Mat having integrated TPE bottom backing border and preparation method therefor

Abstract

The present invention provides a mat having an integrated TPE bottom backing border and a preparation method therefor. The mat comprises a mat surface layer and a bottom backing border integrated layer; the bottom backing border integrated layer comprises an upper TPE layer, an intermediate layer, and a lower TPE layer, where the intermediate layer is positioned between the upper TPE layer and the lower TPE layer; the upper TPE layer is completely surrounded by a border; and the bottom surface of the mat surface layer is connected to the top surface of the upper TPE layer. The mat having an integrated TPE bottom backing border of the present invention has a stable structure and size; by means of adding an intermediate layer (i.e., a high-strength lightweight fabric layer or a high-strength membrane) into the bottom backing border integrated layer, the mat is not prone to the corners curling up, has high break strength, is highly safe, and has excellent slip resistance and durability, thereby improving consumer experience. Additionally, the preparation method of the present invention does not use molds and supports large-scale continuous production, which has the advantages of high manufacturing efficiency, energy savings, and eco-friendliness.

Description

TPE bottom, back and frame integrated carpet and preparation method thereof Technical Field

[0001] The invention belongs to the field of textile carpets and relates to a TPE bottom, back and frame integrated carpet and a preparation method thereof. Background Art

[0002] Doormats are common floor covering materials in daily life, used to absorb moisture, dust, etc. and keep the room clean. Traditional doormats with frames are mainly made of PVC (polyvinyl chloride) or rubber materials. Although doormats made of these materials have certain use effects, they are complicated in process, inefficiency, weak tear strength of the product frame, strong odor, and the production process has certain harm to the environment. There are still certain problems in recycling and other aspects. In addition, the existing carpets using TPE frames require the production of molds and are hot-pressed by a hot press, resulting in low efficiency and high cost. Therefore, those skilled in the art are committed to developing a carpet production method that can be produced on a large scale and continuously without the use of molds.

[0003] Summary of the Invention

[0004] The present invention aims to overcome the shortcomings and deficiencies of existing technologies by providing a TPE carpet with an integrated base, back, and frame, and a method for its preparation. This method eliminates the need for molds and allows for continuous, large-scale production. Furthermore, by adding an intermediate layer and forming an integrated base, back, and frame structure, the breaking strength of the frame is enhanced, while also preventing the carpet's corners from warping.

[0005] The present inventors discovered that, because the TPE layer in existing frameless TPE carpets is covered with a cushioning carpet surface layer, the breaking strength requirement for the TPE layer is not high. However, the frame surface of framed carpets is not covered with a carpet surface layer, which makes the frame prone to breaking during actual use. Therefore, the carpet in the present invention comprises a carpet surface layer, a TPE bottom-back-frame layer embedded below the carpet back layer, and an intermediate layer (i.e., a thin fabric layer or a high-strength film) within the bottom-back-frame layer. The addition of this intermediate layer improves the frame's breaking strength, making it more environmentally friendly, easier to recycle, and more environmentally friendly during the recycling process.

[0006] The purpose of the present invention can be achieved by the following solutions:

[0007] In a first aspect, the present invention provides a TPE bottom, back, and frame integrated carpet, the carpet comprising a carpet surface layer and a bottom, back, and frame integrated layer; the bottom, back, and frame integrated layer comprising an upper TPE layer, an intermediate layer, and a lower TPE layer, wherein an intermediate layer is provided between the upper and lower TPE layers, and the upper TPE layer has a frame around it; the bottom surface of the carpet surface layer is connected to the top surface of the upper TPE layer;

[0008] The middle layer includes at least one of a light and thin fabric and a high-strength film; the material of the light and thin fabric includes at least one of a natural material, a chemical fiber material, and a glass fiber; the material of the high-strength film includes at least one of PP, PA, PE, and PET.

[0009] The upper TPE layer, the lower TPE layer, the middle layer and the frame are an integrally formed structure.

[0010] As an embodiment of the present invention, the material of the thin fabric includes at least one of polyester, polypropylene, nylon, and glass fiber.

[0011] As an embodiment of the present invention, the fabric process of the thin fabric includes at least one of woven, knitted, and non-woven fabrics.

[0012] In the present invention, an intermediate layer is added to the bottom, back and frame integrated layer, so that the four corners of the carpet are not easy to warp and the breaking strength of the carpet frame is improved.

[0013] As an embodiment of the present invention, the TPE dosage of the bottom, back and frame integrated layer is 300-3000 g / m2.

[0014] In this invention, the upper and lower TPE layers, the middle layer, and the frame are integrally molded. This creates an integrated base, back, and frame layer with excellent frame breaking strength, enabling large-scale continuous production without the use of molds. The TPE base, back, and frame integrated carpet of this invention, through its integrated structure and the addition of the middle layer, synergistically improves the frame breaking strength of the carpet.

[0015] As an embodiment of the present invention, the carpet surface layer includes one of a tufted carpet surface layer, a knitted carpet surface layer, a woven carpet surface layer, a needle-punched carpet surface layer, a flocked carpet surface layer, and a hand-woven carpet surface layer; the material of the carpet surface layer includes one or more of chemical fibers, natural fibers, and blended fibers.

[0016] As an embodiment of the present invention, the weight of the carpet surface layer is 120-2000 g / m 2 .

[0017] As an embodiment of the present invention, the height of the pile in the carpet surface layer ranges from 3 to 20 mm.

[0018] In the present invention, the surface layer of the upper blanket can be printed with various patterns, or decorated with patches, embroidery and other decorative techniques using homogeneous fabrics.

[0019] As an embodiment of the present invention, the width of the frame is 0.3-6 cm. If the frame width is less than 0.3 cm, it is too narrow, which makes the frame less practical and is not conducive to production operations; if the frame width is greater than 6 cm, it is too wide and uncoordinated.

[0020] In a second aspect, the present invention provides a method for preparing a TPE base, back, and frame integrated carpet, comprising the following steps:

[0021] S1. Apply TPE material to both sides of the middle layer to form an integrated bottom, back and frame layer;

[0022] S2. Coating TPE material on the bottom surface of the carpet surface layer, then compounding it with the bottom back frame integral layer, heating and rolling to form a frame, and obtaining a TPE bottom back frame integral carpet.

[0023] As an embodiment of the present invention, in step S1, the method for preparing the TPE material includes: using a laminating machine, an injection molding machine, or a casting machine to extrude, press, and cool the TPE particles into a film to form a TPE film.

[0024] In some preferred embodiments, the Shore A hardness of the TPE particles is 30-85 A. If the Shore A hardness of the TPE particles is less than 30 A, they are too soft and may deform after washing. If the hardness is greater than 85 A, they are too hard, resulting in slow recovery after curling and extrusion, or difficulty in regaining their shape after being heated and extruded.

[0025] In some preferred embodiments, the working temperature of the laminating machine is 130-250° C., and the speed is 1-10 m / min; the working temperature of the casting machine is 170-220° C., and the speed is 2-10 m / min.

[0026] As an embodiment of the present invention, step S1 further includes coating TPE material on either side of the middle layer as an upper TPE layer; and the TPE material penetrates the middle layer to form an anti-slip surface layer on the other side as a lower TPE layer.

[0027] As an embodiment of the present invention, in step S2, the method for preparing the TPE material includes: melting the TPE particles using a laminating machine, an injection molding machine, a casting machine, a roller-coating hot melt adhesive machine, or a hot melt adhesive spraying machine.

[0028] As an embodiment of the present invention, in step S2, the amount of TPE used is 100-3000 g / m2.

[0029] In the present invention, the size (length×width) of the carpet surface layer is smaller than that of the backing integrated layer (length×width), that is, the area of ​​the backing integrated layer is larger than that of the carpet surface layer, and a TPE frame is formed around the carpet surface layer.

[0030] As one embodiment of the present invention, in step S2, the heating temperature is 90-250°C, and the pressure of the pressure roller is 2-8 kg. After the heating softens the TPE on the bottom surface of the carpet surface layer and the TPE on the backing layer to a semi-molten state, the pressure rollers are used to bond the carpet surface layer and the backing layer together, forming a frame. The carpet surface layer is now a single piece of carpet tile, and the backing layer can be a single sheet or a roll.

[0031] In some preferred embodiments, in step S2, the carpet surface layer is placed on top of the backing integrated layer, and the layers are placed in an oven for heating or placed on a Teflon mesh belt and sent to a transfer printing machine for heating and pressurization.

[0032] The present invention can also replace TPE with EVA to obtain an EVA bottom, back and frame integrated carpet.

[0033] Compared with the prior art, the present invention has the following beneficial effects:

[0034] 1. The present invention improves the breaking strength of the carpet frame by adding an intermediate layer (i.e., a thin fabric layer or a high-strength film) to the bottom, back, and frame integrated layer. As a result, the prepared TPE bottom, back, and frame integrated carpet has excellent breaking strength, meeting the durability requirements of carpets with frames.

[0035] 2. The present invention adopts an integrated structure of the upper TPE layer, the lower TPE layer, the middle layer and the frame, which further improves the breaking strength of the frame. At the same time, the addition of the middle layer makes the four corners of the carpet less likely to warp, solving the problem of easy warping of traditional carpets with frames.

[0036] 3. The preparation method of the present invention forms a frame by cutting a carpet surface layer of a certain size and compounding it with the bottom and back frame integral layer of the reserved frame; compared with the frame obtained by using a pressing machine in the traditional pressing method, which is level with and connected to the carpet surface layer, the frame formed by the preparation method of the present invention is not connected to the carpet surface layer, which solves the technical problems such as easy tearing of the frame and the carpet surface layer; at the same time, the preparation method does not need to use a mold and can be used for continuous large-scale production, with the characteristics of high manufacturing efficiency, energy saving and environmental protection.

[0037] 4. The TPE bottom, back and frame integrated carpet of the present invention has high safety, good anti-slip properties, and is durable, thereby improving the consumer experience. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Other features, objects and advantages of the present invention will become more apparent upon reading the detailed description of non-limiting embodiments with reference to the following drawings:

[0039] FIG1 is a schematic structural diagram of Example 1;

[0040] FIG2 is a schematic structural diagram of Example 2;

[0041] Figure 3 is a schematic structural diagram of Comparative Example 1;

[0042] Reference numerals: 1, carpet surface layer, 2, bottom, back and frame integrated layer, 3, upper TPE layer, 4, middle layer, 5, lower TPE layer, 6, frame. DETAILED DESCRIPTION

[0043] The present invention is described in detail below with reference to the accompanying drawings and specific embodiments. The following examples are implemented under the premise of the technical solution of the present invention, provide detailed implementation methods and specific operating procedures, and will help those skilled in the art to further understand the present invention. It should be pointed out that the scope of protection of the present invention is not limited to the following embodiments, and a number of adjustments and improvements made under the premise of the concept of the present invention all fall within the scope of protection of the present invention.

[0044] Example 1

[0045] This embodiment provides a TPE base, back and frame integrated carpet, the structure of which is shown in FIG1 , and the preparation steps are as follows:

[0046] Step 1: Select a roll of thin, lightweight, 120gsm, 159cm wide, all-polyester Oxford fabric as the middle layer 4. Select TPE particles with a Shore A hardness of 75A. Use a laminating machine operating at a temperature of 170°C and a speed of 5m / min to coat the molten TPE film on both sides of the all-polyester Oxford fabric, forming an upper TPE layer 3 and a lower TPE layer 5. This creates a blanket with an integrated bottom, back, and frame layer. The blanket is then cut into 40x60cm pieces for later use. The TPE usage is 1400gsm.

[0047] Step 2: A tufted cut-pile nylon carpet with a pile height of 4 mm and a non-woven long-fiber base fabric is selected, and the blanket weight is 350 gsm. The blanket is placed in a TPE laminating machine and coated with 400 gsm of TPE on the back of the blanket surface to form the blanket surface layer of the present invention, i.e., the blanket surface layer 1. After cooling, the blanket is cut into 36 x 56 cm small pieces for standby use; TPE particles with a Shore hardness (HS hardness) of 75A are selected; the laminating machine operates at a temperature of 170 degrees and a speed of 5 m / min.

[0048] Step 3: Heat the TPE layers of the bottom, back, and frame integrated layer to 140 degrees Celsius to soften the TPE. Then place the back of the softened carpet surface layer and the bottom, back, and frame integrated layer together, and use a pressure roller to press the upper and lower layers together. The pressure is 4 kg to form a bottom, back, and frame integrated layer 2 with a frame 6. The frame width is 2 cm, and a TPE bottom, back, and frame integrated carpet is obtained.

[0049] Step 4: Trim, pack and ship.

[0050] Example 2

[0051] This embodiment provides a TPE base, back and frame integrated carpet, the preparation steps of which are as follows:

[0052] Step 1: Prepare a roll of meshed 80gsm glass fiber cloth, 159cm wide, as the middle layer 4. Use a TPE laminating machine to laminate the TPE and glass fiber cloth to form a blanket with an integrated backing layer for later use. One side of the blanket is completely covered with TPE, with no visible glass fiber cloth on the surface; this is called the TPE-covered surface, or upper TPE layer 3. The other side of the blanket has a non-slip surface formed by TPE penetrating the glass fiber cloth, forming dots, or lower TPE layer 5. The laminating machine operates at a temperature of 170°C and a speed of 5m / min. The TPE used is 1200gsm, and the TPE particles are black HS 65A.

[0053] Step 2: Select a 6mm polypropylene cut pile two-color horizontally shifted blanket with a weight of 450gsm and a PP woven base fabric. Coat the back of the tufted blanket roll with 350gsm TPE. Use HS 45A TPE particles. Set the machine operating temperature at 200°C and the laminating speed at 7m / min. Allow the roll to cool on the edge before cutting into 46x76cm pieces to form the blanket surface layer 1 of the present invention.

[0054] Step 3: Place the rolled carpet produced in Step 1 on the Teflon mesh belt of the oven, with the TPE-covered surface facing upward and the non-slip surface facing downward in contact with the mesh belt; then place the carpet surface layers produced in Step 2 side by side on the rolled carpet, with the backing of the carpet surface layers in contact with the covering surface of the integrated layer; then rotate the mesh belt to carry the integrated layer and the carpet surface layer on the mesh belt into an oven at 130 degrees Celsius for 3 minutes; rotate the pressing roller at the oven exit to bond the upper and lower layers together, forming the bottom-back-frame integrated layer 2 having a frame 6; then rapidly cool the carpet and cut it into pieces to obtain the carpet of the present invention;

[0055] Step 4: Inspect the packaging before shipment.

[0056] Example 3

[0057] This embodiment provides a TPE base, back and frame integrated carpet, the preparation steps of which are basically the same as those in Example 1, except that a high-strength film is selected as the middle layer in step 1; the high-strength film is made of PP, has a thickness of 0.4 mm and a gram weight of 350 gsm.

[0058] Performance Testing

[0059] 1. Frame Fracture Strength Comparison Test

[0060] Testing method: A commercially available carpet with a PVC frame (double-striped PVC rubber-soled composite floor mat from Taobao) and a carpet according to an embodiment of the present invention were selected as comparison samples with identical parameters, square weight, and dimensions. The breaking strength values ​​of the two test samples were tested on a tensile testing machine for comparison.

[0061] The specific steps are as follows:

[0062] 1. Select a carpet with a PVC border on the market. The PVC weight is 1400gsm. Cut a PVC border with a width of 2cm and a length of 15cm. Select three test samples and number them 1#, 2#, and 3# respectively.

[0063] 2. Select the carpet in Example 1, the TPE weight is 1400gsm, cut a TPE frame with a width of 2cm and a length of 15cm, and select three test samples, numbered 4#, 5#, and 6# respectively;

[0064] 3. Put 1# and 4#, 2# and 5#, 3# and 6# as three groups of comparative test samples into the TH-8203A computer desktop tensile testing machine for fracture strength test, and then compare the values;

[0065] The following is a comparison of three sets of data for two test samples:

[0066] Group 1: The tensile force value of the test sample 1# with PVC frame on the market when it breaks is 50.5N;

[0067] The tensile force value of the test sample 4# with the TPE frame of Example 1 when it breaks is: 100.7N.

[0068] Group 2: The tensile force value of the test sample 2# with PVC frame on the market when it breaks is 52.3N;

[0069] The tensile force value of the test sample 5# with the TPE frame of Example 1 when it breaks is: 99.2N.

[0070] Group 3: The tensile force value of the test sample 3# with PVC frame on the market when it breaks is 48.6N;

[0071] The tensile force value of the test sample 6# with a TPE frame in Example 1 when it breaks is: 101.4N.

[0072] In summary, after comparing multiple sets of test data, it is known that since the bottom, back and frame integrated layer of the TPE bottom, back and frame integrated carpet in the present invention has an intermediate layer (i.e., a thin fabric or a high-strength film), the frame breaking strength of the TPE bottom, back and frame integrated carpet described in the present invention is better than the frame breaking strength of carpets with PVC frames on the market, making the TPE bottom, back and frame integrated carpet of the present invention more durable.

[0073] 2. Washing appearance comparison test

[0074] Testing method: A commercially available PVC anti-slip carpet (a double-striped PVC rubber-soled composite floor mat from Taobao) and a TPE-bottomed, back-framed carpet prepared in Example 2 of the present invention were selected. Comparative test samples of the same size were selected to ensure that the frames of the two test samples were identical. The two comparative test samples were then subjected to a water washing test, and the appearance of the edge protective layer of the test samples was observed after different wash times.

[0075] The specific test steps are as follows:

[0076] 1. Choose a PVC anti-slip carpet on the market, the size of which is 50X80cm, with an edge protection layer of 2cm in width;

[0077] 2. Select a TPE base, back, and frame integrated carpet from Example 2 of the present invention, with a size of 50 x 80 cm and an edge protection layer width of 2 cm;

[0078] 3. Wash the two test samples in a washing machine at the same time. The washing temperature is 45°C, the washing time is 35 minutes per wash, and the drying temperature is 70°C, the drying time is 15 minutes per wash. The washing and drying times are 1, 3, and 5 times. After different washing times, the test positions are the four borders of the two test samples.

[0079] The test results are as follows:

[0080] The appearance changes of the frame after washing and drying once:

[0081] The appearance of the borders of carpets with PVC borders on the market has changed: None

[0082] Changes in the border appearance of the TPE base, back and border integrated carpet of Example 2: None;

[0083] The appearance of the edge after washing and drying 3 times:

[0084] The appearance of the border of the carpet with PVC border on the market has changed: there is a total of 1 crack on the surface of the border

[0085] The border appearance changes of the TPE base, back and border integrated carpet of Example 2: the border surface is not cracked;

[0086] Changes in the appearance of the edges after washing and drying 5 times:

[0087] The appearance of the borders of carpets with PVC borders on the market has changed: there are three cracks on the border surface, and the border has obvious wavy edges;

[0088] The appearance change of the border of the TPE base, back and border integrated carpet of Example 2: the border surface is not cracked, and the border has a slightly wavy edge;

[0089] In summary, since PVC itself has poor durability, the TPE bottom, back and frame integrated carpet of the present invention has an intermediate layer (i.e., a thin fabric or a high-strength film) in the bottom, back and frame integrated layer, which greatly improves the overall stability of the frame. Data comparison after multiple comparative tests shows that the TPE bottom, back and frame integrated carpet has little change in the surface appearance of the frame after multiple washings, and has higher safety and user experience.

[0090] Comparative Example 1

[0091] The preparation method of this comparative example is essentially the same as that of Example 1, differing only in step 3: The TPE of the two layers of the base, back, and frame integral layer is heated to 140°C to soften the TPE. The back of the softened carpet surface layer is then placed together with the base, back, and integral layer. A press is then used to bend the edges of the softened base, back, and integral layer upward, wrapping around the intermediate layer and the carpet surface layer, flattening them, and squeezing them around the carpet surface layer. The resultant layer is then cured to form a raised TPE frame. After the heating and curing process is complete, the positioning clamps on the press are opened and the product is removed, thereby obtaining a sample carpet. The carpet structure is shown in Figure 3.

[0092] Comparative Example 2

[0093] The preparation method of this comparative example is basically the same as that of Example 1, except that no intermediate layer is used in step 1, and TPE particles with a Shore A hardness (HS) of 75A are selected. The laminating machine operates at a temperature of 170°C and a speed of 3 m / min. The molten TPE is extruded using the TPE laminating machine to form a blank blanket with an integrated bottom, back, and frame layer. The blank blanket is then cut into 40 x 60 cm pieces for later use. The amount of TPE used is 1400 gsm.

[0094] Comparative Example 3

[0095] The preparation method of this comparative example is basically the same as that of Example 1, except that the all-polyester Oxford cloth is replaced with a 30 gsm spunlace non-woven fabric in step 1.

[0096] Performance Testing

[0097] 1. Frame Fracture Strength Comparison Test

[0098] Test method: Carpets of Comparative Examples 1-3 and Example 1 were selected, and comparison samples with the same parameters, square weight, and size were selected. The breaking strength values ​​of four test samples were tested on a tensile testing machine for comparison;

[0099] The specific steps are as follows:

[0100] 1. Select the carpets of Comparative Examples 1-3, respectively, with a frame weight of 2520 gsm, cut a frame with a width of 2 cm and a length of 15 cm, and select 3 test samples respectively, numbered A1, A2, A3, B1, B2, B3, C1, C2, C3;

[0101] 2. Select the carpet border in Example 1, the TPE weight is 2520gsm, cut the TPE border with a width of 2cm and a length of 15cm, and select three test samples, numbered D, E, and F respectively;

[0102] 3. Take A1-A3 and D, B1-B3 and E, C1-C3 and F as three groups of comparative test samples and put them into the TH-8203A computer desktop tensile testing machine for fracture strength test, and then compare the values;

[0103] The following is a data comparison of four test samples:

[0104] Group 1: The tensile force value of the border test sample A1 of the carpet of comparative example 1 when it broke was 100.9N;

[0105] The tensile force value of the border test sample A2 of the carpet of comparative example 2 when it breaks is 101.7N;

[0106] The tensile force value of the border test sample A3 of the carpet of comparative example 3 when it broke was 101.4N;

[0107] The tensile force value of the test sample D of the carpet frame of Example 1 when it breaks is 101.8N.

[0108] Group 2: The tensile force value of the border test sample B1 of the carpet of comparative example 1 when it broke was 77.8N;

[0109] The tensile force value of the border test sample B2 of the carpet of comparative example 2 when it breaks is 76N;

[0110] The tensile force value of the border test sample B3 of the carpet of comparative example 3 when it broke was 78.3N;

[0111] The tensile force value of the test sample E of the carpet frame of Example 1 when it breaks is 100.4N.

[0112] Group 3: The tensile force value of the border test sample C1 of the carpet of comparative example 1 at break was 90.5N;

[0113] The tensile force value of the border test sample C2 of the carpet of comparative example 2 when it breaks is 89.9N;

[0114] The tensile force value of the border test sample C3 of the carpet of comparative example 3 when it breaks is 90.2N;

[0115] The tensile force value of the test sample F of the carpet frame of Example 1 when it breaks is 101.7N.

[0116] 2. Washing appearance comparison test

[0117] Testing method: Select one carpet each from Comparative Examples 1-3 and Example 1, and select comparison test samples of the same size to ensure that the edge protection layers of the four test samples are identical. The four comparison test samples are then subjected to a water wash test, and the changes in the appearance of the edge protection layers of the test samples after different wash cycles are observed.

[0118] The specific test steps are as follows:

[0119] 1. Select the carpets of Comparative Examples 1-3, respectively, with a size of 50x80 cm, an edge protection layer width of 2 cm, and a frame weight of 2520 gsm;

[0120] 2. Select a carpet from Example 1, with a size of 50 x 80 cm, an edge protection layer width of 2 cm, and a frame weight of 2520 gsm;

[0121] 3. Wash four test samples in a washing machine at the same time. The washing temperature is 45°C, the washing time is 35 minutes per wash, and the drying temperature is 70°C, the drying time is 15 minutes per wash. The washing and drying times are 1, 3, and 5 times. After different washing times, the test positions are the four frames of each of the four test samples.

[0122] The test results are as follows:

[0123] The appearance changes of the frame after washing and drying once:

[0124] Change in the appearance of the border of the carpet of Comparative Example 1: No change;

[0125] Change in appearance of border of carpet of comparative example 2: no change;

[0126] Changes in the appearance of the border of the carpet of Comparative Example 3: No change;

[0127] Example 1 Carpet border appearance change: no change.

[0128] The appearance changes of the frame after washing and drying 3 times:

[0129] Comparative Example 1: Changes in the appearance of the carpet border: No change in appearance, but two separations at the border with the carpet cover;

[0130] Comparative Example 2 Carpet Border Appearance Changes: Slightly Wavy Edge;

[0131] Changes in the appearance of the border of the carpet of Comparative Example 3: No change;

[0132] Example 1 Carpet border appearance change: no change.

[0133] The appearance changes of the frame after washing and drying 5 times:

[0134] Comparative Example 1: Changes in the appearance of the carpet border: No change in appearance, but separation at four locations where the carpet is joined;

[0135] Comparative Example 2: Changes in the border appearance of the carpet: wavy edges and warped corners;

[0136] Comparative Example 3 Carpet Border Appearance Changes: Slightly Wavy Edge;

[0137] Example 1 Carpet border appearance change: no change.

[0138] In summary, Comparative Example 1 has the same intermediate layer as Example 1, and has basically no significant difference from Example 1 in terms of breaking strength and changes in appearance after washing, but its frame and carpet surface layer are prone to separation after washing; Comparative Example 2 lacks the intermediate layer compared to Example 1, resulting in its performance in breaking strength and washed appearance being significantly insufficient; the intermediate layer of Comparative Example 3 uses a light and thin fabric that is not high-strength, so the intermediate layer on the TPE integrated layer cannot demonstrate better performance in terms of integrity, breaking strength and washed appearance like the intermediate layer of Example 1. Therefore, through comparison of several comparative examples with Example 1, it can be concluded that the TPE bottom, back and frame integrated carpet of the present invention has excellent breaking strength, and at the same time makes the carpet less likely to curl up at the four corners, making it safer.

[0139] The above describes the specific embodiments of the present invention. It should be understood that the present invention is not limited to the above specific embodiments, and those skilled in the art may make various variations or modifications within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A TPE base, back and frame integrated carpet, characterized in that: The carpet comprises a carpet surface layer and an integrated bottom and back frame layer; the integrated bottom and back frame layer comprises an upper TPE layer, an intermediate layer, and a lower TPE layer, wherein an intermediate layer is provided between the upper and lower TPE layers, and the upper TPE layer has a frame around it; the bottom surface of the carpet surface layer is connected to the top surface of the upper TPE layer; The intermediate layer includes at least one of a light and thin fabric and a high-strength film; the material of the light and thin fabric includes at least one of natural materials, chemical fiber materials, and glass fiber, and the material of the high-strength film includes at least one of PP, PA, PE, and PET; The upper TPE layer, the lower TPE layer, the middle layer and the frame are an integrally formed structure.

2. The carpet according to claim 1, characterized in that The material of the thin fabric includes at least one of polyester, polypropylene, nylon and glass fiber.

3. The carpet according to claim 1, characterized in that The TPE dosage of the bottom and back frame integrated layer is 300-3000 g / m2.

4. The carpet according to claim 1, characterized in that The carpet surface layer includes one of a tufted carpet surface layer, a knitted carpet surface layer, a woven carpet surface layer, a needle-punched carpet surface layer, a flocked carpet surface layer, and a hand-woven carpet surface layer; the material of the carpet surface layer includes one or more of chemical fibers, natural fibers, and blended fibers.

5. The carpet according to claim 1, characterized in that The width of the frame is 0.3-6 cm.

6. A method for preparing a carpet according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Apply TPE material to both sides of the middle layer to form an integrated bottom, back and frame layer; S2. Coating TPE material on the bottom surface of the carpet surface layer, then compounding it with the bottom back frame integral layer, heating and rolling to form a frame, and obtaining a TPE bottom back frame integral carpet.

7. The preparation method according to claim 6, characterized in that In step S1, the preparation method of the TPE material includes: extruding, pressing, and cooling TPE particles to form a film to form a TPE film; the Shore hardness of the TPE particles is 30-85A.

8. The preparation method according to claim 6, characterized in that Step S1 also includes coating TPE material on any one side of the middle layer as an upper TPE layer; and the TPE material penetrates the middle layer to form an anti-slip surface layer on the other side as a lower TPE layer.

9. The preparation method according to claim 6, characterized in that In step S2, the amount of TPE used is 100-3000 g / m2.

10. The preparation method according to claim 6, characterized in that In step S2, the heating temperature is 90-250°C, and the pressure of the pressing roller is 2-8 kg.

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