阅读说明：本技术 一种隔音降噪簇绒工程毯及其制备方法 (Sound-insulation noise-reduction tufting engineering blanket and preparation method thereof ) 是由 庄跃进 苏添福 王宝荣 于 2020-06-12 设计创作，主要内容包括：本发明提供了一种隔音降噪簇绒工程毯及其制备方法,通过功能层的设置,可以有效的反射声波,防止声波直接穿过底层到达地毯的外部,再接合表层和底层,底层的纤维板使得本工程毯具有良好的隔音效果,纤维板内的空腔可以增加声波在吸音层内的吸音率,进一步的减弱声波,从而进行吸音,而且,本发明工程毯包括绒高后的总体厚度仅为5.5-6.2cm,相比现有技术,本发明显著的减低了地毯体积,减少了生产成本；同时还具有良好的阻燃性和防霉抗菌性。(The invention has provided a sound insulation to fall tufted engineering blanket and its preparation method of making an uproar, through the arrangement of the functional layer, can reflect the sound wave effectively, prevent the sound wave from passing the bottom layer to reach the outside of the carpet directly, join surface course and bottom layer, the fibrous plate of the bottom layer makes this engineering blanket have good sound insulation effects, the cavity pocket in the fibrous plate can increase the sound absorption rate of the sound wave in the sound absorption layer, further weaken the sound wave, thus absorb sound, moreover, the engineering blanket of the invention includes the overall thickness after the fine hair is only 5.5-6.2cm, compare with prior art, the invention has reduced the carpet volume apparently, has reduced the production cost; meanwhile, the flame retardant also has good flame retardance and mildew-proof antibacterial property.)

1. A sound-insulation noise-reduction tufting engineering carpet comprises a surface layer and a bottom layer, and is characterized in that: a functional layer is arranged between the surface layer and the bottom layer; the functional layer is prepared from the following raw materials in parts by weight: 800-1200 parts of non-woven fabric, 40-80 parts of ceramsite, 5-10 parts of nano carbon, 80-170 parts of coal gangue, 5-10 parts of EVA emulsion with the content of 10-12%, 1-5 parts of antioxidant, 1-5 parts of alkyl ketene dimer, 40-80 parts of nano vermiculite, 10-15 parts of aluminum hydroxide, 1-5 parts of diisobutyl phthalate, 1-5 parts of tribasic lead sulfate and 50-200 parts of isotactic polypropylene.

2. A sound-insulating noise-reducing tufted engineered carpet as claimed in claim 1, wherein: the reverse side on top layer and the front of bottom all attach waterproof bonding layer, the respective total thickness of top layer and the attached waterproof bonding layer of bottom is 1.5cm, the thickness of functional layer is 2 cm.

3. A sound-insulating noise-reducing tufted engineered carpet as claimed in claim 1, wherein: the front surface of the surface layer is provided with a tufting layer, and the height of the tufting layer is 5-12 mm.

4. A sound-insulating noise-reducing tufted engineered carpet as claimed in claim 1, wherein: the bottom layer comprises a fiberboard.

5. A method for preparing a sound insulation and noise reduction tufted engineering carpet as claimed in any one of claims 1 to 5, comprising the steps of:

1) preparing a functional layer, namely taking non-woven fabric as a main material, mixing ceramsite, nanocarbon, coal gangue, 10-12% of EVA emulsion, an antioxidant, alkyl ketene dimer, nano vermiculite, aluminum hydroxide, diisobutyl phthalate, tribasic lead sulfate and isotactic polypropylene as auxiliary materials, and coating the mixture on the front surface and the back surface of the non-woven fabric to obtain the functional layer;

2) attaching waterproof bonding layers to the back side of the surface layer and the front side of the bottom layer, and then respectively attaching the front side and the back side of the functional layer to the waterproof bonding layers on the surface layer and the bottom layer;

3) feeding the functional layer attached to the surface layer and the bottom layer into a dryer for drying; setting the parameters of a dryer at 20-30 ℃ and drying for 30min to obtain the engineering blanket base cloth;

3) sending the dried engineering blanket base cloth into a hot press, and carrying out hot-pressing, bonding and shaping by using a hot-pressing roller to obtain an engineering blanket;

4) forming a tufted carpet surface on the surface layer of the base fabric of the engineering carpet by using cut pile and/or needling of the shaped engineering carpet through a needle arranging machine; obtaining the tufted engineering carpet.

6. A method for preparing a sound insulation and noise reduction tufted engineering carpet as claimed in claim 5, wherein in the step 1), the method for preparing the functional layer comprises the following steps:

A1. respectively drying the ceramsite and the coal gangue according to the formula ratio to remove water, wherein the drying temperature is 110-120 ℃, the drying time is 2-3h, mixing, crushing in a crusher, sieving with a 10-20 mesh sieve, ball-milling, drying, grinding into powder, sieving with a 200-250 mesh sieve to obtain mixed powder, controlling the content of SiO2, MgO and Al2O3 in the mixed powder, then putting the mixed powder into 5-30% ethanol solution, stirring, carrying out microwave hydrothermal reaction, centrifuging, washing and drying the obtained precipitate to obtain mixed particles.

A2, adding nano vermiculite and mixed particles into a high-speed mixer according to the formula ratio, stirring and mixing at the temperature of 170-210 ℃ at the speed of 1200-1800rpm for 1-5min, adding alkyl ketene dimer and oxidant, continuously blending for 5-8min to obtain a first mixture, and cooling the materials to normal temperature for later use;

A3. adding 10-12% of EVA emulsion, diisobutyl phthalate and tribasic lead sulfate into a mixing machine according to the formula ratio for primary mixing for 10-15min, then carrying out ultrasonic treatment for 40-50min to disperse the materials in the emulsion, then adding nano carbon, aluminum hydroxide and isotactic polypropylene, stirring at the speed of 2000-2500rpm at the temperature of 150-210 ℃ for 1-3min to obtain a second mixture, and cooling the materials to normal temperature for later use;

A4. mixing the first mixture and the second mixture, fully and uniformly stirring, and then putting the mixture into a double-screw extruder to melt, extrude and granulate at the temperature of 180-190 ℃ to obtain master batches;

A5. b, putting the master batch prepared in the step A4 into a screw extruder to be melted at the temperature of 150-180 ℃, spraying the melt through a spinneret orifice of a melt-blowing die head at the temperature of 260-320 ℃, and drawing under the action of high-speed hot air flow at the temperature of 250-280 ℃;

A6. and B, feeding the drawn wires obtained in the step A5 into a wire drawing device for overlapping and forming a net to form a functional layer with the thickness of 2 cm.

8. A method for preparing sound-insulating noise-reducing tufted engineering carpet as claimed in claim 7, wherein in step a1, the contents of SiO2, MgO and Al2O3 in the mixed particles are respectively: 20% -35%, 0.50% -2.30% and 40% -55%.

9. A method for preparing a sound insulation and noise reduction tufted engineering carpet as claimed in claim 5, wherein in the step 2), the bottom layer is made of a fiber board, and the fiber board is subjected to soaking treatment by using flame retardant liquid and antibacterial functional liquid.

Technical Field

The invention relates to the technical field of carpets, in particular to a sound-insulation noise-reduction tufted engineering carpet and a preparation method thereof.

Background

The carpet is a ground laying object made of natural fibers or chemical synthetic fibers such as cotton, hemp, wool, silk and grass yarn through manual or mechanical knitting, tufting or weaving. It is one of the traditional arts with a long history worldwide. The floor covering is covered on the ground of houses, hotels, entertainment venues, gymnasiums, vehicles, ships, airplanes and the like, and has the effects of reducing noise, insulating heat, improving foot feel with decorative effect, preventing slipping and preventing air pollution. Particularly, in a quieter space such as a teacher, a library, a piano room, a conference room, a studio and the like, the carpet is required to have excellent noise reduction performance.

Disclosure of Invention

In order to overcome the problems, the invention provides a tufted engineering carpet with strong sound insulation and noise reduction capabilities and low cost and a preparation method thereof.

In order to achieve the purpose, the technical scheme provided by the invention is as follows:

a sound-insulation noise-reduction tufting engineering blanket comprises a surface layer and a bottom layer, wherein a functional layer is arranged between the surface layer and the bottom layer; the functional layer is prepared from the following raw materials in parts by weight: 800-1200 parts of non-woven fabric, 40-80 parts of ceramsite, 5-10 parts of nano carbon, 80-170 parts of coal gangue, 5-10 parts of EVA emulsion with the content of 10-12%, 1-5 parts of antioxidant, 1-5 parts of alkyl ketene dimer, 40-80 parts of nano vermiculite, 10-15 parts of aluminum hydroxide, 1-5 parts of diisobutyl phthalate, 1-5 parts of tribasic lead sulfate and 50-200 parts of isotactic polypropylene.

Specifically, waterproof bonding layer is all attached to the reverse side on top layer and the front of bottom, respective total thickness is 1.5cm behind the attached waterproof bonding layer of top layer and bottom, the thickness of functional layer is 2 cm.

Specifically, the front surface of the surface layer is provided with a tufting layer, and the height of the tufting layer is 5-12 mm; the provision of the tufted layer can significantly improve the feel of the carpet in use.

Specifically, the bottom layer comprises a fiberboard; the fiber board is used as a bottom layer, so that the ground gripping capability of the engineering blanket can be increased, and the displacement of the engineering blanket is prevented; in addition, the fiber board can further improve the noise reduction capability through the sound absorption effect.

A preparation method of a sound-insulation noise-reduction tufted engineering carpet comprises the following steps:

1) preparing a functional layer, namely taking non-woven fabric as a main material, mixing ceramsite, nanocarbon, coal gangue, 10-12% of EVA emulsion, an antioxidant, alkyl ketene dimer, nano vermiculite, aluminum hydroxide, diisobutyl phthalate, tribasic lead sulfate and isotactic polypropylene as auxiliary materials, and coating the mixture on the front surface and the back surface of the non-woven fabric to obtain the functional layer;

2) attaching waterproof bonding layers to the back side of the surface layer and the front side of the bottom layer, and then respectively attaching the front side and the back side of the functional layer to the waterproof bonding layers on the surface layer and the bottom layer;

3) feeding the functional layer attached to the surface layer and the bottom layer into a dryer for drying; setting the parameters of a dryer at 20-30 ℃ and drying for 30min to obtain the engineering blanket base cloth;

3) sending the dried engineering blanket base cloth into a hot press, and carrying out hot-pressing, bonding and shaping by using a hot-pressing roller to obtain an engineering blanket;

4) forming a tufted carpet surface on the surface layer of the base fabric of the engineering carpet by using cut pile and/or needling of the shaped engineering carpet through a needle arranging machine; obtaining the tufted engineering carpet.

Specifically, in step 1), the method for preparing the functional layer includes the following steps:

A1. respectively drying the ceramsite and the coal gangue according to the formula ratio to remove water, wherein the drying temperature is 110-120 ℃, the drying time is 2-3h, mixing, crushing in a crusher, sieving with a 10-20 mesh sieve, ball-milling, drying, grinding into powder, sieving with a 200-250 mesh sieve to obtain mixed powder, controlling the content of SiO2, MgO and Al2O3 in the mixed powder, then putting the mixed powder into 5-30% ethanol solution, stirring, carrying out microwave hydrothermal reaction, centrifuging, washing and drying the obtained precipitate to obtain mixed particles.

A2. Adding nano vermiculite and mixed particles into a high-speed mixer according to the formula ratio, stirring and mixing at the temperature of 170-210 ℃ at the speed of 1200-1800rpm for 1-5min, adding alkyl ketene dimer and oxidant, continuously blending for 5-8min to obtain a first mixture, and cooling the materials to normal temperature for later use;

A3. adding 10-12% of EVA emulsion, diisobutyl phthalate and tribasic lead sulfate into a mixing machine according to the formula ratio for primary mixing for 10-15min, then carrying out ultrasonic treatment for 40-50min to disperse the materials in the emulsion, then adding nano carbon, aluminum hydroxide and isotactic polypropylene, stirring at the speed of 2000-2500rpm at the temperature of 150-210 ℃ for 1-3min to obtain a second mixture, and cooling the materials to normal temperature for later use;

A4. mixing the first mixture and the second mixture, fully and uniformly stirring, and then putting the mixture into a double-screw extruder to melt, extrude and granulate at the temperature of 180-190 ℃ to obtain master batches;

A5. b, putting the master batch prepared in the step A4 into a screw extruder to be melted at the temperature of 150-180 ℃, spraying the melt through a spinneret orifice of a melt-blowing die head at the temperature of 260-320 ℃, and drawing under the action of high-speed hot air flow at the temperature of 250-280 ℃;

A6. and B, feeding the drawn wires obtained in the step A5 into a wire drawing device for overlapping and forming a net to form a functional layer with the thickness of 2 cm.

More specifically, in step a1, the contents of SiO2, MgO, and Al2O3 in the mixed microparticles are respectively: 20% -35%, 0.50% -2.30% and 40% -55%.

Specifically, in the step 2), the bottom layer is made of a fiber board, and the fiber board is soaked in a flame retardant liquid and an antibacterial functional liquid; through the arrangement, the mildew-proof antibacterial performance and the flame retardance of the carpet can be improved, and the service life of the engineering carpet is prolonged.

The technical scheme has the advantages that:

the invention has provided a sound insulation to fall tufted engineering blanket and its preparation method of making an uproar, through the arrangement of the functional layer, can reflect the sound wave effectively, prevent the sound wave from passing the bottom layer to reach the outside of the carpet directly, join surface course and bottom layer, the fibrous plate of the bottom layer makes this engineering blanket have good sound insulation effects, the cavity pocket in the fibrous plate can increase the sound absorption rate of the sound wave in the sound absorption layer, further weaken the sound wave, thus absorb sound, moreover, the engineering blanket of the invention includes the overall thickness after the fine hair is only 5.5-6.2cm, compare with prior art, the invention has reduced the carpet volume apparently, has reduced the production cost; meanwhile, the flame retardant also has good flame retardance and mildew-proof antibacterial property.

The technical solutions of the present invention will be described clearly and completely with reference to the following detailed description, and it should be understood that the described embodiments are a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.

Detailed Description