High-flatness stretch-resistant formed carpet
By optimizing the carpet structure, using PET non-woven fabric, PE/PA/PE co-extruded film and latex materials, the carpet flatness and reserve problems are solved, the carpet's high flatness and tensile resistance are achieved, and the automobile interior automation process and environmentally friendly production are promoted.
Patent Information
- Application Number
- CN202422452821.0
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-10-11
- Publication Date
- 2025-07-18
- Estimated Expiration
- 2034-10-11
AI Technical Summary
The flatness problem of existing carpets has seriously affected the automation process of automobile interiors, resulting in the inability to realize the material grabbing function of the equipment. The traditional production method requires a large inventory, with a large area of land and a great impact on environmental protection. Material storage has the risk of aging and deterioration.
The high-flat tensile-resistant carpet structure is adopted, including the PET non-woven fabric base layer, the PE/PA/PE co-extruded film tensile layer, the latex support layer, the coating material wear-resistant layer and the phase twisted polyester monofilament tuft layer. Through interlayer bonding and design optimization, it can fill and absorb the tensile and shrinkage stress of the coating material, and maintain the stable shape of the material.
It improves the flatness and tensile resistance of the carpet, reduces material reserves, reduces floor area and operating costs, improves environmental protection level, promotes the equipment's automatic grabbing function, and extends the service life of the carpet.
Smart Images
Figure CN223116242U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the field of interior decoration of automobile driving cabs, and particularly relates to a carpet with high flatness and anti-tensile forming. Background Art
[0002] In current automobile production, the client is committed to lean and miniaturized production to improve production efficiency, reduce costs and adapt to the rapid changes in the market. An important measure is to replace the traditional manual feeding method with automatic material grabbing by equipment. However, the current carpet flatness problem seriously affects the automation process, making it impossible to realize the equipment material grabbing function. The current in-vehicle carpets on the market are mainly composed of suede and coated film materials. Due to the shrinkage force of the coated film material itself, the curling angle of the carpet reaches 70°-90°. This curling not only makes the anti-tensile effect of the carpet poor, but also there is a risk of carpet tearing in the structure of new energy vehicle models; in addition, the current production method requires advance material storage, about 3 days of inventory, which has certain impacts on floor area, material storage and environmental protection. In a limited production space, excessive material storage will affect the smoothness of the production process, reduce space utilization rate, and increase the operating costs of the enterprise; in terms of environmental protection, a large amount of material storage may generate more packaging waste, having a negative impact on the environment; in addition, too long inventory time may also lead to problems such as material aging and deterioration, further affecting the environment.
[0003] In summary, the current flatness problem in carpet production and the traditional production method can no longer meet the needs of the client's lean and miniaturized production. To solve these problems, there is an urgent need for a new carpet production technology that can improve the flatness of the carpet, realize automatic material grabbing by equipment, reduce material storage, reduce floor area, and improve environmental protection level, so as to promote the automation process and sustainable development of the automobile manufacturing industry. Summary of the Invention
[0004] To solve the above problems, the present utility model provides a high-flatness anti-tensile formed carpet. This high-flatness anti-tensile formed carpet for automotive interiors has a certain hardness and extensibility, and has the advantages of simple process, high cost performance, light weight, low odor, strong impact resistance, good sound absorption performance, etc. The specific implementation scheme is as follows: A high-flatness anti-tensile formed carpet includes a fabric base layer 1 and an anti-tensile layer 2. A support layer 3 is provided between the fabric base layer 1 and the anti-tensile layer 2. The upper and lower sides of the support layer 3 are respectively adhesively fixed to the fabric base layer 1 and the anti-tensile layer 2. On the side of the anti-tensile layer 1 away from the support layer 3, a wear-resistant layer 4 is adhesively fixed. On the outer surface of the fabric base layer 1 of the high-flatness anti-tensile formed carpet, a tufting layer 5 is also fixed. The tufting layer 5 is composed of yarn bundles with the tops fixed in the anti-tensile layer 2, and the lower ends of the yarn bundles sequentially penetrate the support layer 3 and the fabric base layer 1.
[0005] Further, the fabric base layer 1 is made of PET non-woven fabric material. The fabric base layer made of PET non-woven fabric material has characteristics such as high strength, good dimensional stability, and corrosion resistance. After being made into a non-woven fabric base layer, it can provide good structural support for the fabric and maintain the integrity of the overall fabric structure.
[0006] Further, the anti-tensile layer 2 is made of PE / PA / PE co-extruded film material. In the PE / PA / PE co-extruded film material, the PE layer plays an elastic buffering role and can stretch to a certain extent to absorb part of the stress transmitted during the stretching of the coated material. The PA layer has a high strength and can prevent the co-extruded film from deforming excessively, thereby sharing and offsetting the tensile stress of the coated material and avoiding damage to the coated material due to excessive stretching.
[0007] Further, the support layer 3 is made of latex material. As a support layer, latex can increase the overall stability of the carpet, improve the sound absorption performance, enhance the wear resistance, and has anti-aging properties, which can ensure that the carpet maintains a complete structure and extend the service life of the carpet.
[0008] Further, the wear-resistant layer (4) is made of coated material. The coated material has high hardness and wear resistance, and also has certain anti-fouling and moisture-proof properties. However, there are certain tensile and shrinkage stresses, which will cause problems such as deformation and warping of the composite material, and further lead to unevenness on the surface of the carpet. The present utility model adopts the design of bonding the PE / PA / PE co-extruded film material with the coated material, which can effectively offset and absorb the tensile and shrinkage stresses of the coated material, maintain the shape stability of the composite material, reduce the occurrence of problems such as deformation, and thus improve the yield rate of carpet production.
[0009] Further, the yarn bundle is polyester monofilament with parallel twisting. The polyester monofilament with parallel twisting has the advantages of high strength, good abrasion resistance, strong dimensional stability, non-water absorption, good stain resistance, soft touch, etc. This design ensures that the carpet will not deform significantly due to changes in the vehicle interior environment, maintaining a proper size and shape at all times, perfectly fitting the vehicle interior space, and providing a more comfortable experience for drivers and passengers.
[0010] Further, the yarn bundle is fixed to the anti-tensile layer (2) by means of "V"-shaped tufting at a position 0.4 - 0.5 mm on the side of the anti-tensile layer (2) close to the support layer (3). Compared with the prior art method of directly planting the tufting layer on the outer surface of the fabric base layer, the design of the present utility model makes the tufting layer of the carpet more solid, less likely to slip or fall off.
[0011] Further, the length of the yarn exposed outside the fabric base layer (1) is 4 - 5 mm. This design enables the carpet to effectively save vehicle interior space while ensuring comfort.
[0012] Further, the overall thickness of the high flatness anti-tensile formed carpet is 8 - 12 mm, and the weight per square meter ≤ 750 g. This design gives the carpet a significant advantage of being lighter in terms of thickness and weight compared with the prior art. When subjected to a certain external force for stretching, the carpet is less likely to deform or be damaged, effectively promoting the automation process of the equipment's material grabbing function. In addition, this design also saves raw material costs while maintaining comfort.
[0013] On the premise of meeting laws, regulations and environmental protection requirements, the present utility model makes the carpet flatter by adjusting the product structure, improving the anti-tensile effect by 5%, enhancing the flatness of its appearance, improving the overall quality of the carpet, making it fit the ground more closely during the laying process, and reducing the appearance of wrinkles and unevenness; the PE / PA / PE co-extruded film material can offset and absorb the tensile and shrinkage stresses of the lamination material during the composite process, contributing to maintaining the stability of the carpet during production, reducing problems such as dimensional instability and deformation caused by stress changes in the lamination material, improving the yield rate of carpet production. At the same time, the improvement of the anti-tensile effect makes the carpet less likely to deform or be damaged when subjected to a certain external force for stretching, promoting the automation process of the equipment's material grabbing function, meeting market demands, and enhancing the competitiveness of the product in the market. BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Figure 1 It is a schematic structural diagram of an anti-tensile shaped flat carpet for an automobile in an embodiment of the present utility model; wherein, 1 is the fabric base layer, 2 is the anti-tensile layer, 3 is the support layer, 4 is the wear-resistant layer, and 5 is the tufting layer.
[0015] Embodiment
[0016] To more clearly illustrate the technical solutions in the embodiments of the present utility model, the attached drawings required for the description of the embodiments are briefly introduced. Obviously, the attached drawings in the following description are only one embodiment of the present utility model. For those of ordinary skill in the art, without creative efforts, other attached drawings can be obtained based on these attached drawings.
[0017] A high-flatness and anti-tensile formed carpet, as Figure 1 shown, includes a fabric base layer 1 made of PET non-woven fabric material and an anti-tensile layer 2 made of PE / PA / PE co-extruded film material. The fabric base layer made of PET non-woven fabric material has characteristics such as high strength, good dimensional stability, and corrosion resistance. After being made into the non-woven fabric base layer, it can provide good structural support for the fabric and maintain the integrity of the overall fabric structure. In the PE / PA / PE co-extruded film material, the PE layer plays an elastic buffering role and can stretch to a certain extent to absorb part of the stress transmitted during the stretching of the coated material. The PA layer has high strength and prevents the co-extruded film from deforming excessively, thereby sharing and offsetting the tensile stress of the coated material and avoiding damage to the coated material due to excessive stretching.
[0018] A support layer 3 made of latex material is provided between the fabric base layer 1 and the anti-tensile layer 2. As the support layer, latex can increase the overall stability of the carpet, improve the sound absorption performance, enhance the wear resistance, and has anti-aging properties, which can ensure that the carpet maintains a complete structure and extends the service life of the carpet. The upper and lower sides of the support layer 3 are adhesively fixed to the fabric base layer 1 and the anti-tensile layer 2 respectively;
[0019] On the side of the anti-tensile layer 2 away from the support layer 3, a wear-resistant layer 4 made of coated material is adhesively fixed. The coated material has high hardness and wear resistance, and also has certain anti-fouling and moisture-proof properties. However, there are certain tensile and shrinkage stresses, which will cause problems such as deformation and warping of the composite material, and then lead to unevenness on the surface of the carpet. The present utility model adopts the design of bonding the PE / PA / PE co-extruded film material with the coated material, which can effectively offset and absorb the tensile and shrinkage stresses of the coated material, maintain the shape stability of the composite material, reduce the occurrence of problems such as deformation, and thus improve the yield rate of carpet production.
[0020] The high flatness and anti-tensile formed carpet further has a tufting layer 5 fixed on the outer surface of the fabric base layer 1. The tufting layer 5 is composed of yarn bundles with the top ends fixed in the anti-tensile layer 2. The lower ends of the yarn bundles sequentially penetrate through the support layer 3 and the fabric base layer 1. The yarn bundles are polyester monofilaments twisted together. The yarn bundles are fixed to the anti-tensile layer 2 by the "V"-type pile planting method at a position 0.45 mm away from the side of the anti-tensile layer 2 close to the support layer 3. The length of the yarn exposed outside the fabric base layer 1 is 4 mm. Compared with the prior art method of directly planting the tufting layer on the outer surface of the fabric base layer, the design of the present utility model makes the tufting layer of the carpet stronger and not easily fall off.
[0021] The above are only the preferred embodiments of the present utility model and are not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present utility model shall be included in the protection scope of the present utility model.
Claims
1. A carpet with high flatness and anti-tensile forming, characterized in that, It includes a fabric base layer (1) and a tensile-resistant layer (2). A support layer (3) is provided between the fabric base layer (1) and the tensile-resistant layer (2), and the upper and lower sides of the support layer (3) are adhesively fixed to the fabric base layer (1) and the tensile-resistant layer (2) respectively; on the side of the tensile-resistant layer (2) away from the support layer (3), a wear-resistant layer (4) is adhesively fixed; on the outer surface of the fabric base layer (1) of the high-flatness tensile-resistant formed carpet, a tufted layer (5) is also fixed. The tufted layer (5) is composed of yarn bundles with the tops fixed in the tensile-resistant layer (2), and the lower ends of the yarn bundles sequentially penetrate the support layer (3) and the fabric base layer (1). The tensile-resistant layer (2) is made of a PE / PA / PE co-extruded film material.
2. The high-flatness anti-tensile formed carpet according to claim 1, wherein, The fabric base layer (1) is made of a PET non-woven fabric material.
3. The high flatness and anti-tensile formed carpet according to claim 1, wherein The support layer (3) is made of a latex material.
4. A high flatness and anti-tensile formed carpet according to claim 1, characterized in that, The wear-resistant layer (4) is made of a film laminating material.
5. A high flatness and anti-tensile formed carpet according to claim 1, characterized in that, The yarn bundles are parallel-twisted polyester monofilaments.
6. The high flatness and anti-tensile formed carpet according to claim 1, wherein, The yarn bundles are fixed to the tensile-resistant layer (2) by the "V"-type tufting method at a position 0.4 - 0.5 mm away from the support layer (3) on the side of the tensile-resistant layer (2).
7. The high flatness and anti-tensile formed carpet according to claim 1, wherein The length of the yarns exposed outside the fabric base layer (1) is 4 - 5 mm.
8. A high flatness and anti-tensile formed carpet according to claim 1, characterized in that, The overall thickness of the high-flatness tensile-resistant formed carpet is 8 - 12 mm.
9. The high flatness and anti-tensile formed carpet according to claim 1, wherein The weight of the high-flatness tensile-resistant formed carpet per square meter is ≤ 750 g.