A full flow carpet production system and production method and application

Abstract

The application discloses a full-process carpet preparation system and a preparation method and application, and belongs to the technical field of carpet preparation. The system comprises an opening and blending cotton unit, a carding and needling unit, a raising unit, a winding unit and a gluing unit. The gluing unit comprises a blending tank, a granular applicability foaming machine and a gluing machine. Main blades and bottom blades close to the bottom of the tank body are arranged in the blending tank to reduce PE powder deposition. The granular applicability foaming machine adopts a cylindrical stator and a rotor and forms an annular flow channel to reduce granular retention and blockage. After needling, the yarn net directly enters the raising unit without intermediate winding. Mixed glue containing PE powder is directly coated after mixing and foaming, so that the carpet production process is continuous and the gluing and powder scattering processes are integrated.

Description

Technical Field

[0001] This invention relates to the field of carpet manufacturing technology, and in particular to a complete carpet manufacturing system, manufacturing method and application. Background Technology

[0002] The traditional manufacturing process of needle-punched carpets mainly includes steps such as opening, carding and needle punching, pile raising, gluing, and dusting. In the current production model, each step is mostly arranged independently, which presents the following prominent problems: The process is fragmented, resulting in high transportation costs and mismatched production capacity: the carding and needle punching processes and the napping process are independent of each other. The fiber felt completed by carding and needle punching needs to be wound into semi-finished rolls before being transported to the napping process. After unwinding, it enters the napping machine for processing. In this model, the process is redundant, the intermediate transportation and storage costs are high, and the semi-finished products are prone to quality problems such as weight fluctuations and width shrinkage during storage, which can easily lead to batches of defective products.

[0003] Separating the adhesive coating and powder application processes makes integrated mass production difficult: The adhesive coating and powder application processes are also set up independently. The carpet fabric is first coated with adhesive by an adhesive coating machine, and then transferred to a powder application machine for PE powder coating. This process is lengthy, requires a lot of equipment, and has high manufacturing costs. If PE powder is directly mixed into the adhesive solution and completed in one step through the adhesive coating process, problems such as easy sedimentation of PE powder, easy clogging of the conveying pipes and foaming machine mixing heads, and uneven coating weight will occur, making stable mass production impossible.

[0004] Therefore, it is urgent to systematically optimize the entire carpet manufacturing process to solve the technical problems of fragmented processes, mismatched production capacity, and difficulty in achieving integrated and stable production of adhesive and powder coating. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a complete carpet manufacturing system, method and application. By setting the opening and blending, carding and punching, pile raising and winding processes in the carpet manufacturing process continuously, and by focusing on structural improvements to the mixing tank and granule-suitable foaming machine in the adhesive unit, the mixture containing adhesive and solid particles is kept in a better dispersed state, and the probability of solid particles depositing and clogging during the foaming process is reduced, thereby improving the production efficiency and adhesive stability in the carpet production process.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: This invention provides a complete carpet manufacturing system, including an opening and blending unit, a carding and punching unit, a pile raising unit, a winding unit, and a gluing unit, wherein the opening and blending unit, the carding and punching unit, the pile raising unit, and the winding unit are arranged sequentially along the material conveying direction; The adhesive application unit includes a mixing tank, a granule-suitable foaming machine, and an adhesive applicator. The mixing tank includes a tank body, a feed cover, a stirring shaft, a main blade and a bottom blade mounted on the stirring shaft. The stirring shaft passes through the feed cover and extends into the tank body. The main blade is positioned above the bottom blade, and the bottom blade is positioned at the bottom end of the stirring shaft. The distance between the bottom blade and the bottom of the tank body is no more than 3 cm. The main blade and the bottom blade are each provided with a plurality of circular holes; The granule-compatible foaming machine includes a stator and a rotor that cooperate with each other. The working surfaces of the stator and the rotor are both cylindrical curved surfaces, and an annular flow channel for the rubber powder mixture to pass through is formed between the stator and the rotor. The mixing tank is used to stir the mixture containing adhesive and solid particles to keep the solid particles in a dispersed state. The particle-suitable foaming machine is used to foam the material mixed in the mixing tank. The foamed material is conveyed to the coating machine and coated onto the napped yarn.

[0007] Furthermore, the cotton opening and blending unit includes a first opening machine, a multi-compartment cotton blending machine and a second opening machine arranged in sequence, and a bale opener is also provided on the feed side of the first opening machine.

[0008] Furthermore, the rotation speed of the first loosening machine is 1200-1500 r / min, and the rotation speed of the second loosening machine is 2000-2500 r / min.

[0009] Furthermore, the carding and needle punching unit includes a carding machine, a web laying machine, a first needle punching machine, and a second needle punching machine arranged in sequence, and a cotton feeder is provided on the feed side of the carding machine.

[0010] Furthermore, the yarn web after being needled by the first needle punch and the second needle punch enters the pile raising unit directly without being wound up; The napping unit includes a first napping machine and a second napping machine arranged sequentially along the yarn conveying direction. The yarn after being napped by the second napping machine enters the winding machine in the winding unit for winding.

[0011] Furthermore, a motor is connected to the top of the stirring shaft, and the motor is positioned above the feed cover; Both the main blade and the bottom blade are provided with multiple circular holes, the diameter of which is 1 to 2 cm.

[0012] Furthermore, the adhesive application unit also includes a dryer located at the output end of the adhesive applicator, the dryer being used to dry and shape the coated carpet.

[0013] The present invention also provides a method for preparing carpets using the above-described complete carpet preparation system, comprising the following steps: S1. Opening and mixing the fiber raw materials; S2. The opened and mixed fibers are combed and laid into a mixed fiber web, and the mixed fiber web is needle-punched. The needle-punched mixed fiber web is directly napped without being wound up. After napping, it is wound up. S3. Add water-based foam adhesive, PE powder, water and thickener to the mixing tank, and stir the materials by the main blade and the bottom blade to disperse the PE powder in the adhesive solution; S4. The mixture after being stirred in the mixing tank is conveyed to the granule-suitable foaming machine, so that the mixture is foamed through the annular flow channel between the stator and the rotor. The rolled-up pile yarn is unwound and conveyed to the coating machine, and the foamed mixed adhesive is coated on the pile yarn. S5. The coated mesh is combined with the backing felt and dried to obtain a carpet.

[0014] Further, in step S1, after the fiber and cotton are opened separately by the opening machine, they are fed into the first opening machine and opened for the first time at 1200 r / min. After being mixed by the multi-compartment cotton blender, they are fed into the second opening machine and opened for the second time at 2000 r / min. In step S2, the opened mixed fibers are fed into the carding machine at a rate of 500 kg / h. The cylinder speed of the carding machine is 900 rpm. The mixed fiber web with a basis weight of 500 g / m² is formed. The linear speed of the first and second needle punches is 4.9 m / min. The linear speed of the napping process is 4.2 m / min. The napped web is wound up at a linear speed of 4 m / min. In step S3, the mass ratio of the water-based foaming adhesive, PE powder, water and thickener is 50:29:29:10, the particle size of the PE powder is 80 mesh, and the stirring shaft is stirred at a speed of 100 r / min for 30 min. In step S4, the foamed mixed adhesive is applied to the napped yarn at a coating amount of 180g / m². In step S5, the yarn mesh after the composite base felt is dried at 80°C for 2 hours.

[0015] The present invention also provides an application of the aforementioned end-to-end carpet preparation system in the preparation of automotive carpets, wherein the end-to-end carpet preparation system is used to prepare automotive carpets.

[0016] The beneficial effects of this invention are: 1. The present invention provides a mixing tank in the coating unit, and provides a main blade and a bottom blade in the lower middle part and bottom end of the stirring shaft, respectively. The distance between the bottom blade and the bottom of the tank is no more than 3cm, so that the bottom blade can continuously stir the adhesive liquid and solid particles in the area near the bottom of the tank, reducing the probability of solid particles such as PE powder depositing, agglomerating and clumping at the bottom of the tank, which is beneficial to maintaining the dispersion state of the adhesive powder mixture.

[0017] 2. The present invention provides multiple circular holes on the main blade and the bottom blade, so that the material can flow and mix through the circular holes during the stirring process, which is beneficial to improving the mixing uniformity between the adhesive and the solid particles.

[0018] 3. In this invention, the mating working surfaces of the stator and rotor in the granule-compatible foaming machine are set as cylindrical curved surfaces, and an annular flow channel is formed between the stator and rotor. This allows the adhesive powder mixture to flow along the annular flow channel, reducing particle retention caused by angular flow areas. This helps to reduce the probability of PE powder particles getting stuck inside the foaming machine and improves the operational stability of the adhesive liquid containing solid particles during continuous foaming.

[0019] 4. This invention mixes water-based foaming adhesive, PE powder, water, and thickener in a mixing tank to keep the PE powder in a dispersed state. The mixed material is then transported to a granule-suitable foaming machine for foaming. The foamed mixture is then coated onto a pile yarn mesh by a coating machine, allowing the PE powder to directly enter the coating process through the mixed adhesive. This integrates the traditional coating and separate powdering processes, reducing the need for separate powdering equipment and the corresponding material transfer process.

[0020] 5. In this invention, the yarn web after being needled by the first needle punch and the second needle punch does not go through winding and directly enters the raising unit for raising treatment. This can reduce the intermediate winding, transfer and rewinding processes between the needle punching and raising processes. Furthermore, the yarn web is raised sequentially by the first raising machine and the second raising machine, which helps to improve the continuity of the production process.

[0021] 6. This invention combines the processes of opening and blending cotton, carding and punching, pile raising, winding and gluing to form a complete carpet preparation system. It also achieves the mixing, dispersion and foaming of PE powder-containing adhesive liquid through mixing tanks and granule-suitable foaming machines, which helps to improve the continuity and stability of the carpet production process. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the structure of the cotton opening and blending unit in this invention; Figure 2 This is a schematic diagram of the combing needle unit in this invention; Figure 3 This is a schematic diagram of the structure of the napping unit in this invention; Figure 4 This is a schematic diagram of the winding unit in this invention; Figure 5 This is a schematic diagram of the adhesive coating unit in this invention; Figure 6 This is a schematic diagram of the mixing tank in this invention; The labels in the diagram are as follows: 1. Opening and blending unit; 2. Carding and needle punching unit; 3. Raising unit; 4. Rewinding unit; 5. Gluing unit; 10. Opening machine; 11. First opening machine; 12. Multi-bin blending machine; 13. Second opening machine; 20. Feeding machine; 21. Carding machine; 22. Web forming machine; 23. First needle punching machine; 24. Second needle punching machine; 301. First raising machine; 302. Second raising machine; 40. Rewinding machine; 51. Blending tank; 52. Pellet applicability foaming machine; 53. Gluing machine; 54. Dryer; 501. Tank body; 502. Feed cover; 503. Motor; 504. Main blade; 505. Bottom blade. Detailed Implementation

[0023] The present invention will be further described in detail below with reference to the embodiments.

[0024] Example 1 This embodiment provides a complete carpet manufacturing system, including an opening and blending unit 1, a carding and punching unit 2, a pile raising unit 3, a winding unit 4, and a gluing unit 5. The opening and blending unit 1, the carding and punching unit 2, the pile raising unit 3, and the winding unit 4 are arranged sequentially along the material conveying direction.

[0025] The cotton opening and blending unit 1 includes a first opening machine 11, a multi-bin blending machine 12, and a second opening machine 13 arranged sequentially. A bale opener 10 is also provided on the feed side of the first opening machine 11. After the raw material is opened by the bale opener 10, it enters the first opening machine 11 for the first opening, then enters the multi-bin blending machine 12 for blending. The blended raw material then enters the second opening machine 13 for the second opening. The rotation speed of the first opening machine 11 is 1200–1500 r / min, and the rotation speed of the second opening machine 13 is 2000–2500 r / min.

[0026] The carding and needle-punching unit 2 includes a carding machine 21, a web-laying machine 22, a first needle-punching machine 23, and a second needle-punching machine 24 arranged sequentially. A feeder 20 is provided on the feed side of the carding machine 21. The fibers processed by the opening and blending unit 1 enter the carding machine 21 through the feeder 20 for carding. The carded fibers enter the web-laying machine 22 to form a mixed fiber web, and then pass through the first needle-punching machine 23 and the second needle-punching machine 24 for needle-punching in sequence.

[0027] The mixed fiber web, after being needled by the first needle punch 23 and the second needle punch 24, enters the raising unit 3 directly without intermediate winding. The raising unit 3 includes a first raising machine 301 and a second raising machine 302 arranged sequentially along the conveying direction of the mixed fiber web. The mixed fiber web undergoes raising treatment by passing through the first raising machine 301 and the second raising machine 302 in sequence. The web raised by the second raising machine 302 enters the winding machine 40 in the winding unit 4 for winding.

[0028] By eliminating the intermediate winding, semi-finished product handling, and rewinding processes between the carding and punching unit 2 and the napping unit 3, the needle-punched mixed fiber web can continuously enter the napping process, thereby reducing downtime and manual operation caused by process switching, and reducing the possibility of width and local weight changes in the semi-finished roll during transportation and storage.

[0029] The adhesive coating unit 5 includes a mixing tank 51, a granule-suitable foaming machine 52, and an adhesive coating machine 53.

[0030] The mixing tank 51 includes a tank body 501, a feed cover 502, a stirring shaft, a main blade 504 and a bottom blade 505 disposed on the stirring shaft, the stirring shaft passes through the feed cover 502 and extends into the tank body 501, and a motor 503 is connected to the top of the stirring shaft.

[0031] The main impeller 504 is positioned above the bottom impeller 505 and is used to mix the material in the main area of ​​the tank 501. The bottom impeller 505 is positioned at the bottom end of the stirring shaft, and the distance between the bottom impeller 505 and the bottom of the tank 501 is no more than 3 cm.

[0032] Since PE powder is a solid particle dispersed in the adhesive, it tends to settle towards the bottom of the tank 501 under the action of gravity. By setting the bottom paddle 505 close to the bottom of the tank 501, the bottom paddle 505 can continuously drive the movement of the mixture near the bottom of the tank during the stirring process, reducing the formation of a low flow rate area at the bottom of the tank 501, thereby inhibiting the deposition, aggregation and agglomeration of PE powder at the bottom of the tank, and keeping the PE powder in a relatively stable dispersion state in the adhesive.

[0033] The main blade 504 and the bottom blade 505 are each provided with a plurality of circular holes. During the stirring process, some of the mixture can pass through the circular holes, allowing further material exchange to occur around the blades, which is beneficial for the mixing of the adhesive and PE powder.

[0034] The granule-compatible foaming machine 52 includes a stator and a rotor that cooperate with each other. The working surfaces of the stator and the rotor are both cylindrical curved surfaces, and an annular flow channel for the rubber powder mixture to pass through is formed between the stator and the rotor.

[0035] After the rubber powder mixture enters the granule-suitable foaming machine 52, it passes through the working area between the stator and rotor along the annular flow channel. Compared with the mating working surface with sharp corners, the annular flow channel formed by the cylindrical curved surface reduces the corner areas where particles are easily trapped, allowing the rubber powder mixture containing PE powder to pass through the working area between the stator and rotor more continuously, thereby reducing the probability of PE powder accumulating locally inside the foaming machine and further forming blockages.

[0036] The mixed adhesive, foamed by the granule-suitable foaming machine 52, is conveyed to the coating machine 53 and coated onto the napped yarn. The coating unit 5 also includes a dryer 54 located at the output end of the coating machine 53. After the yarn coated with the mixed adhesive is laminated with the base felt, it enters the dryer 54 for drying and shaping.

[0037] With the above structure, the PE powder first forms a dispersed powder mixture with the adhesive in the mixing tank 51, and then is foamed by the granule-suitable foaming machine 52 and directly enters the coating machine 53, so that the PE powder is coated on the mesh together with the foamed mixed adhesive, thus eliminating the need for a separate PE powder sprinkling process after the coating is completed.

[0038] Example 2 This embodiment uses the full-process carpet preparation system described in Example 1 to prepare carpets, including the following steps: S1. After the fiber and cotton are opened separately by the opening machine 10, they are fed into the first opening machine 11 and opened for the first time at 1200 r / min. The fiber and cotton after being opened by the first opening machine 11 are fed into the multi-compartment cotton blender 12 for mixing. The mixed fiber is fed into the second opening machine 13 and opened for the second time at 2000 r / min. S2. The opened mixed fibers are fed to the carding machine 21 at a rate of 500 kg / h by the cotton feeder 20. The cylinder speed of the carding machine 21 is set to 900 rpm. The carded mixed fibers enter the web laying machine 22 and are laid to form a mixed fiber web with a basis weight of 500 g / m². The mixed fiber web is then sequentially needled by the first needle punch 23 and the second needle punch 24. The linear speed of the first needle punch 23 and the second needle punch 24 is set to 4.9 m / min. The needled mixed fiber web is directly fed into the napping unit 3 without being wound up. It is then napped by the first napping machine 301 and the second napping machine 302 at a linear speed of 4.2 m / min. The napped web is then wound up by the winding unit 4 at a linear speed of 4 m / min. S3. Add water-based foaming adhesive, PE powder, water and thickener to mixing tank 51 in a mass ratio of 50:29:29:10, wherein the particle size of PE powder is 80 mesh. Start motor 503 to drive stirring shaft, main blade 504 and bottom blade 505 to rotate. The stirring shaft speed is 100 r / min. Continue stirring for 30 min to disperse PE powder in the adhesive liquid to form adhesive powder mixture. During the above stirring process, the main blade 504 mixes the material in the main area of ​​the tank 501, and the bottom blade 505 set near the bottom of the tank 501 continuously stirs the bottom area of ​​the tank to reduce the deposition and aggregation of PE powder at the bottom of the tank. S4. The mixture after being stirred in the mixing tank 51 is conveyed to the granule-suitable foaming machine 52, so that the mixture is foamed through the annular flow channel between the stator and the rotor. The coiled pile yarn is unwound and conveyed to the coating machine 53, and the foamed mixed adhesive is coated on the pile yarn at a coating amount of 180g / m². S5. The coated mesh is combined with the base felt and then conveyed to the dryer 54 and dried at 80°C for 2 hours to obtain the needle-punched mesh carpet.

[0039] In the above preparation process, the mixed fiber web after carding and needle punching can enter the napping process without intermediate winding and rewinding, reducing the material transfer process between the needle punching and napping processes; at the same time, the adhesive liquid containing PE powder is continuously mixed by the mixing tank 51, and the adhesive powder mixture is foamed by the granular foaming machine 52 with a cylindrical stator and rotor, so that the PE powder can be directly coated with the mixed adhesive, thereby integrating the traditional adhesive coating and separate powdering processes.

[0040] Comparative Example 1 This comparative example uses a traditional segmented production method for carpet preparation. The system includes a bag opener, a first opening machine, a multi-compartment blending machine, a second opening machine, a cotton feeder, a carding machine, a web laying machine, a first needle punching machine, a second needle punching machine, a winding machine, an unwinding machine, a pile raising machine, and subsequent adhesive coating equipment.

[0041] Unlike Example 2, after the first and second needle punching machines complete the needle punching process, the needle-punched fiber web needs to be wound into a semi-finished roll by a winding machine. The semi-finished roll is then transferred to the napping process, and after unwinding, it enters the napping machine for napping. Therefore, winding, transferring, and unwinding operations are added between the needle punching and napping processes.

[0042] Furthermore, Example 2 eliminates the corresponding processes of winding, storing, transferring, and rewinding semi-finished products, thus reducing the space occupied by semi-finished product turnover and the cost of auxiliary equipment related to transfer. The aforementioned space costs and auxiliary equipment costs vary depending on the equipment configuration and usage conditions of different production sites; therefore, this example does not limit their specific amounts.

[0043] From the perspective of production continuity, in Example 2, the linear speeds of the first and second needle punching machines are 4.9 m / min, the linear speed of the napping process is 4.2 m / min, and the winding speed after napping is 4 m / min. Each process can be seamlessly connected using a continuous conveying method. Compared to Comparative Example 1, which requires a pause for winding, transfer, and rewinding after needle punching, Example 2 reduces the non-processing time caused by process transitions, thus increasing the effective operating time of the equipment per unit production cycle.

[0044] As can be seen from the above production process, Comparative Example 1 requires sequential operations such as semi-finished product winding, manual roll changing and transfer, and unwinding for the napping process after the needle punching process. During these operations, the fiber web cannot be continuously napped. Example 2, on the other hand, allows the mixed fiber web after needle punching to directly enter the napping unit, eliminating the above three intermediate operation steps. Therefore, under the condition that the processing capacity of the needle punching equipment and the napping equipment remains unchanged, Example 2 can reduce the non-production time caused by winding, transfer, and unwinding, increase the effective processing time of the equipment within a unit production cycle, and reduce the manual input required for intermediate turnover.

[0045] Comparative Example 2 This comparative example uses the same carpet coating process as Example 2. The difference is that the distance between the bottom paddle 505 in the mixing tank 51 and the bottom of the tank body 501 is set to 10cm, and the stator and rotor in the granule-suitable foaming machine 52 adopt a conventional structure with corner areas. The remaining process conditions are consistent with those in Example 2.

[0046] Under the above conditions, continuous coating production of PE powder mixed adhesive was carried out. After 30m of continuous production of the mesh, the granule-suitable foaming machine 52 became clogged and could not continue normal production.

[0047] In contrast, Example 2 uses a bottom impeller 505 located no more than 3 cm from the bottom of the tank 501 to continuously agitate the bottom area of ​​the tank, and uses a cylindrical stator and rotor to form an annular flow channel. On the one hand, this reduces the tendency of PE powder to deposit and aggregate at the bottom of the mixing tank 51, and on the other hand, it reduces the corner areas where particles are easily trapped during the process of the adhesive powder mixture passing through the particle-suitable foaming machine 52. This is beneficial to improving the operational stability of the continuous mixing, foaming and coating process of the PE powder mixed adhesive.

[0048] As can be seen from the results of Example 2 and Comparative Example 2, the bottom paddle 505 located near the bottom of the mixing tank 51, in conjunction with the annular flow channel formed by the cylindrical stator and rotor in the granule-suitable foaming machine 52, can improve the problems of particle deposition and equipment blockage that are easily generated in the continuous production process of PE powder-containing adhesive liquid.

[0049] The opening machine, first opening machine, multi-compartment cotton blending machine, second opening machine, cotton feeder, carding machine, web laying machine, first needle punching machine, second needle punching machine, first lint roller, second lint roller, winding machine, gluing machine, and dryer in this invention can all be existing equipment in the field. The mixing tank and granule suitability foaming machine are based on existing equipment with the above-mentioned structural improvements. Except for the improved structures explicitly defined in this invention, the other structures and working principles of each piece of equipment can all adopt existing technology in the field, and will not be described in detail here.

[0050] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any other way. Any modifications or equivalent changes made based on the technical essence of the present invention shall still fall within the scope of protection claimed by the present invention.

Claims

1. A complete carpet manufacturing system, characterized in that, It includes an opening and blending unit (1), a carding and needle punching unit (2), a napping unit (3), a winding unit (4), and a gluing unit (5), wherein the opening and blending unit (1), the carding and needle punching unit (2), the napping unit (3), and the winding unit (4) are arranged sequentially along the material conveying direction; The adhesive application unit (5) includes a mixing tank (51), a granule-suitable foaming machine (52), and an adhesive applicator (53). The mixing tank (51) includes a tank body (501), a feed cover (502), a stirring shaft, a main blade (504) and a bottom blade (505) disposed on the stirring shaft. The stirring shaft passes through the feed cover (502) and extends into the tank body (501). The main blade (504) is disposed above the bottom blade (505). The bottom blade (505) is disposed at the bottom end of the stirring shaft. The distance between the bottom blade (505) and the bottom of the tank body (501) is not greater than 3cm. The main blade (504) and the bottom blade (505) are respectively provided with multiple circular holes; The granule-compatible foaming machine (52) includes a stator and a rotor that cooperate with each other. The working surfaces of the stator and the rotor are both cylindrical curved surfaces, and an annular flow channel for the rubber powder mixture to pass through is formed between the stator and the rotor. The mixing tank (51) is used to stir the mixture containing the adhesive and solid particles to keep the solid particles in a dispersed state. The particle-suitable foaming machine (52) is used to foam the material after mixing in the mixing tank (51). The foamed material is conveyed to the coating machine (53) and coated on the yarn after the napping treatment.

2. The end-to-end carpet manufacturing system according to claim 1, characterized in that, The opening and blending unit (1) includes a first opening machine (11), a multi-compartment blending machine (12), and a second opening machine (13) arranged in sequence. The feeding side of the first opening machine (11) is also provided with a bag opener (10).

3. The end-to-end carpet manufacturing system according to claim 2, characterized in that, The first loosening machine (11) has a rotation speed of 1200-1500 r / min, and the second loosening machine (13) has a rotation speed of 2000-2500 r / min.

4. The end-to-end carpet manufacturing system according to claim 1, characterized in that, The carding and needle punching unit (2) includes a carding machine (21), a web laying machine (22), a first needle punching machine (23), and a second needle punching machine (24) arranged in sequence. A cotton feeder (20) is provided on the feed side of the carding machine (21).

5. The end-to-end carpet manufacturing system according to claim 4, characterized in that, The yarn web after being needled by the first needle punch (23) and the second needle punch (24) enters the pile raising unit (3) directly without being wound up. The napping unit (3) includes a first napping machine (301) and a second napping machine (302) arranged sequentially along the yarn conveying direction. The yarn after being napped by the second napping machine (302) enters the winding machine (40) in the winding unit (4) for winding.

6. The end-to-end carpet manufacturing system according to claim 1, characterized in that, A motor (503) is connected to the top of the stirring shaft, and the motor (503) is located above the feed cover (502); Both the main blade (504) and the bottom blade (505) are provided with multiple circular holes, the diameter of which is 1 to 2 cm.

7. The end-to-end carpet manufacturing system according to claim 1, characterized in that, The adhesive application unit (5) also includes a dryer (54) located at the output end of the adhesive applicator (53), which is used to dry and shape the coated carpet.

8. A method for preparing carpets using the complete carpet preparation system according to any one of claims 1 to 7, characterized in that, Includes the following steps: S1. Opening and mixing the fiber raw materials; S2. The opened and mixed fibers are combed and laid into a mixed fiber web, and the mixed fiber web is needle-punched. The needle-punched mixed fiber web is directly napped without being wound up. After napping, it is wound up. S3. Add water-based foaming adhesive, PE powder, water and thickener to the mixing tank (51), and stir the materials by the main blade (504) and the bottom blade (505) to disperse the PE powder in the adhesive liquid; S4. The mixture after being stirred in the mixing tank (51) is conveyed to the particle-suitable foaming machine (52), so that the mixture is foamed through the annular flow channel between the stator and the rotor. The coiled pile yarn is unwound and conveyed to the coating machine (53), and the foamed mixed adhesive is coated on the pile yarn. S5. The coated mesh is combined with the backing felt and dried to obtain a carpet.

9. The method for preparing a carpet according to claim 8, characterized in that, In step S1, the fiber and cotton are opened separately by the opening machine (10) and then sent to the first opening machine (11) for the first opening at 1200 r / min. After being mixed by the multi-compartment cotton blender (12), the cotton is sent to the second opening machine (13) for the second opening at 2000 r / min. In step S2, the opened mixed fibers are fed into the carding machine (21) at a rate of 500 kg / h. The cylinder speed of the carding machine (21) is 900 rpm. The mixed fiber web with a basis weight of 500 g / m² is formed. The linear speed of the first needle punch (23) and the second needle punch (24) is 4.9 m / min. The linear speed of the napping process is 4.2 m / min. The napped web is wound up at a linear speed of 4 m / min. In step S3, the mass ratio of the water-based foaming adhesive, PE powder, water and thickener is 50:29:29:10, the particle size of the PE powder is 80 mesh, and the stirring shaft is stirred at a speed of 100 r / min for 30 min. In step S4, the foamed mixed adhesive is applied to the napped yarn at a coating amount of 180g / m². In step S5, the yarn mesh after the composite base felt is dried at 80°C for 2 hours.

10. The application of the complete carpet manufacturing system according to any one of claims 1 to 7 in the manufacture of automotive carpets, characterized in that, The complete carpet manufacturing system is used to manufacture automotive carpets.

Images