schemes. Taking "A and / or B" as an example, it includes scheme A, or scheme B, or a scheme that satisfies both A and B. In addition, the technical solutions between the various embodiments can be combined with each other, but it must be based on the ability of ordinary technicians in the field to implement. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such a combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0024] Reference Figure 1-3 In one embodiment of the invention, a square carpet is characterized in that it includes a base 1, a panel 2 is clamped on the top of the base 1, a clamping frame 3 is fixedly installed on the opposite sides of the base 1 and the panel 2, a buckle 4 is fixedly installed on the right side of the panel 2, and two clamping slots 5 are provided on the left side of the panel 2, a non-woven fabric layer 6 is fixedly installed inside the base 1, a glass fiber layer 7 is bonded to the top of the non-woven fabric layer 6, a polyolefin hot melt adhesive layer 8 is bonded to the top of the glass fiber layer 7, an EVA coating 9 is bonded to the top of the polyolefin hot melt adhesive layer 8, and a glue surface layer 10 is bonded to the top of the EVA coating 9.

[0025] The technical solution of the present invention can effectively improve the extrusion stretchability of the carpet, increase the service life of the carpet, has good barrier properties and can effectively isolate sweat and moisture from entering the interior of the carpet, has the advantages of high resilience, water resistance, excellent weather resistance, heat insulation, UV resistance, anti-aging and the ability to prevent moisture from accumulating inside the carpet, making the square carpet more comfortable, more resilient, and more waterproof, and better meeting the needs of users.

[0026] Typically, the nonwoven fabric layer 6 is made of the following raw materials in parts by weight: 40 parts of polypropylene resin, 10 parts of polyester fiber, 15 parts of polyester fiber; The nonwoven fabric layer 6 is produced by using the above-mentioned materials through a spunbonding process.

[0027] By adopting the above technical method, the non-woven fabric has the advantages of moisture-proof, breathable, flexible, thin and flame-retardant. It can be used in carpets to increase the breathability and flexibility of the carpets.

[0028] In this embodiment, the glass fiber layer 7 is made of the following raw materials in parts by weight: 40 parts of pyrophyllite, 10 parts of quartz sand, 2 parts of limestone, 1.5 parts of dolomite, 2 parts of colemanite, 4 parts of boraxite; The glass fiber layer 7 is manufactured by the above materials through high temperature melting, wire drawing, yarn winding and weaving processes.

[0029] In the above technical solution, the glass fiber has high tensile strength, high elastic modulus, large elongation within the elastic limit and high tensile strength, large impact energy absorption, good processability, can be made into products in different forms such as strands, bundles, felts, and woven fabrics, is not easy to burn, and can effectively improve the extrusion and stretchability of the carpet and increase the service life of the carpet.

[0030] In this embodiment, further, the polyolefin hot melt adhesive layer 8 is made of the following raw materials in parts by weight: 35 parts of amorphous propylene, 10 parts of amorphous propylene-ethylene, 5 parts of amorphous propylene-butene, 2 parts of amorphous propylene-hexene, 10 parts of amorphous propylene-ethylene-butene, 3 parts of tackifier, 3 parts of wax and 1 part of plasticizer.

[0031] In the above technical solution, the polyolefin hot melt adhesive has good barrier properties and can effectively isolate sweat and moisture from entering the interior of the carpet.

[0032] In this embodiment, optionally, the EVA coating 9 is made of the following raw materials in parts by weight: 5 parts of maleic anhydride graft compatibilizer, 10 parts of thermoplastic polyolefin elastomer, 2 parts of wax, 2 parts of tackifying resin, 70 parts of filler and 3 parts of reinforcing agent; The EVA coating 9 is a polyolefin elastomer hot melt adhesive.

[0033] In this embodiment, the EVA coating has the advantages of high resilience, excellent water resistance, weather resistance, heat insulation, UV resistance, anti-aging and the ability to prevent moisture from accumulating inside the carpet.

[0034] A method for manufacturing a carpet tile, characterized in that it comprises the method for manufacturing a carpet tile according to any one of claims 1 to 8, and the manufacturing method is as follows: Step 1: Appearance manufacturing: hot press the rubber raw material into a square frame of 50cm×50cm×1cm, and glue the plush blanket blank to the bottom of the square frame with industrial glue; Step 2: Filling layer manufacturing: ① Take the above-mentioned raw materials of polypropylene resin, polyester fiber and polyester fiber in parts by weight and make a non-woven fabric layer 6 through a spunbond process; ② Take the above raw materials in parts by weight, such as pyrophyllite, quartz sand, limestone, dolomite, colemanite and magnesia stone, and make them into glass fiber layer 7 through high temperature melting, wire drawing, yarn winding and weaving; ③ Take the above-mentioned raw materials in parts by weight of amorphous propylene, amorphous propylene-ethylene, amorphous propylene-butene, amorphous propylene-hexene, amorphous propylene-ethylene-butene, tackifier, wax and plasticizer, mix and react to make a polyolefin hot melt adhesive layer 8; ④ Take the above-mentioned raw materials in parts by weight of maleic anhydride graft compatibilizer, thermoplastic polyolefin elastomer, wax, tackifying resin, filler and reinforcing agent and mix them to make EVA coating 9 through hot melting; Step 3, carpet assembly: stack the above filling layers in sequence, heat-press them, and then apply a glue surface layer 10 on the surface, and put the processed filling layers into the inside of the snap-fit ​​frame 3 to ensure that the four sides are completely in contact with the snap-fit ​​frame 3; Step 4: Carpet packaging: Inject industrial glue into the interior of the snap-fit ​​frame 3, adhere the top layer of the carpet plush blank to the top of the snap-fit ​​frame 3, and squeeze the square carpet to achieve a specification of 60cm×60cm×2cm.

[0035] Furthermore, in step 2, each filling layer is made into a block with a size of 48 cm×48 cm×0.8 cm, and in step 3, the filling layers are arranged from bottom to top in the order of non-woven fabric layer 6, glass fiber layer 7, polyolefin hot melt adhesive layer 8 and EVA coating 9.

[0036] The above description is only a preferred embodiment of the present invention, and does not limit the patent scope of the present invention. All equivalent structural changes made by using the contents of the present invention specification and drawings under the inventive concept of the present invention, or directly / indirectly applied in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A carpet tile, characterized in that: The invention comprises a base (1), a panel (2) being clamped on the top of the base (1), a clamping frame (3) being fixedly mounted on opposite sides of the base (1) and the panel (2), a buckle (4) being fixedly mounted on the right side of the panel (2), two clamping slots (5) being provided on the left side of the panel (2), a non-woven fabric layer (6) being fixedly mounted inside the base (1), a glass fiber layer (7) being bonded to the top of the non-woven fabric layer (6), a polyolefin hot melt adhesive layer (8) being bonded to the top of the polyolefin hot melt adhesive layer (8), an EVA coating (9) being bonded to the top of the EVA coating (9), and a glue surface layer (10) being bonded to the top of the EVA coating (9).

2. A carpet tile as claimed in claim 1, characterized in that: The base (1) and the panel (2) are both plush blanket blanks, the snap-fit ​​frame (3) is a rubber frame, and the base (1), the snap-fit ​​frame (3) and the panel (2) are spliced ​​together by a hot-melt process.

3. A carpet tile as claimed in claim 1, characterized in that: The inner diameter of the clamping slot (5) is adapted to the buckle (4) and is arranged in a bilaterally symmetrical manner.

4. A carpet tile as claimed in claim 1, characterized in that: The non-woven fabric layer (6) is made of the following raw materials in parts by weight: 40-50 parts of polypropylene resin, 10-18 parts of polyester fiber, 8-15 parts of polyester fiber; The non-woven fabric layer (6) is produced by using the above-mentioned material using a spunbonding process.

5. The carpet tile according to claim 1, characterized in that: The glass fiber layer (7) is made of the following raw materials in parts by weight: 20-40 parts of pyrophyllite, 10-15 parts of quartz sand, 2-4 parts of limestone, 0.5-3 parts of dolomite, 1-3 parts of colemanite, 2-7 parts of boraxite; The glass fiber layer (7) is manufactured by the above-mentioned material through a process of high-temperature melting, wire drawing, yarn winding, and weaving.

6. A carpet tile as claimed in claim 1, characterized in that: The polyolefin hot melt adhesive layer (8) is made of the following raw materials in parts by weight: 20-35 parts of amorphous propylene, 10-18 parts of amorphous propylene-ethylene, 5-11 parts of amorphous propylene-butene, 2-8 parts of amorphous propylene-hexene, 10-15 parts of amorphous propylene-ethylene-butene, 3-12 parts of tackifier, 2-5 parts of wax and 1-3 parts of plasticizer.

7. The carpet tile according to claim 1, characterized in that: The EVA coating (9) is made of the following raw materials in parts by weight: 3-5 parts of maleic anhydride graft compatibilizer, 10-25 parts of thermoplastic polyolefin elastomer, 2-5 parts of wax, 2-5 parts of tackifying resin, 50-70 parts of filler and 3-8 parts of reinforcing agent; The EVA coating (9) is a polyolefin elastomer hot melt adhesive.

8. The carpet tile according to claim 2, characterized in that: The plush blanket blanks used in the base (1) and the panel (2) are fixedly mounted on the top and bottom of the snap-fit ​​frame (3); the non-woven fabric layer (6), the glass fiber layer (7), the polyolefin hot melt adhesive layer (8), the EVA coating (9) and the glue surface layer (10) are all located inside the snap-fit ​​frame (3).

9. A method for manufacturing a carpet tile, characterized in that: A method for making a carpet tile according to any one of claims 1 to 8, wherein the method is as follows: Step 1: Appearance manufacturing: hot press the rubber raw material into a square frame of 50cm×50cm×1cm, and glue the plush blanket blank to the bottom of the square frame with industrial glue; Step 2: Filling layer manufacturing: ① Taking the above-mentioned raw materials of polypropylene resin, polyester fiber and polyester fiber in parts by weight and making a non-woven fabric layer (6) through a spunbond process; ② The above raw materials of pyrophyllite, quartz sand, limestone, dolomite, colemanite and magnesia stone in parts by weight are melted at high temperature, drawn, wound and woven to form a glass fiber layer (7); ③ Taking the above raw materials in parts by weight of amorphous propylene, amorphous propylene-ethylene, amorphous propylene-butene, amorphous propylene-hexene, amorphous propylene-ethylene-butene, tackifier, wax and plasticizer, mixing and reacting them to prepare a polyolefin hot melt adhesive layer (8); ④ Take the above raw materials in parts by weight of maleic anhydride graft compatibilizer, thermoplastic polyolefin elastomer, wax, tackifying resin, filler and reinforcing agent and mix them to make EVA coating (9); Step 3, carpet assembly: stack the above filling layers in sequence, heat-press them, and then apply a glue surface layer (10) on the surface, and place the processed filling layers into the inside of the snap-fit ​​frame (3), ensuring that the four sides are completely in contact with the snap-fit ​​frame (3); Step 4: Carpet packaging: Inject industrial glue into the interior of the snap-fit ​​frame (3), then adhere the top layer of carpet plush to the top of the snap-fit ​​frame (3), and squeeze the square carpet to achieve a specification of 60cm×60cm×2cm.

10. The method for manufacturing a carpet tile according to claim 9, characterized in that: In step 2, each filling layer is made into a block with a size of 48 cm×48 cm×0.8 cm. In step 3, the filling layers are arranged from bottom to top in the order of non-woven fabric layer (6), glass fiber layer (7), polyolefin hot melt adhesive layer (8) and EVA coating layer (9).

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