Glue-free environment-friendly flame-retardant full-paving blanket preparation device and preparation process thereof

Abstract

The invention provides a glue-free environment-friendly flame-retardant full-paving carpet preparation device and a preparation process thereof. Comprising a spinning machine used for preparing colored flame-retardant yarns, a non-woven machine used for preparing non-woven base cloth, a tufting jacquard machine used for tufting the colored flame-retardant yarns on the non-woven base cloth to prepare a colored jacquard blank blanket, and a composite mechanism used for forming a composite blanket bottom on the back surface of the blank blanket. The carpet back of the blank carpet is roughened, so that the fiber entanglement effect of subsequent hot melting fibers and the blank carpet is improved.

Description

Technical Field

[0001] This invention relates to the field of carpet technology, specifically to a glue-free, environmentally friendly, flame-retardant whole-cover carpet preparation device and its preparation process. Background Technology

[0002] Traditional wall-to-wall carpets (carpet tiles or rolls) are generally produced using a "fiber layer + backing coating" structure. The backing coating is typically made of styrene-butadiene latex (SBR), PVC, or polyurethane (PU), and its function is to fix the pile fibers, provide dimensional stability, and reinforcement. However, this method has significant drawbacks: First, it is environmentally unfriendly, as the extensive use of chemical adhesives releases VOCs during production, leaving organic residues and odors in the finished carpet, which are difficult to separate during recycling, causing environmental pollution. Second, flame retardancy depends on additives: flame retardant performance relies on adding flame retardants to the fibers or adhesives, and these flame retardants may migrate, become ineffective, or produce toxic fumes. Third, it results in a stiff feel: the adhesive backing increases the overall hardness of the carpet, reducing its feel and softness underfoot. While spunlace nonwoven fabric technology is mature, it is mainly used for thin materials. When used directly for thick, high-loft carpets, it suffers from insufficient entanglement, loose structure, and poor dimensional stability.

[0003] In view of this, the inventor conducted in-depth research on the aforementioned deficiencies in the prior art, which led to the creation of this case. Summary of the Invention

[0004] The purpose of this invention is to address the above-mentioned shortcomings by providing a glue-free, environmentally friendly, flame-retardant whole-coverage carpet preparation device that can produce carpets with high-strength composite carpet bases using physical bonding, without glue, and with good flame retardant effect.

[0005] To achieve the above objectives, the solution of the present invention is: a glue-free, environmentally friendly flame-retardant full-coverage carpet preparation device, comprising a spinning machine for producing colored flame-retardant yarn, a non-woven machine for producing non-woven base fabric, a tufting jacquard machine for tufting colored flame-retardant yarn onto the non-woven base fabric to produce a colored jacquard raw carpet, and a composite mechanism for forming a composite carpet base on the back of the raw carpet.

[0006] The composite mechanism includes a frame on which are provided a conveying assembly for conveying a blank blanket, a roughening assembly for roughening the back of the blank blanket, a pre-laying assembly for laying a layer of hot melt fiber mesh as a base layer on the roughened blank blanket, a web-laying assembly for covering the pre-lay hot melt fiber mesh with multiple layers of hot melt fiber mesh, a needle-punching assembly for needle-punching the web, and a setting assembly for heat setting. The roughening assembly, pre-laying assembly, web-laying assembly, needle-punching assembly, and setting assembly are arranged sequentially above the conveying assembly along the conveying direction.

[0007] Furthermore, in order to improve the composite effect of the raw blanket and the blanket base, the napping assembly includes a napping roller and a napping motor for driving the napping roller to rotate. The rotation direction of the napping roller is opposite to the conveying direction of the raw blanket, and the napping roller is evenly distributed with a number of elastic hooks.

[0008] Furthermore, in order to form burr fibers on the blank blanket to improve the welding effect between the blank blanket and the hot melt fiber web, the elastic hooks are arranged in a spiral on the brushing roller. The elastic hooks are made of plastic and include a body on the brushing roller and a hook at the end of the body.

[0009] Furthermore, in order to pre-lay a layer of hot-melt fiber mesh of the same material as the blanket base on the blank blanket to improve the blanket base composite effect, the pre-laying assembly includes an injection pump filled with molten hot-melt fiber and a feed group for driving the injection pump to reciprocate. The feed group is mounted on the frame, the injection pump is mounted on the feed group, and the injection pump is equipped with a spray needle, which is connected to a high-voltage power supply.

[0010] Furthermore, in order to transport the blank blanket to below the pre-laying assembly, the conveying assembly includes a conveyor belt and a pulley assembly for driving the conveyor belt to rotate. The conveyor belt includes a working section on the upper side for transporting the blank blanket and a rotating section on the lower side in a rotating state. The injection needle is located above the working section to inject hot melt fibers into the back of the blank blanket on the working section.

[0011] Furthermore, in order to increase the temperature of the blank blanket so that the hot-melt fibers sprayed from the pre-laying component can be directly melted onto the blank blanket; the composite mechanism also includes a preheating component located behind the napping component and in front of the pre-laying component. The preheating component includes an infrared heater, which is located above the conveying component to preheat the blank blanket on the conveying component.

[0012] Furthermore, to ensure that the fibers of the blanket base are entangled together, the needle-punching assembly includes an upper needle plate and a driver for driving the upper needle plate to move up and down. The upper needle plate is evenly distributed with a plurality of needles. Each needle includes a needle handle and a needle rod. The lower end of the needle handle is provided with a cylindrical cavity. The upper end of the needle rod is rotatably mounted in the cylindrical cavity. The needle rod is provided with a plurality of barbs. The plurality of barbs are spirally arranged on the needle rod so that the needle rod is driven to rotate relative to the needle handle by the lateral force received by the needle rod when it is inserted into the fiber web, thereby agitating the fibers and improving the fiber entanglement effect.

[0013] Furthermore, in order to perform high-temperature shaping on the composite blanket base, the shaping assembly includes a high-temperature shaping group, which includes a hot air chamber, several hot pressure rollers and negative pressure rollers. The hot pressure rollers and negative pressure rollers are rotatably installed in the hot air chamber and are rotatably engaged with the hot pressure blanket blank. The hot pressure rollers are connected to a heater and a fan, and hot air holes are evenly distributed on the hot pressure rollers. The negative pressure rollers are connected to a negative pressure fan, and negative pressure holes are evenly distributed on the negative pressure rollers.

[0014] Furthermore, in order to perform low-temperature shaping on the composite blanket base, the shaping assembly also includes a low-temperature cooling group, which includes an air-cooling hood, a cold-pressing roller, and an elastic roller. The cold-pressing roller and the elastic roller are rotatably installed inside the air-cooling hood and are rotatably engaged with the cold-pressing blanket blank. The cold-pressing roller is provided with a circulating water cooling channel.

[0015] Another objective of this invention is to address the above-mentioned shortcomings by providing a manufacturing process for a glue-free, environmentally friendly, flame-retardant whole-coverage carpet preparation device that uses physical bonding, is glue-free, has good flame-retardant properties, and has a high-strength composite carpet base.

[0016] Another solution adopted by the present invention to solve the above-mentioned technical problems is: a preparation process of a glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device, comprising the following steps:

[0017] S1: The tufted blanket with the surface facing down is fed into the conveying assembly, and the blanket back is brushed by the brushing assembly.

[0018] S2: After the napped blanket backing is preheated by the preheating component, it enters the pre-laying component. After the blanket backing is preheated, the jet needle sprays out a hot melt fiber stream. Under the action of the electric field, the hot melt fiber stream is vertically implanted into the blanket backing, forming a layer of preheated melt fiber web on the napped blanket backing.

[0019] S3: A blank blanket with a layer of hot melt fiber web pre-laid on it enters the web laying assembly, which forms multiple layers of hot melt fiber web on the blank blanket;

[0020] S4: Enter the needle punching assembly, the needle is inserted into the hot melt fiber mesh, the barbs on the needle bar tie the multiple layers of hot melt fiber mesh together, and through the rotation of the needle bar, the multiple layers of hot melt fiber mesh are rotated and entangled in space;

[0021] S5: Entering the high-temperature setting group, under the hot pressing of hot and negative pressure rollers, the hot melt fibers are melted and bonded to the back of the blank blanket;

[0022] S6: Finally, the composite blank is obtained by pressing and cooling in a low-temperature cooling group.

[0023] Compared with the prior art, the present invention has the following advantages: The present invention improves the fiber entanglement effect between the subsequent hot melt fibers and the back of the raw blanket by roughening the back of the raw blanket. Furthermore, before laying the hot melt fiber web, the present invention pre-forms a layer of hot melt fiber web on the back of the raw blanket through electrospinning process, ensuring that the hot melt fibers are vertically implanted into the back of the raw blanket. At the same time, since the back of the raw blanket is preheated before pre-laying, the higher temperature can ensure that the hot melt fibers are implanted and fused with the back of the raw blanket, thereby effectively improving the composite strength of the hot melt fiber web. Moreover, since the pre-laid fiber web and the subsequently laid fiber web are of the same material, the fusion effect is better, thereby effectively ensuring the structural strength of the composite blanket bottom. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings and embodiments:

[0025] Figure 1 This is a schematic diagram of the structure of the present invention;

[0026] Figure 2 This is a schematic diagram of the structure of the brushing roller;

[0027] Figure 3 This is a structural diagram of the pre-laid components;

[0028] Figure 4 This is a schematic diagram of the structure of a lancet;

[0029] Figure 5 This is a schematic diagram of the high-temperature setting assembly;

[0030] Figure 6 This is a schematic diagram of the structure of the hot pressure roller and the negative pressure roller.

[0031] In the diagram: Conveying assembly 1; Working section 11; Rotating section 12; Roughening assembly 2; Roughening roller 21; Elastic hook 22; Pre-laying assembly 3; Infrared heater 31; Injection pump 32; Feeding group 33; High voltage power supply 34; Web laying assembly 4; Needle punching assembly 5; Upper needle plate 51; Needle 52; Needle handle 521; Needle bar 522; Barb 523; Shaping assembly 6; High temperature shaping group 61; Hot air chamber 611; Hot pressure roller 612; Negative pressure roller 613; Low temperature cooling group 62; Air cooling cover 621; Cold pressure roller 622; Elastic roller 623. Detailed Implementation

[0032] To further explain the technical solution of the present invention, the present invention will be described in detail below through specific embodiments.

[0033] Example 1: As Figure 1-6As shown, this embodiment provides a glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device, including a spinning machine for producing colored flame-retardant yarn, a non-woven machine for producing non-woven base fabric, a tufting jacquard machine for tufting colored flame-retardant yarn onto the non-woven base fabric to produce a colored jacquard greige carpet, and a composite mechanism for forming a composite carpet bottom on the back of the greige carpet (the colored jacquard greige carpet is referred to as the greige carpet, the same below).

[0034] The composite mechanism includes a frame on which are provided a conveying assembly 1 for conveying a blank blanket, a roughening assembly 2 for roughening the back of the blank blanket, a pre-laying assembly 3 for laying a layer of hot melt fiber mesh as a base on the back of the roughened blank blanket, a web-laying assembly 4 for covering the pre-lay hot melt fiber mesh with multiple layers of hot melt fiber mesh, a needle-punching assembly 5 for needle-punching and web-forming, and a shaping assembly 6 for heat-setting. The roughening assembly 2, pre-laying assembly 3, web-laying assembly 4, needle-punching assembly 5, and shaping assembly 6 are arranged sequentially above the conveying assembly 1 along the conveying direction.

[0035] In this embodiment, in order to improve the composite effect of the blank blanket and the blanket base, the napping assembly 2 includes a napping roller 21 and a napping motor for driving the napping roller 21 to rotate. The rotation direction of the napping roller 21 is opposite to the conveying direction of the blank blanket, and a plurality of elastic hooks 22 are evenly distributed on the napping roller 21.

[0036] In this embodiment, in order to form burr fibers on the blank blanket to improve the welding effect between the blank blanket and the hot melt fiber web, the elastic hooks 22 are spirally arranged on the brushing roller 21. The elastic hooks 22 are made of plastic and include a body disposed on the brushing roller 21 and a hook located at the end of the body. The curling direction of the hook is the same as the rotation direction of the brushing roller 21.

[0037] In this embodiment, in order to pre-lay a layer of hot-melt fiber mesh of the same material as the blanket backing on the blank blanket to improve the blanket backing composite effect, the pre-laying component 3 includes an injection pump 32 filled with molten hot-melt fiber and a feed group 33 for driving the injection pump 32 to reciprocate. The feed group 33 is mounted on the frame and includes a conventional X-axis lead screw feed structure, Y-axis lead screw feed structure and Z-axis lead screw feed structure. The injection pump 32 is mounted on the feed group 33 and the feed group 33 is also provided with a cylinder for pumping the injection pump 32. The injection pump 32 is provided with a spray needle and the spray needle is connected to a high-voltage power supply 34.

[0038] In this embodiment, in order to transport the blank blanket to below the pre-laying assembly 3, the conveying assembly 1 includes a conveyor belt and a pulley group for driving the conveyor belt to rotate. Here, the conveying assembly 1 is grounded to ensure the formation of a high-voltage electric field. The conveyor belt includes a working section 11 located on the upper side for transporting the blank blanket and a rotating section 12 located on the lower side in a rotating state. The injection needle is located above the working section 11 to inject hot melt fibers into the back of the blank blanket on the working section 11.

[0039] In this embodiment, in order to increase the temperature of the blank blanket, the hot melt fibers sprayed from the pre-laying component 3 are directly melted onto the blank blanket; the composite mechanism also includes a preheating component located behind the napping component 2 and in front of the pre-laying component 3. The preheating component includes an infrared heater 31, which is located above the conveying component 1 to preheat the blank blanket on the conveying component 1.

[0040] In this embodiment, to ensure that the fibers of the blanket bottom are entangled together, the needle punching assembly 5 includes an upper needle plate 51 and a driver for driving the upper needle plate 51 to move up and down. The upper needle plate 51 is evenly distributed with a plurality of needles 52. Each needle 52 includes a needle handle 521 and a needle rod 522. The lower end of the needle handle 521 is provided with a cylindrical cavity. The upper end of the needle rod 522 is rotatably installed in the cylindrical cavity. The needle rod 522 is provided with a plurality of barbs 523. The plurality of barbs 523 are spirally arranged on the needle rod 522 so that the needle rod 522 is driven to rotate relative to the needle handle 521 by the lateral force received by the needle rod 522 when it is inserted into the fiber web, thereby agitating the fibers and improving the fiber entanglement effect. Here, the conveying assembly 1 is provided with a groove for the needles to be inserted.

[0041] In this embodiment, in order to perform high-temperature shaping on the composite blanket base, the shaping component 6 includes a high-temperature shaping group 61, which includes a hot air chamber 611, a plurality of hot pressure rollers 612 and negative pressure rollers 613. The hot pressure rollers 612 and negative pressure rollers 613 are rotatably installed in the hot air chamber 611 and are rotatably engaged with the hot pressure blanket. The hot pressure rollers 612 are connected to a heater and a fan, and hot air holes are evenly distributed on the hot pressure rollers 612. The negative pressure rollers 613 are connected to a negative pressure fan, and negative pressure holes are evenly distributed on the negative pressure rollers 613.

[0042] In this embodiment, in order to perform low-temperature shaping on the composite blanket base, the shaping component 6 further includes a low-temperature cooling group 62, which includes an air-cooling hood 621, a cold-pressing roller 622, and an elastic roller 623. The cold-pressing roller 622 and the elastic roller 623 are rotatably mounted inside the air-cooling hood 621 and are rotatably engaged with the cold-pressing roller 622 to cold-press the blank blanket. The cold-pressing roller 622 is provided with a circulating water cooling channel.

[0043] Example 2: This example provides a preparation process for an adhesive-free, environmentally friendly, flame-retardant whole-coverage carpet preparation device, including the following steps:

[0044] S1: The tufted blanket with the tufted surface facing down is fed into the conveying assembly 1, and the blanket back is brushed by the brushing assembly 2.

[0045] S2: After the napped blanket backing is preheated by the preheating component, it enters the pre-laying component 3. After the blanket backing is preheated, the jet needle sprays out a hot melt fiber stream. Under the action of the electric field, the hot melt fiber stream is vertically implanted into the blanket backing, forming a layer of preheated melt fiber web on the napped blanket backing.

[0046] S3: A blank blanket with a layer of hot melt fiber web pre-laid is introduced into the web laying assembly 4, and the web laying assembly 4 forms multiple layers of hot melt fiber web on the blank blanket;

[0047] S4: Enter the needle assembly 5, the needle 52 is inserted into the hot melt fiber mesh, the barbs 523 on the needle bar 522 entangle the multiple layers of hot melt fiber mesh together, and through the rotation of the needle bar 522, the multiple layers of hot melt fiber mesh are rotated and entangled in space.

[0048] S5: Entering the high-temperature setting group 61, under the hot pressing of the hot pressure roller 612 and the negative pressure roller 613, the hot melt fiber melts and is composited on the back of the blank blanket;

[0049] S6: Finally, the composite blank is obtained by pressing and cooling in the low-temperature cooling group 62.

[0050] This invention improves the fiber entanglement effect between the raw blanket and the raw blanket by roughening the backing. Furthermore, before laying the hot-melt fiber web, this invention pre-forms a layer of hot-melt fiber web on the raw blanket backing through electrospinning, ensuring that the hot-melt fibers are vertically implanted into the raw blanket backing. At the same time, because the raw blanket backing is preheated before pre-laying, the higher temperature ensures that the hot-melt fibers are implanted and fused with the raw blanket backing, thereby effectively improving the composite strength of the hot-melt fiber web. Moreover, since the pre-laid fiber web and the subsequently laid fiber web are made of the same material, the fusion effect is better, thus effectively ensuring the structural strength of the composite blanket bottom.

[0051] The above embodiments and figures are not intended to limit the product form and style of the present invention. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of the present invention.

Claims

1. A glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device, characterized in that: It includes a spinning machine for producing colored flame-retardant yarn, a non-woven machine for producing non-woven base fabric, a tufting jacquard machine for tufting colored flame-retardant yarn onto non-woven base fabric to produce colored jacquard raw blankets, and a composite mechanism for forming a composite blanket base on the back of the raw blanket. The composite mechanism includes a frame on which are provided a conveying assembly for conveying a blank blanket, a roughening assembly for roughening the back of the blank blanket, a pre-laying assembly for laying a layer of hot melt fiber mesh as a base layer on the roughened blank blanket, a web-laying assembly for covering the pre-lay hot melt fiber mesh with multiple layers of hot melt fiber mesh, a needle-punching assembly for needle-punching the web, and a setting assembly for heat setting. The roughening assembly, pre-laying assembly, web-laying assembly, needle-punching assembly, and setting assembly are arranged sequentially above the conveying assembly along the conveying direction.

2. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 1, characterized in that: The deburring assembly includes a deburring roller and a deburring motor for driving the deburring roller to rotate. The rotation direction of the deburring roller is opposite to the conveying direction of the blank blanket. The deburring roller is evenly distributed with a number of elastic hooks.

3. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 2, characterized in that: The elastic hooks are arranged in a spiral on the brushing roller. The elastic hooks are made of plastic and include a body on the brushing roller and a hook at the end of the body.

4. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 1, characterized in that: The pre-laying assembly includes an injection pump filled with molten hot-melt fibers and a feed assembly for driving the injection pump to reciprocate. The feed assembly is mounted on a frame, the injection pump is mounted on the feed assembly, and the injection pump is equipped with a jetting needle connected to a high-voltage power supply.

5. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 4, characterized in that: The conveying assembly includes a conveyor belt and a pulley assembly for driving the conveyor belt to rotate. The conveyor belt includes a working section on the upper side for conveying the blank blanket and a rotating section on the lower side in a rotating state. The injection needle is located above the working section to inject hot melt fibers into the back of the blank blanket on the working section.

6. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 1, characterized in that: The composite mechanism also includes a preheating component located behind the napping component and in front of the pre-laying component. The preheating component includes an infrared heater, which is located above the conveying component to preheat the blank blanket on the conveying component.

7. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 1, characterized in that: The needle-punching assembly includes an upper needle plate and a driver for driving the upper needle plate to move up and down. The upper needle plate is evenly distributed with a plurality of needles. Each needle includes a needle handle and a needle rod. The lower end of the needle handle is provided with a cylindrical cavity. The upper end of the needle rod is rotatably mounted in the cylindrical cavity. The needle rod is provided with a plurality of barbs. The plurality of barbs are spirally arranged on the needle rod so that the needle rod is driven to rotate relative to the needle handle by the lateral force received by the needle rod when it is inserted into the fiber web, thereby agitating the fibers and improving the fiber entanglement effect.

8. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 1, characterized in that: The shaping assembly includes a high-temperature shaping group, which includes a hot air chamber, several hot pressure rollers and negative pressure rollers. The hot pressure rollers and negative pressure rollers are rotatably installed in the hot air chamber and are rotatably engaged with the hot pressing blank. The hot pressure rollers are connected to a heater and a fan, and hot air holes are evenly distributed on the hot pressure rollers. The negative pressure rollers are connected to a negative pressure fan, and negative pressure holes are evenly distributed on the negative pressure rollers.

9. The glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device according to claim 8, characterized in that: The shaping assembly also includes a low-temperature cooling group, which includes an air-cooled hood, a cold-pressing roller, and an elastic roller. The cold-pressing roller and the elastic roller are rotatably installed inside the air-cooled hood and are rotatably engaged with the cold-pressing blank. The cold-pressing roller is provided with a circulating water cooling channel.

10. A preparation process for a glue-free, environmentally friendly, flame-retardant full-coverage carpet preparation device as described in any one of claims 1-9, characterized in that: Includes the following steps: S1: The tufted blanket with the surface facing down is fed into the conveying assembly, and the blanket back is brushed by the brushing assembly. S2: After the napped blanket backing is preheated by the preheating component, it enters the pre-laying component. After the blanket backing is preheated, the jet needle sprays out a hot melt fiber stream. Under the action of the electric field, the hot melt fiber stream is vertically implanted into the blanket backing, forming a layer of preheated melt fiber web on the napped blanket backing. S3: A blank blanket with a layer of hot melt fiber web pre-laid on it enters the web laying assembly, which forms multiple layers of hot melt fiber web on the blank blanket; S4: Enter the needle punching assembly, the needle is inserted into the hot melt fiber mesh, the barbs on the needle bar tie the multiple layers of hot melt fiber mesh together, and through the rotation of the needle bar, the multiple layers of hot melt fiber mesh are rotated and entangled in space; S5: Entering the high-temperature setting group, under the hot pressing of hot and negative pressure rollers, the hot melt fibers are melted and bonded to the back of the blank blanket; S6: Finally, the composite blank is obtained by pressing and cooling in a low-temperature cooling group.

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