CN114376395A - 一种新型经编拼接方块地毯及其连续生产方法 - Google Patents
一种新型经编拼接方块地毯及其连续生产方法 Download PDFInfo
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Abstract
本发明公开了一种新型经编拼接方块地毯及其连续生产方法,地毯结构由上至下包括:面层、聚烯烃热熔胶层、底层、条状压敏胶层,离型膜。采用面层采用100%涤纶(PET)作为面层原料,具有较高的强度、耐磨性,更适用于商用办公领域,采用100%涤纶毛毡作为底层,回弹性好,具有优异的隔音效果。且具有优异的耐磨性能,脚轮椅测试,在90kg负载下,3000圈无损坏;防水,防污性能强:毯面上表面经过特殊表面处理,可以起到很好的防水,防污的效果,水珠滴落在毯面完全呈球状,不会润湿地毯,浸入地毯结构内部。此外,连续生产方法,有效提高生产效率,有利于大规模进行生产。
Description
技术领域
本发明涉及地毯的制备领域,尤其是涉及一种新型经编拼接方块地毯及其连续生产方法。
背景技术
方块地毯是近几年比较流行的一种高档低碳装饰材料,它并不是单独作为室内某一特定位置铺垫,通常是通过大量的拼合来进行铺设,形状小巧,一般为50x50cm或者60x60cm两种。
方块拼接地毯主要用于办公室、商务会议等场所,安装简单,图案组合随意,目前市场上常见的方块拼接地毯毯面分为丙纶和尼龙两种。按照底背材料的不同分为沥青方块地毯、PVC方块地毯。沥青方块地毯的一个缺点就是,铺到地面时间太久就无法揭起更换。因此市场上PVC方块地毯非常受到欢迎,但是毛绒毯面易存储灰尘,且商用场合耐磨需进一步提高。
因此,开发如何采用新型的材料技术结合工艺过程制备出一种易于清洁打理,且耐磨,防水防污的新型编织地毯值得研究。
发明内容
发明目的:为了解决现有技术中所存在的问题,本发明提出了一种新型经编拼接方块地毯连续生产方法,制备的地毯耐磨,防水防污。
技术方案:为达以上目的,本发明采取以下技术方案:
一种新型经编拼接方块地毯,从上到下包括面层、聚烯烃热熔胶层、底层、条状压敏胶层以及离型膜。
所述面层为100%涤纶面料、抗静电剂、着色剂经熔融色纺成2-5旦长纤维丝;其中涤纶为PET,聚对苯二甲酸乙二醇酯。采用PET作为原材料,具有良好的力学性能,耐油、耐稀酸、耐稀碱,耐大多数溶剂,且具有优异的耐磨性能。PET还可以采用回收PET料,绿色环保,解决了PET回收问题,实现了废弃高分子材料的再生利用。每年PET塑料瓶消费量很高,PET塑料瓶再回收进行纺丝变废为宝,不仅解决了中国PET原材料不足的问题,也减少了环境污染和资源浪费,有助于形成资源循环型社会。采用色纺工艺着色均匀、色牢度好、水洗不掉色、生产周期短、成本低、上染率高、色彩丰富绚丽,绿色环保。
所述底层为100%涤纶纤维毛毡,重量为600-800g/m2,厚度为3-5mm。比传统地毯使用PVC底层或者沥青,具有更好的消音隔音效果,富有弹性,减震效果好。
所述聚烯烃热熔胶层中的热熔胶具体聚乙烯热熔胶膜,胶量为150-300g/m2。聚乙烯热熔胶粘结效果好,价格低。
本发明还公开了上述新型经编拼接方块地毯的连续生产方法,其特征在于包括如下步骤:
1)面层的生产:采用100%涤纶面料经熔体纺丝而成,再经经编成面层布料,成卷;
2)底层的生产:采用100%涤纶纤维针刺而成4mm的垫层,成卷;
3)连续化复合生产:
3-1)复合段:首先按从下往上底层卷,热熔胶膜卷,面层卷放置,经加热热压辊,压花辊复合成型;
3-2)表面处理段:喷淋段进行表面处理剂的喷淋,经干燥段进行干燥;
3-3)裁切大张:干燥后经裁切装置横切成大张地毯;
3-4)翻转:然后经翻转机翻转为地毯背面;
3-5)背胶段:在背胶段进行热熔压敏胶条带状喷涂,再用覆膜机贴离型膜;
3-6)裁切小片:经裁切机竖切成小片地毯;
4)成品检验、包装入库。
更进一步的,步骤1)中的面层采用1000D*1000D经编而成;脱散性小,不容易散掉,硬挺,不会卷边。纱支较粗,强度高,耐磨。无簇绒,可有效防止水、污渍、灰尘深入。
步骤3)中的热压粘贴采用压花辊压制,粘接压花一体成型,提高生产效率,可规模化生产。
更进一步的,步骤3)中的表面处理剂为氟碳高分子乳液型防油防水剂,应用制备方法用去离子水将表面处理剂稀释成固含量3~5%的溶液,干燥温度:100℃,时间2~3min。
有益效果:本发明提供的一种新型经编拼接方块地毯及其连续生产方法,与现有技术相比,具备以下优点:
(1)耐磨:此款新型拼接采用100%PET面层经编而成,PET具有优异的耐磨性能,脚轮椅测试,在90kg负载下,3000圈无损坏。
(2)防水,防污:毯面上表面经过特殊表面处理,可以起到很好的防水,防污的效果,水珠滴落在毯面完全呈球状,不会润湿地毯,浸入地毯结构内部。
(3)防尘,易清洁:此款毯面零网眼经编编织较密,灰尘不易侵入毯面,使得打理清洁非常容易。
(4)铺装方便:铺装时,直接撕去背面离型膜,拼接安装即可,减少大量的安装人工成本。
附图说明
图1为地毯结构示意图;
图2为地毯连续生产方法流程示意图。
具体实施方式
实施例1:
一种新型经编拼接方块地毯,如图1所示,地毯的结构从上到下包括面层1、聚烯烃热熔胶层2、底层3、条状压敏胶层4以及离型膜5。
所述面层1为100%涤纶面料、抗静电剂、着色剂经熔融色纺成2-5旦长纤维丝;其中涤纶为PET,聚对苯二甲酸乙二醇酯,且采用1000D*1000D经编而成;脱散性小,不容易散掉,硬挺,不会卷边,纱支较粗,强度高,耐磨。无簇绒,可有效防止水、污渍、灰尘深入。
所述底层3为100%涤纶纤维毛毡,重量为600g/m2,厚度为3mm。比传统地毯使用PVC底层或者沥青,具有更好的消音隔音效果,富有弹性,减震效果好。所述聚烯烃热熔胶层2中的热熔胶具体聚乙烯热熔胶膜,胶量为150g/m2。
请参考图2所示,上述地毯的连续生产方法,具体包括如下步骤:
1)面层的生产:采用100%涤纶面料经熔体纺丝而成,再经经编成面层布料,成卷;
2)底层的生产:采用100%涤纶纤维针刺而成4mm的垫层,成卷;
3)连续化复合生产:
3-1)复合段:首先按从下往上底层卷6,热熔胶膜卷7,面层卷9放置,经加热热压辊8,压花辊10复合成型;热压粘贴采用压花辊压制,粘接压花一体成型,提高生产效率,可规模化生产;
3-2)表面处理段:喷淋段11进行表面处理剂的喷淋,经干燥段12进行干燥;表面处理剂为氟碳高分子乳液型防油防水剂,应用制备方法为用去离子水将表面处理剂稀释成固含量3%的溶液,干燥温度:100℃,时间2min;
3-3)裁切大张:干燥后经裁切装置13横切成大张地毯;
3-4)翻转:然后经翻转机14翻转为地毯背面;
3-5)背胶段:在背胶段15进行热熔压敏胶条带状喷涂,再用覆膜机16贴离型膜;
3-6)裁切小片:经裁切机17竖切成小片地毯;
4)成品检验、包装入库。
实施例2:
一种新型经编拼接方块地毯,如图1所示,地毯的结构从上到下包括面层1、聚烯烃热熔胶层2、底层3、条状压敏胶层4以及离型膜5。
所述面层1为100%涤纶面料、抗静电剂、着色剂经熔融色纺成2-5旦长纤维丝;其中涤纶为PET,聚对苯二甲酸乙二醇酯,且采用1000D*1000D经编而成;脱散性小,不容易散掉,硬挺,不会卷边,纱支较粗,强度高,耐磨。无簇绒,可有效防止水、污渍、灰尘深入。
所述底层3为100%涤纶纤维毛毡,重量为800g/m2,厚度为5mm。比传统地毯使用PVC底层或者沥青,具有更好的消音隔音效果,富有弹性,减震效果好。所述聚烯烃热熔胶层2中的热熔胶具体聚乙烯热熔胶膜,胶量为300g/m2。
请参考图2所示,上述地毯的连续生产方法,具体包括如下步骤:
1)面层的生产:采用100%涤纶面料经熔体纺丝而成,再经经编成面层布料,成卷;
2)底层的生产:采用100%涤纶纤维针刺而成4mm的垫层,成卷;
3)连续化复合生产:
3-1)复合段:首先按从下往上底层卷6,热熔胶膜卷7,面层卷9放置,经加热热压辊8,压花辊10复合成型;热压粘贴采用压花辊压制,粘接压花一体成型,提高生产效率,可规模化生产;
3-2)表面处理段:喷淋段11进行表面处理剂的喷淋,经干燥段12进行干燥;表面处理剂为氟碳高分子乳液型防油防水剂,应用制备方法为用去离子水将表面处理剂稀释成固含量5%的溶液,干燥温度:100℃,时间3min;
3-3)裁切大张:干燥后经裁切装置13横切成大张地毯;
3-4)翻转:然后经翻转机14翻转为地毯背面;
3-5)背胶段:在背胶段15进行热熔压敏胶条带状喷涂,再用覆膜机16贴离型膜;
3-6)裁切小片:经裁切机17竖切成小片地毯;
4)成品检验、包装入库。
实施例3:
一种新型经编拼接方块地毯,如图1所示,地毯的结构从上到下包括面层1、聚烯烃热熔胶层2、底层3、条状压敏胶层4以及离型膜5。
所述面层1为100%涤纶面料、抗静电剂、着色剂经熔融色纺成2-5旦长纤维丝;其中涤纶为PET,聚对苯二甲酸乙二醇酯,且采用1000D*1000D经编而成;脱散性小,不容易散掉,硬挺,不会卷边,纱支较粗,强度高,耐磨。无簇绒,可有效防止水、污渍、灰尘深入。
所述底层3为100%涤纶纤维毛毡,重量为700g/m2,厚度为4mm。比传统地毯使用PVC底层或者沥青,具有更好的消音隔音效果,富有弹性,减震效果好。所述聚烯烃热熔胶层2中的热熔胶具体聚乙烯热熔胶膜,胶量为200g/m2。
请参考图2所示,上述地毯的连续生产方法,具体包括如下步骤:
1)面层的生产:采用100%涤纶面料经熔体纺丝而成,再经经编成面层布料,成卷;
2)底层的生产:采用100%涤纶纤维针刺而成4mm的垫层,成卷;
3)连续化复合生产:
3-1)复合段:首先按从下往上底层卷6,热熔胶膜卷7,面层卷9放置,经加热热压辊8,压花辊10复合成型;热压粘贴采用压花辊压制,粘接压花一体成型,提高生产效率,可规模化生产;
3-2)表面处理段:喷淋段11进行表面处理剂的喷淋,经干燥段12进行干燥;表面处理剂为氟碳高分子乳液型防油防水剂,应用制备方法为用去离子水将表面处理剂稀释成固含量4%的溶液,干燥温度:100℃,时间3min;
3-3)裁切大张:干燥后经裁切装置13横切成大张地毯;
3-4)翻转:然后经翻转机14翻转为地毯背面;
3-5)背胶段:在背胶段15进行热熔压敏胶条带状喷涂,再用覆膜机16贴离型膜;
3-6)裁切小片:经裁切机17竖切成小片地毯;
4)成品检验、包装入库。
对比例1:市售沥青方块圈绒地毯。
对比例2:市售PVC方块圈绒地毯。
将实施例1-3制备的地毯成品和对比例1-2的地毯进行耐磨性能测试:
1)耐磨性能测试:使用脚轮椅测试,在90kg负载下进行测试,本发明实施例1-3制备的地毯5500圈无损坏;而对比例1的市售沥青方块圈绒地毯3000圈,表面圈绒磨损;对比例2的市售PVC方块圈绒地毯3000,表面圈绒磨损。
2)防水,防污性能测试:本发明实施例1-3制备的地毯水珠滴落在毯面完全呈球状,不会润湿地毯,不浸入地毯结构内部;将碘酒滴落在实施例1-3上,碘酒呈珠状,不进入地毯内部,用纸即可将其吸干,表面如新,而对比例1的市售沥青方块圈绒地毯和对比例2的市售PVC方块圈绒地毯,碘酒滴落,表面立刻被碘酒浸润,纸巾无法擦拭,即使用酒精,也不能完全擦掉。
3)耐老化:将样品置于老化箱中100℃,20h进行加速老化试验,实施例1-3底层没有明显的老化现象,而对比例1市售沥青方块圈绒地毯出现了明显的***变脆等老化现象。
Claims (8)
1.一种新型经编拼接方块地毯,其特征在于从上到下包括面层(1)、聚烯烃热熔胶层(2)、底层(3)、条状压敏胶层(4)以及离型膜(5)。
2.根据权利要求1所述的新型经编拼接方块地毯,其特征在于:所述面层(1)为100%涤纶面料、抗静电剂、着色剂经熔融色纺成2-5旦长纤维丝;其中涤纶为PET,聚对苯二甲酸乙二醇酯。
3.根据权利要求1所述的新型经编拼接方块地毯,其特征在于:所述底层(3)为100%涤纶纤维毛毡,重量为600-800g/m2,厚度为3-5mm。
4.根据权利要求1所述的新型经编拼接方块地毯,其特征在于:所述聚烯烃热熔胶层(2)中的热熔胶具体聚乙烯热熔胶膜,胶量为150-300g/m2。
5.一种权利要求1所述的新型经编拼接方块地毯的连续生产方法,其特征在于包括如下步骤:
1)面层的生产:采用100%涤纶面料经熔体纺丝而成,再经经编成面层布料,成卷;
2)底层的生产:采用100%涤纶纤维针刺而成4mm的垫层,成卷;
3)连续化复合生产:
3-1)复合段:首先按从下往上底层卷(6),热熔胶膜卷(7),面层卷(9)放置,经加热热压辊(8),压花辊(10)复合成型;
3-2)表面处理段:喷淋段(11)进行表面处理剂的喷淋,经干燥段(12)进行干燥;
3-3)裁切大张:干燥后经裁切装置(13)横切成大张地毯;
3-4)翻转:然后经翻转机(14)翻转为地毯背面;
3-5)背胶段:在背胶段(15)进行热熔压敏胶条带状喷涂,再用覆膜机(16)贴离型膜;
3-6)裁切小片:经裁切机(17)竖切成小片地毯;
4)成品检验、包装入库。
6.根据权利要求5所述的一种新型经编拼接方块地毯的连续生产方法,其特征在于:步骤1)中的面层采用1000D*1000D经编而成。
7.根据权利要求5所述的一种新型经编拼接方块地毯的连续生产方法,其特征在于:步骤3)中的热压粘贴采用压花辊压制,粘接压花一体成型。
8.根据权利要求1所述的一种新型经编拼接方块地毯的连续生产方法,其特征在于:步骤3)中的表面处理剂为氟碳高分子乳液型防油防水剂,应用制备方法用去离子水将表面处理剂稀释成固含量3~5%的溶液,干燥温度:100℃,时间2~3min。
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