Composite carpet production line and processing method

Abstract

The invention discloses a composite carpet production line and a processing method. The composite carpet production line comprises a tufted carpet unwinding device, a PVC film unwinding device and a composite carpet winding device, and further comprises a composite leveling device; the tufted carpet unwinding device, the PVC film unwinding device and the composite leveling device are all fixedly installed on the main support, the tufted carpet unwinding device and the PVC film unwinding device are arranged in parallel, and the composite leveling device is located between the composite carpet winding devices; the tufted blanket unwinding device is used for unwinding the tufted blanket to be compounded with the PVC film; the tufted blanket unwinding device is an unwinding roller wound with a tufted blanket; the PVC film unwinding device is used for unwinding a PVC film to be compounded; the PVC film unwinding device is an unwinding roller wound with a PVC film; the composite carpet winding device is used for winding the preliminarily fitted composite carpet; the composite leveling device is used for leveling the tufted blanket located on the surface of the PVC film, so that the tufted blanket is attached to the PVC film, and the tufted blanket is prevented from wrinkling on the surface of the PVC film.

Description

Technical Field

[0001] The invention relates to the field of carpet processing, in particular to a composite carpet production line and a processing method. 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 array 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, 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 them into the anti-skid layer.

[0003] During use of existing composite carpet fabric composite equipment, the carpet fabric is prone to slackening during the laying process, resulting in partial wrinkles on the composite carpet fabric.

[0004] Therefore, it is necessary for us to improve such a structure to overcome the above-mentioned defects. Summary of the invention

[0005] The object of the present invention is to provide a composite carpet production line and a processing method to solve the problems raised in the above background technology.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] Composite carpet production line, including tufted carpet unwinding device, PVC film unwinding device and composite carpet winding device, and also including composite flattening device;

[0008] The tufted carpet unwinding device, the PVC film unwinding device and the composite flattening device are all fixedly mounted on the main bracket, wherein the tufted carpet unwinding device and the PVC film unwinding device are arranged in parallel, and the composite flattening device is located between the composite carpet winding device;

[0009] The tufted carpet unwinding device is used for unwinding the tufted carpet to be laminated with the PVC film; the tufted carpet unwinding device is an unwinding roller wound with the tufted carpet;

[0010] The PVC film unwinding device is used for unwinding the PVC film to be compounded; the PVC film unwinding device is an unwinding roller wound with the PVC film;

[0011] The composite carpet rolling device is used to roll up the composite carpet that has been preliminarily fitted;

[0012] The composite leveling device is fixedly installed on the main bracket, and the composite leveling device includes a linear module, a movable leveling platform and a fixed leveling platform; the movable leveling platform is fixedly installed on the slide of the linear module; first side plates are arranged on both sides of the top of the movable leveling platform, and a first top plate is arranged on the top of the first side plate, wherein a first leveling cylinder is fixedly installed on the first top plate, and the output shaft of the first leveling cylinder passes through the first top plate and is fixedly connected to the first leveling roller; the fixed leveling platform is fixedly installed on the main bracket and is located on one side of the movable leveling platform, wherein second side plates are arranged on both sides of the top of the fixed leveling platform, and a second top plate is arranged on the top of the second side plate, wherein a second leveling cylinder is fixedly installed on the second top plate, and the output shaft of the second leveling cylinder passes through the second top plate and is fixedly connected to the second leveling roller; the composite leveling device also includes a smooth guide belt, and the smooth guide belt transmission is arranged between the front guide roller, the rear guide roller and between the two lower guide rollers, and the smooth guide belt is an inverted isosceles trapezoid as a whole, and the smooth guide belt is located above the fixed leveling platform and the movable leveling platform and below the first leveling roller and the second leveling roller.

[0013] The processing method of the composite carpet specifically comprises the following steps:

[0014] S1, making a base fabric, needle-punching the non-woven fiber into a base fabric through a needle-punching machine;

[0015] S2, coating, applying latex on one side of the base fabric layer to form a glue layer on one side of the base fabric layer; the coating amount of the latex is -g / m;

[0016] S3, tufting, implanting fiber filaments on the base fabric through a tufting machine, when implanting the fiber filaments on the base fabric, the fiber filaments penetrate into the base fabric from the side of the base fabric away from the adhesive layer, and then penetrate out from the side of the adhesive layer away from the base fabric, the fiber filaments form loop pile on the side of the base fabric away from the adhesive layer, and the loop pile formed on the base fabric constitutes a tufting layer;

[0017] S4, hot-bottoming, using a hot-bottoming machine to heat the side of the adhesive layer away from the base fabric to melt the fiber filaments passing through the base fabric;

[0018] S5, smoothing, smoothing the melted fiber filaments on the adhesive layer to shorten the length of the fiber filaments after passing through the base fabric;

[0019] S6, cooling, so that the melted and smoothed fiber filaments are cooled and solidified to obtain a tufted carpet;

[0020] S7: attaching a PVC film, laminating the PVC film on the end surface of the adhesive layer away from the base fabric, and rolling it up; in this step, the composite carpet production line described above is used to obtain a preliminarily fitted composite carpet;

[0021] S8. Move the film into a heat press for heat pressing, so that the melted and smoothed fiber filaments are sandwiched between the PVC film and the adhesive layer.

[0022] Furthermore, the yarn in step S1 is white yarn.

[0023] Furthermore, the step S2 also includes printing a preset pattern on one side of the tufted yarn after drying the latex; the printing process is to put the dried tufted carpet surface into a printer, and after printing by the printer, pass through a steamer for color fixation, a washing machine for water washing and an oven for drying.

[0024] Furthermore, the drying temperature is 100° C. and the drying time is 5-10 minutes.

[0025] Furthermore, the latex is selected from SBR latex or NBR latex, and is first foamed by a foaming machine, and then coated on the non-tufted side of the non-woven fabric by a rubber coating roller, and the latex plays a role in bonding the TPE backing and the non-woven fabric.

[0026] Furthermore, the temperature range of the hot press during hot pressing is 180°C-200°C.

[0027] Furthermore, the pressure range of the hot press during hot pressing is 0.1-0.3 MPA.

[0028] Furthermore, the holding time of the hot press during hot pressing is in the range of 1-3 minutes.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] Due to the different elasticity of the PVC film and the tufted carpet, the tufted carpet is prone to wrinkles on the surface of the PVC film before entering the hot press for compounding, which makes the PVC at the bottom of the composite carpet after hot pressing easy to break; the composite flattening device is used to flatten the tufted carpet on the surface of the PVC film, thereby ensuring the fit of the tufted carpet and the PVC film and preventing the tufted carpet from wrinkling on the surface of the PVC film. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 It is a structural schematic diagram of a composite carpet production line.

[0032] Figure 2 It is a front view of a composite carpet production line.

[0033] Figure 3 A side view of a composite carpet production line.

[0034] Figure 4 A top view of a composite carpet production line.

[0035] Figure 5 It is a schematic diagram of the structure of the composite flattening device in the composite carpet production line.

[0036] Figure 6It is a front view of the composite flattening device in the composite carpet production line.

[0037] Figure 7 It is a side view of the composite flattening device in the composite carpet production line.

[0038] Figure 8 It is a top view of the composite flattening device in the composite carpet production line.

[0039] Fig. 9 for Figure 7 Sectional view along AA direction. DETAILED DESCRIPTION

[0040] In order to make the purpose, technical scheme and advantages of the embodiments of the present invention clearer, the technical scheme in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. The components of the embodiments of the present invention generally described and shown in the drawings here can be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the present invention. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work belong to the scope of protection of the present invention.

[0041] See also Figure 1-4 , a composite carpet production line, comprising a tufted carpet unwinding device 1, a PVC film unwinding device 2 and a composite carpet winding device 3, and also comprising a composite flattening device 4;

[0042] The tufted carpet unwinding device 1, the PVC film unwinding device 2 and the composite flattening device 4 are all fixedly mounted on the main bracket 5, wherein the tufted carpet unwinding device 1 and the PVC film unwinding device 2 are arranged in parallel, and the composite flattening device 4 is located between the composite carpet winding device 3;

[0043] The tufted carpet unwinding device 1 is used for unwinding the tufted carpet to be laminated with the PVC film; the tufted carpet unwinding device 1 is an unwinding roller wound with the tufted carpet;

[0044] The PVC film unwinding device 2 is used for unwinding the PVC film to be compounded; the PVC film unwinding device 2 is an unwinding roller wound with the PVC film;

[0045] The composite carpet rolling device 3 is used to roll up the composite carpet that has been preliminarily fitted;

[0046] Due to the different elasticity of the PVC film and the tufted carpet, the tufted carpet is prone to wrinkles on the surface of the PVC film before entering the hot press for compounding, which makes the PVC at the bottom of the composite carpet after hot pressing easy to break; the composite flattening device 4 is used to flatten the tufted carpet on the surface of the PVC film, thereby ensuring the adhesion of the tufted carpet and the PVC film and preventing the tufted carpet from wrinkling on the surface of the PVC film;

[0047] like Figure 5-9 As shown, the composite leveling device 4 is fixedly installed on the main bracket 5, and the composite leveling device 4 includes a linear module 401, a movable leveling platform 402 and a fixed leveling platform 410;

[0048] A movable leveling platform 402 is fixedly installed on the slide of the linear module 401; first side plates 403 are arranged on both sides of the top of the movable leveling platform 402, and a first top plate 404 is arranged on the top of the first side plate 403, wherein a first leveling cylinder 405 is fixedly installed on the first top plate 404, and the output shaft of the first leveling cylinder 405 passes through the first top plate 404 and is fixedly connected to a first leveling roller 406;

[0049] The fixed leveling platform 410 is fixedly mounted on the main support 5 and is located on one side of the movable leveling platform 402, wherein second side plates 411 are arranged on both sides of the top of the fixed leveling platform 410, and a second top plate 412 is arranged on the top of the second side plate 411, wherein a second leveling cylinder 413 is fixedly mounted on the second top plate 412, and an output shaft of the second leveling cylinder 413 passes through the second top plate 412 and is fixedly connected to a second leveling roller 414;

[0050] The composite leveling device 4 further includes a smooth guide belt 420, which is arranged between a front guide roller 421, a rear guide roller 422 and two lower guide rollers 423, and the smooth guide belt 420 is an inverted isosceles trapezoid as a whole, and is located above the fixed leveling platform 410 and the movable leveling platform 402 and below the first leveling roller 406 and the second leveling roller 414;

[0051] The preliminarily fitted composite carpet passes under the first flattening roller 406 and the second flattening roller 414 and over the smooth guide belt 420; and finally is rolled up on the composite carpet rolling device 3. When the composite carpet rolling device 3 is wrinkled on the PVC film,

[0052] The second leveling roller 414 and the first leveling roller 406 both press down the composite carpet, and the linear module 401 moves the movable leveling platform 402 to the right, and the wrinkled tufted carpet is smoothed.

[0053] The smooth guide strip 420 can also be used to prevent the fixed whole platform 410 and the movable whole platform 402 from scratching the PVC film;

[0054] At the same time, the smooth guide belt 420 also serves to reduce the friction between the PVC film and the fixed leveling platform 410 and the movable leveling platform 402; when the second leveling roller 414 and the first leveling roller 406 exert too much pressure on the composite carpet, the smooth guide belt 420 can move the composite carpet to prevent the PVC film from being pulled apart.

[0055] The processing method of the composite carpet specifically comprises the following steps:

[0056] S1, making a base fabric, needle-punching the non-woven fiber into a base fabric through a needle-punching machine;

[0057] S2. Glue coating: Apply latex to one side of the base fabric layer to form a glue layer on one side of the base fabric layer; the coating amount of latex is 30-50g / m 2 ;

[0058] The non-woven fabric in step S1 can be made of colored yarn or white yarn.

[0059] When the yarn in step S1 is white yarn, step S2 further comprises printing a preset pattern on one side of the tufted yarn after drying the latex.

[0060] Specifically, the printing process is to put the dried tufted carpet surface into the printer, and after printing by the printer, pass through a steamer for color fixation, a washing machine for water washing, and an oven for drying, and then perform step three.

[0061] Among them, the drying temperature is 100℃, and the drying time is 5-10 minutes.

[0062] The latex is selected from SBR latex or NBR latex, and is first foamed by a foaming machine, and then coated on the non-tufted side of the non-woven fabric by a rubber coating roller. The latex plays a role in bonding the TPE backing and the non-woven fabric.

[0063] S3, tufting, implanting fiber filaments on the base fabric through a tufting machine, when implanting the fiber filaments on the base fabric, the fiber filaments penetrate into the base fabric from the side of the base fabric away from the adhesive layer, and then penetrate out from the side of the adhesive layer away from the base fabric, the fiber filaments form loop pile on the side of the base fabric away from the adhesive layer, and the loop pile formed on the base fabric constitutes a tufting layer;

[0064] S4, hot-bottoming, using a hot-bottoming machine to heat the side of the adhesive layer away from the base fabric to melt the fiber filaments passing through the base fabric;

[0065] S5, smoothing, smoothing the melted fiber filaments on the adhesive layer to shorten the length of the fiber filaments after passing through the base fabric;

[0066] S6, cooling, so that the melted and smoothed fiber filaments are cooled and solidified to obtain a tufted carpet;

[0067] S7: attaching a PVC film, laminating the PVC film on the end surface of the adhesive layer away from the base fabric, and rolling it up; in this step, the composite carpet production line described above is used to obtain a preliminarily fitted composite carpet;

[0068] S8 is moved into a heat press machine for heat pressing, so that the PVC film and the adhesive layer sandwich the melted and smoothed fiber filaments in the middle;

[0069] Specifically, the temperature range of the hot press during hot pressing is 180°C-200°C, and the specific value can be 180°C, 190°C or 200°C. The hot pressing temperature can be appropriately adjusted according to the situation;

[0070] The pressure range of the hot press during hot pressing is 0.1-0.3MPA, and the specific value can be 0.1MPA, 0.2MPA or 0.3MPA. The size of the hot pressing pressure can be appropriately adjusted according to the situation;

[0071] The holding time of the hot press during hot pressing is in the range of 1-3 minutes, and the specific value can be 1 minute, 2 minutes or 3 minutes. The hot pressing time can be appropriately adjusted according to the situation.

[0072] In this solution, the non-woven fibers are needled into a base fabric by a needle punching machine, thereby forming a base fabric;

[0073] Then, a gluing step is performed to apply glue to one side of the base fabric, so that a glue layer is formed on the one side of the base fabric; the glue layer enhances the strength of the base fabric, so that the base fabric is not easily loosened due to pulling;

[0074] Then, a tufting step is performed, wherein fiber filaments are implanted into the base fabric by a tufting machine. When implanting the fiber filaments into the base fabric, the fiber filaments penetrate into the base fabric from a side of the base fabric away from the adhesive layer, and then penetrate out from a side of the adhesive layer away from the base fabric. The fiber filaments form loop pile on the side of the base fabric away from the adhesive layer. The loop pile 731 formed on the base fabric constitutes a tufting layer.

[0075] Then, the step of hot-pressing is performed, in which the side of the adhesive layer away from the base fabric is heated by a hot-pressing machine to melt the fiber filaments passing through the base fabric;

[0076] Then, a smoothing step is performed to smooth the melted fiber filaments on the adhesive layer; since the adhesive layer enhances the hardness of the base fabric, the fiber filaments passing through the adhesive layer are melted and smoothed on the adhesive layer, and are not easy to fall off from the base fabric;

[0077] Then, a cooling step is performed to cool and solidify the melted and smoothed fiber filaments, so that the fiber filaments regain strength and reduce the probability of the fiber filaments falling off the base fabric;

[0078] Finally, the PVC attachment step is carried out to laminate the PVC film on the bottom of the tufted carpet.

[0079] The PVC film and the adhesive layer sandwich the melted and smoothed fiber filaments in the middle. The PVC film is used to fix the base cloth to further improve the strength of the base cloth, so that the base cloth is not easily loosened due to pulling. The PVC film is also used to protect the fiber filaments passing through the base cloth, so that this part of the fiber filaments is not easily worn, thereby reducing the probability of the fiber filaments falling off the base cloth.

[0080] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "left", "right" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship in which the invention product is usually placed when in use, or the orientation or positional relationship commonly understood by those skilled in the art, which is only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second" and the like are only used to distinguish the description, and cannot be understood as indicating or implying relative importance. In the description of the present invention, it should also be noted that, unless otherwise clearly specified and limited, the terms "set", "connection" and the like should be understood in a broad sense, for example, "connection" 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, or it can be a connection between the two elements. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to the specific circumstances.

Claims

1. A composite carpet production line, comprising a tufted carpet unwinding device, a PVC film unwinding device and a composite carpet winding device, characterized in that: Also included is a composite leveling device; The tufted carpet unwinding device, the PVC film unwinding device and the composite flattening device are all fixedly mounted on the main bracket, wherein the tufted carpet unwinding device and the PVC film unwinding device are arranged in parallel, and the composite flattening device is located between the composite carpet winding device; The tufted carpet unwinding device is used for unwinding the tufted carpet to be laminated with the PVC film; the tufted carpet unwinding device is an unwinding roller wound with the tufted carpet; The PVC film unwinding device is used for unwinding the PVC film to be compounded; The PVC film unwinding device is an unwinding roller wound with the PVC film; The composite carpet rolling device is used to roll up the composite carpet that has been preliminarily fitted; The composite leveling device is fixedly installed on the main bracket, and the composite leveling device includes a linear module, a movable leveling platform and a fixed leveling platform; the movable leveling platform is fixedly installed on the slide of the linear module; first side plates are arranged on both sides of the top of the movable leveling platform, and a first top plate is arranged on the top of the first side plate, wherein a first leveling cylinder is fixedly installed on the first top plate, and the output shaft of the first leveling cylinder passes through the first top plate and is fixedly connected to the first leveling roller; the fixed leveling platform is fixedly installed on the main bracket and is located on one side of the movable leveling platform, wherein second side plates are arranged on both sides of the top of the fixed leveling platform, and a second top plate is arranged on the top of the second side plate, wherein a second leveling cylinder is fixedly installed on the second top plate, and the output shaft of the second leveling cylinder passes through the second top plate and is fixedly connected to the second leveling roller; the composite leveling device also includes a smooth guide belt, and the smooth guide belt transmission is arranged between the front guide roller, the rear guide roller and between the two lower guide rollers, and the smooth guide belt is an inverted isosceles trapezoid as a whole, and the smooth guide belt is located above the fixed leveling platform and the movable leveling platform and below the first leveling roller and the second leveling roller.

2. A method for processing a composite carpet, characterized in that: The specific steps include: S1, making a base fabric, needle-punching the non-woven fiber into a base fabric through a needle-punching machine; S2, coating, applying latex on one side of the base fabric layer to form a glue layer on one side of the base fabric layer; the coating amount of the latex is -g / m; S3, tufting, implanting fiber filaments on the base fabric through a tufting machine, when implanting the fiber filaments on the base fabric, the fiber filaments penetrate into the base fabric from the side of the base fabric away from the adhesive layer, and then penetrate out from the side of the adhesive layer away from the base fabric, the fiber filaments form loop pile on the side of the base fabric away from the adhesive layer, and the loop pile formed on the base fabric constitutes a tufting layer; S4, hot-bottoming, using a hot-bottoming machine to heat the side of the adhesive layer away from the base fabric to melt the fiber filaments passing through the base fabric; S5, smoothing, smoothing the melted fiber filaments on the adhesive layer to shorten the length of the fiber filaments after passing through the base fabric; S6, cooling, so that the melted and smoothed fiber filaments are cooled and solidified to obtain a tufted carpet; S7: attaching a PVC film, laminating the PVC film on the end surface of the adhesive layer away from the base fabric, and rolling it up; In this step, the composite carpet production line described above is used to obtain a preliminarily fitted composite carpet; S8. Move the film into a heat press for heat pressing, so that the melted and smoothed fiber filaments are sandwiched between the PVC film and the adhesive layer.

3. The method for processing a composite carpet according to claim 2, characterized in that: The yarn in step S1 is white yarn.

4. The method for processing a composite carpet according to claim 3, characterized in that: The step S2 also includes printing a preset pattern on one side of the tufted yarn after drying the latex; the printing process is to put the dried tufted carpet surface into a printer, and after printing by the printer, pass through a steamer for color fixation, a washing machine for water washing and an oven for drying.

5. The method for processing a composite carpet according to claim 4, characterized in that: The drying temperature is 100° C. and the drying time is 5 minutes.

6. The method for processing a composite carpet according to claim 5, characterized in that: The latex is selected from SBR latex or NBR latex, and is first foamed by a foaming machine, and then coated on the non-tufted side of the non-woven fabric by a rubber coating roller. The latex plays a role in bonding the TPE backing and the non-woven fabric.

7. The method for processing a composite carpet according to claim 2, characterized in that: The temperature range of the hot press during hot pressing is 180°C-200°C.

8. The method for processing a composite carpet according to claim 7, characterized in that: The pressure range of the hot press during hot pressing is 0.1-0.3 MPa.

9. The method for processing a composite carpet according to claim 8, characterized in that: The holding time of the hot press during hot pressing is in the range of 1-3 minutes.

Images