Crease-free antiskid carpet and processing method thereof

Abstract

The invention relates to the technical field of carpets, in particular to a crease-free anti-slip carpet and a processing method thereof.The crease-free anti-slip carpet comprises a carpet body, the carpet body is composed of a carpet body located on the upper portion and a carpet base connected to the lower portion of the carpet body, an anti-slip layer is arranged below the carpet base, and the anti-slip layer is composed of a fluff layer connected to the lower portion of the carpet base through a flocking technology. The imitation leather layer is connected to the outer edge of the fluff layer in a wrapping manner and is formed on the outer edge of the fluff layer by foaming through a PVC imitation leather process. The processing method of the crease-free anti-slip carpet comprises the following steps: step 1, providing a carpet body at the upper part of the carpet; 2, a blanket base with an anti-skid layer is provided, and the anti-skid layer is formed by connecting fluff to a base piece through a flocking technology and then foaming the outer edge of the fluff through a PVC leather imitation technology to form a leather imitation layer made of a PVC anti-skid material; 3, the carpet body and the carpet base are bonded to form the carpet body. The crease-free anti-slip carpet is not prone to crease generation, good in anti-slip performance, soft, comfortable and free of damage to floors.

Description

Technical Field

[0001] The invention relates to the technical field of carpets, in particular to a crease-free anti-slip carpet and a processing method thereof. Background Art

[0002] Carpet is a floor covering made of natural fibers such as cotton, linen, wool, silk, grass, or chemical synthetic fibers, which is knitted, planted, or woven by hand or mechanical processes. It is not only practical but also decorative, and is widely used in various architectural spaces.

[0003] Traditional carpets are prone to creases during transportation or storage. For example, when mailing, in order to save space and facilitate handling, the carpet often needs to be folded multiple times and put into smaller bags or cartons for mailing. This makes it very easy for the product to crease, affecting its appearance during use. In addition, if the bottom of the carpet is hard, it is easy to wear the ground or have poor anti-slip properties. Summary of the invention

[0004] 1. Technical issues to be resolved

[0005] In view of the deficiencies in the prior art, the present invention provides a crease-free anti-slip carpet and a processing method thereof.

[0006] (II) Technical solution

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: a crease-free anti-skid carpet, comprising a carpet body, wherein the carpet body is composed of a carpet body located above and a carpet base connected thereto, wherein: an anti-skid layer is provided below the carpet base, and the anti-skid layer is composed of a pile layer connected to the carpet base below by a flocking process, and an imitation leather layer covering and connected to the outer edge of the pile layer and formed on the outer edge of the pile layer by foaming through a PVC imitation leather process.

[0008] Preferably, the carpet base comprises an intermediate layer, and the intermediate layer is bonded between the upper carpet body and the lower anti-slip layer.

[0009] Preferably, the blanket body is made of cotton, polyester or linen.

[0010] Preferably, the middle layer is a non-woven fabric layer or a polyester fabric layer.

[0011] Preferably: the anti-slip layer also includes two or more anti-slip auxiliary sheets connected thereto, the top of the anti-slip auxiliary sheet is a hooked and barbed surface with a plurality of elastic hooks, and the bottom of the anti-slip auxiliary sheet is provided with a viscose layer, and when the hooked and barbed surface contacts the anti-slip layer formed by foaming flocking powder, the elastic hooks hook the fibers on the anti-slip layer, thereby connecting the two together.

[0012] The present invention also provides a method for processing a crease-free anti-slip carpet, which comprises the following steps:

[0013] Step 1, providing a carpet body with the carpet located on the top;

[0014] Step 2, providing a blanket base with an anti-skid layer at the bottom, wherein the anti-skid layer is formed by first connecting the fluff on the base sheet through a flocking process, and then foaming the outer edge of the fluff through a PVC imitation leather process to form an imitation leather layer with PVC anti-skid material;

[0015] Step 3: Bond the carpet body and carpet base to form a carpet body.

[0016] Preferably, the PVC imitation leather process in step 2 comprises the following steps:

[0017] Step a1, selecting appropriate weight portions of PVC resin, plasticizer, foaming agent, stabilizer, filler and auxiliary agent and putting them into a high-speed mixer for stirring to form a preliminary mixture;

[0018] Step a2, putting the mixed material into a mixing machine for mixing to obtain a plasticized material;

[0019] Step a3, combining the plasticized material with the base fabric having the fluff by calendering or coating;

[0020] Step a4, sending the calendered or coated base fabric and PVC composite material into an oven for drying to remove moisture, etc., and then preheating to a suitable foaming temperature;

[0021] Step a5, sending the preheated material into a foaming box for foaming;

[0022] Step a6, performing surface treatment on the foamed base layer;

[0023] Step a7, cooling and cutting the surface-treated base layer to obtain an imitation leather layer having a PVC anti-slip material.

[0024] Preferably, the corresponding component materials and their corresponding weight proportions in step a1 are:

[0025] Resin latex PVC: 90-120 parts

[0026] Foaming agent AC: 2-5 parts

[0027] Plasticizer DOP: 60-70 parts

[0028] Stabilizer liquid Ba / Zn: 2-5 parts

[0029] Filler CaCO3: 15-25 parts.

[0030] Preferably: the weight parts of the raw materials are:

[0031] Resin latex PVC: 100 parts

[0032] Foaming agent AC: 3 parts

[0033] Plasticizer DOP: 65 parts

[0034] Stabilizer liquid Ba / Zn: 3 parts

[0035] Filler CaCO3: 20 parts

[0036] The corresponding component materials and corresponding weight proportions of the auxiliary agents are as follows:

[0037] Pigment: 4 parts

[0038] Active regulator, propoxylated fatty acid: 0.5 parts

[0039] Dispersant: 0.2 parts.

[0040] Preferably: in the step a3, before rolling or coating, the base fabric is cleaned, dried and primed with glue.

[0041] Preferably, the surface of the base layer is provided with embossing.

[0042] (III) Beneficial effects

[0043] Compared with the prior art, the present invention provides a non-crease anti-slip carpet and a processing method thereof, which has the following beneficial effects:

[0044] The crease-free anti-skid carpet and its processing method adopt a multi-layer substrate structure composed of a carpet body and a carpet base, and the materials of each layer cooperate with each other to enhance the flexibility and strength of the carpet as a whole. There is an anti-skid layer under the carpet base, and the anti-skid layer is composed of a pile layer connected to the bottom of the carpet base through a flocking process, and an imitation leather layer coated and connected to the outer edge of the pile layer through a PVC imitation leather process to form the outer edge of the pile layer, thereby enhancing the flexibility and strength of the carpet as a whole. At the same time, the lower anti-skid layer has a structure that is formed under the carpet base through a flocking process and the pile is oriented downward, so its texture is extremely soft compared to ordinary carpets. At the same time, because the outer edge of the pile has a PVC imitation leather layer formed on the outside of the pile through a leather imitation process, the entire anti-skid layer is not only significantly softer than ordinary carpets, but also has extremely strong anti-skid performance.

[0045] The present invention is overall soft and comfortable, has good elasticity, and is very unlikely to have creases. During transportation or storage, when subjected to squeezing or bending forces, the anti-skid layer can absorb part of the energy like a spring to reduce the generation of creases. The lower end surface is soft and does not damage the floor. It has extremely strong anti-skid performance and can effectively unfold the carpet to eliminate the creases. And through the design of the anti-skid auxiliary sheet, when using the carpet, even if there are creases on it, more than two anti-skid auxiliary sheets can be used to easily position the carpet at the desired position, and at the same time, the creases on the upper end can be flattened. The design is very user-friendly. Compared with traditional carpets with harder bottoms, the material characteristics of the imitation leather layer make it possible to have better friction when in contact with the ground. Its own soft texture protects the ground and floor, further increasing the comfort of contact between people and the carpet. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a schematic diagram of the main structure of the present invention;

[0047] Figure 2 It is a schematic diagram of the explosion of the structure of the present invention.

[0048] In the figure: 1. Carpet body; 2. Middle layer; 3. Anti-slip layer; 4. Anti-slip auxiliary sheet. DETAILED DESCRIPTION

[0049] 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.

[0050] See also Figure 1-Figure 2 A non-crease anti-skid carpet comprises a carpet body, wherein the carpet body is composed of a carpet body 1 located above and a carpet base connected thereto, wherein: an anti-skid layer 3 is provided below the carpet base, and the anti-skid layer is composed of a pile layer connected to the carpet base below by a flocking process, and an imitation leather layer formed on the outer edge of the pile layer by a PVC imitation leather process and covering the outer edge of the pile layer. The imitation leather layer is coated on the outer edge of the flock, and the material characteristics determine that its surface is not only soft but also has a certain degree of roughness. When in contact with the ground, this roughness increases the friction between the ground and the carpet, which can effectively prevent the carpet from sliding on the ground, thereby improving the anti-skid performance. At the same time, the imitation leather layer is relatively soft in texture, and when in contact with the ground, it will not cause wear to the ground like the traditional harder bottom. For example, when a person walks on the carpet, the imitation leather layer can buffer the impact of footsteps on the ground, reduce friction and scratches on the ground, and play a role in protecting the ground.

[0051] Preferably: the carpet base includes an intermediate layer 2, which is bonded between the upper carpet body 1 and the lower anti-skid layer 3. It plays a role of buffering and supporting. It has a certain thickness and elasticity. When the stress transmitted from the carpet body exceeds its tolerance range, the non-woven fabric can further disperse the stress, just like a sponge, absorbing and buffering external forces, preventing stress from concentrating on a certain point, thereby reducing the possibility of crease formation. When flocking the anti-skid layer below it, it can be flocked directly on the intermediate layer 2, or another base sheet can be used for flocking, which is not limited here.

[0052] Preferably, the blanket body is made of cotton cloth, polyester cloth or linen cloth, and the material is not limited, and a variety of blanket fabrics in the prior art can be selected.

[0053] Preferably, the middle layer is a non-woven fabric layer or a polyester fabric layer, but this is not limited thereto.

[0054] Preferably: the anti-slip layer also includes two or more anti-slip auxiliary sheets 4 connected thereto, the top of the anti-slip auxiliary sheet is a hooked and barbed surface with a plurality of elastic hooks, and the bottom of the anti-slip auxiliary sheet is provided with a viscose layer, and when the hooked and barbed surface contacts the anti-slip layer formed by foaming flocking powder, the elastic hooks hook the fibers on the anti-slip layer, thereby connecting the two together.

[0055] The present invention also provides a method for processing a crease-free anti-slip carpet, which comprises the following steps:

[0056] Step 1, providing a carpet body with the carpet located on the top;

[0057] Step 2, providing a blanket base with an anti-skid layer at the bottom, wherein the anti-skid layer is formed by first connecting the fluff on the base sheet through a flocking process, and then foaming the outer edge of the fluff through a PVC imitation leather process to form an imitation leather layer with PVC anti-skid material;

[0058] Step 3: Bond the carpet body and carpet base to form a carpet body.

[0059] Preferably, the PVC imitation leather process in step 2 comprises the following steps:

[0060] Step a1, selecting appropriate weight portions of PVC resin, plasticizer, foaming agent, stabilizer, filler and auxiliary agent and putting them into a high-speed mixer for stirring to form a preliminary mixture;

[0061] Step a2, putting the mixed material into a mixing machine for mixing to obtain a plasticized material;

[0062] Step a3, combining the plasticized material with the base fabric having the fluff by calendering or coating;

[0063] Step a4, sending the calendered or coated base fabric and PVC composite material into an oven for drying to remove moisture, etc., and then preheating to a suitable foaming temperature;

[0064] Step a5, sending the preheated material into a foaming box for foaming;

[0065] Step a6, performing surface treatment on the foamed base layer;

[0066] Step a7, cooling and cutting the surface-treated base layer to obtain an imitation leather layer having a PVC anti-slip material.

[0067] Preferably, the corresponding component materials and their corresponding weight proportions in step a1 are:

[0068] Resin latex PVC: 90-120 parts

[0069] Foaming agent AC: 2-5 parts

[0070] Plasticizer DOP: 60-70 parts

[0071] Stabilizer liquid Ba / Zn: 2-5 parts

[0072] Filler CaCO3: 15-25 parts.

[0073] Preferably: the weight parts of the raw materials are:

[0074] Resin latex PVC: 100 parts

[0075] Foaming agent AC: 3 parts

[0076] Plasticizer DOP: 65 parts

[0077] Stabilizer liquid Ba / Zn: 3 parts

[0078] Filler CaCO3: 20 parts

[0079] The materials of the auxiliary agent corresponding to the components can be conventional materials and proportions in the prior art, preferably the following materials and proportions by weight:

[0080] Pigment: 4 parts

[0081] Active regulator, propoxylated fatty acid: 0.5 parts

[0082] Dispersant: 0.2 parts.

[0083] Of course, the weight portions of the raw materials may also be:

[0084] Resin latex PVC: 110 parts

[0085] Foaming agent AC: 4 parts

[0086] Plasticizer DOP: 62 parts

[0087] Stabilizer liquid Ba / Zn: 4 parts

[0088] Filler CaCO3: 16 parts

[0089] The corresponding component materials and corresponding weight proportions of the auxiliary agents are as follows:

[0090] Pigment: 4 parts

[0091] Active regulator, propoxylated fatty acid: 0.5 parts

[0092] Dispersant: 0.2 parts.

[0093] Preferably: in the step a3, before rolling or coating, the base fabric is cleaned, dried and primed with glue.

[0094] Preferably, the surface of the base layer is provided with embossing.

[0095] Auxiliary agents may include pigments for dyeing, lubricants, colorants, antioxidants, and anti-ultraviolet agents.

[0096] Step a2, putting the mixed material into a mixing machine for mixing, under high temperature and strong shearing action, the PVC resin is further plasticized, the components are dispersed more evenly, the uniformity and plasticity of the material are improved, and a plasticized material is obtained;

[0097] Step a3, combining the plasticized material with the base fabric by calendering or coating, the base fabric is first pretreated, including cleaning, drying, priming and gluing, etc., to improve the bonding force between the base fabric and the PVC slurry;

[0098] Step a4, sending the calendered or coated base fabric and PVC composite material into an oven for drying, removing moisture, etc., and then preheating to a suitable foaming temperature. Before sending the material into the oven for drying, the material can be subjected to a coagulation bath treatment (the base fabric coated with PVC slurry is placed in a coagulation bath, which is usually a solution containing a solvent and a coagulant, such as a dimethylformamide (DMF) aqueous solution. The plasticizer and other solvents in the PVC slurry are exchanged with the solvent in the coagulation bath, so that the PVC resin is coagulated to form a wet leather with a certain strength and shape) and water treatment (after the wet leather is taken out of the coagulation bath, it is washed with water to remove the coagulant, solvent and other impurities remaining on the surface, so as to improve the quality and performance of the product), and then dried;

[0099] Step a5, feeding the preheated material into a foaming box for foaming, controlling the temperature, time, ventilation and other parameters of the oven to obtain a uniform, fine pore structure and a good foaming effect;

[0100] Step a6, performing surface treatment on the foamed base layer 4, such as embossing, printing and painting, to increase the aesthetics and simulation of the leather;

[0101] Step a7, cooling, cutting and rolling up the surface-treated base layer 4.

[0102] When the rolled carpet is used, a double-sided adhesive anti-skid auxiliary sheet can be attached to the four corners or both ends under the carpet to quickly flatten the carpet and eliminate creases. According to needs, you can choose to attach or remove the anti-skid auxiliary sheet. It has the soft property of imitation leather, and even if the anti-skid auxiliary sheet is attached, the overall flatness of the carpet surface can be guaranteed, and the anti-skid auxiliary sheet itself is very thin.

[0103] The PVC imitation leather process of the present invention is described in detail below:

[0104] 1) Prepare the raw materials first, including the following:

[0105] Resin: Use suspension PVC resin to provide the basic properties of imitation leather;

[0106] Plasticizers: such as dioctyl phthalate (DOP), which increase flexibility and plasticity;

[0107] Foaming agent: organic foaming agents such as azodicarbonamide (AC) decompose under heat to produce gas to form bubbles;

[0108] Stabilizer: such as calcium zinc stabilizer, which improves the thermal stability of PVC during processing;

[0109] Fillers: such as calcium carbonate, to reduce costs, improve dimensional stability, etc.;

[0110] Other additives: including lubricants, colorants, antioxidants, anti-ultraviolet agents, etc.;

[0111] 2) Put the measured PVC resin, plasticizer, foaming agent, stabilizer, filler and other additives into a high-speed mixer, stir evenly at a certain temperature and time to form a preliminary mixture;

[0112] The preliminary mixture is put into an internal mixer for internal mixing, and further plasticized under high temperature and strong shearing action to make the components disperse more evenly;

[0113] 3) Calendering or coating

[0114] Calendering: Put the mixed and plasticized materials into the calender, and through the action of multiple calendering rollers, the materials are calendered into a film of the required thickness, and at the same time, it is laminated with the base fabric with fluff;

[0115] Coating: Use a coating machine to evenly coat the PVC slurry on the base fabric with fluff, and control the coating thickness and uniformity;

[0116] 4) Foaming treatment

[0117] Drying and preheating: The calendered or coated base fabric with fluff and PVC composite material are sent into an oven for drying to remove moisture, etc., and then preheated to a suitable foaming temperature.

[0118] Foaming molding: In the foaming oven, when the material reaches a certain temperature, the foaming agent decomposes to produce gas, forming a cellular structure in the PVC resin. By controlling the temperature, time, ventilation and other parameters of the oven, a uniform, delicate cellular structure and a good foaming effect can be obtained.

[0119] 5) Surface treatment

[0120] Embossing: The foamed PVC imitation leather is embossed by an embossing roller with patterns to form various leather textures on its surface.

[0121] Finishing: coating the surface of PVC imitation leather with a layer of finishing agent with special properties, such as a finishing agent that improves wear resistance, scratch resistance, glossiness, etc.;

[0122] 6) Post-processing

[0123] Cooling and shaping: The surface treated PVC imitation leather is cooled by cooling rollers and other equipment to stabilize its shape and performance;

[0124] Cutting and rolling: According to product specifications and customer needs, the PVC imitation leather is cut to remove irregular edges.

[0125] The carpet body and the carpet base are preferably bonded together by thermoplastic rubber, and part of the thermoplastic rubber passes through the carpet base to contact the ground, further improving the anti-slip performance.

[0126] Reference to "embodiment" herein means that the specific features, structures or characteristics described in conjunction with the embodiment may be included in at least one embodiment of the present application. The term "embodiment" appearing in various places in the specification does not necessarily refer to the same embodiment, nor does it particularly limit its independence or association with other embodiments. In principle, in the present application, as long as there is no technical contradiction or conflict, the various technical features mentioned in the embodiments can be combined in any way to form a corresponding implementable technical solution.

[0127] Unless otherwise defined, the technical terms used in this document have the same meanings as those generally understood by those skilled in the art to which this application belongs; the use of relevant terms in this document is only for describing specific embodiments and is not intended to limit this application.

[0128] While the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that many changes, modifications, substitutions and variations can be made to the embodiments without departing from the principles and spirit of the invention.

Claims

1. A non-crease anti-slip carpet, comprising a carpet body, wherein the carpet body is composed of a carpet body located at the top and a carpet base connected thereto, characterized in that: The blanket base is provided with an anti-skid layer, which is composed of a pile layer connected to the blanket base through a flocking process, and an imitation leather layer covering and connected to the outer edge of the pile layer and formed on the outer edge of the pile layer through a PVC imitation leather process.

2. The crease-free anti-slip carpet according to claim 1, characterized in that: The carpet base comprises a middle layer, and the middle layer is bonded between the upper carpet body and the lower anti-slip layer.

3. The non-crease anti-slip carpet according to claim 2, characterized in that: The blanket body is made of cotton cloth, polyester cloth or linen cloth.

4. The non-crease anti-slip carpet according to claim 3, characterized in that: The middle layer is a non-woven fabric layer or a polyester fabric layer.

5. A non-crease anti-slip carpet according to any one of claims 1 to 4, characterized in that: The anti-slip layer also includes two or more anti-slip auxiliary sheets connected below it. The top of the anti-slip auxiliary sheet is a hooked and barbed surface with a plurality of elastic hooks. The bottom of the anti-slip auxiliary sheet is provided with a viscose layer. When the hooked and barbed surface contacts the anti-slip layer formed by foaming flocking powder, the elastic hooks hook the fibers on the anti-slip layer, thereby connecting the two together.

6. A method for processing a crease-free anti-slip carpet, characterized in that: The steps include: Step 1, providing a carpet body with the carpet located on the top; Step 2, providing a blanket base with an anti-skid layer at the bottom, wherein the anti-skid layer is formed by first connecting the fluff on the base sheet through a flocking process, and then foaming the outer edge of the fluff through a PVC imitation leather process to form an imitation leather layer with PVC anti-skid material; Step 3: Bond the carpet body and carpet base to form a carpet body.

7. The method for processing a crease-free anti-slip carpet according to claim 6, characterized in that: The PVC imitation leather process in step 2 comprises the following steps: Step a1, selecting appropriate weight portions of PVC resin, plasticizer, foaming agent, stabilizer, filler and auxiliary agent and putting them into a high-speed mixer for stirring to form a preliminary mixture; Step a2, putting the mixed material into a mixing machine for mixing to obtain a plasticized material; Step a3, combining the plasticized material with the base fabric having the fluff by calendering or coating; Step a4, sending the calendered or coated base fabric and PVC composite material into an oven for drying to remove moisture, etc., and then preheating to a suitable foaming temperature; Step a5, sending the preheated material into a foaming box for foaming; Step a6, performing surface treatment on the foamed base layer; Step a7, cooling and cutting the surface-treated base layer to obtain an imitation leather layer having a PVC anti-slip material.

8. The method for processing a crease-free anti-slip carpet according to claim 7, characterized in that: The corresponding component materials and their corresponding weight percentages in step a1 are: Resin latex PVC: 90-120 parts Foaming agent AC: 2-5 parts Plasticizer DOP: 60-70 parts Stabilizer liquid Ba / Zn: 2-5 parts Filler CaCO3: 15-25 parts.

9. The method for processing a crease-free anti-slip carpet according to claim 8, characterized in that: The weight parts of the raw materials are: Resin latex PVC: 100 parts Foaming agent AC: 3 parts Plasticizer DOP: 65 parts Stabilizer liquid Ba / Zn: 3 parts Filler CaCO3: 20 parts The corresponding component materials and corresponding weight proportions of the auxiliary agents are as follows: Pigment: 4 parts Active regulator, propoxylated fatty acid: 0.5 parts Dispersant: 0.2 parts.

10. The method for processing a crease-free anti-slip carpet according to claim 8, characterized in that: In the step a3, before rolling or coating, the base fabric is cleaned, dried and primed with glue; in the step a6, the surface treatment includes embossing and finishing the base layer.

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