Composite polymer coconut shell charcoal tufted carpet as well as preparation method and application thereof

Abstract

The invention provides a composite polymer coconut shell charcoal tufted carpet as well as a preparation method and application thereof, and belongs to the field of polymer composite carpets. The adsorption layer is compounded on the back surface of the bonding layer, so that organic matters and toxic and harmful substances in the carpet are efficiently removed. The coconut shell charcoal in the adsorption layer is acidified by nitric acid, then an active functional group is introduced, the coconut shell charcoal and a titanium source are subjected to a hydrothermal reaction, then calcination is performed to improve the crystallinity and the interface bonding force, and the adsorption-photocatalytic decomposition dynamic cycle of volatile organic compounds is achieved. And meanwhile, interlayer adhesion is enhanced by combining a needling process, and high mechanical strength and environmental protection performance are synchronously realized. Through multi-component cooperation and process optimization, a carpet solution with functionality and durability is provided for the fields of automotive interiors and the like.

Description

Technical Field

[0001] The present invention relates to the field of polymer composite carpets, and particularly to a tufted carpet composite with polymer coconut shell charcoal, a preparation method thereof, and an application thereof. Background Art

[0002] With the gradual development of new energy vehicles, the requirements for vehicle environmental protection are also gradually increasing, which is not only limited to vehicle exhaust emission standards, but also related to the environmental protection of vehicle-related accessories. Among vehicle accessories, vehicle seat covers and vehicle carpets are the main sources of odor inside the vehicle. Due to the relatively small space inside the vehicle and the limitations of the ventilation system, the air circulation efficiency is low, which also makes it difficult to effectively discharge harmful gases in the vehicle carpet. The most common volatile organic compounds in vehicle carpets are benzene series, aldehydes, alkanes, etc. Among them, the contents of formaldehyde and benzene are the highest, the harm to the human body is the greatest, and they are also the most difficult to remove. With the increase in temperature in summer, organic compounds will continuously be released, seriously threatening the health of drivers and passengers. Long-term exposure may cause problems such as respiratory diseases and nervous system damage.

[0003] Therefore, in the preparation process of existing vehicle carpets, an adsorption layer structure will be added to adsorb volatile organic compounds, or environmentally friendly adhesives with less organic matter will be selected. For example, Patent CN201736863U discloses a vehicle carpet. An adsorption layer is provided on the upper surface of the carpet body, and the adsorption layer is made of bamboo charcoal fibers. A shaping layer is provided below the adsorption layer, and a sound insulation layer is provided below the shaping layer.

[0004] CN109627418A discloses a preparation method of a highly sound-absorbing polyurethane vehicle carpet. The highly sound-absorbing polyurethane vehicle carpet includes Material A and Material B. Among them, Material A includes polyester polyol, polyether polyol, tertiary amine catalyst, hydroxyl silicone oil, chain extender, and foaming agent; Material B includes liquefied MDI, crude MDI, and pure 2,4'-MDI.

[0005] Although the above method of setting an adsorption layer can adsorb some organic compounds, due to the small specific surface area in the adsorption layer, the content of adsorbed organic compounds is limited, and it adsorbs or decomposes the released pollutants, and cannot inhibit the release of TVOC from the source. In addition, the addition of some adsorption layers will also affect the strength and other properties of the carpet, and the cost of using "formaldehyde-free" glue has increased significantly compared with the traditional latex content. This leads to obvious limitations in the traditional technical means for improving the air quality inside the vehicle in the industry.

[0006] In summary, as the main source of odor inside the vehicle, the content of volatile organic compounds in vehicle carpets is relatively high. There are problems that need to be solved urgently, such as high cost, limited removal amount in the method of removing volatile organic compounds, and adverse effects on the strength of the carpet. Summary of the Invention

[0007] In view of the above problems, the present invention provides a tufted carpet made of composite polymer coconut shell charcoal, a preparation method and an application thereof. By preparing a specific adsorbent material and compounding it in the tufted carpet, the adsorbent material can continuously absorb the organic substances in the tufted carpet, effectively reducing the release of organic substances in the carpet and weakening the unpleasant smell during the use of the carpet.

[0008] The present invention provides a tufted carpet made of composite polymer coconut shell charcoal. The tufted carpet made of composite polymer coconut shell charcoal has a multi-layer structure, which is successively a bottom layer, a reinforcing layer, an adsorption layer, an adhesive layer, a base fabric layer and a pile layer from bottom to top. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, a compatibilizer and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is obtained by high-temperature preparation. The thickness of the tufted carpet made of composite polymer coconut shell charcoal is 12.4 - 12.9 mm, and the gram weight is 1910 - 1997 g / m 2 , the number of cut pile loops is 2550 - 2660 per 100 cm 2 , the pile height is 4 - 5 mm, and the pile extraction force is 26 - 30 N; The peel strength of the tufted carpet made of composite polymer coconut shell charcoal is 58 - 66 N, the weft direction breaking strength is 1340 - 1410 N / 5 cm, the warp direction breaking strength is 1520 - 1630 N / 5 cm, the weft direction tearing strength is 210 - 270 N, and the warp direction tearing strength is 210 - 280 N; The odor grade of the tufted carpet made of composite polymer coconut shell charcoal is 3.5 - 5, the content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg; In the volatile organic compound content of the tufted carpet made of composite polymer coconut shell charcoal, the formaldehyde content < 19 μg / m 3 , the acetaldehyde content < 48.5 μg / m 3 , the toluene content < 5.2 μg / m 3 , and acrylic acid, acetone, benzene, ethylbenzene, xylene (o / m / p), styrene are not detected; the total volatile organic compound (TVOC) content < 1170 μg / m 3 .

[0009] Furthermore, after the low-temperature impact test, the tufted carpet made of composite polymer coconut shell charcoal has no cracks, does not break, and does not delaminate.

[0010] The present invention also provides a preparation method of the tufted carpet made of composite polymer coconut shell charcoal, which includes the following steps: Step 1: Tuft the bulk continuous filament (BCF yarn) onto the non-woven base fabric through a tufting machine to obtain a pile layer and a base fabric layer; and coat the bottom of the base fabric layer with aqueous foaming latex, and dry it to obtain an adhesive layer; Step 2: Add concentrated nitric acid to coconut shell charcoal under low-temperature stirring, gradually increase the temperature and stir for acidification. After acidification, wash the coconut shell charcoal with deionized water, and dry it after washing to obtain activated coconut shell charcoal; Step 3: Stir and disperse the activated coconut shell charcoal and formaldehyde-removing crystals in absolute ethanol and deionized water, carry out a reaction under ultrasonic and sealed hydrothermal conditions, cool and filter, and dry the solid product to obtain in-situ grown coconut shell charcoal; Step 4: Calcinate the in-situ grown coconut shell charcoal and cool it to room temperature to obtain loaded coconut shell charcoal. Uniformly mix the loaded coconut shell charcoal with a compatibilizer and polyethylene powder to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal powder on the back of the adhesive layer, and heat it to make the organic coconut shell charcoal melt and bond on the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Continue to laminate a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer. After cooling to room temperature, a reinforcement layer is obtained. Laminate the bottom layer of a polyethylene terephthalate (PET) needle-punched felt on the back of the reinforcement layer to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0011] Further, in Step 1, the gram weight of the bulk continuous filament is 350-500 gsm.

[0012] Further, in Step 1, the gram weight of the non-woven base fabric is 100-120 gsm.

[0013] Further, in Step 1, the non-woven base fabric is a polyethylene terephthalate non-woven base fabric.

[0014] Further, in Step 1, the stitch density of the tufting machine is 50.39 stitches / 10 cm, the row density is 50-55 stitches / 10 cm, the needle penetration depth is 5-6 mm, and the needle frequency is 1000-1300 RPM.

[0015] Further, in Step 1, the gram weight of the aqueous foaming latex is 180-200 gsm.

[0016] Further, in Step 1, the aqueous foaming latex is an ethylene-vinyl acetate copolymer (EVA) aqueous foaming latex.

[0017] Further, in Step 1, the dry glue gram weight in the aqueous foaming latex is 80-100 gsm, the wet latex solid content is 30-50%, and the foaming ratio is 2-3 times.

[0018] Further, the coating speed in step 1 is 8 - 12 m / min.

[0019] Further, the drying temperature in step 1 is 180 - 200 °C, and the drying time is 2 - 3 min.

[0020] Further, the mass - volume ratio of the coconut shell charcoal to the concentrated nitric acid in step 2 is (1:5) - (1:10).

[0021] Further, the mesh number of the coconut shell charcoal in step 2 is 200 - 240 mesh.

[0022] Further, the temperature of the low - temperature stirring in step 2 is - 5 to 0 °C, and the speed of the low - temperature stirring is 100 - 200 rpm.

[0023] Further, the temperature of the temperature rise in step 2 is 70 - 90 °C.

[0024] Further, the stirring speed of the stirring acidification in step 2 is 300 - 450 rpm, and the time of the stirring acidification is 3 - 4 h.

[0025] Further, in step 2, it is washed until the pH value of the washing liquid is 6 - 7.

[0026] Further, the drying temperature in step 2 is 120 - 140 °C, and the drying time is 10 - ......

[0027] Further, the molar ratio of the activated coconut shell charcoal to the formaldehyde - removing crystal in step 3 is (18 - 22):1.

[0028] Further, the formaldehyde - removing crystal in step 3 is tetrabutyl titanate.

[0029] Further, the stirring and dispersing speed in step 3 is 300 - 500 rpm, and the stirring and dispersing time is 10 - 15 min.

[0030] Further, the volume ratio of the absolute ethanol to the deionized water in step 3 is 1:1.

[0031] Further, the mass - volume ratio of the activated coconut shell charcoal to the absolute ethanol in step 3 is (1:5) - (1:6), where the unit of mass is g and the unit of volume is mL.

[0032] Further, the ultrasonic time in step 3 is 10 - 20 min.

[0033] Further, during the hydrothermal reaction in step 3, stirring is performed, and the stirring speed is 300 - 500 rpm.

[0034] Further, the temperature of the hydrothermal reaction in step 3 is 150 - 160 °C, and the time of the hydrothermal reaction is 12 - 15 h.

[0035] Further, the temperature of the drying in step 3 is 120 - 150 °C, and the time of the drying is 12 - 18 h.

[0036] Further, the temperature of the calcination in step 4 is 500 - 600 °C, the heating rate of the calcination is 5 °C / min, and the holding time of the calcination is 1 - 1.5 h.

[0037] Further, the mass ratio of the loaded coconut shell charcoal, compatibilizer, and polyethylene powder in step 4 is (1:0.05:2) - (1:0.1:2).

[0038] Further, the compatibilizer in step 4 is maleic anhydride grafted polyethylene.

[0039] Further, the grammage of the organic coconut shell charcoal in the adsorption layer in step 5 is 270 - 330 gsm.

[0040] Further, the processing temperature of the adsorption layer in step 5 is 170 - 180 °C.

[0041] Further, the grammage of the polyethylene - polyamide - polyethylene composite film in the reinforcing layer in step 5 is 180 - 200 gsm.

[0042] Further, the composite method of the polyethylene - polyamide - polyethylene composite film and the polyethylene terephthalate needle punched felt in step 5 is all by laminating polyethylene, and the laminating temperature is 190 - 200 °C, and the grammages of the polyethylene are 200 - 500 gsm respectively.

[0043] Further, the grammage of the polyethylene terephthalate needle punched felt in the bottom layer in step 5 is 1000 - 1200 gsm.

[0044] The present invention also provides a low - odor automotive carpet, and the low - odor automotive carpet is composed of the tufted carpet of the composite polymer coconut shell charcoal.

[0045] The beneficial effects of the present invention: 1. The present invention reduces the odor, organic matter, toxic and harmful substances content of the tufted carpet by compounding an adsorption layer on the back of the adhesive layer of the tufted carpet. The adsorption layer in the present invention contains coconut shell charcoal, compatibilizer and polyethylene. The compatibilizer is maleic anhydride grafted polyethylene, and its anhydride groups will react with the functional groups on the surface of the coconut shell charcoal, and the double bond functional groups will be compatibilized with polyethylene, improving the compatibility of coconut shell charcoal with polyethylene and the adhesive layer, etc., and avoiding the reduction of the adhesion of the tufted carpet caused by the introduction of coconut shell charcoal. In addition, polyethylene powder wraps the organic coconut shell charcoal in a molten state and composites it in the adsorption layer, enabling it to continuously adsorb organic matter in the tufted carpet. The adsorption performance of the coconut shell charcoal itself adsorbs organic matter, etc., and then the loaded titanium dioxide decomposes the organic matter under photocatalysis, realizing a dynamic cycle of adsorption - decomposition, thereby reducing the content of organic matter in the carpet. The combination of coconut shell charcoal and titanium dioxide enables the decomposition of organic matter under daily sunlight without special conditions, and other substances that cannot be decomposed will also be adsorbed in the coconut shell charcoal; 2. The coconut shell charcoal in the present invention has active functional groups on its surface after being acidified with nitric acid, increasing the active sites. When hydrothermally treated with tetrabutyl titanate, more titanium compounds can grow in situ in the coconut shell charcoal. Tetrabutyl titanate gradually hydrolyzes in an anhydrous ethanol and water solvent, and anhydrous ethanol provides a slow hydrolysis environment for tetrabutyl titanate, avoiding the aggregation of hydrolyzed titanium dioxide, which leads to uneven distribution on the coconut shell charcoal. In addition, the reaction is mild at the hydrothermal temperature in the present invention, also avoiding the aggregation of titanium dioxide. After hydrothermal treatment, the coconut shell charcoal is calcined, which improves the crystallinity of titanium dioxide and its interfacial bonding force with the coconut shell charcoal, avoiding shedding or uneven dispersion during subsequent mixing with polymers, and also removing the substances remaining on the surface of the coconut shell charcoal during the hydrothermal process; 3. In the present invention, through different substances and processing methods between different layers, a tufted carpet with high mechanical strength, high adsorption and low odor is realized. The base cloth layer and the pile layer in the present invention achieve high - density tufting by a tufting machine under specific process conditions, and the pull - out force of the pile is also improved after being bonded with water - based foaming latex. Since the organic matter content in the latex is relatively high, an adsorption layer is compounded on the back of the adhesive layer and compounded at a specific temperature. Subsequently, in order to improve the mechanical properties of the tufted carpet, a high - strength reinforcing layer is set. Finally, through a specific needling method, the inter - layer bonding strength, mechanical strength and durability of the tufted carpet in the present invention are further improved. Description of the Drawings

[0046] Figure 1 It is the peel strength test chart of the tufted carpet with the composite polymer coconut shell charcoal in the present invention; Figure 2 It is the breaking strength test chart of the tufted carpet with the composite polymer coconut shell charcoal in the present invention; Figure 3 Tear strength test chart of the tufted carpet of the composite polymer coconut shell charcoal described in the present invention; Figure 4 Low-temperature impact test chart of the tufted carpet of the composite polymer coconut shell charcoal described in the present invention. Specific embodiments

[0047] The following is a detailed description of the invention in combination with embodiments: The present invention provides a tufted carpet of composite polymer coconut shell charcoal, its preparation method and application. By compounding through the adsorption layer prepared in the present invention, the odor and organic matter content of the carpet are greatly reduced, and the mechanical properties of the carpet are improved through the compounding of the adsorption layer.

[0048] Example 1 This embodiment provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of composite polymer coconut shell charcoal has a multi-layer structure, which is successively a bottom layer, a reinforcing layer, an adsorption layer, an adhesive layer, a base cloth layer and a pile layer from bottom to top. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, compatibilizer and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high temperature; The thickness of the tufted carpet of the composite polymer coconut shell charcoal is 12.70 mm, and the gram weight is 1996.20 g / m 2 , the number of cut pile loops is 2550 per 100 cm 2 , the pile height is 4 mm, and the pile extraction force is 29.6 N; The peel strength of the tufted carpet of the composite polymer coconut shell charcoal is 66 N, the weft breaking strength is 1388 N / 5 cm, the warp breaking strength is 1529 N / 5 cm, the weft tearing strength is 231.0 N, and the warp tearing strength is 244.1 N; The odor grade of the tufted carpet of the composite polymer coconut shell charcoal at dry state and 80 °C for 2 h is 3.5, the odor grade at wet state and 40 °C for 24 h is 4.0, and the odor grade at wet state and 23 °C for 24 h is 4.5. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg; The content of formaldehyde in the volatile organic compounds of the tufted carpet of the composite polymer coconut shell charcoal is 18.63 μg / m 3 , the content of acetaldehyde is 48.28 μg / m 3 , the content of toluene is 5.15 μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene (o / m / p), styrene are not detected; total volatile organic compounds (C6-C 16The content is 1114.27 μg / m 3 ; After the tufted carpet made of the composite polymer coconut shell charcoal is tested by low-temperature impact, there are no cracks, no breakage, and no delamination.

[0049] This embodiment also provides a preparation method for the tufted carpet made of the composite polymer coconut shell charcoal, which includes the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric through a tufting machine, and control the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base fabric layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) water-based foaming latex (dry glue weight per unit area is 80 gsm, wet latex solid content is 40%, foaming ratio is 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and dry it at 180 °C for 2 min to obtain an adhesive layer; Step 2: Add concentrated nitric acid (the mass-volume ratio with the coconut shell charcoal is 1:5) to coconut shell charcoal (200 mesh) at 0 °C and a speed of 200 rpm, then gradually raise the temperature to 70 °C, and stir and acidify for 3 h at 350 rpm. Wash the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and dry it at 120 °C for 12 h after washing to obtain activated coconut shell charcoal; Step 3: Stir the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 at 300 rpm for 10 min and disperse them in anhydrous ethanol and deionized water (the volume ratio of anhydrous ethanol to deionized water is 1:1, the mass-volume ratio of the activated coconut shell charcoal to anhydrous ethanol is 1:5, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 15 min, carry out a closed hydrothermal reaction at 300 rpm and 150 °C for 12 h. After cooling and filtration, dry the solid product at 120 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 4: Heat the in-situ grown coconut shell charcoal to 500 °C at a rate of 5 °C / min for calcination, keep it warm for 1 h and then cool it to room temperature to obtain loaded coconut shell charcoal. Uniformly mix the loaded coconut shell charcoal with maleic anhydride-grafted polyethylene and polyethylene powder at a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) is repeatedly laminated on the back of the adsorption layer at 180 gsm. After cooling to room temperature, a reinforcement layer is obtained. A bottom layer of 1000 gsm polyethylene terephthalate (PET) needle punched felt is laminated on the back of the reinforcement layer. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm polyethylene at 190 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0050] Example 2 This example provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of the composite polymer coconut shell charcoal has a multi-layer structure, which is composed of a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base cloth layer and a pile layer from bottom to top. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, compatibilizer and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high temperature. The thickness of the tufted carpet of the composite polymer coconut shell charcoal is 12.84 mm, and the grammage is 1914.81 g / m 2 , the number of cut pile loops is 2660 per 100 cm 2 , the pile height is 4 mm, and the pile pulling force is 27.3 N; The peeling force of the tufted carpet of the composite polymer coconut shell charcoal is 64 N, the weft breaking strength is 1371 N / 5 cm, the warp breaking strength is 1578 N / 5 cm, the weft tearing strength is 249.9 N, and the warp tearing strength is 279.6 N; The odor grade of the tufted carpet of the composite polymer coconut shell charcoal at dry state and 80 °C for 2 h is 4.0, the odor grade at wet state and 40 °C for 24 h is 4.5, and the odor grade at wet state and 23 °C for 24 h is 5.0. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg; The content of formaldehyde in the volatile organic compounds of the tufted carpet of the composite polymer coconut shell charcoal is 18.06 μg / m 3 , the content of acetaldehyde is 48. 3 00 μg / m , the content of toluene is 5.12 μg / m 3 , while acrylic acid, acetone, benzene, ethylbenzene, xylene (o / m / p), styrene are not detected; the total volatile organic compounds (C6-C 16) The content is 1167.53 μg / m 3 ; After the tufted carpet made of the composite polymer coconut shell charcoal is subjected to a low-temperature impact test, there are no cracks, no breakage, and no delamination.

[0051] This embodiment also provides a method for preparing a tufted carpet made of the composite polymer coconut shell charcoal, which includes the following steps: Step 1: Tuft 400 gsm bulk continuous filaments onto a 100 gsm polyethylene terephthalate non-woven fabric through a tufting machine, and control the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 50 stitches / 10 cm, the needle penetration depth to be 5 mm, and the needle frequency to be 1100 RPM to obtain a pile layer and a base fabric layer; and coat 180 gsm ethylene-vinyl acetate copolymer water-based foaming latex (dry glue weight is 90 gsm, wet latex solid content is 30%, foaming ratio is 2 times) on the bottom of the base fabric layer at a speed of 8 m / min, and dry it at 190 °C for 2.5 min to obtain an adhesive layer; Step 2: Add concentrated nitric acid (the mass-volume ratio with the coconut shell charcoal is 1:7) to coconut shell charcoal (220 mesh) at -3 °C and a speed of 150 rpm, gradually raise the temperature to 90 °C, and stir and acidify for 3 h at 300 rpm. The acidified coconut shell charcoal is washed with deionized water until the pH of the filtrate is 7, and after washing, it is dried at 120 °C for 12 h to obtain activated coconut shell charcoal; Step 3: Stir the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 18:1 at 400 rpm for 10 min and disperse them in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water is 1:1, the mass-volume ratio of the activated coconut shell charcoal to the anhydrous ethanol is 1:5, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 18 min, carry out a sealed hydrothermal reaction at 300 rpm and 155 °C for 12 h. After cooling and filtering, the solid product is dried at 130 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 4: Heat the in-situ grown coconut shell charcoal to 550 °C at a rate of 5 °C / min for calcination, keep it warm for 1 h, and then cool it to room temperature to obtain loaded coconut shell charcoal. The loaded coconut shell charcoal, maleic anhydride-grafted polyethylene, and polyethylene powder are uniformly mixed in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 270 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal on the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) is repeatedly laminated on the back of the adsorption layer at 180 gsm. After cooling to room temperature, a reinforcement layer is obtained. A bottom layer of 1200 gsm polyethylene terephthalate (PET) needle punched felt is laminated on the back of the reinforcement layer. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 400 gsm polyethylene at 200 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0052] Example 3 This example provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of the composite polymer coconut shell charcoal has a multi-layer structure, which from bottom to top are a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base fabric layer and a pile layer. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, compatibilizer and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high temperature. The thickness of the tufted carpet of the composite polymer coconut shell charcoal is 12.56 mm, and the grammage is 1973.03 g / m 2 , the number of cut pile loops is 2550 per 100 cm 2 , the pile height is 4 mm, and the pile pull-out force is 26.7 N; The peel strength of the tufted carpet of the composite polymer coconut shell charcoal is 58 N, the weft breaking strength is 1344 N / 5 cm, the warp breaking strength is 1589 N / 5 cm, the weft tearing strength is 264.6 N, and the warp tearing strength is 239.0 N; The odor grade of the tufted carpet of the composite polymer coconut shell charcoal at dry state and 80 °C for 2 h is 4.0, the odor grade at wet state and 40 °C for 24 h is 4.5, and the odor grade at wet state and 23 °C for 24 h is 5.0. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg; After the low-temperature impact test, the tufted carpet of the composite polymer coconut shell charcoal has no cracks, no breakage and no delamination.

[0053] This example also provides a preparation method of the tufted carpet of the composite polymer coconut shell charcoal, which includes the following steps: Step 1: Tuft 450 gsm bulk continuous filament onto a 110 gsm polyethylene terephthalate non-woven base fabric through a tufting machine, controlling the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 52 stitches / 10 cm, the needle penetration depth to be 6 mm, and the needle frequency to be 1200 RPM to obtain a pile layer and a base fabric layer; and coat 190 gsm ethylene-vinyl acetate copolymer water-based foaming latex (dry glue weight is 100 gsm, wet latex solid content is 50%, foaming ratio is 3 times) on the bottom of the base fabric layer at a speed of 8 m / min, and dry it at 200 °C for 2 min to obtain an adhesive layer; Step 2: Add concentrated nitric acid (mass-volume ratio with the coconut shell charcoal is 1:10) to coconut shell charcoal (240 mesh) at -5 °C and a speed of 100 rpm, gradually heat up to 80 °C, and stir and acidify for 3 h at 400 rpm. Wash the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 6, and dry it at 130 °C for 15 h to obtain activated coconut shell charcoal; Step 3: Stir the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 22:1 at 500 rpm for 10 min and disperse them in anhydrous ethanol and deionized water (the volume ratio of anhydrous ethanol to deionized water is 1:1, the mass-volume ratio of activated coconut shell charcoal to anhydrous ethanol is 1:6, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 20 min, carry out a sealed hydrothermal reaction at 500 rpm and 150 °C for 15 h. After cooling and filtering, dry the solid product at 140 °C for 15 h to obtain in-situ grown coconut shell charcoal; Step 4: Heat the in-situ grown coconut shell charcoal to 600 °C at a rate of 5 °C / min for calcination, keep it warm for 1.5 h and then cool it to room temperature to obtain loaded coconut shell charcoal. Uniformly mix the loaded coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal at 330 gsm on the back of the adhesive layer, and heat it to 180 °C to melt and bond the organic coconut shell charcoal on the back of the adhesive layer. After cooling to room temperature, obtain an adsorption layer. Continue to laminate a polyethylene-polyamide-polyethylene composite film (PEPAPE film) with a weight of 180 gsm on the back of the adsorption layer. After cooling to room temperature, obtain a reinforcement layer. Laminate the bottom layer of a 1100 gsm polyethylene terephthalate (PET) needle punched felt on the back of the reinforcement layer. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm polyethylene at 190 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0054] Example 4 This embodiment provides a tufted carpet made of composite polymer coconut shell charcoal. The tufted carpet made of composite polymer coconut shell charcoal has a multi-layer structure, which is composed of a bottom layer, a reinforcing layer, an adsorption layer, an adhesive layer, a base cloth layer and a pile layer from bottom to top. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, compatibilizer and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high-temperature treatment; The thickness of the tufted carpet made of composite polymer coconut shell charcoal is 12.82 mm, and the gram weight is 1956.14 g / m 2 , and the pile pull-out force is 26.1 N; The peeling force of the tufted carpet made of composite polymer coconut shell charcoal is 61 N, the weft breaking strength is 1404 N / 5 cm, the warp breaking strength is 1616 N / 5 cm, the weft tearing strength is 220.7 N, and the warp tearing strength is 219.9 N; The odor grade of the tufted carpet made of composite polymer coconut shell charcoal at 80 °C for 2 h in the dry state is 4.0, the odor grade at 40 °C for 24 h in the wet state is 4.5, and the odor grade at 23 °C for 24 h in the wet state is 5.0. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg; After the tufted carpet made of composite polymer coconut shell charcoal is tested by low-temperature impact, there are no cracks, no breakage, and no delamination.

[0055] This embodiment also provides a preparation method of the tufted carpet made of composite polymer coconut shell charcoal, including the following steps: Step 1: Tuft 500 gsm bulk continuous filaments onto a 120 gsm polyethylene terephthalate non-woven base cloth through a tufting machine, and control the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 54 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1300 RPM to obtain the pile layer and the base cloth layer; and coat 200 gsm ethylene-vinyl acetate copolymer water-based foaming latex (dry glue gram weight is 80 gsm, wet latex solid content is 30%, foaming ratio is 3 times) on the bottom of the base cloth layer at a speed of 12 m / min, and dry it at 200 °C for 2.5 min to obtain the adhesive layer; Step 2: Add concentrated nitric acid (mass-volume ratio with the coconut shell charcoal is 1:5) to the coconut shell charcoal (200 mesh) at 0 °C and a speed of 100 rpm, gradually heat up to 80 °C, and stir and acidify for 3 h at 450 rpm. The acidified coconut shell charcoal is washed with deionized water until the pH of the filtrate is 7, and then dried at 140 °C for 10 h to obtain activated coconut shell charcoal; Step 3: Disperse the activated coconut shell charcoal with a molar ratio of 20:1 and tetrabutyl titanate under the condition of 300 rpm for 15 min in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water is 1:1, and the mass-volume ratio of the activated coconut shell charcoal to the anhydrous ethanol is 1:5, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 10 min, carry out a reaction under sealed hydrothermal conditions at 300 rpm and 160 °C for 12 h. After cooling and filtration, dry the solid product at 150 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 4: Heat the in-situ grown coconut shell charcoal to 500 °C at a rate of 5 °C / min for calcination. After holding for 1.5 h, cool it to room temperature to obtain loaded coconut shell charcoal. Uniformly mix the loaded coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder at a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal on the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, on the back of the adsorption layer, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) is laminated at 190 gsm. After cooling to room temperature, a reinforcement layer is obtained. On the back of the reinforcement layer, a bottom layer of 1000 gsm polyethylene terephthalate (PET) needle punched felt is laminated. The lamination method is to use 500 gsm polyethylene to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt at 200 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0056] Example 5 This example provides a tufted carpet of composite polymer coconut shell charcoal. The tufted carpet of the composite polymer coconut shell charcoal has a multi-layer structure, which is composed of a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base cloth layer, and a pile layer from bottom to top. Among them, the raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystals, compatibilizer, and coconut shell charcoal. The formaldehyde-removing crystals are loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high-temperature treatment; The thickness of the tufted carpet of the composite polymer coconut shell charcoal is 12.48 mm, and the grammage is 1938.22 g / m 2 , and the pile pull-out force is 27.2 N; The peeling force of the tufted carpet of the composite polymer coconut shell charcoal is 66 N, the weft direction breaking strength is 1404 N / 5 cm, the warp direction breaking strength is 1623 N / 5 cm, the weft direction tearing strength is 212.1 N, and the warp direction tearing strength is 211.1 N; The tufted carpet made of the composite polymer coconut shell charcoal has an odor rating of 4.0 at 80°C for 2 hours in the dry state, an odor rating of 4.5 at 40°C for 24 hours in the wet state, and an odor rating of 5.0 at 23°C for 24 hours in the wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤100 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤0.2 mg / kg; After the tufted carpet made of the composite polymer coconut shell charcoal undergoes a low-temperature impact test, there are no cracks, no breakage, and no delamination.

[0057] This embodiment also provides a method for preparing the tufted carpet made of the composite polymer coconut shell charcoal, which includes the following steps: Step 1: Tuft 350 gsm bulk continuous filaments onto a 120 gsm polyethylene terephthalate nonwoven base fabric through a tufting machine. Control the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 55 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base fabric layer. Then, coat 200 gsm ethylene-vinyl acetate copolymer water-based foaming latex (dry gum weight is 80 gsm, wet latex solid content is 40%, and foaming ratio is 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and dry it at 180°C for 2.5 min to obtain an adhesive layer; Step 2: Add concentrated nitric acid (mass-to-volume ratio with the coconut shell charcoal of 1:5) to coconut shell charcoal (200 mesh) at 0°C and a speed of 100 rpm, gradually heat up to 80°C, and stir and acidify for 4 hours at 300 rpm. Wash the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and dry it at 140°C for 10 hours to obtain activated coconut shell charcoal; Step 3: Stir the activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 at 300 rpm for 10 min and disperse them in anhydrous ethanol and deionized water (the volume ratio of anhydrous ethanol to deionized water is 1:1, and the mass-to-volume ratio of the activated coconut shell charcoal to anhydrous ethanol is 1:5, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 15 min, carry out a sealed hydrothermal reaction at 300 rpm and 150°C for 12 hours. After cooling and filtering, dry the solid product at 120°C for 18 hours to obtain in-situ grown coconut shell charcoal; Step 4: Heat the in-situ grown coconut shell charcoal to 500°C at a rate of 5°C / min for calcination, keep it at a constant temperature for 1 hour, and then cool it to room temperature to obtain loaded coconut shell charcoal. Uniformly mix the loaded coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder in a mass ratio of 1:0.1:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, repeat the lamination of a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at 200 gsm. After cooling to room temperature, a reinforcement layer is obtained. On the back of the reinforcement layer, laminate the bottom layer of a 1000 gsm polyethylene terephthalate (PET) needle-punched felt. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle-punched felt with 200 gsm of polyethylene at 190 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0058] Comparative Example 1 This comparative example provides a composite tufted carpet. The composite tufted carpet has a multi-layer structure, which is composed of a bottom layer, a reinforcement layer, an adhesive layer, a base cloth layer, and a pile layer from bottom to top; The thickness of the composite tufted carpet is 7 mm, and the gram weight is 1790.01 g / m 2 , the number of cut pile loops is 2821 per 100 cm 2 , the pile height is 4.5 mm, and the pile pull-out force is 15 N; The peel strength of the composite tufted carpet is 42 N, the weft direction breaking strength is 1246 N / 5 cm, the warp direction breaking strength is 1324 N / 5 cm, the weft direction tear strength is 178 N, and the warp direction tear strength is 183 N; The odor grade of the composite tufted carpet at 80 °C for 2 h in the dry state is 3, the odor grade at 40 °C for 24 h in the wet state is 3.5, and the odor grade at 23 °C for 24 h in the wet state is 3.5. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 1000 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 10 mg / kg; The content of formaldehyde in the volatile organic compounds of the composite tufted carpet is 188.28 μg / m 3 , the content of acetaldehyde is 335.31 μg / m 3 , the content of toluene is 52.41 μg / m 3 , the content of ethylbenzene is 15.17 μg / m 3 , the content of xylene is 66.09 μg / m 3 , the content of acetone is 143.24 μg / m 3 , the content of total volatile organic compounds (C6-C 16 ) is 20124.04 μg / m 3 , the content of butyl acetate is 72.92 μg / m 3 , the content of benzene is 5.69 μg / m 3, the styrene content is 3.91 μg / m 3 ; After the composite tufted carpet is tested by low-temperature impact, there are no cracks, no breakage, and no delamination.

[0059] This comparative example also provides a method for preparing the composite tufted carpet, including the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate nonwoven fabric base by a tufting machine, controlling the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) aqueous foaming latex (dry glue weight per unit area is 80 gsm, wet latex solid content is 40%, and foaming ratio is 3 times) on the bottom of the base layer at a speed of 12 m / min, and dry it at 180 °C for 2.5 min to obtain an adhesive layer; Step 2: Compound a polyethylene-polyamide-polyethylene composite film (PEPAPE film) with a weight per unit area of 180 gsm on the back of the adhesive layer, and cool it to room temperature to obtain a reinforcement layer. Compound the bottom layer of 1000 gsm polyethylene terephthalate (PET) needle punched felt on the back of the reinforcement layer. The compounding method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm polyethylene at 190 °C respectively to obtain the composite tufted carpet.

[0060] Comparative Example 2 This comparative example provides a tufted carpet with composite coconut shell charcoal. The tufted carpet with composite coconut shell charcoal is a multi-layer structure, which is composed of a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base layer, and a pile layer from bottom to top. The raw materials in the adsorption layer include polyethylene powder and coconut shell charcoal; The thickness of the tufted carpet with composite coconut shell charcoal is 8 mm, and the weight per unit area is 1981.25 g / m 2 , the number of cut pile loops is 2700 per 100 cm 2 , the pile height is 4 mm, and the pile pull-out force is 19 N; The peel strength of the tufted carpet with composite coconut shell charcoal is 39 N, the weftwise breaking strength is 1152 N / 5 cm, the warpwise breaking strength is 1290 N / 5 cm, the weftwise tear strength is 171 N, and the warpwise tear strength is 179 N; The tufted carpet made of the composite coconut shell charcoal has an odor rating of 3.5 after being kept at 80°C for 2 hours in the dry state, an odor rating of 4 after being kept at 40°C for 24 hours in the wet state, and an odor rating of 4 after being kept at 23°C for 24 hours in the wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg; In the content of volatile organic compounds in the tufted carpet made of the composite coconut shell charcoal, the content of formaldehyde is 99.76 μg / m 3 and the content of acetaldehyde is 111.58 μg / m 3 and the content of acetone is 32.61 μg / m 3 and the content of total volatile organic compounds (TVOC, C6-C 16 ) is 3261.75 μg / m 3 ; while toluene, ethylbenzene, xylene (ortho, meta, para), butyl acetate, benzene, and styrene are not detected; After the tufted carpet made of the composite coconut shell charcoal undergoes a low-temperature impact test, there are no cracks, no breakage, and no delamination.

[0061] This comparative example also provides a preparation method for the tufted carpet made of the composite coconut shell charcoal, including the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven base fabric through a tufting machine, and control the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base fabric layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) aqueous foaming latex (dry glue weight per unit area is 80 gsm, wet latex solid content is 40%, and foaming ratio is 3 times) at a speed of 10 m / min on the bottom of the base fabric layer, and dry it at 180°C for 2.5 minutes to obtain an adhesive layer; Step 2: Add concentrated nitric acid (the mass-volume ratio with the coconut shell charcoal is 1:5) to coconut shell charcoal (200 mesh) at 0°C and a speed of 200 rpm, gradually heat up to 70°C, and stir and acidify for 3 hours at 350 rpm. Wash the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and dry it at 120°C for 12 hours after washing to obtain activated coconut shell charcoal; Step 3: Uniformly mix the activated coconut shell charcoal and polyethylene powder at a mass ratio of 1:2 to obtain organic coconut shell charcoal; Step 4: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, repeat the lamination of a polyethylene-polyamide-polyethylene composite film (PEPAPE film) on the back of the adsorption layer at 180 gsm. After cooling to room temperature, a reinforcement layer is obtained. On the back of the reinforcement layer, laminate the bottom layer of a 1000 gsm polyethylene terephthalate (PET) needle punched felt. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm of polyethylene at 190 °C respectively to obtain the tufted carpet with the composite coconut shell charcoal.

[0062] Comparative Example 3 This comparative example provides a tufted carpet with composite coconut shell charcoal. The tufted carpet with composite coconut shell charcoal has a multi-layer structure, which is, from bottom to top, a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a base cloth layer, and a pile layer; The thickness of the tufted carpet with composite coconut shell charcoal is 8 mm, and the grammage is 1863.11 g / m 2 , the number of cut pile loops is 2793 per 100 cm 2 , the pile height is 4 mm, and the pile pull-out force is 22 N; The peel strength of the tufted carpet with composite coconut shell charcoal is 45 N, the weft direction breaking strength is 1097 N / 5 cm, the warp direction breaking strength is 1175 N / 5 cm, the weft direction tearing strength is 169 N, and the warp direction tearing strength is 176 N; The odor grade of the tufted carpet with composite coconut shell charcoal at dry state and 80 °C for 2 h is Grade 3, at wet state and 40 °C for 24 h is Grade 4, at wet state and 23 °C for 24 h is Grade 4. The content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 1000 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 10 mg / kg; In the volatile organic compound content of the tufted carpet with composite coconut shell charcoal, the formaldehyde content is 71.55 μg / m 3 , the acetaldehyde content is 101.21 μg / m 3 , the acetone content is 10.63 μg / m 3 , the content of total volatile organic compounds (TVOC, C6-C 16 ) is 1792.00 μg / m 3 ; while toluene, ethylbenzene, xylene (o / m / p), butyl acetate, benzene, and styrene are not detected; After the low-temperature impact test, the tufted carpet with composite coconut shell charcoal has no cracks, does not break, and does not delaminate.

[0063] This comparative example also provides a method for preparing a tufted carpet with the composite coconut shell charcoal, comprising the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate non-woven substrate through a tufting machine, controlling the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a substrate layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) aqueous foaming latex (dry glue weight of 80 gsm, wet latex solid content of 40%, foaming ratio of 3 times) on the bottom of the substrate layer at a speed of 10 m / min, and dry it at 180 °C for 2.5 min to obtain an adhesive layer; Step 2: Stir coconut shell charcoal (200 mesh) and tetrabutyl titanate with a molar ratio of 20:1 at 300 rpm for 10 min and disperse them in anhydrous ethanol and deionized water (the volume ratio of the anhydrous ethanol to the deionized water is 1:1, and the mass-volume ratio of the coconut shell charcoal to the anhydrous ethanol is 1:5, where the unit of mass is g and the unit of volume is mL), after ultrasonic treatment for 15 min, carry out a closed hydrothermal reaction at 300 rpm and 150 °C for 12 h, cool and filter, and then dry the solid product at 120 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 3: Heat the in-situ grown coconut shell charcoal to 500 °C at a rate of 5 °C / min for calcination, keep it at this temperature for 1 h, and then cool it to room temperature to obtain supported coconut shell charcoal. Uniformly mix the supported coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder at a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal; Step 4: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal on the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) is laminated on the back of the adsorption layer at 180 gsm. After cooling to room temperature, a reinforcement layer is obtained. A bottom layer of 1000 gsm polyethylene terephthalate (PET) needle punched felt is laminated on the back of the reinforcement layer. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm polyethylene at 190 °C respectively to obtain the tufted carpet with the composite polymer coconut shell charcoal.

[0064] Comparative Example 4 This comparative example provides a tufted carpet with composite coconut shell charcoal. The tufted carpet with composite coconut shell charcoal is a multi-layer structure, which is, from bottom to top, a bottom layer, a reinforcement layer, an adsorption layer, an adhesive layer, a substrate layer, and a pile layer; The tufted carpet made of the composite coconut shell charcoal has a thickness of 8 mm and a weight of 1822.67 g / m 2 , with 2665 cut pile loops per 100 cm 2 , a pile height of 4 mm, and a pile withdrawal force of 23 N; The tufted carpet made of the composite coconut shell charcoal has a peel strength of 43 N, a weftwise breaking strength of 1090 N / 5 cm, a warpwise breaking strength of 1128 N / 5 cm, a weftwise tear strength of 175 N, and a warpwise tear strength of 172 N; The tufted carpet made of the composite coconut shell charcoal has an odor rating of 3.5 after being kept at 80 °C for 2 h in the dry state, an odor rating of 4 after being kept at 40 °C for 24 h in the wet state, and an odor rating of 4 after being kept at 23 °C for 24 h in the wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg; In the volatile organic compound content of the tufted carpet made of the composite coconut shell charcoal, the formaldehyde content is 82.50 μg / m 3 , the acetaldehyde content is 121.10 μg / m 3 , the acetone content is 21.65 μg / m 3 , and the content of total volatile organic compounds (C6-C 16 ) is 1507.57 μg / m 3 ; while toluene, ethylbenzene, xylene (ortho, meta, para), butyl acetate, benzene, and styrene are not detected; After the tufted carpet made of the composite coconut shell charcoal undergoes a low-temperature impact test, there are no cracks, no breakage, and no delamination.

[0065] This comparative example also provides a preparation method for the tufted carpet made of the composite coconut shell charcoal, including the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate nonwoven fabric base through a tufting machine, controlling the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) water-based foaming latex (dry glue weight of 80 gsm, wet latex solid content of 40%, foaming ratio of 3 times) on the bottom of the base layer at a speed of 10 m / min, and dry it at 180 °C for 2.5 min to obtain an adhesive layer; Step 2: Concentrated nitric acid (with a mass-to-volume ratio of 1:5 with respect to the coconut shell charcoal) was added to the coconut shell charcoal (200 mesh) at 0 °C and a speed of 200 rpm, and then the temperature was gradually raised to 70 °C, followed by stirring and acidification at 350 rpm for 3 h. The acidified coconut shell charcoal was washed with deionized water until the pH of the filtrate reached 7, and then dried at 120 °C for 12 h to obtain activated coconut shell charcoal; Step 3: The activated coconut shell charcoal and tetrabutyl titanate with a molar ratio of 20:1 were stirred in deionized water (with a mass-to-volume ratio of 1:5 between the activated coconut shell charcoal and the deionized water, where the unit of mass is g and the unit of volume is mL) at 300 rpm for 10 min for dispersion. After ultrasonic treatment for 15 min, the reaction was carried out under hydrothermal conditions at 300 rpm and 300 °C for 12 h. After cooling and filtration, the solid product was dried at 120 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 4: The in-situ grown coconut shell charcoal was heated to 500 °C at a rate of 5 °C / min for calcination, held at this temperature for 1 h, and then cooled to room temperature to obtain supported coconut shell charcoal. The supported coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder were uniformly mixed at a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal; Step 5: The organic coconut shell charcoal was evenly sprinkled on the back of the adhesive layer at 300 gsm, and then heated to 170 °C to melt and bond the organic coconut shell charcoal to the back of the adhesive layer. After cooling to room temperature, an adsorption layer was obtained. Then, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) was laminated on the back of the adsorption layer at 180 gsm. After cooling to room temperature, a reinforcing layer was obtained. The bottom layer of a 1000 gsm polyethylene terephthalate (PET) needle punched felt was laminated on the back of the reinforcing layer. The lamination method was to use 200 gsm polyethylene to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt at 190 °C respectively, to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0066] Comparative Example 5 This comparative example provides a tufted carpet of composite coconut shell charcoal. The tufted carpet of composite coconut shell charcoal has a multi-layer structure, which from bottom to top are a bottom layer, a reinforcing layer, an adsorption layer, an adhesive layer, a base cloth layer, and a pile layer; The thickness of the tufted carpet of composite coconut shell charcoal is 8 mm, and the grammage is 1859.28 g / m 2 , the number of cut pile loops is 2660 per 100 cm 2 , the pile height is 4 mm, and the pile pull-out force is 29 N; The peel strength of the tufted carpet of composite coconut shell charcoal is 44 N, the weft direction breaking strength is 1121 N / 5 cm, the warp direction breaking strength is 1164 N / 5 cm, the weft direction tearing strength is 164 N, and the warp direction tearing strength is 171 N; The odor level of the tufted carpet made of the composite coconut shell charcoal is 3.5 at 80°C for 2 hours in the dry state, 4 at 40°C for 24 hours in the wet state, and 4 at 23°C for 24 hours in the wet state. The content of toxic and harmful substances is ≤1000 mg / kg, the content of cadmium is ≤1000 mg / kg, and the content of polycyclic aromatic hydrocarbons is ≤10 mg / kg; In the volatile organic compound content of the tufted carpet made of the composite coconut shell charcoal, the formaldehyde content is 65.28 μg / m 3 , the acetaldehyde content is 105.95 μg / m 3 , the acetone content is 45.16 μg / m 3 , and the total volatile organic compound (TVOC, C6-C 16 ) content is 111.92 μg / m 3 ; while toluene, ethylbenzene, xylene (ortho, meta, para), butyl acetate, benzene, and styrene are not detected; After the low-temperature impact test, the tufted carpet made of the composite coconut shell charcoal has no cracks, does not break, and does not delaminate.

[0067] This comparative example also provides a method for preparing the tufted carpet made of the composite coconut shell charcoal, including the following steps: Step 1: Tuft 350 gsm bulk continuous filament (BCF yarn) onto a 120 gsm polyethylene terephthalate nonwoven base fabric through a tufting machine, controlling the stitch density of the tufting machine to be 50.39 stitches / 10 cm, the row density to be 51 stitches / 10 cm, the needle penetration depth to be 5.5 mm, and the needle frequency to be 1000 RPM to obtain a pile layer and a base fabric layer; and coat 200 gsm ethylene-vinyl acetate copolymer (EVA) water-based foaming latex (dry glue weight is 80 gsm, wet latex solid content is 40%, and foaming ratio is 3 times) on the bottom of the base fabric layer at a speed of 10 m / min, and dry it at 180°C for 2.5 min to obtain an adhesive layer; Step 2: Add concentrated nitric acid (mass-volume ratio with the coconut shell charcoal is 1:5) to coconut shell charcoal (200 mesh) at 0°C and a speed of 200 rpm, gradually heat up to 70°C, and stir and acidify for 3 hours at 350 rpm. Wash the acidified coconut shell charcoal with deionized water until the pH of the filtrate is 7, and dry it at 120°C for 12 hours to obtain activated coconut shell charcoal; Step 3: Disperse the activated coconut shell charcoal with a molar ratio of 20:1 and tetrabutyl titanate under the condition of 300 rpm for 10 min in absolute ethanol and deionized water (the volume ratio of the absolute ethanol to the deionized water is 1:1, and the mass-volume ratio of the activated coconut shell charcoal to the absolute ethanol is 1:5, where the unit of mass is g and the unit of volume is mL). After ultrasonic treatment for 15 min, carry out a reaction under sealed hydrothermal conditions at 300 rpm and 150 °C for 12 h. After cooling and filtration, dry the solid product at 120 °C for 12 h to obtain in-situ grown coconut shell charcoal; Step 4: Uniformly mix the in-situ grown coconut shell charcoal, maleic anhydride grafted polyethylene, and polyethylene powder in a mass ratio of 1:0.05:2 to obtain organic coconut shell charcoal; Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer at 300 gsm, and heat it to 170 °C to melt and bond the organic coconut shell charcoal on the back of the adhesive layer. After cooling to room temperature, an adsorption layer is obtained. Then, on the back of the adsorption layer, a polyethylene-polyamide-polyethylene composite film (PEPAPE film) is laminated at 180 gsm. After cooling to room temperature, a reinforcement layer is obtained. On the back of the reinforcement layer, a bottom layer of 1000 gsm polyethylene terephthalate (PET) needle punched felt is laminated. The lamination method is to bond the polyethylene-polyamide-polyethylene composite film and the polyethylene terephthalate needle punched felt with 200 gsm polyethylene at 190 °C respectively to obtain the tufted carpet of the composite polymer coconut shell charcoal.

[0068] The performance of the tufted carpet of the composite polymer coconut shell charcoal in Examples 1-5 of the present invention

[0069] The content of volatile organic compounds (μg / m 3 )

[0070] The performance of the tufted carpet in Comparative Examples 1-5 of the present invention

[0071] The content of volatile organic compounds (μg / m 3 )

[0072] As can be seen from the above table, the properties of the tufted carpet in the embodiments of the present invention, such as thickness, gram weight, number of loops, pile height, etc., are stable, and the pile pulling force is large, indicating that the carpet is not prone to shedding and has good firmness. Moreover, the peeling force, breaking strength, and tearing strength of the carpet are large, meeting the usage requirements of automotive tufted carpets. In particular, the odor level of the tufted carpet in the present invention is high. Although there is some odor, the content of toxic and harmful substances and volatile organic compounds is extremely low, and even some organic compounds are not detected in the carpet. In Comparative Example 1, there is no composite adsorption layer, and the volatilization is completely carried out by the organic substances in the carpet, so the content of its toxic and harmful substances and organic substances increases significantly, and the odor level also decreases accordingly. In Comparative Example 2, only coconut shell charcoal is added as an adsorbent to adsorb organic substances. Although the odor of the carpet is reduced, due to the weak binding force between it and the organic substances, the mechanical properties of the carpet are reduced. At the same time, although coconut shell charcoal can temporarily adsorb some organic substances, with the increase of temperature, the organic substances will still be released. In Comparative Example 3, the coconut shell charcoal is not acidified, which results in fewer surface functional groups on the surface of the coconut shell charcoal, and less titanium dioxide is loaded when interacting with titanium dioxide, so less organic substances can be adsorbed. In Comparative Example 4, only deionized water is used as a solvent, and the hydrothermal temperature is increased at the same time. This leads to violent hydrolysis of tetrabutyl titanate and titanium dioxide loading process during the hydrothermal process, and the rapid aggregation of titanium dioxide makes its loading on the coconut shell charcoal uneven, resulting in hindrance to the subsequent adsorption and decomposition processes and an increase in the organic substance content of the carpet. In Comparative Example 5, the grown coconut shell charcoal is not calcined, resulting in weak binding force of titanium dioxide on the coconut shell charcoal, making it unstable during the subsequent mixing process with polyethylene and reducing the content of organic substances it can adsorb.

[0073] The odor level evaluation standard in the present invention: Grade 1: There is an unbearable odor; Grade 2: There is a strong interfering odor; Grade 3: There is an interfering odor; Grade 4: There is an obvious odor but no interference; Grade 5: There is an odor but no interference; Grade 6: There is no odor; The toxic and harmful substances in the present invention include lead (Pb), mercury (Hg), hexavalent chromium (Cr 6+ ), polybrominated biphenyls (PBBs), polybrominated diphenyl ethers (PBDEs); The conditions for the low-temperature impact test in the present invention are as follows: After the sample is placed at 80°C for 24 hours, then at 23°C for 2 hours, and then continued to be placed at -40°C for 4 hours, the sample is impacted by a drop hammer with a diameter of 50 mm and a weight of 500 g falling vertically from a height of 400 mm. The test standard for the content of volatile organic compounds in the present invention is 《Q / JQ 11241-2023》.

[0074] As can be seen from the above, the tufted carpet made of the composite polymer coconut shell charcoal in the present invention has a very wide range of uses, low cost, and extremely high market prospects.

[0075] The above are only the preferred embodiments of the present invention, and do not impose any other form of limitation on the present invention. Any modification or equivalent change made according to the technical essence of the present invention still falls within the scope claimed by the present invention.

Claims

1. A tufted carpet made of a composite polymer coconut shell charcoal, characterized in that, The tufted carpet of the composite polymer coconut shell charcoal is a multi-layer structure, which from bottom to top are the bottom layer, the reinforcement layer, the adsorption layer, the adhesive layer, the base fabric layer and the pile layer. The raw materials in the adsorption layer include polyethylene powder, formaldehyde-removing crystal, compatibilizer and coconut shell charcoal. The formaldehyde-removing crystal is loaded on the coconut shell charcoal, and then mixed with the compatibilizer and polyethylene powder and sprinkled on the adhesive layer, and the adsorption layer is prepared by high-temperature treatment. The tufted carpet made of the composite polymer coconut shell charcoal has a thickness of 12.4 - 12.9 mm and a grammage of 1910 - 1997 g / m 2 , and the number of cut pile loops is 2550 - 2660 per 100 cm 2 , the pile height is 4 - 5 mm, and the pile extraction force is 26 - 30 N; The peeling force of the tufted carpet of the composite polymer coconut shell charcoal is 58 - 66 N, the weft breaking strength is 1340 - 1410 N / 5 cm, the warp breaking strength is 1520 - 1630 N / 5 cm, the weft tearing strength is 210 - 270 N, and the warp tearing strength is 210 - 280 N. The odor level of the tufted carpet of the composite polymer coconut shell charcoal is 3.5 - 5 levels, the content of toxic and harmful substances ≤ 1000 mg / kg, the content of cadmium ≤ 100 mg / kg, and the content of polycyclic aromatic hydrocarbons ≤ 0.2 mg / kg. The formaldehyde content in the volatile organic compounds of the tufted carpet made of the composite polymer coconut shell charcoal is < 19 μg / m 3 , the acetaldehyde content is < 48.5 μg / m 3 , the toluene content is < 5.2 μg / m 3 , and acrylic acid, acetone, benzene, ethylbenzene, xylene, and styrene are not detected; the total volatile organic compound content is < 1170 μg / m 3 .

2. A method for preparing a tufted carpet of the composite polymer coconut shell charcoal according to claim 1, characterized in that, It includes the following steps: Step 1: Tuft the bulk continuous filament onto the non-woven base fabric through a tufting machine to obtain the pile layer and the base fabric layer; and coat the bottom of the base fabric layer with aqueous foaming latex, and obtain the adhesive layer after drying. Step 2: Add concentrated nitric acid to the coconut shell charcoal under low-temperature stirring, gradually raise the temperature and stir for acidification. The acidified coconut shell charcoal is washed with deionized water and dried after washing to obtain activated coconut shell charcoal. Step 3: Stir and disperse the activated coconut shell charcoal and the formaldehyde-removing crystal in absolute ethanol and deionized water, carry out a reaction under ultrasonic sealing and hydrothermal conditions, cool and filter, and dry the solid product to obtain in-situ grown coconut shell charcoal. Step 4: Calcinate the in-situ grown coconut shell charcoal and cool it to room temperature to obtain loaded coconut shell charcoal. The loaded coconut shell charcoal is uniformly mixed with the compatibilizer and polyethylene powder to obtain organic coconut shell charcoal. Step 5: Uniformly sprinkle the organic coconut shell charcoal on the back of the adhesive layer, and heat it to make the organic coconut shell charcoal melt and adhere to the back of the adhesive layer. After cooling to room temperature, the adsorption layer is obtained. Continuously compound a polyethylene-polyamide-polyethylene composite film on the back of the adsorption layer, and after cooling to room temperature, the reinforcement layer is obtained. Compound the bottom layer of polyethylene terephthalate needle punched felt on the back of the reinforcement layer to obtain the tufted carpet of the composite polymer coconut shell charcoal.

3. The preparation method according to claim 2, wherein The aqueous foaming latex in Step 1 is ethylene-vinyl acetate copolymer aqueous foaming latex.

4. The preparation method according to claim 2, characterized in that, The molar ratio of the activated coconut shell charcoal to the formaldehyde-removing crystal in Step 3 is (18 - 22):

1.

5. The preparation method according to claim 2, characterized in that, The formaldehyde-removing crystal in Step 3 is tetrabutyl titanate.

6. The preparation method according to claim 2, characterized in that, The mass-volume ratio of the activated coconut shell charcoal to the absolute ethanol in Step 3 is (1:5) - (1:6), where the unit of mass is g and the unit of volume is mL.

7. The preparation method according to claim 2, wherein The temperature of the hydrothermal reaction in Step 3 is 150 - 160 °C, and the time of the hydrothermal reaction is 12 - 15 h.

8. The preparation method according to claim 2, characterized in that, The mass ratio of the loaded coconut shell charcoal to the compatibilizer and polyethylene powder in Step 4 is (1:0.05:2) - (1:0.1:2).

9. The preparation method according to claim 2, characterized in that, The compatibilizer in Step 4 is maleic anhydride grafted polyethylene.

10. A low-odor automotive carpet, characterized in that, The low-odor automotive carpet is composed of a tufted carpet of the composite polymer coconut shell charcoal described in claim 1.

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