carpet

Abstract

A carpet, relating to the field of decorative technology, is disclosed. The carpet includes a support layer, a first outer layer, and an insulating connecting layer. The first outer layer is disposed on a first side of the support layer. The insulating connecting layer is at least partially disposed between the support layer and the first outer layer to prevent substances from the support layer from diffusing into the first outer layer. The first outer layer, the insulating connecting layer, and the support layer are integrally connected via a composite process, and the insulating connecting layer does not contain volatile organic compounds (VOCs). This application can reduce the introduction of VOCs and decrease the concentration of VOCs in the space while ensuring the connection strength of each functional layer, thereby improving air quality, enhancing user comfort, and reducing the impact on user health.

Description

Technical Field

[0001] This application relates to the field of decorative arts, and more particularly to a carpet. Background Technology

[0002] With the rapid development of my country's automobile industry, passenger cars have become increasingly common, and various small passenger vehicles have entered ordinary households. People are also paying more attention to the comfort of their cars. Due to the small interior space and high mobility of vehicles, external conditions such as temperature are difficult to control. For example, prolonged exposure to sunlight can cause the temperature to rise, making it easier for harmful substances in interior parts and decorative materials to volatilize, resulting in an unpleasant odor. Another type of harmful volatile organic compound (VOC) may not immediately cause discomfort, but when the concentration of VOCs in a given space reaches a certain level, inhaling them can cause headaches and nausea in a short period. Inhaling large amounts of VOCs can damage the liver, kidneys, brain, and nervous system. The effects of VOCs on the health of children and pregnant women are particularly significant. Therefore, car manufacturers have extremely strict controls on odor and VOCs.

[0003] Currently, the various functional layers of trunk carpets are primarily connected using a spray adhesive process. While adhesives offer high bonding strength, they often contain volatile organic compounds (VOCs), which can be released into the vehicle's interior during use, leading to decreased air quality, potentially causing noticeable odors, affecting user comfort, and even impacting user health. Furthermore, the support layer of the trunk carpet may also contain VOCs, which, if diffused into the vehicle's interior, will also affect user comfort and health. Utility Model Content

[0004] The purpose of this application is to provide a carpet that, while ensuring the connection strength of each functional layer, reduces the introduction of volatile organic compounds and the concentration of volatile organic compounds in the space, thereby improving air quality, enhancing user comfort, and reducing the impact on user health.

[0005] To address the aforementioned technical problems, this application provides the following technical solutions:

[0006] The first aspect of this application provides a carpet, comprising:

[0007] Support layer;

[0008] The first outer layer is disposed on the first side of the support layer;

[0009] An isolation bonding layer is at least partially disposed between the support layer and the first outer layer to prevent the material of the support layer from diffusing into the first outer layer.

[0010] The first outer layer, the isolation and connection layer, and the support layer are integrated through a composite process, and the isolation and connection layer does not contain volatile organic compounds.

[0011] In some modified embodiments of the first aspect of this application, the isolation connection layer includes:

[0012] An isolation layer is integrally connected to the first outer layer through a composite process to prevent the material of the support layer from diffusing into the first outer layer.

[0013] The connecting layer is integrally connected to the isolation layer and the support layer through a composite process.

[0014] In some modified embodiments of the first aspect of this application, both the isolation layer and the connecting layer are film-like structures. The isolation layer is connected to the first outer layer by a coating process, and the connecting layer is connected to the support layer by a hot-pressing process. The melting point of the isolation layer is greater than that of the connecting layer.

[0015] In some modified embodiments of the first aspect of this application, the support layer includes:

[0016] The functional core layer has multiple first gaps;

[0017] The reinforcement layer is disposed on both sides of the functional core layer, and the reinforcement layer has multiple second gaps.

[0018] The filling structure has a first part filling the first gap and the second gap, and a second part being disposed on the side of the reinforcing layer away from the functional core layer. The connecting layer is connected to the filling structure by a hot pressing process, and the isolation layer can prevent the filling structure from diffusing into the first appearance layer.

[0019] In some modified embodiments of the first aspect of this application, the connecting layer is a polyethylene film and the separating layer is a polyamide film.

[0020] In some modified embodiments of the first aspect of this application, the isolation bonding layer is at least partially disposed on the second side of the support layer to prevent the material of the support layer from diffusing to the second side thereon.

[0021] Some modified embodiments of the first aspect of this application also include:

[0022] The second appearance layer is disposed on the second side of the support layer and is integrally connected with the isolation connection layer disposed on the second side through a composite process.

[0023] In some modified embodiments of the first aspect of this application, the isolation bonding layer is wrapped around the outside of the support layer to prevent the material of the support layer from spreading outward.

[0024] In some modified embodiments of this application, it also includes:

[0025] The second outer layer is connected to the second side of the support layer by a connecting structure, which is different from that of the isolation connecting layer.

[0026] In some modified embodiments of this application, the first outer layer is non-woven fabric, and the second outer layer has fluff on the side away from the connecting structure.

[0027] Compared to existing technologies, the carpet provided in this application utilizes an isolation bonding layer that does not contain volatile organic compounds to integrally connect the first outer layer and the support layer through a composite process. This ensures the connection strength between the first outer layer and the support layer without introducing new volatile organic compounds. Furthermore, the isolation bonding layer prevents the substances in the support layer from diffusing into the first outer layer, thereby relatively reducing the concentration of volatile organic compounds in the space, thus improving air quality, enhancing user comfort, and reducing the impact on user health. Attached Figure Description

[0028] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily understood by reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of this application are illustrated by way of example and not limitation, with the same or corresponding reference numerals denoteing the same or corresponding parts, wherein:

[0029] Figure 1 A schematic diagram of the structure of a first embodiment of a carpet is shown;

[0030] Figure 2 A schematic diagram of a second embodiment of a carpet is shown.

[0031] Figure 3 A schematic diagram of a third embodiment of a carpet is shown.

[0032] Explanation of icon numbers:

[0033] 1. Support layer; 11. Functional core layer; 12. Reinforcing layer; 13. Filling structure; 14. Second gap; 15. First gap; 2. Isolation and connection layer; 21. Isolation layer; 22. Connection layer; 3. First appearance layer; 4. Second appearance layer; 5. Connection structure; 6. Hot pressing mold; 61. Upper mold; 62. Lower mold. Detailed Implementation

[0034] Exemplary embodiments of this application will now be described in more detail with reference to the accompanying drawings. While exemplary embodiments of this application are shown in the drawings, it should be understood that this application may be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided to enable a more thorough understanding of this application and to fully convey the scope of this application to those skilled in the art.

[0035] It should be noted that, unless otherwise stated, the technical or scientific terms used in this application shall have the ordinary meaning as understood by one of ordinary skill in the art to which this disclosure pertains.

[0036] With the rapid development of my country's automobile industry, passenger cars have become increasingly common, and various small passenger vehicles have entered ordinary households. People are also paying more attention to the comfort of their cars. Due to the small interior space and high mobility of vehicles, external conditions such as temperature are difficult to control. For example, prolonged exposure to sunlight can cause the temperature to rise, making it easier for harmful substances in interior parts and decorative materials to volatilize, resulting in an unpleasant odor. Another type of harmful volatile organic compound (VOC) may not immediately cause discomfort, but when the concentration of VOCs in a given space reaches a certain level, inhaling them can cause headaches and nausea in a short period. Inhaling large amounts of VOCs can damage the liver, kidneys, brain, and nervous system. The effects of VOCs on the health of children and pregnant women are particularly significant. Therefore, car manufacturers have extremely strict controls on odor and VOCs.

[0037] However, the various functional layers of the trunk carpet are primarily connected using an adhesive spraying process. While the adhesive has high bonding strength, it often contains volatile organic compounds (VOCs), which can be released into the vehicle's interior during use, leading to a decline in air quality and potentially causing a noticeable odor, affecting passenger comfort and health. Furthermore, the support layer of the trunk carpet may also contain VOCs, which, if diffused into the vehicle's interior, will also impact the user's comfort and health.

[0038] To address the aforementioned technical problems, this application provides a carpet that, while ensuring the connection strength of each functional layer, reduces the introduction of volatile organic compounds (VOCs) and decreases the concentration of VOCs in the space, thereby improving air quality, enhancing user comfort, and reducing the impact on user health.

[0039] Example 1

[0040] like Figure 1As shown, a carpet includes a support layer 1, a first outer layer 3, and an isolation connecting layer 2; the first outer layer 3 is disposed on a first side of the support layer 1; the isolation connecting layer 2 is at least partially disposed between the support layer 1 and the first outer layer 3 to prevent the material of the support layer 1 from diffusing to the first outer layer 3; wherein the first outer layer 3, the isolation connecting layer 2, and the support layer 1 are integrally connected by a composite process, and the isolation connecting layer 2 does not contain volatile organic compounds.

[0041] Support layer 1 refers to one or more layers located on one side of the first outer layer 3. Its main function is to provide structural support for the carpet, increase stability, and improve overall performance. Support layer 1 can be made of various materials and may contain single-layer or multi-layer composite structures. Support layer 1 can be a sandwich composite structure, consisting of upper and lower panels and a lightweight core material in between. The panels can be made of high-strength materials such as fiberglass or carbon fiber; the core material can be paper honeycomb, foam plastic, or other lightweight materials. This significantly reduces weight while ensuring sufficient rigidity and strength, making it particularly suitable for weight-sensitive applications such as automotive interiors. For example, a structure of "fiberglass + paper honeycomb core + fiberglass" combines the advantages of high-strength panels and lightweight core materials. Support layer 1 can also include a cushioning layer, placed under the backing layer, designed to increase the carpet's comfort and sound insulation. Materials for support layer 1 include foam plastic (such as polyurethane foam), rubber pads, or other elastic materials, absorbing impact, improving foot comfort, and helping to reduce noise transmission. Support layer 1 can also be a moisture-proof layer, a functional layer specifically designed to prevent moisture from penetrating into the carpet's interior, often using waterproof membranes or coated materials. It can protect carpets from ground moisture, making it especially suitable for carpet installation in damp environments such as basements and near bathrooms.

[0042] The first outermost layer 3 refers to the outermost layer of the carpet, which is in direct contact with the user or exposed to the external environment. This layer plays a crucial role not only in the product's visual appeal but also directly affects its feel, durability, and functionality. The first outermost layer 3 can be a nonwoven fabric. For example, it can be polyester (PET) nonwoven fabric, which has good strength, abrasion resistance, and chemical resistance, and is widely used in automotive interiors, furniture protection, and other fields. It can also be polypropylene (PP) nonwoven fabric, which is lightweight, soft, and low-cost, with good waterproof performance, and can be used in disposable products such as packaging materials and protective clothing, as well as in the first outermost layer 3 of some carpets. Alternatively, it can be nylon (PA) nonwoven fabric, which has high strength, high abrasion resistance, and excellent tear resistance, suitable for applications requiring high abrasion resistance, such as high-end automotive interiors or industrial textiles. The first outer layer 3 can also be a woven fabric, woven from warp and weft threads, with a tight structure, high strength, good abrasion resistance, durability, and easy cleaning. It is suitable for applications requiring high strength and aesthetics, such as high-end automotive interiors and home décor. The first outer layer 3 can also be a knitted fabric, made through a knitting process, possessing good elasticity and softness, excellent comfort, a pleasant feel, and good breathability. It is suitable for products requiring a soft and comfortable experience, such as stroller cushions and lounge chair cushions. The first outer layer 3 can also be leather or artificial leather. Natural leather has a high-end feel, while artificial leather is more economical and easier to maintain, durable, easy to clean, and has good water resistance, making it widely used in applications requiring high abrasion resistance and aesthetics. The first outer layer 3 can also combine two or more different types of materials to obtain new materials with superior overall performance.

[0043] The insulating bonding layer 2 is a material located between the first outer layer 3 and the support layer 1. It does not contain volatile organic compounds (VOCs) and its main function is to prevent substances in the support layer 1 (such as VOCs, filler structure 13, etc.) from diffusing to the first outer layer 3, thereby affecting the performance of the outer layer or causing odor problems. In addition, it enhances the bonding strength between the two layers and provides additional functional properties such as waterproofing, moisture resistance, or sound insulation. The insulating bonding layer 2 can be a metallized film, such as a very thin layer of metal (such as aluminum) plated on the surface of a plastic film, providing excellent barrier properties with excellent gas and water vapor barrier capabilities while maintaining lightweight characteristics, suitable for applications with high barrier requirements. The insulating bonding layer 2 can also be a composite film, composed of multiple layers of different materials. Each layer leverages its own advantages to achieve a good barrier effect. Appropriate material combinations can be selected according to specific needs, offering high flexibility, such as PA (polyamide) and PE (polyethylene) films. Volatile organic compounds (VOCs) are organic compounds that are easily volatilized at room temperature and pressure and exist in the air in gaseous form. These compounds have high vapor pressure and can evaporate rapidly into the atmosphere at room temperature or slightly higher temperatures.

[0044] Composite processes refer to the process of combining two or more different types of materials or structures in a certain way to form a single integrated structure. This process aims to utilize the advantages of each component material and overcome the limitations of a single material or structure, thereby obtaining new materials or products with superior overall performance. Composite processes can be hot-pressing or lamination processes, which involve stacking multiple layers of different materials together and applying heat and pressure to tightly bond them; this is suitable for large-scale production and can effectively improve the mechanical and barrier properties of products. For example, the first outer layer 3, the insulating connecting layer 2, and the support layer 1 can be integrally formed using a hot-pressing or lamination process. In some specific embodiments, the insulating connecting layer 2 may include two connecting layers 22 and an insulating layer 21, with the insulating layer 21 disposed between the two connecting layers 22. The two connecting layers 22 are used to connect to the first outer layer 3 and the support layer 1, respectively. Composite processes can also be lamination processes; for example, the insulating connecting layer 2 and the first outer layer 3 can be first connected using a lamination process, and then connected to the support layer 1 using hot-pressing or lamination processes.

[0045] Compared to existing technologies, the carpet provided in this application utilizes an isolation and connection layer 2 that does not contain volatile organic compounds to integrally connect the first outer layer 3 and the support layer 1 through a composite process. This ensures the connection strength between the first outer layer 3 and the support layer 1 without introducing new volatile organic compounds. Furthermore, the isolation and connection layer 2 prevents the diffusion of substances in the support layer 1 (such as volatile organic compounds that may be contained in polyurethane and rubber) to the first outer layer 3, thereby relatively reducing the concentration of volatile organic compounds in the space, improving air quality, enhancing user comfort, and reducing the impact on user health.

[0046] like Figure 1 As shown, in some modified embodiments of this application, the isolation connection layer 2 includes an isolation layer 21 and a connection layer 22. The isolation layer 21 is integrally connected to the first appearance layer 3 through a composite process to prevent the material of the support layer 1 from diffusing to the first appearance layer 3. The connection layer 22 is integrally connected to the isolation layer 21 and the support layer 1 through a composite process.

[0047] The isolation layer 21 is located between the first outer layer 3 and the support layer 1. Its main function is to prevent substances in the support layer 1 (such as plasticizers, volatile organic compounds (VOCs), etc.) from diffusing into the first outer layer 3, thereby affecting its performance or causing odor problems. Furthermore, the isolation layer 21 does not contain VOCs, thus avoiding the introduction of new VOCs and increasing the concentration of VOCs in the space. For example, the isolation layer 21 can be a metal plating, providing excellent gas and water vapor barrier properties, containing no VOCs, and neither the metal layer nor the substrate itself releases VOCs. The isolation layer 21 can also be an inorganic coating, such as silicon oxide (SiO2), aluminum oxide (Al2O3), or other inorganic nano-coatings. These provide excellent barrier properties, especially against oxygen and water vapor, are highly stable, and do not release any volatile organic compounds. They can be coated onto the substrate using physical vapor deposition (PVD) or chemical vapor deposition (CVD) techniques. The isolation layer 21 can also be a membrane structure such as PA (polyamide) that does not contain volatile organic compounds and has excellent gas and water vapor barrier properties, and can be connected to the first appearance layer 3 through a coating process.

[0048] The connecting layer 22 is located between the insulating layer 21 and the support layer 1, and its main function is to ensure a strong bond between the two layers. The connecting layer 22 also does not contain volatile organic compounds (VOCs), thus avoiding the introduction of new VOCs and increasing the concentration of VOCs in the space. The connecting layer 22 can be a membrane structure, connected to the insulating layer 21 and the support layer 1 via a hot-pressing process. For example, the connecting layer 22 can be a thermoplastic film such as polyethylene (PE).

[0049] like Figure 1As shown, in some modified embodiments of this application, both the isolation layer 21 and the connecting layer 22 are film structures. The isolation layer 21 is connected to the first appearance layer 3 by a coating process, and the connecting layer 22 is connected to the support layer 1 by a hot pressing process. The melting point of the isolation layer 21 is greater than that of the connecting layer 22.

[0050] The fact that both the isolation layer 21 and the connecting layer 22 are membrane structures indicates that they are continuous, thin-layered structures, facilitating processing, lamination, and functional realization. The coating process involves melting thermoplastic resin and uniformly coating it onto the substrate surface through a die, then cooling to form a composite material. This process offers strong continuity, is suitable for large-scale production, achieves good sealing and adhesion, and allows for controllable thickness to meet various functional requirements. The isolation layer 21, as a functional membrane, blocks the migration of harmful substances such as VOCs and plasticizers from the support layer 1 to the first appearance layer 3. The coating process ensures a tight bond with the first appearance layer 3, guaranteeing the stability and functionality of the composite structure and thus ensuring its excellent barrier effect.

[0051] Hot pressing refers to the process of bonding or curing material layers under specific temperature and pressure to form an integrated structure. This improves interlayer bonding strength and is suitable for composite materials with porous or complex structures, achieving a combination of lightweight and high strength. The connecting layer 22, as an intermediate adhesive layer, is responsible for firmly bonding the isolation layer 21 to the support layer 1. The hot pressing process achieves an integrated connection, enhancing the stability and durability of the overall structure.

[0052] The melting point of the isolation layer 21 is higher than that of the connecting layer 22. During the hot pressing process, the connecting layer 22 softens or melts first, acting as an adhesive, while the isolation layer 21 maintains its shape, preventing structural damage or functional failure due to high temperatures. This thermal matching design facilitates the smooth progress of the composite process while ensuring the stability of each layer's function. For example, the isolation layer 21 can be made of materials with higher melting points, such as VOC-free PA, solvent-free PET (polyethylene terephthalate), and PVC (polyvinyl chloride), while the connecting layer 22 can be made of materials with lower melting points, such as VOC-free PE and plasticizer-free EVA (ethylene-vinyl acetate copolymer).

[0053] like Figure 1As shown, in some modified embodiments of this application, the support layer 1 includes a functional core layer 11, a reinforcing layer 12, and a filling structure 13. The functional core layer 11 is provided with a plurality of first gaps 15. The reinforcing layer 12 is provided on both sides of the functional core layer 11 and is provided with a plurality of second gaps 14. The first part of the filling structure 13 fills the first gaps 15 and the second gaps 14, and the second part of the filling structure 13 is provided on the side of the reinforcing layer 12 away from the functional core layer 11. The connecting layer 22 is connected to the filling structure 13 by a hot pressing process, and the isolation layer 21 can prevent the filling structure 13 from diffusing to the first outer layer 3.

[0054] The functional core layer 11 is the core component of the support layer 1, and has multiple first gaps 15 (such as honeycomb, lattice, or porous structures) to achieve functions such as lightweighting, shock absorption, and heat insulation. The reinforcing layer 12 is disposed on the upper and lower sides of the functional core layer 11, and has multiple second gaps 14 to enhance structural strength and allow the filling material to permeate. For example, the reinforcing layer 12 can be a fiber fabric (such as fiberglass cloth or carbon fiber cloth), a metal mesh (such as stainless steel mesh or aluminum foil mesh), a non-woven fabric, or a knitted fabric (to enhance flexibility). The filling structure 13 is divided into two parts: the first part fills the gaps between the functional core layer 11 and the reinforcing layer 12; the second part covers the outside of the reinforcing layer 12, forming an integral structure. The filling structure 13 can be a thermoplastic elastomer (such as TPE, TPU), a low-density foam (such as EVA foam, XPE foam), or a functional filler material (such as flame retardant filler, thermally conductive filler, sound-absorbing material).

[0055] The gap structure of the functional core layer 11 enables lightweighting. The synergistic effect of the reinforcing layer 12 and the filling structure 13 enhances the overall structural strength. The filling structure 13 can provide functions such as buffering, sound insulation, flame retardancy, and thermal conductivity. The first part of the filling is used for structural reinforcement, and the second part is used for surface smoothing or functional realization. The isolation layer 21 can effectively prevent the migration of harmful substances during hot pressing and after product molding, avoiding damage to the structure of the first appearance layer 3 and improving the product's environmental performance. It is suitable for scenarios with high air quality requirements, such as automotive interiors, medical equipment, and household goods. The hot pressing process enables the integrated molding of multi-layer structures, improving production efficiency and reducing subsequent processing steps.

[0056] In some modified embodiments of this application, the connecting layer 22 is a polyethylene film, and the separating layer 21 is a polyamide film. Polyethylene (PE) is a common thermoplastic with good flexibility, chemical resistance, and processing performance. As the connecting layer 22, the polyethylene film softens or melts during the hot-pressing process, achieving adhesion to other layers (such as the filling structure 13 or the support layer 1); it provides a certain degree of cushioning and sealing, is low in cost, easy to process, and suitable for large-scale production. Furthermore, the polyethylene film itself does not contain harmful substances, and the production process does not require the use of organic solvents and does not contain volatile organic compounds. Polyamide (PA) is a high-performance engineering plastic with excellent heat resistance, abrasion resistance, and barrier properties. As the separating layer 21, it can prevent substances in the support layer 1 or the filling structure 13 (such as plasticizers, VOCs, low-molecular-weight residues, etc.) from migrating to the first outer layer 3, providing good mechanical strength and thermal stability, and acting as a "barrier layer" in the composite structure. PE and PA films with plasticizer-free and solvent-free processes can be selected to ensure that the entire composite structure has no VOC release, meeting environmental protection standards, and without introducing new volatile organic compounds while ensuring the connection strength between the first appearance layer 3 and the support layer 1.

[0057] like Figure 1 As shown, in some modified embodiments of this application, the isolation connecting layer 2 is at least partially disposed on the second side of the support layer 1 to prevent the material of the support layer 1 from diffusing to the second side. The second side of the support layer 1 is the side opposite to the first side of the support layer 1, that is, the isolation connecting layer 2 is disposed on both sides of the support layer 1, thereby preventing the support layer 1 from diffusing to both sides, reducing its diffusion into the opposite space, thereby further reducing the concentration of volatile organic compounds in the space, thereby improving air quality, enhancing user comfort, and reducing the impact on user health.

[0058] like Figure 1 As shown, in some modified embodiments of this application, a second appearance layer 4 is also included. The second appearance layer 4 is disposed on the second side of the support layer 1 and is integrally connected with the isolation connection layer 2 disposed on the second side through a composite process.

[0059] The second outer layer 4 refers to the material located on the outermost side of the structural component (i.e., the second side of the support layer 1), and its main functions are to provide aesthetics, protection, and functionality. It provides visual appeal and can be monochrome or patterned. The second outer layer 4 protects the internal structure from external environmental influences such as ultraviolet radiation, moisture, and mechanical damage. The structure of the second outer layer 4 can be the same as or different from that of the first outer layer 3, depending on the requirements. For example, the second outer layer 4 can be wear-resistant, with high surface hardness and strong wear resistance, suitable for frequent contact applications. The second outer layer 4 can also be waterproof, possessing good waterproof performance and preventing water vapor penetration, suitable for roof waterproofing, basement damp-proofing, etc. The second outer layer 4 can also be antibacterial, containing antibacterial ingredients to inhibit bacterial growth and maintain hygiene. The second outer layer 4 can also be fire-retardant, with good flame-retardant properties, improving safety. The second outer layer 4 can also be anti-slip, with a textured surface design to increase friction and prevent slipping.

[0060] like Figure 2 As shown, in some modified embodiments of this application, for example...

[0061] like Figure 3 As shown, in some modified embodiments of this application, the isolation connecting layer 2 is wrapped around the outside of the support layer 1 to prevent the material of the support layer 1 from diffusing outward. The isolation connecting layer 2 wrapping around the outside of the support layer 1 means that this layer completely or partially covers the periphery of the support layer 1, forming a "covering" structure that provides sealing and protection, preventing the material of the support layer 1 from diffusing outward and inhibiting the migration of substances that may be present in the support layer 1 (such as volatile organic compounds (VOCs), plasticizers, low molecular weight residues, etc.) to the outside, thereby improving environmental friendliness, safety, and product stability. It also provides physical protection for the support layer 1, preventing moisture, oxidation, mechanical damage, etc.

[0062] like Figure 2 As shown, in some modified embodiments of this application, the second outer layer is connected to the second side of the support layer via a connecting structure, which is different from the isolation connecting layer. For example, the second outer layer 4 can also be directly connected to the support layer 1 via a VOC-free connecting structure 5. For example, the connecting structure 5 can be a two-component solvent-free adhesive, which is chemically cured after mixing two components (e.g., a resin and a curing agent). It does not contain volatile organic solvents, provides high-strength adhesive performance, is suitable for various substrates, does not release VOCs, and has good durability because no organic solvents are added to the formulation, making it suitable for applications requiring long-term stability.

[0063] In some modified embodiments of this application, the first outer layer is a non-woven fabric, and the second outer layer has a pile on the side away from the connecting structure. Since the second outer layer 4 has a piled appearance structure, it is not suitable for thermoforming with other structures, as high temperature will affect the appearance of the pile. A two-component solvent-free adhesive connecting structure 5 can be used to connect it to the first outer layer, avoiding the introduction of new volatile organic compounds while ensuring the stability of the connection.

Claims

1. A carpet, characterized in that, include: Support layer; A first outer layer is disposed on a first side of the support layer; An isolation connection layer is provided at least partially between the support layer and the first outer layer to prevent material from the support layer from diffusing into the first outer layer. The first outer layer, the isolation and connection layer, and the support layer are integrally connected through a composite process, and the isolation and connection layer does not contain volatile organic compounds.

2. The carpet according to claim 1, characterized in that, The isolation connection layer includes: An isolation layer, which is integrally connected to the first outer layer through a composite process, is used to prevent the material of the support layer from diffusing into the first outer layer; A connecting layer is integrally connected to the isolation layer and the support layer through a composite process.

3. The carpet according to claim 2, characterized in that, Both the isolation layer and the connecting layer are film structures. The isolation layer is connected to the first outer layer through a coating process, and the connecting layer is connected to the support layer through a hot pressing process. The melting point of the isolation layer is greater than that of the connecting layer.

4. The carpet according to claim 3, characterized in that, The support layer includes: A functional core layer, wherein the functional core layer is provided with a plurality of first gaps; A reinforcement layer is disposed on both sides of the functional core layer, and the reinforcement layer is provided with a plurality of second gaps; The filling structure has a first portion filling the first gap and the second gap, a second portion being disposed on the side of the reinforcing layer away from the functional core layer, a connecting layer being connected to the filling structure by a hot-pressing process, and an isolation layer preventing the filling structure from diffusing into the first outer layer.

5. The carpet according to claim 3, characterized in that, The connecting layer is a polyethylene film, and the separating layer is a polyamide film.

6. The carpet according to claim 1, characterized in that, The isolation bonding layer is at least partially disposed on the second side of the support layer to prevent the material of the support layer from diffusing to the second side.

7. The carpet according to claim 6, characterized in that, Also includes: The second appearance layer is disposed on the second side of the support layer and is integrally connected with the isolation connection layer disposed on the second side through a composite process.

8. The carpet according to claim 1, characterized in that, The insulating connecting layer wraps around the outside of the support layer to prevent the material of the support layer from diffusing outward.

9. The carpet according to claim 6, characterized in that, Also includes: A second outer layer is connected to the second side of the support layer via a connection structure, which is different from the isolation connection layer.

10. A carpet as described in claim 9, characterized in that, The first outer layer is a non-woven fabric, and the second outer layer has a pile on the side away from the connecting structure. The connecting structure does not contain volatile organic compounds.

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