Carpet for TPE floor covering having a composite multilayer structure
The TPE carpet with a multi-layer structure addresses environmental and cost issues of PVC carpets by enhancing anti-slip and wear resistance, offering recyclability and design flexibility, while being environmentally safe and cost-effective.
Patent Information
- Application Number
- JP2025001180U
- Authority / Receiving Office
- JP · JP
- Patent Type
- Utility models
- Current Assignee / Owner
- Filing Date
- 2025-04-15
- Publication Date
- 2025-06-25
- Estimated Expiration
- 2035-04-15
AI Technical Summary
Conventional PVC carpets face issues of environmental incompatibility due to harmful emissions, high production costs, poor anti-slip and wear resistance, and difficulty in forming a deep anti-slip texture.
A carpet with a composite multi-layer structure using TPE material, comprising a base material layer, a printing layer, an upper TPE layer with anti-slip texture, and a lower TPE layer with an adsorbent adhesive, where nano-silica is added to enhance anti-slip performance, and a protective film is applied.
The TPE carpet provides excellent anti-slip, wear, and moisture resistance, is environmentally friendly, and can be recycled, reducing production costs while maintaining performance and design flexibility.
Smart Images
Figure 0003251745000001_ABST
Abstract
Description
Technical Field
[0001] The present utility model belongs to the technical field of carpets, and particularly relates to a carpet for a TPE floor covering having a composite multi-layer structure.
Background Art
[0002] Conventional PVC carpets are widely used and sold per square meter or per piece, and the price is relatively high. Since harmful gases such as hydrogen chloride are emitted during the manufacturing process, it has an adverse effect on the environment and soil, lacks environmental compatibility, and the PVC material is difficult to recycle. Furthermore, due to poor thermoplasticity, it is difficult to form a deep anti-slip texture on the surface. In order to solve such problems, a technology for manufacturing a carpet for a floor covering using a TPE material has been proposed. Thereby, it is possible to achieve both cost reduction and environmental consideration, provide a product excellent in moisture resistance and wear resistance, and realize the renewal and evolution of products such as carpets, table mats, and floor mats.
Summary of the Invention
Problems to be Solved by the Invention
[0003] In order to solve the above problems, the present utility model provides a carpet for a TPE floor covering having a composite multi-layer structure, and aims to solve problems such as environmental incompatibility, insufficient anti-slip and wear resistance, poor surface texture, and high production cost in conventional PVC carpets.
Means for Solving the Problems
[0004] This utility model is achieved by the following technical means. That is, a carpet for a TPE floor covering having a composite multi-layer structure, comprising a main body; the main body is composed of a base material layer, a printing layer, an upper TPE layer and a lower TPE layer. The base material layer is made of needle-punched non-woven fabric. The printing layer is a pattern layer disposed on the surface of the base material layer. The upper TPE layer is located above the printing layer, and an anti-slip texture is pressure-formed. The lower TPE layer is composed of an adsorbent TPE adhesive layer, located on the lower surface of the base material layer, and a protective film is applied to its lower surface. Furthermore, the upper TPE layer is a wear-resistant layer, formed by heating the TPE composite material to 170 °C in a laminating method, and 20 - 30 wt% of nano-silica can be added to the TPE material to improve the anti-slip performance. Furthermore, the pattern of the printing layer is formed by printing design data onto the surface of the base material layer by a computer. Furthermore, the thickness of the lower TPE layer is smaller than that of the upper TPE layer. The protective film is made of transparent plastic. As the combination of the base material layer and the lower TPE layer, any one of non-woven fabric + silicon dot forming, non-woven fabric + PVC dot forming, non-woven fabric + SEBS anti-slip hot melt adhesive, non-woven fabric + adsorbent TPE + transparent protective film, or non-woven fabric + general TPE is used. Furthermore, as the base material layer, multi-layer high-pressure compressed cotton cloth or PVC can be used as an alternative to needle-punched non-woven fabric. Also, a material obtained by adding 15% of recycled rubber particles to foamed TPE with a density of 0.6 g / cm 3 can also be used.
Advantages of the Invention
[0005] After the whole is laid, this utility model provides a soft feel and good resilience due to the multi-layer structure, enhances comfort, and is applicable to hotels, gyms, offices, etc. The TPE material and the pressure-applied anti-slip texture achieve excellent anti-slip performance, wear resistance, and moisture resistance. Cleaning is also convenient by water washing, and it is suitable for humid environments such as kitchens and bathrooms. In addition, the TPE material does not contain harmful substances such as phthalic acid esters and formaldehyde, and complies with relevant standards, so it can be safely used in sensitive environments such as children's rooms and pet spaces. Moreover, the TPE base material can be recycled due to its thermoplasticity, and the performance retention rate of the recycled material is also high, which conforms to the concept of circular economy. Furthermore, by cutting the main body into a predetermined size, it can also be applied to uses such as living carpets, kitchen mats, and dining table mats. Compared with conventional PVC carpets, since the layer structure is simple, the TPE lower layer can be omitted according to needs, and an adhesive layer is directly applied to the bottom surface of the base material layer, thereby suppressing the manufacturing cost and enhancing the market competitiveness and practicality. Moreover, TPE is excellent in ultraviolet resistance and weather resistance, and is less likely to fade or crack even after long-term use, so it is also suitable for use in indoor balconies, gardens, outdoor pool sides, camping sites, etc.
Brief Description of the Drawings
[0006]
Figure 1
Figure 2
Figure 3
Embodiments for Carrying out the Invention
[0007] Hereinafter, the embodiments of this utility model will be described in more detail with reference to the drawings and examples. (Example 1) As shown in Figures 1 to 3, This utility model provides a TPE floor covering carpet having a composite multi-layer structure, including a main body, and the main body is composed of a base material layer 1, a printing layer 2, a TPE upper layer 3, and a TPE lower layer 4. The base material layer 1 is formed of a needle-punched non-woven fabric, and the printing layer 2 is a pattern layer and is disposed on the surface of the base material layer 1. The TPE upper layer 3 is disposed on the surface of the printing layer 2, and an anti-slip texture is embossed. The TPE lower layer 4 is formed of an adsorptive TPE adhesive layer, is disposed on the lower surface of the base material layer 1, and a protective film 401 is provided on the lower surface thereof. As shown in FIGS. 2 and 3, the thickness of the TPE lower layer is smaller than that of the TPE upper layer, and the protective film is formed of a transparent plastic film. As the combination of the base material layer and the TPE lower layer, any one of non-woven fabric + silicone dot forming, non-woven fabric + PVC dot forming, non-woven fabric + SEBS anti-slip hot melt adhesive, non-woven fabric + TPE + transparent protective film 401, or non-woven fabric + general TPE can be used. As an example, when adsorptive TPE + transparent protective film 401 is used as the TPE lower layer, by peeling the protective film 401 before laying, it can be directly pasted on the installation surface by the adsorption layer of the TPE lower layer 4, and rapid laying can be realized by self-adsorption. As shown in FIGS. 2 and 3, the TPE upper layer 3 is a wear-resistant layer, is formed by a laminating method using a TPE composite material and a laminating machine heated to 170 ° C. 20 to 30 wt% of nano-silica can be added to the TPE material, thereby improving the anti-slip performance. The anti-slip texture embossed on the surface of the TPE upper layer 3 has wear resistance and anti-slip effect, and the surface after laying exhibits an anti-slip effect and is also excellent in moisture-proof and water resistance, so it is applicable to floor applications such as indoor and outdoor, offices, etc. As shown in FIGS. 1 and 2, the pattern of the printing layer 2 is formed by printing a designed pattern on the surface of the base material layer 1 by a computer. After printing, by performing lamination and pressurization treatment with the TPE upper layer 3, it is possible to impart various simulated flooring patterns, colors or patterns to the surface of the main body, and realize the designability according to the use scene.
[0008] (Example 2) Based on Example 1, as shown in Figure 1, for the base material layer 1, instead of using needle-punched non-woven fabric, multilayer high-pressure compressed cotton fabric can be used, and PVC can also be used as an alternative material. Thus, according to the actual usage situation and customer needs, the materials can be changed to manufacture products. Furthermore, with a density of 0.6 g / cm 3 By using a material in which 15% recycled rubber particles are added to the foamed TPE, the sound insulation performance (noise reduction coefficient) can be improved.
[0009] (Example 3) Based on Example 2, the main body may be configured such that an adhesive layer is provided on the bottom surface of the TPE upper layer 3, the printing layer 2, and the base material layer 1. The adhesive layer is composed of an adhesive that meets environmental standards. While reducing the number of layers by one, excellent anti-slip performance and wear resistance can be maintained, and the production cost can be significantly reduced, so it has a competitive advantage in terms of market price.
[0010] (Specific usage method and function in this example) In this utility model, during actual use, first peel off the protective film 401 to expose the adsorptive adhesive layer of the TPE lower layer 4, and paste it on the floor surface of the object to be used. By pre-adjusting the dimensions of adjacent main bodies and laying them closely without gaps, the laying of the main body is completed. Furthermore, according to the change of the use environment, the main body can also be cut into a desired dimension and laid and used in the necessary places. It should be noted that the above examples and the content described in the specification are a preferred example of this utility model and do not limit this utility model. Various changes and improvements are possible without departing from the spirit and scope of this utility model. For example, regarding the embossed texture in the TPE upper layer 3, the patterns, pseudo-patterns or colors printed on the printing layer 2, the dimensions, thickness or material composition of the base material layer 1, the number of layer configurations of the main body, etc., they can be changed or adjusted according to customer requirements, and all these changes and improvements are also included in the protection scope of the claims of this utility model.
Explanation of reference numerals
[0011] 1: Substrate layer; 2: Printing layer; 3: TPE upper layer; 4: TPE lower layer; 401: Protective film.
Claims
1. A TPE floor carpet having a composite multi-layer structure, comprising a main body, The main body portion is composed of a base material layer (1), a printing layer (2), a TPE upper layer (3), and a TPE lower layer (4), The printed layer (2) is a pattern layer and is disposed on the surface of the base layer (1), a TPE upper layer (3) is disposed on the surface of the printed layer (2) and is press-formed with an anti-slip texture, and a TPE lower layer (4) is formed by an adhesive TPE layer and is disposed on the lower surface of the base layer (1), and a protective film (401) is provided on the lower surface of the TPE lower layer (4).
2. In the TPE floor carpet according to claim 1, The base layer (1) is made of any one of needle punched nonwoven fabric, multi-layer highly compressed cotton fabric, PVC, and foamed TPE with added recycled rubber particles.
3. In the TPE floor carpet according to claim 2, The pattern of the printing layer (2) is formed by printing a design onto the surface of the base layer (1) using a computer.
4. In the TPE floor carpet according to claim 1, The TPE upper layer (3) is an abrasion-resistant layer, and is formed by laminating a TPE composite material in a laminating machine heated to 170°C.
5. The TPE floor carpet according to claim 4, The thickness of the TPE lower layer (4) is less than that of the TPE upper layer (3), the protective film (401) is made of a transparent plastic film, and the TPE lower layer (4) is made of either a base layer made of a general TPE material, an absorbent TPE + transparent film (401), a SEBS anti-slip hot melt adhesive, a PVC dot nonwoven fabric molding layer, or a silicone dot nonwoven fabric molding layer.