A multi-layer structure carpet with a convex surface and a preparation process thereof

Abstract

The application relates to the technical field of automobile accessories, in particular to a multi-layer structure carpet with a convex surface and a preparation process thereof, which comprises a decorative layer, a framework layer and an acoustic layer; the decorative layer, the framework layer and the acoustic layer are arranged in sequence from top to bottom; the decorative layer adopts a TPO rubber film; the framework layer adopts a PP-PET fiber felt; the acoustic layer adopts a hot air felt; the decorative layer and the framework layer are made into a base layer by adopting a mold pressing forming process; the upper surface of the base layer is provided with a convex structure in a grid array; the base layer and the acoustic layer are connected by using hot melt glue; the TPO rubber film and the convex structure on the surface of the TPO rubber film make the carpet have the characteristics of easy cleaning, waterproofness, skid resistance and wear resistance.

Description

Technical Field

[0001] This invention relates to the field of automotive parts technology, specifically to a multi-layered carpet with a textured surface and its manufacturing process. Background Technology

[0002] As a component of a car, car carpets primarily function to protect the interior floor and reduce friction noise. They also serve a decorative purpose. Car carpets are generally made of synthetic fiber materials, such as polyester and nylon fibers.

[0003] Currently, most car carpets have a three-layer structure: a decorative layer, a skeleton layer, and an acoustic layer. The decorative layer is mostly made of needle-punched or tufted fabric, providing the carpet with a rich variety of colors and textures. The skeleton layer has a certain degree of rigidity. The acoustic layer is mostly made of PU foam or felt, which helps to reduce noise inside the car.

[0004] However, the entanglement between the fibers of the decorative layer fabric makes it easy for dust to fall into the gaps between the fibers, making it difficult to clean and thus making carpet cleaning difficult. At the same time, the non-waterproof fabric is prone to mold growth in the long term, which reduces the carpet's wear resistance.

[0005] To address this, existing technology has proposed a car carpet sound insulation pad. This car carpet pad uses polyester fiber cotton as the sound insulation and shock absorption material, which plays a role in sound absorption and noise reduction. At the same time, it has a flame retardant effect, ensuring the fire resistance of the car carpet. However, it still does not solve the problems of difficult cleaning and non-waterproofing caused by the fabric of the car carpet.

[0006] In view of this, the present invention proposes a multi-layer structure carpet with a textured surface and its manufacturing process. Summary of the Invention

[0007] The technical problem to be solved by the present invention is to provide a multi-layer structure carpet with a textured surface and its manufacturing process, which addresses the shortcomings of the prior art.

[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A multi-layered carpet with a textured surface, comprising a decorative layer, a skeleton layer, and an acoustic layer; The decorative layer provides a rich variety of colors and textures for the carpet; the skeleton layer has a certain degree of rigidity and plays a supporting role; the acoustic layer material has a certain degree of sound absorption and insulation, which helps to reduce noise inside the vehicle. The decorative layer, the skeleton layer, and the acoustic layer are arranged in order from top to bottom; The decorative layer is made of TPO rubber film, which is waterproof and scratch-resistant. At the same time, its smooth and seamless surface makes it difficult for dust to enter the carpet, making it easy to clean. The skeleton layer is made of PP-PET fiber felt, which is made of PP and PET composite materials. It has high strength and rigidity, which can play a good supporting role, while also having a certain degree of toughness, thus improving the service life of the carpet. The acoustic layer is made of hot air felt, which has a fluffy and porous structure. The porous structure allows sound to be reflected multiple times within the hot air felt, effectively reducing the sound energy and providing good noise reduction. The decorative layer and the skeleton layer are made into a base layer using a molding process. The molding process improves processing efficiency by pressing the material in one step, while ensuring the accurate size and smooth surface of the product, thus guaranteeing the aesthetics of the carpet. The upper surface of the base layer has a grid array with a raised structure, which serves as an anti-slip feature to prevent drivers from slipping on wet shoes in rainy weather. The base layer and the acoustic layer are connected by hot melt adhesive.

[0009] Preferably, the TPO rubber film consists of a TPO film, a POE recoating layer, and a polyurethane layer from bottom to top; TPO film is used as a base film to prepare TPO rubber layer; POE recoating layer has the characteristics of no odor, low density, high flowability and good wettability; polyurethane layer is applied as adhesive layer to the outermost surface to give the carpet waterproof and scratch-resistant effect.

[0010] Preferably, the TPO layer has a unit area mass of 300-500 gsm.

[0011] Preferably, the POE recoating layer has a unit area mass of 1000-2000 gsm.

[0012] Preferably, the PP-PET fiber felt has a unit area mass of 1000-2000 gsm.

[0013] Preferably, the acoustic felt has a unit area mass of 1000-2000 gsm.

[0014] A preparation process, S1. Apply a POE recoating layer to the upper surface of a TPO film using a coating process, and then apply polyurethane as a coating onto the POE recoating layer to form a TPO rubber film; A TPO rubber film is made by sequentially coating a POE recoating layer and a polyurethane coating onto a TPO film, thereby giving the carpet good waterproof, scratch-resistant and easy-to-clean properties. S2. Bond the TPO rubber film to the PP-PET fiber felt, and heat the bonded TPO rubber film and PP-PET fiber felt into a mold to extrude and form a base layer; The TPO rubber film is bonded to the PP-PET fiber felt, and then the whole thing is heated to make the product thermoplastic. Then it is placed in a mold and pressed to form a base layer with a raised structure, which makes the carpet have a non-slip function. S3. Apply hot melt adhesive evenly to the underside of the base layer, and then use the hot melt adhesive to tightly bond the base layer and the hot air felt to form a carpet; Hot melt adhesive is used as a binder to tightly bond the base layer to the hot air felt to make a carpet.

[0015] The present invention, by adopting the above technical solution, can bring the following beneficial effects: 1. The present invention relates to a multi-layer structure carpet with a textured plastic surface and its manufacturing process. The present invention utilizes a TPO rubber film and its surface protrusion structure to make the carpet easy to clean, waterproof, slip-resistant and wear-resistant.

[0016] 2. The present invention relates to a multi-layer structure carpet with a textured surface and its manufacturing process. The present invention utilizes the fluffy and porous structure of the hot air felt to allow sound to be reflected multiple times within the hot air felt, thereby reducing the sound energy and giving the carpet a good noise reduction function.

[0017] 3. The present invention relates to a multi-layer structure carpet with a textured plastic surface and its preparation process. The present invention replaces the fabric with a TPO rubber film, which makes the carpet waterproof and thus solves the problem of carpets accumulating dirt and mold. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a half-section of the carpet according to the present invention; Figure 2 For the present invention Figure 1 A magnified view of point A. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see Figures 1 to 2 As shown, the present invention discloses a multi-layered carpet with a textured surface and its manufacturing process: A multi-layered carpet with a textured surface, comprising a decorative layer, a skeleton layer, and an acoustic layer; The decorative layer provides a rich variety of colors and textures for the carpet; the skeleton layer has a certain degree of rigidity and plays a supporting role; the acoustic layer material has a certain degree of sound absorption and insulation, which helps to reduce noise inside the vehicle. The decorative layer, the skeleton layer, and the acoustic layer are arranged in order from top to bottom; The decorative layer uses a TPO rubber film, which is waterproof and scratch-resistant, improving the carpet's lifespan. Its smooth, seamless surface prevents dust from entering the carpet, avoiding the problem of dust getting trapped in the weave and difficult to clean. The TPO rubber film consists of a TPO film, a POE recoating layer, and a polyurethane layer from bottom to top. The TPO film serves as the base film for the TPO rubber layer. The POE recoating layer is odorless, low-density, has high flowability and good wetting properties. The polyurethane layer is applied as the adhesive layer to the outermost surface, giving the carpet waterproof and scratch-resistant properties. The TPO layer has a unit area mass of 300-500 gsm, and the POE recoating layer has a unit area mass of 1000-2000 gsm. The POE recoating layer exhibits excellent adhesion and weather resistance, ensuring a tight bond between the TPO film and the polyurethane layer. It also maintains the stability and aesthetics of the polyurethane layer over a long period, and is not easily affected by ultraviolet radiation, high temperatures, or humidity. The skeleton layer is made of PP-PET fiber felt, which is a composite of PP and PET materials. It has high strength and rigidity, which can play a good supporting role, while also having a certain degree of toughness, thus improving the service life of the carpet. The unit area mass of the PP-PET fiber felt is 1000-2000 gsm. PP-PET fiber felt is made of PP and PET through melt spinning and weaving. It has high strength and rigidity, as well as good thermal insulation and sound insulation properties, and can play a role in heat preservation and noise reduction. The acoustic layer is made of hot air felt, which has a fluffy and porous structure. The porous structure allows sound to be reflected multiple times within the hot air felt, effectively reducing the sound energy and providing good noise reduction. The acoustic felt has a unit area mass of 1000-2000 gsm. By controlling the unit area mass of each layer of the carpet, the overall mass of the carpet can be controlled, thereby improving the overall lightness of the carpet and making it easier to disassemble and install. The decorative layer and the skeleton layer are made into a base layer using a molding process. The base layer is made using hot molding technology, where the decorative layer and the skeleton layer are heated before being extruded into a mold. This molding process allows the base layer to be formed in one step, improving processing efficiency. At the same time, the product has accurate dimensions and a smooth surface, ensuring the carpet's aesthetics. The upper surface of the base layer has a grid array with raised protrusions, which serve as anti-slip features to prevent drivers from slipping on wet shoes in rainy weather. The base layer is connected to the acoustic layer using hot melt adhesive.

[0021] Figure 1This is a half-sectional schematic diagram of the carpet of the present invention. From top to bottom, it consists of a decorative layer, a skeleton layer, and an acoustic layer. The decorative layer and the skeleton layer are provided with raised structures formed by hot molding process, which play a role in anti-slip.

[0022] Figure 2 For the present invention Figure 1 The enlarged view of point A shows in detail the arrangement and shape of the carpet layers.

[0023] A preparation process, S1. A POE recoating layer is applied to the surface of a TPO film using a coating process. Then, polyurethane is applied to the POE recoating layer to form a TPO rubber film. The POE recoating layer and polyurethane are then applied to the TPO film in sequence to form a TPO rubber film, thereby giving the carpet good waterproof, scratch-resistant, and easy-to-clean properties. S2. Bond the TPO rubber film to the PP-PET fiber felt, heat the bonded TPO rubber film and PP-PET fiber felt and send them into the mold to be extruded to form the base layer; bond the TPO rubber film to the PP-PET fiber felt, then heat the whole to make the product thermoplastic, and then place it in the mold to press and form a base layer with a boss structure, so that the carpet has an anti-slip function. S3. Apply hot melt adhesive evenly to the lower surface of the base layer, and then use the hot melt adhesive to tightly bond the base layer and the hot air felt to form a carpet; the hot melt adhesive acts as an adhesive to tightly bond the base layer and the hot air felt to form a carpet.

[0024] This invention provides a multi-layered carpet with a textured surface and its manufacturing process. Many methods and approaches exist to achieve this technical solution; the above description is merely a preferred embodiment of the invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications should also be considered within the scope of protection of this invention. All components not explicitly stated in this embodiment can be implemented using existing technologies.

Claims

1. A multi-layered carpet with a textured surface, characterized in that: It includes a decorative layer, a skeleton layer, and an acoustic layer; The decorative layer, the skeleton layer, and the acoustic layer are arranged in order from top to bottom; The decorative layer is made of TPO rubber film; The skeleton layer is made of PP-PET fiber felt; The acoustic layer is made of hot air felt; The decorative layer and the skeleton layer are formed into a base layer using a molding process; the upper surface of the base layer has a grid array with a boss structure; the base layer and the acoustic layer are connected by hot melt adhesive.

2. The multi-layer structure carpet according to claim 1, characterized in that: The TPO rubber membrane consists of a TPO membrane, a POE recoating layer, and a polyurethane layer from bottom to top.

3. The multi-layer structure carpet according to claim 2, characterized in that: The TPO layer has a unit area mass of 300-500 gsm.

4. The multi-layer structure carpet according to claim 2, characterized in that: The POE recoating layer has a unit area mass of 1000-2000 gsm.

5. The multi-layered carpet according to claim 1, characterized in that: The PP-PET fiber felt has a unit area mass of 1000-2000 gsm.

6. The multi-layer structure carpet according to claim 1, characterized in that: The acoustic felt has a unit area mass of 1000-2000 gsm.

7. A manufacturing process for preparing the multi-layer structure carpet according to any one of claims 1-6, characterized in that: S1. Apply a POE recoating layer to the upper surface of a TPO film using a coating process, and then apply polyurethane as a coating onto the POE recoating layer to form a TPO rubber film; S2. Bond the TPO rubber film to the PP-PET fiber felt, and heat the bonded TPO rubber film and PP-PET fiber felt into a mold to extrude and form a base layer; S3. Apply hot melt adhesive evenly to the lower surface of the base layer, and then use the hot melt adhesive to tightly bond the base layer and the hot air felt to form a carpet.

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