CN111904239A - 一种可水洗不变形的三维立体夹层复合地毯 - Google Patents

一种可水洗不变形的三维立体夹层复合地毯 Download PDF

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CN111904239A
CN111904239A CN202010910768.8A CN202010910768A CN111904239A CN 111904239 A CN111904239 A CN 111904239A CN 202010910768 A CN202010910768 A CN 202010910768A CN 111904239 A CN111904239 A CN 111904239A
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layer
carpet
composite
dimensional
interlayer
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曹顺林
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Kunshan Yijiaju Textile Co ltd
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Kunshan Yijiaju Textile Co ltd
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Priority to CN202010910768.8A priority Critical patent/CN111904239A/zh
Publication of CN111904239A publication Critical patent/CN111904239A/zh
Priority to CA3100151A priority patent/CA3100151C/en
Priority to US17/100,550 priority patent/US20220064830A1/en
Priority to EP21863606.6A priority patent/EP4074224A4/en
Priority to PCT/CN2021/115735 priority patent/WO2022048542A1/zh
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Abstract

本发明提供了一种可水洗不变形的三维立体夹层复合地毯，包括面层、三维立体夹层和防滑层；所述三维立体夹层由上层针织面料、下层针织面料以及中间竖向排列且连接上层和下层的复合丝连接层组成。本发明的采用复合丝连接结构的三维立体夹层的复合地毯，支撑力强，延展性能高，可以反复折叠1000次以上；10次水洗的水洗缩率不超过2％；在长时间的挤压和受热及受潮的情况下不会变形。

Description

一种可水洗不变形的三维立体夹层复合地毯
技术领域
本发明涉及纺织行业的地毯，具体涉及一种可水洗不变形的三维立体夹层复合地毯。
背景技术
目前市面上的3D间网布是一种双针床经编网布，由网孔表面，连接单丝，平布底面组成，构成了其三维立体网布结构。其中间连接层可以有各种形状，包括管状、褶状以及其他形状，这使得这种三层织物具有非常广泛的应用前景。通常，上下两面丝是涤纶单丝，中间连接丝也为涤纶单丝。
目前家用地毯基本无法清洗，部分可清洗地毯为干洗。重量超过9公斤，洗衣机无法承受且由于地毯太大，无法放入洗衣机，这个是家庭不愿使用地毯的主要原因之一。而用在市面上的应用了3D网眼布的地毯在长时间的挤压和受热及受潮的情况下导致变形，导致使用寿命短。且普通3D网眼布经过折叠放入洗衣机或水槽在水洗过程中，在水流及机械摩擦力以及温度的作用下，中间连接层的单丝纤维会出现不规则倾斜现象，导致表面有凹陷，容易产生褶皱，边缘无法与地面平齐，铺设困难，从而产生人员绊倒的风险。
因此需要一种环保可全回收利用地毯，既要具有常规地毯的功能，又要方便使用者能够任意折叠水洗且不易产生变形，从而延长地毯的使用寿命。
通过对现有专利文献的检索发现，申请号为201220471847.4的中国实用新型专利公开了一种具有透气性结构的复合地毯，包括地毯本体，所述的地毯本体从表层到底层分为三层结构，中间一层为海绵层，表层和底层均为网眼布层。这种地毯必须是基体层与连接组合使用，成本高，使用不方便，而且基体层与连接层容易结合不牢并产生滑动风险。另外，将该地毯折叠放入洗衣机水洗后会产生明显的褶皱，与地面无法平齐；中间海绵层在水洗后，由于海绵的吸水性强，使地毯的重量加重，导致洗衣机无法承受其重量。而且，人走在这种地毯的上面时由于连接基体层的顶面和底面的单丝相互摩擦，会发出让人感觉不舒适的响声。
发明内容
本发明的目的在于提供一种可水洗不变形的三维立体夹层复合地毯。该复合地毯的防滑层在使用1公斤/㎡以内的弹性物质或面料且厚度不超过2cm的情况下可以任意折叠，水洗且不易变形；可以满足当前人们将地毯折叠后放入洗衣机水洗的需求。
本发明的目的是通过以下技术方案来实现的：
本发明涉及一种可水洗不变形的三维立体夹层复合地毯，包括面层、三维立体夹层和防滑层；所述三维立体夹层由上层、下层以及中间竖向排列且连接所述上层和下层的复合丝连接层组成。
作为本发明的一个实施方案，所述复合丝连接层中，连接上层和下层的复合丝为涤纶、丙纶或尼龙复合丝。
作为本发明的一个实施方案，所述复合丝连接层中，连接上层和下层的复合丝为48D-1200D。
作为本发明的一个实施方案，所述三维立体夹层的厚度为1.5mm～5mm。
作为本发明的一个实施方案，所述上层、下层分别为针织面料层。
作为本发明的一个实施方案，所述针织面料层为单丝针织面料层(所述针织面料为单丝构成)。
作为本发明的一个实施方案，所述单丝为20D-100D的涤纶、丙纶或尼龙单丝。
作为本发明的一个实施方案，所述防滑层的厚度为0.1mm-20mm。
作为本发明的一个实施方案，所述防滑层为热塑弹性体层(TPE、TPU、TPR)、热熔胶层、点塑布、PVC网格布、发泡胶层或EVA层，或其他具有防滑功能的面料。
作为本发明的一个实施方案，所述三维立体夹层为一体化结构。
作为本发明的一个实施方案，所述三维立体夹层由上下层的单丝及连接上下层的复合丝通过双针床经编机织造而成的一体化结构。
作为本发明的一个实施方案，所述三维立体夹层织造成一体化结构后经80℃-230℃高温定型而得。所述三维立体夹层为由上层、下层以及中间竖向排列且连接所述上层和下层的复合丝连接层经80℃-230℃高温定型构成。具体是采用48D-1200D的复合丝与20D-100D的单丝通过双针床经编机织成一体化结构，且经80℃-230℃高温定型的三维立体夹层。
作为本发明的一个实施方案，所述面层为毯面层，或是毯面和功能性面料复合而成的面层；所述功能性面料位于毯面和三维立体夹层中间。优选功能性面料为防水透气膜。
与现有技术相比，本发明具有如下有益效果：
1、本发明的具有复合丝连接层结构的三维立体夹层的复合地毯，支撑力强，延展性能高，可以反复折叠1000次以上；10次水洗的水洗缩率不超过2％；
2、本发明的具有复合丝连接层结构的三维立体夹层的复合地毯，在长时间的挤压和受热及受潮的情况下不会变形；
3、本发明的具有复合丝连接层结构的三维立体夹层的复合地毯，在水洗10次后复合丝连接层内的复合丝没有出现不规则倾斜现象，地毯表面无明显凹陷，无褶皱；
4、本发明的复合地毯在三维立体夹层下方可设有带防滑功能的面料作为防滑层，具有较强的防滑功能，并同时有保护地面及增强隔音的功能。
附图说明
通过阅读参照以下附图对非限制性实施例所作的详细描述，本发明的其它特征、目的和优点将会变得更明显：
图1为三维立体夹层的结构示意图
图2为割绒三维立体夹层复合地毯的结构示意图；
图3为圈绒三维立体夹层复合地毯的结构示意图；
图4为平织三维立体夹层复合地毯的结构示意图；
图5为毯面及三维立体夹层中间加入功能性面料的结构示意图；
其中，1为上层针织面料层，2为复合丝连接层，3为下层针织面料层，4为割绒层，5为基布层，6为防滑层，7为圈绒层，8为平织面料层，9为功能性面料。
具体实施方式
下面结合实施例对本发明进行详细说明。以下实施例将有助于本领域的技术人员进一步理解本发明，但不以任何形式限制本发明。应当指出的是，对本领域的普通技术人员来说，在不脱离本发明构思的前提下，还可以做出若干调整和改进。这些都属于本发明的保护范围。
实施例1
本实施例涉及一种三维立体夹层复合地毯，如图3所示，包括：
由圈绒层7和基布层5组成的面层，由上层针织面料层1、复合丝连接层2和下层针织面料层3组成的三维立体夹层以及防滑层6。
面层中，绒面采用2400D合股纱线使用簇绒圈绒工艺在长纤基布上进行织造，毛高为5mm。
三维立体夹层中，如图1所示，由上层针织面料层1、下层针织面料层3以及中间竖向排列且连接所述上层和下层的复合丝连接层2组成。该三维立体夹层的厚度为5mm。三维立体夹层上、下层的针织面料的经纬密度为3mmX3mm。
本实施例中，使用双针床经编机采用2穿8空针的穿线方式，进行织造，上下层表面材料为30D涤纶单丝，中间竖向排列且连接该上下两层的材料为规格为300D/576F涤纶DTY复合丝(即由576根单丝组合成300D粗度的复合丝)。两种材料共同织成三维夹层布。三维立体夹层布经过160℃高温定型，缩率变小但同时保持着弹性。
面层与三维立体夹层之间采用耐水PUR热熔胶进行粘合。
防滑层为SEBS热熔胶层。具体是采用SEBS热熔胶在三维立体夹层的底部进行复合防滑处理；防滑层厚度为0.1mm，胶量为20克/㎡。
实施例2
本实施例涉及一种三维立体夹层复合地毯，如图2所示；包括：
由割绒层4和基布层5组成的面层，由上层针织面料层1、复合丝连接层2和下层针织面料层3组成的三维立体夹层以及防滑层6。
面层中，绒面采用涤纶1200D的合股纱线使用簇绒割绒工艺在PP网络丝基布上进行织造，毛高为6mm。
三维立体夹层的厚度为3mm。三维立体夹层上、下层的针织面料的经纬密度为3mmX2.5mm。
本实施例中，使用双针床经编机采用3穿6空针的穿线方式，进行织造，上下层表面材料为60D涤纶单丝，中间竖向排列且连接该上下两层的材料为规格为150D/144F的涤纶复合丝(即由144根单丝组合成150D粗度的复合丝)的涤纶复合丝，两种材料共同织成三维立体夹层。三维立体夹层经过180℃高温定型，缩率变小但同时保持着弹性。
面层与三维立体夹层采用TPE淋膜工艺复合。
防滑层为TPE层。具体是使用淋膜工艺将SHORE 45℃的TPE融化后淋膜涂布在三维立体夹层的底部形成防滑层。防滑层厚度为0.5mm，胶量为350克/㎡。
实施例3
本实施例涉及一种三维立体夹层复合地毯，如图4所示，包括：
面层(平织面料层8，也可为针织面料层)，由上层针织面料层1、复合丝连接层2和下层针织面料层3组成的三维立体夹层以及防滑层6。
面层中，平织面料层可采用梭织提花雪尼尔面料机织工艺织造。
三维立体夹层的厚度为2mm。三维立体夹层上、下层的针织面料的经纬密度为3mmX2.5mm。
本实施例中，使用双针床经编机采用4穿8空针的穿线方式，进行织造，上下层表面材料为20D涤纶单丝，中间竖向排列且连接该上下两层的材料为规格为300D/96F的涤纶复合丝(即由96根单丝组合成300D粗度的复合丝)，两种材料共同织成三维立体夹层。三维立体夹层经过120℃高温定型，缩率变小但同时保持着弹性。
机织面料层与三维立体夹层采用TPE淋膜工艺复合。
防滑层为点塑无纺布层5。具体是使用淋膜工艺将点塑无纺布与三维立体夹层的底部进行粘合。防滑层厚度为3mm。
作为本实施例的一个变化例，如图5所示，面层由平织面料层8和功能性面料9组成，功能性面料9采用防水透气膜，通过热熔胶粘合在平织面料层8和三维立体夹层的上层针织面料层1之间。
对比例1
本对比例涉及一种三维立体夹层复合地毯，基本同实施例2，所不同之处仅在于：
三维立体夹层由上层针织面料层、单丝连接层和下层针织面料层组成。
本对比例中，使用双针床经编机采用3穿6空针的穿线方式，进行织造，上下层表面材料为60D涤纶单丝，中间竖向排列且连接该上下两层的材料为规格为150D的单丝涤纶，两种材料共同织成三维立体夹层。三维立体夹层经过180℃高温定型。
性能验证
1、水洗测试对比验证
实验条件：取140×200cm的大小的以下地毯，在480W功率的家用洗衣机水洗30分钟，脱水10分钟，烘干温度摄氏70°条件下进行测试。
依照申请号为201220471847.4制备140×200cm的大小的复合地毯。由于中间层为海绵层，吸水后重量加重使洗衣机无法承受，且经过挤压浸水后中间的单丝不规则的倾斜，使表面有凹陷，褶皱。经过浸水后在潮湿状态下烘干后缩率为2.5％。
取140×200cm大小的对比例1的复合地毯。水洗后发现三维立体夹层的单丝不规则的倾斜，地毯表面和毯背出现轻微凹陷，褶皱。水洗后在潮湿状态下烘干后缩率为1.8％。水洗、烘干重复操作10次后的水洗收缩率为2.06％；此时，地毯表面和毯背出现明显凹陷，褶皱。每次烘干时间需要30分钟。
取140×200cm大小的实施例1中的圈绒三维立体夹层复合地毯。水洗后表面和毯背没有明显凹陷，四周与地面平齐。水洗后在潮湿状态下烘干后缩率为1.25％。水洗、烘干重复操作10次后的水洗收缩率为1.5％；此时，地毯表面和毯背仍无凹陷，四周与地面平齐；三维立体夹层中的复合丝未见倾斜。每次烘干时间需要30分钟。
取140×200cm大小的实施例2中的割绒三维立体夹层复合地毯。水洗后表面和毯背没有明显凹陷，四周与地面平齐。水洗后在潮湿状态下烘干后缩率为1.15％。水洗、烘干重复操作10次后的水洗收缩率为1.4％；此时，地毯表面和毯背仍无凹陷，四周与地面平齐；三维立体夹层中的复合丝未见倾斜。每次烘干时间需要40分钟。
取140×200cm大小的实施例3中的梭织雪尼尔三维立体夹层复合地毯。水洗后，水洗后表面和毯背没有明显凹陷，四周与地面平齐。水洗后在潮湿状态下烘干后缩率为1.5％。水洗、烘干重复操作10次后的水洗收缩率为1.95％；此时，地毯表面和毯背仍无凹陷，四周与地面平齐；三维立体夹层中的复合丝未见倾斜。每次烘干时间需要40分钟。
2、折叠效果对比验证
依照申请号为201220471847.4制备100×100cm的大小的复合地毯，在环境温度50度、环境湿度90％(模拟货物在海运过赤道条件下)将其不规则折叠并在折叠处用50KG的重物压住，24小时后将重物移开后摊平地毯后。地毯表面和背面有明显凹陷、褶皱，底面部分区域无法放平，摊平后放置24小时后部分褶皱有所改善但毯面和毯背仍有部分区域呈现出明显的斑块状、凹陷、褶皱现象。
取100×100cm大小的对比例1的复合地毯；在环境温度50度、环境湿度90％(模拟货物在海运过赤道条件下)将其不规则折叠并在折叠处用50KG的重物压住，24小时后将重物移开后摊平地毯。地毯表面和背面有明显斑块状、凹陷、褶皱，底面部分区域无法放平；摊平后放置24小时后部分褶皱有所改善但毯面和毯背仍有部分区域呈现出明显的斑块状、凹陷、褶皱现象。
取100×100cm大小的实施例1中的圈绒三维立体夹层复合地毯，在环境温度50度、环境湿度90％(模拟货物在海运过赤道条件下)将其不规则折叠并在折叠处用50KG的重物压住，24小时后将重物移开后摊平地毯。表面快速回弹，部分地区有轻微褶皱、折痕。四周与地面稍微翘起。摊平放置24小时后毯面和毯背无明显折痕、褶皱和斑块状现象四周与地面平齐。
取100×100cm大小的实施例2中的割绒三维立体夹层复合地毯，在环境温度50度、环境湿度90％(模拟货物在海运过赤道条件下)将其不规则折叠并在折叠处用50KG的重物压住，24小时后将重物移开后摊平地毯。表面快速回弹，部分地区有轻微褶皱、折痕。四周与地面稍微翘起。摊平放置24小时后表面无明显折痕、褶皱四周与地面平齐。
取100×100cm大小的实施例3中的梭织提花雪尼尔三维立体夹层复合地毯，在环境温度50度、环境湿度90％(模拟货物在海运过赤道条件下)将其不规则折叠并在折叠处用50KG的重物压住，24小时后将重物移开后摊平地毯。表面快速回弹，部分地区有轻微褶皱、折痕。摊平放置24小时后表面无明显折痕、褶皱四周与地面平齐。
综上所述，本发明提供了一种可水洗不变形的三维立体夹层复合地毯。并且，不局限于以上实施例的，本发明的复合地毯的毯面层可以采用多种工艺织造而成的面料，如圈绒面料、割绒面料、机织面料、针织面料等可以用于地毯的面料；三维立体夹层可采用48D—1200D的涤纶复合丝与20-100D单丝组合织造出多种支撑力强，延展性能高的花型；底层可复合热塑弹性体(如TPE、TPU，EVA等)，热熔胶、发泡胶，EVA,点塑布等防滑材料，提高复合地毯的防滑性、弹性以及隔音功能；还可通过使用热塑弹性体材料(TPE、TPU，EVA等)、热熔胶及具有不溶于水的粘合材料，并采用热压工艺使面层、三维立体夹层和防滑层紧密结合在一起。
以上对本发明的具体实施例进行了描述。需要理解的是，本发明并不局限于上述特定实施方式，本领域技术人员可以在权利要求的范围内做出各种变形或修改，这并不影响本发明的实质内容。

Claims (10)

1.一种可水洗不变形的三维立体夹层复合地毯，其特征在于，包括面层、三维立体夹层和防滑层；所述三维立体夹层由上层、下层以及中间竖向排列且连接所述上层和下层的复合丝连接层组成。
2.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述复合丝连接层中，连接上层和下层的复合丝为涤纶、丙纶或尼龙复合丝。
3.根据权利要求1或2所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述复合丝连接层中，连接上层和下层的复合丝为48D-1200D。
4.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述三维立体夹层的厚度为1.5mm-5mm。
5.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述上层、下层分别为单丝针织面料层；所述单丝为20D-100D的涤纶、丙纶或尼龙单丝。
6.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述面层为毯面和功能性面料复合而成的面层；所述功能性面料位于毯面和三维立体夹层中间。
7.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述防滑层的厚度为0.1mm-20mm。
8.根据权利要求7所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述防滑层为热塑弹性体层、热熔胶层、点塑布、PVC网格布、发泡胶层或EVA层。
9.根据权利要求1所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述三维立体夹层为一体化结构。
10.根据权利要求1或9所述的可水洗不变形的三维立体夹层复合地毯，其特征在于，所述三维立体夹层由上下层的单丝及连接上下层的复合丝通过双针床经编机织造而成后经80℃-230℃高温定型而得。
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