Crease-free antiskid carpet

Abstract

The utility model relates to the technical field of carpets, in particular to a crease-free anti-skidding carpet which comprises a carpet body, the carpet body is composed of a carpet body located on the upper portion and a carpet base connected to the lower portion of the carpet body, an anti-skidding layer is arranged below the carpet base, and the anti-skidding layer is composed of a fluff layer connected to the lower portion of the carpet base through the flocking technology. The imitation leather layer is connected to the outer edge of the fluff layer in a wrapping manner and is formed on the outer edge of the fluff layer by foaming through a PVC imitation leather process. The crease-free anti-skidding carpet is not prone to generating creases, good in anti-skidding performance, soft, comfortable and free of damaging floors.

Description

Technical Field

[0001] This utility model relates to the field of carpet technology, specifically to a non-slip carpet without creases. Background Technology

[0002] Carpets are floor coverings made from natural fibers such as cotton, linen, wool, silk, and grass, or chemically synthesized fibers, through hand or machine processes of weaving, tufting, or spinning. They not only have practical functions but also decorative qualities, and are widely used in various architectural spaces.

[0003] Traditional carpets are prone to creases during transportation or storage. For example, when mailing, in order to save space and make them easier to handle, carpets often need to be folded multiple times and put into smaller bags or boxes for shipping, which makes the product very easy to crease. This affects the appearance when used. In addition, if the carpet has a hard bottom, it is easy to wear down the floor or have poor anti-slip properties. Utility Model Content

[0004] (a) Technical problems to be solved

[0005] To address the shortcomings of existing technologies, this utility model provides a crease-free anti-slip carpet and its processing method.

[0006] (II) Technical Solution

[0007] To achieve the above objectives, this utility model provides the following technical solution: a crease-free anti-slip carpet, comprising a carpet body, wherein the carpet body consists of a carpet body located on top and a carpet base connected below it, wherein: an anti-slip layer is provided below the carpet base, the anti-slip layer consists of a pile layer connected below the carpet base by a flocking process, and an imitation leather layer covering and connected to the outer edge of the pile layer by a PVC imitation leather foaming process formed on the outer edge of the pile layer.

[0008] Preferably, the blanket base includes an intermediate layer, which is bonded between the upper blanket body and the lower anti-slip layer.

[0009] Preferably, the blanket is made of cotton, polyester or linen.

[0010] Preferably, the intermediate layer is a non-woven fabric layer or a polyester fabric layer.

[0011] Preferably, the anti-slip layer further includes two or more anti-slip auxiliary pieces connected below it. The upper part of the anti-slip auxiliary piece is a hooked and bristled surface with a plurality of elastic hooks, and the lower part of the anti-slip auxiliary piece is an adhesive layer. When the hooked and bristled surface comes into contact with the anti-slip layer formed by foaming the flocking powder, the elastic hooks catch the fibers on the anti-slip layer, thereby connecting the two together.

[0012] This utility model also provides a method for processing a wrinkle-free anti-slip carpet, which includes the following steps:

[0013] Step 1: Provide the rug body on top;

[0014] Step 2: Provide a blanket base with an anti-slip layer underneath. The anti-slip layer is formed by first connecting pile to the base through a flocking process, and then foaming the outer edge of the pile through a PVC imitation leather process to form an imitation leather layer with PVC anti-slip material.

[0015] Step 3: Bond the carpet body and carpet base together to form the carpet body.

[0016] Preferably, the PVC imitation leather process in step 2 includes the following steps:

[0017] Step a1: Select appropriate weight parts of PVC resin, plasticizer, foaming agent, stabilizer, filler and auxiliary agent and put them into a high-speed mixer for mixing to form a preliminary mixture;

[0018] Step a2: Put the mixture into a mixer for intensive mixing to obtain a well-plasticized material;

[0019] Step a3: Combine the plasticized material with a fluffy base fabric by calendering or coating;

[0020] Step a4: Place the calendered or coated base fabric and PVC composite material into an oven to dry, remove moisture, etc., and then preheat to a suitable foaming temperature.

[0021] Step a5: The preheated material is fed into the foaming box for foaming;

[0022] Step a6: Perform surface treatment on the foamed substrate;

[0023] Step a7: Cool and cut the surface-treated base layer to obtain a faux leather layer with PVC anti-slip material.

[0024] Preferred: The corresponding material composition and its weight percentage in step a1 are as follows:

[0025] PVC resin emulsion: 90-120 parts

[0026] Foaming agent AC: 2-5 parts

[0027] Plasticizer DOP: 60-70 parts

[0028] Liquid stabilizer Ba / Zn: 2-5 parts

[0029] Filler CaCO3: 15-25 parts.

[0030] Preferably, the weight parts of each raw material are as follows:

[0031] PVC resin emulsion: 100 parts

[0032] Foaming agent AC: 3 parts

[0033] Plasticizer DOP: 65 parts

[0034] Liquid stabilizer Ba / Zn: 3 parts

[0035] Filler CaCO3: 20 parts

[0036] The corresponding components and their respective weight percentages of the auxiliary agent are as follows:

[0037] Pigment: 4 parts

[0038] The activity regulator is selected from propoxy fatty acids: 0.5 parts.

[0039] Dispersant: 0.2 parts.

[0040] Preferably, in step a3, the base fabric is cleaned, dried, and primed with adhesive before pressing or coating.

[0041] Preferably, the surface of the base layer is embossed.

[0042] (III) Beneficial Effects

[0043] Compared with the prior art, this utility model provides a wrinkle-free anti-slip carpet and its processing method, which has the following beneficial effects:

[0044] This crease-free anti-slip carpet and its processing method employ a multi-layered substrate structure consisting of a carpet body and a carpet base. The materials in each layer work together to enhance the overall flexibility and strength of the carpet. Below the carpet base is an anti-slip layer, composed of a pile layer connected to the carpet base via a flocking process, and a PVC imitation leather layer foamed and attached to the outer edge of the pile layer, thus enhancing the overall flexibility and strength of the carpet. Furthermore, because the lower anti-slip layer is formed below the carpet base via a flocking process with the pile facing downwards, it is extremely softer than ordinary carpets. The PVC imitation leather layer foamed and attached to the outer edge of the pile further enhances the anti-slip properties, making the entire anti-slip layer not only significantly softer than ordinary carpets but also possessing extremely strong anti-slip performance.

[0045] This utility model is soft, comfortable, and highly elastic, making it extremely resistant to creases. During transportation or storage, when subjected to compression or bending forces, the anti-slip layer acts like a spring, absorbing some energy and reducing crease formation. The soft lower surface won't damage the floor while providing excellent anti-slip performance, effectively smoothing out creases. Furthermore, the design of the anti-slip auxiliary pieces allows for easy positioning of the carpet in desired locations even with creases, using two or more pieces to flatten the creases at the top – a very user-friendly design. Compared to traditional carpets with a harder bottom, the leather-like material provides better friction when in contact with the floor. Its soft texture protects the floor and further enhances comfort for users. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of the main structure of this utility model;

[0047] Figure 2 This is an exploded view of the structure of this utility model.

[0048] In the diagram: 1. Blanket body; 2. Middle layer; 3. Anti-slip layer; 4. Anti-slip auxiliary sheet. Detailed Implementation

[0049] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0050] Please see Figures 1-2 A crease-free anti-slip carpet includes a carpet body comprising a carpet layer 1 located at the top and a carpet base connected below it. The carpet base has an anti-slip layer 3 below it. This anti-slip layer consists of a pile layer connected to the carpet base via a flocking process, and an imitation leather layer formed on the outer edge of the pile layer using a PVC imitation leather foaming process. The imitation leather layer covers the outer edge of the flocked pile, and its material properties determine that its surface is not only soft but also has a certain degree of roughness. When in contact with the ground, this roughness increases the friction between the carpet and the ground, effectively preventing the carpet from sliding on the ground and thus improving its anti-slip performance. At the same time, the imitation leather layer is relatively soft and will not cause wear and tear on the ground like a traditional, harder backing carpet. For example, when a person walks on the carpet, the imitation leather layer can cushion the impact of footsteps on the ground, reducing friction and scratches, and protecting the ground.

[0051] Preferably, the carpet base includes an intermediate layer 2, which is bonded between the upper carpet body 1 and the lower anti-slip layer 3. It serves as a buffer and support. It has a certain thickness and elasticity; when the stress transmitted from the carpet body exceeds its bearing capacity, the non-woven fabric can further disperse the stress, acting like a sponge to absorb and buffer external forces, preventing stress concentration at a single point and thus reducing the possibility of crease formation. During flocking, the lower anti-slip layer can be flocked directly onto the intermediate layer 2, or a separate base sheet can be used for flocking; this is not limited here.

[0052] Preferably, the blanket body is made of cotton, polyester or linen, and the material is not limited. Various existing blanket fabrics can be selected.

[0053] Preferably, the intermediate layer is a non-woven fabric layer or a polyester fabric layer, but it is not limited to either.

[0054] Preferably, the anti-slip layer further includes two or more anti-slip auxiliary pieces 4 connected below it. The upper part of the anti-slip auxiliary piece is a hooked and bristled surface with a plurality of elastic hooks, and the lower part of the anti-slip auxiliary piece is an adhesive layer. When the hooked and bristled surface comes into contact with the anti-slip layer formed by foaming the flocking powder, the elastic hooks catch the fibers on the anti-slip layer, thereby connecting the two together.

[0055] This utility model also provides a method for processing a wrinkle-free anti-slip carpet, which includes the following steps:

[0056] Step 1: Provide the rug body on top;

[0057] Step 2: Provide a blanket base with an anti-slip layer underneath. The anti-slip layer is formed by first connecting pile to the base through a flocking process, and then foaming the outer edge of the pile through a PVC imitation leather process to form an imitation leather layer with PVC anti-slip material.

[0058] Step 3: Bond the carpet body and carpet base together to form the carpet body.

[0059] Preferably, the PVC imitation leather process in step 2 includes the following steps:

[0060] Step a1: Select appropriate weight parts of PVC resin, plasticizer, foaming agent, stabilizer, filler and auxiliary agent and put them into a high-speed mixer for mixing to form a preliminary mixture;

[0061] Step a2: Put the mixture into a mixer for intensive mixing to obtain a well-plasticized material;

[0062] Step a3: Combine the plasticized material with a fluffy base fabric by calendering or coating;

[0063] Step a4: Place the calendered or coated base fabric and PVC composite material into an oven to dry, remove moisture, etc., and then preheat to a suitable foaming temperature.

[0064] Step a5: The preheated material is fed into the foaming box for foaming;

[0065] Step a6: Perform surface treatment on the foamed substrate;

[0066] Step a7: Cool and cut the surface-treated base layer to obtain a faux leather layer with PVC anti-slip material.

[0067] Preferred: The corresponding material composition and its weight percentage in step a1 are as follows:

[0068] PVC resin emulsion: 90-120 parts

[0069] Foaming agent AC: 2-5 parts

[0070] Plasticizer DOP: 60-70 parts

[0071] Liquid stabilizer Ba / Zn: 2-5 parts

[0072] Filler CaCO3: 15-25 parts.

[0073] Preferably, the weight parts of each raw material are as follows:

[0074] PVC resin emulsion: 100 parts

[0075] Foaming agent AC: 3 parts

[0076] Plasticizer DOP: 65 parts

[0077] Liquid stabilizer Ba / Zn: 3 parts

[0078] Filler CaCO3: 20 parts

[0079] The auxiliary agent can be made of conventional materials and proportions found in the prior art, with the following materials and weight proportions preferred:

[0080] Pigment: 4 parts

[0081] The activity regulator is selected from propoxy fatty acids: 0.5 parts.

[0082] Dispersant: 0.2 parts.

[0083] Of course, the weight parts of each raw material can also be as follows:

[0084] PVC resin emulsion: 110 parts

[0085] Foaming agent AC: 4 parts

[0086] Plasticizer DOP: 62 parts

[0087] Liquid stabilizer Ba / Zn: 4 parts

[0088] Filler CaCO3: 16 parts

[0089] The corresponding components and their respective weight percentages of the auxiliary agent are as follows:

[0090] Pigment: 4 parts

[0091] The activity regulator is selected from propoxy fatty acids: 0.5 parts.

[0092] Dispersant: 0.2 parts.

[0093] Preferably, in step a3, the base fabric is cleaned, dried, and primed with adhesive before pressing or coating.

[0094] Preferably, the surface of the base layer is embossed.

[0095] Auxiliary agents may include pigments, lubricants, colorants, antioxidants, and UV protectants used for dyeing.

[0096] Step a2: Put the mixture into an internal mixer for internal mixing. Under high temperature and strong shear, the PVC resin is further plasticized, the components are more evenly dispersed, the uniformity and plasticity of the material are improved, and a well plasticized material is obtained.

[0097] Step a3: The plasticized material is bonded to the base fabric by calendering or coating. The base fabric is first pretreated, including cleaning, drying, and applying a base coat of adhesive, to improve the adhesion between the base fabric and the PVC slurry.

[0098] Step a4: The calendered or coated base fabric and PVC composite material are placed in an oven to dry, removing moisture, etc., and then preheated to a suitable foaming temperature. Before being placed in the oven for drying, the material can undergo coagulation bath treatment (the base fabric coated with PVC slurry is placed in a coagulation bath, which is usually a solution containing solvent and coagulant, such as dimethylformamide (DMF) aqueous solution. The plasticizers and other solvents in the PVC slurry exchange with the solvent in the coagulation bath, causing the PVC resin to coagulate and form a wet leather with a certain strength and shape) and water treatment (after the wet leather is removed from the coagulation bath, it is washed with water to remove residual coagulant, solvent and other impurities on the surface, improving the quality and performance of the product), and then dried.

[0099] Step a5: After the preheated material is fed into the foaming box for foaming, the temperature, time and ventilation parameters of the oven are controlled to obtain a uniform and fine cell structure and a good foaming effect.

[0100] Step a6: Perform surface treatment on the foamed base layer 4, such as embossing, printing and coating, to increase the aesthetics and simulation of the leather;

[0101] Step a7: Cool, cut and roll up the surface-treated base layer 4.

[0102] When using a rolled-up carpet, double-sided adhesive anti-slip pads can be attached to the four corners or both ends of the carpet to quickly flatten it and eliminate creases. Depending on your needs, you can choose to use the anti-slip pads with or without them. They have the soft properties of imitation leather and can ensure the overall flatness of the carpet surface even when the anti-slip pads are attached. The anti-slip pads themselves are also very thin.

[0103] The PVC imitation leather process in this utility model is described in detail below:

[0104] 1) First, prepare the raw materials, including the following:

[0105] Resin: Suspension PVC resin is selected to provide the basic properties of imitation leather;

[0106] Plasticizers, such as dioctyl phthalate (DOP), increase flexibility and plasticity;

[0107] Foaming agent: Organic foaming agents such as azodicarbonamide (AC) decompose when heated to produce gas and form bubbles;

[0108] Stabilizers: such as calcium-zinc stabilizers, improve the thermal stability of PVC during processing;

[0109] Fillers, such as calcium carbonate, reduce costs and improve dimensional stability;

[0110] Other additives include lubricants, colorants, antioxidants, and UV stabilizers.

[0111] 2) Add the measured PVC resin, plasticizer, foaming agent, stabilizer, filler and other additives into a high-speed mixer and stir evenly at a certain temperature and time to form a preliminary mixture;

[0112] The preliminary mixture is fed into an internal mixer for internal mixing, where it is further plasticized under high temperature and strong shear, so that the components are more evenly dispersed.

[0113] 3) Calendering or coating

[0114] Calendering: The mixed and plasticized material is fed into a calendering machine, and through the action of multiple calendering rollers, the material is calendered into a film of the required thickness, and at the same time, it is laminated with a base fabric with a nap.

[0115] Coating: A coating machine is used to evenly coat the PVC slurry onto the velvety base fabric, controlling the coating thickness and uniformity;

[0116] 4) Foaming treatment

[0117] Drying and preheating: The calendered or coated base fabric with fluff and PVC composite material are sent into an oven to dry and remove moisture, and then preheated to a suitable foaming temperature.

[0118] Foaming molding: In a foaming oven, when the material reaches a certain temperature, the foaming agent decomposes to produce gas, forming a cell structure in the PVC resin. By controlling the temperature, time, and ventilation parameters of the oven, a uniform and delicate cell structure and a good foaming effect can be obtained.

[0119] 5) Surface treatment

[0120] Embossing: The foamed PVC imitation leather is embossed using an embossing roller with patterns to create various leather textures on its surface.

[0121] Finishing: Applying a layer of special finishing agent to the PVC imitation leather surface, such as a finishing agent that improves wear resistance, scratch resistance, gloss, etc.

[0122] 6) Post-processing

[0123] Cooling and shaping: The surface-treated PVC imitation leather is cooled using equipment such as cooling rollers to stabilize its shape and performance;

[0124] Cutting and rolling: Cut the PVC imitation leather according to product specifications and customer requirements, removing any uneven edges.

[0125] The blanket body and the blanket base are preferably bonded together with thermoplastic rubber, and part of the thermoplastic rubber extends out of the blanket base to contact the ground, further improving the anti-slip performance.

[0126] In this document, the term "embodiment" means that a specific feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The term "embodiment" appearing in various places throughout the specification does not necessarily refer to the same embodiment, nor does it specifically limit its independence or connection with other embodiments. In principle, in this application, as long as there are no technical contradictions or conflicts, the technical features mentioned in each embodiment can be combined in any way to form corresponding implementable technical solutions.

[0127] Unless otherwise defined, the technical terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the use of related terms herein is merely for the purpose of describing particular embodiments and is not intended to limit this application.

[0128] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention.

Claims

1. A creaseless non-slip carpet comprising a carpet body consisting of a carpet top located above and a carpet base connected below, characterized in that: The anti-skid layer is composed of a layer of fluff connected under the carpet base by a flocking process and a layer of imitation leather formed on the outer edge of the fluff layer by a PVC imitation leather process.

2. A creaseless, non-slip carpet as claimed in claim 1, wherein: The carpet base comprises an intermediate layer bonded between the upper carpet and the lower anti-skid layer.

3. A creaseless, non-slip carpet as defined in claim 2, wherein: The carpet is made of cotton, polyester or hemp.

4. The creaseless, slip-resistant carpet of claim 3, wherein: The intermediate layer is made of a non-woven fabric layer or a polyester layer.

5. A creaseless, non-slip carpet according to any one of claims 1 to 4, wherein: The anti-skid layer further comprises two or more anti-skid auxiliary sheets connected thereunder, the upper surface of the anti-skid auxiliary sheets is provided with a plurality of elastic hooks, and the lower surface of the anti-skid auxiliary sheets is provided with an adhesive layer. When the surface with hooks contacts the anti-skid layer formed by foaming the flocking powder, the elastic hooks hook the fibers on the anti-skid layer, so that the two are connected together.

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