Carpet bottom covering line adopting ironing instead of coating
Through heating and extrusion and hot melt adhesive composite technology on the bottom surface of the tufted blanket, the problems of high energy consumption and high cost in the production of tiled carpets are solved, and energy-saving and environmentally friendly bottoming processing is achieved, which simplifies the process flow and improves production efficiency.
Patent Information
- Application Number
- CN202510518166.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-24
- Publication Date
- 2025-07-29
AI Technical Summary
The existing block carpet production process requires two heating, drying and plasticization, resulting in high energy consumption, high production costs and large space occupancy, and traditional pre-coating processes have an impact on the environment.
By heating and extruding the bottom surface of the tufted blanket, the velvet root and the blanket base cloth are melted and bonded to form a pre-scaling blanket, the pre-coated glue drying process is omitted, and hot melt glue composite technology is used to simplify the bottom-covered processing line and reduce the use of high-temperature ovens.
Save energy, reduce production costs, shorten process flow, reduce equipment space, improve labor environment, improve production efficiency, and reduce safety hazards. Use environmentally friendly hot melt adhesive to replace traditional PVC materials.
Smart Images
Figure CN120384380A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a production device for modular carpets, and in particular to a carpet bottom line covering method that replaces coating with ironing. Background Art
[0002] Modular carpets are commonly known as "square carpets". Modular carpets have many advantages: they are convenient for transportation, storage, handling, paving, and replacement; they have good wear resistance, sound insulation, stain resistance, and dust absorption effects; the patterns can be assembled randomly, and the paving pattern effect can be easily changed. Modular carpets are widely used in office buildings, offices, reception rooms, airports and other places. The structure of a modular carpet consists of a carpet surface on the upper surface and a bottom back under the carpet surface. The carpet surface and the bottom back are bonded together by different adhesives. The carpet surface is made of a non-woven base fabric through a tufting machine to form a tufted blank carpet. Then, EVA latex (to prevent tufting from falling off, increase the pulling force of the pile, and play a flame retardant role at the same time) is coated on the bottom surface of the tufted blank carpet, and then dried in an oven at 155-175°C, which is called a tufted pre-coated carpet surface. The materials of the carpet surface include nylon fiber, polypropylene fiber, polyester fiber, etc. The bottom back is usually made of PVC bottom back material, which is mainly composed of calcium powder (CaCO3), commonly known as stone powder, polyvinyl chloride (PVC), DINP oil, plasticizer (C24H3804), calcium oxide (Cao), commonly known as quicklime, viscosity reducer, stabilizer, etc., stirred into a paste-like PVC mixture. The PVC mixture is coated on the upper and lower surfaces of a fiberglass cloth and compounded on the back of the pre-coated carpet to form the bottom back. After being heated in a special oven at 155-190°C, the bottom back is plasticized to bond with the carpet surface, which is called bottom covering. The bottom back of the plasticized bottom-covered carpet is embossed and cooled and shaped, and then fed into a carpet cutting machine to cut the carpet into modular carpets of a certain specification size. Among them, the bottom back can also be made of polyolefin hot melt adhesive and calcium powder (CaCO3), naphthenic oil and antioxidant, coated on the back of the carpet and compounded with polyester non-woven fabric, and then cut into modular carpets after cooling and temperature reduction. There is also a type made of asphalt material, which is mainly composed of calcium powder (CaCO3), No. 10 asphalt, No. 90 asphalt and polyester non-woven fabric. This type of modular carpet with an asphalt bottom back has a relatively low grade. From the above production process, it can be seen that during the production process of the carpet surface, heating is required to quickly bond and cure the EVA latex or binder with the pile roots of the tufting above and the non-woven fabric and dry it, which is called pre-coating drying heating. At present, almost all the bottom surfaces of the tufted blank carpets used for modular carpets are pre-coated with glue, and after being dried and cured to form a tufted pre-coated carpet surface, they enter the bottom line covering and are bonded and compounded with other bottom covering materials and dried and cured, or cooled and cured, and cooled and cut to form modular carpets. Therefore, the production of ordinary modular carpets usually requires two heating, drying and plasticizing processes. Summary of the Invention
[0003] The object of the present invention is to provide a modular carpet which does not require the tufted carpet surface to be pre-coated with glue through a pre-coating process, nor does it require the pre-coated carpet surface to be cured in an oven, and does not require heating in a drying room during the bottom covering process. It is a bottom covering line for a carpet with ironing instead of coating which saves pre-coating materials and energy, shortens the time for pre-coating and drying the carpet surface and covering the bottom with the backing, has a compact structure, reduces the floor area occupied by the bottom covering line in the production workshop, can significantly reduce the manufacturing cost of the modular carpet and simplify the manufacturing process.
[0004] In order to meet the above requirements, the present invention is realized through the following technical solutions, and its characteristics are: it includes a pre-ironing processing line that heats and extrudes the bottom surface of the tufted blank carpet, so that the roots between the tufted roots at the bottom of the tufted blank carpet and the yarns and the carpet bottom base fabric are melted and bonded together to form a pre-ironed blank carpet, and a bottom covering processing line that directly composites the pre-ironed blank carpet with the carpet bottom backing material, or the made pre-ironed blank carpet is received on a carpet winding rack and formed into a cylinder for future bottom covering processing. The pre-ironing processing line, according to the sequence of the pre-ironed blank carpet processing technological process, successively includes a blank carpet winding drum device for storing the tufted blank carpet, a U-shaped carpet storage rack, a deviation correction device and several groups of heating and ironing roller devices for clamping the tufted blank carpet. Among them, the high-temperature heat-conducting oil adjustable ironing roller in contact with the bottom surface of the tufted blank carpet, and the low-temperature adjustable cold water roller in contact with the carpet surface of the tufted blank carpet. The surface temperature of the high-temperature heat-conducting oil adjustable ironing roller reaches the temperature at which the tufted roots are melted according to the variety of tufted materials and the contact time with the high-temperature heat-conducting oil adjustable ironing roller. Through the contact of the tufted roots of the tufted blank carpet with the high-temperature heat-conducting oil adjustable ironing roller, the tufted roots on the bottom back of the tufted blank carpet are instantly melted, and the melted tufted roots are bonded and cured with each other on the tufted base fabric, making the tufted yarn tufts integrated and not easily pulled out, replacing the traditional pre-coating, gluing and drying process of the tufted carpet surface.
[0005] The surface temperature of the high-temperature heat-conducting oil adjustable ironing roller is 170 - 270 °C.
[0006] The high-temperature heat-conducting oil adjustable ironing roller is heated by injecting circulating heat-conducting oil into the ironing roller.
[0007] The low-temperature adjustable cold water roller cools the carpet surface of the tufted blank carpet by the chiller reducing the normal temperature water to low-temperature water below zero, and the low-temperature water circulates in the low-temperature adjustable cold water roller.
[0008] The pair of rollers of the high-temperature heat-conducting oil adjustable ironing roller and the low-temperature adjustable cold water roller of the heating and ironing roller device are composed of 3 - 5 groups.
[0009] The bottom-covering processing line is a processing assembly line for laminating a pre-ironed blank carpet and a carpet bottom-back material. According to the processing sequence, it successively includes an unwinding device for storing the tufted pre-ironed blank carpet, a U-shaped carpet storage rack for bottom-covering, which guides the pre-ironed blank carpet into the U-shaped storage rack to ensure a certain carpet storage capacity on the bottom-covering processing line. Its function is that when the supply of carpet is temporarily stopped at the rear end, the bottom-covering processing line does not need to stop; a bottom-covering deviation rectifying device to ensure the centering of the position of the imported pre-ironed blank carpet; a fiberglass mesh unwinding rack and a non-woven fabric unwinding rack; a bottom-covering coater that injects a hot-melt adhesive between the imported fiberglass mesh, non-woven fabric and pre-ironed blank carpet, and squeezes it with a compound roller to bond and fix the fiberglass mesh, non-woven fabric and pre-ironed blank carpet together to form a wide-width carpet blank. The structure of the formed carpet blank from top to bottom is: pre-ironed blank carpet, fiberglass mesh, non-woven fabric; 4-8 consecutive cooling rollers that cool and solidify the hot-melt adhesive in the carpet blank through the cooling rollers, and the interlayer materials are further compacted and bonded. The cooling water is circulated in the cooling rollers; then it enters a cold water plate to further cool the carpet blank and then enters a finished product storage rack to ensure a certain reserve of carpet blanks on the bottom-covering processing line; a precision deviation rectifying device to ensure the centering of the position of the imported carpet blank for preparation of correct cutting of the subsequent carpet; a carpet cutting machine that cuts the wide-width carpet blank into carpet blanks of required specifications and sends them to an inspection platform.
[0010] The cold water plate mentioned above is a metal flat plate with a sandwich layer, and circulating cooling water is injected into the sandwich layer.
[0011] A kind of carpet bottom covering line that replaces coating with ironing designed according to the above scheme. Due to heating and extrusion of the bottom surface of the tufted blank carpet, the roots of the tufted yarns at the bottom of the tufted blank carpet and the tufted yarns and the carpet bottom base fabric material are melted and bonded together to form a pre-ironed blank carpet, changing the traditional process that the tufted blank carpet must be pre-coated with glue on the bottom surface and then enter the oven, so that the applied glue is cured and bonded with the pile roots and the tufted base fabric on the bottom surface of the tufted blank carpet to increase the connection strength between the tufted yarns and the base fabric, and then enter the bottom covering process. This invention simplifies the process by replacing coating with ironing, omits the drying process and equipment, saves energy, and replaces the cost of pre-coated glue and its impact on the environment. A hot melt adhesive composite carpet is used on the bottom covering line. It is an environmentally friendly plastic adhesive. Its physical state changes with temperature within a certain temperature range while its chemical properties remain unchanged. It is non-toxic and odorless, belonging to an environmentally friendly chemical product. Due to the advantages of simple production process, high added value, large bonding strength, and fast speed of the hot melt adhesive, it has been widely used. Using hot melt adhesive to replace the traditional bonding material of PVC mixture, there is no need for a special oven heating up to about 155°C to bond the bottom back and the carpet surface material together during the whole bottom covering process, greatly shortening the length of the carpet bottom covering line, reducing heat energy consumption. Except for the hot melt adhesive being sent to the bottom covering coating head through a heat-insulated pipeline on the whole bottom covering processing line, the rest work at normal temperature, improving the working environment of workers and reducing the potential safety hazards easily caused by high-temperature ovens. In the design of the pre-ironing processing line, the adopted pre-ironing processing line can process the tufted blank carpet into a pre-ironed blank carpet, which is wound into a roll by a roll carpet rack and then compounded with the carpet on the bottom covering processing line in the future, or the pre-ironed blank carpet can be pulled into the carpet bottom covering line to directly produce modular carpets for bottom covering. BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Figure 1 It is a schematic structural diagram of a carpet bottom covering line that replaces coating with ironing. The right end is a schematic structural diagram of the pre-ironing processing line, and the left end is a schematic structural diagram of the bottom covering processing line. Among them, the pre-ironed blank carpet processed on the pre-ironing processing line is wound into a cylinder by a roll carpet rack, and the pre-ironed blank carpet on the bottom covering processing line is installed on the unwinding device of the bottom covering processing line;
[0013] Figure 2 is Figure 1 The partial enlarged view of area A in
[0014] Figure 3 is Figure 1 The partial enlarged view of area B in
[0015] Figure 4 is Figure 1 The partial enlarged view of area C in
[0016] Figure 5 It is a schematic structural diagram of directly supplying the pre-ironed blank carpet made by the pre-ironing processing line to the bottom covering processing line;
[0017] Figure 6 is Figure 5 The partial enlarged view of area D in it is the local enlarged view of the pre-ironing processing line;
[0018] Figure 7 is Figure 5 The partial enlarged view of area E in it;
[0019] Figure 8 is Figure 5 The partial enlarged view of area F in it.
[0020] In the figure: 1. Tufted blank carpet; 2. Pre-ironed blank carpet; 3. Pre-ironing processing line; 4. Bottom covering processing line; 5. Carpet roll rack; 6. Blank carpet reel device; 7. U-shaped carpet storage rack; 8. Deviation rectifying device; 9. Heating ironing roller device; 10. High-temperature heat-conducting oil adjustable ironing roller; 11. Low-temperature adjustable cold water roller; 12. Unwinding device; 13. Bottom covering U-shaped carpet storage rack; 14. Bottom covering deviation rectifying device; 15. Mesh cloth unwinding rack; 16. Non-woven fabric unwinding rack; 17. Bottom covering coating head; 18. Mesh cloth; 19. Non-woven fabric; 20. Composite roller; 21. Patch carpet blank; 22. Cooling roller; 23. Cold water plate; 24. Finished product carpet storage rack; 25. Precision deviation rectifying device; 26. Carpet cutting machine; 27. Inspection platform. Specific embodiments
[0021] The present invention will be further described below in conjunction with the accompanying drawings and specific embodiments.
[0022] Figure 1 , Figure 2 , Figure 3 , Figure 4 is a schematic structural diagram of a carpet bottom covering line using ironing instead of coating. As can be seen from Figure 1 in it, it includes heating and extruding the bottom surface of the tufted blank carpet 1, so that the roots of the tufted yarns at the bottom of the tufted blank carpet 1 and the base fabric material between the tufted yarns and the carpet bottom are melted and bonded together to form the pre-ironing processing line 3 of the pre-ironed blank carpet 2; the pre-ironed blank carpet 2 is wound onto the carpet roll rack 5 and wound into a cylinder as Figure 2 shown, for future bottom covering processing use as Figure 2 Figure 3 shown. Another one is the schematic structural diagram of a carpet bottom covering line using ironing instead of coating as Figure 5 , Figure 6 , Figure 7 , Figure 8 shown. It passes the pre-ironed blank carpet 2 made by the pre-ironing processing line 3 under the carpet roll rack 5 and the unwinding device 12 and is directly connected to the bottom covering processing line 4 for compounding with the carpet bottom back material to be used for making patch carpets. The pre-ironing processing line 3 is as Figure 2As shown, in the order of the technological process of the tufted blanket 1, it successively includes a blanket reel device 6 for storing the tufted blanket 1, a U-shaped blanket storage rack 7, a deviation rectifying device 8, and 3 - 5 groups of heating and ironing roller devices 9 for clamping the tufted blanket 1 (4 groups in the figure). Among them, the high-temperature heat-conducting oil adjustable ironing roller 10 is in contact with the bottom surface of the tufted blanket 1, and the low-temperature adjustable cold water roller 11 is in contact with the blanket surface of the tufted blanket 1. The surface temperature of the high-temperature heat-conducting oil adjustable ironing roller 10 is 170 - 270 °C. This temperature is based on the tufting material and the contact time with the high-temperature heat-conducting oil adjustable ironing roller 10 to reach the temperature at which the root of the pile is melted. For example, the melting temperature of nylon material is about 260 °C, the melting point of polypropylene is 165 - 173 °C, and the melting point of polyester is between 240 - 255 °C. The roots of the piles on the bottom and back of the tufted blanket 1 are melted through contact with the high-temperature heat-conducting oil adjustable ironing roller 10, and the melted roots of the piles are bonded and solidified with each other on the tufted base fabric, making it difficult to pull out the tufted pile yarns, replacing the traditional process of pre-coating, drying, and baking on the tufted blanket surface. The high-temperature heat-conducting oil adjustable ironing roller is heated by injecting high-temperature circulating heat-conducting oil into the ironing roller. The low-temperature adjustable cold water roller 11 cools the tufted blanket surface by circulating the normal temperature water cooled to below zero by a chiller to prevent the tufted blanket surface from being scalded. The pre-ironed blanket 2 obtained can be wound into a cylinder by the winding rack 5 as Figure 1 shown, or directly enter the bottom covering processing line 4 as Figure 5 shown.
[0023] The bottom covering processing line 4 mentioned above is a processing assembly line for compounding the pre-ironed blanket 2 with the carpet bottom back material; according to the processing sequence, it includes an unwinding device 12 for storing the tufted and pre-ironed blanket as Figure 1 shown, or as Figure 5The pre-ironed blank carpet 2 coming from the shown pre-ironing processing line 3 is introduced into the U-shaped carpet storage rack 13 with a bottom cover through the U-shaped carpet storage rack 13, so that there is a certain amount of carpet storage on the bottom covering processing line 4. The function is that when the supply of the carpet is temporarily stopped at the rear end, the bottom covering processing line 4 does not need to stop; the bottom covering deviation correction device 14 ensures that the position of the introduced pre-ironed blank carpet 2 is centered; the mesh fabric unwinding rack 15 and the non-woven fabric unwinding rack 16; the bottom covering coating head 17 injects the adhesive of hot-melt adhesive between the introduced mesh fabric 18, non-woven fabric 19 and pre-ironed blank carpet 2, and is extruded by the compounding roller 20 to bond and fix the mesh fabric 18, non-woven fabric 19 and pre-ironed blank carpet 2 together to form a wide-width block carpet blank 21; 4-8 groups of continuous cooling rollers 22 cool and solidify the hot-melt adhesive in the block carpet blank 21 through the cooling rollers 22, and the interlayer materials are further compacted and bonded. The cooling water is circulated in the cooling rollers 22; then it enters the cold water plate 23. The cold water plate 23 is a metal flat plate with a sandwich layer, and the circulating cooling water is injected into the sandwich layer. After the block carpet blank 21 in contact with the cold water plate 23 is further cooled, it enters the finished product carpet storage rack 24, so that there is a certain reserve of the block carpet blank 21 on the bottom covering processing line 4; the precision deviation correction device 25 ensures that the position of the introduced block carpet blank 21 is centered, preparing for the subsequent carpet cutting process; the carpet cutting machine 26 cuts the wide-width block carpet blank into block carpets of the required specifications and sends them to the inspection platform 27.
Claims
1. A carpet bottom covering line that replaces coating with ironing, characterized in that: It includes heating and extruding the bottom surface of the tufted blanket blank, so that the roots of the tufts on the bottom of the tufted blanket blank and the yarns and the blanket bottom base fabric are melted and bonded together to form a pre-ironing processing line for the pre-ironed blanket blank, and a bottom covering processing line for directly compounding the pre-ironed blanket blank with the carpet bottom back material, or receiving the made pre-ironed blanket blank onto a blanket roll stand to form a cylinder for future bottom covering processing. The pre-ironing processing line, according to the sequence of its pre-ironed blanket blank processing technological process, successively includes a blanket roll device for storing the tufted blanket blank, a U-shaped blanket storage rack, a deviation rectifying device, and several groups of heating and ironing roller devices for clamping the tufted blanket blank. Among them, the high-temperature heat-conducting oil adjustable ironing roller contacts the bottom surface of the tufted blanket blank, and the low-temperature adjustable cold water roller contacts the surface of the tufted blanket blank. The surface temperature of the high-temperature heat-conducting oil adjustable ironing roller reaches the temperature at which the tuft roots are melted according to the variety of tufting materials and the contact time with the high-temperature heat-conducting oil adjustable ironing roller. Through contact with the high-temperature heat-conducting oil adjustable ironing roller, the tuft roots on the bottom back of the tufted blanket blank are instantly melted, and the melted tuft roots are bonded and solidified with each other on the tufted base fabric, making the tufted yarn pile heads integrate and not easily be pulled out, replacing the traditional process of pre-coating glue on the tufted blanket surface and drying.
2. The bottom thread for carpet covering by ironing instead of coating according to claim 1, characterized in that The surface temperature of the high-temperature heat-conducting oil adjustable ironing roller is 170 - 270 °C.
3. A bottom thread for carpet with ironing instead of coating according to claim 1, characterized in that The high-temperature heat-conducting oil adjustable ironing roller is heated by injecting circulating heat-conducting oil into the ironing roller.
4. A bottom thread for carpet covering by ironing instead of coating according to claim 1, characterized in that The low-temperature adjustable cold water roller is cooled by a chiller to low-temperature water below zero, and the low-temperature water circulates in the low-temperature adjustable cold water roller to cool the surface of the tufted blanket blank.
5. A bottom thread for carpet covering by ironing instead of coating according to claim 1, characterized in that The pair of rollers of the high-temperature heat-conducting oil adjustable ironing roller and the low-temperature adjustable cold water roller in the heating and ironing roller device consists of 3 - 5 groups.
6. The bottom thread of the carpet with ironing instead of coating according to any one of claims 1 to 5, characterized in that The bottom covering processing line is a processing production line for compounding the pre-ironed blanket blank with the carpet bottom back material; according to the processing sequence, it successively includes a pay-off device for storing the tufted pre-ironed blanket blank, a bottom covering U-shaped blanket storage rack, which guides the pre-ironed blanket blank into the U-shaped blanket storage rack to ensure a certain amount of blanket storage on the bottom covering processing line. Its function is that when the supply of the blanket temporarily stops at the rear end, the bottom covering processing line does not need to stop; a bottom covering deviation rectifying device to ensure the centering of the position of the imported pre-ironed blanket blank; a mesh fabric pay-off rack, a non-woven fabric pay-off rack; A bottom covering coating head injects a hot-melt adhesive between the imported mesh fabric, non-woven fabric, and pre-ironed blanket blank, and uses a compounding roller to extrude and bond the mesh fabric, non-woven fabric, and pre-ironed blanket blank together to form a wide-width carpet blank. The structure of the formed carpet blank from top to bottom is: pre-ironed blanket blank, mesh fabric, non-woven fabric; 4 - 8 consecutive groups of cooling rollers, through which the hot-melt adhesive in the carpet blank is cooled and solidified, and the interlayer materials are further compacted and bonded. The cooling roller is injected with circulating cooling water; then it enters a cold water plate to further cool the carpet blank and then enters a finished product blanket storage rack to ensure a certain reserve of carpet blanks on the bottom covering processing line; a precision deviation rectifying device to ensure the centering of the position of the imported carpet blank, preparing for the correct cutting process of the subsequent carpet; a carpet cutting machine to cut the wide-width carpet blank into carpet pieces of the required specifications to the inspection platform.
7. A bottom thread for carpet covering by ironing instead of coating according to claim 6, characterized in that The described cold plate is a metal flat plate with a sandwich layer, and circulating cooling water is injected into the sandwich layer.