A non-woven floor mat and its manufacturing process

Abstract

This invention discloses a nonwoven floor mat and its manufacturing process, belonging to the technical field of floor protection materials. The mat comprises, from top to bottom, a PE film layer, a nonwoven fabric layer, a self-adhesive layer, and a release paper layer. The PE film layer is a cast PE film, anchored to the nonwoven fabric layer by solvent-free hot pressing. The nonwoven fabric layer is a three-dimensional interconnected porous structure formed by pre-needling and reverse main needle punching of chemical fibers, with an air permeability ≥300mm / s and a saturated moisture absorption rate ≥15%. The self-adhesive layer is a grid-like water-based acrylic pressure-sensitive adhesive layer, and the width and length ratio of the PE film to the nonwoven fabric is 1:1. The manufacturing process includes four main steps: nonwoven fabric preparation, self-adhesive coating, nonwoven fabric-PE film lamination, and finished product post-processing. This invention, through synergistic optimization of structure and process, simultaneously achieves the core properties of waterproofing, anti-slip, self-adhesive, breathability, residue-free application, and moisture absorption and mildew prevention, making it widely adaptable to the surface protection needs of various scenarios such as construction, decoration, maintenance, painting, and warehousing.

Description

Technical Field

[0001] This invention relates to the field of ground protection materials technology, specifically to a non-woven floor mat and its manufacturing process. Background Technology

[0002] In scenarios such as building decoration, wall painting, warehousing and storage, and home protection, non-woven protective floor mats are currently the most widely used surface protection product due to their low cost, convenient installation, and softness / flexibility. While numerous publicly available solutions have been developed for the research and development of non-woven protective floor mats, several long-standing industry pain points remain unresolved, specifically as follows:

[0003] For example, Chinese utility model patent CN218714377U discloses a floor protection film for decoration, which adopts a double-layer structure of non-woven fabric layer and PVC film composite. However, its waterproof membrane is set at the bottom layer, which cannot achieve surface anti-fouling and waterproof. After paint and water stains come into direct contact with the non-woven fabric layer, they can easily penetrate to the protected base surface. In addition, the adhesive composite process is used, and the layers are prone to delamination and curling. At the same time, PVC film has the defects of poor environmental protection and easy brittleness at low temperature.

[0004] For example, Chinese invention patent application CN116181238A discloses a non-slip and wear-resistant non-woven protective film. Rubber anti-slip particles are set in the bottom layer of the non-woven fabric. Although the anti-slip function is achieved, the anti-slip particles are easy to fall off, and after being torn off, they are very easy to leave glue residue on the surface of ceramic tiles and wooden floors, causing damage to the base surface. At the same time, its non-woven fabric substrate is prepared by a single needle punching process, with low fiber entanglement density, poor puncture resistance and wear resistance, and is very easy to be punctured by sand and tools during construction, resulting in a high risk of protective failure.

[0005] In addition, existing technologies also have a long-standing core technical contradiction: existing ground protection films either use a full-coat glue + sealed membrane structure for waterproofing and self-adhesion, completely losing breathability. After the wood flooring is laid, condensation cannot escape, and long-term accumulation can easily lead to mold, bulging, and deformation of the wood flooring; or they sacrifice waterproofing and self-adhesion functions for breathability, making it impossible to simultaneously achieve waterproofing, self-adhesion, breathability, and moisture absorption, resulting in fatal flaws in the protection of wood flooring and solid wood furniture.

[0006] To address the long-standing industry pain points mentioned above, existing technologies have yet to offer effective solutions. Therefore, developing a non-woven floor mat that combines all-dimensional protective performance, structural stability, environmental friendliness, and mass production capabilities, along with its manufacturing process, has significant industrial value and application implications. Summary of the Invention

[0007] Therefore, it is necessary to provide a non-woven floor mat and its manufacturing process to address the above problems.

[0008] A nonwoven floor mat includes, from top to bottom, a PE film layer, a nonwoven fabric layer, a self-adhesive layer, and a release paper layer stacked sequentially. The PE film layer is a cast PE film, which is anchored to the upper surface of the nonwoven fabric layer by a solvent-free hot-press bonding process. The nonwoven fabric layer is a three-dimensional through-pore structure needle-punched nonwoven fabric formed by pre-needling and reverse main needle punching of chemical fiber. The needle exit direction of the pre-needling is opposite to that of the main needle punching. The air permeability of the nonwoven fabric layer is ≥300mm / s, and the saturated moisture absorption rate is ≥15%. The self-adhesive layer is a water-based acrylic pressure-sensitive adhesive layer uniformly coated in a grid pattern. The self-adhesive layer is coated on the lower surface of the nonwoven fabric layer, and the release paper layer is laminated on the side of the self-adhesive layer opposite to the nonwoven fabric layer. The width and length ratio of the PE film layer and the nonwoven fabric layer are both 1:1.

[0009] Furthermore, the thickness of the PE film layer is 0.02mm-0.2mm, and the basis weight of the nonwoven fabric layer is 80g / ㎡-800g / ㎡, which can be flexibly adjusted according to the strength requirements of different protection scenarios.

[0010] Furthermore, the dry adhesive coating of the self-adhesive layer is 10g / ㎡-50g / ㎡, which balances anti-slip fixing effect with traceless tear-off performance.

[0011] Furthermore, the chemical fiber of the nonwoven fabric layer is one or a mixture of two of polypropylene fibers and polyester fibers, taking into account the strength, wear resistance and softness of the substrate.

[0012] Furthermore, the pre-needling has a needle density of 80-200 needles / cm² and a needle depth of 6-12mm; the main needle has a needle density of 200-500 needles / cm² and a needle depth of 4-10mm. Through bidirectional double needleing, deep fiber entanglement is achieved, forming a stable three-dimensional through-pore structure.

[0013] A production process for the aforementioned nonwoven floor mat includes sequentially performed steps of nonwoven fabric preparation, self-adhesive coating, nonwoven fabric-PE film lamination, and finished product post-processing. The specific steps are as follows:

[0014] S1 nonwoven fabric preparation process: After chemical fiber is opened, mixed with cotton and carded in sequence, it is first pre-needled and shaped by forward pre-needling, and then solidified by reverse main needle punching in the opposite direction of the pre-needling needle direction to form a nonwoven fabric blank with a three-dimensional through-pore structure; the blank is used after passing the full-width needle inspection and winding inspection.

[0015] S2 self-adhesive coating process: Water-based acrylic pressure-sensitive adhesive is uniformly coated in a grid pattern on the lower surface of qualified non-woven fabric. After step drying, release paper is simultaneously laminated on the surface of the self-adhesive layer, and the fabric is rolled up to obtain the adhesive non-woven fabric semi-finished product.

[0016] S3 Nonwoven Fabric-PE Film Composite Process: The adhesive nonwoven fabric semi-finished product and the cast PE film are simultaneously fed onto the machine. The conveying parameters of the two are calibrated to make the width and length ratio 1:1. After heating and maintaining a constant temperature, solvent-free hot pressing is performed. Then, the composite blank is obtained by roller drying for strengthening and forced cooling for shaping.

[0017] S4 Finished Product Post-processing: After the composite blank is precisely cut, it undergoes full-item inspection and a second full-width needle inspection before being packaged and shipped.

[0018] Furthermore, in S1, the pre-needling density is 80-200 needles / cm² and the needle depth is 6-12mm; the main needleling density is 200-500 needles / cm² and the needle depth is 4-10mm.

[0019] Furthermore, in S3, the heating temperature for hot pressing is 110℃-160℃, the hot pressing pressure is 0.2MPa-1.0MPa, and the composite linear speed is 5m / min-30m / min.

[0020] Furthermore, in S3, the temperature of the drum drying is 80℃-120℃, and the residence time of the composite billet in the drying drum is 3-15s; the needle detection in S1 and S4 both adopt a full-width continuous needle detector with a sensitivity ≥0.8mm.

[0021] Furthermore, in S1, the opening process adopts a two-stage opening process, with the first-stage opening roller speed being 600-800 r / min and the second-stage opening roller speed being 1000-1200 r / min; in S2, the temperature of the stepped drying is 80℃-100℃.

[0022] The specific advantages of this invention compared to the prior art are as follows:

[0023] The four-layer synergistic structural design breaks through the performance bottleneck of existing technologies: This invention adopts an integrated structure of "surface cast PE film + middle three-dimensional porous non-woven fabric + bottom mesh water-based pressure-sensitive adhesive layer + release paper protective layer". The surface PE film blocks external water stains and coatings, achieving waterproof, stain-proof and easy-to-wipe properties; the middle non-woven fabric provides wear-resistant and impact-resistant physical protection, while providing a stable bonding base for the upper and lower layers; the bottom mesh pressure-sensitive adhesive achieves anti-slip self-adhesion and fixation, preventing displacement during installation, leaving no residue after removal, and not damaging the base surface such as tiles, wood flooring, and painted furniture. The four layers work together to solve the long-standing industry pain point of existing technologies that "waterproofing and anti-slip properties cannot be achieved at the same time, and protection and environmental protection cannot be balanced".

[0024] The reverse double needle-punching consolidation process breaks through the performance bottleneck of the substrate: The present invention adopts a double needle-punching process of "forward pre-needling + reverse main needle-punching". Pre-needling realizes the initial shaping of the fiber web, and reverse main needle-punching realizes the deep entanglement of fibers in both directions, forming a stable three-dimensional through-pore structure. Compared with the existing conventional process, the fiber entanglement density is increased by more than 50%, the breaking strength is increased by more than 40%, and it has excellent puncture resistance and flexibility at the same basis weight. It can be perfectly adapted to the covering and protection of stairs, irregular furniture, and inside and outside corners, and completely breaks through the technical bottleneck of "strength and flexibility cannot be achieved at the same time" in the existing technology.

[0025] This invention achieves a dual effect of breathability and moisture absorption, completely solving the problem of mold growth on wood flooring: The invention utilizes a three-dimensional interconnected pore structure of non-woven fabric combined with a mesh-like adhesive layer. While the surface PE film blocks external water stains, the middle non-woven fabric layer efficiently absorbs condensation on the wood flooring surface. Simultaneously, air circulation is achieved through the pores not covered by the adhesive layer, preventing long-term moisture accumulation that leads to mold, bulging, and deformation of the wood flooring. The finished product boasts an air permeability ≥300mm / s and a saturated moisture absorption rate ≥15%, overcoming the existing technical bias that "waterproofing and breathability / moisture absorption cannot be achieved simultaneously."

[0026] The solvent-free hot-pressing anchoring composite process balances environmental friendliness and structural stability: This invention employs a 1:1 precise ratio closed-loop control to achieve completely synchronous delivery of the nonwoven fabric and PE film, avoiding problems such as stretching deformation and wrinkling; simultaneously, it uses a solvent-free hot-pressing bonding process, where the PE film is embedded into the gaps between the surface fibers of the nonwoven fabric through thermal melting, forming an anchoring bond without the need for adhesives, resulting in environmentally friendly VOC-free production that fully meets indoor environmental protection requirements; coupled with drying and strengthening, cooling and shaping processes, the peel strength of the finished product is increased by more than 60%, and the heat shrinkage rate is controlled within 1%, completely solving the common industry problems of easy delamination, edge curling, and dimensional instability of existing composite layers.

[0027] The entire process features systematic quality control, balancing mass production efficiency with adaptability to all scenarios: This invention sets up a dual-node full-range needle inspection process of "substrate preparation + final inspection of finished product" to intercept metal foreign objects throughout the process and eliminate safety hazards; the entire process adopts a continuous connection design, which improves production efficiency by more than 40%, reduces raw material loss by more than 15%, and increases the finished product qualification rate from the current 75% to more than 98%, enabling large-scale mass production; at the same time, through flexible parameter adjustment, it can perfectly adapt to the needs of all scenarios such as light-load home protection, medium-load decoration construction, and heavy-load warehousing and stacking. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the layered structure of the nonwoven floor mat described in this invention;

[0029] Figure 2 This is a flowchart of the first process of the nonwoven floor mat described in this invention;

[0030] Figure 3 This is a flowchart of the second process of the nonwoven floor mat described in this invention.

[0031] 1. PE film layer; 2. Non-woven fabric layer; 3. Self-adhesive layer; 4. Release paper layer. Detailed Implementation

[0032] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention are described in detail below. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0033] As used herein, the terms “prepared from” and “comprising” are synonymous. The terms “comprising,” “including,” “having,” “containing,” or any other variations thereof, as used herein, are intended to cover non-exclusive inclusion. For example, a composition, step, method, article, or apparatus that includes the listed elements is not necessarily limited to those elements, but may include other elements not expressly listed or elements inherent to such composition, step, method, article, or apparatus.

[0034] When a quantity, concentration, or other value or parameter is expressed as a range, a preferred range, or a range defined by a series of upper and lower preferred values, this should be understood as specifically disclosing all ranges formed by any pair of any upper or preferred value with any lower or preferred value, regardless of whether the range is disclosed individually. For example, when the range “1 to 5” is disclosed, the described range should be interpreted as including the ranges “1 to 4”, “1 to 3”, “1 to 2”, “1 to 2 and 4 to 5”, “1 to 3 and 5”, etc. When numerical ranges are described herein, unless otherwise stated, the range is intended to include its endpoints and all integers and fractions within that range.

[0035] Furthermore, the indefinite articles “a” and “an” preceding the elements or components of this invention do not impose any limitation on the quantity requirement (i.e., the number of times) of the elements or components. Therefore, “an” or “a” should be interpreted as including one or at least one, and the singular form of an element or component also includes the plural form, unless the quantity clearly refers to the singular form.

[0036] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0037] In the following embodiments and comparative examples of this invention, all raw materials used are commercially available conventional industrial-grade products, specifically as follows: the chemical fiber is polypropylene fiber (PP fiber) or polyester fiber (PET fiber), with a fineness of 1.5D-6D and a length of 38mm-65mm; the PE film is cast PE film, conforming to GB4806.7-2016 standard for plastic materials and products for food contact; the water-based acrylic pressure-sensitive adhesive has a solid content of 40%-60%, conforming to GB18583-2008 standard for limits of harmful substances in adhesives for interior decoration and renovation materials; the release paper is single-sided silicone paper with a basis weight of 60g / ㎡-120g / ㎡.

[0038] Example 1

[0039] The thin nonwoven floor mat prepared in this embodiment is suitable for light-load protection scenarios such as daily home protection, furniture covering, and wall painting. It fully covers the lower limits of parameters such as 80g / ㎡ nonwoven fabric basis weight, 0.02mm PE film thickness, and 10g / ㎡ dry adhesive content in the claims. The specific preparation process is as follows:

[0040] S1 Nonwoven Fabric Preparation Process

[0041] S1.1 Opening of chemical fibers: Select 100% polypropylene fiber raw materials with a fineness of 1.5D and a length of 38mm. Feed them into the opening machine for two-stage opening treatment. The first-stage opening roller speed is 800r / min, and the second-stage opening roller speed is 1200r / min to break up the fiber clumps and obtain fluffy and dispersed single fibers.

[0042] S1.2 Blending: The opened fibers are fed into a multi-compartment blender and mixed in two cycles for 10 minutes to ensure that the uniformity deviation of the fiber components is ≤3%.

[0043] S1.3 Carding and forming: The uniformly mixed fibers are fed into a double cylinder double doffer carding machine. The cylinder speed is 1300 r / min and the doffer speed is 25 r / min. The fibers are carded to form a continuous fiber web with uniform basis weight. The fiber web surface density is 80 g / m² and the basis weight deviation is ≤5%.

[0044] S1.4 Double Needling Consolidation: First, the fiber web is fed into a pre-needling machine for forward pre-needling treatment. The pre-needling needle density is 80 needles / cm², the needle depth is 6mm, the needle type is 25#, and the pre-needling machine frequency is 280 times / min, so that the fiber web is initially entangled and shaped. Then, the pre-needled fiber web is fed into a main needleling machine for reverse main needleling treatment. The main needle density is 200 needles / cm², the needle depth is 4mm, the needle type is 22#, and the main needleling machine frequency is 380 times / min, so that the fibers are deeply entangled in both directions, forming a nonwoven fabric preform with a three-dimensional through-pore structure.

[0045] S1.5 Single Needle Inspection: The nonwoven fabric blank is passed through a full-width continuous needle inspection machine with a needle inspection machine sensitivity of Fe 0.8mm to perform full-width continuous metal impurity detection and remove unqualified blanks.

[0046] S1.6 Rewinding Inspection: Nonwoven fabric blanks that pass the needle inspection are rewound under constant tension. The rewinding tension is 8N and the rewinding speed is 20m / min. After passing all inspections of appearance, weight, air permeability and breaking strength, the fabric is sealed in moisture-proof film for later use.

[0047] S2 Self-adhesive Coating Process

[0048] S2.1 Nonwoven fabric unwinding: The finished nonwoven fabric obtained in S1 is fed into the anilox roller coating machine through a closed-loop tension unwinding mechanism with an unwinding tension of 6N.

[0049] S2.2 Precision Coating: Water-based acrylic pressure-sensitive adhesive is uniformly coated in a grid pattern on the lower surface of the nonwoven fabric. The grid porosity is 40%, the dry adhesive amount is controlled at 10g / ㎡, the anilox roller line count is 150 lines, and the coating speed is 20m / min.

[0050] S2.3 Step drying: The coated nonwoven fabric is sent into a two-stage step drying oven with the oven temperature set at 80℃ and 80℃ respectively, and the moisture in the adhesive layer is removed by constant temperature drying.

[0051] S2.4 Release paper lamination: 60g / ㎡ single-sided release paper is simultaneously laminated onto the surface of the dried self-adhesive layer, and the adhesive non-woven fabric semi-finished product is obtained after constant tension winding.

[0052] S3 Nonwoven Fabric-PE Film Composite Process

[0053] S3.1 Synchronous Fabric Loading: The adhesive-coated nonwoven fabric semi-finished product obtained in S2 and the 0.02mm thick cast PE film are synchronously loaded onto the machine through a closed-loop tension unwinding mechanism. The unwinding tension of the nonwoven fabric is 6N and the unwinding tension of the PE film is 3N. They are then synchronously conveyed to the thermal lamination station.

[0054] S3.2 1:1 ratio calibration: Adjust the conveying line speed of the nonwoven fabric and PE film to 20m / min to ensure that the width and length ratio of the two are precisely controlled to 1:1, and the line speed synchronization deviation is ≤0.5%.

[0055] S3.3 Heating and Temperature Control: Start the thermal composite double roller heating system. The upper roller temperature is 110℃ and the lower roller temperature is 105℃. After reaching the preset temperature, maintain the temperature for 8 minutes to ensure uniform roller surface temperature.

[0056] S3.4 Solvent-free hot-pressing: The nonwoven fabric and PE film are fed into the hot-pressing roller simultaneously. The hot-pressing pressure is 0.2MPa. Through the hot-pressing action, the PE film melts and embeds into the gaps between the surface fibers of the nonwoven fabric to form an anchor bond, thus producing a composite preform.

[0057] S3.5 Roller Drying Enhancement: The composite billet is fed into a two-section constant temperature drying drum assembly, with a drying temperature of 80℃ for both sections. The residence time of the composite billet in the drying drum is 3 seconds.

[0058] S3.6 Forced Cooling and Shaping: The dried composite billet is passed through a double-roller cooling unit. The cooling rollers are circulated with 20°C cooling water to rapidly cool the composite billet to below 35°C, thus completing the crystallization and shaping.

[0059] S4 Finished Product Post-Processing Process

[0060] S4.1 Precise Slitting: Based on the preset finished product size (width 1.2m, length 50m / roll), the composite blank is slitted to a fixed length and width, and the slitting size tolerance is controlled within ±0.5mm.

[0061] S4.2 Secondary needle inspection and final inspection: The semi-finished products after slitting undergo full performance testing, and a secondary metal impurity test is performed using a needle detector with a sensitivity of 0.8mm Fe to remove unqualified products.

[0062] S4.3 Packaging and Shipping: Finished products that pass inspection are sealed in moisture-proof film, each roll is accompanied by a product certificate, and after scanning the barcode and entering the warehouse, they are shipped according to the order.

[0063] Example 2

[0064] The standard nonwoven floor mat prepared in this embodiment is suitable for medium-load scenarios such as home decoration, commercial projects, and wood flooring / tile / staircase protection. It fully covers the intermediate values ​​of parameters such as 300g / ㎡ nonwoven fabric basis weight, 0.08mm PE film thickness, and 25g / ㎡ dry adhesive content in the claims. The specific preparation process is as follows:

[0065] S1 Nonwoven Fabric Preparation Process

[0066] S1.1 Opening of chemical fibers: Select a mixture of polyester fiber (75% by mass) and polypropylene fiber (25% by mass), with a fineness of 3D and a length of 51mm. Feed it into an opening machine for two-stage opening treatment. The first-stage opening roller rotates at 700r / min and the second-stage opening roller rotates at 1100r / min to break up the fiber clumps and obtain fluffy and dispersed single fibers.

[0067] S1.2 Blending: The opened fibers are fed into a multi-compartment blender and mixed in 4 cycles for 20 minutes to ensure that the uniformity deviation of the fiber components is ≤3%.

[0068] S1.3 Carding and forming: The uniformly mixed fibers are fed into a double cylinder double doffer carding machine. The cylinder speed is 1100 r / min and the doffer speed is 18 r / min. The fibers are carded to form a continuous fiber web with uniform basis weight. The fiber web surface density is 300 g / m² and the basis weight deviation is ≤5%.

[0069] S1.4 Double Needling Consolidation: First, the fiber web is fed into a pre-needling machine for forward pre-needling treatment. The pre-needling needle density is 150 needles / cm², the needle depth is 9mm, the needle type is 25#, and the pre-needling machine frequency is 350 times / min, so that the fiber web is initially entangled and shaped. Then, the pre-needled fiber web is fed into a main needleling machine for reverse main needleling treatment. The main needle density is 350 needles / cm², the needle depth is 7mm, the needle type is 22#, and the main needleling machine frequency is 450 times / min, so that the fibers are deeply entangled in both directions, forming a nonwoven fabric preform with a three-dimensional through-pore structure.

[0070] S1.5 Single Needle Inspection: The nonwoven fabric blank is passed through a full-width continuous needle inspection machine with a needle inspection machine sensitivity of Fe 0.8mm to perform full-width continuous metal impurity detection and remove unqualified blanks.

[0071] S1.6 Rewinding Inspection: Nonwoven fabric blanks that pass the needle inspection are rewound under constant tension. The rewinding tension is 15N and the rewinding speed is 12m / min. After passing all inspections, the blanks are sealed in moisture-proof film for later use.

[0072] S2 Self-adhesive Coating Process

[0073] S2.1 Nonwoven fabric unwinding: The finished nonwoven fabric obtained in S1 is fed into the comma doctor blade coating machine through a closed-loop tension unwinding mechanism with an unwinding tension of 12N.

[0074] S2.2 Precision Coating: Water-based acrylic pressure-sensitive adhesive is uniformly coated in a grid pattern on the lower surface of the nonwoven fabric. The grid porosity is 35%, the dry adhesive amount is controlled at 25g / ㎡, and the coating speed is 12m / min.

[0075] S2.3 Step drying: The coated nonwoven fabric is sent into a four-stage step drying oven with oven temperatures of 85℃, 95℃, 90℃ and 85℃ respectively, to remove moisture from the adhesive layer by constant temperature drying.

[0076] S2.4 Release paper lamination: 100g / ㎡ single-sided release paper is simultaneously laminated onto the surface of the dried self-adhesive layer, and the adhesive non-woven fabric semi-finished product is obtained after constant tension winding.

[0077] S3 Nonwoven Fabric-PE Film Composite Process

[0078] S3.1 Synchronous Fabric Loading: The adhesive-coated nonwoven fabric semi-finished product obtained in S2 and the 0.08mm thick cast PE film are synchronously loaded onto the machine through a closed-loop tension unwinding mechanism. The unwinding tension of the nonwoven fabric is 12N and the unwinding tension of the PE film is 7N. They are synchronously conveyed to the thermal lamination station.

[0079] S3.2 1:1 ratio calibration: Adjust the conveying line speed of the nonwoven fabric and PE film to 12m / min to ensure that the width and length ratio of the two are precisely controlled to 1:1, and the line speed synchronization deviation is ≤0.5%.

[0080] S3.3 Heating and Temperature Control: Start the thermal composite double roller heating system. The upper roller temperature is 135℃ and the lower roller temperature is 130℃. After reaching the preset temperature, maintain the temperature for 15 minutes to ensure uniform roller surface temperature.

[0081] S3.4 Solvent-free hot-pressing: The nonwoven fabric and PE film are fed into the hot-pressing roller at a pressure of 0.6 MPa. The hot-pressing action causes the PE film to melt and embed into the gaps between the surface fibers of the nonwoven fabric, forming an anchor bond and producing a composite blank.

[0082] S3.5 Roller Drying Enhancement: The composite billet is fed into a four-section constant temperature drying drum assembly, with drying temperatures of 95℃, 105℃, 105℃ and 95℃ respectively, and the residence time of the composite billet in the drying drum is 10s.

[0083] S3.6 Forced Cooling and Shaping: The dried composite billet is rapidly cooled to below 35°C using a double-roller cooling unit to complete the crystallization and shaping.

[0084] S4 Finished Product Post-Processing Process

[0085] S4.1 Precise Slitting: Based on the preset finished product size (width 2m, length 50m / roll), the composite blank is slitted to a fixed length and width, and the slitting size tolerance is controlled within ±0.5mm.

[0086] S4.2 Secondary needle inspection and final inspection: All semi-finished products after slitting are subjected to full-item inspection, and secondary metal impurity detection is performed using a needle detector with a sensitivity of Fe0.8mm to remove unqualified products.

[0087] S4.3 Packaging and Shipping: Qualified finished products are sealed in packaging, scanned for entry into the warehouse, and then shipped according to the order.

[0088] Example 3

[0089] The heavy-duty nonwoven floor mat prepared in this embodiment is suitable for heavy-duty protection needs in warehouse cargo stacking, heavy equipment construction, and high-wear scenarios. It fully covers the upper limits of parameters such as 800g / ㎡ nonwoven fabric basis weight, 0.2mm PE film thickness, and 50g / ㎡ dry adhesive content in the claims. The specific preparation process is as follows:

[0090] S1 Nonwoven Fabric Preparation Process

[0091] S1.1 Opening of chemical fibers: Select 100% polyester fiber raw materials with a fineness of 6D and a length of 65mm. Feed them into the opening machine for two-stage opening treatment. The first-stage opening roller speed is 600r / min, and the second-stage opening roller speed is 1000r / min to break up the fiber clumps and obtain fluffy and dispersed single fibers.

[0092] S1.2 Blending: The opened fibers are fed into a multi-compartment blender and mixed in 5 cycles for 25 minutes to ensure that the uniformity deviation of the fiber components is ≤3%.

[0093] S1.3 Carding and forming: The uniformly mixed fibers are fed into a double cylinder double doffer carding machine. The cylinder speed is 1000 r / min and the doffer speed is 15 r / min. The fibers are carded to form a continuous fiber web with uniform basis weight. The fiber web surface density is 800 g / m² and the basis weight deviation is ≤5%.

[0094] S1.4 Double Needling Consolidation: First, the fiber web is fed into a pre-needling machine for forward pre-needling treatment. The pre-needling needle density is 200 needles / cm², the needle depth is 12mm, the needle type is 28#, and the pre-needling machine frequency is 400 times / min, so that the fiber web is initially entangled and shaped. Then, the pre-needled fiber web is fed into a main needleling machine for reverse main needleling treatment. The main needle density is 500 needles / cm², the needle depth is 10mm, the needle type is 25#, and the main needleling machine frequency is 500 times / min, so that the fibers are deeply entangled in both directions, forming a nonwoven fabric preform with a three-dimensional through-pore structure.

[0095] S1.5 Single Needle Inspection: The nonwoven fabric blank is passed through a full-width continuous needle inspection machine with a needle inspection machine sensitivity of Fe 0.8mm to perform full-width continuous metal impurity detection and remove unqualified blanks.

[0096] S1.6 Rewinding Inspection: Nonwoven fabric blanks that pass the needle inspection are rewound under constant tension. The rewinding tension is 25N and the rewinding speed is 5m / min. After passing all inspections, the blanks are sealed in moisture-proof film for later use.

[0097] S2 Self-adhesive Coating Process

[0098] S2.1 Nonwoven fabric unwinding: The finished nonwoven fabric obtained in S1 is fed into the comma doctor blade coating machine through a closed-loop tension unwinding mechanism with an unwinding tension of 20N.

[0099] S2.2 Precision Coating: Water-based acrylic pressure-sensitive adhesive is uniformly coated in a grid pattern on the lower surface of the nonwoven fabric. The grid porosity is 30%, the dry adhesive amount is controlled at 50g / ㎡, and the coating speed is 5m / min.

[0100] S2.3 Step drying: The coated nonwoven fabric is sent into a four-stage step drying oven with oven temperatures of 90℃, 100℃, 100℃ and 90℃ respectively, and the adhesive layer is dried at a constant temperature to remove moisture.

[0101] S2.4 Release paper lamination: 120g / ㎡ single-sided release paper is simultaneously laminated onto the surface of the dried self-adhesive layer, and the adhesive non-woven fabric semi-finished product is obtained after constant tension winding.

[0102] S3 Nonwoven Fabric-PE Film Composite Process

[0103] S3.1 Synchronous Fabric Loading: The adhesive-coated nonwoven fabric semi-finished product obtained in S2 and the 0.2mm thick cast PE film are synchronously loaded onto the machine through a closed-loop tension unwinding mechanism. The unwinding tension of the nonwoven fabric is 20N and the unwinding tension of the PE film is 12N. They are synchronously conveyed to the thermal lamination station.

[0104] S3.2 1:1 ratio calibration: Adjust the conveying line speed of the nonwoven fabric and PE film to 5m / min to ensure that the width and length ratio of the two are precisely controlled to 1:1, and the line speed synchronization deviation is ≤0.5%.

[0105] S3.3 Heating and Temperature Control: Start the thermal composite double roller heating system. The upper roller temperature is 160℃ and the lower roller temperature is 155℃. After reaching the preset temperature, maintain the temperature for 20 minutes to ensure uniform roller surface temperature.

[0106] S3.4 Solvent-free hot-pressing: The nonwoven fabric and PE film are fed into the hot-pressing roller at a pressure of 1.0 MPa. The PE film melts and embeds into the gaps between the surface fibers of the nonwoven fabric through the hot-pressing action, forming an anchor bond and producing a composite preform.

[0107] S3.5 Roller Drying Enhancement: The composite billet is fed into a four-section constant temperature drying drum assembly, with a drying temperature of 120℃. The residence time of the composite billet in the drying drum is 15s.

[0108] S3.6 Forced Cooling and Shaping: The dried composite billet is rapidly cooled to below 35°C using a double-roller cooling unit to complete the crystallization and shaping.

[0109] S4 Finished Product Post-Processing Process

[0110] S4.1 Precise Slitting: Based on the preset finished product size (width 2m, length 20m / roll), the composite blank is slitted to a fixed length and width, and the slitting size tolerance is controlled within ±0.5mm.

[0111] S4.2 Secondary needle inspection and final inspection: All semi-finished products after slitting are subjected to full-item inspection, and secondary metal impurity detection is performed using a needle detector with a sensitivity of Fe0.8mm to remove unqualified products.

[0112] S4.3 Packaging and Shipping: Qualified finished products are sealed in packaging, scanned for entry into the warehouse, and then shipped according to the order.

[0113] Comparative Example 1: The closest existing technology for conventional nonwoven floor mats

[0114] This comparative example was prepared using the core scheme of CN218714377U in the background technology as a reference for existing technology. The specific process is as follows:

[0115] Nonwoven fabric preparation: 300g / ㎡ polyester fiber is used to prepare nonwoven fabric blanks through a single needle punching process. The needle punching density is 350 needles / square centimeter and the needle punching depth is 8mm. There is no needle inspection process. After winding, it is ready for use.

[0116] Composite process: Organic solvent-based polyurethane adhesive is used to fully coat the non-woven fabric with a 0.08mm PE film. There is no 1:1 ratio synchronous control. After lamination, it is naturally air-dried without drying, cooling and shaping processes.

[0117] Anti-slip treatment: Spray solvent-based anti-slip adhesive onto the bottom surface of the non-woven fabric, let it air dry naturally, without release paper protective layer.

[0118] Cutting and Packaging: Manually cut to the same size as in Example 2, and packaged and shipped after appearance inspection.

[0119] Comparative Example 2: Control mat without reverse double needle puncture

[0120] The only difference between this comparative example and Example 2 is that in the nonwoven fabric preparation process, the needle exit direction of the pre-needling and the main needleling is the same, while the rest of the processes, parameters, and raw materials are completely consistent with Example 2.

[0121] Performance comparison test

[0122] The nonwoven floor mats prepared in Examples 1-3 and Comparative Examples 1-2 of this invention were subjected to full performance tests according to current national standards. The test results are shown in the table below:

[0123]

[0124] Test Result Analysis:

[0125] Examples 1-3 of this invention are significantly superior to Comparative Example 1 of the prior art in all dimensions, including mechanical strength, waterproof performance, interlayer bonding stability, anti-slip performance, breathability and moisture absorption performance, environmental protection, and finished product qualification rate. They completely solve the core pain points of the prior art and have outstanding substantive features and significant progress.

[0126] Compared to the same-direction double needle punching process in Comparative Example 2, the reverse double needle punching process of the present invention increases the breaking strength by more than 35% under the same weight and parameters, directly verifying the irreplaceability and technical advantages of the core innovation of the present invention.

[0127] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0128] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A nonwoven floor mat, characterized in that, The PE film layer, the non-woven fabric layer, the self-adhesive layer and the release paper layer are sequentially stacked from top to bottom; the PE film layer is a cast PE film, the PE film layer is anchored and combined with the upper surface of the non-woven fabric layer through a solvent-free hot pressing lamination process; the non-woven fabric layer is a three-dimensional through-pore structure needle-punched non-woven fabric formed by pre-needling and reverse main needling of chemical fiber; the pre-needling direction is opposite to the main needling direction; the air permeability of the non-woven fabric layer is greater than or equal to 300 mm / s, and the saturated moisture absorption rate is greater than or equal to 15%; the self-adhesive layer is a grid-shaped uniform water-based acrylate pressure-sensitive adhesive layer, the self-adhesive layer is coated on the lower surface of the non-woven fabric layer, and the release paper layer is laminated on the side of the self-adhesive layer away from the non-woven fabric layer; the width and length ratio of the PE film layer and the non-woven fabric layer is 1:

1.

2. A nonwoven floor mat according to claim 1, wherein The thickness of the PE film layer is 0.02mm-0.2mm, and the grammage of the non-woven fabric layer is 80g / ㎡-800g / ㎡.

3. A nonwoven floor mat according to claim 2, wherein The dry adhesive coating amount of the self-adhesive layer is 10g / ㎡-50g / ㎡.

4. A nonwoven floor mat according to claim 3, wherein The chemical fiber of the non-woven fabric layer is one or a mixture of two of polypropylene fiber and polyester fiber.

5. A nonwoven floor mat according to claim 4, wherein The pre-needling density is 80-200 needles per square centimeter, and the needling depth is 6-12mm; the main needling density is 200-500 needles per square centimeter, and the needling depth is 4-10mm.

6. A process for producing a nonwoven floor mat as claimed in any one of claims 1 to 5, characterized in that, The non-woven fabric preparation process, the self-adhesive coating process, the non-woven fabric-PE film composite process and the finished product post-processing process are sequentially performed, and the specific steps are as follows: S1 non-woven fabric preparation process: after the chemical fiber is sequentially opened, blended, and carded, it is first pre-needled in the forward direction to preliminarily entangle and set, and then it is reverse main needled in the opposite direction to the pre-needling direction to form a three-dimensional through-pore structure non-woven fabric blank; the blank is verified and rolled after full-width needle inspection and passes the inspection for standby; S2 self-adhesive coating process: grid-shaped uniform water-based acrylate pressure-sensitive adhesive is coated on the lower surface of the qualified non-woven fabric, and after step-by-step drying, release paper is simultaneously laminated on the surface of the self-adhesive layer to obtain a semi-finished product of adhesive non-woven fabric; S3 non-woven fabric-PE film composite process: the semi-finished product of adhesive non-woven fabric and the cast PE film are simultaneously introduced into the machine, the conveying parameters of the two are calibrated to make the width and length ratio 1:1, and after temperature rising and constant temperature, solvent-free hot pressing lamination is performed, and then drum drying strengthening and forced cooling setting are performed to obtain a composite blank; S4 finished product post-processing process: after the composite blank is accurately cut, the finished product is fully inspected, and after the second full-width needle inspection is qualified, it is packaged and shipped.

7. The production process according to claim 6, characterized in that, In S1, the pre-needling density is 80-200 needles per square centimeter, and the needled depth is 6-12mm; the main needling density is 200-500 needles / cm2, and the needling depth is 4-10mm.

8. The production process according to claim 7, characterized in that, In S3, the temperature rising temperature of hot pressing lamination is 110℃-160℃, the hot pressing pressure is 0.2MPa-1.0MPa, and the composite line speed is 5m / min-30m / min.

9. The production process according to claim 8, characterized in that, In the S3, the temperature of the drying roller is 80-120℃, and the residence time of the composite blank in the drying roller is 3-15s; the needle detection in the S1 and S4 is carried out by using a full-width continuous needle detector with a sensitivity of ≥Fe0.8mm.

10. The production process according to claim 9, characterized in that, In the S1, the opening treatment is carried out by using two-stage opening, the rotation speed of the first-stage opening roller is 600-800r / min, and the rotation speed of the second-stage opening roller is 1000-1200r / min; in the S2, the temperature of the step drying is 80-100℃.

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