Waffle knit floor mat

Abstract

The application discloses a waffle-weave floor mat, which comprises a carpet body formed by interlacing a plurality of knitting warps and a plurality of knitting wefts, and the top surface and the bottom surface of the carpet body are both divided into a plurality of squares, each square has a rebounding concave part gradually recessed from the edge to the center, and a supporting convex part is formed between two adjacent rebounding concave parts; the knitting warps comprise bottom warps located on the bottom surface of the carpet body and body warps located at other positions, and the knitting wefts comprise bottom wefts located on the bottom surface of the carpet body and body wefts located at other positions; wherein the bottom warps and / or the bottom wefts are made of long fibers, the body warps and the body wefts comprise short fibers, and the bottom warps and the bottom wefts are coated with antiskid glue on at least one side away from the top surface of the carpet body. The waffle-weave floor mat can reduce the degumming rate after multiple cleanings.

Description

Technical Field

[0001] This application relates to the field of floor mat technology, and in particular to a waffle woven floor mat. Background Technology

[0002] Waffle-woven floor mats, with their unique waffle-patterned surface providing excellent foot comfort, are increasingly popular among users. Currently, most waffle-woven floor mats on the market use short-fiber yarns as the weaving material and have an anti-slip adhesive layer coated on the bottom. The anti-slip function is achieved through the adhesion between the adhesive and the ground.

[0003] However, when this type of waffle woven floor mat is put into a washing machine for washing, the short-fiber yarn is composed of shorter fibers, and the cohesion between the fibers is limited, resulting in a relatively weak adhesive coating ability. Furthermore, due to the mechanical action of water flow and friction inside the washing machine, the bonding force between the anti-slip adhesive coated on the bottom of the floor mat and the yarn decreases during the washing process. After multiple washes, the anti-slip adhesive can easily fall off the floor mat.

[0004] Once the anti-slip adhesive comes off, the anti-slip performance of the bottom of the mat will be greatly reduced. This will not only affect the normal use of the mat, but also pose a serious safety hazard to users, especially in damp and slippery environments such as bathrooms, where users are more likely to fall and get injured.

[0005] To address this issue, while the industry has been trying to improve the performance of anti-slip adhesive or optimize the coating process, there is currently no effective method to fundamentally solve the problem of anti-slip adhesive peeling off short-fiber woven waffle mats after washing. Therefore, developing a waffle woven mat that maintains good anti-slip performance after washing is of significant practical importance and market demand.

[0006] The above content is only used to assist in understanding the technical solution of the utility model and does not represent an admission that the above content is prior art. Utility Model Content

[0007] In view of the above problems, this utility model proposes a waffle woven floor mat, which aims to solve the technical problem that the anti-slip adhesive of the waffle woven floor mat is easy to fall off after washing.

[0008] To achieve the above objectives, the waffle-woven floor mat proposed in this utility model includes a carpet body, which is woven from multiple knitted warp yarns and multiple knitted weft yarns. The top and bottom surfaces of the carpet body are divided into multiple squares, each square having a resilient recess that gradually indents from the edge towards the center, with a supporting protrusion formed between adjacent resilient recesses. The knitted warp yarns include bottom warp yarns located on the bottom surface of the carpet body and main warp yarns located in other positions. The knitted weft yarns include bottom weft yarns located on the bottom surface of the carpet body and main weft yarns located in other positions.

[0009] The bottom warp and / or the bottom weft are long-fiber yarns, the main warp and the main weft are short-fiber yarns, and the bottom warp and the bottom weft are coated with anti-slip adhesive on at least one side away from the top surface of the carpet body.

[0010] This invention utilizes long-fiber yarns for the bottom layer of the waffle mat (the very bottom layer), with anti-slip adhesive wrapped around them, while the remaining portion uses short-fiber yarns. This ensures the mat remains fluffy, soft, resilient, and resistant to snagging. The cured anti-slip adhesive layer firmly bonds to the long-fiber yarns at the bottom, forming a continuous and dense coating. Compared to using short-fiber yarns, this effectively prevents the adhesive layer from peeling off during washing due to yarn lint, significantly enhancing the mat's overall adhesive retention. This reduces the rate of adhesive stripping after multiple washes, greatly improving the mat's long-term anti-slip performance, preventing safety hazards caused by adhesive stripping, and extending the product's lifespan. Attached Figure Description

[0011] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0012] Figure 1 A schematic diagram of the structure of an embodiment of the waffle woven floor mat of this utility model is shown;

[0013] Figure 2 for Figure 1 A magnified view of a section at point A in the middle;

[0014] Figure 3 This is a schematic diagram of the bottom surface of another embodiment of the waffle woven floor mat of this utility model;

[0015] Figure 4 for Figure 3A magnified view of a section at point B in the middle;

[0016] Figure 5 for Figure 3 Front view of a waffle-woven floor mat;

[0017] Figure 6 for Figure 3 A schematic diagram of the top surface of a Zhonghua woven floor mat.

[0018] The realization of the purpose, functional features and advantages of this utility model will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of the embodiments. Based on the embodiments of this application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of this application. In addition, the technical solutions of various embodiments can be combined with each other, but this must be based on the ability of those of ordinary skill in the art to implement them. When the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this utility model.

[0020] It should be noted that if the embodiments of this utility model involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a specific posture. If the specific posture changes, the directional indicators will also change accordingly.

[0021] In this embodiment of the utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0022] In this embodiment of the invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0023] Furthermore, if the embodiments of this utility model involve descriptions such as "first" or "second," these descriptions are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the meaning of "and / or" throughout the text is to include three parallel solutions. For example, "A and / or B" includes solution A, solution B, or a solution that simultaneously satisfies both A and B.

[0024] To address the technical problem of anti-slip adhesive easily detaching after washing waffle woven floor mats, the inventors discovered during the research and development process that the core reason for this detachment lies in the yarn structure characteristics. Short-fiber yarns have numerous surface hairs and loose fibers, failing to provide a stable adhesion base for the anti-slip adhesive. Through material substitution, the yarn in the bottom load-bearing layer was replaced with continuous long-fiber yarns, utilizing their smooth surface and dense structure to enhance adhesive adhesion. Simultaneously, the short-fiber yarns in the main body were retained to maintain the original soft feel of the floor mat, forming a composite structural design.

[0025] Based on this, this utility model proposes a waffle-woven floor mat. The waffle-woven floor mat adopts a waffle-like grid design, forming a three-dimensional, hollow, textured pattern, similar to a honeycomb structure. This significantly increases the surface area of ​​the mat, improving its absorbency and breathability.

[0026] In this embodiment of the utility model, please refer to Figures 1 to 4The waffle-woven rug includes a rug body 100, which is woven from multiple knitted warp yarns 110 and multiple knitted weft yarns 120. The top and bottom surfaces of the rug body 100 are divided into multiple squares 130. Each square 130 has a springy recess 131 that gradually recedes from the edge to the center, and a supporting protrusion 132 is formed between two adjacent springy recesses 131. The knitted warp yarns 110 include the bottom layer located on the bottom surface of the rug body 100. The warp yarn 111 and the main warp yarn 112 located in other positions, and the knitted weft yarn 120 include the bottom weft yarn 121 located on the bottom surface of the carpet body 100 and the main weft yarn 122 located in other positions; wherein, the bottom warp yarn 111 and / or the bottom weft yarn 121 are long fiber yarns, the main warp yarn 112 and the main weft yarn 122 are short fiber yarns, and the bottom warp yarn 111 and the bottom weft yarn 121 are covered with anti-slip rubber on at least one side away from the top surface of the carpet body 100.

[0027] In this embodiment, the carpet body 100, formed by the interlacing of knitted warp yarns 110 and knitted weft yarns 120, is softer, fluffier, more resilient, and has better moisture absorption and breathability. A double-sided weaving process can be used, resulting in a woven structure with multiple squares 130 on both the top and bottom surfaces of the carpet body 100. Each square 130 has a spring-loaded recess 131 that gradually indents from the edge to the center, thus forming a structure similar to a concave pyramid. The spring-loaded recess 131 refers to a three-dimensional concave structure formed by the difference in float length between the warp and weft yarns. Specifically, this can be achieved by adjusting the heald raising sequence on the loom to shorten the float length of the yarn in the central area and gradually increase the float length at the edges.

[0028] Because the top and bottom surfaces of this waffle-woven floor mat are divided into multiple squares 130, each square 130 has a resilient recess 131 that gradually indents from the edge to the center. A support protrusion 132 is formed between adjacent resilient recesses 131. Therefore, the top and bottom surfaces of the floor mat are composed of the support protrusions 132. Thus, when a foot steps on the floor mat, it only contacts the support protrusions 132. Moisture absorbed by the support protrusions 132 is partially evaporated and quickly transferred to the resilient recesses 131. In this way, the support protrusions on the top surface of the floor mat remain dry, allowing the entire floor mat to combine strong absorbency with quick-drying properties.

[0029] The anti-slip adhesive is essentially a polymer coating covering the surface of the bottom yarn, specifically achieved using thermoplastic polyurethane or rubber-based adhesives, and formed as a continuous coating layer through processes such as impregnation or brushing. At least one side of the bottom warp and weft yarns in contact with the ground is coated with the anti-slip adhesive. To improve the coating rate, optionally, both the surfaces of the bottom warp yarns 111 and the bottom weft yarns 121 are coated with an anti-slip adhesive layer. It should be noted that long-fiber yarns are yarns made from single or multiple long fibers reaching kilometer lengths, with continuous and uninterrupted fibers. Long-fiber yarns can specifically be made from synthetic fiber filaments such as nylon and polyester. Long-fiber yarns have a smooth, fuzz-free surface and are less prone to pilling. In contrast, short-fiber yarns are made from short fibers ranging from a few millimeters to tens of millimeters in length through a spinning process. Short-fiber yarns have a fuzzy surface, exhibiting a fluffy feel; the fibers are dispersed, resulting in lower inter-fiber frictional resistance, leading to weaker fiber cohesion and easier breakage.

[0030] Therefore, when both long-fiber and short-fiber yarns are coated with anti-slip adhesive, if the floor mat is repeatedly washed in a washing machine, the anti-slip adhesive will peel off due to the mechanical action of water flow and friction inside the machine, as yarn fibers are shed. This reduces the adhesion between the anti-slip adhesive coated on the short-fiber yarn and the yarn itself. However, the smooth surface of the long-fiber yarn allows the anti-slip adhesive to fully penetrate the yarn gaps and form a mechanical bond. After curing, the adhesive layer forms a strong bond with the long-fiber yarn. Therefore, after multiple washes, the adhesion between the anti-slip adhesive coated on the long-fiber yarn and the long-fiber yarn remains largely unchanged. Consequently, the degumming rate of the short-fiber yarn is significantly higher than that of the long-fiber yarn.

[0031] To prevent snagging and ensure the softness and cushioning performance of the floor mats, current waffle floor mats are all woven from short-fiber yarns. Therefore, the bottom layer of existing floor mats is made of short-fiber yarns, resulting in insufficient adhesion of the adhesive layer. This solution replaces the yarns on the bottom of the floor mat with long-fiber yarns, which, while maintaining the comfort of the main structure, specifically enhances the strength of the anti-slip adhesive interface. The high strength of the long-fiber yarns also improves the wear resistance of the bottom woven layer, forming a double protection mechanism.

[0032] This application utilizes long-fiber yarns for the bottom layer of the waffle mat, specifically the bottom warp yarns 111 and / or bottom weft yarns 121, and coats these yarns with anti-slip adhesive, while the remaining areas use short-fiber yarns. This ensures the mat remains fluffy, soft, resilient, and resistant to snagging. The cured anti-slip adhesive layer firmly bonds to the long-fiber yarns at the bottom of the mat, forming a continuous and dense coating. Compared to using short-fiber yarns at the bottom, this effectively prevents the adhesive layer from peeling off during washing due to yarn lint. This significantly enhances the mat's overall adhesive retention, effectively reducing the rate of adhesive stripping after multiple washes. This greatly improves the mat's long-term anti-slip performance, avoids safety hazards caused by adhesive stripping, and extends the product's lifespan.

[0033] In one embodiment, such as Figure 1 and Figure 2 As shown, both the bottom warp yarn 111 and the bottom weft yarn 121 are made of long fibers, and the diameter of the bottom warp yarn 111 is larger than the diameter of the main warp yarn 112, while the diameter of the bottom weft yarn 121 is larger than the diameter of the main weft yarn 122.

[0034] In this embodiment, both the bottom warp yarn 111 and the bottom weft yarn 121 are made of long-fiber yarns, ensuring that the bottom layer of the mat is entirely composed of long-fiber yarns, effectively improving the overall anti-adhesion performance of the mat. The diameter of the bottom warp yarn 111 is larger than that of the main warp yarn 112, meaning the cross-sectional dimension of the bottom warp yarn 111 is larger than that of the main warp yarn 112. Similarly, the diameter of the bottom weft yarn 121 is larger than that of the main weft yarn 122, meaning the cross-sectional dimension of the bottom weft yarn 121 is larger than that of the main weft yarn 122. This can be achieved by increasing the number of individual fibers in the bottom yarns or by using a twisting process.

[0035] By using smaller diameter yarns for the main warp yarns 112 and 122, the tightness and strength of the mat's weave are ensured. By making the bottom warp yarn 111 larger in diameter than the main warp yarn 112, and the bottom weft yarn 121 larger in diameter than the main weft yarn 122, the contact area between the bottom yarns and the anti-slip adhesive is increased. With both the bottom warp yarns 111 and bottom weft yarns 121 made of long-fiber yarns, a more stable adhesive base can be formed on the bottom of the mat, reducing the risk of the anti-slip adhesive peeling off during washing. In other words, the larger diameter and long fiber characteristics of the bottom yarns resist the shearing effect of water flow on the adhesive layer, thus maintaining the anti-slip performance of the mat's bottom surface.

[0036] Furthermore, the ratio of the diameter of the bottom warp yarn 111 to the diameter of the main warp yarn 112 is greater than 2, and / or the ratio of the diameter of the bottom weft yarn 121 to the diameter of the main weft yarn 122 is greater than 2. This further increases the contact area between the bottom yarn and the anti-slip adhesive, further enhancing the adhesion of the anti-slip adhesive to the bottom yarn and strengthening the bond strength between the bottom yarn and the anti-slip adhesive layer. This ensures that the adhesive layer remains intact even after multiple washes, thereby further reducing the rate of adhesive stripping from the mat.

[0037] In one embodiment, the bottom warp yarn 111 is formed by twisting at least two yarns together, and the bottom weft yarn 121 is formed by twisting at least two yarns together. The bottom warp yarn 111 and bottom weft yarn 121 are composite yarns formed by twisting two or more yarns, for example, by combining two filament yarns with a low twist to form a composite yarn with a larger diameter. During weaving, the interlacing density of the bottom warp yarn 111 and bottom weft yarn 121 formed by the composite yarn is lower than that of the short-fiber yarn area, allowing the anti-slip adhesive to fully penetrate the gaps between the yarns of the bottom yarn and coat the yarn surface, further enhancing the bonding strength between the bottom warp yarn 111, bottom weft yarn 121, and the anti-slip adhesive.

[0038] Furthermore, such as Figure 1 and Figure 2 As shown, the diameter of each yarn in the bottom warp 111 is greater than or equal to the diameter of the main warp 112, and the diameter of each yarn in the bottom weft 121 is greater than or equal to the diameter of the main weft 122. Thus, since the bottom warp 111 and bottom weft 121 are composite yarns, by ensuring that the diameter of each yarn is greater than or equal to the diameter of the main yarn, the contact area between the anti-slip adhesive and the yarns after curing is significantly increased, further extending the durability of the mat's anti-slip performance.

[0039] In one embodiment, the twist of at least two strands of the bottom warp 111 is less than the twist of the main warp 112.

[0040] Twist refers to the number of twists per unit length of yarn during the twisting process, i.e., the tightness of the spiral arrangement of fibers or strands in the yarn. Lower twist makes the bottom warp yarn 111 structure looser, increasing the gaps between fibers and thus increasing the contact area with the anti-slip adhesive. The main warp yarn 112 and main weft yarn 122 have higher twist, ensuring the compactness and wear resistance of the main structure of the mat. The multiple strands of the bottom warp yarn 111 are designed with low twist, allowing the anti-slip adhesive to penetrate into the fiber gaps within the yarn during the coating process, forming a three-dimensional bond between the anti-slip adhesive layer and the yarn. Because the low-twist yarn has a larger surface area and porosity, the increased penetration depth of the adhesive enhances the bonding strength between the anti-slip adhesive layer and the bottom warp yarn 111. The adhesive layer remains stably attached even under mechanical impact and is not easily peeled off from the yarn, thus maintaining the long-term anti-slip performance of the mat.

[0041] Furthermore, the twist of each yarn in the bottom warp 111 is less than that in the main warp 112. The main warp 112 and the main weft 122 maintain a high degree of twist to maintain the stability of the weaving structure. Meanwhile, each yarn in the bottom warp 111 forms a loose fiber surface by reducing the number of twists. During the coating process, the loose fiber surface forms more microporous structures, allowing the anti-slip adhesive to penetrate into the fiber gaps and form mechanical anchoring. This increases the adhesive contact area of ​​the bottom warp 111, further enhancing the bonding strength between the anti-slip adhesive and the bottom yarn.

[0042] In one embodiment, the twist of at least two strands of the bottom weft yarn 121 is less than the twist of the main weft yarn 122.

[0043] The main warp yarns 112 and 122 have high twist, ensuring the compactness and wear resistance of the mat's main structure. The lower twist makes the bottom weft yarn 121 more loosely structured, increasing the gaps between fibers and thus increasing the contact area with the anti-slip adhesive. The multi-strand yarns of the warp and weft yarns employ a low-twist design, allowing the anti-slip adhesive to penetrate into the fiber gaps during the coating process, creating a three-dimensional bond between the anti-slip adhesive layer and the yarn. Because the low-twist yarn has a larger surface area and porosity, the increased penetration depth of the adhesive enhances the bonding strength between the anti-slip adhesive layer and the bottom warp yarns 111. The adhesive layer remains stably attached even under mechanical impact, preventing it from peeling off the yarn and maintaining the mat's long-term anti-slip performance.

[0044] In one embodiment, the twist of each yarn in the bottom weft 121 is less than that in the main weft 122. The main warp 112 and the main weft 122 maintain a high degree of twist to maintain the stability of the weave structure. The bottom weft 121, by reducing the number of twists, forms a loose fiber surface. During the coating process, the loose fiber surface forms more microporous structures, allowing the anti-slip adhesive to penetrate into the fiber gaps and form mechanical anchoring. This increases the adhesive contact area of ​​the bottom weft 121, further enhancing the bonding strength between the anti-slip adhesive and the bottom yarn.

[0045] In one embodiment, the twist of at least two strands of the bottom warp yarn 111 is less than the twist of the main warp yarn 112, and the twist of at least two strands of the bottom weft yarn 121 is less than the twist of the main weft yarn 122.

[0046] The main warp yarns 112 and 122 have high twist, ensuring the compactness and wear resistance of the mat's main structure. Lower twist results in a looser yarn structure at the bottom, increasing the gaps between fibers and thus increasing the contact area with the anti-slip adhesive. Meanwhile, the multiple strands of the bottom warp yarns 111 and 121 employ a low-twist design. During the adhesive application process, the anti-slip adhesive can penetrate into the fiber gaps within the yarns, creating a three-dimensional bond between the adhesive layer and the yarns. Because the low-twist yarns have a larger surface area and porosity, the increased penetration depth of the adhesive enhances the bonding strength between the anti-slip adhesive layer and the bottom warp yarns 111 and 121. The adhesive layer remains stably attached even under mechanical impact, preventing it from peeling off the yarns and maintaining the mat's long-term anti-slip performance.

[0047] Furthermore, the twist of each yarn in the bottom warp 111 is less than that in the main warp 112; the twist of each yarn in the bottom weft 121 is less than that in the main weft 122. The main warp 112 and main weft 122 maintain a high degree of twist to maintain the stability of the weaving structure. Meanwhile, each yarn in the bottom weft 121 and bottom warp 111 forms a loose fiber surface by reducing the number of twists. During the coating process, the loose fiber surface forms more microporous structures, allowing the anti-slip adhesive to penetrate into the fiber gaps and form mechanical anchoring. This increases the adhesive contact area between the bottom weft 121 and bottom warp 111, further enhancing the bonding strength between the anti-slip adhesive and the bottom yarn.

[0048] In one embodiment, please refer to Figures 3 to 6 The warp and weft floats of the carpet body 100 gradually transition from short to long from the center bottom of the rebound recess 131 to the surrounding edges, so that the warp and weft floats on the top and bottom surfaces of the carpet body 100 are greater than the warp and short floats in other positions.

[0049] In this context, warp float length refers to the length of warp yarns that continuously float on the fabric surface, while weft float length refers to the length of weft yarns that continuously float on the fabric surface. The gradual transition between warp and weft float lengths creates a pyramid-like groove structure on the fabric surface that extends gradually from the center to the edges. This short float length interlacing structure enhances overall elasticity and strengthens the mechanical support relationship between the rebound recesses 131 and the supporting protrusions 132. The longer float length structure on the bottom surface of the carpet body 100 increases the bonding area between the yarns and the anti-slip adhesive, while the short float length interlacing structure in the middle layer buffers external impacts through elastic deformation, thereby reducing the possibility of the anti-slip adhesive detaching during washing.

[0050] In one example, the bottom warp yarn 111 and bottom weft yarn 121 are made of filament polyester. Specifically, the bottom warp yarn 111 and bottom weft yarn 121 can be made of high-strength filament polyester, which has a smooth surface and continuous fiber length, high breaking strength and abrasion resistance (not easy to break), which can enhance the bonding force between the bottom yarn and the anti-slip adhesive, so that the anti-slip adhesive attached to the bottom warp yarn 111 and bottom weft yarn 121 is not easy to fall off.

[0051] In one example, both the main warp yarn 121 and the main weft yarn 122 are made of a blend of long and short fibers. Blending long and short fibers refers to combining continuous filaments with fibers cut into short segments through twisting or doubling. Specifically, short fibers can be made from a blend of shrinkable polyester and acrylic yarns, spun using a semi-worsted spinning process to form the main warp yarn 121 and the main weft yarn 122. When the main yarn is a blend of long and short fibers, the long fibers act as a core layer, providing skeletal support and maintaining yarn strength, while inhibiting yarn deformation during washing. The short fibers coat the core layer, increasing surface hairiness and ensuring fluffiness and softness, preventing snagging. Optionally, the lengths of the main warp yarn 121 and the main weft yarn are 10-20 cm to ensure the fluffiness and softness of the mat.

[0052] In one embodiment, both the bottom warp yarn 111 and the bottom weft yarn 121 are made of hollow yarn.

[0053] In this embodiment, hollow yarn refers to yarn with a continuous or discontinuous hollow structure inside. When the bottom warp yarn 111 and bottom weft yarn 121 are woven with hollow yarn, the capillary effect of the hollow part of the hollow yarn can enhance the adsorption of adhesive, allowing the adhesive to contact both the inner and outer surfaces of the yarn, improving the uniformity of coverage. Furthermore, the hollow structure can increase the surface area of ​​the yarn and form micropores or grooves on the surface, providing more adhesion sites for the anti-slip adhesive, forming a mechanically interlocking structure after curing. During the cleaning process, when water flow impacts the anti-slip adhesive, the bonding force between the anti-slip adhesive and the bottom warp yarn 111 and bottom weft yarn 121 depends not only on surface adhesion but also on the adhesive anchoring effect within the micropores to resist peeling, further improving the adhesive-fixing performance of the bottom yarn of the mat and reducing the delamination rate. In addition, the hollow structure of the hollow yarn can reduce the yarn density, allowing the bottom surface of the mat to maintain its lightweight characteristics after adhesive application, and can buffer water absorption deformation during cleaning, reducing stress concentration in the adhesive layer.

[0054] In one embodiment, the hollow yarn has a hollowness ratio greater than or equal to 15% and less than or equal to 40%. Hollowness ratio refers to the ratio of the area of ​​the hollow portion to the total cross-sectional area of ​​the yarn. If the hollow yarn's hollowness ratio is less than 15%, the hollow effect is weak, and the advantage of improving the bond strength between the yarn and the anti-slip adhesive is not significant. If the hollow yarn's hollowness ratio is greater than 40%, it will reduce the spinning yield and yarn strength. By using hollow yarn for both the bottom warp yarn 111 and the bottom weft yarn 121, and controlling the hollowness ratio within the range of 15%-40%, it ensures that the hollow structure of the yarn provides sufficient adhesive-coated surface, effectively improving the bond strength between the anti-slip adhesive and the bottom yarn, while avoiding insufficient yarn strength due to excessively high hollowness.

[0055] This utility model also proposes a method for preparing a waffle-woven floor mat, wherein the waffle-woven floor mat is any of the floor mats described in the above embodiments.

[0056] The preparation method includes the steps of raw material preparation, warping, reed threading, weaving, finishing, and sizing; among which,

[0057] Raw material preparation steps include:

[0058] Prepare staple fiber yarn and long fiber yarn;

[0059] Therefore, the weaving steps include:

[0060] The carpet body 100 is formed by using a rapier loom and the warp and weft floating and sinking patterns to form a multi-square 130 structure. Each square 130 has a rebound recess 131 that gradually indents from the edge to the center, and a supporting protrusion 132 is formed between two adjacent rebound recesses 131. The bottom layer of the carpet body 100 is woven with long yarns, and the rest is woven with short yarns.

[0061] The sorting steps include:

[0062] After the floor mat is woven, it is cut into individual pieces and placed in a high-temperature steam oven. It is then steamed at high temperature for a preset time to shrink the size of the floor mat and increase its thickness. The temperature is controlled between 140 and 160 degrees Celsius.

[0063] The adhesive coating process includes:

[0064] The long-fiber bottom surface of the finished floor mat is coated with adhesive using an adhesive coating machine;

[0065] Place the glued floor mats into a drying oven for drying and curing.

[0066] Rapier looms are weaving machines that use a reciprocating rapier weft insertion mechanism to introduce the weft yarn. High-temperature steam treatment refers to using the hot and humid environment of saturated steam to shape the floor mat. This can be achieved using a pressure vessel in conjunction with a steam jet system. Through the effect of heat and humidity, the overall size of the floor mat shrinks, while the yarn thickness expands and increases.

[0067] Specifically, in the weaving step, long-fiber yarns are placed on the bottom layer of the mat, and their continuous fiber structure can form a more stable adhesive base. In the finishing step, high-temperature steam treatment causes partial shrinkage of short-fiber yarns, making the three-dimensional structure of the rebound concave portion 131 and the supporting convex portion 132 more obvious. At the same time, the long-fiber yarns maintain the flatness of the base due to their higher thermal stability. In the adhesive coating step, the surface of the long-fiber yarns is smooth and the fibers are tightly bonded, providing a uniform adhesion interface for the anti-slip adhesive. After drying and curing, a firmly bonded anti-slip layer is formed.

[0068] Existing waffle mats use short-fiber yarns as the base material, and the loose fiber ends result in insufficient adhesion of the adhesive layer. This solution, however, uses a long-fiber yarn base combined with a high-temperature setting process to create a dense structure on the yarn surface. This significantly enhances the mechanical interlocking between the adhesive layer and the long-fiber yarns, maintaining anti-slip performance even after multiple washes. At the same time, the steam shrinkage process increases the thickness of the mat, improving the three-dimensional structural stability of the rebound recess 131 and the support protrusion 132, thus enhancing the performance of the mat.

[0069] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A waffle-knitted floor mat, comprising a carpet body, said carpet body being woven from multiple knitted warp yarns and multiple knitted weft yarns, characterized in that, The top and bottom surfaces of the carpet body are divided into multiple squares, each square having a spring-loaded recess that gradually indents from the edge to the center, and a supporting protrusion is formed between two adjacent spring-loaded recesses; the knitted warp yarns include bottom warp yarns located on the bottom surface of the carpet body and main warp yarns located in other positions, and the knitted weft yarns include bottom weft yarns located on the bottom surface of the carpet body and main weft yarns located in other positions. The bottom warp and / or the bottom weft are long-fiber yarns, the main warp and the main weft are short-fiber yarns, and the bottom warp and the bottom weft are coated with anti-slip adhesive on at least one side away from the top surface of the carpet body.

2. The waffle-woven floor mat as described in claim 1, characterized in that, Both the bottom warp yarn and the bottom weft yarn are made of long fibers, and the diameter of the bottom warp yarn is larger than the diameter of the main warp yarn, and the diameter of the bottom weft yarn is larger than the diameter of the main weft yarn.

3. The waffle-woven floor mat as described in claim 2, characterized in that, The ratio of the diameter of the bottom warp yarn to the diameter of the main warp yarn is greater than 2, and / or the ratio of the diameter of the bottom weft yarn to the diameter of the main weft yarn is greater than 2.

4. The waffle-woven floor mat as described in claim 2, characterized in that, The bottom warp yarn is made of at least two strands of yarn twisted together, and the bottom weft yarn is made of at least two strands of yarn twisted together.

5. The waffle-woven floor mat as described in claim 4, characterized in that, The diameter of each yarn in the bottom warp is greater than or equal to the diameter of the main warp, and the diameter of each yarn in the bottom weft is greater than or equal to the diameter of the main weft.

6. The waffle-woven floor mat as described in claim 4, characterized in that, The twist of at least two strands of the bottom warp yarn is less than the twist of the main warp yarn.

7. The waffle-woven floor mat as described in claim 6, characterized in that, The twist of each yarn in the bottom warp is less than that in the main warp.

8. The waffle-woven floor mat as described in claim 4, characterized in that, The twist of at least two strands of the bottom weft yarn is less than the twist of the main weft yarn.

9. The waffle-woven floor mat as described in claim 8, characterized in that, The twist of each yarn in the bottom weft yarn is less than the twist of the main weft yarn.

10. The waffle-woven floor mat as described in claim 5, characterized in that, The twist of at least two strands of the bottom warp yarn is less than that of the main warp yarn, and the twist of at least two strands of the bottom weft yarn is less than that of the main weft yarn.

11. The waffle-woven floor mat as described in claim 10, characterized in that, The twist of each yarn in the bottom warp is less than that in the main warp; the twist of each yarn in the bottom weft is less than that in the main weft.

12. The waffle-woven floor mat as described in claim 1, characterized in that, The warp and weft floats of the carpet body gradually transition from short to long from the center bottom of the rebound recess to the surrounding edges, so that the warp and weft floats on the top and bottom surfaces of the carpet body are greater than the warp and short floats at other locations.

13. The waffle-woven floor mat as described in claim 1, characterized in that, The bottom warp and bottom weft yarns are made of long-filament polyester.

14. The waffle-woven floor mat as described in claim 1, characterized in that, Both the main warp yarn and the main weft yarn are made of a blend of long and short fibers.

15. The waffle-woven floor mat as described in claim 1, characterized in that, Both the bottom warp yarn and the bottom weft yarn are made of hollow yarn.

16. The waffle-woven floor mat as described in claim 15, characterized in that, The hollow yarn has a hollowness ratio greater than or equal to 15% and less than or equal to 40%.

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