WO2023040052A1 - 一种地毯垫 - Google Patents

一种地毯垫 Download PDF

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Publication number
WO2023040052A1
WO2023040052A1 PCT/CN2021/133812 CN2021133812W WO2023040052A1 WO 2023040052 A1 WO2023040052 A1 WO 2023040052A1 CN 2021133812 W CN2021133812 W CN 2021133812W WO 2023040052 A1 WO2023040052 A1 WO 2023040052A1
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WO
WIPO (PCT)
Prior art keywords
layer
monofilaments
raised
monofilament
flame
Prior art date
Application number
PCT/CN2021/133812
Other languages
English (en)
French (fr)
Inventor
曹顺林
张怡
翟梓翔
孙玉好
Original Assignee
昆山怡家居纺织有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 昆山怡家居纺织有限公司 filed Critical 昆山怡家居纺织有限公司
Priority to JP2023526257A priority Critical patent/JP2023548839A/ja
Priority to EP21957316.9A priority patent/EP4248806A1/en
Publication of WO2023040052A1 publication Critical patent/WO2023040052A1/zh

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
    • A47G27/0406—Laying rugs or mats
    • A47G27/0418—Fasteners; Buttons; Anchoring devices
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/02—Carpets; Stair runners; Bedside rugs; Foot mats
    • A47G27/0243—Features of decorative rugs or carpets
    • A47G27/0281—Resisting skidding or creeping
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47G—HOUSEHOLD OR TABLE EQUIPMENT
    • A47G27/00—Floor fabrics; Fastenings therefor
    • A47G27/04—Carpet fasteners; Carpet-expanding devices ; Laying carpeting; Tools therefor
    • A47G27/0406—Laying rugs or mats
    • A47G27/0412—Anti-skid layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
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    • B32B5/279—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by a knit fabric layer next to a non-woven fabric layer
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    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B32B5/2795—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary characterised by a knit fabric layer next to a woven fabric layer
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    • B32B7/04—Interconnection of layers
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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
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Definitions

  • the invention relates to the field of carpets in the textile industry, in particular to a carpet pad.
  • the prior patent CN201921334346.X discloses a non-slip carpet rubber cushion; the non-slip carpet rubber cushion includes a bottom non-slip water-repellent layer and an upper bonding layer, and the bonding layer is a single surface with several raised monofilaments fabric.
  • the bonding layer is a single-sided fabric with protrusions made of monofilament above 20D or a single-sided structural layer formed by cutting the middle of the three-dimensional mesh structural layer; the three-dimensional mesh structural layer is composed of two upper and lower layers. It consists of warp-knitted mesh fabric and several polyester, polypropylene or nylon monofilaments arranged vertically in the middle to connect the upper and lower layers of warp-knitted mesh fabric.
  • non-slip carpet rubber pad layer of the invention can be used in combination with various carpet surfaces, the bonding strength is moderate, and the carpet surface will not easily shift and warp due to too low bonding force;
  • the thorns formed by the polyester, polypropylene or nylon monofilaments in the layer may fall off after repeated use. Comfort; and when traditional carpets are used together, the hooking force between the monofilament in the cushion and the carpet above it is relatively low in the vertical direction, and it needs to be pressed once before it can hook up with the carpet above it.
  • the present invention aims at the problems existing in the traditional anti-skid cushion layer and the above-mentioned anti-slip carpet rubber cushion layer when it is used in combination with the carpet, the monofilament sticks to the hand, the hooking force is relatively weak, and the monofilament of the polyester, polypropylene fiber or nylon on the surface falls off, etc., and provides a Newer carpet pads.
  • the present invention provides a carpet pad.
  • the carpet pad includes an upper layer of hooking layer and a lower layer of anti-skid layer; the upper surface of the hooking layer is distributed with curved raised monofilaments, and the top has raised monofilaments.
  • a pimple that forms after the silk melts/softens.
  • the top of the raised monofilament melts/softens to form small bumps.
  • the monofilament has a certain radian and inclination due to the heat treatment, which can be matched with various carpets placed above it.
  • the hooking will form a strong friction force, so as to hook up with the carpet laid above it and form a locking effect.
  • the height of the raised monofilament is 0.50mm-10mm; the thickness of the raised monofilament is 18DTEX-4400DTEX. If the height of the raised monofilaments is too high, the hooking layer and the carpet will not fit tightly enough, and the laid carpet will be displaced under the action of external force, and people will easily fall when walking on the carpet. When it is combined with the fabric, it cannot be hooked firmly. If the thickness of the raised monofilament is too thin, it is easy to break, and the sintered lumps are too small, and the hooking effect is not good; When the thickness of the monofilament is too thick, the hardness is relatively high, and it is easy to hurt the hand when using it.
  • the thickness of the raised monofilament is 20DTEX-800DTEX.
  • the density of the raised monofilaments is 6/cm2-80/cm2mm2.
  • the density of raised monofilaments is too high, and multiple monofilaments are easily sintered into one body, resulting in multiple monofilaments being sintered into a larger lump during sintering, instead of forming a single distribution of small lumps, and the bumps are too large to enter the gap on the back of the carpet. , cannot hook up with the carpet and form a locking effect; if the density is too small, the number of raised monofilaments is insufficient, the hooking strength is insufficient, and the anti-skid performance decreases.
  • the material of the raised monofilament is polyester, polypropylene or nylon.
  • the preparation process of the raised monofilament includes one of warp and weft knitting, weaving, tufting, flocking or warp and weft knitting.
  • the raised monofilaments are made by tufting or flocking on the interlocking layer.
  • the raised monofilament is obtained when warp and weft knitting or weaving is used to prepare the hooking layer.
  • the thickness of the hooking layer is 0.50mm-10mm.
  • the carpet pad can be used in combination with a carpet surface.
  • the heat-treated carpet pad can be combined with a variety of carpets or various knitted fabrics and woven fabrics to form a combined carpet.
  • the combined carpet can be disassembled repeatedly without destroying the fabric structure of the upper and lower layers.
  • the present invention also provides the preparation method of above-mentioned carpet pad, described method comprises the steps:
  • the monofilament is made into a cut velvet fabric with raised monofilaments on the upper surface;
  • Heat treatment of raised monofilaments heat treatment process is used to melt/soften the top of raised monofilaments in the hooking layer, and form small lumps after cooling, and the raised monofilaments are irregularly inclined and bent;
  • an intermediate layer is provided between the hooking layer and the anti-skid layer.
  • the material of the middle layer is one of non-woven fabric, knitted fabric and woven fabric.
  • the middle layer is a fabric with a certain support force, and the middle layer has the effects of support, dimensional stability, comfort and smoothness.
  • the middle layer can be removed, so that the hooking layer and the anti-skid layer are directly combined into one body.
  • the anti-slip layer is a foamed latex layer, a thermoplastic elastomer material layer, an acrylic resin layer, an EVA foam layer, a polyurethane foam layer, a non-woven fabric layer, a hot melt adhesive layer, and an XPE foam layer. , IXPE foam layer and knitted fabrics, woven fabrics.
  • the heat treatment process described in step A2 is flame burning; the specific step is to place the interlocking layer above the flame of the composite machine, the flame temperature is 400°C-1000°C, and the flame height is 0.1-10cm, The distance between the flame and the interlocking layer is about 1-5cm; the burnt fabric leaves the flame driven by the rollers behind the flame compounding machine; after the interlocking layer is burnt, the top of the raised monofilament in the interlocking layer melts/ Soften, after cooling treatment, form small lumps with irregular inclinations, and monofilaments bend.
  • the flame height is 1-5 cm.
  • the pulling speed of the roller is 2m/min-20m/min.
  • the heat treatment process described in step A2 is far-infrared ray baking; the specific steps are to put the hook-up layer into a mesh belt type far-infrared oven, and the far-infrared lamp tube is preset at the top of the box, and the distance between the far-infrared lamp tube
  • the blanket surface is 0-20cm, and the far-infrared temperature is set at 180°C-800°C; after the hook-link layer is baked, the top of the raised monofilament in the hook-link layer melts/softens, and after cooling, small lumps are formed with irregular inclinations. The monofilament bends.
  • the far-infrared lamp is 3-20cm away from the carpet surface.
  • the running speed of the mesh belt is 2m/min-15m/min.
  • the heat treatment described in step A2 is heat oven treatment; the specific steps are to place the linking layer in a hot oven, the temperature of the oven is 120°C-230°C, and after passing through the high temperature environment in the oven, the linking layer The top of the protruding monofilament is melted/softened, and the mesh belt or roller is driven to leave the flame, and at the same time it is located between the pressure rollers of the coiling traction equipment, so that the monofilaments of the interlocking layer are in a softened state and pass through the pressure rollers, so that the monofilaments are produced Bend and form small knots at the top.
  • the pressure of the upper and lower pressing rollers can be adjusted by a cylinder, and the pressure is 0.2 kg-10 kg.
  • the running speed of the mesh belt or the roller is 2m/min-15m/min.
  • the heat-treated hooking layer is subjected to anti-slip, water-repellent and moisture-proof treatment.
  • steps A2 and A3 can be changed, and the interlocking layer is first compounded with the anti-slip layer, and then heat-treated.
  • the flame temperature is too high, the blanket surface is too close to the heat source, and the traction speed is too slow, the yarn and base fabric will be directly melted and scrapped; if the flame temperature is too low, the blanket surface is too far away from the heat source, and the traction speed Too fast and the raised monofilaments will fail to form a pimple.
  • the present invention has the following beneficial effects:
  • the present invention uses high temperature to bend the raised monofilament and suede to form a hooking effect with the carpet placed above it, with better bonding force, greater friction and firmer.
  • the monofilaments and fibers of the interlocking layer are not easy to fall off by melting and solidifying through high temperature.
  • the monofilament of the surface layer of the present invention has a certain degree of curvature and the surface of the small bumps of the pile is passivated, which prevents the user from inadvertently hurting the hand, and at the same time enhances the locking effect with the carpet above.
  • Fig. 1 is a kind of carpet pad schematic diagram through heat treatment
  • Fig. 2 is a kind of schematic diagram of carpet pad through heat treatment
  • Fig. 3 is a schematic diagram of a heat-treated carpet pad
  • the surface is distributed with a hooking layer with raised monofilaments, 2, an intermediate layer, 3, an anti-skid layer, 4, a short fleece layer.
  • This embodiment relates to a carpet pad. As shown in FIG. 1 , it includes, from top to bottom: a hooking layer 1 with protruding monofilaments distributed on the surface, an intermediate layer 2 , and an anti-slip layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment transport the interlocking layer with protruding monofilaments on the surface to the flame compounding machine through the mesh belt, the speed of the interlocking layer passing through the flame compounding machine is 20 meters per minute, and the distance between the surface of the interlocking layer and the flame is 4cm. After being burned by a flame at 730°C, the flame height is 4cm. At the same time, it leaves the flame under the drive of the roller. After heat treatment, the raised monofilament has a height of 1-2mm, and small lumps are formed on the top after cooling.
  • thermoplastic elastomer to perform anti-slip treatment on the back of the middle layer.
  • This embodiment relates to a heat-treated carpet pad. As shown in FIG. 1 , it includes, from top to bottom: an interlocking layer 1 with protruding monofilaments distributed on the surface, an intermediate layer 2 , and an anti-skid layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment Put the raised monofilament made by the above steps into the mesh belt oven with its face up.
  • the far infrared lamp tube is preset on the top of the oven.
  • the distance between the infrared lamp tube and the mesh belt is 6cm, and the infrared temperature is set to 800 °C.
  • the surface of the three-dimensional sandwich mesh fabric will form curved small bumps; the speed of the mesh belt is 10 meters per minute. At the same time, it leaves under the drive of the roller.
  • the height of the raised monofilament after heat treatment is 1-3mm.
  • Anti-slip layer preparation use foam latex to carry out anti-slip treatment on the back of the non-woven fabric;
  • Hemming carry out the hemming process on the trimmed embryonic blanket.
  • This embodiment relates to a heat-treated carpet pad. As shown in FIG. 2 , it includes, from top to bottom: a hooking layer 1 with raised monofilaments distributed on the surface, a short pile layer 4 , and an anti-skid layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • non-woven fabrics select polyester woven fabrics with a weight of 85 grams/m2 and a density of 114 warps ⁇ 63 wefts as the base material, and lay 140 g/m2 polyester staple fibers on the base material and then use RY1-4000 non-woven acupuncture
  • the needles on the needle punching machine repeatedly puncture and pierce the fiber web of the non-woven fabric, and the fluff is brought out, so that a fleece layer is formed on one side of the composite base fabric layer, and the pile height is 3mm, and a composite base fabric is formed.
  • the needle planting density is 15000 needles/m2
  • the acupuncture frequency is 450 times/min
  • the cloth running speed is 1.8 m/min
  • the acupuncture stroke is 2.1cm.
  • High temperature treatment The tufted fabric is transported to the flame compounding machine through the mesh belt.
  • the speed of the knitted fabric passing through the flame compounding machine is 16 meters per minute, and the distance between the surface of the tufted fabric and the flame is 4cm.
  • the needle-punched non-woven fabric is burnt by a flame at 780°C with a flame height of 3 cm, and at the same time leaves the flame driven by the roller.
  • the monofilament height after heat treatment is 2-4mm.
  • Anti-slip layer preparation use EVA foam layer for anti-slip treatment.
  • This embodiment relates to a heat-treated carpet pad. As shown in FIG. 3 , it includes, from top to bottom: a hooking layer 1 with raised monofilaments distributed on the surface, and an anti-skid layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • Nylon monofilaments are used to make convex fabrics by warp knitting and cut velvet.
  • the height of the raised monofilaments is 4mm, and the thickness of the nylon monofilaments is 2000D.
  • This embodiment relates to a heat-treated carpet pad. As shown in FIG. 1 , it includes, from top to bottom: an interlocking layer 1 with protruding monofilaments distributed on the surface, an intermediate layer 2 , and an anti-skid layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment The polyester fabric with protrusions on the surface is transported to the flame compounding machine through the mesh belt.
  • the fabric made of polyester monofilament with weft knitting and cut velvet process passes through the flame compounding machine at a speed of 20 meters per minute.
  • Polyester monofilament The distance between the surface of the silk weft-knitted cut velvet fabric and the flame is 2cm.
  • the weft-knitted cut velvet fabric for polyester monofilament is burned by a flame at 730°C, and the flame height is 4cm. At the same time, it leaves the flame under the drive of the roller.
  • the raised monofilament after heat treatment has a height of 2-4mm.
  • Acupuncture composite process use the above-mentioned fabric as the base material, lay 300 g/m2 polyester staple fiber on the base material, and then perform acupuncture processing on the RY1-4000 non-woven needling machine to form a whole.
  • the needle planting density is 15,000 needles /m2, the acupuncture frequency is 350 times/min, the cloth walking speed is 1.1 m/min, and the acupuncture stroke is 1.10cm to form an integrated body;
  • This embodiment relates to a heat-treated carpet pad, as shown in 3, which includes from top to bottom: a hooking layer 1 with raised monofilaments distributed on the surface, and an anti-skid layer 3 .
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • the polyester monofilament is transported to the oven through the mesh belt through the tufting and cutting process, and the raised fabric made of the polyester monofilament is passed through the oven at a speed of 12 meters per minute.
  • the temperature of the oven is 180°C. After passing through the high temperature environment, it leaves under the drive of the roller at the rear of the oven. At the same time, it is located between the upper and lower pressure rollers of the coiling traction equipment, so that the monofilament of the interlocking layer is in a melted/softened state and passes through the pressure roller to make it single.
  • the pressure is 3 kg
  • This comparative example relates to a carpet pad, and the preparation method is basically the same as that of Example 1, except that the height of the raised monofilament is 15mm.
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment transport the interlocking layer with protruding monofilaments on the surface to the flame compounding machine through the mesh belt, the speed of the interlocking layer passing through the flame compounding machine is 20 meters per minute, and the distance between the surface of the interlocking layer and the flame is 4cm.
  • the flame height After burning with a flame at 730°C, the flame height is 5cm, and at the same time, it leaves the flame under the drive of the roller.
  • the raised monofilament has a height of 15mm, and small lumps are formed on the top after cooling.
  • thermoplastic elastomer to perform anti-slip treatment on the back of the middle layer.
  • This comparative example relates to a carpet pad, and the preparation method is basically the same as that of Example 1, except that the height of the raised monofilament is 0.3 mm.
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment transport the interlocking layer with protruding monofilaments on the surface to the flame compounding machine through the mesh belt, the speed of the interlocking layer passing through the flame compounding machine is 20 meters per minute, and the distance between the surface of the interlocking layer and the flame is 4cm. After burning with a flame at 730°C, the height of the flame is 5cm. At the same time, it leaves the flame under the drive of the roller. After heat treatment, the height of the raised monofilament is 0.1-0.3mm, and small bumps are formed on the top after cooling.
  • thermoplastic elastomer to perform anti-slip treatment on the back of the middle layer.
  • This comparative example relates to a carpet pad, and the preparation method is basically the same as that of Example 1, except that the thickness of the raised monofilaments is 10D.
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment transport the interlocking layer with protruding monofilaments on the surface to the flame compounding machine through the mesh belt, the speed of the interlocking layer passing through the flame compounding machine is 20 meters per minute, and the distance between the surface of the interlocking layer and the flame is 4cm. After burning with a flame at 730°C, the height of the flame is 5cm. At the same time, it leaves the flame under the drive of the roller. After heat treatment, the height of the raised monofilament is 0.1-0.3mm, and small bumps are formed on the top after cooling.
  • thermoplastic elastomer to perform anti-slip treatment on the back of the middle layer.
  • This comparative example relates to a carpet pad, and the preparation method is basically the same as that of Example 1, except that the thickness of the raised monofilament is 5000D.
  • This a kind of heat-treated carpet pad preparation comprises the steps:
  • High temperature treatment transport the interlocking layer with protruding monofilaments on the surface to the flame compounding machine through the mesh belt, the speed of the interlocking layer passing through the flame compounding machine is 20 meters per minute, and the distance between the surface of the interlocking layer and the flame is 4cm. After burning with a flame at 730°C, the height of the flame is 5cm. At the same time, it leaves the flame under the drive of the roller. After heat treatment, the height of the raised monofilament is 0.1-0.3mm, and small bumps are formed on the top after cooling.
  • thermoplastic elastomer to perform anti-slip treatment on the back of the middle layer.
  • Example 1 Take a heat-treated carpet pad in Example 1 with a size of 30cm x 30cm, and a knitted fabric with a size of 30cmx30cm, overlap each other, roll it twice with a 6 kg roller, and do three times of lateral peeling with a tensile tester Force test, the test results are 214.87 Newtons; 235.213 Newtons; 198.186 Newtons.
  • test result is 52.128 Newton; 52.128 Newton; 53,252 Newton;
  • Example 3 Take a heat-treated carpet pad in Example 1 with a size of 30cm x 30cm, and a knitted fabric with a size of 30cmx30cm, overlap each other, roll it twice with a 6 kg roller, and peel it off three times with a tensile tester Force test, the test result is 5.258 Newton; 5.587 Newton; 6.487 Newton.
  • the heat-treated carpet pad of the present invention has better bonding force and firmness than the prior patent CN2019107593, and greatly reduces the phenomenon of falling monofilaments.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Carpets (AREA)

Abstract

一种地毯垫，地毯垫包括上层的勾连层（1）和底层的防滑层（3）；勾连层（1）上表面分布有弯曲状的凸起单丝，且顶端有凸起单丝熔化/软化、冷却后形成的疙瘩。勾连层（1）上的凸起单丝经过热处理后，凸起的单丝顶端熔化/软化后，形成小疙瘩，同时单丝因为热处理具有一定的弧度和倾斜度，可以与置于其上方的多种地毯勾连同时形成较强的摩擦力，特别在垂直方向也有一定的勾连力。通过设置凸起单丝的长度及密度，从而与铺设在其上方的地毯勾连并形成卡锁效果，同时单丝凸起较柔软，形成的疙瘩摸上去不扎手。

Description

一种地毯垫 技术领域
本发明涉及纺织行业的地毯领域，具体涉及一种地毯垫。
背景技术
地毯作为一种装饰家庭或工作环境的产品已成为大众广泛接受，但目前市面上传统的地毯水洗不便，且大部分地毯在光滑的地面上容易滑动位移进而产生人员跌倒的风险，需要在地毯下方铺设一层能与地毯产生勾连作用的防滑垫以减少地毯位移带来的风险。尽管目前市面上有人将PVC网状或点塑布等防滑布铺在传统地毯的下层，但这些防滑布轻薄、容易起皱且不耐磨，也无法与其上方的地毯形成勾连，上方地毯依然存在位移进而导致人员摔倒风险。以上缺点影响地毯的进一步推广和使用。
在先专利CN201921334346.X公开了一种防滑地毯胶垫层；所述防滑地毯胶垫层包括底层的防滑拒水层和上层的结合层，所述结合层为布设若干凸起单丝的单面面料。所述结合层为用20D以上的单丝制成的具有凸起的单面面料或为三维网布结构层中间剖开形成的单面结构层；所述三维网布结构层是由上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶、丙纶或尼龙单丝组成。尽管该发明的防滑地毯胶垫层可与多种地毯毯面结合使用，结合强度适中，也不会因结合力过低导致毯面容易移位、起翘；但是，该发明中所述防滑垫层中的涤纶、丙纶或尼龙单丝形成的刺经过多次使用后，可能出现表面涤纶、丙纶或尼龙单丝掉落，单丝长期使用后易变形，且在手感上容易扎手并给人不舒适感；而且将传统地毯一起使用时，垫层中的单丝与其上方的地毯勾连力特别在垂直方向上相对较低，需要经过一遍按压后，才能与上方的地毯毯面层产生勾连。
发明内容
本发明针对传统防滑垫层以及上述防滑地毯胶垫层所存在的与地毯结合使用时单丝扎手，勾连力相对较弱，表面涤纶、丙纶或尼龙部分单丝掉落等问题，提供了一种新型的地毯垫。
本发明的目的可以通过以下方案来实现：
第一方面，本发明提供了一种地毯垫，所述地毯垫包括上层的勾连层和下层的防滑 层；所述勾连层上表面分布有弯曲状的凸起单丝，且顶端有凸起单丝熔化/软化后形成的疙瘩。勾连层上的凸起单丝经过热处理后，凸起的单丝顶端熔化/软化后，形成小疙瘩，同时单丝因为热处理具有一定的弧度和倾斜度，可以与置于其上方的多种地毯勾连同时形成较强的摩擦力，从而与铺设在其上方的地毯勾连并形成卡锁效果。
作为本发明的一个实施方案，所述凸起单丝的高度为0.50mm-10mm；凸起单丝的粗度为18DTEX-4400DTEX。所述凸起单丝高度过高，会导致勾连层与地毯勾连时，贴合不够紧凑，铺设的地毯在外力作用下会产生位移，人在地毯上行走容易摔倒，凸起过低，会使其与面料结合时，无法勾连牢固。凸起单丝粗度过细，容易断裂，烧结疙瘩过小，勾连效果不佳；粗度过粗，烧结时不易弯曲，不能形成卡锁勾连，同时烧结疙瘩容易过大，地毯拆卸时易损坏。单丝粗度过粗时，硬度较大，使用时易扎伤手。
在一些实施例中，凸起单丝的粗度为20DTEX-800DTEX。
作为本发明的一个实施方案，所述凸起单丝的密度为6根/cm2—80根/cm2平方毫米。凸起单丝密度过大，多根单丝易烧结为一体，造成烧结时多根单丝被烧结成一个较大的疙瘩，而不是形成单个分布的小疙瘩，疙瘩过大不易进入地毯背面空隙，不能与地毯勾连并形成卡锁效果；密度过小，凸起单丝数量不足，勾连力度不足，防滑性能下降。
作为本发明的一个实施方案，所述凸起单丝的材料为涤纶、丙纶、尼龙。
作为本发明的一个实施方案，所述凸起单丝的制备工艺包括经纬编针织、梭织、簇绒、植绒或经纬编中的一种。
作为本发明的一个实施方案，凸起单丝是在勾连层上采用簇绒或植绒工艺制得的。
作为本发明的一个实施方案，凸起单丝是采用经纬编针织或梭织制备勾连层时获得的。
作为本发明的一个实施方案，所述勾连层的厚度为0.50mm-10mm。
作为本发明的一个实施方案，所述地毯垫可与地毯毯面结合使用。经过热处理的地毯垫可以与多种地毯或者各种针织面料、梭织面料随意组合形成一种组合式地毯，组合后的地毯可以反复拆卸且不破坏上下层的织物组织结构。
第二方面，本发明还提供了上述地毯垫的制备方法，所述方法包括如下步骤：
A1、勾连层制备：将单丝制成上表面有凸起单丝的割绒面料；
A2、凸起单丝热处理：使用热处理工艺，将勾连层中凸起单丝的顶端熔化/软化，经过冷却后形成小疙瘩，凸起单丝无规则的倾斜并发生弯曲；
A3、防滑层制备：将防滑层复合在勾连层的下表面。
作为本发明的一个实施方案，采用纬编针织、梭织工艺时，勾连层与防滑层之间还设有中间层。所述中间层的材料为无纺布、针织面料、梭织面料中的一种。中间层是具有一定支撑力的面料，该中间层起到支撑性、尺寸稳定性、舒适性、平整性的效果。
作为本发明的一个实施方案，所述中间层可以除掉，使勾连层与防滑层直接复合成一体。
作为本发明的一个实施方案，防滑层为发泡乳胶层、热塑弹性体材料层、腈纶树脂层、EVA发泡层、聚氨酯发泡层、无纺布层、热熔胶层、XPE发泡、IXPE发泡层及针织面料、梭织面料。
作为本发明的一个实施方案，步骤A2中所述热处理工艺为火焰灼烧；具体步骤为将勾连层置于复合机的火焰上方，火焰温度为400℃-1000℃，火焰高度为0.1-10cm，火焰与勾连层的距离约为1-5cm；经过灼烧过的面料在火焰复合机后方的辊轮罗拉带动下离开火焰；勾连层被灼烧后，勾连层中凸起单丝的顶端熔化/软化，经过冷却处理后形成小疙瘩无规则的倾斜，单丝发生弯曲。
在一些实施例中，所述火焰高度为1-5cm。
作为本发明的一个实施方案，辊轮罗拉的牵引速度为2m/min-20m/min。
作为本发明的一个实施方案，步骤A2中所述热处理工艺为远红外线炙烤；具体步骤为将勾连层放入网带式远红外烘箱，箱顶部预设远红外线灯管，远红外线灯管距离毯面0-20cm,远红外线温度设定为180℃-800℃；勾连层被炙烤后，勾连层中凸起单丝的顶端熔化/软化，经过冷却处理后形成小疙瘩无规则的倾斜，单丝发生弯曲。
在一些实施例中，所述远红外线灯管距离毯面3-20cm。
作为本发明的一个实施方案，网带的走速为2m/min-15m/min。
作为本发明的一个实施方案，步骤A2中所述热处理为热烘箱处理；具体步骤为将勾连层置于热烘箱中，烘箱温度为120℃-230℃，经过高温环境在烘箱后，勾连层中凸起单丝的顶端熔化/软化，网带或辊轮带动下离开火焰，同时位于打卷牵引设备的压辊之间，使得勾连层的单丝处于软化状态经过压辊，使其单丝发生弯曲并在顶端形成小疙瘩。
作为本发明的一个实施方案，上下压辊的压力可用气缸调节，压力为0.2公斤-10公斤。
作为本发明的一个实施方案，网带或辊轮的走速为2m/min-15m/min。
作为本发明的一个实施方案，将经过热处理后的勾连层进行防滑拒水、防潮处理。
作为本发明的一个实施方案，步骤A2、A3顺序可换，将勾连层先与防滑层进行复合，再进行热处理。
本发明热处理过程中，如果火焰温度过高、毯面离热源过近、牵引速度过慢，会导致纱线及基布直接融化导致报废；火焰温度过低、毯面离热源过远、牵引速度过快，会导致凸起单丝无法形成疙瘩。
与现有技术相比，本发明具有如下有益效果：
1、本发明利用高温将凸起的单丝及绒面，使其弯曲使其与置于其上方的地毯形成勾连作用，结合力更好、摩擦力更大、更牢固。
2、本发明的通过高温使其融固，勾连层的单丝及纤维不易脱落。
3、本发明表面层的单丝具有一定的弯度且绒头的小疙瘩表面钝化，防止使用者不慎伤手，同时增强与上方的地毯的卡锁效果。
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为一种经过热处理的地毯垫示意图；
图2为一种经过热处理的地毯垫示意图；
图3为一种经过热处理的地毯垫示意图；
其中1、表面分布有凸起单丝的勾连层，2、中间层，3、防滑层，4、短绒层。
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
本实施例涉及一种地毯垫，如图1所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、中间层2、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶单丝组成的三维夹层网眼布中间剖开形成的单面结构层；该三维夹层网眼布具体是采用300D的涤纶单丝纱线一体化编织而成。凸起的单丝高度为3mm。
2)中间层复合：将勾连层做基材，在基材下表面上铺设300克/㎡涤纶短纤维后在RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm，使其形成一体；
3)高温处理：将表面具有凸起单丝的勾连层通过网带输送到火焰复合机上，勾连层通过火焰复合机的速度为20米/每分钟，勾连层表面与火焰距离为4cm。经过730℃的火焰灼烧，火焰高度为4cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为1-2mm，冷却后顶端形成小疙瘩。
4)防滑层制备：使用热塑弹性体在中间层背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
实施例2
本实施例涉及一种经过热处理的地毯垫，如图1所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、中间层2、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选取涤纶单丝用梭织工艺制成表面带有凸起单丝的面料，凸起单丝的高度为5mm，凸起单丝的粗度为400D。
2)复合工艺：将梭织面料使用热熔胶与无纺布进行复合。
3)高温处理：将上述步骤制成的凸起单丝面朝上放入网带式烘箱中，烘箱顶部预设有远红外线灯管，红外灯管距离网带6cm，将红外线温度设为800℃。在高温照射的过程中剖开的三维夹层网眼布表面会形成弯曲的小疙瘩；网带走速为10米/每分钟。同时在辊轮的带动下离开。经过热处理后的凸起的单丝高度为1-3mm。
4)防滑层制备：使用发泡乳胶在无纺布背部进行防滑处理；
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
6)缝边：将裁剪好的胚毯进行包边工艺。
实施例3
本实施例涉及一种经过热处理的地毯垫，如图2所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、短绒层4、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用无纺布：选取克重85克/㎡，密度114经×63纬涤纶梭织布做基材，在基材上铺设140g/㎡涤纶短纤维后在RY1-4000的无纺针刺机上，通过针刺机上的刺针对无纺布的纤网进行反复穿刺并刺透，将其绒毛带出，使在复合基布层单面形成绒层，绒 高为3mm,并形成复合基布，植针密度为15000针/㎡，针刺频率为450次/分钟，走布速度为1.8米/分钟，针刺行程为2.1cm。
2)选用面料：采用20D的丙纶单丝在上述无纺布上使用簇绒工艺。凸起单丝的高度为6mm。
3)高温处理：将簇绒好的面料通过网带输送到火焰复合机上，针织面料通过火焰复合机的速度为16米/每分钟，簇绒面料表面与火焰距离为4cm。针刺无纺布经过780℃的火焰灼烧，火焰高度为3cm，同时在辊轮的带动下离开火焰。经过热处理后的单丝高度为2-4mm。
4)防滑层制备：使用EVA发泡层进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
6)缝边：将裁剪好的胚毯进行锁边工艺。
实施例4
本实施例涉及一种经过热处理的地毯垫，如图3所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用尼龙单丝用经编割绒工艺制成凸起状的面料，凸起单丝的高度为4mm，尼龙单丝的粗度为2000D。
2)高温处理：将尼龙单丝用经编割绒工艺通过网带输送到火焰复合机上，尼龙单丝用经编割绒工艺制成凸起状的面料通过火焰复合机的速度为19米/每分钟，尼龙单丝用经编割绒工艺制成凸起状的面料表面与火焰距离为3cm。尼龙单丝用经编割绒工艺制成凸起状的面料经过690℃的火焰灼烧，火焰高度为3cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为1-3mm。
3)防滑层制备：使用热塑弹性体进行防滑处理。
4)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
实施例5
本实施例涉及一种经过热处理的地毯垫，如图1所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、中间层2、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选取涤纶单丝用纬编割绒工艺制成凸起状的面料，凸起单丝的高度为5mm，涤纶单丝的粗度为500D。
2)高温处理：将涤纶表面具有凸起的面料通过网带输送到火焰复合机上，涤纶单丝用纬编割绒工艺制成的面料通过火焰复合机的速度为20米/每分钟，涤纶单丝用纬编割绒工艺面料表面与火焰距离为2cm。涤纶单丝用纬编割绒工艺面料经过730℃的火焰灼烧，火焰高度为4cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为2-4mm。
3)针刺复合工艺：将上述面料做基材，在基材上铺设300克/㎡涤纶短纤维后在RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm所形成一体；
4)防滑层制备：使用热熔胶在无纺布背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
实施例6
本实施例涉及一种经过热处理的地毯垫，如3所示，从上往下依次包括：表面分布有凸起单丝的勾连层1、防滑层3。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：采用260D的涤纶单丝在上述无纺布上使用簇绒工艺。凸起单丝的高度为5mm。
2)高温处理：将涤纶单丝用簇绒割绒工艺通过网带输送到烘箱中，涤纶单丝用簇绒割绒工艺制成凸起状的面料通过烘箱的速度为12米/每分钟，烘箱温度为180℃，经过高温环境在烘箱后方的辊轮带动下离开，同时位于打卷牵引设备的上下压辊之间，使得勾连层的单丝处于熔化/软化状态经过压辊，使其单丝发生弯曲。压力为3公斤，
3)防滑层制备：使用热塑弹性体进行防滑处理。
4)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
对比例1
本对比例涉及一种地毯垫，与实施例1制备方法基本相同，不同之处在于凸起单丝的高度为15mm。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶单丝组成的三维夹层网眼布中间剖开形成的单面结构层；该三维夹层网眼布具体是采用300D的涤纶单丝纱线一体化编织而成。凸起的单丝高度为15mm。
2)中间层复合：将勾连层做基材，在基材下表面上铺设300克/㎡涤纶短纤维后在 RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm，使其形成一体；
3)高温处理：将表面具有凸起单丝的勾连层通过网带输送到火焰复合机上，勾连层通过火焰复合机的速度为20米/每分钟，勾连层表面与火焰距离为4cm。经过730℃的火焰灼烧，火焰高度为5cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为15mm，冷却后顶端形成小疙瘩。
4)防滑层制备：使用热塑弹性体在中间层背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
对比例2
本对比例涉及一种地毯垫，与实例1制备方法基本相同，不同之处在于凸起单丝的高度为0.3mm。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶单丝组成的三维夹层网眼布中间剖开形成的单面结构层；该三维夹层网眼布具体是采用300D的涤纶单丝纱线一体化编织而成。凸起的单丝高度为0.3mm。
2)中间层复合：将勾连层做基材，在基材下表面上铺设300克/㎡涤纶短纤维后在RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm，使其形成一体；
3)高温处理：将表面具有凸起单丝的勾连层通过网带输送到火焰复合机上，勾连层通过火焰复合机的速度为20米/每分钟，勾连层表面与火焰距离为4cm。经过730℃的火焰灼烧，火焰高度为5cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为0.1-0.3mm，冷却后顶端形成小疙瘩。
4)防滑层制备：使用热塑弹性体在中间层背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
对比例3
本对比例涉及一种地毯垫，与实例1制备方法基本相同，不同之处在于凸起单丝的粗度为10D。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶单丝组成的三维夹层网眼布中间剖开形成的单面结构层；该三维夹层 网眼布具体是采用1D的涤纶单丝纱线一体化编织而成。凸起的单丝高度为3mm。
2)中间层复合：将勾连层做基材，在基材下表面上铺设300克/㎡涤纶短纤维后在RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm，使其形成一体；
3)高温处理：将表面具有凸起单丝的勾连层通过网带输送到火焰复合机上，勾连层通过火焰复合机的速度为20米/每分钟，勾连层表面与火焰距离为4cm。经过730℃的火焰灼烧，火焰高度为5cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为0.1-0.3mm，冷却后顶端形成小疙瘩。
4)防滑层制备：使用热塑弹性体在中间层背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
对比例4
本对比例涉及一种地毯垫，与实例1制备方法基本相同，不同之处在于凸起单丝的粗度为5000D。
该一种经过热处理的地毯垫制备包括如下步骤：
1)选用面料：选用上下两层的经编网眼布和中间竖向排列的连接该上下两层经编网眼布的若干涤纶单丝组成的三维夹层网眼布中间剖开形成的单面结构层；该三维夹层网眼布具体是采用210D的涤纶单丝纱线一体化编织而成。凸起的单丝高度为3mm。
2)中间层复合：将勾连层做基材，在基材下表面上铺设300克/㎡涤纶短纤维后在RY1-4000的无纺针刺机上进行针刺加工形成一体，植针密度为15000针/㎡，针刺频率为350次/分钟，走布速度为1.1米/分钟，针刺行程为1.10cm，使其形成一体；
3)高温处理：将表面具有凸起单丝的勾连层通过网带输送到火焰复合机上，勾连层通过火焰复合机的速度为20米/每分钟，勾连层表面与火焰距离为4cm。经过730℃的火焰灼烧，火焰高度为5cm，同时在辊轮的带动下离开火焰，经过热处理后的凸起单丝高度为0.1-0.3mm，冷却后顶端形成小疙瘩。
4)防滑层制备：使用热塑弹性体在中间层背部进行防滑处理。
5)裁剪：将经过防滑处理的胚毯，按照尺寸裁剪。
性能对比试验验证
一、结合力牢度测试
1、取30cm x 30cm大小的实例1中的一种经过热处理的地毯垫，及30cmx30cm大小的针织面料，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做三次横向 剥离力测试，测试结果为214.87牛顿；235.213牛顿；198.186牛顿。
2、取申请号为CN201921334346.X 30cm x 30cm的防滑地垫胶垫层，及30cmx30cm大小的针织面料，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做三次横向剥离力测试，测试结果为52.128牛顿；52.128牛顿；53,252牛顿；
3、取30cm x 30cm大小的实例1中的一种经过热处理的地毯垫，及30cmx30cm大小的针织面料，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做三次向上剥离力测试，测试结果为5.258牛顿；5.587牛顿；6.487牛顿。
4、取申请号为CN201921334346.X 30cm x 30cm的防滑地垫胶垫层，及30cmx30cm大小的针织面料，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做三次向上剥离力测试，测试结果为1.387牛顿；1.325牛顿；1.467牛顿；
由此得出本发明一种经过热处理的防滑及防潮垫比在先专利CN 201921334346.X的结合力更好、摩擦力大、更牢固。
二、拆卸寿命试验：
1、取30cm x 30cm大小的实例3的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做20次纵向和横向分离测试，其结果表面完整无破损处，且无掉落单丝现象。
2、取30cm x 30cm大小的申请号为CN201921334346.X的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用6千克的滚筒滚压2次，用拉力试验机做20次纵向和横向分离测试，其结果表面有部分单丝掉落。
由此得出本发明一种经过热处理的地毯垫比在先专利CN2019107593，的结合力更好，跟牢固，且很大程度减少了掉落单丝的现象。
三、结合力测试：
取30cm x 30cm大小的实例1的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用手前后移动，发现结合处牢固，并无毯面位移状况。
取30cm x 30cm大小的对比例1的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用手前后移动，发现毯面位移厉害，无法固定毯面。
取30cm x 30cm大小的对比例2的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用手前后移动，发现由于单丝凸起过低，与面层勾连作用低。
取30cm x 30cm大小的对比例3的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用手前后移动，发现由于单丝太细，无法支撑，无法固定毯面。
取30cm x 30cm大小的对比例4的一种经过热处理的地毯垫，与地毯面层，相互重合在一起，用手前后移动，发现单丝过粗，在触感上扎人，并且有可能使人受到划伤。
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 (11)

  1. 一种地毯垫，其特征在于，所述地毯垫包括上层的勾连层和下层的防滑层；所述勾连层上表面分布有弯曲状的凸起单丝，且顶端有凸起单丝熔化/软化形成的疙瘩。
  2. 根据权利要求1所述地毯垫，其特征在于，所述凸起单丝高度为0.50mm-10mm；单丝的粗度为18DTEX-4400DTEX。
  3. 根据权利要求1所述地毯垫，其特征在于，所述凸起单丝的密度为6根/cm 2-80根/cm 2。
  4. 根据权利要求1所述地毯垫，其特征在于，所述凸起单丝的材料为涤纶、丙纶、尼龙中的一种。
  5. 根据权利要求1所述地毯垫，其特征在于，所述勾连层的厚度为0.50mm-10mm。
  6. 根据权利要求1所述地毯垫，其特征在于，所述凸起单丝的制备工艺为针织、簇绒、植绒、梭织、经纬编中的一种。
  7. 根据权利要求1所述地毯垫，其特征在于，所述地毯垫与地毯毯面结合使用，所述结合为可拆卸式结合。
  8. 一种如权利要求1所述地毯垫的制备方法，其特征在于，所述方法包括如下步骤：
    A1、勾连层制备：将单丝制成上表面有凸起单丝的割绒面料；
    A2、凸起单丝热处理：使用热处理工艺，将勾连层中凸起单丝的顶端熔化/软化，经过冷却后形成小疙瘩，凸起单丝在无规则的倾斜并发生弯曲；
    A3、防滑层制备：将防滑层复合在勾连层的下表面。
  9. 根据权利要求8所述的制备方法，其特征在于，步骤A2中所述热处理为火焰灼烧；具体步骤为将勾连层置于复合机的火焰上方，火焰温度为400℃-1000℃，火焰高度为0.1-10cm，火焰与勾连层的距离约为1-5cm；经过灼烧过的面料在火焰复合机后方的辊轮带动下离开火焰；勾连层被灼烧后，勾连层中凸起单丝的顶端熔化/软化，经过冷却处理后形成小疙瘩无规则的倾斜，单丝发生弯曲。
  10. 根据权利要求8所述的制备方法，其特征在于，步骤A2中所述热处理为远红外线炙烤；具体步骤为将勾连层放入网带式远红外烘箱，箱顶部预设远红外线灯管，远红外线灯管距离毯面0-20cm，远红外线温度设定为180℃-800℃；勾连层被炙烤后，勾连层中凸起单丝的顶端熔化/软化，经过冷却处理后形成小疙瘩无规则的倾斜，单丝发 生弯曲。
  11. 根据权利要求8所述的制备方法，其特征在于，步骤A2中所述热处理为热烘箱处理；具体步骤为将勾连层置于热烘箱中，烘箱温度为120℃-230℃，经过高温环境在烘箱后，勾连层中凸起单丝的顶端熔化/软化，网带或辊轮带动下离开火焰，同时位于打卷牵引设备的压辊之间，使得勾连层的单丝处于软化状态经过压辊，使其单丝发生弯曲并在顶端形成小疙瘩。
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CN113598588A (zh) * 2021-09-17 2021-11-05 昆山怡家居纺织有限公司 一种地毯垫
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