Easy-to-wash detachable carpet and preparation method therefor

Abstract

Disclosed is an easy-to-wash detachable carpet, including a surface layer and a base layer. The surface layer is a warp-knitted suede-like fabric layer, including a first pile surface made up of first pile fibers, and the base layer is a single-sided cut-pile fabric layer, including a second pile surface made up of second pile fibers, where the second pile fibers are inclined. The first pile surface faces the second pile surface, and the first pile fibers penetrate the second pile fibers and interlock with the second pile fibers. A preparation method for the easy-to-wash detachable carpet is further disclosed. Compared with the prior art, the easy-to-wash detachable carpet of the present has advantages including that the lightweight surface layer can be removed and cleaned easily when needed, which meets hygiene requirements for carpet use.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of carpet manufacturing, and specifically relates to an easy-to-wash detachable carpet and a preparation method therefor.BACKGROUND

[0002] A carpet is a high-grade floor-covering decorative material made from raw materials such as animal hair, plant fibers, synthetic fibers and the like through processing steps of weaving, cutting, and the like. Carpets have the characteristics of being soft, comfortable and safe in use, and are particularly suitable for floor decoration in bedrooms, living rooms, and studies of homes. Wall-to-wall carpeting or partial carpeting is performed as part of home decoration, and a satisfactory decorative effect can be achieved. However, carpets will become increasingly dirty due to dust accumulation and bacteria proliferation after use over time, which will lead to discomfort and even cause symptoms such as skin allergies and inflammation. Therefore, carpets need to be washed and cleaned after a period of use. Due to a heavy weight and a significant increase in water absorption during washing, a carpet is cleaned in an extremely inconvenient manner. Moreover, frequent replacement of new carpets also results in resource waste, which does not conform to the life concept of being low-carbon and environmentally friendly.

[0003] Therefore, there is an urgent need for an easy-to-wash carpet.SUMMARY

[0004] In order to overcome the common defects of carpets in the prior art including washing difficulty and maintenance inconvenience, an objective of the present disclosure is to provide an easy-to-wash detachable carpet where a surface layer and a base layer thereof are detachable, and the lightweight surface layer can be removed and cleaned easily when needed, which meets hygiene requirements for carpet use.

[0005] To achieve the above objective, the present disclosure adopts the following technical solution:

[0006] an easy-to-wash detachable carpet, including:

[0007] a surface layer, a warp-knitted suede-like fabric layer, including a first pile surface made up of first pile fibers;

[0008] a base layer, a single-sided cut-pile fabric layer, including a second pile surface made up of second pile fibers, where the second pile fibers are inclined; and

[0009] the first pile surface faces the second pile surface, and the first pile fibers penetrate the second pile fibers and interlock with the second pile fibers.

[0010] Further, the first pile fibers interlock with the second pile fibers at roots thereof, and an angle of interlocking formed between the first pile fibers and the second pile fibers is 45°-75°.

[0011] Further, a length of the first pile fibers is 1-5 mm, and the first pile fibers are in a curled shape; and a length of the second pile fibers is also 1-5 mm, and the second pile fibers are in an inclined rod shape.

[0012] Further, anti-slip silicone is arranged at a bottom of the single-sided cut-pile fabric layer.

[0013] The present disclosure further provides a preparation method for the easy-to-wash detachable carpet, and the preparation method includes the following steps:

[0014] preparation of the surface layer: warp-knitting with a polyester or polyamide sea-island multifilament with a fineness of 100-160 dtex as a raw material, where a 5-satin or 6-satin weave structure is used for warp knitting; then performing alkali deweighting with an alkaline solution; after heat-setting, performing unilateral sanding to form the first pile fibers; and

[0015] preparation of the base layer: weaving with polyester or polypropylene fibers with a fineness of 100-500 dtex; after weaving, brushing pile fibers to erect same vertically; then heat-pressing the erected pile fibers on an inclined heating plane, to make the heat-pressed pile fibers inclined and form the second pile fibers; and

[0016] lamination: making the second pile fibers of the base layer face upward, making the first pile fibers of the surface layer face downward, and using a compression roller to press the surface layer onto the base layer, such that the first pile fibers penetrate and interlock with the second pile fibers.

[0017] Further, the alkaline solution used for the alkali deweighting during preparation of the surface layer is NaOH, with a concentration of 1-5 g / L, a temperature of 100-150° C., and a treatment duration of 30-60 min; a heat-setting temperature is 150-180° C., and a heat-setting duration is 15-30 min; and 600-650-grit sandpaper is used for sanding.

[0018] Further, during preparation of the base layer, pile fibers are heat-pressed on a soldering iron heating plane at a temperature of 120-150° C. for 1-10 s, and an angle between the soldering iron heating plane and the second pile fibers is 15°-45°.

[0019] Further, during preparation of the base layer, the erected pile fibers are sheared before the heat-pressing, until a length of the pile fibers is 1-5 mm.

[0020] Further, a gram weight of the surface layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; a gram weight of the base layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; the first pile fibers are polyester or nylon fibers with a fineness of 0.1-0.6 dtex, and a density of the first pile fibers is 400-1600 fibers / cm2; the second pile fibers are polyester or polypropylene fibers with a fineness of 100-500 dtex, a density of the second pile fibers is 625-2500 fibers / cm2, and an initial modulus of the second pile fibers is greater than 60 cN / dtex.

[0021] Further, the step of applying anti-slip silicone to a bottom surface of the base layer is further included, and dots of the anti-slip silicone are arranged in an array, with a density of 400-500 dots / m2.

[0022] Compared with the prior art, the present disclosure has the beneficial effects as follows:

[0023] The easy-to-wash detachable carpet of the present disclosure includes the surface layer and the base layer, the surface layer and the base layer can be detached from each other, and a detachable structure therebetween is achieved through an interlocking structure between the first pile fibers of the surface layer and the second pile fibers of the base layer. The two layers are combined very tightly and are not displaced easily during use, but the surface layer can be manually removed for washing in a lightweight and very convenient manner. Moreover, detachable connection can be achieved without need of additional detachable accessories (such as hook-and-loop fasteners) and adhesives, thereby reducing the carpet cost, and ensuring to be environmentally friendly cost-effective.

[0024] The anti-slip silicone is arranged at a bottom of the base layer (i.e., a surface in contact with the ground) of the easy-to-wash detachable carpet of the present disclosure, which enhances the anti-slip performance of the carpet in contact with the ground and ensures safety during use.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a structural schematic diagram of an easy-to-wash detachable carpet of the present disclosure.

[0026] FIG. 2 is a structural schematic diagram of a surface layer of an easy-to-wash detachable carpet of the present disclosure.

[0027] FIG. 3 is an exploded view of a structure of a surface layer of an easy-to-wash detachable carpet of the present disclosure.

[0028] FIG. 4 is a structural schematic diagram of a base layer of an easy-to-wash detachable carpet of the present disclosure.

[0029] FIG. 5 is an exploded view of a structure of a base layer of an easy-to-wash detachable carpet of the present disclosure.

[0030] FIG. 6 is a schematic diagram of heat-pressing a base layer of an easy-to-wash detachable carpet of the present disclosure.REFERENCE NUMERALS IN THE FIGURES

[0031] 1. surface layer; 11. first pile fibers; 12. first pile surface; 2. base layer; 21. second pile fibers; 22. second pile surface; and 30. heating plane.DETAILED DESCRIPTIONS OF THE EMBODIMENTS

[0032] In order to make the objectives, technical solutions and advantages of the examples of the present disclosure clearer, the technical solutions in the examples of the present disclosure will be clearly and completely described below in combination with the accompanying drawings in the examples of the present disclosure. Apparently, the examples described are merely some rather than all of the examples of the present disclosure. Based on the examples of the present disclosure, all other examples acquired by those of ordinary skill in the art without making creative efforts fall within the scope of protection of the present disclosure.

[0033] In the present disclosure, the term “comprising” and other equivalent descriptions mentioned in the specification and claims are intended to cover non-exhaustive inclusions, and encompass the content explicitly described in the specification and claims, and also steps or units inherent in the products, methods or structures that are not described in the specification and claims.

[0034] With reference to FIGS. 1-5, an easy-to-wash detachable carpet is disclosed in this embodiment, including a surface layer 1 and a base layer 2, where the base layer 2 is located below, and the surface layer 1 is detachably connected above the base layer. The surface layer is a warp-knitted suede-like fabric layer, including a first pile surface 12 made up of first pile fibers 11. The base layer is a single-sided cut-pile fabric layer, including a second pile surface 22 made up of second pile fibers 21, where the second pile fibers 21 are inclined, indicating that they are tilted at a certain angle relative to a horizontal plane. The first pile surface 12 faces the second pile surface 22, and the first pile fibers 11 penetrate the second pile fibers 21 and interlock with the second pile fibers 21. Specifically, the first pile fibers interlock with the second pile fibers at roots thereof, and an angle of interlocking formed between the first pile fibers and the second pile fibers is 45°-75°.

[0035] In this embodiment, a length of the first pile fibers is 1-5 mm, and the first pile fibers are in a curled shape; and a length of the second pile fibers is also 1-5 mm, and the second pile fibers are in an inclined rod shape.

[0036] In this embodiment, anti-slip silicone is arranged at a bottom of the single-sided cut-pile fabric layer to prevent the base layer from slipping relative to the ground during use.

[0037] In this embodiment, a gram weight of the surface layer 1 is 300-600 g / m2 and a thickness thereof is 3-10 mm; a gram weight of the base layer 2 is 300-600 g / m2 and a thickness thereof is 3-10 mm; the first pile fibers 11 are polyester or nylon fibers with a fineness of 0.1-0.6 dtex, and a density of the first pile fibers 11 is 400-1600 fibers / cm2; the second pile fibers 21 are polyester or polypropylene fibers with a fineness of 100-500 dtex, a density of the second pile fibers 21 is 625-2500 fibers / cm2, and an initial modulus of the second pile fibers is greater than 60 cN / dtex. The first pile fibers 11 are ultra-fine fibers with a small fineness and a curled shape, and the second pile fibers have a high initial modulus, rigidity and an inclined shape, such that the first pile fibers 11 easily penetrate the second pile fibers 21 and interlock with the second pile fibers 21, thereby ensuring that the surface layer 1 will not slide apart from the base layer 2. Moreover, the first pile fibers 11 are curled fine fibers, and are easily separated from the second pile fibers 21 under the action of a large pulling force, and a detachable connection between the surface layer and the base layer is achieved through a morphology and connection structure of the first pile fibers 11 and the second pile fibers 21.

[0038] The easy-to-wash detachable carpet of this embodiment is prepared through the following method:

[0039] preparation of the surface layer: warp-knit with a polyester or polyamide sea-island multifilament with a fineness of 100-160 dtex as a raw material, where a 5-satin or 6-satin weave structure is used for warp knitting; then perform alkali deweighting with an alkaline solution; after heat-setting, perform unilateral sanding to form the first pile fibers; and

[0040] preparation of the base layer: weave with polyester or polypropylene fibers with a fineness of 100-500 dtex; after weaving, brush pile fibers to erect same vertically; then heat-press the erected pile fibers on an inclined heating plane, to make the heat-pressed pile fibers inclined and form the second pile fibers; and with reference to FIG. 6, during the heat-pressing, form an angle α between a heating plane 30 and the second pile surface 22, then horizontally transmit the second pile fibers 21, and heat same through the heating plane 30, until the second pile fibers 21 tilt at the angle α relative to the horizontal plane.

[0041] Lamination: make the second pile fibers of the base layer face upward, make the first pile fibers of the surface layer face downward, and use a compression roller to press the surface layer onto the base layer, such that the first pile fibers interlock with the second pile fibers.

[0042] In this embodiment, the alkaline solution used for the alkali deweighting during preparation of the surface layer is NaOH, with a concentration of 1-5 g / L, a temperature of 100-150° C., and a treatment duration of 30-60 min; a heat-setting temperature is 150-180° C., and a heat-setting duration is 15-30 min; and 600-650-grit sandpaper is used for sanding.

[0043] In this embodiment, during preparation of the base layer, pile fibers are heat-pressed on a soldering iron heating plane at a temperature of 120-150° C. for 1-10 s, and an angle between the soldering iron heating plane and the second pile fibers is 45°-75°.

[0044] In this embodiment, during preparation of the base layer, the erected pile fibers are sheared before the heat-pressing, until a length of the pile fibers is 1-5 mm.

[0045] In this embodiment, the compression roller is used for lamination at room temperature and a pressure of 10-50 N / m2.

[0046] In this embodiment, anti-slip silicone is applied to a bottom surface of the base layer, and a specific method is as follows: place TPU or EVA pellets into a glue barrel of a glue dispenser, heat the glue barrel to 150° C. until the pellets are melt, and stir evenly; and use a dispensing needle with a diameter of 2-3 mm for dispensing at a pressure of 0.5-0.7 MPa for 0.1-0.5 s, where a dispensing spacing in both warp and weft directions is 3-6 cm, with a circular shape, an array arrangement, and a density of 400-500 dots / m2.Specific Example ParametersAngleofheatingSandpaperHeat-planeRawRawforHeat-pressingforLengthLengthmaterialmaterialsandingpressingdurationheat-of theof thefinenessfinenessRaw materialRaw materialthetemperatureof thepressingfirstsecondof theof theof the surfaceof the basesurfaceof the basebasethe basepilepilesurfacebaselayerlayerlayerlayerlayerlayerfibersfiberslayerlayerExample 1PolyesterPolyester600-grit120° C.10 s 30°1 mm5 mm100100dtexdtexExample 2PolyamidePolypropylene650-grit130° C.7 s45°2 mm4 mm130200sea-islandfibersdtexdtexmultifilamentExample 3PolyesterPolypropylene700-grit140° C.4 s60°3 mm5 mm150300fibersdtexdtexExample 4PolyamidePolyester600-grit150° C.1 s75°4 mm2 mm160500sea-islanddtexdtexmultifilamentExample 5PolyesterPolypropylene550-grit160° C.1 s80°5 mm1 mm200500fibersdtexdtexComparativeViscosePolyester600-grit120° C.10 s 30°1 mm5 mm100100Example 1fibersdtexdtexComparativeVinylonPolypropylene550-grit130° C.7 s45°5 mm1 mm150200Example 2fibersdtexdtexComparativePolyesterViscose fibers650-grit150° C.5 s75°1 mm5 mm200300Example 3dtexdtexComparativePolyamideVinylon700-grit160° C.3 s80°5 mm1 mm200500Example 4sea-islanddtexdtexmultifilamentPerformance Test:

[0047] (1) peeling strength: the peeling strength between the surface layer and the base layer is measured in accordance with GB / T 26843-2011 Carpet-Determination of resistance to delamination of the backing; and

[0048] (2) relative sliding displacement between the surface layer and the base layer: an adult steps on the carpet laid flat on the ground for 10 min, after which relative displacement between an edge of the surface layer and the base layer is observed and recorded.

[0049] Grade 1: stable connection between the surface layer and the base layer, and no relative sliding displacement;

[0050] grade 2: basically stable connection between the surface layer and the base layer, slight displacement between an edge of the surface layer and the base layer, and a displacement distance of <1 mm;

[0051] grade 3: generally stable connection between the surface layer and the base layer, relative displacement between an edge of the surface layer and the base layer, which does not affect normal use, where 1 mm<a displacement distance≤3 mm;

[0052] grade 4: instable connection between the surface layer and the base layer, relative displacement between an edge of the surface layer and the base layer, which affects normal use, where a displacement distance is >3 mm; and

[0053] grade 5: extremely instable connection between the surface layer and the base layer, significant displacement between an edge of the surface layer and the base layer, and a displacement distance of >3 mm.

[0054] The performance testing results are as follows:Peeling strengthRelative slidingbetween thedisplacement betweensurface layer andthe surface layerthe base layer / Nand the base layerExample 141Grade 3Example 253Grade 1Example 340Grade 3Example 447Grade 2Example 548Grade 3Comparative Example 110Grade 4Comparative Example 28Grade 5Comparative Example 39Grade 4Comparative Example 47Grade 5

[0055] The above performance test results show that polyester, polyamide sea-island multifilaments and polypropylene fibers can be combined to prepare the surface layer and the base layer of the easy-to-wash detachable carpet of the present disclosure that interlock with each other. However, it is difficult to prepare the surface layer and the base layer that interlock with each other when using any other fabrics. Stability of interlocked connection between the surface layer and the base layer is also significantly related to sanding, heat-pressing and heating angle, and any layer of pile fibers of the surface layer and the base layer should not be too short. The 650-grit sandpaper is used for sanding the surface layer, heat-pressing is performed at 130° C., and the second pile fibers are inclined at 45°, to obtain the carpet with the surface layer and the base layer that interlock with each other stably.

[0056] Based on the disclosures and teachings in the above specification, those skilled in the art may also make changes and modifications to the above embodiments. Therefore, the present disclosure is not limited to the specific embodiments disclosed and described above. Any modifications and changes to the present disclosure should also fall within the protection scope of the claims of the present disclosure. Furthermore, although some specific terms have been used in the specification, these terms are merely for convenience of description and shall not be construed as limiting the present disclosure.

Examples

Embodiment Construction

[0032]In order to make the objectives, technical solutions and advantages of the examples of the present disclosure clearer, the technical solutions in the examples of the present disclosure will be clearly and completely described below in combination with the accompanying drawings in the examples of the present disclosure. Apparently, the examples described are merely some rather than all of the examples of the present disclosure. Based on the examples of the present disclosure, all other examples acquired by those of ordinary skill in the art without making creative efforts fall within the scope of protection of the present disclosure.

[0033]In the present disclosure, the term “comprising” and other equivalent descriptions mentioned in the specification and claims are intended to cover non-exhaustive inclusions, and encompass the content explicitly described in the specification and claims, and also steps or units inherent in the products, methods or structures that are not descri...

TECHNICAL FIELD

[0001] The present disclosure relates to the technical field of carpet manufacturing, and specifically relates to an easy-to-wash detachable carpet and a preparation method therefor.BACKGROUND

[0002] A carpet is a high-grade floor-covering decorative material made from raw materials such as animal hair, plant fibers, synthetic fibers and the like through processing steps of weaving, cutting, and the like. Carpets have the characteristics of being soft, comfortable and safe in use, and are particularly suitable for floor decoration in bedrooms, living rooms, and studies of homes. Wall-to-wall carpeting or partial carpeting is performed as part of home decoration, and a satisfactory decorative effect can be achieved. However, carpets will become increasingly dirty due to dust accumulation and bacteria proliferation after use over time, which will lead to discomfort and even cause symptoms such as skin allergies and inflammation. Therefore, carpets need to be washed and cleaned after a period of use. Due to a heavy weight and a significant increase in water absorption during washing, a carpet is cleaned in an extremely inconvenient manner. Moreover, frequent replacement of new carpets also results in resource waste, which does not conform to the life concept of being low-carbon and environmentally friendly.

[0003] Therefore, there is an urgent need for an easy-to-wash carpet.SUMMARY

[0004] In order to overcome the common defects of carpets in the prior art including washing difficulty and maintenance inconvenience, an objective of the present disclosure is to provide an easy-to-wash detachable carpet where a surface layer and a base layer thereof are detachable, and the lightweight surface layer can be removed and cleaned easily when needed, which meets hygiene requirements for carpet use.

[0005] To achieve the above objective, the present disclosure adopts the following technical solution:

[0006] an easy-to-wash detachable carpet, including:

[0007] a surface layer, a warp-knitted suede-like fabric layer, including a first pile surface made up of first pile fibers;

[0008] a base layer, a single-sided cut-pile fabric layer, including a second pile surface made up of second pile fibers, where the second pile fibers are inclined; and

[0009] the first pile surface faces the second pile surface, and the first pile fibers penetrate the second pile fibers and interlock with the second pile fibers.

[0010] Further, the first pile fibers interlock with the second pile fibers at roots thereof, and an angle of interlocking formed between the first pile fibers and the second pile fibers is 45°-75°.

[0011] Further, a length of the first pile fibers is 1-5 mm, and the first pile fibers are in a curled shape; and a length of the second pile fibers is also 1-5 mm, and the second pile fibers are in an inclined rod shape.

[0012] Further, anti-slip silicone is arranged at a bottom of the single-sided cut-pile fabric layer.

[0013] The present disclosure further provides a preparation method for the easy-to-wash detachable carpet, and the preparation method includes the following steps:

[0014] preparation of the surface layer: warp-knitting with a polyester or polyamide sea-island multifilament with a fineness of 100-160 dtex as a raw material, where a 5-satin or 6-satin weave structure is used for warp knitting; then performing alkali deweighting with an alkaline solution; after heat-setting, performing unilateral sanding to form the first pile fibers; and

[0015] preparation of the base layer: weaving with polyester or polypropylene fibers with a fineness of 100-500 dtex; after weaving, brushing pile fibers to erect same vertically; then heat-pressing the erected pile fibers on an inclined heating plane, to make the heat-pressed pile fibers inclined and form the second pile fibers; and

[0016] lamination: making the second pile fibers of the base layer face upward, making the first pile fibers of the surface layer face downward, and using a compression roller to press the surface layer onto the base layer, such that the first pile fibers penetrate and interlock with the second pile fibers.

[0017] Further, the alkaline solution used for the alkali deweighting during preparation of the surface layer is NaOH, with a concentration of 1-5 g / L, a temperature of 100-150° C., and a treatment duration of 30-60 min; a heat-setting temperature is 150-180° C., and a heat-setting duration is 15-30 min; and 600-650-grit sandpaper is used for sanding.

[0018] Further, during preparation of the base layer, pile fibers are heat-pressed on a soldering iron heating plane at a temperature of 120-150° C. for 1-10 s, and an angle between the soldering iron heating plane and the second pile fibers is 15°-45°.

[0019] Further, during preparation of the base layer, the erected pile fibers are sheared before the heat-pressing, until a length of the pile fibers is 1-5 mm.

[0020] Further, a gram weight of the surface layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; a gram weight of the base layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; the first pile fibers are polyester or nylon fibers with a fineness of 0.1-0.6 dtex, and a density of the first pile fibers is 400-1600 fibers / cm2; the second pile fibers are polyester or polypropylene fibers with a fineness of 100-500 dtex, a density of the second pile fibers is 625-2500 fibers / cm2, and an initial modulus of the second pile fibers is greater than 60 cN / dtex.

[0021] Further, the step of applying anti-slip silicone to a bottom surface of the base layer is further included, and dots of the anti-slip silicone are arranged in an array, with a density of 400-500 dots / m2.

[0022] Compared with the prior art, the present disclosure has the beneficial effects as follows:

[0023] The easy-to-wash detachable carpet of the present disclosure includes the surface layer and the base layer, the surface layer and the base layer can be detached from each other, and a detachable structure therebetween is achieved through an interlocking structure between the first pile fibers of the surface layer and the second pile fibers of the base layer. The two layers are combined very tightly and are not displaced easily during use, but the surface layer can be manually removed for washing in a lightweight and very convenient manner. Moreover, detachable connection can be achieved without need of additional detachable accessories (such as hook-and-loop fasteners) and adhesives, thereby reducing the carpet cost, and ensuring to be environmentally friendly cost-effective.

[0024] The anti-slip silicone is arranged at a bottom of the base layer (i.e., a surface in contact with the ground) of the easy-to-wash detachable carpet of the present disclosure, which enhances the anti-slip performance of the carpet in contact with the ground and ensures safety during use.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is a structural schematic diagram of an easy-to-wash detachable carpet of the present disclosure.

[0026] FIG. 2 is a structural schematic diagram of a surface layer of an easy-to-wash detachable carpet of the present disclosure.

[0027] FIG. 3 is an exploded view of a structure of a surface layer of an easy-to-wash detachable carpet of the present disclosure.

[0028] FIG. 4 is a structural schematic diagram of a base layer of an easy-to-wash detachable carpet of the present disclosure.

[0029] FIG. 5 is an exploded view of a structure of a base layer of an easy-to-wash detachable carpet of the present disclosure.

[0030] FIG. 6 is a schematic diagram of heat-pressing a base layer of an easy-to-wash detachable carpet of the present disclosure.REFERENCE NUMERALS IN THE FIGURES

[0031] 1. surface layer; 11. first pile fibers; 12. first pile surface; 2. base layer; 21. second pile fibers; 22. second pile surface; and 30. heating plane.DETAILED DESCRIPTIONS OF THE EMBODIMENTS

[0032] In order to make the objectives, technical solutions and advantages of the examples of the present disclosure clearer, the technical solutions in the examples of the present disclosure will be clearly and completely described below in combination with the accompanying drawings in the examples of the present disclosure. Apparently, the examples described are merely some rather than all of the examples of the present disclosure. Based on the examples of the present disclosure, all other examples acquired by those of ordinary skill in the art without making creative efforts fall within the scope of protection of the present disclosure.

[0033] In the present disclosure, the term “comprising” and other equivalent descriptions mentioned in the specification and claims are intended to cover non-exhaustive inclusions, and encompass the content explicitly described in the specification and claims, and also steps or units inherent in the products, methods or structures that are not described in the specification and claims.

[0034] With reference to FIGS. 1-5, an easy-to-wash detachable carpet is disclosed in this embodiment, including a surface layer 1 and a base layer 2, where the base layer 2 is located below, and the surface layer 1 is detachably connected above the base layer. The surface layer is a warp-knitted suede-like fabric layer, including a first pile surface 12 made up of first pile fibers 11. The base layer is a single-sided cut-pile fabric layer, including a second pile surface 22 made up of second pile fibers 21, where the second pile fibers 21 are inclined, indicating that they are tilted at a certain angle relative to a horizontal plane. The first pile surface 12 faces the second pile surface 22, and the first pile fibers 11 penetrate the second pile fibers 21 and interlock with the second pile fibers 21. Specifically, the first pile fibers interlock with the second pile fibers at roots thereof, and an angle of interlocking formed between the first pile fibers and the second pile fibers is 45°-75°.

[0035] In this embodiment, a length of the first pile fibers is 1-5 mm, and the first pile fibers are in a curled shape; and a length of the second pile fibers is also 1-5 mm, and the second pile fibers are in an inclined rod shape.

[0036] In this embodiment, anti-slip silicone is arranged at a bottom of the single-sided cut-pile fabric layer to prevent the base layer from slipping relative to the ground during use.

[0037] In this embodiment, a gram weight of the surface layer 1 is 300-600 g / m2 and a thickness thereof is 3-10 mm; a gram weight of the base layer 2 is 300-600 g / m2 and a thickness thereof is 3-10 mm; the first pile fibers 11 are polyester or nylon fibers with a fineness of 0.1-0.6 dtex, and a density of the first pile fibers 11 is 400-1600 fibers / cm2; the second pile fibers 21 are polyester or polypropylene fibers with a fineness of 100-500 dtex, a density of the second pile fibers 21 is 625-2500 fibers / cm2, and an initial modulus of the second pile fibers is greater than 60 cN / dtex. The first pile fibers 11 are ultra-fine fibers with a small fineness and a curled shape, and the second pile fibers have a high initial modulus, rigidity and an inclined shape, such that the first pile fibers 11 easily penetrate the second pile fibers 21 and interlock with the second pile fibers 21, thereby ensuring that the surface layer 1 will not slide apart from the base layer 2. Moreover, the first pile fibers 11 are curled fine fibers, and are easily separated from the second pile fibers 21 under the action of a large pulling force, and a detachable connection between the surface layer and the base layer is achieved through a morphology and connection structure of the first pile fibers 11 and the second pile fibers 21.

[0038] The easy-to-wash detachable carpet of this embodiment is prepared through the following method:

[0039] preparation of the surface layer: warp-knit with a polyester or polyamide sea-island multifilament with a fineness of 100-160 dtex as a raw material, where a 5-satin or 6-satin weave structure is used for warp knitting; then perform alkali deweighting with an alkaline solution; after heat-setting, perform unilateral sanding to form the first pile fibers; and

[0040] preparation of the base layer: weave with polyester or polypropylene fibers with a fineness of 100-500 dtex; after weaving, brush pile fibers to erect same vertically; then heat-press the erected pile fibers on an inclined heating plane, to make the heat-pressed pile fibers inclined and form the second pile fibers; and with reference to FIG. 6, during the heat-pressing, form an angle α between a heating plane 30 and the second pile surface 22, then horizontally transmit the second pile fibers 21, and heat same through the heating plane 30, until the second pile fibers 21 tilt at the angle α relative to the horizontal plane.

[0041] Lamination: make the second pile fibers of the base layer face upward, make the first pile fibers of the surface layer face downward, and use a compression roller to press the surface layer onto the base layer, such that the first pile fibers interlock with the second pile fibers.

[0042] In this embodiment, the alkaline solution used for the alkali deweighting during preparation of the surface layer is NaOH, with a concentration of 1-5 g / L, a temperature of 100-150° C., and a treatment duration of 30-60 min; a heat-setting temperature is 150-180° C., and a heat-setting duration is 15-30 min; and 600-650-grit sandpaper is used for sanding.

[0043] In this embodiment, during preparation of the base layer, pile fibers are heat-pressed on a soldering iron heating plane at a temperature of 120-150° C. for 1-10 s, and an angle between the soldering iron heating plane and the second pile fibers is 45°-75°.

[0044] In this embodiment, during preparation of the base layer, the erected pile fibers are sheared before the heat-pressing, until a length of the pile fibers is 1-5 mm.

[0045] In this embodiment, the compression roller is used for lamination at room temperature and a pressure of 10-50 N / m2.

[0046] In this embodiment, anti-slip silicone is applied to a bottom surface of the base layer, and a specific method is as follows: place TPU or EVA pellets into a glue barrel of a glue dispenser, heat the glue barrel to 150° C. until the pellets are melt, and stir evenly; and use a dispensing needle with a diameter of 2-3 mm for dispensing at a pressure of 0.5-0.7 MPa for 0.1-0.5 s, where a dispensing spacing in both warp and weft directions is 3-6 cm, with a circular shape, an array arrangement, and a density of 400-500 dots / m2.Specific Example ParametersAngleofheatingSandpaperHeat-planeRawRawforHeat-pressingforLengthLengthmaterialmaterialsandingpressingdurationheat-of theof thefinenessfinenessRaw materialRaw materialthetemperatureof thepressingfirstsecondof theof theof the surfaceof the basesurfaceof the basebasethe basepilepilesurfacebaselayerlayerlayerlayerlayerlayerfibersfiberslayerlayerExample 1PolyesterPolyester600-grit120° C.10 s 30°1 mm5 mm100100dtexdtexExample 2PolyamidePolypropylene650-grit130° C.7 s45°2 mm4 mm130200sea-islandfibersdtexdtexmultifilamentExample 3PolyesterPolypropylene700-grit140° C.4 s60°3 mm5 mm150300fibersdtexdtexExample 4PolyamidePolyester600-grit150° C.1 s75°4 mm2 mm160500sea-islanddtexdtexmultifilamentExample 5PolyesterPolypropylene550-grit160° C.1 s80°5 mm1 mm200500fibersdtexdtexComparativeViscosePolyester600-grit120° C.10 s 30°1 mm5 mm100100Example 1fibersdtexdtexComparativeVinylonPolypropylene550-grit130° C.7 s45°5 mm1 mm150200Example 2fibersdtexdtexComparativePolyesterViscose fibers650-grit150° C.5 s75°1 mm5 mm200300Example 3dtexdtexComparativePolyamideVinylon700-grit160° C.3 s80°5 mm1 mm200500Example 4sea-islanddtexdtexmultifilamentPerformance Test:

[0047] (1) peeling strength: the peeling strength between the surface layer and the base layer is measured in accordance with GB / T 26843-2011 Carpet-Determination of resistance to delamination of the backing; and

[0048] (2) relative sliding displacement between the surface layer and the base layer: an adult steps on the carpet laid flat on the ground for 10 min, after which relative displacement between an edge of the surface layer and the base layer is observed and recorded.

[0049] Grade 1: stable connection between the surface layer and the base layer, and no relative sliding displacement;

[0050] grade 2: basically stable connection between the surface layer and the base layer, slight displacement between an edge of the surface layer and the base layer, and a displacement distance of <1 mm;

[0051] grade 3: generally stable connection between the surface layer and the base layer, relative displacement between an edge of the surface layer and the base layer, which does not affect normal use, where 1 mm<a displacement distance≤3 mm;

[0052] grade 4: instable connection between the surface layer and the base layer, relative displacement between an edge of the surface layer and the base layer, which affects normal use, where a displacement distance is >3 mm; and

[0053] grade 5: extremely instable connection between the surface layer and the base layer, significant displacement between an edge of the surface layer and the base layer, and a displacement distance of >3 mm.

[0054] The performance testing results are as follows:Peeling strengthRelative slidingbetween thedisplacement betweensurface layer andthe surface layerthe base layer / Nand the base layerExample 141Grade 3Example 253Grade 1Example 340Grade 3Example 447Grade 2Example 548Grade 3Comparative Example 110Grade 4Comparative Example 28Grade 5Comparative Example 39Grade 4Comparative Example 47Grade 5

[0055] The above performance test results show that polyester, polyamide sea-island multifilaments and polypropylene fibers can be combined to prepare the surface layer and the base layer of the easy-to-wash detachable carpet of the present disclosure that interlock with each other. However, it is difficult to prepare the surface layer and the base layer that interlock with each other when using any other fabrics. Stability of interlocked connection between the surface layer and the base layer is also significantly related to sanding, heat-pressing and heating angle, and any layer of pile fibers of the surface layer and the base layer should not be too short. The 650-grit sandpaper is used for sanding the surface layer, heat-pressing is performed at 130° C., and the second pile fibers are inclined at 45°, to obtain the carpet with the surface layer and the base layer that interlock with each other stably.

[0056] Based on the disclosures and teachings in the above specification, those skilled in the art may also make changes and modifications to the above embodiments. Therefore, the present disclosure is not limited to the specific embodiments disclosed and described above. Any modifications and changes to the present disclosure should also fall within the protection scope of the claims of the present disclosure. Furthermore, although some specific terms have been used in the specification, these terms are merely for convenience of description and shall not be construed as limiting the present disclosure.

Examples

Embodiment Construction

[0032]In order to make the objectives, technical solutions and advantages of the examples of the present disclosure clearer, the technical solutions in the examples of the present disclosure will be clearly and completely described below in combination with the accompanying drawings in the examples of the present disclosure. Apparently, the examples described are merely some rather than all of the examples of the present disclosure. Based on the examples of the present disclosure, all other examples acquired by those of ordinary skill in the art without making creative efforts fall within the scope of protection of the present disclosure.

[0033]In the present disclosure, the term “comprising” and other equivalent descriptions mentioned in the specification and claims are intended to cover non-exhaustive inclusions, and encompass the content explicitly described in the specification and claims, and also steps or units inherent in the products, methods or structures that are not descri...

Claims

1. An easy-to-wash detachable carpet, comprising:a surface layer, a warp-knitted suede-like fabric layer, comprising a first pile surface made up of first pile fibers;a base layer, a single-sided cut-pile fabric layer, comprising a second pile surface made up of second pile fibers, wherein the second pile fibers are inclined; andthe first pile surface faces the second pile surface, and the first pile fibers penetrate the second pile fibers and interlock with the second pile fibers.

2. The easy-to-wash detachable carpet according to claim 1, wherein the first pile fibers interlock with the second pile fibers at roots thereof, and an angle of interlocking formed between the first pile fibers and the second pile fibers is 45°-75°.

3. The easy-to-wash detachable carpet according to claim 2, wherein a length of the first pile fibers is 1-5 mm, and the first pile fibers are in a curled shape; and a length of the second pile fibers is also 1-5 mm, and the second pile fibers are in an inclined rod shape.

4. The easy-to-wash detachable carpet according to claim 1, wherein anti-slip silicone is arranged at a bottom of the single-sided cut-pile fabric layer.

5. A preparation method for the easy-to-wash detachable carpet according to claim 1, comprising the following steps:preparation of the surface layer: warp-knitting with a polyester or polyamide sea-island multifilament with a fineness of 100-160 dtex as a raw material, wherein a 5-satin or 6-satin weave structure is used for warp knitting; then performing alkali deweighting with an alkaline solution; after heat-setting, performing unilateral sanding to form the first pile fibers; andpreparation of the base layer: weaving with polyester or polypropylene fibers with a fineness of 100-500 dtex; after weaving, brushing pile fibers to erect same vertically; then heat-pressing the erected pile fibers on an inclined heating plane, to make the heat-pressed pile fibers inclined and form the second pile fibers; andlamination: making the second pile fibers of the base layer face upward, making the first pile fibers of the surface layer face downward, and using a compression roller to press the surface layer onto the base layer, such that the first pile fibers penetrate and interlock with the second pile fibers.

6. The preparation method for the easy-to-wash detachable carpet according to claim 5, wherein the alkaline solution used for the alkali deweighting during preparation of the surface layer is NaOH, with a concentration of 1-5 g / L, a temperature of 100-150° C., and a treatment duration of 30-60 min; a heat-setting temperature is 150-180° C., and a heat-setting duration is 15-30 min; and 600-650-grit sandpaper is used for sanding.

7. The preparation method for the easy-to-wash detachable carpet according to claim 5, wherein during preparation of the base layer, pile fibers are heat-pressed on a soldering iron heating plane at a temperature of 120-150° C. for 1-10 s, and an angle between the soldering iron heating plane and the second pile fibers is 15°-45°.

8. The preparation method for the easy-to-wash detachable carpet according to claim 5, wherein during preparation of the base layer, the erected pile fibers are sheared before the heat-pressing, until a length of the pile fibers is 1-5 mm.

9. The preparation method for the easy-to-wash detachable carpet according to claim 5, wherein a gram weight of the surface layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; a gram weight of the base layer is 300-600 g / m2 and a thickness thereof is 3-10 mm; the first pile fibers are polyester or nylon fibers with a fineness of 0.1-0.6 dtex, and a density of the first pile fibers is 400-1600 fibers / cm2; the second pile fibers are polyester or polypropylene fibers with a fineness of 100-500 dtex, a density of the second pile fibers is 625-2500 fibers / cm2, and an initial modulus of the second pile fibers is greater than 60 cN / dtex.

10. The preparation method for the easy-to-wash detachable carpet according to claim 5, wherein the step of applying anti-slip silicone to a bottom surface of the base layer is further comprised, and dots of the anti-slip silicone are arranged in an array, with a density of 400-500 dots / m2.

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