New Technology: The Carpet Industry Of "Industry, Research And Research Achievements" Usher In A New Era Of "Non Gel Production".

Entering the Oriental carpet exhibition hall, one of the most beautiful carpets is seen in the eyes of visitors, handicraft cut flowers, pure wool carpet, household process blankets, business assembly blankets, HD printing engineering carpets, craft tapestries...

The most prominent position in the exhibition hall is the "3D nine dragon wall art tapestry" and "Qingming Riverside art tapestries", which is attracting people's attention and letting people seem to enter the hall of carpet art.

Oriental carpet is a leading enterprise in the carpet industry. Its products have already covered home, hotel, business, ship, automobile, aviation and other fields. It is the designated carpet supplier of Atlantis, Hilton and other international hotels. The products of the company represent the direction of the development of the industry.

A few days ago, the key technology research and industrialization project of the non latex environmental protection carpet was identified by the appraisal committee of science and technology achievements of the Ministry of science and technology of the Chinese Textile Industry Federation as "the level of technology reached the international leading level". Once again, Oriental carpet became the focus of attention of the industry.

The innovative achievement of non latex carpet is a revolution in the carpet industry. For the first time in the world, new products of carpet, green and pollution-free were abandoned.

The expert evaluation of the appraisal said that this innovative achievement has solved the bottleneck problem of low efficiency, high energy consumption and great environmental impact on the carpet gluing process, and is a major innovation in the technology of carpet production technology.

Market demand, innovation and pformation are imminent.

There are three "household flower" - carpet, floor tiles and flooring in the paving material sector. Among them, the carpet is favored by the users because of its excellent decorative effect, excellent sound insulation performance, improving indoor air quality and preventing knock injuries. It is widely used worldwide.

At present, carpet consumption accounts for about 70% of the total material consumption in developed countries such as Europe and the United States, and presents a trend of commercially oriented to commercial household development. China's carpet consumption market is mainly concentrated in hotels, business offices and public venues, and household consumption accounts for less than 10%.

In recent years, the residential area of our country has increased year by year. In 2017 alone, it added nearly 1 billion 200 million square meters, and the per capita residential building area in the city has reached 32 square meters.

Therefore, with carpet as an important paving material to enter the family, the carpet industry will usher in the opportunity of rapid development and become a new economic growth point of China's textile industry.

At the same time, in recent years, with the continuous development of the world economy and science and technology, automobile industry, rail pportation, air pportation, marine pportation and many new industries have been unprecedentedly developed. It has provided broad development space and broad prospects for the development of carpet applications and the enhancement of added value.

The carpet has become the main force in the current carpet Market (about 90%) compared with traditional hand-made carpet because of its advantages of high production efficiency, large production, convenient scale production, short customization cycle and various price levels.

In the production of carpet, the latex glue process is generally used, that is to say, latex is used as adhesive to consolidate the yarn and lining cloth. This brings the bottleneck that the industry can not avoid.

According to the statistics of "30 years" of Chinese carpet, the total amount of carpet machine-made in 2016 was 281 million 753 thousand and 600 square meters, of which, the output of carpet and Wilton carpet was 66 million 356 thousand and 400 square meters, and the tufted carpet was 156 million 161 thousand and 200 square meters. According to this calculation, the whole industry latex was 10 million tons of latex.

Carpet latex is mainly composed of styrene butadiene latex and vinyl acetate latex. Most of the latex is polymerized by butadiene, styrene, vinyl acetate, butyl acetate, vinyl acetate and other monomers. The upstream production process is chemical synthesis, which is not environmentally friendly. During drying, solvent evaporation, residual harmful monomers and polymers are harmful to the environment due to heat decomposition and volatilization. Carpet manufacturers must invest in the purchase of "VOC" treatment facilities in order to meet the corresponding environmental requirements. Drying process will cause wet heat shrinkage of carpet and reduce the rate of product production; in the whole production process, the glue and drying curing process is inefficient, high energy consumption and high production environment, which is not conducive to the health of workers.

In addition, in order to achieve the standard of the pulling force of the pile and reduce the coefficient of variation, the method of increasing the amount of glue is often used, which leads to the phenomenon of rubber penetration and seriously reduces the quality of the carpet.

As a medium and high grade carpet variety, Wilton and its carpet often lose elasticity due to overcoating, making it difficult to match the quality of hand-made carpets. The tufted carpet with high gel content can only be used as a low grade carpet, seriously damaging the product image of the industry, and limiting the potential of carpet manufacturers to enhance their economic efficiency.

In recent years, in order to overcome the defects of carpet latex gum process, hot melt adhesive, hot melt powder, hot-melt film and jet technology have been developed at home and abroad. However, due to the limited applicability, high energy consumption and quality assurance, the factors can not be popularized.

In the actual use of the scene, most of the mechanism carpet because of calcium carbonate powder, after the waste is difficult to recycle, with the increasing use of the market, the treatment of carpet garbage has become a difficult disease.

With the promotion of the level of economic consumption, consumers are increasingly demanding for the indoor environment of work and life. At the national level, "energy saving, emission reduction, low carbon cycle, green production" environment, production, manufacturing, high energy consumption and exhaust emissions, many environmental factors such as "Yali mountain" and so on, forced the entire carpet industry to abandon the obsolete production process, and innovation is imminent.

Reverse thinking, innovative latex production

The existing application of carpet and latex has entered the bottleneck stage. In spite of the changes and upgrading, under the existing technology and material conditions, green production and application can not be fully realized.

Innovation often requires reverse thinking, "refrigeration."

Abandoning freon, can we discard latex? "Dongfang carpet Group's technical team boldly put forward this assumption.

Completely abandon the latex, respond to the national low carbon green environmental protection industry policy, cater to the needs of consumers to enhance work and living environment, end the production and application of latex from the source, and realize the revolutionary pformation of carpet production mode has become the direction of innovation.

A few days ago, the Oriental carpet "key technology research and industrialization of non latex environmental carpets" was successfully passed by the expert group of China Textile Industry Federation. The expert group agreed that the innovation results improved the texture and performance of the products, and solved the bottleneck problems such as low production efficiency, high energy consumption and great environmental impact. It is a major innovation in the technology of carpet production technology. The project has achieved large-scale production, and the product has been tested in line with the national standard (grade GB18587-2001- a), the added value of products is high, the social benefits and economic benefits are significant, the market prospect is broad, the project has independent intellectual property rights, and the overall technology has reached the international leading level.

As a leader in the carpet industry, Dongfang carpet has been committed to providing customers with better quality carpet products, so as to inherit oriental culture and create quality life.

Since its inception, it has always focused on product development and upgrading, with emphasis on investment in technology research and development.

Since 2014, Dongfang carpet and Tianjin University of Technology and Qiingdao University have jointly carried out joint research on production, teaching and research. Two institutions are responsible for theoretical and technical research, and a special task tackling group for oriental carpet establishment.

After 4 years of research and trial and error, the project team's independent innovation has completed the pformation from process optimization to equipment R & D, and finally realized the industrialization of non latex carpet.

In terms of theoretical innovation, the results creatively put forward the mechanism of in situ infiltration and consolidation of carpet hot melt adhesive materials in the velvet / foundation, and built in situ infiltration model for the mechanism of hot melt adhesive material of carpet, which solved the defects of traditional adhesive technology in mechanism and laid a theoretical foundation for carpet carpet / in situ consolidation.

In terms of technological innovation, we have invented the hot melt adhesive material embryo blanket in situ implantation technology, providing technical support for the high viscosity hot melt adhesive material as a carpet carpet / base binder, effectively protecting and improving carpet Velvet / base adhesion, and improving the quality of carpet machine-made products.

In terms of material innovation, a special hot melt adhesive material suitable for different carpet materials has been developed, and a design system of velvet yarn hot-melt adhesive material based on carpet pile yarn, hot melt adhesive material characteristics and effective diffusion interface molecular interaction has been constructed.

In the aspect of equipment innovation, we have developed a non latex environmental protection mechanism special thermal adhesive equipment for carpet. When the carpet substrate is effectively protected, the hot-melt adhesive material can quickly and efficiently fill and infiltrate the pile and base cloth, effectively protecting and improving the adhesion of carpet carpet / base cloth.

A new theoretical model of carpet carpet is put forward, and a hot melt adhesive material for carpet is developed, which is suitable for different carpet materials.

In terms of patent accumulation, the project has independent intellectual property rights, and a total of 21 patents have been applied, including 6 authorized invention patents and 8 utility model patents.

Technological innovation benefits society

The Oriental carpet's "key technology research and industrialization of non latex environmental protection carpet" is based on the hot melt adhesive material for carpet pile and base cloth adhesive. With the goal of high efficiency and cleanliness of production process, healthy use of products and high value of product quality, the carpet manufacturing technology has been thoroughly changed, and the whole process of green life of carpet life chain has been thoroughly changed. The production process flow is short, energy consumption is low, production efficiency is high, cost is low, non-toxic pollutants are discharged and production environment is optimized.

The achievement of this innovation results in greatly reducing the technological process of carpet production, saving electricity and gas consumption by about 25%, eliminating the release of harmful substances in the production process, reducing processing equipment and reducing carbon emissions by about 20%.

According to the statistics of "30 years" of China's carpet, in 2016, the output of the national machine-made carpet is about 222 million 300 thousand square meters. If the technology is popularized and adopted, the cost and product benefit of the whole industry can be increased by 2 billion 962 million yuan, the amount of latex used will be reduced by 10 million tons, and the investment in environmental protection treatment facilities will be reduced by 360 million yuan. This will play an important role in promoting the pformation and upgrading of carpet industry and technological progress, realizing the ecological development of carpet, upgrading product grades and added value, and enhancing international competitiveness.

From the consumer's point of view, the technology of "non glue environmental carpets" makes the quality of machine-made carpets comparable with manual carpets for the first time. The price of machine-made carpets enjoy the quality of hand-made carpets, which fully meets the needs of green environmental protection in the current home environment.

The application prospect is broad.

Focus on upgrading and create competitiveness

"When the world carpet industry is developing along with the idea of improving latex, we have another way to do it, completely without latex, which makes the industry unbelievable."

Han Hongliang, chairman of Oriental carpet, said excitedly.

The development of non latex carpet successfully overturned the traditional process of rubber production, and realized a carpet production with a brand new green process.

The success of any disruptive innovation is no accident. Since its establishment for more than 20 years, the Oriental carpet has always focused on R & D investment, focused on product development and upgrading, and gradually enhanced its R & D design capability.

According to Han Hongliang, there are nearly a hundred R & D design teams in Eastern carpet, and more than 120 patents are available. Through the cooperation with the world's top technology companies, we continue to develop cutting-edge products in the world: cooperate with DuPont Co to develop "Solana carpet", adding 37% jade meters to the products.

With its excellent easy cleaning characteristics, it achieves lifelong anti fouling performance. In cooperation with Austria Lenzing Co, the development of Tencel carpet is the first in China to achieve recyclable degradation of carpet products, greatly reducing environmental pollution.

With the full pformation of the old and new energy conversion in Shandong Province, the eastern carpet has led the pformation of technology with innovation, and has carried out industry university research cooperation with Harbin Institute of Technology, Donghua University, Tianjin University of Technology, Luxun Academy of Fine Arts, and so on. The industry chain of Eco environmental carpets has been built, and the first national carpet monitoring center has been established. The carpet industry is the only "national ecological carpet technology research and development center". In 2016, the first industrial 4 demonstration factory was established in the industry.

As the vice president of China Household Textile Industry Association, Oriental carpet is the first drafting unit in the industry through the quality management system and the environmental management system certification. It is the main drafting unit of the national standard for woven carpet, and has been well certified by the China conformity assessment committee (CANS), the Chinese Classification Society (CCS), the China Civil Aviation Administration (CAAC), and the international environmental protection (GRI).

At present, the eastern carpet products cover home carpet, hotel engineering carpet, business office carpet, ship carpet, automobile carpet, aviation carpet and other fields, and the comprehensive strength ranks the forefront in the carpet industry.

In order to make consumers more convenient to enjoy high-quality carpet products, in 2017, the company set up Binzhou Oriental carpet personalized customization service platform (WeChat applet). Through this service platform, we can achieve instant information interaction among terminal customers, channel distributors and manufacturers, and participate in the whole chain of "R & D, design, manufacture, warehousing and pportation" of carpet products, and ultimately achieve the social benefits of win win win.

"Our goal is to make Oriental carpet the first brand of Chinese carpets," Han Hongliang, the famous carpet designer in the world, said. "In order to let more colleagues know about" no glue and environmental protection carpet production technology ", we will declare this year's" textile light "China Textile Industry Association Science and technology award, looking forward to the East carpet's innovation results in the industry.