Ultralow-pile-weight tufted polyester stretch-resistant carpet

Abstract

The utility model discloses an ultra-low pile weight tufted polyester stretch-resistant carpet which is implemented in a light weight mode, the tufted density of the ultra-low pile weight tufted polyester stretch-resistant carpet is 240 g / m < 2 > and is reduced by 100-160 g / m < 2 > compared with that of a daily carpet, the weight of the carpet can be obviously reduced by reducing the pile weight of the carpet, and the carpet is more convenient to take and install. Besides, the tufting layer of the carpet is composed of yarn bundles with the top ends fixed to a fixed knot planting part, the fixed knot planting part is fixed in the elasticity enhancing layer, the lower ends of the yarn bundles sequentially penetrate through the supporting layer and the fabric base layer, and a fixed knot is arranged at the position, penetrating through the lower surface of the fabric base layer, of each yarn bundle. By means of the design, comfort and firmness of the carpet are guaranteed, meanwhile, the overall thickness of the carpet is reduced, and occupied space in a vehicle is reduced. Meanwhile, the EVA filler is added, so that the strength and the tensile effect of the carpet can be improved, and the carpet is more durable; and the low-VOC-EVA filler can meet the requirements of environmental protection laws and regulations and cannot pollute the environment in the vehicle, so that the health of a driver and passengers is guaranteed.

Description

Technical Field

[0001] The utility model belongs to the field of automobile cabin interior decoration, and particularly relates to an ultra-low pile weight tufted polyester anti-stretch carpet. Background Art

[0002] In the current automotive interior field, carpet is a key component, and its performance and quality are receiving more and more attention. Currently, the tufting weight of carpet is usually maintained at 300-400g / m 2 , which makes the carpet cumbersome to pick up, not only increasing the labor cost during the production and installation process, but also using more yarn, which is not conducive to cost control and resource conservation; secondly, the higher pile height and thicker structure make the carpet prone to damage during the molding process, which not only seriously affects the appearance quality of the carpet, but also may reduce its service life and increase the frequency of replacement, and cannot meet customers' high-quality requirements for car interiors; in addition, the tufted layer of the car carpets currently sold on the market is generally planted on the surface of the carpet, resulting in a larger overall thickness of the carpet. The thick carpet will occupy more space in the car, making the driver's compartment space appear narrower, reducing the passengers' experience of the driver's compartment space.

[0003] In summary, as consumers' demands for automotive interiors continue to rise, they are not only concerned with carpet's appearance and quality, but also place higher demands on its environmental performance and comfort. Therefore, developing carpets that combine attractive appearance with enhanced comfort and environmental compliance has become a pressing issue for improving automotive product quality. Summary of the Invention

[0004] In order to solve the problems existing in existing carpets, this utility model proposes an ultra-low pile weight tufted polyester anti-stretch carpet, which achieves lightweight and thinning of the carpet, while having a better stretching effect than conventional carpets. The specific implementation plan is as follows:

[0005] A super low pile weight tufted polyester stretch-resistant carpet comprises: a fabric base layer 1 and a stretch-resistant layer 2, a support layer 3 and an elastic layer 4 are sequentially arranged between the fabric base layer 1 and the stretch-resistant layer 2, the upper and lower sides of the support layer 3 are respectively bonded and fixed to the fabric base layer 1 and the elastic layer 4; the stretch-resistant layer 2 is bonded and fixed to the side of the elastic layer 4 away from the support layer 3; the super low pile weight tufted polyester stretch-resistant carpet is also fixed with a tufted layer 5 on the outer surface of the fabric base layer 1, the tufted layer 5 is composed of a yarn bundle whose top end is fixed to a fixed knot planting part 7, the fixed knot planting part 7 is fixed in the elastic layer 4, the lower end of the yarn bundle penetrates the support layer 3 and the fabric base layer 1 in sequence, and a fixed knot 6 is provided at the lower surface where the yarn bundle penetrates the fabric base layer 1, and the fixed knot planting part 7 is used to plant the fixed knot 6.

[0006] Furthermore, the flocking density is 230-250g / m 2 .

[0007] Furthermore, the thickness of the fabric base layer 1 is 5-6 mm, the thickness of the anti-stretching layer 2 is 0.43-0.53 mm, the thickness of the supporting layer 3 is 0.1-0.15 mm, and the thickness of the elastic layer 4 is 1.5-2.5 mm.

[0008] Furthermore, 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 the characteristics of high strength, good dimensional stability, corrosion resistance, etc. 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 structure of the fabric.

[0009] Furthermore, the anti-stretching layer 2 is made of hot-rolled cloth material. After the hot-rolled cloth is processed by the hot-rolling process, its internal fiber structure is more compact and orderly. When used as an anti-stretching layer in the carpet, it can effectively resist tensile forces from all directions. Regardless of whether the carpet is locally pulled or the entire carpet is stretched by a large external force, the hot-rolled cloth anti-stretching layer can maintain structural stability, prevent the carpet from deformation or tearing, and thus extend the service life of the carpet.

[0010] Furthermore, the support layer 3 is made of latex material. Latex as a support layer can increase the overall stability of the carpet, improve the sound absorption performance, enhance the wear resistance and have anti-aging properties, which can ensure that the carpet maintains its intact structure and extend the service life of the carpet.

[0011] Furthermore, the elastic layer 4 is made of low-volatile organic compound ethylene-vinyl acetate copolymer (VOC-EVA). The EVA material has good elasticity and can better fit the shape and unevenness of the ground, thereby improving the stability of the carpet and the flatness of the overall appearance. It can also provide the carpet with a comfortable elastic feel. The low-VOC-EVA material releases very few volatile organic compounds into the indoor air, which meets the requirements of environmental protection and people's pursuit of health.

[0012] Furthermore, the yarn bundles are parallel-twisted polyester monofilaments. Polyester has the advantages of good flexibility, comfortable touch, good air permeability, high strength, good wear resistance, strong stain resistance, and good chemical stability, and is very suitable for use as a tufted layer of automotive interior carpets.

[0013] Furthermore, the fixing knot planting portion 7 is fixed to the elastic layer 4 at 0.4-0.6 mm on one side of the elastic layer 4 close to the support layer 3, and the fixing knot planting portion 7 is used to plant the fixing knot 6. Compared with the prior art method of directly planting the tufted layer on the outer surface of the fabric base layer, the design of the utility model not only reduces the thickness of the carpet and saves space in the car, but also makes the tufted layer of the carpet stronger and less likely to fall off.

[0014] Furthermore, the length of the yarn exposed outside the fabric base layer 1 is 4-5 mm.

[0015] Furthermore, the fixing knot 6 can firmly fix the yarn inside the carpet fabric base 1, which effectively avoids the shedding phenomenon caused by the yarn slipping during use of the carpet, and well maintains the flatness of the carpet, thereby enhancing the aesthetic effect of the carpet.

[0016] Furthermore, the ultra-low pile weight tufted polyester tensile-resistant carpet has an overall thickness of 11-15 mm, which is 10-15 mm thinner than the existing vehicle-mounted carpet, effectively saving interior space in the car, providing passengers with a more spacious and comfortable feeling, and enhancing the riding experience.

[0017] Furthermore, the ultra-low pile weight tufted polyester tensile-resistant carpet weighs ≤1900g per square meter, making the carpet lighter while saving raw material costs. The lightness of the carpet is not only convenient for transportation and installation, but also brings a more convenient user experience. The cost reduction also makes the carpet more competitive in the market.

[0018] The utility model is an ultra-low pile weight tufted polyester stretch-resistant carpet using 230-250g / m 2 The pile density is 150-170g / m2 lower than that of ordinary carpets 2 , lightweight implementation was carried out. By reducing the pile weight of the carpet, the weight of the carpet can be significantly reduced, making it easier to pick up and install. At the same time, the lightweight carpet also helps to reduce the overall weight of the vehicle, improve fuel economy and environmental performance; in addition, the design of fixing the yarn to the elastic layer 4 in a "V"-shaped flocking manner ensures the comfort of the carpet while reducing the overall thickness of the carpet, reducing the space occupied in the car, making the driving and passenger compartment space appear more spacious, and improving the passengers' experience of the driving and passenger compartment space; at the same time, adding EVA filling can improve the strength and tensile resistance of the carpet, making it more durable; low VOC-EVA filling can meet environmental protection laws and regulations, will not cause pollution to the environment inside the car, and protect the health of the driver and passengers. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1This is a structural diagram of an anti-stretching and shaped flat carpet for automobiles in an embodiment of the present utility model; wherein 1 is a fabric base layer, 2 is an anti-stretching layer, 3 is a supporting layer, 4 is an elastic layer, 5 is a tufting layer, and 6 is a fixing knot.

[0020] Example

[0021] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, a brief introduction is given to the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only one embodiment of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0022] An ultra-low pile weight tufted polyester stretch-resistant carpet, such as Figure 1 As shown, the fabric base layer 1 is made of PET non-woven fabric material and the anti-stretching layer 2 is made of hot-rolled fabric material. The thickness of the fabric base layer 1 is 5.5 mm, and the thickness of the anti-stretching layer 2 is 0.48 mm. The fabric base layer made of PET non-woven fabric material has the characteristics of high strength, good dimensional stability, and corrosion resistance. After being made into a non-woven fabric fabric base layer, it can provide good structural support for the fabric and maintain the integrity of the overall structure of the fabric. After the hot-rolled fabric is treated by the hot-rolling process, its internal fiber structure is more compact and orderly. When used as an anti-stretching layer in the carpet, it can effectively resist tensile forces from all directions. Whether the carpet is pulled locally or subjected to large external forces as a whole, the hot-rolled fabric anti-stretching layer can maintain structural stability, prevent the carpet from deformation or tearing, and thus extend the service life of the carpet.

[0023] A support layer 3 made of latex material and an elastic layer 4 made of low-VOC EVA material are sequentially arranged between the fabric base layer 1 and the anti-stretch layer 2. The support layer 3 is 0.1 mm thick, and the elastic layer 4 is 2 mm thick. Latex as a support layer can increase the overall stability of the carpet, improve sound absorption performance, enhance wear resistance, and have anti-aging properties, ensuring that the carpet maintains its structural integrity and extending its service life. The EVA material has good elasticity and can better conform to the shape and unevenness of the floor, improving the stability and overall smoothness of the carpet's appearance. It also provides the carpet with a comfortable, elastic feel. The low-VOC EVA material releases very few volatile organic compounds into the indoor air, meeting environmental protection requirements and people's pursuit of health.

[0024] The upper and lower sides of the support layer 3 are respectively bonded and fixed to the fabric base layer 1 and the elastic layer 4, and the anti-stretching layer 2 is bonded and fixed to the side of the elastic layer 4 away from the support layer 3;

[0025] The outer surface of the fabric base layer 1 is also fixed with a tufted layer 5, and the tufted layer 5 is composed of a yarn bundle whose top end is fixed in the elastic layer 4. The lower end of the yarn bundle penetrates the support layer 3 and the fabric base layer 1 in sequence. The yarn bundle is a twisted polyester monofilament. Polyester has the advantages of good flexibility, comfortable touch, good air permeability, high strength, good wear resistance, strong stain resistance, and good chemical stability. It is very suitable for use as a tufted layer of a car interior carpet; the fixed knot planting part 7 is 0.5 mm on the side of the elastic layer 4 close to the support layer 3. Fixed to the elastic layer 4, a fixing knot 6 is provided at the lower surface where the yarn bundle penetrates the fabric base layer 1, and the fixing knot planting portion 7 is used to plant the fixing knot 6. This design makes the carpet stronger and more durable without increasing the thickness; the length of the yarn exposed outside the fabric base layer 1 is 4.5 mm. Compared with the method of directly planting the tufting layer on the outer surface of the fabric base layer in the prior art, the design of the utility model not only reduces the thickness of the carpet and saves space in the car, but also makes the tufting layer of the carpet stronger and less likely to fall off.

[0026] The fixing knot 6 can firmly fix the yarn inside the carpet fabric base 1, which effectively avoids the carpet from shedding due to yarn slipping during use, and also maintains the flatness of the carpet, thereby enhancing the aesthetic effect of the carpet.

[0027] The ultra-low pile weight tufted polyester anti-stretch carpet has an overall thickness of 12.6mm and a weight of ≤1900g per square meter. Compared with the existing automotive carpet, the thickness is reduced by 10mm and the weight is reduced by 160g / m 2 , lighter and space-saving.

[0028] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent replacements, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An ultra-low pile weight tufted polyester stretch-resistant carpet, characterized in that: include: A fabric base layer (1) and an anti-stretching layer (2), wherein a support layer (3) and an elastic layer (4) are sequentially provided between the fabric base layer (1) and the anti-stretching layer (2), wherein the upper and lower sides of the support layer (3) are bonded and fixed to the fabric base layer (1) and the elastic layer (4) respectively; the anti-stretching layer (2) is bonded and fixed to the side of the elastic layer (4) away from the support layer (3); the ultra-low pile weight tufted polyester anti-stretching carpet is further fixed with a tufting layer (5) on the outer surface of the fabric base layer (1), wherein the tufting layer (5) is composed of a yarn bundle whose top end is fixed to a fixed knot planting part (7), wherein the fixed knot planting part (7) is fixed in the elastic layer (4), and the lower end of the yarn bundle sequentially penetrates the support layer (3) and the fabric base layer (1), and a fixed knot (6) is provided at the lower surface where the yarn bundle penetrates the fabric base layer (1).

2. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The flocking density is 230-250g / m 2 .

3. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The thickness of the fabric base layer (1) is 5-6 mm, the thickness of the anti-stretching layer (2) is 0.43-0.53 mm, the thickness of the supporting layer (3) is 0.1-0.15 mm, and the thickness of the elastic layer (4) is 1.5-2.5 mm.

4. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The fabric base layer (1) is made of PET non-woven fabric material.

5. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The anti-stretching layer (2) is made of hot-rolled cloth material.

6. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The supporting layer (3) is made of latex material.

7. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The elastic layer (4) is made of ethylene-vinyl acetate copolymer with low volatile organic compounds.

8. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The yarn bundles are parallel-twisted polyester monofilaments.

9. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The fixed knot planting portion (7) is fixed to the elastic layer (4) at a position 0.4-0.6 mm on one side of the elastic layer (4) close to the support layer (3), and the length of the yarn bundle exposed outside the fabric base layer (1) is 4-5 mm.

10. The ultra-low pile weight tufted polyester stretch-resistant carpet according to claim 1, characterized in that: The ultra-low pile weight tufted polyester stretch-resistant carpet has an overall thickness of 11-15 mm and a weight per square meter of ≤1900 g.

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