阅读说明：本技术 一种3d超回弹地垫的制作方法 (Manufacturing method of 3D super-elastic floor mat ) 是由 王红星 于 2020-11-10 设计创作，主要内容包括：本发明属于家具地垫产品领域,提供了一种3D超回弹地垫的制作方法,该地垫采用经编间隔涤纶织物作为地垫的回弹层,其织物结构为3D结构,然后将上层面料和中间海绵经复合的方式固定在网眼布的上层底布上,形成超回弹地垫,其3D结构为弹力层表面为网孔设计,底面为网孔或密织平版经编结构；其中的经编间隔涤纶织物具有独特的弹性功能,其超回弹性能完全恢复地垫因受力造成的变形,使地垫能始终保持平整的外观；同时增加了产品的耐用性,延长产品的使用寿命,具有良好的透气性,通过空气的流通使表面维持舒适干爽,防霉效果良好。(The invention belongs to the field of furniture floor mat products, and provides a manufacturing method of a 3D super-rebound floor mat, wherein the floor mat adopts warp-knitted spaced polyester fabric as a rebound layer of the floor mat, the fabric structure of the floor mat is a 3D structure, then an upper layer fabric and a middle sponge are fixed on an upper layer base fabric of eyelet fabric in a composite mode to form the super-rebound floor mat, the 3D structure is that the surface of an elastic layer is designed into meshes, and the bottom surface is in a mesh or a closely-woven lithographic warp-knitted structure; the warp-knitted spaced polyester fabric has a unique elastic function, and the super-resilience performance of the warp-knitted spaced polyester fabric completely recovers the deformation of the floor mat caused by stress, so that the floor mat can keep a flat appearance all the time; meanwhile, the durability of the product is improved, the service life of the product is prolonged, the air permeability is good, the surface is kept comfortable and dry through the circulation of air, and the mildew-proof effect is good.)

1. A manufacturing method of a 3D super-elastic floor mat is characterized by comprising the following steps: the method comprises the following specific steps:

(1) production of 3D mesh cloth:

the 3D mesh fabric consists of an upper base fabric, a lower base fabric and a middle upright layer, wherein the upper base fabric and the lower base fabric are of mesh structures or plain cloth structures, and a middle upright post connecting the upper base fabric and the lower base fabric is a polyester monofilament;

the raw material for weaving the upper and lower base fabrics is preferably 150D-300D polyester filament yarns and 75D-400D polyester monofilament yarns in the middle; the weaving is carried out on a Raschel warp knitting machine, and the gauge setting of the weaving machine is as follows: the adjustable range of the spacing is 5-40 mm;

(2) preparing an intermediate filling layer:

the middle filling layer is made of upright cotton, slow-rebound sponge or common sponge or combination of the two and is compounded with the elastic 3D fabric; bonding the compound middle filling layer and the 3D mesh cloth obtained in the step (1) by using the glue A and the glue B as adhesives, and then heating and drying the mixture by a heating roller of a compound machine to form a compound middle filling layer; the temperature of the heating roller of the compound machine is set to be about 150-170 ℃; standing for 24 hours and naturally airing;

(3) preparing a composite surface layer fabric:

and (3) bonding the composite intermediate filling layer and the surface fabric together by using the glue A and the glue B as adhesives, heating and drying the composite intermediate filling layer and the surface fabric by using a heating roller of a compound machine, wherein the temperature of the heating roller is set at 150-200 ℃, and the gluing amount is as follows: when the surface fabric is a cotton product, the fabric is 80-120g per square meter, and the chemical fiber is 60-70g per square meter; the surface fabric is selected from cotton products or chemical fiber products;

(4) anti-skid treatment:

pouring the granular anti-skid glue into a gluing machine to be heated and melted, enabling the product obtained in the step (3) to face upwards and be close to a gluing roller to enable the product to uniformly pass through the gluing roller, and setting the temperature at 220 ℃ in the anti-skid treatment process;

(5) and (5) after the product is compounded, entering a cutting and trimming stage, and cutting according to the size requirement of the product.

2. The method for manufacturing a 3D ultra-resilient floor mat according to claim 1, wherein: the base fabric raw material is 32^SThe middle upright post of the cotton yarn is 200D terylene monofilament, and the weight of the fabric is 400g/m²The thickness of the mesh cloth was set to 10 mm.

3. The method for manufacturing a 3D ultra-resilient floor mat according to claim 1, wherein: the weight ratio of the glue A to the glue B in the steps (2) and (3) is 1: 0.05.

4. The method for manufacturing a 3D ultra-resilient floor mat according to claim 1, wherein: the non-slip glue selected in the step (4) is non-slip glue XJ-026.

Technical Field

The invention belongs to the field of household ground mat products, and particularly relates to a manufacturing method of a 3D super-resilience ground mat.

Background

The floor mat is a common home decoration product, and is generally used in living rooms, bedrooms and bathrooms. The floor mat product has the characteristics of comfortable and soft foot feeling, high elasticity, good wear resistance, difficult deformation, difficult generation of static electricity and the like besides the beautiful effect of home decoration. General ground mat that requires elasticity, common middle filling layer usually adopt ordinary sponge, slow resilience sponge, upright cotton etc. these fillers all have certain resilience effect, also have certain defect simultaneously, and the concrete expression is in: common sponge and upright cotton are not easy to recover after poor resilience and deformation; the elasticity and the durability of the slow rebound sponge are relatively good, but the performance stability along with the temperature change is poor. This has resulted in mats of a quality which has been difficult for consumers to satisfy and which have a low degree of market dissatisfaction.

Therefore, it is one of the problems to be solved in the art to provide a floor mat with a novel structure and material.

Disclosure of Invention

Aiming at the problems in the prior art, the invention provides a method for manufacturing a 3D super-rebound ground mat, the ground mat adopts warp-knitted spaced polyester fabric as a rebound layer of the ground mat, the fabric structure is a 3D structure, then an upper layer fabric and a middle sponge are fixed on an upper layer base fabric of eyelet fabric in a composite mode to form the super-rebound ground mat, the 3D structure is that the surface of the elastic layer is designed into meshes, and the bottom surface is in a mesh or closely-woven flat warp-knitted structure; the warp-knitted spaced polyester fabric has a unique elastic function, and the super-resilience performance of the warp-knitted spaced polyester fabric completely recovers the deformation of the floor mat caused by stress, so that the floor mat can keep a flat appearance all the time; meanwhile, the durability of the product is improved, the service life of the product is prolonged, the product has good air permeability, the surface is kept comfortable and dry through the circulation of air, and the mildew-proof effect is good.

The invention adopts the following specific technical scheme:

a manufacturing method of a 3D super-elastic floor mat comprises the following specific steps:

(1) production of 3D mesh cloth:

the 3D mesh fabric consists of an upper base fabric, a lower base fabric and a middle upright layer, wherein the upper base fabric and the lower base fabric are of mesh structures or flat fabric structures, and a middle upright post connecting the upper base fabric and the lower base fabric is a polyester monofilament;

the raw material for weaving the upper and lower base fabrics is preferably 150D-300D polyester filament yarns and 75D-400D polyester monofilament yarns in the middle;

furthermore, the material can be other fiber materials besides terylene;

the weaving is carried out on a Raschel warp knitting machine, and the gauge setting of the weaving machine is as follows: the thickness of the 3D mesh fabric is designed according to the required thickness of the ground mat, and the fabric thickness is determined by the monofilament height between the two base fabrics. The height of the monofilament is determined by the space between the groove plates of the two needle beds of the Raschel warp knitting machine, and the adjustable range of the space is 5-40 mm;

the preferable base cloth raw material is 150D terylene fully drawn filament, the middle upright post is 200D terylene monofilament, and the weight of the fabric is 600g/m²The thickness of the mesh cloth is set to be 15 mm; the structure has good elasticity and buffering effect on external force;

(2) preparing an intermediate filling layer:

the middle filling layer is made of upright cotton, slow-rebound sponge or common sponge or combination of the two and is compounded with the elastic 3D fabric; bonding the compound middle filling layer and the 3D mesh cloth obtained in the step (1) by using the glue A and the glue B as adhesives, and then heating and drying the mixture by a heating roller of a compound machine to form a compound middle filling layer; the temperature of the heating roller of the compound machine is set to be about 150-; naturally airing after being placed for about 24 hours;

(3) preparing a composite surface layer fabric:

the composite type intermediate filling layer and the surface fabric are bonded together by using the glue A and the glue B as adhesives, and are heated and dried by a heating roller of a compound machine, wherein the temperature of the heating roller is set at 150-200 ℃, the preferable temperature is 150-170 ℃ in summer, 170-200 ℃ in winter, and the gluing amount is as follows: when the surface fabric is a cotton product, the fabric is 80-120g per square meter, and the chemical fiber is 60-70g per square meter;

the surface fabric can be cotton products or chemical fiber products, such as flannel surface fabric and the like; the sponge is selected in the middle layer to increase the comfort level of the surface of the floor mat. The influence of the mesh structure on the surface fabric flatness is compensated; the thickness of the sponge is 3-5 mm.

(4) Anti-skid treatment:

pouring the granular anti-skid glue into a gluing machine to be heated and melted, enabling the product obtained in the step (3) to face upwards and be close to a gluing roller to enable the product to uniformly pass through the gluing roller, and setting the temperature at 220 ℃ in the anti-skid treatment process;

in the treatment, the melted anti-slip glue is transferred to the 3D fabric through the gluing roller. Because the anti-skid glue is immediately changed into solid after the temperature is reduced, after the anti-skid glue leaves the gluing roller, the anti-skid glue is quickly solidified on the reverse side of the product obtained in the step (3) to form an anti-skid structure;

generally controlling the height of the upper glue roller to be the same as the thickness of the product obtained in the step (3), so that the anti-skid glue can be uniformly coated and prevented from skidding on the 3D surface, and the anti-skid glue can not block round holes on the 3D surface to ensure the air permeability;

(5) and (4) after the product is compounded, cutting and trimming the product, and cutting the product according to the size requirement of the product.

Preferably, the weight ratio of the glue A to the glue B in the preparation process steps (2) and (3) is preferably 1:0.05, and the preparation process can be adaptively adjusted according to the requirements of products;

the anti-slip glue selected in the step (4) is XJ-026, and because the anti-slip glue coats the bottom layer of the 3D structure in a molten state, the glue can penetrate into the bottom cloth structure to wrap the yarns, and the glue is solidified after cooling and cannot easily fall off as a whole with the bottom cloth. The finally obtained product still has good anti-skid function after being washed for 10 times, and the anti-skid test result shows that the static friction coefficient is 1.8-2.4, thereby meeting the anti-skid requirement.

The 3D mesh fabric with the structure is used as warp knitting interval polyester fabric and consists of an upper surface, a middle surface and a lower surface, the upper base fabric and the lower base fabric are of mesh structures or plain cloth structures, the middle layer is high-modulus monofilaments for connecting the surfaces and the bottom surfaces, the middle polyester monofilaments are regularly crossed with each other, the structure has a unique elastic function, and when external force is applied, the upper base fabric can horizontally disperse the force to the periphery to reduce the action of vertical force; the vertical direction force is applied to the middle upright post, the upright post deforms, the stress can be dispersed to the periphery along the direction of the force and the acting force can be buffered, the stress relieving effect is achieved, meanwhile, the stress deformation can be completely recovered, the ultrahigh resilience effect of the spacer fabric is determined by the characteristic of the spacer fabric, the fabric is used as the filler or the base fabric of the ground mat, the ground mat has the permanent resilience effect and is completely resilient, and meanwhile, the product of which the bottom surface is subjected to the anti-slip treatment is used as the anti-slip base fabric of the composite ground mat, so that the durability of the product can be improved, and the service life of the product can be prolonged; the three-dimensional reticular structure has good air permeability, the surface is kept comfortable and dry through the circulation of air, and the mildew-proof effect is good.

In conclusion, in the method for manufacturing the 3D super-resilience ground mat, the warp-knitted spaced polyester fabric is used as the resilience layer of the ground mat, so that the super-resilience performance of the ground mat completely recovers the deformation of the ground mat caused by stress, and the ground mat can always keep a smooth appearance; meanwhile, the durability and the service life of the product are improved, the quality is greatly improved, and the product has better market popularization value.

Drawings

Figure 1 is a schematic structural view of a 3D ultra-resilient floor mat product obtained in example 1;

fig. 2 is a schematic structural view of the 3D ultra-resilient floor mat product obtained in example 2.

Detailed Description

The following examples are given solely for the purpose of illustrating the principles of the present invention and are subject to various changes and modifications without departing from the spirit and scope of the invention as hereinafter claimed. The scope of the invention is defined by the appended claims and equivalents, and the processes and equipment in the following examples are all commonly selected in the art;

example 1

A manufacturing method of a 3D super-elastic floor mat comprises the following specific steps:

(1) production of 3D mesh cloth:

the 3D mesh fabric consists of an upper base fabric, a lower base fabric and a middle upright layer, wherein the upper base fabric and the lower base fabric are of mesh structures or flat fabric structures, and a middle upright post connecting the upper base fabric and the lower base fabric is a polyester monofilament;

the base fabric is made of 150D polyester fully-drawn filaments, the middle upright posts are 200D polyester monofilaments, and the weight of the fabric is 600g/m²The thickness of the mesh cloth is set to be 15 mm;

the weaving is carried out on a Raschel warp knitting machine, and the gauge setting of the weaving machine is as follows: the thickness of the 3D mesh fabric is designed according to the required thickness of the ground mat, and the fabric thickness is determined by the monofilament height between the two base fabrics. The height of the monofilament is determined by the space between the groove plates of the two needle beds of the Raschel warp knitting machine, and the adjustable range of the space is 5-40 mm;

the structure has good elasticity and buffering effect on external force;

(2) compounding of the intermediate filling layer and the 3D mesh fabric:

the middle filling layer is formed by compounding vertical cotton, slow rebound sponge and 3D mesh cloth; preferably 5mm, 40D slow rebound sponge is compounded with 3D mesh cloth; bonding the sponge and the 3D mesh cloth obtained in the step (1) together by using the glue A and the glue B as adhesives, and then heating and drying the mixture by a heating roller of a compound machine to form a compound body; the temperature of the heating roller of the compound machine is set to be about 150-; naturally airing after being placed for 24 hours;

the weight ratio of the glue A to the glue B in the preparation process steps (2) and (3) is preferably 1: 0.05;

(3) preparing a composite surface layer fabric:

the composite type intermediate filling layer and the surface fabric are bonded together by using the glue A and the glue B as adhesives, and are heated and dried by a heating roller of a compound machine, wherein the temperature of the heating roller is set at 150-200 ℃, the preferable temperature is 150-170 ℃ in summer, 170-200 ℃ in winter, and the gluing amount is as follows: when the surface fabric is a cotton product, the fabric is 80-120g per square meter, and the chemical fiber is 60-70g per square meter;

the surface fabric is selected from flannel surface fabrics; the surface fabric is compounded, so that the comfort level of the surface of the floor mat can be increased, and the influence of the mesh structure on the flatness of the surface fabric is compensated;

(4) anti-skid treatment:

pouring the granular anti-skid glue into a gluing machine to be heated and melted, enabling the product obtained in the step (3) to face upwards and be close to a gluing roller to enable the product to uniformly pass through the gluing roller, and setting the temperature at 220 ℃ in the anti-skid treatment process;

in the treatment, the melted anti-slip glue is transferred to the 3D fabric through the gluing roller. Because the anti-skid glue is immediately changed into solid after the temperature is reduced, after the anti-skid glue leaves the gluing roller, the anti-skid glue is quickly solidified on the reverse side of the product obtained in the step (3) to form an anti-skid structure;

the anti-slip glue selected in the step (4) is XJ-026, and after the product is washed by water for 10 times, the static friction coefficient of the product is 0.8;

generally controlling the height of the upper glue roller to be the same as the thickness of the product obtained in the step (3), so that the anti-skid glue can be uniformly coated and prevented from skidding on the 3D surface, and the anti-skid glue can not block round holes on the 3D surface to ensure the air permeability;

(5) after the product is compounded, the product enters a cutting and trimming stage, and the product is cut according to the size requirement of the product, the cross section structure of the product is shown in figure 1, the rebound effect of the product is tested by pressure, and the elastic recovery rate of the product is 99.1 percent (the height of the product is changed).

Example 2

A manufacturing method of a 3D super-elastic floor mat comprises the following specific steps:

(1) production of 3D mesh cloth:

the 3D mesh fabric consists of an upper base fabric, a lower base fabric and a middle upright layer, wherein the upper base fabric and the lower base fabric are mesh structures and can be woven by selecting different raw materials, a middle upright column connecting the upper base fabric and the lower base fabric is a terylene monofilament, and the yarn count can be changed;

the preferred material for weaving the upper substrate is 32^SThe lower bottom cloth of the/2 polyester cotton yarn is preferably 250D polyester low stretch yarn. The middle part is a 200D terylene monofilament; the weaving is carried out on a Raschel warp knitting machine, and the gauge setting of the weaving machine is as follows: the adjustable range of the spacing is 5-32 mm; preferably 10 mm.

(2) Preparing an intermediate filling layer:

the middle filling layer is made of vertical cotton; bonding the middle filling layer and the 3D mesh cloth obtained in the step (1) by using glue A and glue B as adhesives, and then heating and drying the mixture by a heating roller of a compound machine to form a combined body with the supporting and springback functions on the lower layer; the temperature of the heating roller of the compound machine is set to be about 150-170 ℃; the effect is better as the air is naturally dried after being placed for 24 hours; the composite body is an intermediate filling layer.

(3) Preparing a composite surface layer fabric:

and (3) bonding the complex and the surface fabric together by using the glue A and the glue B as adhesives, heating and drying the complex and the surface fabric by using a heating roller of a compound machine, wherein the temperature of the heating roller is set at 150-200 ℃, and the gluing amount is as follows: when the surface fabric is a cotton product, the fabric is 80-120g per square meter, and the chemical fiber is 60-70g per square meter; the surface fabric is selected from cotton products or chemical fiber products; preferably, the ground surface material is selected to be 300g/m²The pure cotton terry cloth.

(4) Base fabric composite SBR:

taking the glue A and the glue B as adhesives, enabling the 3D surface of the product obtained in the step (3) to be upward, attaching the product to a gluing roller to enable the product to uniformly pass through the gluing roller, paving SBR on the gluing surface of the product, and setting the temperature at 200-220 ℃; preferably the temperature is 200 ℃. Such that the non-slip backing is bonded to the 3D structure. The product is then compounded, and the product structure is shown in fig. 2. The static coefficient of friction of the tested product was 0.7.

(5) And (4) after the product is compounded, cutting and trimming the product, and cutting the product according to the size requirement of the product. The elastic recovery rate of the product after a pressure test is 98.6 percent (the product is highly changed).