High-flame-retardant low-odor ecological car foot mat

Abstract

The utility model discloses a high flame-retardant low-odor ecological car foot mat which comprises a carpet surface layer, a middle layer and a bottom surface layer, the carpet surface layer, the middle layer and the bottom surface layer are connected in sequence, the carpet surface layer is bonded with the middle layer, the edges of the carpet surface layer and the middle layer are sewn and covered through sewing lines, an anti-skid pedal is arranged on the carpet surface layer, and the bottom surface layer is provided with an anti-skid layer. The carpet surface layer is made of flame-retardant PA (polyamide) fluff, and embossed patterns are arranged on the surface of the carpet surface layer. The flame-retardant PA6 yarn is prepared by improving the PA6 yarn of the fluff layer, directly blending the flame retardant and the PA6 resin and then performing the processes of melt extrusion or injection molding and the like, and the flame retardant can slow down the combustion speed of the yarn, prolong the combustion time, inhibit the release of smoke and toxic gas and reduce the harm of fire to a human body; therefore, the flame retardant property of the carpet surface layer is obviously improved.

Description

Technical Field

[0001] The utility model belongs to the technical field of automotive floor mats, and particularly relates to a highly flame-retardant, low-odor and ecological automotive floor mat. Background Art

[0002] An electric vehicle refers to a vehicle that uses an on-vehicle power source and drives the wheels with an electric motor, meeting the requirements of road traffic and safety regulations.

[0003] An automotive floor mat is an environmental-friendly automotive interior part that integrates five main functions: water absorption, dust absorption, dirt removal, sound insulation, and protection of the main carpet. The automotive floor mat belongs to an interior decoration, which protects the cleanliness inside and outside the car and plays a role in beautifying, comfort and embellishment.

[0004] According to the floor mat provided by the application publication number: CN107719205A, it mainly includes a floor mat surface layer, an intermediate layer and a floor mat bottom layer. The floor mat surface layer is composed of flocking materials, and the intermediate layer is composed of a paper-plastic composite material. The flocking material can provide a comfortable foot feeling, and the intermediate layer uses a paper-plastic composite material, with a moderate hardness, and its hardness changes little with temperature. The floor mat bottom layer is a fixed-point flocking material, and the fixed-point flocking is an array of regular patterns. For this kind of floor mat, its intermediate interlayer is a paper-plastic composite layer, and the overall feeling is firm, but both the upper and lower surfaces are relatively soft and elastic, making the feet feel more comfortable. The lower surface is a partial flocking layer, so that it is not in close contact with the ground and there is a certain gap. When there is water on the ground under the floor mat, the water is also easy to volatilize, keeping the ground dry, and at the same time making the service life of the floor mat longer. Moreover, the friction coefficient between the fixed-point planting material and the ground is relatively large, and the anti-slip effect is more ideal.

[0005] Some problems in the prior art: Due to the characteristics of electric vehicle batteries and flammable interior materials, once a vehicle catches fire, it is very difficult to control the fire, often endangering the lives and property safety of the passengers in the vehicle. Therefore, we propose a highly flame-retardant, low-odor and ecological automotive floor mat. Summary of the Utility Model

[0006] Aiming at the problems existing in the prior art, the purpose of the utility model is to provide a highly flame-retardant, low-odor and ecological automotive floor mat. By setting a PA6 fluff layer, a PET non-woven base layer, a flame-retardant latex and an anti-slip layer, the hierarchical structure is simple, and through the flame retardancy of the PA6 fluff layer and the bottom glue layer, the overall flame retardancy of the floor mat can be significantly improved, and the intensity of internal fire in an electric vehicle can be reduced.

[0007] The utility model is realized as follows: A highly flame-retardant, low-odor and ecological automotive floor mat includes a carpet surface layer, an intermediate layer and a bottom surface layer. The carpet surface layer, the intermediate layer and the bottom surface layer are connected in sequence. The carpet surface layer is bonded to the intermediate layer, and the edges of the carpet surface layer and the intermediate layer are sewn and edge-wrapped with sewing threads.

[0008] Optionally, anti-slip pedals are provided on the carpet layer. Linear patterns are provided on the anti-slip pedals, and the anti-slip pedals are used to increase friction.

[0009] Optionally, the carpet layer is made of flame-retardant PA fluff, and embossing is provided on the surface of the carpet layer for anti-slip effect.

[0010] Optionally, the intermediate layer is made of PET non-woven fabric, and flame-retardant latex is provided between the intermediate layer and the bottom layer.

[0011] Optionally, a glue edge is provided on the bottom layer, and the glue edge is used to increase the adhesion of the bottom layer.

[0012] Optionally, vertical and horizontal lines are provided at the bottom of the bottom layer. The vertical lines and the horizontal lines are arranged alternately. Rubber blocks are provided between the vertical lines and the horizontal lines. A gauze cloth is provided on the rubber blocks, and flame-retardant glue is applied to the gauze cloth.

[0013] Compared with the prior art, the beneficial effects of the present utility model are as follows:

[0014] 1. By improving the PA6 yarn of the fluff layer, the flame retardant is directly blended with the PA6 resin, and then the flame-retardant PA6 yarn is prepared by processes such as melt extrusion or injection molding. The flame retardant can slow down the burning speed of the yarn, extend the burning time, inhibit the release of smoke and toxic gases, reduce the harm of fire to the human body, and thus significantly improve the flame retardant performance of the carpet layer.

[0015] 2. By making the PET non-woven fabric into the intermediate layer, using the high tensile strength and tear strength of the PET non-woven fabric, it can withstand greater external forces and abrasions, increase the overall durability of the intermediate layer of the foot mat, and the melting point of the PET non-woven fabric is relatively high, about 260 °C, and it can still maintain a stable size and shape in a high-temperature environment, which helps the foot mat to remain flat and not easily deformed.

[0016] 3. The bottom layer is provided with an anti-slip gauze cloth, and flame-retardant glue is applied to the anti-slip gauze cloth. The flame-retardant glue has good adhesion, can firmly bond the gauze cloth to the bottom layer of the foot mat, and a flame retardant is added to the glue to make the overall carpet not burn in the presence of an open flame.

[0017] Other features and advantages of the present utility model will become clear through the following detailed description of the exemplary embodiments of the present utility model with reference to the accompanying drawings. Description of the Drawings

[0018] Figure 1 It is a schematic diagram of the overall structure provided by the present utility model;

[0019] Figure 2It is a partially enlarged schematic diagram of the middle layer provided by the present utility model;

[0020] Figure 3 It is a schematic diagram of the bottom structure of the bottom layer provided by the present utility model;

[0021] Figure 4 It is a schematic diagram of the gauze cloth structure provided by the present utility model.

[0022] In the figure: 1. Blanket surface layer; 11. Anti-slip pedal; 2. Middle layer; 21. Suture; 3. Bottom layer; 31. Glue edge; 32. Vertical stripe; 33. Horizontal stripe; 34. Rubber block; 35. Gauze cloth. Detailed implementation manners

[0023] To further understand the content, features and effects of the present utility model, the following embodiments are hereby exemplified and described in detail with reference to the accompanying drawings.

[0024] As Figures 1 to 4 shown, a highly flame-retardant and low-odor ecological automotive foot mat provided by an embodiment of the present utility model includes a blanket surface layer 1, a middle layer 2 and a bottom layer 3. The blanket surface layer 1, the middle layer 2 and the bottom layer 3 are connected in sequence. The blanket surface layer 1 is bonded to the middle layer 2, and the edges of the blanket surface layer 1 and the middle layer 2 are stitched and edge-wrapped through a suture 21.

[0025] Furthermore, the blanket surface layer 1 and the middle layer 2 are connected by an adhesive technology to ensure a tight combination between the two layers and not easy to separate. An eco-friendly hot melt adhesive is used for bonding. After melting at an appropriate temperature, the eco-friendly hot melt adhesive can quickly penetrate to the surface of the fibers or materials of the blanket surface layer 1 and the middle layer 2, forming a strong intermolecular bonding force to ensure a tight combination between the two layers. Even under long-term use and temperature changes inside the vehicle, it is not easy to separate. Moreover, the content of volatile organic compounds such as formaldehyde and benzene in the eco-friendly hot melt adhesive is extremely low, even reaching the standard of no addition. Therefore, it hardly produces irritating odors and has a minimal impact on the air quality inside the vehicle.

[0026] Furthermore, at the edge of the blanket surface layer 1 and the middle layer 2, suture and edge-wrapping treatment is carried out through a suture 21, which not only enhances the edge strength of the foot mat, prevents edge wear or detachment, but also improves the overall aesthetics and durability of the foot mat.

[0027] Specifically, the blanket surface layer 1 is made of flame-retardant PA fluff, and the surface of the blanket surface layer 1 is provided with embossing for anti-slip effect.

[0028] Furthermore, by improving the fluff layer PA6 yarn, the flame retardant is directly blended with the PA6 resin to form a composite material with flame retardant effect, and then the flame retardant PA6 yarn is prepared by processes such as melt extrusion or injection molding. The flame retardant can slow down the burning speed of the yarn, extend the burning time, and at the same time, can inhibit the release of smoke and toxic gases, reducing the harm of fire to the human body, thus significantly improving the flame retardant performance of the carpet layer 1;

[0029] Furthermore, the surface of the carpet layer 1 is provided with embossing, which can not only improve the aesthetics of the foot mat, but more importantly, can play an anti-slip role. The embossing process forms concave and convex textures on the carpet surface, increasing the friction between the surface of the foot mat and the sole of the shoe, so that passengers can step on the foot mat stably during the vehicle driving process, avoiding inconvenience or safety hazards caused by slipping.

[0030] Specifically, an anti-slip pedal 11 is provided on the carpet layer 1, and straight lines are provided on the anti-slip pedal 11, and the anti-slip pedal 11 is used to increase the friction.

[0031] Furthermore, the anti-slip pedal 11 can enhance the stability and safety of passengers on the foot mat. Especially in the case of emergency braking or rapid turning, the anti-slip pedal 11 can be specially set;

[0032] Furthermore, the anti-slip pedal 11 is fixedly connected to the carpet layer 1, and straight lines are provided on the surface to form an anti-slip structure. When the sole of the passenger's shoe contacts the anti-slip pedal 11, the straight lines can increase the contact area between the sole and the pedal and generate more friction, thus providing a stable stepping point for passengers;

[0033] Furthermore, the straight lines are easy to clean and maintain, not easy to accumulate dust or debris, and keep the surface of the pedal clean and anti-slip performance;

[0034] Furthermore, the anti-slip pedal 11 is made of the same flame retardant PA6 yarn as the carpet layer 1 to ensure its consistency with the carpet layer 1 in physical properties and flame retardant properties. At the same time, the anti-slip pedal 11 is fixedly connected to the carpet layer 1 to ensure the firmness and stability of the connection, preventing loosening or falling off during use.

[0035] Specifically, the intermediate layer 2 is made of PET non-woven fabric, and a flame retardant latex is provided between the intermediate layer 2 and the bottom layer 3.

[0036] Furthermore, the intermediate layer 2 is made of PET (polyethylene terephthalate) non-woven fabric. The PET non-woven fabric has good mechanical properties, chemical stability and heat resistance, can well support the carpet layer 1, and at the same time maintain the overall structural stability of the foot mat;

[0037] Furthermore, the PET non-woven base fabric is processed by subjecting PET fibers to a non-woven process. This process forms an interlaced and entangled structure between the fiber layers, thereby endowing the material with high strength and wear resistance. In addition, the PET non-woven base fabric also has good air permeability and moisture absorption, which helps to keep the interior of the foot mat dry and comfortable.

[0038] Furthermore, setting a flame-retardant latex between the intermediate layer 2 and the bottom layer 3 is one of the key measures to enhance the overall flame-retardant performance of the foot mat;

[0039] Firstly, the flame-retardant latex not only has excellent adhesion performance, which can ensure a firm bond between the intermediate layer 2 and the bottom layer 3, but also can rapidly expand to form a heat-insulating layer under the action of a fire source, effectively preventing the further spread of the fire;

[0040] Secondly, this flame-retardant latex usually contains special flame-retardant components, which can decompose at high temperatures to generate water vapor or other non-combustible gases, thereby diluting the concentration of combustible gases and reducing the fire risk;

[0041] Specifically, a glue edge 31 is provided on the bottom layer 3, and the glue edge 31 is used to increase the adhesion of the bottom layer 3.

[0042] Furthermore, the glue edge 31 provided on the bottom layer 3 is mainly used to increase the adhesion between the bottom layer 3 and the car floor, ensuring that the foot mat can be firmly fixed on the floor during use and is not prone to sliding or displacement;

[0043] Furthermore, the glue edge 31 is made of a sticky material, making the glue edge 31 have good adhesiveness and wear resistance. It can closely adhere to the surface of the car floor and withstand the friction and wear during daily use. When the foot mat is placed on the car floor, the glue edge 31 will come into contact with the floor surface and generate adhesion force, thereby firmly fixing the foot mat on the floor;

[0044] Moreover, in addition to increasing the adhesion, the glue edge 31 also has a certain buffering effect, which can reduce the direct impact and noise between the foot mat and the floor;

[0045] Furthermore, when passengers get on and off the vehicle or move their feet, the foot mat will be subjected to certain pressure and impact. As the transition layer between the foot mat and the floor, the glue edge 31 can absorb and disperse these impact energies, reduce the direct impact on the floor, thereby protecting the floor from damage and extending the service life of the foot mat and the floor;

[0046] During vehicle driving, the foot mat may rub or collide with the floor due to vibration, thereby generating noise. The glue edge 31 has certain elastic and damping properties, which can reduce the noise generated by this friction and collision, providing a quiet and comfortable driving environment;

[0047] The buffering effect of the rubber edge 31 helps to reduce the minute displacement of the floor mat caused by vibration, thereby enhancing the stability of the floor mat to a certain extent.

[0048] Specifically, vertical stripes 32 and horizontal stripes 33 are provided at the bottom of the bottom layer 3. The vertical stripes 32 and the horizontal stripes 33 are arranged alternately. Rubber blocks 34 are provided between the vertical stripes 32 and the horizontal stripes 33. A gauze cloth 35 is provided on the rubber blocks 34, and a flame retardant glue is applied on the gauze cloth 35.

[0049] Furthermore, in daily life, when a car is washed, the floor mat will be rinsed to keep it clean. Since the floor mat is easy to get wet, when the wet floor mat is placed in the closed car, if it is not dried in time, it is easy to produce an odor.

[0050] When water penetrates to the bottom of the floor mat, the vertical stripes 32 and the horizontal stripes 33 provided at the bottom of the bottom layer 3 can increase the air permeability of the bottom layer 3 and accelerate the drying speed of the floor mat. These textures can form multiple minute channels, enabling air to circulate more smoothly between the floor mat and the floor. This not only helps to accelerate the evaporation of water but also effectively reduces the mold and bacteria generated due to dampness at the bottom of the floor mat.

[0051] Furthermore, the rubber blocks 34, as the structure connecting the vertical stripes 32 and the horizontal stripes 33, can play a role in strengthening the overall strength of the bottom layer 3 and can also provide buffering and anti-slip functions. The rubber material has good elasticity and wear resistance, which can reduce the direct friction between the floor mat and the floor and absorb the vibration and impact during vehicle driving at the same time.

[0052] Secondly, the gauze cloth 35 is a porous material with good air permeability and hygroscopicity. It can promote air circulation, accelerate the drying process of the floor mat, and reduce the growth of bacteria and the generation of odor.

[0053] The gauze cloth 35 coated with the flame retardant glue improves the air permeability and durability of the floor mat on the one hand and enhances the flame retardant performance of the floor mat on the other hand. It enables the bottom layer 3 to quickly form a heat insulation layer under the action of a fire source, preventing the spread and diffusion of the fire. Therefore, even if the floor mat accidentally comes into contact with a fire source, it can effectively slow down the burning speed and reduce the fire risk.

[0054] Working principle: By improving the PA6 yarn of the fluff layer, the flame retardant is directly blended with the PA6 resin to form a composite material with flame retardant effect, and then the flame retardant PA6 yarn is prepared through processes such as melt extrusion or injection molding. The flame retardant can slow down the burning speed of the yarn, extend the burning time, and at the same time, can inhibit the release of smoke and toxic gases, reducing the harm of fire to the human body, thereby significantly enhancing the flame retardant performance of the carpet layer 1.

[0055] Utilizing the relatively high tensile strength and tear strength of the PET non-woven base fabric, it can withstand greater external forces and abrasion, increasing the overall durability of the middle layer 2 of the foot mat. Moreover, the melting point of the PET non-woven fabric is relatively high, about 260 °C, and it can still maintain a stable size and shape in a high-temperature environment, helping the foot mat to remain flat and not easily deformed;

[0056] The bottom layer 3 is provided with an anti-slip gauze fabric 35, and a flame-retardant glue is applied on the anti-slip gauze fabric 35. The flame-retardant glue has good adhesiveness and can firmly bond the gauze fabric 35 to the bottom layer 3 of the foot mat. And a flame retardant is added to the glue to make the overall carpet in a state of not burning when encountering an open flame.

[0057] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principle and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A highly flame-retardant, low-odor, ecological car mat, comprising a carpet surface layer (1), an intermediate layer (2) and a bottom layer (3), characterized in that: The carpet surface layer (1), the middle layer (2) and the bottom layer (3) are connected in sequence; the carpet surface layer (1) and the middle layer (2) are bonded; the edges of the carpet surface layer (1) and the middle layer (2) are sewn and hemmed by sewing threads (21); the carpet surface layer (1) is made of flame-retardant PA6 fluff; the middle layer (2) is made of PET non-woven fabric; and flame-retardant latex is provided between the middle layer (2) and the bottom layer (3).

2. The highly flame-retardant, low-odor, ecological car mat according to claim 1, characterized in that: An anti-skid pedal (11) is provided on the carpet surface layer (1), and straight lines are provided on the anti-skid pedal (11). The anti-skid pedal (11) is used to increase friction.

3. The highly flame-retardant, low-odor, ecological car mat according to claim 1, characterized in that: The surface of the carpet surface layer (1) is provided with embossing for anti-slip effect.

4. The highly flame-retardant, low-odor, ecological car mat according to claim 1, characterized in that: The bottom surface layer (3) is provided with a glue edge (31), and the glue edge (31) is used to increase the adhesion of the bottom surface layer (3).

5. The highly flame-retardant, low-odor, ecological car mat according to claim 1, characterized in that: The bottom of the bottom surface layer (3) is provided with vertical stripes (32) and horizontal stripes (33), the vertical stripes (32) and the horizontal stripes (33) are arranged in a staggered manner, a rubber block (34) is arranged between the vertical stripes (32) and the horizontal stripes (33), a gauze cloth (35) is arranged on the rubber block (34), and the gauze cloth (35) is coated with flame retardant glue.

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