Anti-slip carpet having hollowed-out net-shaped TPE film, and preparation method therefor

Abstract

Disclosed in the present invention are an anti-slip carpet having a hollowed-out net-shaped TPE film, and a preparation method therefor. The carpet comprises a carpet body and a hollowed-out net-shaped film layer which are arranged from top to bottom, wherein a plurality of hollow holes are formed in the hollowed-out net-shaped film layer and penetrate through the hollowed-out net-shaped film layer, and the hollowed-out net-shaped film layer is integrally formed. A preparation method A comprises: A1, melting TPE, then coating same onto a carrier, and then forming holes, so as to prepare a hollowed-out net-shaped film layer; and A2, compositing the hollowed-out net-shaped film layer with a carpet body by means of bonding. A preparation method B comprises: B1, melting TPE, then coating same onto release paper and forming holes, or, melting and extruding TPE to form a film, then forming holes and compositing same with the release paper, so as to prepare a composite coiled material; and B2, compositing the composite coiled material with a carpet body by means of hot pressing. A preparation method C comprises: C1, melting TPE, then coating same onto a carpet body, and forming holes. The carpet prepared by the present invention has good anti-slip resistance, good durability, good air permeability and good anti-aging performance, can be easily spin-dried, and is suitable for promotion and use.

Description

Anti-slip carpet with hollow mesh TPE film and preparation method thereof TECHNICAL FIELD

[0001] The present application belongs to the field of textile carpets, and relates to an anti-slip carpet with a hollow mesh TPE film and a preparation method thereof. BACKGROUND

[0002] With the improvement of home living environment and life quality, more and more families begin to choose to lay carpets on indoor and outdoor floors such as doors, living rooms, bedrooms and bathrooms. Carpets with TPE, foamed latex and acrylic resin backings have certain slip resistance and are increasingly used on carpet backings.

[0003] However, most of the TPE backing carpets on the market at present adopt full TPE coating. Since TPE is not easy to foam (even if it is foamed, it is closed-cell foaming) when it is coated, the full TPE carpet has the problems of poor air permeability, difficulty in drying, inability to drain water when laid on a wet and slippery floor, water film effect reducing the friction coefficient and causing deviation of the anti-slip effect. The foamed latex backing carpet has a deviation in the anti-aging performance due to the foamed latex formula and porous structure. The acrylic resin backing carpet has strong adhesion, and the carpet is particularly easy to get dirty during packaging or transportation, so a release paper must be attached to the carpet backing, resulting in additional waste and cost.

[0004] The existing Chinese patent with the publication number CN113907588A discloses a carpet anti-slip pad with strip-shaped anti-slip strips and a use method thereof. The carpet anti-slip pad with strip-shaped anti-slip strips includes a non-woven fabric layer and anti-slip strips. The lower side of the non-woven fabric layer is fixed with the anti-slip strips, the length of the anti-slip strips is the same as the length of the carpet anti-slip pad, and the upper surface of the non-woven fabric layer is used to place the carpet. The carpet anti-slip pad with strip-shaped anti-slip strips in the patent solves the problems of poor air permeability, difficulty in drying and deviation of the anti-slip effect when encountering water to a certain extent by using strip-shaped anti-slip strips as the backing. However, due to the structure of the strip-shaped anti-slip strips, the strip-shaped anti-slip strips are easy to break after washing due to friction, and the carpet surface is concave due to the unevenness of the overall carpet for relatively thin carpets.

[0005] In addition, the prior art also gives a carpet with a bottom provided with a suction disc structure and a suction disc-shaped air-permeable and moisture-removing hole. Through the design of the suction disc structure and the suction disc-shaped air-permeable and moisture-removing hole, the air in the suction disc structure is discharged from the suction disc-shaped air-permeable and moisture-removing hole beside the suction disc structure under the action of an external force, so as to form a negative pressure in the suction disc structure, and thus the carpet has a certain anti-skid performance. However, since the carpet bottom is provided with multiple suction disc structures and suction disc-shaped air-permeable and moisture-removing holes, the overall carpet is not flat enough. In addition, the suction disc-shaped air-permeable and moisture-removing hole of the carpet is not provided in a penetrating manner, and the water discharge effect is too poor, and only the negative pressure is used to play a role in anti-skid, so it can only be applied to smooth and flat ground. In addition, the suction disc structure and the suction disc-shaped air-permeable and moisture-removing hole at the bottom of the carpet are realized by injection molding on a single carpet, and the production efficiency is low and the economy is poor.

[0006] SUMMARY

[0007] The present application aims at the deficiencies of the prior art, and provides an anti-skid carpet with a hollow mesh TPE film and a preparation method thereof. The present application prepares a TPE film, and then processes the TPE film to form a mesh TPE film with a plurality of hollow holes distributed thereon. Since the hollow holes penetrate the TPE film, when the hollow mesh TPE film contacts a wet and slippery ground, water and air are discharged through the holes under the action of gravity and external force, eliminating the water film effect, and the carpet back closely contacts the ground, and the carpet surface layer at the hole position is adsorbed to the ground, greatly improving the anti-skid performance. In addition, the hollow mesh TPE film is integrally formed, and the TPE layer of the carpet is not easy to break after multiple uses and washing, and the safety and use experience are better. The carpet prepared by the present application has good anti-skid performance, strong durability, good air permeability, easy to dry, and good anti-aging performance.

[0008] The object of the present application can be achieved by the following solutions:

[0009] In a first aspect, the present application provides an anti-skid carpet with a hollow mesh TPE film, comprising a carpet body and a hollow mesh film layer arranged from top to bottom; the hollow mesh film layer is distributed with a plurality of hollow holes, and the holes penetrate the hollow mesh film layer.

[0010] As an embodiment of the present application, the area of the hole is 0.0314-400mm 2 , and the spacing between adjacent holes is 0.5-200mm.

[0011] Further, the area of the hole is 0.1256-100mm 2The distance between the adjacent holes is 1-7.9 mm. If the area of the holes is too large or too small, the effect of the carpet layer on the ground will be weakened, and the anti-skid property will be reduced, and the manufacturing difficulty will be increased. If the area of the holes is too small, the water and air discharge effect will be too poor, and the anti-skid property will be reduced. If the distance between the adjacent two holes is too large or too small, the manufacturing difficulty will be increased. If the distance between the adjacent two holes is too large, the water and air discharge effect will be too poor, and the anti-skid property will be reduced.

[0012] As an embodiment of the present application, the hollow reticular film layer is integrally formed. Each hole of the present application extends from the bottom surface of the hollow reticular film layer to the joint of the carpet body and the hollow reticular film layer, that is, penetrates the hollow reticular film layer.

[0013] As an embodiment of the present application, the material of the hollow reticular film layer includes TPE.

[0014] Further, the specific gravity of the TPE is not more than 1.3, the Shore hardness of the TPE is 10-50A, and the content of SEBS or SBS in the TPE is 10-50 wt.%. If the specific gravity of the TPE is too large, the Shore hardness of the TPE is too high, and the content of SEBS or SBS in the TPE is too low, the anti-skid property of the TPE will be poor. If the content of SEBS or SBS in the TPE is too high, the cost of the TPE will be too high.

[0015] As an embodiment of the present application, the thickness of the hollow reticular film layer is 0.1-5 mm, and the unit area mass of the hollow reticular film layer is 30-1500 g / m 2 .

[0016] As an embodiment of the present application, the shape of the hole includes at least one of a circle, an ellipse, a rhombus, a cross, a triangle, a rectangle, a plum blossom shape, a cloud shape, and other irregular shapes.

[0017] As an embodiment of the present application, the carpet body includes at least one of a tufted fabric, a knitted fabric, a woven fabric, a needle-punched fabric, a flocked fabric, a hand-woven fabric, and a non-woven fabric.

[0018] As an embodiment of the present application, a carrier is arranged between the carpet body and the hollow reticular film layer.

[0019] Further, the carrier includes at least one of a non-woven fabric, a woven fabric, and a knitted fabric.

[0020] According to the preparation method of the hollow reticular film layer, a carrier is arranged between the carpet body and the hollow reticular film layer, and the carrier is used to carry the hollow reticular film and increase the stiffness and flatness of the whole carpet.

[0021] In a second aspect, the present application provides a preparation method of the anti-skid carpet with the hollow mesh TPE film, wherein the preparation method comprises any one of A, B and C.

[0022] The preparation method A comprises the following steps:

[0023] A1, coating the TPE in a molten state on the carrier and making holes to form a hollow mesh film layer with the carrier;

[0024] A2, bonding and compounding the hollow mesh film layer formed in A1 with the carpet body to obtain the anti-skid carpet;

[0025] The preparation method B comprises the following steps:

[0026] B1, coating the TPE in a molten state on the release paper and making holes,

[0027] or, extruding the TPE in a molten state into a film, making holes and compounding with the release paper,

[0028] to form a composite roll of the hollow mesh film layer and the release paper;

[0029] B2, hot-pressing the composite roll formed in B1 with the carpet body and separating the release paper to obtain the anti-skid carpet;

[0030] The preparation method C comprises the following steps:

[0031] C1, coating the TPE in a molten state on the carpet body and making holes to obtain the anti-skid carpet.

[0032] As an embodiment of the present application, in the step A1 or B1 or C1, the melting mode comprises one of a casting machine, a coating machine and a film pouring machine.

[0033] Further, the working temperature of the casting machine is 150-220℃, and the speed is 2-10 meters / minute; the working temperature of the coating machine is 150-220℃, and the speed is 0.5-8 meters / minute; the working temperature of the film pouring machine is 130-250℃, and the speed is 1-10 meters / minute.

[0034] As an embodiment of the present application, in the step A1 or B1 or C1, the hole making mode comprises one of mechanical punching, laser punching, ultrasonic punching, microwave punching and roller punching.

[0035] Further, the roller punching is to pour the TPE in a molten state through a die head to a roller with a predetermined hole shape to make holes; the surface of the roller comprises a flat area and a concave area, and the flat area is in the shape of a hole.

[0036] The present application uses a casting machine, coating machine or film coating machine to heat the TPE to a molten state, the molten TPE is sprayed onto the roller with a predetermined hole shape through the die (the roller surface includes flat areas and recessed areas, the shape of the flat area is the hole shape), while the carrier or release paper is wound from below the roller to the roller, under the action of the rear scraper, the carrier or release paper is tightly attached to the roller, and then under the extrusion of the rear pressure roller, the carrier or release paper and the TPE are pressed together.

[0037] As an embodiment of the present application, in step A2, the adhesive used in the adhesive composite includes one of hot melt adhesive, TPE, styrene-butadiene rubber, water-based adhesive, and solvent-based adhesive.

[0038] In step B1 of the present application, the specific process of melting and extruding TPE into a film, then making holes, and physically combining with release paper includes: using a casting machine, coating machine or film coating machine to heat the TPE to a molten state, the molten TPE passes through the die to form a uniform film, the TPE film is rapidly cooled by a cooling roller to fix the shape and structure of the film, after the film is cooled, the punched TPE film is physically combined with the release paper roll.

[0039] As an embodiment of the present application, in step B2, the specific process of hot pressing includes:

[0040] Place the carpet body bottom surface upwards on the Teflon mesh belt, and wind the hollow mesh film layer of the composite material made in B1 upwards on the heating roller, and during the forward conveying of the mesh belt and the rolling of the heating roller, the mesh belt and the heating roller are extruded to each other, so that the bottom surface of the carpet body is bonded with the hollow mesh film layer, and the release paper is separated;

[0041] Or, wind the hollow mesh film layer of the composite material made in B1 downwards on the lower pressing roller, and wind the carpet body bottom surface upwards on the upper pressing roller, wherein the lower pressing roller is a heating roller, and the upper pressing roller is a cooling roller, and the upper and lower layers are bonded under pressure, and the release paper is separated.

[0042] Further, the heating temperature of the heating roller is 130-230℃, the pressure of the pressing is 3-8 kg, and the speed is 3-9 m / min.

[0043] Compared with the prior art, the present application has the following beneficial effects:

[0044] 1. The application sets a hollow reticular film layer on the bottom surface of the carpet, the hollow reticular film layer is distributed with hollow holes penetrating through the layer, when the hollow reticular TPE film contacts with the wet and slippery ground, water and air are discharged through the holes under the action of gravity and external force, the water film effect is eliminated, the carpet back bottom is in close contact with the ground, and the carpet surface layer located in the hole part is adsorbed with the ground, so that the anti-skid property is greatly improved. Compared with the carpet with suction cup structure on the bottom, the carpet of the application can achieve good anti-skid effect on uneven ground; in addition, the application can also use a TPE back bottom with lower weight according to the need, which saves the cost and avoids the problem of too heavy carpet; in addition, the application has high production efficiency and good economy.

[0045] 2. The application sets a hollow reticular film layer on the bottom surface of the carpet, the hollow reticular film layer is distributed with hollow holes, so that the anti-skid carpet with the hole film has excellent air permeability, is easy to dry, and has better anti-skid effect on smooth and uneven ground after water is poured on the smooth and flat ceramic tile or uneven ground.

[0046] 3. The application sets an integrally formed hollow reticular film layer on the bottom surface of the carpet, compared with the strip-shaped anti-skid strip, the hollow reticular film layer is not easy to break after washing, is close to the full-coated TPE water washing performance, and for relatively thin carpets, the problem of carpet surface depression caused by uneven carpet caused by strip-shaped anti-skid strip does not occur; compared with the foamed latex back bottom carpet, the anti-aging performance is better.

[0047] 4. The application can also use a hollow reticular film layer with a carrier, which is beneficial to increase the stiffness and flatness of the whole carpet. BRIEF DESCRIPTION OF DRAWINGS

[0048] Other features, objects and advantages of the application will become more apparent from the following detailed description of non-limiting embodiments, made with reference to the accompanying drawings:

[0049] Fig. 1 is a schematic view of the cross-sectional structure of the carpet in embodiments 1, 2 and 5;

[0050] Fig. 2 is a schematic view of the cross-sectional structure of the carpet in embodiments 3, 4 and 6;

[0051] Fig. 3 is a schematic view of the cross-sectional structure of the hollow reticular film layer in the embodiment of the application;

[0052] Fig. 4 is a bottom view of the hollow reticular film layer in embodiment 3 of the application;

[0053] Fig. 5 is a bottom view of the hollow reticular film layer in embodiment 4 of the application;

[0054] Fig. 6 is a bottom view of the hollow reticular film layer in embodiment 5 of the application;

[0055] Figure 7 is a bottom view of the hollow reticular film layer of Example 1 of the present application;

[0056] Figure 8 is a bottom view of the hollow reticular film layer of Example 2 of the present application;

[0057] Reference signs: 1, carpet body; 2, hollow reticular film layer; 3, hole; 4, carrier. DETAILED DESCRIPTION

[0058] The present application will be described in detail below with reference to the accompanying drawings and specific examples. The following examples are implemented on the premise of the technical solutions of the present application, and detailed implementation modes and specific operation processes are provided, which will help those skilled in the art to further understand the present application. It should be pointed out that the protection scope of the present application is not limited to the following examples, and several adjustments and improvements made on the premise of the concept of the present application all belong to the protection scope of the present application.

[0059] Example 1

[0060] The present embodiment provides a preparation method of a non-slip carpet with a hollow reticular TPE film, and the carpet structure is shown in Figure 1, and the preparation steps are as follows:

[0061] Step one: use a casting machine to heat TPE particles to a molten state, and the molten TPE passes through the casting machine head to form a uniform film. The TPE film is rapidly cooled by a cooling roller to fix the shape and structure of the film. After the film is cooled, a mechanical punching device is used to punch holes on the TPE film according to the predetermined shape and spacing of the holes 3, and then a clean release paper roll is prepared. The punched TPE film is physically combined with the release paper roll to form a composite roll of the hollow reticular film layer 2 and the release paper. The shape of the hole 3 is rhombus, the area of the hole 3 is 8.66mm 2 , the spacing between adjacent holes 3 is 30mm, the working temperature of the casting machine is 200℃, and the speed is 5m / min; the TPE model is TPE_KBT-15A-1, the SEBS content is 40%, the color is colorless and transparent, the Shore hardness (HShardness) is 15A, the specific gravity is 0.9, the usage is 200g / m 2 , and the thickness is 0.5mm.

[0062] Step two: select a square gram weight of 1100gsm polyester plain weave base carpet, i.e. the carpet body 1. The composite roll of the hollow reticular film layer 2 prepared in step one is wound with the side facing down to the lower pressure roller, and the carpet body 1 is wound with the bottom facing up to the upper pressure roller. The lower pressure roller is a heating roller, and the upper pressure roller is a cooling roller. The upper and lower layers are bonded together under pressure, and the release paper is separated. The heating roller temperature is 190℃, and the pressure is 5kg. The cross-sectional structure and bottom view of the hollow reticular film layer 2 are shown in Figures 3 and 7, respectively.

[0063] Step three: cutting the blank carpet prepared in step two to a size of 50X80cm, using 40s / 3 polyester sewing thread to overlock, overlock width 10mm, to prepare the anti-slip carpet with the hollow mesh TPE film of the application.

[0064] Example 2

[0065] The present embodiment provides a preparation method of an anti-slip carpet with a hollow mesh TPE film, and the carpet structure is shown in Figure 1, and the preparation steps are as follows:

[0066] Step one: select a polyester cut pile tufted carpet with a pile height of 35mm and a base cloth of 100gsm PP woven base cloth, i.e. the carpet body 1, and the weight of the blank carpet is 860gsm. Use a TPE film coating machine to melt the TPE and coat it onto the bottom surface of the carpet body 1, then laser punch the composite blank carpet according to the shape and spacing of the predetermined holes 3 to prepare a blank carpet with a hollow mesh film layer 2 on the bottom. The shape of the hole 3 is cross-shaped, the area of the hole 3 is 36mm 2 , and the spacing between the holes 3 is 50mm. The working temperature of the film coating machine is 210℃, and the speed is 4m / min; the TPE model is TPE_KBT-50A-1, the SEBS content is 21%, the color is dark gray, the Shore hardness (HShardness) is 50A, the specific gravity is 1.3, the usage is 500g / m 2 , and the thickness is 0.8mm. The laser power of the laser punching device is 80W, the pulse width is 15ns, and the pulse frequency is 20kHz. The cross-sectional structure and the bottom view of the hollow mesh film layer 2 are shown in Figures 3 and 8 respectively.

[0067] Step two: cutting the blank carpet prepared in step one to a size of 50x80cm, using 2020D polyester D3-2 overlock yarn to overlock, overlock width 7mm, to prepare the anti-slip carpet with the hollow mesh TPE film of the application.

[0068] Example 3

[0069] The present embodiment provides a preparation method of an anti-slip carpet with a hollow mesh TPE film, and the carpet structure is shown in Figure 2, and the preparation steps are as follows:

[0070] Step one: select a roll of polyester non-woven fabric with a square weight of 350g / m 2 , use a TPE film coating machine to melt the TPE and coat it onto the polyester non-woven fabric, then use mechanical punching, and pass the composite base cloth through the rotating hot needle roller with protruding needles distributed above with the shape and spacing of the predetermined holes 3 to prepare the hollow mesh film layer 2 with the polyester non-woven fabric (i.e. the carrier 4). The shape of the hole 3 is circular, the area of the hole 3 is 28.26mm 2, the distance between the holes 3 is 6mm. The working temperature of the showering machine is 210℃, the speed is 5m / min; the TPE model is TPE_KBT-001N, the SEBS content is 28%, the color is white, the Shore hardness is 30A, the specific gravity is 1.19, and the usage is 350g / m 2 , the thickness is 0.6mm; the heating temperature of the hot roller is 90℃, the speed is 5m / min. The cross-sectional structure and the bottom view of the hollow reticular film layer 2 are shown in Figures 3 and 4.

[0071] Step two: select a polyester knitted base carpet with a square gram weight of 350g / m 2 , that is, the carpet body 1, and composite the hollow reticular film layer 2 with the polyester non-woven fabric prepared in step one by using 15g / m 2 PUR hot melt adhesive, connect the bottom surface of the carpet body 1 with the surface where the polyester non-woven fabric of the hollow reticular film layer 2 is located, and prepare the composite base carpet.

[0072] Step three: cut the base carpet prepared in step two to a size of 50x80cm, use the polyester D3-2 overlock yarn of 2020D to overlock, the overlock width is 7mm, and prepare the anti-skid carpet with the hollow reticular TPE film of the application.

[0073] Example 4

[0074] The embodiment provides a preparation method of an anti-skid carpet with a hollow reticular TPE film, and the carpet structure is shown in Figure 2, and the preparation steps are as follows:

[0075] Step one: select a roll of polyester non-woven fabric with a square gram weight of 100g / m 2 . Heat the TPE to a molten state by using a coating machine, pass the TPE in a molten state through a die head to a roller with a predetermined shape and distance of holes 3, and wind the polyester non-woven fabric from below the roller to the roller, under the action of a rear scraper, so that the polyester non-woven fabric is tightly attached to the roller, and then under the extrusion action of a rear pressure roller, the polyester non-woven fabric and the TPE are pressed together to prepare a hollow reticular film layer 2 with the polyester non-woven fabric. The shape of the hole 3 is oval, the area of the hole 3 is 17.52mm 2 , the distance between the holes 3 is 20mm, the working temperature of the coating machine is 200℃, the speed is 4m / min; the TPE model is TPE_KBT-C002, the SEBS content is 23%, the color is beige, the Shore hardness is 45A, the specific gravity is 1.26, and the usage is 400g / m 2 , the thickness is 0.6mm. The cross-sectional structure and the bottom view of the hollow reticular film layer 2 are shown in Figures 3 and 5.

[0076] Step two: select the pile height of 18mm, base cloth for 100g / m 2 PP woven base cloth of polyester cut pile carpet blank, that is, the carpet body 1, the weight of the blank carpet is 720g / m 2 The carpet body 1 is compounded with the hollow mesh film layer 2 with polyester non-woven fabric prepared by TPE in step one by TPE film coating machine, the bottom surface of the carpet body 1 is connected with the surface of the hollow mesh film layer 2 with polyester non-woven fabric, and the blank carpet after compounding is prepared. The working temperature of the film coating machine is 195℃, the speed is 5m / min; the TPE model is TPE_KBT-40A-1, the SEBS content is 15%, the color is white, the HS hardness is 40A, the specific gravity is 1.25, and the usage is 400g / m 2 .

[0077] Step three: cutting the blank carpet prepared in step two, the cutting size is 50x80cm, using 2020D polyester D3-2 overlock yarn to overlock, the overlock width is 7mm, and the anti-skid carpet with hollow mesh TPE film of the application is prepared.

[0078] Example 5

[0079] The embodiment provides a preparation method of an anti-skid carpet with a hollow mesh TPE film, and the carpet structure is shown in Figure 2, and the preparation steps are as follows:

[0080] Step one: using a coating machine to heat TPE to a molten state, the molten TPE is coated on the roller with a predetermined hole 3 shape and spacing through a die, at the same time, the release paper is wound from the roller below to the roller, under the action of the rear scraper, the release paper is tightly attached to the roller, and then under the extrusion action of the rear pressure roller, the release paper and TPE are pressed together to form a composite roll of the hollow mesh film layer 2 and the release paper. The shape of the hole 3 is plum blossom, the area of the hole 3 is 125.5mm 2 , the spacing between the holes 3 is 200mm, the working temperature of the coating machine is 200℃, the speed is 4.5m / min; the TPE model is TPE_KBT-15A-1, the SEBS content is 40%, the color is colorless and transparent, the HS hardness is 15A, the specific gravity is 0.9, and the usage is 180g / m 2 , the thickness is 0.4mm. The cross-sectional structure and the bottom view of the hollow mesh film layer 2 are shown in Figures 3 and 6.

[0081] Step two: select the pile height of 26 mm, base cloth for 100 gsm PP woven base cloth of polyester cut pile carpet blank, that is, the carpet body 1, the blank carpet weight is 1050 gsm. Place the carpet body bottom up on the Teflon mesh belt, and wrap the hollow mesh film layer 2 of the composite coiled material prepared in step one on the heating roller. During the forward conveying of the mesh belt and the rolling of the heating roller, the mesh belt and the heating roller are extruded, so that the bottom surface of the carpet body is bonded with the hollow mesh film layer 2, and the release paper is separated. The heating roller temperature is 190℃, and the pressure is 5 kg.

[0082] Step three: cut the blank carpet prepared in step two, the cutting size is 50x80 cm, use 2020D polyester D3-2 overlock yarn to lock edge, the lock edge width is 7 mm, and the anti-skid carpet with hollow mesh TPE film of the application is prepared.

[0083] Example 6

[0084] The preparation method of this example is basically the same as that of example 3, the difference is only that the amount of TPE used in step one is 1500 g / m 2 .

[0085] Comparative example 1

[0086] The preparation method of this example is basically the same as that of example 3, the difference is only that the hollow mesh film layer 2 is not prepared, but the conventional full TPE coating method is used to re-coat the bottom.

[0087] The preparation steps are as follows:

[0088] Step one: select a square gsm of 350 g / m 2 of polyester knitted carpet, that is, the carpet body 1; select a square g / m 2 of 350 g / m 2 of polyester non-woven fabric. The carpet body 1 is combined with the polyester non-woven fabric through the composite machine using 15 g / m 2 PUR hot melt adhesive, the bottom surface of the carpet body 1 is connected with the top surface of the polyester non-woven fabric, and the composite blank carpet is prepared.

[0089] Step two: use TPE film coating machine to melt coat TPE to the bottom surface of the composite blank carpet prepared in step one. The die head used in the film coating machine is a full TPE die head; the working temperature of the film coating machine is 210℃, the speed is 5 meters / minute; the TPE type is TPE_KBT-001N, the SEBS content is 28%, the color is white, the Shore hardness (HShardness) is 30A, the specific gravity is 1.19, and the amount used is 350 g / m 2 .

[0090] Step three: cut the blank carpet prepared in step two to a size of 50x80cm, use polyester D3-2 lock thread of 2020D to lock the edge, the lock edge width is 7mm, and the carpet is prepared.

[0091] Comparative Example 2

[0092] The preparation method of the present comparative example is basically the same as that of Example 3, except that the hollow mesh film layer 2 is not prepared, but a strip-shaped TPE is used to re-bottom.

[0093] The preparation steps are as follows:

[0094] Step one: select a polyester knitted blank carpet with a square gram weight of 350g / m 2 , i.e. the carpet body 1; select a roll of polyester non-woven fabric with a square gram weight of 350g / m 2 . The carpet body 1 is compounded together with the polyester non-woven fabric through a compounding machine using 15g / m 2 PUR hot melt adhesive, the bottom surface of the carpet body 1 is connected with the top surface of the polyester non-woven fabric, and the compounded blank carpet is prepared.

[0095] Step two: use a TPE film coating machine to melt and coat TPE to the bottom surface of the compounded blank carpet prepared in step one. The die head used by the film coating machine is a strip-shaped TPE die head, the width of the strip-shaped TPE is 10mm, and the pitch is 10mm; the working temperature of the film coating machine is 210℃, the speed is 5m / min; the TPE type is TPE_KBT-001N, the SEBS content is 28%, the color is white, the Shore hardness (HShardness) is 30A, the specific gravity is 1.19, and the usage is 350g / m 2 .

[0096] Step three: cut the blank carpet prepared in step two to a size of 50x80cm, use polyester D3-2 lock thread of 2020D to lock the edge, the lock edge width is 7mm, and the carpet is prepared.

[0097] Comparative Example 3

[0098] The preparation method of the present comparative example is basically the same as that of Example 3, except that the carpet body and the polyester non-woven fabric are completely the same, and the difference lies in that the back bottom is re-bottomed with foamed latex.

[0099] The preparation steps are as follows:

[0100] Step one: select a polyester knitted blank carpet with a square gram weight of 350g / m 2 , i.e. the carpet body 1; select a roll of polyester non-woven fabric with a square gram weight of 350g / m 2 . The carpet body 1 is compounded together with the polyester non-woven fabric through a compounding machine using 15g / m 2The PUR hot melt glue is compounded with the dacron non-woven fabric, the bottom surface of the carpet body 1 is connected with the top surface of the dacron non-woven fabric, and the compounded blank carpet is prepared.

[0101] Step two: the blank carpet prepared in step one is back-glued with light gray foaming latex, the foaming ratio is 550g / L, the temperature is 140 DEG C, and the glue amount is 600gsm.

[0102] Step three: the blank carpet prepared in step two is cut, the cutting size is 50x80cm, the dacron D3-2 lock edge yarn of 2020D is used for edge locking, the edge locking width is 7mm, and the carpet is prepared.

[0103] Comparative example 4

[0104] The preparation method of the comparative example is compared with example 3, and the difference is only that the area of the hole 3 is 0.0314mm 2 , and the distance between the adjacent two holes 3 is 0.5mm.

[0105] Comparative example 5

[0106] The preparation method of the comparative example is compared with example 3, and the difference is only that the area of the hole 3 is 314mm 2 , and the distance between the adjacent two holes 3 is 120mm.

[0107] Comparative example 6

[0108] The preparation method of the comparative example is compared with example 3, and the difference is only that the TPE type is TPE_KBT-70A-1, the SEBS content is 14%, the color is white, the Shore hardness (HShardness) is 70A, and the specific gravity is 1.37.

[0109] Comparative example 7

[0110] The preparation method of the comparative example is compared with example 6, and the difference is that the structure of the hole 3 is replaced by the suction disc-shaped breathable and moisture-removing hole.

[0111] The preparation steps are as follows:

[0112] Step one: select a roll of dacron non-woven fabric with a square gram weight of 350g / m 2 and a roll of dacron knitted blank carpet with a square gram weight of 350g / m 2 , and compound them together through a compound machine by using 15g / m 2 PUR hot melt glue, the bottom surface of the dacron knitted blank carpet is connected with the top surface of the dacron non-woven fabric.

[0113] Step two: the compounded blank carpet prepared in step one is cut, and the cutting size is 51x81cm.

[0114] Step three: Put the 51x81cm carpet prepared in step two into the mold, which is fixed by four symmetrical fixed pillars on the top and bottom, and the middle of the mold is hollowed out into a suction disc-shaped breathable and moisture-removing hole shape, specifically, the lower part is a suction disc shape, and the upper part is a cylindrical shape, which are an integral whole. Use an injection molding machine to melt TPE with model number TPE_KBT-001N, SEBS content of 28%, color white, Shore hardness (HShardness) of 30A, and specific gravity of 1.19 at a high temperature of 200°C, and inject it from the left side of the mold. The TPE molten liquid fills the mold in 10 seconds, and is pressed up and down. After cooling, the carpet and TPE form an integral whole, and the mold is opened and taken out. The suction disc-shaped part of the suction disc-shaped breathable and moisture-removing hole is a circle with a diameter of 6mm, and the corresponding area is 28.26mm 2 , the cylindrical part of the suction disc-shaped breathable and moisture-removing hole is a circle with a diameter of 1mm, and the distance between two adjacent suction disc-shaped breathable and moisture-removing holes is 6mm.

[0115] Step four: Trim the carpet prepared in step three, and the size after trimming is 50x80cm. Use 2020D polyester D3-2 overlock thread to overlock, and the overlock width is 7mm, to prepare the carpet with suction disc-shaped breathable and moisture-removing holes.

[0116] Comparative Example 8

[0117] The preparation method of this comparative example is different from Example 6 in that the structure of hole 3 is replaced by a suction disc-shaped structure and a suction disc-shaped breathable and moisture-removing hole.

[0118] The preparation steps are as follows:

[0119] Step one: Select one roll of polyester non-woven fabric with a square gram weight of 350g / m 2 and one roll of polyester knitted base carpet with a square gram weight of 350g / m 2 , and composite them together by a compounding machine using 15g / m 2 PUR hot melt adhesive. The bottom surface of the polyester knitted base carpet is connected to the top surface of the polyester non-woven fabric.

[0120] Step two: Cut the composite base carpet prepared in step one to a size of 51x81cm.

[0121] Step three: Put the 51x81cm carpet prepared in step two into the mold, which is fixed by four symmetrical fixed pillars on the top and bottom, and the middle of the mold is hollowed out into a suction cup-shaped structure and a suction cup-shaped breathable and moisture-removing hole shape. The suction cup-shaped breathable and moisture-removing hole is specifically a suction cup shape at the bottom and a cylinder shape at the top, which are an integral whole. Use an injection molding machine to melt TPE with model TPE_KBT-001N, SEBS content of 28%, color white, Shore hardness (HShardness) of 30A, and specific gravity of 1.19 at a high temperature of 200℃, and inject it from the left side of the mold. The TPE melt liquid fills the mold in 10 seconds, and is pressed up and down. After cooling, the carpet and TPE form an integral whole, and the mold is opened and taken out. The suction cup-shaped structure is a circle with a diameter of 6mm, and the corresponding area is 28.26mm 2 , the suction cup-shaped part of the suction cup-shaped breathable and moisture-removing hole is a circle with a diameter of 6mm, and the corresponding area is 28.26mm 2 , the cylinder-shaped part of the suction cup-shaped breathable and moisture-removing hole is a circle with a diameter of 1mm, and the suction cup-shaped structure and the suction cup-shaped breathable and moisture-removing hole are arranged at intervals, and the interval is 6mm.

[0122] Step four: Trim the carpet prepared in step three, and the size after trimming is 50x80cm. Lock the edge with 2020D polyester D3-2 lock edge yarn, and the lock edge width is 7mm. The carpet with suction cup-shaped structure and suction cup-shaped breathable and moisture-removing hole is prepared.

[0123] Performance test

[0124] 1. Anti-slip comparison test

[0125] Test method: Select the anti-slip carpet with hollow mesh TPE film in Example 3 of the application, the conventional full-coated TPE back carpet in Comparative Example 1, the carpet with too small hole area and spacing in Comparative Example 4, the carpet with too large hole area and spacing in Comparative Example 5, the carpet with too high TPE Shore hardness (HShardness) in Comparative Example 6, the anti-slip carpet with hollow mesh TPE film and high TPE back carpet weight in Example 6, the carpet with suction cup-shaped breathable and moisture-removing hole in Comparative Example 7, and the carpet with suction cup-shaped structure and suction cup-shaped breathable and moisture-removing hole in Comparative Example 8, a 100X100cm ceramic tile, a steel ruler, a 50x50cm pressure plate with a mass of 135g, a 2500g weight, a 500ml beaker, and tap water for standby. Use a portable tension scale with model HL-139 to test the anti-slip value of the test sample when pulling the same distance on the contact surface.

[0126] The specific operation steps are as follows:

[0127] (1) Sampling

[0128] <1、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0129] <2、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0130] <3、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0131] <4、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0132] <5、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0133] <6、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0134] <7、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively;

[0135] <8、Select the anti-skid carpet 1 in the example 3 of the application, the carpet square gram weight is 1065g / m 2 , cut into 50X60cm size, numbered as A1, A2, A3, A4 respectively.

[0136] (2) test

[0137] <1, smooth and flat ceramic tile on the water without paving anti-skid test:

[0138] Place the test sample on a smooth porcelain tile, place a 50x50cm size and 135g weight pressing plate on the carpet body of the test sample, align with three edges of the test sample, leave out 50x10cm of the carpet body, place 2500g weight in the center position of the pressing plate, use portable tension scale HL-139 to test the maximum tension value of the test sample pulled by 10cm on the porcelain tile. Test samples A1, B1, C1, D1, E1, F1, G1, H1 respectively by this method;

[0139] <2, water on smooth porcelain tile slip resistance test:

[0140] Use a measuring cup to pour 200ml tap water on a smooth porcelain tile, then place the test sample on the water poured porcelain tile, place a 50x50cm size and 135g weight pressing plate on the carpet body of the test sample, align with three edges of the test sample, leave out 50x10cm of the carpet body, place 2500g weight in the center position of the pressing plate, after 10 seconds, use portable tension scale HL-139 to test the maximum tension value of the test sample pulled by 10cm on the porcelain tile. Test samples A2, B2, C2, D2, E2, F2, G2, H2 respectively by this method;

[0141] <3, uneven ground without water slip resistance test:

[0142] Place the test sample on the uneven ground, place a 50x50cm size and 135g weight pressing plate on the carpet body of the test sample, align with three edges of the test sample, leave out 50x10cm of the carpet body, place 2500g weight in the center position of the pressing plate, use portable tension scale HL-139 to test the maximum tension value of the test sample pulled by 10cm on the ground. Test samples A3, B3, C3, D3, E3, F3, G3, H3 respectively by this method;

[0143] <4, uneven ground with water slip resistance test:

[0144] Use a measuring cup to pour 200ml tap water on the uneven ground, then place the test sample on the water poured ground, place a 50x50cm size and 135g weight pressing plate on the carpet body of the test sample, align with three edges of the test sample, leave out 50x10cm of the carpet body, place 2500g weight in the center position of the pressing plate, after 10 seconds, use portable tension scale HL-139 to test the maximum tension value of the test sample pulled by 10cm on the ground. Test samples A4, B4, C4, D4, E4, F4, G4, H4 respectively by this method.

[0145] The following is the test data:

[0146] In summary, compared with Example 3, the conventional full-coated TPE backing carpet in Comparative Example 1 has poor slip resistance on smooth and flat ceramic tiles; the hole area and spacing of the carpet in Comparative Examples 4 and 5 are too small or too large, which weakens the effect of the carpet surface layer on the ground in the hole-shaped part and leads to poor water and air exhaust effect, thereby reducing the slip resistance of the carpet, especially on smooth and flat ceramic tiles; the TPE used in the carpet in Comparative Example 6 has a high HS hardness, which leads to poor slip resistance of the TPE, thereby reducing the slip resistance of the carpet.

[0147] Compared with Example 6, the carpet with the suction disc-shaped breathable and moisture-removing hole in Comparative Example 7 is not suitable for slip resistance on smooth and flat ceramic tiles or uneven ground, and has poor slip resistance; the carpet with the suction disc-shaped structure and the suction disc-shaped breathable and moisture-removing hole in Comparative Example 8 has a suction disc structure that is insufficient to adsorb the ground under small load, and has poor slip resistance on smooth and flat ceramic tiles or uneven ground.

[0148] 2. Water washing appearance comparison test

[0149] Test method: select the slip-resistant carpet with the hollow mesh TPE film in Example 3 of the application and the carpet with the strip-shaped TPE backing in Comparative Example 2, and perform 1, 3, and 5 times of water washing and drying, and then compare the appearance changes of the bottom of the test sample and grade.

[0150] The specific test steps are as follows:

[0151] <1. Select two pieces of the slip-resistant carpet with the hollow mesh TPE film in Example 3 of the application, with a carpet square gram weight of 1065 g / m 2 and a size of 50X80 cm;

[0152] <2. Select two pieces of the carpet with the strip-shaped TPE backing in Comparative Example 2 of the application, with a carpet square gram weight of 1065 g / m 2 and a size of 50X80 cm;

[0153] <3. Put one piece of each of the two test samples into a washing machine for water washing at the same time, with a water washing temperature of 45°C, a water washing time of 35 min each time, a drying temperature of 70°C, a drying time of 15 min each time, and a water washing and drying number of 1, 3, and 5 times. After different water washing times, compare the appearance changes of the bottom of the test sample and grade.

[0154] The test results are as follows:

[0155] Appearance changes of the bottom of the test sample after 1 time of water washing and drying:

[0156] The bottom appearance change of the carpet in Example 3: 4.5 levels;

[0157] The bottom appearance change of the carpet in Comparative Example 2: 4.5 levels.

[0158] The bottom appearance change of the test sample after washing and drying 3 times:

[0159] The bottom appearance change of the carpet in Example 3: 4.5 levels;

[0160] The bottom appearance change of the carpet in Comparative Example 2: 4.0 levels (slight fracture of the strip-shaped TPE strip).

[0161] The bottom appearance change of the test sample after washing and drying 5 times:

[0162] The bottom appearance change of the carpet in Example 3: 4.5 levels;

[0163] The bottom appearance change of the carpet in Comparative Example 2: 3.5 levels (slight fracture of the strip-shaped TPE strip).

[0164] In summary, since the TPE back of the anti-slip carpet with the hollow mesh TPE film in Example 3 of the present application is an integral structure, and the TPE back of the strip-shaped TPE back carpet in Comparative Example 2 is a relatively independent strip-shaped structure, the TPE layer of the carpet of the present application is not prone to fracture after friction after multiple uses and washing, and the safety and use experience are better.

[0165] 3. Anti-aging performance comparison test

[0166] Test method: select the anti-slip carpet with the hollow mesh TPE film in Example 3 of the present application and the carpet with the foamed latex back in Comparative Example 3, one circulating air oven, cut 5 test samples according to 20x5cm from the carpet, put 4 test samples into the oven according to 120℃, take one test sample out of the oven every 24h, 48h, 72h, 96h, and compare the original sample to observe the adhesion, color, cracking, and fracture after bending of the bottom of the test sample.

[0167] The specific test steps are as follows:

[0168] <1. Select one anti-slip carpet with a hollow mesh TPE film in Example 3 of the present application, the carpet square gram weight is 1065g / m 2 , the size is 50X80cm, cut 5 test samples according to 20x5cm;

[0169] <2. Select one carpet with a foamed latex back in Comparative Example 3 of the present application, the carpet square gram weight is 1315g / m 2 , the size is 50X80cm, cut 5 test samples according to 20x5cm;

[0170] <3. Heat the oven to 120°C. Place four test samples from Example 3 and Comparative Example 3 onto the oven grid, with the back facing up. Remove one test sample from the oven every 24 hours, 48 ​​hours, 72 hours, and 96 hours. Allow the test sample to cool for at least 15 minutes. Evaluate the test sample by comparing it with the original sample according to the following criteria:

[0171] Adhesion: Non-sticky / sticky;

[0172] Color variations: yellow, beige, brown, etc.;

[0173] Cracking: Longitudinal / Transverse: No cracking / Slight cracking / Moderate cracking / Severe cracking;

[0174] Bending fracture: Longitudinal / Transverse: No cracking / Slight cracking / Medium cracking / Severe cracking.

[0175] The test results are as follows:

[0176] Test results of the anti-aging performance of the anti-slip carpet with a perforated mesh TPE film in Example 3 of this invention:

[0177] Test results of the anti-aging performance of the carpet with foamed latex backing in Comparative Example 3 of this invention:

[0178] In summary, the anti-slip carpet backing with a perforated mesh TPE film in Example 3 of this invention has a stable TPE structure and good anti-aging performance. In contrast, the foamed latex backing of the carpet in Comparative Example 3 changes color under high temperature conditions due to its own formula and porous structure, and slightly cracks after bending after baking for 72 hours and 96 hours, thus exhibiting poor anti-aging performance. Therefore, the carpet of this invention has better anti-aging performance.

[0179] The specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, and those skilled in the art can make various modifications or variations within the scope of the claims, which do not affect the essence of the present invention.

Claims

1. A slip-resistant carpet with a hollow mesh TPE film, characterized by, The anti-skid carpet comprises a carpet body and a hollow mesh film layer arranged from top to bottom.

2. The non-slip carpet of claim 1, wherein, The area of the hole is 0.0314-400mm 2 The distance between adjacent holes is 0.5-200mm.

3. The non-slip carpet of claim 1, wherein, The area of the hole is 0.1256-100mm 2 The distance between the adjacent holes is 1-7.9mm.

4. The non-slip carpet of claim 1, wherein, The hollow mesh film layer is made of TPE, the specific gravity of the TPE is not greater than 1.3, the Shore hardness of the TPE is 10-50A, and the content of SEBS or SBS in the TPE is 10-50 wt.%.

5. The non-slip carpet of claim 1, wherein, The thickness of the hollow reticular film layer is 0.1-5mm; the mass per unit area of the hollow reticular film layer is 30-1500g / m 2 .

6. The non-slip carpet of claim 1, wherein, The carpet body comprises at least one of tufted fabric, knitted fabric, woven fabric, needle-punched fabric, flocked fabric, hand-knitted fabric and non-woven fabric.

7. The non-slip carpet of claim 1, wherein, The carrier is arranged between the carpet body and the hollow mesh film layer, and the carrier comprises at least one of non-woven fabric, woven fabric and knitted fabric.

8. A preparation method of the anti-skid carpet according to any one of claims 1-7, the preparation method comprising any one of A, B and C. Preparation method A comprises the following steps: A1, melting TPE and coating the TPE on a carrier to form a hollow mesh film layer with the carrier, and making holes in the hollow mesh film layer; A2, bonding and compounding the hollow mesh film layer made in A1 with a carpet body to obtain the anti-skid carpet; Preparation method B comprises the following steps: B1, melting TPE and coating the TPE on a release paper to form a hollow mesh film layer, and making holes in the hollow mesh film layer; B2, hot-pressing the composite roll made in B1 with a carpet body, and separating the release paper to obtain the anti-skid carpet; Preparation method C comprises the following steps: C1, melting TPE and coating the TPE on a carpet body to obtain the anti-skid carpet. In steps A1, B1 or C1, the melting mode comprises one of a casting machine, a coating machine and a film coating machine; the working temperature of the casting machine is 150-220℃, and the speed is 2-10 m / min; the working temperature of the coating machine is 150-220℃, and the speed is 0.5-8 m / min; and the working temperature of the film coating machine is 130-250℃, and the speed is 1-10 m / min. In steps A1, B1 or C1, the hole-making mode comprises one of mechanical punching, laser punching, ultrasonic punching, microwave punching and roller punching.

9. The production method according to claim 8, characterized by, ​ 10. The preparation method according to claim 8, characterized in that, ​

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